Comprehensive Evaluation of an Automated Distiller: Performance, Thermal Losses, and Process Reliability

Abstract

Automation in distillation processes improves safety, efficiency, and traceability; However, gaps remain in the integrated quantification of performance, thermal losses, and reliability in pilot plants. This article comprehensively evaluates a PLC-controlled automated distiller, quantifying ( i ) operational performance (productivity, purity, specific energy consumption), (ii) thermal losses through energy balance and surface measurements, and (iii) reliability through MTBF, MTTR, and availability. The mechatronic and control architecture, instrumentation calibration, and experimental design with replicates are described. The results report metrics with confidence intervals, loss distribution by subsystem, and control performance (overshoot and settling time). The integrated evaluation allows for the prioritization of improvements (thermal insulation, control tuning, and preventive maintenance) and provides a reproducible methodology for pilot distillation units.