Software engineering is hard, but software is hard in decidedly virtual ways. Sure, sometimes you’re limited by available people or available hardware, or you don’t have enough CAT5 or the right kind of RAM module, but software problems are generally solvable with a text editor, some caffeine, and patience.
Mechanical engineering is hard, and it is often hard in decidedly physical ways. There are usually wires and pipes and gears and pumps and things. Usually when a computer crashes, there’s a lot of cursing and angst. When something mechanical crashes, there’s also a lot of cursing and angst, but sometimes there is blood. And usually there is a mess to clean up.
Today there was quite a mess to clean up.
But first, a little background: the plastic recycling process that my dad and his partners are designing is what’s called a hydrogravity separation process. This is just a fancy way of saying that some things float and sink in solutions depending on the density of the solution, and if you can make the good stuff float and the bad stuff sink (or vice versa) you’re in pretty good shape. The whole process sounds pretty simple when you hear it explained—this stuff floats, so skim it off the top, and this stuff sinks, so scrape it off the bottom—but the devil is absolutely in the details.
One of the details is that of scale—it’s one thing to have a table-top demonstration of stuff floating and sinking, but when you go from table-top models to a 20,000 square-foot production facility, a lot of things get much, much more complicated. Take water, for instance. When you want to make a lot of stuff float or sink, you need a lot of water. Or a lot of solution. Or, in the case of the plastic recycling plant, you need a lot of both. So you get some big tanks to hold a lot of water or solution. Really big tanks.
I’d never given much thought to what 5,000 gallons of water looks like, but when you see a 5,000-gallon plastic tank, it’s an impressive sight. And when you see four such tanks standing next to each other, your first thought is usually something along the lines of “that’s a damn hell lot of water.” Because it is.
The thing about the tanks, though, is that once you’ve seen them and get over the fact that they hold a damn hell lot of water, you tend to forget about them. A lot of things can go wrong when you’re dealing with motors and pumps and driers and forklifts and propane and half-ton bags of scrap plastic and mixers and such. Things that spin and whir and grind and move are somewhat threatening, but tanks are deceptively innocuous. After all, they’re pretty passive things; they just stand there and hold water. Except when they don’t.
I mentioned that there was a mess to clean up today, right? And I’ve talked a bit about the tanks, right? So how many of you have guessed it was the tanks? Good guess. But hang on—it gets better (or worse, I suppose).
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