Backstepping Methodology to Troubleshoot Plant-Wide Batch Processes in Data-Rich Industrial Environments

Troubleshooting batch processes at a plant-wide level requires first finding the unit causing the fault, and then understanding why the fault occurs in that unit. Whereas in the literature case studies discussing the latter issue abound, little attention has been given so far to the former, which is complex for several reasons: the processing units are often operated in a non-sequential way, with unusual series-parallel arrangements; holding vessels may be required to compensate for lack of production capacity, and reacting phenomena can occur in these vessels; and the evidence of batch abnormality may be available only from the end unit and at the end of the production cycle. We propose a structured methodology to assist the troubleshooting of plant-wide batch processes in data-rich environments where multivariate statistical techniques can be exploited. Namely, we first analyze the last unit wherein the fault manifests itself, and we then step back across the units through the process flow diagram (according to the manufacturing recipe) until the fault cannot be detected by the available field sensors any more. That enables us to isolate the unit wherefrom the fault originates. Interrogation of multivariate statistical models for that unit coupled to engineering judgement allow identifying the most likely root cause of the fault. We apply the proposed methodology to troubleshoot a complex industrial batch process that manufactures a specialty chemical, where productivity was originally limited by unexplained variability of the final product quality. Correction of the fault allowed for a significant increase in productivity.

«Quick, Convenient, and Clean»: Advancing Education in Green Chemistry and Nanocatalysis Using Sol-Gel Catalysts Under Flow

Removing one key barrier to the industrial uptake of green chemistry and nanocatalysis in the fine and specialty chemical industry requires to fill an ongoing “talent shortage” via expanded chemistry education. In this study we show how the use of hybrid sol-gel catalysts to synthesize fine chemicals and active pharmaceutical ingredients in flow chemistry reactors illustrates new ideas to reshape chemistry education based on recent research outcomes, visualization and digital tools. Several lessons learned from the industrial and academic utilization of these materials in continuous-flow conversions conclude the study.

Enterprise Risk Management in the Specialty Chemical Distribution Sector: A Literature Review

A literature review was conducted on risks in businesses, types of risks and risk management in general, and further research was conducted for three of the selected global specialty chemical distributors, namely Brenntag, IMCD and Univar. The purpose of the research is to identify the risks and types of risk confronting the specialty chemical distribution sector, how they identify their risks, manage them, and quantify their risks, if at all.The stakeholder theory approach was adopted for the research on enterprise risk management. There was strong convergence on the risks identified from the research and the differences being only on the extent of the impact each of the risk had on the specific company. The choice of the global specialty chemical distributors, Brenntag, IMCD and Univar, for the research was justified because of their prominence in the global market space and the risks identified would be representative of the risks in the chemical distribution sector. Different companies identify their risks and the type of risks differently, but there are many similarities on the risks identified between each of them. Many of the risks identified revolves around issues in financial, operational, legal and regulatory, economics and political, markets, and safety, health and the environment.The depth of the risks identified and analyzed by Brenntag, IMCD and Univar varies in their risk management process but they all have invested significant effort in their financial risks, especially the impact in fluctuations of interest and foreign exchange rates on their financial performances.

Enzymatic Modification of Native Chitin and Conversion to Specialty Chemical Products

Chitin is one of the most abundant biomolecules on earth, occurring in crustacean shells and cell walls of fungi. While the polysaccharide is threatening to pollute coastal ecosystems in the form of accumulating shell-waste, it has the potential to be converted into highly profitable derivatives with applications in medicine, biotechnology, and wastewater treatment, among others. Traditionally this is still mostly done by the employment of aggressive chemicals, yielding low quality while producing toxic by-products. In the last decades, the enzymatic conversion of chitin has been on the rise, albeit still not on the same level of cost-effectiveness compared to the traditional methods due to its multi-step character. Another severe drawback of the biotechnological approach is the highly ordered structure of chitin, which renders it nigh impossible for most glycosidic hydrolases to act upon. So far, only the Auxiliary Activity 10 family (AA10), including lytic polysaccharide monooxygenases (LPMOs), is known to hydrolyse native recalcitrant chitin, which spares the expensive first step of chemical or mechanical pre-treatment to enlarge the substrate surface. The main advantages of enzymatic conversion of chitin over conventional chemical methods are the biocompability and, more strikingly, the higher product specificity, product quality, and yield of the process. Products with a higher Mw due to no unspecific depolymerisation besides an exactly defined degree and pattern of acetylation can be yielded. This provides a new toolset of thousands of new chitin and chitosan derivatives, as the physio-chemical properties can be modified according to the desired application. This review aims to provide an overview of the biotechnological tools currently at hand, as well as challenges and crucial steps to achieve the long-term goal of enzymatic conversion of native chitin into specialty chemical products.