Automated Process Control Autoclave Engineers Erie, PA USA Improving Polymerization Catalyst Research 3rd Eurokin Workshop - San Donato, Milanese September 2000 www.AutoclaveEngineers.com
Presentation Overview Available hardware for Gas-Solid catalyst research Available hardware for Gas-Liquid-Solid catalyst research Range of Automatic Controls and Instrumentation available as accessories Case Study 1: Automated polymerization synthesis compared to a manual system. Case Study 2: Automated, closed system polymer synthesis compared to a manual system.
Gas-Solid Reaction Equipment BTRS Jr. ®/ BTRS 900
Gas-Solid Reaction Equipment Berty Reactor / Caldwell
Gas-Liquid-Solid Reaction Equipment .
Gas-Liquid-Solid Reaction Equipment
Range of Control Systems Manual Open-loop with display Closed-loop with display Closed-loop with analog retransmission Closed-loop with computer control Remote Manipulation of variables, real-time trending, data logging, etc.. Closed-loop with Custom computer control system Full computer control, batch automation, data logging, alarm interlocks, etc.. Each level of sophistication reduces variations. Case studies demonstrate improvement between Levels 3 and 6.
Case Study 1 Albemarle Corp. - Baton Rouge, LA Application: Sample Preparation for QC of Catalyst Objective: Comparisons between lots of catalyst. Problem: Poor Reproducibility Strategy: Process Automation
Mechanical System Case Study 1
Control System Case Study 1
Case Study 1: Results Catalyst yield variation drops from +/- 20% to +/- 7% Rapidly Implemented Productivity Improved
Case Study 2 WR Grace Columbia, S.C. U.S.A. Application: Polymerization Research-Multi-station Synthesis Objectives: 1. Improve reproducibility for statistical analysis. 2. Eliminate environmental contamination. Problem: System error approx. @ size of experimental effect Strategy: Process Automation, Closed System
Mechanical System Case Study 2
Control System Case Study 2
Case Study 2: Results Undisclosed Improvement in reproducibility. Benefit such that a two additional, four reactor systems, were purchased.
Conclusions Consider Process Automation to improve the ratio of experimental effect (signal) to system error (noise).
Acknowledgements Albemarle Corporation Cryovac Division of Sealed Air Glen McClelland Jamie Strickler Cryovac Division of Sealed Air Paul Hughes Nate Miranda Autoclave Engineers Steven Simon and Tim Porco