2. Automated Process Control Autoclave Engineers Erie, PA USA
Improving Polymerization Catalyst Research
3rd Eurokin Workshop - San Donato, Milanese
September 2000

3. 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.

4. Gas-Solid Reaction Equipment BTRS Jr. ®/ BTRS 900

5. Gas-Solid Reaction Equipment Berty Reactor / Caldwell

6. Gas-Liquid-Solid Reaction Equipment.

7. Gas-Liquid-Solid Reaction Equipment

8. 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.

9. 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

10. Mechanical System Case Study 1

11. Control System Case Study 1

12. Case Study 1: Results
Catalyst yield variation drops from +/- 20% to +/- 7%
Rapidly Implemented
Productivity Improved

13. 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 size of experimental effect
Strategy: Process Automation, Closed System

14. Mechanical System Case Study 2

15. Control System Case Study 2

16. Case Study 2: Results Undisclosed Improvement in reproducibility.
Benefit such that a two additional, four reactor systems, were purchased.

17. Conclusions
Consider Process Automation to improve the ratio of experimental effect (signal) to system error (noise).

18. 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