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Sense of Sensing in the Chemical IndustryMinacNed / COAST workshopHenk-Jan van Manen – April 10, 2019
Henk-Jan van ManenOctober 18, 2018Henk-Jan van ManenOctober 18, 2018
Contents
Sense of Sensing - Chemical Industry 2
Expert Capability Center Deventer
Societal Challenges and the ChemicalIndustry
Process Analytical Technology
Sensor Development Needs and Challenges
Solving yourChallenges usingour Expertise
Expert Capability CenterDeventer
Your center in essential chemistry
Expert Capability Center Deventer 4
Solvingyourchallenges
Firsttimeright!
Using ourexpertise
We assist you to get the rightanswers to the right questions.
The characterization andevaluation of productsand processes
Measurement &Analytical Science
Expert Capability Center Deventer 5
ContactAns van de Bovenkamp+31 622 394 [email protected]
Improve the efficiency,safety and sustainabilityof your production process
Process AnalyticalTechnology
Expert Capability Center Deventer 6
ContactHenk-Jan van Manen+31 570 679 [email protected]
The interface of synthesis,organic & inorganicchemistry andmaterials science
Molecules & MaterialsTechnology
Expert Capability Center Deventer 7
ContactDimitri van Agterveld+31 570 679 [email protected]
The ideation, conceptualdesign, development,scale-up, and optimizationof processes
ProcessTechnology
Expert Capability Center Deventer 8
ContactGerrald Bargeman+31 570 679 [email protected]
Societal Challenges and
the Chemical Industry
Sense of Sensing - Chemical Industry 10
EU Horizon 2020 Societal Challenges
= addressed by SoS programme
Sense of Sensing - Chemical Industry 11
The Chemical Industry• Largest contributor to industrial energy demand worldwide
• EU chemical industry accounts for 20% of the overall EU industrial energy consumption
• Contribution to global industrial greenhouse gas emissions is 7%• Already reduced the emission of CO2 per ton product by 57% since 1990
Smart Chemical Industry
Sense of Sensing - Chemical Industry 12
Towards Excellence in Chemical Manufacturing
Improvements needed in:
• Chemical efficiency
• Energy efficiency
• Circularity
• Sustainability
• New chemistries
• New processes and the way
we control them
• Bio-based renewables
• Waste to chemicals
To Measure is to Know:
Process AnalyticalTechnology
Sense of Sensing - Chemical Industry 14
Purpose of Measurement/Sensing in ChemicalManufacturing• Process monitoring and control
• “Is my process running as expected?”
• Typical sensors: Temperature, pressure, flow, level
• Measurement mode: Predominantly in-line
• Quality control• “Are my materials within specification?”
• Both input (raw materials) and output (products, contaminants)
• Typical sensors: Chemical fingerprinting, chemical concentrations
• Measurement mode: Predominantly off-line in QC laboratory
• Health, Safety, and Environment• “Is there any danger to people and surroundings?”
Big opportunities in
chemical industry for
improvement
Sense of Sensing - Chemical Industry 15
Off-line QC as Bottleneck
• Off-line QC methods are frequently a bottleneck to
achieve manufacturing excellence• Time-consuming
• Require manual sampling (HSE!) and chemicals
• Not compatible with real-time process monitoring & control
Sense of Sensing - Chemical Industry 16
Benefits of PAT• Capacity increase
• Reduction of batch cycle times or QC waiting times
• Optimizing (real-time) process control• Improving consistent product quality
• Right first time improvement
• HSE improvement by reducing manual sampling and/or process monitoring• Environmental monitoring (for example, due to regulations)• Improved process understanding• Aligned with industry objectives
• Manufacturing efficiency• Cost productivity improvement• Safety improvement• Industry 4.0 / Digital / Factory of the Future
Process Analytical Technology at Nouryon
Sense of Sensing - Chemical Industry 17
Track record ofsuccessful PATdevelopment anddeployment projects
Improvingprocess safety,efficiency, andsustainability
• Feasibility studies (lab, pilot)• Development and deployment• Post-deployment support
Dedicated team of expertsin process measurements
• Chemometrics• Statistics• Software
development
PAT example: In-process monitoring usingspectroscopy
Sensing Technologies in the Chemical Industry 18
Mid-infrared (MIR) region:Fundamental vibrations
Near-infrared (NIR) region:Overtones and combinations
• Why NIR?• NIR region is favorable for
many chemistries• C-H, N-H, O-H bonds
• Robust, multi-channelprocess analyzers
• Compatible with (long)optical fibers
• Favorable OPL (mm)• Immersion probes
• Transmission• Transflection• Reflection
• Sensitivity <0.1%
In-line NIR feasibility studies in the lab
Sensing Technologies in the Chemical Industry 19
4 L scale – Deventer
In-line NIR feasibility studies in the pilot plant
Sensing Technologies in the Chemical Industry 20
25 L scaleBrewster (US)
Exploratory multivariate data analysis
Sensing Technologies in the Chemical Industry 21
wateraddition
dosingreactant
postreaction
stripping
0
0.05
0.1
0.15
0.2
0.25
0.3
ReactantIntermediate
Product
Reaction progression
Principal Component Analysis (PCA) Multivariate Curve Resolution (MCR)
From spectra to chemical concentrations
Sensing Technologies in the Chemical Industry 22
1. Raw NIR data
3. Preprocessed data
4. PLSregression
2. Primary methoddata
Total Amine
5. Multivariate PLSmodel
Implementation in the plant: Hardware
Sensing Technologies in the Chemical Industry 23
• Process NIR spectrometer• Conditioned environment
• Air purge, T-stability
• NIR probe• Fit for purpose
• Optical fibers
• Closed loop for instrument monitoring
Sensor Development
Needs for the
Chemical Industry
Sensors of the future: Needs
Sensing Technologies in the Chemical Industry 25
• Quantitative
• Chemically specific
• Accurate (fit-for-purpose)
• Reliable
• Robust
• Fast response time
• IT integration
• Low-cost
• Non-invasive
• Small (miniaturized)
• Low-maintenance
• Sustainable
• Connected to plant DCS
• Easily replaceable
Sensors of the future: Challenges
Sensing Technologies in the Chemical Industry 26
• Robustness in chemical processes• Material compatibility
• Challenging matrix (e.g. concentrated slurries, corrosive chemicals)
• Sensitivity down to ppm-ppb level
• Large dynamic range
• Chemical specificity
• From sensor data to process information/knowledge• Big Data for the plant
• Soft sensors
• Integration of fundamental process models with data-driven models
Scope of SoS proposal for Chemical Industry
Sensing Technologies in the Chemical Industry 27
• In-process sensor design and sensing method development• Robust sensors for demanding environments
• New methods for in-situ particle size and morphology monitoring
• Operando optical techniques with improved chemical specificity for detailed monitoring
of chemical events (e.g. in catalysis)
• Miniaturization of analytical techniques for use in and around the plant• E.g. handheld devices used by operators and/or HSE personnel
• Digitization / soft sensing / chemometrics / big data• Fit-for-purpose sensor design
• Coupling of data from sensor networks
• From data to information and knowledgeà process understanding and control
Thank you for yourattention