Batch process monitoring using on-line MIR spectroscopy

Many high quality products are produced in a batch wise manner. One of the characteristics of a batch process is the recipe driven nature. By repeating the recipe in an identical manner a desired end-product is obtained. However, in spite of repeating the recipe in an identical manner, process differences occur. These differences can be caused by a change of feed stock supplier or impurities in the process. Because of this, differences might occur in the end-product quality or unsafe process situations arise. Therefore, the need to monitor an industrial batch process exists. An industrial process is usually monitored by process measurements such as pressures and temperatures. Nowadays, due to technical developments, spectroscopy is more and more used for process monitoring. Spectroscopic measurements have the advantage of giving a direct chemical insight in the process. Multivariate statistical process control (MSPC) is a statistical way of monitoring the behaviour of a process. Combining spectroscopic measurements with MSPC will notice process perturbations or process deviations from normal operating conditions in a very simple manner. In the following an application is given of batch process monitoring. It is shown how a calibration model is developed and used with the principles of MSPC. Statistical control charts are developed and used to detect batches with a process upset.     

Using computer simulation to assist in the robustness analysis of an ion-exchange chromatography step

This paper presents a methodology to gain process knowledge and assist in the robustness analysis of an ion-exchange step in a protein purification process using a model-based approach. Factorial experimental design is common practice in industry today to obtain robustness characterization of unit operations with respect to variations in process parameters. This work aims at providing a better insight into what process variations affect quality and to further reduce the experimental work to the regions of process variation that are of most interest. This methodology also greatly increases the ability to predict process performance and promotes process understanding. The model calibration part of the methodology involves three consecutive steps to calibrate a steric mass action (SMA) ion-exchange chromatography model. Firstly, a number of gradient elution experiments are performed. Secondly, experimental breakthrough curves have to be generated for the proteins if the adsorption capacity of the medium for each component is not known. Thirdly, a multi-component loading experiment is performed to calibrate the multi-component effects that cannot be determined from the single-component experiments. The separation process studied in this work is the separation of polyclonal IgG from a mixture containing IgG, myoglobin and BSA. The calibrated model is used to simulate six process variations in a full factorial experiment. The results of the simulations provide information about the importance of the different process variations and the simulations are also used to determine the crucial points for the process parameter variations. The methodology can be used to assist in the robustness analysis normally performed in the pharmaceutical industry today as it is able to predict the impact on process performance resulting from variations in salt concentration, column load, protein concentration and flow rate.     

A novel multi‐mode data processing method and its application in industrial process monitoring

Multi‐mode process monitoring is a key issue often raised in industrial process control. Most multivariate statistical process monitoring strategies, such as principal component analysis (PCA) and partial least squares, make an essential assumption that the collected data follow a unimodal or Gaussian distribution. However, owing to the complexity and the multi‐mode feature of industrial processes, the collected data usually follow different distributions. This paper proposes a novel multi‐mode data processing method called weighted k neighbourhood standardisation (WKNS) to address the multi‐mode data problem. This method can transform multi‐mode data into an approximately unimodal or Gaussian distribution. The results of theoretical analysis and discussion suggest that the WKNS strategy is more suitable for multi‐mode data normalisation than the z‐score method is. Furthermore, a new fault detection approach called WKNS‐PCA is developed and applied to detect process outliers. This method does not require process knowledge and multi‐mode modelling; only a single model is required for multi‐mode process monitoring. The proposed method is tested on a numerical example and the Tennessee Eastman process. Finally, the results demonstrate that the proposed data preprocessing and process monitoring methods are particularly suitable and effective in multi‐mode data normalisation and industrial process fault detection. Copyright © 2014 John Wiley & Sons, Ltd.     

Infrared multiphoton decomposition and the possibilities of laser-based heavy water processes

The selective multiphoton decomposition (MPD) process has the potential to provide a stand-alone heavy water process which is competitive with conventional processes. Twelve criteria are discussed for selecting a working molecule to give a process economically competitive with the Girdler-Sulphide process. The dependence of the MPD process on interacting parameters such as laser fluence, intensity and bandwidth as well as collisional effects are discussed. Finally, several potential working molecules are reviewed.     

Stepwise thickening in aqueous foam films stabilized by sodium naphthenates

During drainage of a foam film formed from an aqueous sodium naphthenate solution, a transient, local, stepwise thickening process was observed. Film stratification is related to the stepwise thinning drainage process where individual layers of material are drained from a film. The process typically involves the appearance of a sequence of small, uniformly thick spots that eventually expand to the size of the film. The appearance and growth of each spot represents a discrete decrease in the thickness of the film. The size of each decrease or step typically corresponds to the size of one or more lamella layers of the stratified film. Stepwise thinning was observed in a foam film formed from an aqueous sodium naphthenate solution, as frequently reported for a variety of systems. However, during the drainage process, a transient stepwise thickening process was also observed. Bright spots began to appear and grow, indicate a discrete increase in the thickness of a portion of the film. This local, stepwise thickening process appeared to be an alternate and temporary drainage process directly related to the expansion of the stepwise thinning spots.     

Unusual relaxation process in polybutadiene: Resolving the controversy

We report the observation of an unusual relaxation process in depolarized light scattering spectra of polybutadiene (PBD) with two different vinyl contents. The process showed up in the gigahertz frequency range with relatively mild temperature dependence and was similar to a secondary relaxation process. The most surprising observation was that the process exists even at high temperatures and does not merge with the segmental relaxation up to a temperature of 400 K (T > 2T_g). Possible mechanisms of this particular relaxation in PBD are discussed. The process is compared to the so‐called E process, double‐bond hopping process, and dielectric β process. We emphasize that this process differs from the dielectric β process, is unique for 1,4‐PBD, and has not been observed in other polymers. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 994–999, 2004     

Changes of the Molecular Mobility of Poly(<Emphasis Type="Italic">ε</Emphasis>-caprolactone) upon Drawing,Studied by Dielectric Relaxation Spectroscopy

Dielectric relaxation spectroscopy (DRS) of poly(ε-caprolactone) with different draw ratios showed that the mobility of polymer chains in the amorphous part decreases as the draw ratio increases.The activation energy of the α process,which corresponds to the dynamic glass transition,increases upon drawing.The enlarged gap between the activation energies of the αprocess and the β process results in a change of continuity at the crossover between the high temperature a process and the α and β processes.At low drawing ratios the a process connects with the βprocess,while at the highest drawing ratio in our measurements,the a process is continuous with the a process.This is consistent with X-ray diffraction results that indicate that upon drawing the polymer chains in the amorphous part align and densify upon drawing.As the draw ratio increases,the α relaxation broadens and decreases its intensity,indicating an increasing heterogeneity.We observed slope changes in the α traces,when the temperature decreases below that at which τα ≈ 1 s.This may indicate the glass transition from the ‘rubbery’ state to the non-equilibrium glassy state.     

Liquid-phase hydration process of cyclohexene with zeolites

The liquid-phase hydration process of cyclohexene into cyclohexanol with zeolite is described. The characteristic of this industrial process is that fine particles of zeolite are used in a slurry system, which offers high productivity and a simple separation system. In this process, the hydrophobic property and shape selectivity of ZSM-5 are fully utilized so as to realize an economical industrial process.     

Dynamics of glass-forming liquids. XII. Dielectric study of primary and secondary relaxations in ethylcyclohexane

The dynamics of ethylcyclohexane are investigated by high resolution dielectric spectroscopy aiming to characterize the relevant relaxational features of this simple system in its fluid, supercooled liquid, and glassy states. The dielectric signature of structural relaxation is a primary loss peak with amplitude Deltaepsilon=0.01, and a secondary loss process is found in the glassy state. This beta relaxation is compared with a "slow" process revealed by ultrasonics and with previously found gamma and chi processes in similar materials containing the cyclohexyl group. The results suggest that this secondary process is an intramolecular mode rather than a Johari-Goldstein process, consistent with its persistence in the liquid state at slow relaxation times which exceed those of the alpha process. The dielectric activity of such a slow process requires that the dipole magnitude changes with the intramolecular transition, whereas a change in dipole direction only would be masked by the faster structural relaxation.     

Design of a combined ozone/electron beam process for waste water and economic feasibility of the process

A design of a combined ozone/electron beam irradiation process for treating a 50 m³/h waste water stream from a molasses processing is discussed. Moreover, a cost evaluation of such a process in comparison to a conventional ozonation/biology treatment process has been performed to assess the potential of the irradiation process for technical use. Although the result of this comparison is not bad for the irradiation process an implementation into a full scale plant would not seem to be the thing to do in the present case.     

Dielectric study of the alpha and beta processes in supercooled ethylene glycol oligomer-water mixtures

Broadband dielectric measurements for 65 wt % ethylene glycol oligomer (EGO)-water mixtures with one to six repeat units of EGO molecules were performed in the frequency range of 10 microHz-10 GHz and the temperature range of 128-298 K. In the case of the water-EGO mixtures with one and two repeat units of the EGO molecule (small EGO), the shape of the dielectric loss peak of the primary process is asymmetrical about the logarithm of the frequency of maximum loss above the crossover temperature, T(C). The asymmetric process continues to the alpha process at a low frequency, and an additional beta process appears in the frequency range higher than that of the alpha process below T(C). In contrast, the water-EGO mixtures with three or more repeat units of the EGO molecule (large EGO) show a broad and symmetrical loss peak of the primary process above T(C). The symmetric process continues to the beta process, and an additional alpha process appears in the frequency range lower than that of the beta process below T(C). These different scenarios of the alpha-beta separation related to the shape of the loss peak above T(C) are a result of the difference in the cooperative motion of water and solute molecules. The solute and water molecules move cooperatively in the small EGO-water mixtures above T(C), and this cooperative motion leads to the asymmetric loss peak above T(C) and the alpha process below T(C). For the large EGO-water mixtures, the spatially restricted motion of water confined by solute molecules leads to the symmetric loss peak above T(C) and the beta process below T(C).     

Adsorption process of phenothiazine solution in dimethyl sulfoxide on graphite electrodes

In this paper, an original solution for the modeling and simulation of the adsorption process of a phenothiazine derivative on graphite electrodes is presented. The adsorption process is considered a distributed parameter one, due to the fact that the adsorbed phenothiazine quantity is a function depending on two independent variables. The structure parameters of the adsorption process, which define the influence of both independent variables, are determined using an experimental identification method. The experimental data are obtained through an experiment which is based on the process step response. In order to simulate the adsorption process, the approximate analytical solution, representing the process model, is determined. The simulation results prove the model generality; it is being simulated in relation to both independent variables.     

Generation of surface energy patterns by single pulse laser interference on self-assembled monolayers

Single pulse laser interference lithography is used to structure self-assembled monolayers of thiols on gold. This structuring process is investigated by attenuated total reflection measurements, and a demixing process of a binary polymer blend is used to visualize the produced surface energy pattern. The lithography can be realized with different wavelengths (266, 532, and 1064 nm) which shows that the structuring is a thermal process. As a first demonstration of this process, structures down to 800 nm period and 300 nm width are fabricated.     

Continuous purification of a clotting factor IX concentrate and continuous regeneration by preparative annular chromatography

Preparative continuous annular chromatography, a method to separate proteins in a truly continuous manner, was investigated in an industrial environment. Plasma-derived clotting factor IX concentrate was used as model protein. Separation of vitronectin, a common impurity in commercial available factor IX concentrates, from factor IX was studied and compared to conventional packed bed chromatography in batch mode. As sorbent, Toyopearl DEAE 650M was used. Regeneration was performed simultaneously with the purification of factor IX in continuous mode. All required parameters applied for preparative annular chromatography such as feed flow-rate and elution flow-rate were first estimated from experiments on conventional batch columns. Then preparative annular chromatography and conventional packed beds were compared regarding enrichment, purity and productivity. Three different process scenarios, the optimal batch process,the preparative annular chromatography process and the batch process equivalent to the preparative annular chromatography process were investigated. The productivity of the optimal batch process was higher than that of the preparative annular chromatography and batch process equivalent to the preparative annular chromatography process. Therefore the throughput could not be increased by the use of the continuous chromatographic system.     

ELECTRODIALYTIC PRODUCTION OF HYPOPHOSPHOROUS ACID

Disclosed is a method of preparing hypophosphorous acid comprising contacting an insoluble anode with an aqueous solution of hypophosphite anions and applying a direct current through the insoluble anode to a cathode in electrical contact with the aqueous solution to generate H+ ions in the aqueous solution thereby forming a hypophosphorous acid solution. The process is simple,low cost and high efficient, which can be tied into an existing process for producing sodium hypophosphite wherein the product of sodium hypophosphite process is used as a starting material in the hypophosphorous acid process.     

ELECTRODIALYTIC PRODUCTION OF HYPOPHOSPHOROUS ACID

1. INTRODUCTIONHypophosphorous acid (H3PO2) also known as phosphinic acid, is currently a staple article of commerce which is sold by various companies for purposes such as the manufacture of hypophosphite salts, as well as to prevent the discoloration of phosphate esters, in esterification catalysts, and for the manufacture of cooling water treatment chemicals. It is also sold for use in metal finishing procedures, as a reducing agent for electroless plating, and as a sealer for phosphat…     

Calorimetric monitoring of industrial chemical processes

Enthalpimetric methods used in chemical production and in process development are reviewed.On-line methods are applied to concentration analysis, to safety monitoring and to the control of reaction progress.The most promising applications of thermal methods are found in process development: enthalpimetric process investigation on the bench scale. Design principles for “process calorimeters” are outlined and applications to a pressure reaction, to a highly unstable radical reaction and to fermentations are shown.     

Using near-infrared process analysis to study gas-solid adsorption process as well as its data treatment based on artificial neural network and partial least squares

This paper demonstrates the application of near-infrared (NIR) process analysis to study gas-solid adsorption process non-invasively: its experimental setup, data treatment, and potentials as a convenient tool to investigate the gas-solid adsorption process. The experimental setup includes a differential adsorption bed (DAB) monitored by a NIR spectrometer via an optical fiber probe, which makes it convenient and reliable to construct adsorption mass-transfer models. A chemometrics strategy based on back propagation-artificial neural network (BP-ANN) and partial least squares (PLS) has been developed to treat NIR spectra collected during the adsorption process because of the obvious nonlinearity in concentration prediction. This nonlinear problem results from the great concentration variation of the adsorbate adsorbed by the adsorbent during the whole adsorption process, the extraordinarily low concentration of the adsorbed adsorbate at the beginning of the process, and probably NIR distinction between the adsorbate on the first adsorption layer at the beginning of the process and that on the other layers afterward. With the strategy, NIR spectra are pretreated with PLS for data compression and noise reduction, and then a BP-ANN is built as the nonlinear calibration model. As compared with linear calibration algorithm, our strategy has the higher predication ability for the whole adsorption process, even with less calibration samples. Finally, as an example the kinetics of aniline-silica gel adsorption process has been studied through the experimental setup and chemometrics strategy.     

Cut-off of dilute O/W emulsions through a microfiltration membrane

In order to obtain a monodispersed emulsion, we have used a cut-off process through a microfiltration membrane. Generally in the microfiltration process, a self-rejecting cake-layer formed at the initial stage of filtration would retain droplets, regardless of their size. It was therefore believed that separation based on relative size of pores and droplets through a microfiltration membrane was an impossible process. In the present study, it is assumed that removal of the self-rejecting cake-layer might enable cut-off to be realized through a microfiltration membrane. Based on this idea, both dead-end and cross-flow filtrations with stirred cell under conditions that avoid cake-layer formation were carried out. It is clear from the present experimental results that the cut-off process through microfiltration can be used to control droplet size under the special condition of no cake-layer formation, and the yield of this process can be predicted by values of the cut-off curve. A sieving mechanism should be the process responsible for the cut-off in the present experimental system.