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.     

Unraveling the Homologation Reaction Sequence of the Zeolite‐Catalyzed Ethanol‐to‐Hydrocarbons Process

Although industrialized, the mechanism for catalytic upgrading of bioethanol over solid‐acid catalysts (that is, the ethanol‐to‐hydrocarbons (ETH) reaction) has not yet been fully resolved. Moreover, mechanistic understanding of the ETH reaction relies heavily on its well‐known “sister‐reaction” the methanol‐to‐hydrocarbons (MTH) process. However, the MTH process possesses a C₁‐entity reactant and cannot, therefore, shed any light on the homologation reaction sequence. The reaction and deactivation mechanism of the zeolite H‐ZSM‐5‐catalyzed ETH process was elucidated using a combination of complementary solid‐state NMR and operando UV/Vis diffuse reflectance spectroscopy, coupled with on‐line mass spectrometry. This approach establishes the existence of a homologation reaction sequence through analysis of the pattern of the identified reactive and deactivated species. Furthermore, and in contrast to the MTH process, the deficiency of any olefinic‐hydrocarbon pool species (that is, the olefin cycle) during the ETH process is also noted.     

A Green Method for Recycling 2‐Propanol from Water during Purification Process of Aqueous Nanocrystals

During traditional 2‐propanol‐based purification of aqueous nanocrystals (NCs), it is very difficult to recycle 2‐propanol from the aqueous solution, which brings great consumption of 2‐propanol during the purification process. A major contribution of this work is to provide a simple way to reduce the consumption via recycling of 2‐propanol during the purification process. The recycled 2‐propanol is available for precipitating NCs from aqueous solution in a new round of NC purification process. Due to the recycling of 2‐propanol, the great consumption of 2‐propanol can be avoided, which makes the purification process of aqueous NCs much greener and at a much lower cost.     

Triple‐pulse Method for Monitoring Formate in CO2 Conversion Process

In CO₂‐to‐formic‐acid process, real‐time monitoring of formate is pivotal for the efficient control of the process. A stable sensing method that is suitable for measuring the high concentrations of formate produced during this process is required. Here, we developed a triple‐potential‐step method to monitor the formate in the range of 0.1 to 2.0 M and showed that a long‐term, continuous monitoring is possible. Among the Pd‐, Pt‐, and Au‐electrode materials tested, Au was the best option due to its low sensitivity and its stability in formate oxidation.     

Menthol

The biosynthesis of menthol comprises eight steps, starting from isopentenyl‐ and dimethylallyl diphosphate. On technical scale it is produced from cresol by the Haarmann‐Reimer‐process. The enantiomers are separated by crystallization. The Takasago‐Menthol‐process is one of the most famous enantioselective industrial processes. The key step is a rhodium‐catalyzed double‐bond migration. BASF's new menthol process, which is based on citral, includes an enantioselective hydrogenation.     

Osmotically Driven Formation of Double Emulsions Stabilized by Amphiphilic Block Copolymers

Double emulsions are valuable for the formation of multi‐compartmental structures. A variety of pathways to prepare double emulsions have been developed, but high‐throughput routes to droplets of controlled size and architecture remain scarce. A new single‐step process is introduced for preparation of water‐in‐oil‐in‐water double emulsions by a previously unexplained process of self‐emulsification. We show that the origin of this process is the osmotic stress resulting from the presence of salt impurities within the amphiphilic block copolymers used for emulsion stabilization. Further, we utilize osmotically driven emulsification to tailor the structures of multiple emulsions, which upon solvent evaporation can yield multi‐compartmental capsules or hierarchically structured porous films.     

A Combined Transition‐Metal‐Catalyzed and Photopromoted Process: Synthesis of 2,3‐Fused 4‐Phenylnaphthalen‐1‐yl Carboxylates from 1,7‐Diaryl‐1,6‐diynes

2,3‐Fused 4‐phenylnaphthalen‐1‐yl carboxylates were synthesized in a step‐ and atom‐economical manner using a ruthenium‐catalyzed hydrocarboxylative cyclization of 1,7‐diaryl‐1,6‐diynes and subsequent oxidative photocyclization. The scope of this novel two‐step process was demonstrated by the construction of diverse structures from substrates with various tethers and terminal aryl groups. Late‐stage C?H functionalizations of the arylnaphthalene product further enhance the synthetic potential of the developed process.     

Direct Measurement of Single‐Molecule DNA Hybridization Dynamics with Single‐Base Resolution

Herein, we report label‐free detection of single‐molecule DNA hybridization dynamics with single‐base resolution. By using an electronic circuit based on point‐decorated silicon nanowires as electrical probes, we directly record the folding/unfolding process of individual hairpin DNAs with sufficiently high signal‐to‐noise ratio and bandwidth. These measurements reveal two‐level current oscillations with strong temperature dependence, enabling us to determine the thermodynamic and kinetic properties of hairpin DNA hybridization. More importantly, successive, stepwise increases and decreases in device conductance at low temperature on a microsecond timescale are successfully observed, indicating a base‐by‐base unfolding/folding process. The process demonstrates a kinetic zipper model for DNA hybridization/dehybridization at the single base‐pair level. This measurement capability promises a label‐free single‐molecule approach to probe biomolecular interactions with fast dynamics.     

Interstate Crossing‐Induced Chemiexcitation as the Reason for the Chemiluminescence of Dioxetanones

The decomposition reaction of dimethyl‐1,2‐dioxetanone in dichloromethane was studied by using a DFT approach. The low efficiency of triplet and singlet excited‐state formation was rationalised. A charge‐transfer process was demonstrated to be involved in the chemiluminescence process. Present and previous results allow us to define an interstate crossing‐induced chemiexcitation (ICIC) mechanism for the chemiluminescence of dioxetanones. Charge transfer is needed to reach a transition state, in the vicinity of which direct population of excited states is possible. The chemiexcitation process is then governed by singlet/triplet intersystem crossings. Structural modifications then modify the rate of these crossings and the singlet ground and excited‐state interaction, thereby modulating the efficiency of this process and the spin of the resulting products.     

Shear induced clay organo‐modification: application to plasticized starch nano‐biocomposites

The present paper reports the successful development of a straightforward clay organo‐modification protocol named “Shear Induced Clay Organo‐modification” process, or SICO. To develop such a fast process, natural montmorillonite has been organo‐modified with cationic starch (surfactant) under shearing. According to the obtained results, this process allows the preparation of a pre‐exfoliated montmorillonite, organo‐modified by cationic starch (OMMT‐CS). Then, the OMMT‐CS has been dispersed into different plasticized starch‐based plastics, varying the polysaccharide botanical source, to obtain nano‐biocomposites displaying an exfoliated morphology. To establish the efficiency of this protocol and highlight this nano‐structuration, uniaxial tensile tests have been performed on these materials. The mechanical properties have been compared with those obtained with nano‐biocomposites elaborated with OMMT‐CS prepared with the conventional and efficient Exfoliation/Adsorption technique. Since comparable properties are obtained, we assume that the SICO process is a powerful technique to easily and quickly organo‐modify the montmorillonite clay and to obtain exfoliated nano‐biocomposites. Copyright © 2009 John Wiley & Sons, Ltd.     

Recent progress in separation prediction of counter‐current chromatography

As a liquid‐liquid partition chromatography, counter‐current chromatography has advantages in large sample loading capacity without irreversible adsorption, which has been widely applied in separation and purification fields. The main factors, including partition coefficient, two‐phase solvent systems, apparatus, and operating parameters greatly affect the separation process of counter‐current chromatography. To promote the applications of counter‐current chromatography, it is essential to develop theoretical research to master the principles of counter‐current chromatographic separations so as to achieve predictions before laborious trials. In this article, recent progress about separation prediction methods are reviewed from a point of the steady and unsteady state of the mass transfer process of counter‐current chromatography and its mass transfer characteristics, and then it is divided into three aspects: prediction of partition coefficient, modeling the thermodynamic process of counter‐current chromatography, and modeling the dynamic process of counter‐current chromatography.     

Experimental evaluation of the effect of a modified port‐location mode on the performance of a three‐zone simulated moving‐bed process for the separation of valine and isoleucine

The removal of isoleucine from valine has been a key issue in the stage of valine crystallization, which is the final step in the valine production process in industry. To address this issue, a three‐zone simulated moving‐bed (SMB) process for the separation of valine and isoleucine has been developed previously. However, the previous process, which was based on a classical port‐location mode, had some limitations in throughput and valine product concentration. In this study, a three‐zone SMB process based on a modified port‐location mode was applied to the separation of valine and isoleucine for the purpose of making a marked improvement in throughput and valine product concentration. Computer simulations and a lab‐scale process experiment showed that the modified three‐zone SMB for valine separation led to >65% higher throughput and >160% higher valine concentration compared to the previous three‐zone SMB for the same separation.     

Palladium‐Catalyzed Intramolecular CH Difluoroalkylation: Synthesis of Substituted 3,3‐Difluoro‐2‐oxindoles

The synthesis of 3,3‐difluoro‐2‐oxindoles through a robust and efficient palladium‐catalyzed C? H difluoroalkylation is described. This process generates a broad range of difluorooxindoles from readily prepared starting materials. The use of BrettPhos as the ligand was crucial for high efficiency. Preliminary mechanistic studies suggest that oxidative addition is the rate‐determining step for this process.     

Palladium‐Catalyzed Intramolecular C?H Difluoroalkylation: Synthesis of Substituted 3,3‐Difluoro‐2‐oxindoles

The synthesis of 3,3‐difluoro‐2‐oxindoles through a robust and efficient palladium‐catalyzed C H difluoroalkylation is described. This process generates a broad range of difluorooxindoles from readily prepared starting materials. The use of BrettPhos as the ligand was crucial for high efficiency. Preliminary mechanistic studies suggest that oxidative addition is the rate‐determining step for this process.     

The investigation of proton transfer and fluorescence‐sensing mechanisms of [2‐(2‐hydroxy‐phenyl)‐1H‐benzoimidazol‐5‐yl]‐phenyl‐methanone

Given the tremendous potential of fluorescence sensors in recent years, in this present work, we theoretically explore a novel fluorescence chemosensor [2‐(2‐Hydroxy‐phenyl)‐1H‐benzoimidazol‐5‐yl]‐phenyl‐methanone (HBPM) about its excited state behaviors and probe‐response mechanism. Using density functional theory (DFT) and time‐dependent density functional theory (TDDFT) methods, we explore the S₀‐state and S₁‐state hydrogen bond dynamical behaviors and confirm that the strengthening intramolecular hydrogen bond in the S₁ state may promote the excited state intramolecular proton transfer (ESIPT) reaction. In view of the photoexcitation process, we find that the charge redistribution around the hydroxyl moiety plays important roles in providing driving force for ESIPT. And the constructed potential energy curves further verify that the ESIPT process of HBPM should be ultrafast. That is the reason why the normal HBPM fluorescence cannot be detected in previous experiment. Furthermore, with the addition of fluoride anions, the exothermal deprotonation process occurs spontaneously along with the intermolecular hydrogen bond O–H?F. It reveals the uniqueness of detecting fluoride anions using HBPM molecules. As a whole, the fluoride anions inhibit the initial ESIPT process of HBPM, which results in different fluorescence behaviors. This work presents the clear ESIPT process and fluoride anion‐sensing mechanism of a novel HBPM chemosensor.     

Development of a Simple Adjustable Zinc Acid/Base Hybrid Catalyst for C−C and C−O Bond‐Forming and C−C Bond‐Cleavage Reactions

A newly designed zinc Lewis acid/base hybrid catalyst was developed. By adjusting the Lewis acidity of the zinc center, aldol‐type additions of 2‐picolylamine Schiff base to aldehydes proceeded smoothly to afford syn‐aldol adduct equivalents, trans‐N,O‐acetal adducts, in high yields with high selectivities. NMR experiments, including microchanneled cell for synthesis monitoring (MICCS) NMR analysis, revealed that anti‐aldol adducts were formed at the initial stage of the reactions under kinetic control, but the final products were the trans‐(syn)‐N,O‐acetal adducts that were produced through a retro‐aldol process under thermodynamic control. In the whole reaction process, the zinc catalyst played three important roles: i) promotion of the aldol process (C?C bond formation), ii) cyclization process to the N,O‐acetal product (C?O bond formation), and iii) retro‐aldol process from the anti‐aldol adduct to the syn‐aldol adduct (C?C bond cleavage and C?C bond formation).     

A study on the innovative microlens projection lithography applied to the production of microstructures

Microlens projection lithography is a kind of non‐contact projection lithography that uses microlens array components as the projection lenses to produce a large area of microstructural array patterns on photoresisting film. This technology requires partial masking of light on the non‐lens portion of the microlens array, and the conventional approach is through an aligned exposure followed by the plating process that would require accurate positioning equipment, so it is naturally time‐consuming as well as costly in terms of the entire production process. This study applies an innovative technology in the production process that uses a microcircular‐hole array to penetrate a stainless‐steel substrate as the mold, and in collaboration with gas‐assisted thermal pressuring production process that utilizes surface tension of the plastic film to fabricate the hemisphere‐shaped plastic microlens array that is capable of masking light as the projection lens. With such a lens, in collaboration with optic expansion film, Fresnel lens, and millimeter‐grade single‐pattern photomasks, the microlens array projection lithographical optical system is constructed. Using regular millimeter‐grade photomasks, a micrometer‐grade array pattern is successfully fabricated on the photoresist layer through the process of projection exposure and development using such a microlens array projection lithographical optical system. Copyright © 2007 John Wiley & Sons, Ltd.     

Mechanism of Crystalline Self‐Assembly in Aqueous Medium: A Combined Cryo‐TEM/Kinetic Study

Understanding the crystallization of organic molecules is a long‐standing challenge. Herein, a mechanistic study on the self‐assembly of crystalline arrays in aqueous solution is presented. The crystalline arrays are assembled from perylene diimide (PDI) amphiphiles bearing a chiral N‐acetyltyrosine side group connected to the PDI aromatic core. A kinetic study of the crystallization process was performed using circular dichroism spectroscopy combined with time‐resolved cryogenic transmission electron microscopy (cryo‐TEM) imaging of key points along the reaction coordinate, and molecular dynamics simulation of the initial stages of the assembly. The study reveals a complex self‐assembly process starting from the formation of amorphous aggregates that are transformed into crystalline material through a nucleation–growth process. Activation parameters indicate the key role of desolvation along the assembly pathway. The insights from the kinetic study correlate well with the structural data from cryo‐TEM imaging. Overall, the study reveals four stages of crystalline self‐assembly: 1) collapse into amorphous aggregates; 2) nucleation as partial ordering; 3) crystal growth; and 4) fusion of smaller crystalline aggregates into large crystals. These studies indicate that the assembly process proceeds according to a two‐step crystallization model, whereby initially formed amorphous material is reorganized into an ordered system. This process follows Ostwald’s rule of stages, evolving through a series of intermediate phases prior to forming the final structure, thus providing an insight into the crystalline self‐assembly process in aqueous medium.     

New Synthesis of Donepezil Through Palladium‐Catalyzed Hydrogenation Approach

A new, economical, and efficient process has been developed for large‐scale synthesis of donepezil 1, an anti‐Alzheimer's drug. The process involves palladium‐catalyzed hydrogenation of (2E)‐5,6‐dimethoxy‐2‐(pyridin‐4‐ylmethylene)indan‐1‐one 6 to provide 5,6‐dimethoxy‐2‐(piperidin‐4‐ylmethyl)indan‐1‐one 8 as a key step.     

Self‐Assembly of Metal–Organic Frameworks into Monolithic Materials with Highly Controlled Trimodal Pore Structures

We present a two‐step template‐free approach toward monolithic materials with controlled trimodal porous structures with macro‐, meso‐, and micropores. Our method relies on two ordering processes in discrete length scales: 1) Spontaneous formation of macroporous structures in monolithic materials by the sol–gel process through the short‐range ordered self‐assembly of metal–organic frameworks (MOFs), and 2) reorganization of the framework structures in a mediator solution. The Zr‐terephthalate‐based MOF (UiO‐66‐NH₂) was adopted as a proof of concept. The self‐assembly‐induced phase separation process offered interconnected macropores with diameters ranging from 0.9 to 1.8 μm. The subsequent reorganization process converted the microporous structure from low crystalline framework to crystalline UiO‐66. The resultant mesopore size within the skeletons was controlled in the range from 9 to 21 nm. This approach provides a novel way of designing spaces from nano‐ to micrometer scale in network‐forming materials.