henk-jan van manen - fhi

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


ContactAns van de Bovenkamp+31 622 394 [email protected]

mailto:[email protected]

Improve the efficiency,safety and sustainabilityof your production process

Process AnalyticalTechnology


ContactHenk-Jan van Manen+31 570 679 [email protected]


The interface of synthesis,organic & inorganicchemistry andmaterials science

Molecules & MaterialsTechnology


ContactDimitri van Agterveld+31 570 679 [email protected]


The ideation, conceptualdesign, development,scale-up, and optimizationof processes

ProcessTechnology


ContactGerrald Bargeman+31 570 679 [email protected]


Societal Challenges and

the Chemical Industry


EU Horizon 2020 Societal Challenges

= addressed by SoS programme


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


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


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


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


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


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


4 L scale – Deventer

In-line NIR feasibility studies in the pilot plant


25 L scaleBrewster (US)

Exploratory multivariate data analysis


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


1. Raw NIR data

3. Preprocessed data

4. PLSregression

2. Primary methoddata

Total Amine

5. Multivariate PLSmodel

Implementation in the plant: Hardware


• 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


• 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


• 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


• 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

henk-jan van manen - fhi

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