Batch Operations for Chemical Processes

For many companies, a batch process is a black box. Follow the recipe, hope for the best, and you get what you get. When an exceptionally good batch is produced, the question becomes, “How do we do this every time?” Unfortunately, there is rarely sufficient data to determine why this particular batch was ideal, leading to continuance of this trial-and-error methodology of identifying where and how elements of the process change. 

The answer is yes, because with the right control strategy, batch processing is not a black box. A first step is to determine how the process is progressing. Is the batch reaction rate too slow? Is some variability to a feedstock affecting the process? Do we need to make a mid-stream temperature or pressure adjustment to get things back on track? These are all part of Emerson’s approach, and using it properly results in much improved consistency from batch to batch. This is much more effective than trying to pick apart a single golden batch result. 

This can be related to many causes, such as feedstock variability, inadequate instrumentation leading to inconsistent processing, and lack of operator training with manual processes. Emerson’s batch control strategy finds and eliminates these sources of inconsistency, making the process more reliable and predictable.