Control method and control device for flow type reaction device

Abstract

Provided is a method for controlling a flow-type reaction device having a plurality of reaction fields in which two or more types of chemical substances as raw materials are continuously supplied, respectively, and the raw materials are mixed and chemically reacted, the flow-type reaction device switching between an operating reaction field and a standby reaction field, the control method comprises the following steps: acquiring priorities respectively corresponding to each reaction field; and a step of determining the reaction field to be operated according to the priority determined on the basis of the use performance data of each reaction field.

Description

Cross-reference of related applications

[0001] This application claims priority to Japanese Patent Application No. 2023-135030, filed on August 22, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates to a control method and control device for a flow-type reaction device. Background Technology

[0003] Traditionally, methods for manufacturing chemical substances typically employ batch reactions, which require vigorous stirring to achieve molecular diffusion (stagnant eddy diffusion), resulting in lengthy chemical reaction times. Furthermore, as production volume increases, i.e., as the reaction furnace grows larger, the difficulty of controlling the chemical reaction also increases.

[0004] Against this backdrop, flow reactors, as manufacturing devices characterized by higher yields, lower costs, and greater safety compared to batch reactions, have attracted attention. Furthermore, flow reactors offer the advantage of easily scaling up and improving redundancy by incorporating multiple (increased) reaction fields.

[0005] Patent Document 1 discloses a microchemical reaction system comprising multiple microchemical chips serving as reaction fields. In this system, when an anomaly occurs in a particular reaction field, the supply of raw materials to that reaction field is stopped, and raw materials are supplied to a backup reaction field instead, thereby enabling continued manufacturing (production) without altering the yield per unit time.

[0006] (Existing technical documents)

[0007] (Patent Documents)

[0008] Patent Document 1: Japanese Patent Application Publication No. 2007-222849 Summary of the Invention

[0009] (The problem that the invention aims to solve)

[0010] Switching to a backup reaction field is an advantage of flow reactors. However, a system for controlling this switching has not yet been developed. Patent Document 1 proposes a reactor system with four reaction fields, using three as regular operating fields and one as a backup to improve redundancy. However, operating the system in this manner results in differences in operating times between the regular and backup reaction fields. Furthermore, when multiple backup reaction fields are present and switching from the regular reaction field is required as needed, the switching pattern becomes complex, necessitating the development of a control system for precise control—something not described in the aforementioned prior art.

[0011] Furthermore, in reaction systems that precipitate solids or generate corrosive gases, regular equipment maintenance (such as cleaning and replacement of consumables) may be required. In systems with predetermined operating reaction fields as described in the prior art, a difference in cumulative operating time between operating and standby reaction fields is foreseeable. Performing overall equipment maintenance would result in maintenance being carried out on reaction fields with low usage frequency and no need for cleaning or component replacement, which is economically undesirable. Maintaining each reaction field separately would lead to prolonged equipment downtime or increased labor costs due to dispersed maintenance periods, which is also undesirable.

[0012] Furthermore, the switching mode to the backup reaction site is determined by the number of reaction sites the system carries. For example, in a system with four reaction sites and using two of them for manufacturing, such as... Figure 1A and Figure 1B As shown, it has 48 switching modes. Writing control programs that cover all switching modes would be extremely time-consuming and labor-intensive in terms of production and debugging; therefore, a simpler program format is needed. This demonstrates that there is still room for improvement in the control technology of flow reactors.

[0013] The purpose of this disclosure is to improve the control technology of flow reaction devices.

[0014] (The measures taken to solve the problem)

[0015] Some of the methods disclosed herein are as follows. [one]

[0017] A control method for a flow reaction apparatus, the flow reaction apparatus having multiple reaction fields for continuously supplying two or more chemical substances as raw materials, mixing the raw materials, and carrying out chemical reactions, and for switching between operating reaction fields and standby reaction fields, characterized in that the control method includes:

[0018] Obtain the priority corresponding to each reaction field; and

[0019] Based on the stated priority, determine the reaction sites to be operated.

[0020] The priority was determined based on the actual performance data of each reaction site. [two]

[0022] In the control method described in [a], the actual usage data includes at least one of the cumulative usage time and the cumulative number of uses for each reaction site. [three]

[0024] In the control method described in [II], the priority is updated by updating at least one of the cumulative usage time and the cumulative number of uses based on the operating status of the reaction field. [Four]

[0026] In the control method described in [a], the priority is also determined based on the characteristic data of each reaction field. [five]

[0028] In the control method described in [a], if an abnormality is detected in the operating reaction field, the operation of the reaction field whose abnormality was detected is stopped, and the priority of the reaction fields whose abnormality was not detected is increased. [six]

[0030] In the control method described in [a], the control program for executing the control method includes subroutines. [seven]

[0032] A control device for controlling a flow reaction apparatus, comprising a control unit, wherein the flow reaction apparatus has multiple reaction fields for continuously supplying two or more chemical substances as raw materials, mixing the raw materials, and carrying out chemical reactions, and for switching between operating reaction fields and standby reaction fields, characterized in that...

[0033] The control unit acquires the priority corresponding to each reaction field and determines the reaction field to be operated based on the priority.

[0034] The priority was determined based on the actual performance data of each reaction site.

[0035] (The effect of the invention)

[0036] According to this disclosure, the control technology of flow reaction devices can be improved. Attached Figure Description

[0037] Figure 1A This is a conceptual diagram of the switching mode.

[0038] Figure 1B This is a conceptual diagram of the switching mode.

[0039] Figure 2 A diagram illustrating the architecture of a system according to embodiments of this disclosure.

[0040] Figure 3 A diagram illustrating the architecture of the control device contained in the system according to embodiments of this disclosure.

[0041] Figure 4 A flowchart illustrating the control method involved in the embodiments of this disclosure is provided.

[0042] Figure 5 A diagram illustrating an example of the main program's flow.

[0043] Figure 6 A diagram illustrating an example of the flow of a subroutine.

[0044] Figure 7 Here is an example of a user interface related to priority.

[0045] Figure 8 A diagram showing an example of a table referenced by a subroutine.

[0046] Figure 9 Here is an example of content using actual performance data.

[0047] Figure 10 A diagram illustrating an example of the state of a system according to an embodiment of this disclosure.

[0048] Figure 11 A diagram illustrating an example of the state of a system according to an embodiment of this disclosure.

[0049] Figure 12 A diagram illustrating an example of the state of a system according to an embodiment of this disclosure. Detailed Implementation

[0050] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings.

[0051] In the accompanying drawings, the same or corresponding parts are labeled with the same reference numerals. In the description of this embodiment, the description of the same or corresponding parts will be appropriately omitted or simplified.

[0052] Reference Figure 2 The architecture of system 1 involved in this embodiment will be explained.

[0053] System 1 includes a flow reactor 100 and a control device 200. The flow reactor 100 and the control device 200 are connected in a communicable manner via a network or the like.

[0054] The flow reactor 100 is characterized by having multiple reaction sites for continuously supplying two or more chemical substances as raw materials, mixing the raw materials, and carrying out chemical reactions, and for switching between operating reaction sites and standby reaction sites. The control device 200 is, for example, a computer, such as a general-purpose electronic device or a dedicated electronic device. The control device 200 is capable of communicating with the flow reactor 100 via a network. The control device 200 performs controls related to the flow reactor 100, namely, controls for switching between the operating reaction sites and standby reaction sites within the flow reactor 100.

[0055] First, an overview of this embodiment will be given; details will follow. The control device 200 acquires the priority corresponding to each reaction site. The control device 200 determines the reaction site to be operated based on the priority. Here, the priority is determined based on usage record data of each reaction site.

[0056] Thus, according to this embodiment, the reaction sites to be operated are determined based on the priority determined by the usage performance data of each reaction site. Therefore, since it is possible to appropriately switch between the operating reaction site and the standby reaction site while taking into account the usage performance data of each reaction site, the control technology of the flow reactor with reaction sites is improved.

[0057] (Architecture of the flow reactor 100)

[0058] like Figure 2 As shown, the flow reaction apparatus 100 includes: a gas cylinder 101, a pressure reducing valve 102, a storage tank 103, a liquid transfer pump 104, reaction fields 120, 130, 140, and 150, and a post-reaction fluid collection section 160. Reaction fields 120, 130, 140, and 150 are also referred to herein as reaction field a, reaction field b, reaction field c, and reaction field d, respectively. Furthermore, an example of the flow reaction apparatus 100 having four reaction fields is shown here, but the number of reaction fields is not limited to this. The number of reaction fields can be less than four or more than five.

[0059] Cylinder 101 is used to store the first raw material. Here, the first raw material is a gas, and the following explanation uses a gaseous example as the first raw material. Pressure reducing valve 102 is a valve that supplies the first raw material in cylinder 101 to the reaction site at any pressure and flow rate. Alternatively, pressure reducing valve 102 can be replaced by a throttle needle valve, a bellows valve, a pressure regulating system consisting of a combined pressure gauge and an automatic valve, or a cylinder cabinet.

[0060] Storage tank 103 is used to store a second raw material. Here, the second raw material is a liquid, and the following description uses an example where the second raw material is a liquid. Liquid transfer pump 104 is a pump that supplies the second raw material in storage tank 103 to the reaction site at any pressure and flow rate. Liquid transfer pump 104 can be, for example, a diaphragm pump, plunger pump, piston pump, reciprocating pump, rotary pump, non-positive displacement pump, etc.

[0061] The reaction field 120 (reaction field a) includes: a flow meter 121, a flow meter 122, a mixing unit 123, a reaction unit 124, and a shut-off valve 125. The flow meter 121 can control the flow rate of the first raw material. The flow meter 121 only needs to control the gas flow rate, for example, it can be a mass flow meter (mass flow controller, MFC). The flow meter 122 can control the flow rate of the second raw material. The flow meter 122 only needs to control the liquid flow rate, for example, it can be a combination of a flow measuring instrument (Coriolis flow meter, ultrasonic flow meter) and a flow regulating valve (needle valve, bellows valve, ball valve).

[0062] The mixing unit 123 is a mixer used to mix the first raw material and the second raw material. The mixing unit 123 can be used to mix multiple raw materials, for example, it can be a T-type mixer or a Y-type mixer.

[0063] The reaction section 124 is a reactor used to react the raw materials mixed in the mixer 123. The diameter and length of the reaction section 124 can be arbitrarily changed according to the type of reaction. For example, in the case of an exothermic reaction, heat dissipation to the outside can be promoted by reducing the diameter. In reaction systems with extremely short reaction times, the length of the reactor can be shortened, or the reactor can be omitted.

[0064] The shut-off valve 125 is used to isolate the reaction section 124 from the post-reaction fluid manifold 160. The shut-off valve 125 only needs to be able to isolate the fluid; for example, a diaphragm valve or a bellows valve can be used. Although ball valves and the like have lower shut-off capacity compared to diaphragm valves, they can be used in reactions that produce solids to prevent leakage.

[0065] Reaction field 130 (reaction field b) includes: flow meter 131, flow meter 132, mixing unit 133, reaction unit 134, and shut-off valve 135. Flow meter 131 controls the flow rate of the first raw material. Flow meter 131 only needs to control the gas flow rate; for example, it can be a mass flow meter (mass flow controller, MFC). Flow meter 132 controls the flow rate of the second raw material. Flow meter 132 only needs to control the liquid flow rate; for example, it can be a combination of a flow meter (Coriolis flow meter, ultrasonic flow meter) and a flow regulating valve (needle valve, bellows valve, ball valve).

[0066] The mixing unit 133 is a mixer for mixing the first raw material and the second raw material. The mixing unit 133 can be any type of mixer capable of mixing multiple raw materials, such as a T-type mixer or a Y-type mixer.

[0067] The reaction section 134 is a reactor used to react the raw materials mixed in the mixer 133. The diameter and length of the reaction section 134 can be arbitrarily changed according to the type of reaction. For example, in the case of an exothermic reaction, heat dissipation to the outside can be promoted by reducing the diameter. In reaction systems with extremely short reaction times, the length of the reactor can be shortened, or the reactor can be omitted.

[0068] The shut-off valve 135 is used to isolate the reaction section 134 from the post-reaction fluid manifold 160. The shut-off valve 135 only needs to be able to isolate the fluid; for example, a diaphragm valve or a bellows valve can be used. Although ball valves and the like have lower shut-off capacity compared to diaphragm valves, they can be used in reactions that produce solids to prevent leakage.

[0069] The reaction field 140 (reaction field c) includes: a flow meter 141, a flow meter 142, a mixing unit 143, a reaction unit 144, and a shut-off valve 145. The flow meter 141 can control the flow rate of the first raw material. The flow meter 141 only needs to control the gas flow rate; for example, it can be a mass flow meter (mass flow controller, MFC). The flow meter 142 can control the flow rate of the second raw material. The flow meter 142 only needs to control the liquid flow rate; for example, it can be a combination of a flow meter (Coriolis flow meter, ultrasonic flow meter) and a flow regulating valve (needle valve, bellows valve, ball valve).

[0070] The mixing unit 143 is a mixer for mixing the first raw material and the second raw material. The mixing unit 143 can be used to mix multiple raw materials, for example, it can be a T-type mixer or a Y-type mixer.

[0071] The reaction section 144 is a reactor used to react the raw materials mixed in the mixer 143. The diameter and length of the reaction section 144 can be arbitrarily changed according to the type of reaction. For example, in the case of an exothermic reaction, heat dissipation to the outside can be promoted by reducing the diameter. In reaction systems with extremely short reaction times, the length of the reactor can be shortened, or the reactor can be omitted.

[0072] The shut-off valve 145 is used to isolate the reaction section 144 from the post-reaction fluid manifold 160. The shut-off valve 145 only needs to be able to isolate the fluid; for example, a diaphragm valve or a bellows valve can be used. Although ball valves and the like have lower shut-off capacity compared to diaphragm valves, they can be used in reactions that produce solids to prevent leakage.

[0073] The reaction field 150 (reaction field d) includes: flow meter 151, flow meter 152, mixing unit 153, reaction unit 154, and shut-off valve 155. Flow meter 151 controls the flow rate of the first raw material. Flow meter 151 only needs to control the gas flow rate; for example, it can be a mass flow meter (mass flow controller, MFC). Flow meter 152 controls the flow rate of the second raw material. Flow meter 152 only needs to control the liquid flow rate; for example, it can be a combination of a flow meter (Coriolis flow meter, ultrasonic flow meter) and a flow regulating valve (needle valve, bellows valve, ball valve).

[0074] The mixing unit 153 is a mixer for mixing the first raw material and the second raw material. The mixing unit 153 can be any type of mixer capable of mixing multiple raw materials, such as a T-type mixer or a Y-type mixer.

[0075] The reaction section 154 is a reactor used to react the raw materials mixed in the mixer 153. The diameter and length of the reaction section 154 can be arbitrarily changed according to the type of reaction. For example, in the case of an exothermic reaction, heat dissipation to the outside can be promoted by reducing the diameter. In reaction systems with extremely short reaction times, the length of the reactor can be shortened, or the reactor can be omitted.

[0076] The shut-off valve 155 is used to isolate the reaction section 154 from the post-reaction fluid manifold 160. The shut-off valve 155 only needs to be able to isolate the fluid; for example, a diaphragm valve or a bellows valve can be used. Although ball valves and the like have lower shut-off capacity compared to diaphragm valves, they can be used in reactions that produce solids to prevent leakage.

[0077] The post-reaction fluid manifold 160 is used to collect the fluid discharged from the shut-off valves 125, 135, 145, and 155 of each reaction site. For example, the post-reaction fluid manifold 160 can be a pipeline, storage tank, etc.

[0078] (Architecture of control device 200)

[0079] like Figure 3 As shown, the control device 200 includes: a control unit 201, a storage unit 202, a communication unit 203, an input unit 204, and an output unit 205.

[0080] The control unit 201 includes at least one processor, at least one dedicated circuit, or a combination thereof. The processor is a general-purpose processor such as a CPU (central processing unit) or GPU (graphics processing unit), or a dedicated processor for specific processing. The dedicated circuit is, for example, an FPGA (field-programmable gate array) or an ASIC (application-specific integrated circuit). The control unit 201 controls various parts of the control device 200 to perform processing related to the operation of the control device 200.

[0081] The storage unit 202 includes at least one semiconductor memory, at least one magnetic memory, at least one optical memory, or a combination of at least two of these. The semiconductor memory is, for example, RAM (random access memory) or ROM (read-only memory). The RAM is, for example, SRAM (static random access memory) or DRAM (dynamic random access memory). The ROM is, for example, EEPROM (electrically erasable programmable read-only memory). The storage unit 202 functions as, for example, a main storage device, an auxiliary storage device, or a cache memory. The storage unit 202 stores data used for the operation of the control device 200 and data obtained from the operation of the control device 200.

[0082] The communication unit 203 includes at least one external communication interface. The communication interface can be any interface used in wired or wireless communication. In the case of wired communication, the communication interface is, for example, a LAN (Local Area Network) interface or a USB (Universal Serial Bus) interface. In the case of wireless communication, the communication interface is, for example, an interface corresponding to mobile communication standards such as LTE (Long Term Evolution), 4G (4th generation), or 5G (5th generation), or an interface corresponding to short-range wireless communication such as Bluetooth. The communication unit 203 receives data used for the operation of the control device 200 and transmits data obtained from the operation of the control device 200.

[0083] The input unit 204 includes at least one input interface. The input interface can be, for example, a physical keyboard, an electrostatic capacitive keyboard, a pointing device, or a touchscreen integrated with the display. Alternatively, the input interface can be, for example, a microphone for receiving voice input or a camera for receiving gesture input. The input unit 204 accepts operations for inputting data used in actions of the control device 200. The input unit 204 may not be present in the control device 200, but may be connected to the control device 200 as an external input device. As for the connection method, any method can be used, such as USB (Universal Serial Bus), HDMI (High-Definition Multimedia Interface), or Bluetooth.

[0084] The output unit 205 includes at least one output interface. The output interface may be, for example, a display that outputs information in the form of images, or a speaker that outputs information in the form of sound. The display may be, for example, an LCD (liquid crystal display) or an organic EL (electro luminescence) display. The output unit 205 displays data obtained from the operation of the control device 200. The output unit 205 may not be present in the control device 200, but may be connected to the control device 200 as an external output device. As for the connection method, any method may be used, such as USB, HDMI (registered trademark), or Bluetooth (registered trademark).

[0085] The functions of the control device 200 are realized by executing the program according to this embodiment by a processor, which is equivalent to the control device 200. That is, the functions of the control device 200 are implemented by software. The program causes the computer to perform the actions of the control device 200, thereby enabling the computer to function as the control device 200. In other words, the computer performs the actions of the control device 200 according to the program, thereby functioning as the control device 200.

[0086] In this embodiment, the computer temporarily stores a program recorded on a portable recording medium or a program from a server into the main storage device. The computer then uses its processor to read the program stored in the main storage device and executes processing according to the read program. Alternatively, the computer can directly read a program from a portable recording medium and execute processing according to that program. The computer can also execute processing according to the received program each time it receives a program from an external server. Alternatively, instead of sending the program from an external server to the computer, processing can be performed through a so-called ASP (Application Service Provider) type service, where the ASP performs its function solely by executing instructions and retrieving results. The program includes information equivalent to the program used by the computer for processing. For example, data that is not a direct instruction to the computer but has the nature of specifying the computer's processing is considered "information equivalent to the program."

[0087] In this embodiment, the program can be recorded on a computer-readable recording medium. Computer-readable recording media include non-transitory computer-readable media, such as magnetic recording devices, optical discs, magneto-optical recording media, or semiconductor memory. Distribution of the program is achieved, for example, by selling, transferring, or lending portable recording media such as DVDs (digital versatile discs) or CD-ROMs (compact disc read-only memory) containing the program. Alternatively, the program can be distributed by storing it in the storage device of an external server and then sending the program from the external server to other computers. Furthermore, the program can also be provided as a program product.

[0088] Some or all of the functions of the control device 200 can also be implemented by a dedicated circuit equivalent to the control unit 201. That is, some or all of the functions of the control device 200 can be implemented by hardware.

[0089] (Action of System 1)

[0090] The operation of System 1 according to this embodiment will be described below. Figure 4This is a flowchart illustrating an example of the control performed by the control device 200 according to this embodiment.

[0091] Step S1: The control unit 201 of the control device 200 acquires the priority corresponding to each reaction field (here, reaction field a, reaction field b, reaction field c, and reaction field d). Here, the priority is determined based on the usage performance data of each reaction field. The usage performance data includes, for example, the cumulative usage time of each reaction field. That is, for example, the shorter the cumulative usage time, the higher the determined priority. In addition, the usage performance data may also include, for example, the cumulative number of times each reaction field is used. In this embodiment, the case where the usage performance data includes the cumulative usage time and the cumulative number of times each reaction field is used will be described.

[0092] The priority can be obtained using any method. For example, the storage unit 202 can store priority information for each reaction field, and the control unit 201 can obtain the priority from the storage unit 202. Alternatively, an external device can also store priority information for each reaction field. In this case, the control unit 201 can obtain the priority from the external device via the communication unit 203.

[0093] Step S2: The control unit 201 determines the reaction sites to be run based on the acquired priorities. That is, the control unit 201 determines the reaction sites with high priorities (here, the reaction sites with priorities of 1st and 2nd) as the reaction sites to be run. On the other hand, reaction sites with lower priorities than the high-priority reaction sites are determined as backup reaction sites. Then, the control unit 201 uses the determined reaction sites to implement the target reaction process.

[0094] Step S3: Control unit 201 updates the usage performance data of each reaction site. That is, it updates the usage performance data of the reaction sites determined and running in step S2. Specifically, for example, control unit 201 updates the usage performance data by adding the actual usage time to the cumulative usage time of each reaction site. Alternatively, control unit 201 updates the usage performance data by adding the cumulative number of uses of each reaction site. Furthermore, control unit 201 updates the priority based on the updated usage performance data. For example, control unit 201 updates the priority of each reaction site based on the cumulative usage time in the usage performance data, with shorter cumulative usage time indicating higher priority.

[0095] According to this embodiment, the reactor to be operated is determined based on the priority established by the usage performance data of each reactor. Therefore, by appropriately switching between the operating reactor and the standby reactor considering the usage performance data of each reactor, the control technology of the flow reactor is improved.

[0096] (Example of control program structure)

[0097] To implement the above control method, any control program structure can be adopted. For example, the control program used to execute the above control method may include a main program and a subroutine program. The main program mainly controls equipment other than those involved in reaction fields a, b, c, and d. That is, in this embodiment, the main program mainly controls the pressure reducing valve 102 and the liquid transfer pump 104. On the other hand, the subroutine controls reaction fields a, b, c, and d. That is, in this embodiment, the subroutine controls flow meters 121, 122, 125, 131, 132, 135, 141, 142, 145, 151, 152, and 155.

[0098] Figure 5 and Figure 6 The flowcharts for the main program and subroutines are shown separately. For example... Figure 5 As shown, the main program's operations are divided into three parts: Operation I to Operation III. Operation I includes steps S100 to S500. Operation II includes steps S600 and S700. Operation III includes step S800. The following describes examples of the main program and subroutines' actions.

[0099] (Example of actions in the main program)

[0100] Step S100: The main program causes the control unit 201 of the control device 200 to perform priority processing, prompting the user to input the priority of the reaction field to be used (hereinafter, also referred to as the target reaction field for manufacturing). Figure 5 For example, the example shows reaction fields a and b with priorities of 1 and 2, respectively. Here, priorities are numerical values ​​such as 1, 2, 3, or 4, with smaller values ​​indicating higher priorities. Furthermore, the priority entered here is considered the initial value. That is, regardless of the actual data used, the default priority is set through user input.

[0101] Step S200: The main program causes the control unit 201 to process the priority of prompting the user to input the backup reaction site (hereinafter, also referred to as the target reaction site for switching). Figure 5 The example shown illustrates scenarios where reaction fields c and d have priorities of 3 and 4, respectively. Furthermore, the priorities entered here are considered initial values. In other words, regardless of the actual data used, the default priorities are set through user input.

[0102] Step S300: The main program causes the control unit 201 to execute a process that selects the reaction field to use based on priority. Figure 5 In this process, reaction fields a and b are selected as the target reaction fields for manufacturing, and reaction fields c and d are selected as the target reaction fields for switching.

[0103] In steps S100 and S200, the priority input can be performed using any method. For example, the user interface can be displayed through the output unit 205, and the user input can be received through the input unit 204. Figure 7 An example of the user interface involved is shown. Figure 7 The example shows the case where reaction fields a and b are used at the start of manufacturing, and reaction fields c and d are set to switch target reaction fields.

[0104] Step S400: The main program causes the control unit 201 to perform a process to determine whether there is a problem with the input / processed value. If there is no problem and the selection of the target reaction field has been completed, the process proceeds to step S500. On the other hand, if there is a problem and the selection of the target reaction field has not been completed, the process returns to S100. A problem is defined as, for example, a reaction field being specified repeatedly in the process, or a priority not being specified.

[0105] Step S500: The main program causes the control unit 201 to begin controlling the pressure reducing valve 102 and the liquid transfer pump 104. Additionally, during this stage, since control of any reaction site has not yet begun, no raw material fluid is supplied to any reaction site.

[0106] Step S600: The main program causes the control unit 201 to execute a subroutine. The variable corresponding to the reaction field selected in step S300 as the target reaction field for manufacturing is passed to the subroutine as variable n (hereinafter also referred to as argument n). Here, it is assumed that the variables corresponding to reaction fields a, b, c, and d are a, b, c, and d, respectively. Figure 5 In step S300, since reaction fields a and b are selected as the target reaction fields for manufacturing, a and b become parameters n of the subroutine. Inputting a and b as parameters n initiates the subroutine's execution, and manufacturing is carried out in each reaction field (here, reaction field a and reaction field b). The subroutine will be described in detail later.

[0107] Step S700: The main program causes the control unit 201 to monitor the running status of the subroutine. If the subroutine has finished running, the process proceeds to step S800. On the other hand, if the subroutine has not finished running, the process waits for the subroutine to finish running.

[0108] Step S800: The main program causes the control unit 201 to stop controlling the pressure reducing valve 102 and the liquid transfer pump 104. Subsequently, the manufacturing process ends.

[0109] (Example of subroutine actions)

[0110] A subroutine is a program that controls the equipment for each reaction site. By referring to the value of parameter n entered in step S600 of the main program, the subroutine executes control of the target equipment. Here, the subroutine may refer to a table that associates parameter n with each piece of equipment in each reaction site. Figure 8 An example of a table referenced by a subroutine is shown. Figure 8 As shown, the table associates the values ​​of parameters corresponding to the reaction sites with the equipment involved in each reaction site (in this case, flow meters and shut-off valves). m1, m2, and l are local variables within the subroutine. Specifically, m1, m2, and l represent the first flow meter, the second flow meter, and the shut-off valve, respectively. In this embodiment, the variables m1 corresponding to flow meters 121, 131, 141, and 151 are 1, 3, 5, and 7, respectively. Furthermore, the variables m2 corresponding to flow meters 122, 132, 142, and 152 are 2, 4, 6, and 8, respectively. Furthermore, the variables l corresponding to shut-off valves 125, 135, 145, and 155 are 1, 2, 3, and 4, respectively. For example, when the parameter is 'a', the subroutine treats flow meters 121, 122, and shut-off valve 125 as controlled devices.

[0111] Figure 8 The table shown is stored, for example, in the storage unit 202 of the control device 200. The actions of each subroutine will be explained below. Here, we will use the example of inputting a and b into parameter n as an example.

[0112] Step S601: The subroutine causes the control unit 201 to begin controlling the flow meters corresponding to the local variables m1 and m2. Specifically, here, the control of flow meters 121 and 122, and flow meters 131 and 132 is started. If the control of each flow meter is started, the first raw material is supplied to the mixing unit 123 and the mixing unit 133.

[0113] Step S602: The subroutine causes the control unit 201 to perform a cumulative running time count. Specifically, the control unit 201 begins to accumulate the running time of reaction fields a and b, which are input to parameter n. The usage data (here, the cumulative number of uses and the cumulative running time) can be displayed through an interface such as a management screen. Figure 9 An example of content using performance data is shown.

[0114] Step S603: The subroutine causes the control unit 201 to perform a cumulative usage count. Specifically, the control unit 201 increments the cumulative usage count of reaction field a and reaction field b, which are inputs to parameter n.

[0115] Step S604: The subroutine causes the control unit 201 to begin controlling the shut-off valves corresponding to the local variable l. Specifically, here, control of shut-off valves 125 and 135 begins. That is, shut-off valves 125 and 135 are opened, and the reacted fluid flows through the reacted fluid manifold 160 and is transported to the subsequent process. Figure 10 This shows the current state of system 1. For example... Figure 10 As shown, control of flow meters 141 and 142, and flow meters 151 and 152 has not yet been initiated. Therefore, no raw materials are supplied to reaction sites c and d.

[0116] Step S605: The subroutine monitors the manufacturing completion status and abnormal status of the flow reaction apparatus 100. If an abnormality occurs in the reaction field, manufacturing continues by stopping the reaction field where the abnormality occurred and switching to the target reaction field. For example, the subroutine can use the following values ​​as trigger conditions to detect the manufacturing completion status.

[0117] • Low residual amount of primary raw material

[0118] • Low residual amount of the second raw material

[0119] Manufacturing took a certain amount of time.

[0120] Additionally, for example, a subroutine can use the following values ​​as trigger conditions to detect abnormal states.

[0121] • Fault or abnormal flow rate of the flow meter with local variable m1

[0122] • Fault or abnormal flow rate of the flow meter with local variable m2

[0123] • The pressure / temperature anomaly of the reaction field represented by parameter n

[0124] If the manufacturing of the reaction field is detected to be complete, the process proceeds to step S606. On the other hand, if an abnormality is detected in the reaction field, the process proceeds to step S609.

[0125] Step S606: The subroutine causes the control unit 201 to stop controlling the shut-off valve corresponding to the local variable l. Specifically, here, the control of shut-off valves 125 and 135 is stopped.

[0126] Step S607: The subroutine causes the control unit 201 to stop controlling the flow meters corresponding to the local variables m1 and m2. Specifically, here, the control of flow meters 121 and 122 and flow meters 131 and 132 is stopped, and the manufacturing in the reaction field is stopped.

[0127] Step S608: The subroutine causes the control unit 201 to stop accumulating the running time of the reaction field corresponding to parameter n. Specifically, here, the accumulation of the running time of reaction field a and reaction field b is stopped, and the subroutine ends.

[0128] Step S609: If an anomaly is detected in step S605, the subroutine causes the control unit 201 to perform a priority upgrade process. For example, if an anomaly occurs in reaction field a, the priority value of reaction field a that experienced the anomaly is deleted. If the priority value is deleted, the priority of the reaction fields that did not experience an anomaly is upgraded. Specifically, reaction fields that originally had priorities of 2, 3, and 4 are upgraded to priorities of 1, 2, and 3, respectively. Here, reaction field c, which was originally a switching target with a priority of 3, becomes a manufacturing target with a priority of 2. Subsequently, the process proceeds to steps S601 and S610. That is, for reaction fields whose priorities are upgraded, the process proceeds to step S601 to perform control over the manufacturing target reaction field. On the other hand, for reaction fields whose priorities are deleted, step S610 and subsequent stop processing are performed. In other words, reaction fields whose priorities are deleted will become the lowest priority reaction fields after the anomaly is resolved, thus enabling continued manufacturing.

[0129] Step S610: The subroutine causes the control unit 201 to stop controlling the shut-off valve corresponding to the local variable l related to the reaction field of the abnormal object. For example, if the reaction field a is the reaction field of the abnormal object, the control of the shut-off valve 125 is stopped.

[0130] Step S611: The subroutine causes the control unit 201 to stop controlling the flow meters corresponding to the local variables m1 and m2 related to the reaction field of the abnormal object. Specifically, here, the control of flow meters 121 and 122 and flow meters 131 and 132 is stopped. This stops the manufacturing in the reaction field of the abnormal object.

[0131] Figure 11 The state of system 1 is shown when an anomaly occurs in reaction field a. For example... Figure 11 As shown, the control of flow meters 141 and 142 is started and the control of flow meters 121, 122 and shut-off valve 125 is stopped, thus supplying raw materials to reaction fields b and c, with reaction field c replacing reaction field a for manufacturing.

[0132] Figure 12The diagram shows the state of system 1 when reaction field b, in addition to reaction field a, also experiences an anomaly. For example... Figure 12 As shown, control of flow meters 151 and 152 is initiated, and control of flow meters 131, 132, and shut-off valve 135 is stopped. Therefore, raw materials are supplied to reaction fields c and d, which replace reaction fields a and b for manufacturing.

[0133] (Example)

[0134] The following describes an example of operating a flow-type reaction apparatus for a gas / liquid reaction with five reaction fields (hereinafter also referred to as reaction field a, reaction field b, reaction field c, reaction field d, and reaction field e) using the control method described in this embodiment. The apparatus was manufactured with two reaction fields in operation and three reaction fields as backup. The status of the operating reaction fields was monitored using gas flow meters / liquid flow meters and pressure gauges installed near the mixing section. Five manufacturing runs were performed using the above procedure, and the switching control of the reaction fields and the stability of the apparatus were evaluated. Table 1 shows the evaluation results. In terms of apparatus stability, A indicates good, and B indicates poor.

[0135] [Table 1]

[0136]

[0137] As shown in Table 1, by controlling the flow reactor using the control method described in this embodiment, it is possible to appropriately switch between the operating reactor and the standby reactor, taking into account the actual usage data of each reactor. This also demonstrates that the stability of the flow reactor can be maintained.

[0138] This disclosure is not limited to the embodiments described above. Modifications may be made without departing from the spirit of this disclosure.

[0139] For example, in this embodiment, while the performance data includes the cumulative usage time and cumulative number of uses for each reaction site, it is not limited to this. The performance data may also include only one of the cumulative usage time and cumulative number of uses for each reaction site. In this case, priority is determined based on either the cumulative usage time or the cumulative number of uses. For example, the shorter the cumulative usage time or the fewer the cumulative number of uses, the higher the priority is set. In other words, the performance data includes at least one of the cumulative usage time and cumulative number of uses for each reaction site. Furthermore, priority can be determined based on at least one of the cumulative usage time and cumulative number of uses for each reaction site. Here, when priority is determined based on both cumulative usage time and cumulative number of uses, priority can also be determined by multiplying the cumulative usage time and cumulative number of uses by weighting coefficients respectively. In this case, the weighting coefficients can be adjusted to prioritize cumulative usage time. In addition, in this case, at least one of the cumulative usage time and cumulative number of uses is updated according to the operating status of the reaction sites in operation.

[0140] Furthermore, while the priority in this embodiment is determined based on the actual usage data of each reaction site, it is not limited to this. Priority can also be determined based on the characteristic data of each reaction site. Characteristic data may include, for example, the durability of the reaction site, its size, past abnormal shutdown records, and the reasons for abnormal shutdowns.

[0141] (Explanation of the labels in the attached diagram)

[0142] 1: System 1; 100: Flow reactor 100; 200: Control device; 101: Gas cylinder 101;

[0143] 102: Pressure reducing valve; 103: Storage tank; 104: Liquid transfer pump; 120, 130, 140, 150: Reaction area;

[0144] 160: Post-reaction fluid manifold; 121, 131, 141, 151: Flow meters;

[0145] 122, 132, 142, 152: Flow meters; 123, 133, 143, 153: Mixing section;

[0146] 124, 134, 144, 154: Reaction section; 125, 135, 145, 155: Shut-off valve;

[0147] 201: Control unit; 202: Storage unit; 203: Communication unit; 204: Input unit; 205: Output unit.

Claims

1. A control method for a flow reaction apparatus, wherein the flow reaction apparatus has multiple reaction fields for continuously supplying two or more chemical substances as raw materials, mixing the raw materials, and carrying out chemical reactions, and for switching between operating reaction fields and standby reaction fields, wherein, The control method includes: The steps for obtaining the priority corresponding to each reaction field; and Based on the aforementioned priorities, the steps for operating the reaction field are determined. The priorities are determined based on the actual usage data of each reaction site.

2. The control method according to claim 1, wherein, The usage performance data includes at least one of the cumulative usage time and cumulative usage frequency for each reaction site.

3. The control method according to claim 2, wherein, The priority is updated by updating at least one of the cumulative usage time and cumulative usage count based on the operating status of the reaction field.

4. The control method according to claim 1, wherein, The priority is also determined based on the characteristic data of each reaction field.

5. The control method according to claim 1, wherein, If an anomaly is detected in a running reaction field, the operation of the reaction field with the detected anomaly is stopped, and the priority of reaction fields without detected anomalies is increased.

6. The control method according to claim 1, wherein, The control program used to execute the control method includes subroutines.

7. A control device for controlling a flow reaction apparatus, comprising a control unit, wherein the flow reaction apparatus has multiple reaction fields for continuously supplying two or more chemical substances as raw materials, mixing the raw materials, and carrying out chemical reactions, and for switching between operating reaction fields and standby reaction fields, wherein... The control unit acquires the priority corresponding to each reaction field and determines the reaction field to be operated based on the priority. The priorities are determined based on the actual usage data of each reaction site.

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