Downstream Chemical Process Control Using Package Object Tracking
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Solution Overview
Problem
In industrial chemical production, achieving consistent and predictable quality of chemical products is challenging due to variations in production parameters across multiple stages, leading to inefficiencies and increased costs, particularly in downstream plants receiving precursor materials with varying specifications from upstream plants, and the complexity of integrating time series data for machine learning applications.
Innovation Solution
The method involves creating 'package objects' from input materials using dosing units and managing them with 'object identifiers' that include precursor data, historical process data, and desired performance parameters, allowing for zone-specific control settings to be determined and applied through a computing unit, ensuring consistent product quality by accounting for variations in precursor and process parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional time series approaches are used for machine learning in chemical production, then data processing can be performed, but it is difficult to integrate data according to the needs of horizontal integration across the value chain
Solution Approach 1:
The patent segments continuous production data into discrete package objects with unique identifiers. Each package object represents a specific portion of material with associated process parameters and quality data, enabling modular data integration across different production stages and facilities without requiring complex continuous data stream integration.
Solution Approach 2:
The patent introduces package objects as intermediary entities that mediate data exchange between upstream and downstream production processes. These package objects serve as standardized data containers that can be easily transmitted and integrated across different systems, replacing direct complex time series data integration.
2Productivity
If variations in production parameters are allowed across multiple stages, then production flexibility is maintained, but product quality consistency deteriorates
Solution Approach 1:
The patent implements feedback mechanisms where quality data and process parameters of each package object are tracked throughout the production chain. This feedback enables identification of parameter variations that affect quality, allowing corrective actions to be taken while maintaining production flexibility through localized adjustments.
Solution Approach 2:
The patent enables dynamic adjustment of process parameters based on package object characteristics and historical data. By changing parameters adaptively for each package object while tracking outcomes, the system maintains production flexibility while improving quality consistency through data-driven parameter optimization.
3Adaptability or versatility
If precursor material specifications vary from upstream plants, then production adaptability is maintained, but downstream production efficiency deteriorates
Solution Approach 1:
The patent performs preliminary characterization of precursor materials by creating package objects with complete specification data before downstream processing. This preliminary action includes documenting all relevant properties and process parameters, enabling downstream plants to prepare appropriate processing conditions in advance, thus maintaining adaptability while improving efficiency.
Solution Approach 2:
The patent enables downstream plants to adjust processing parameters based on the specific characteristics of incoming precursor materials documented in package objects. By pre-analyzing material variations and preparing corresponding parameter adjustments, the system maintains production adaptability while minimizing efficiency losses through proactive rather than reactive adjustments.
Data Source
AI summary
The present teachings relate to a method for controlling a downstream production process for manufacturing a chemical product using at least one precursor material, the method comprising: providing a set of downstream control settings for controlling the production of the chemical product, wherein the downstream control settings are determined based on: a downstream object identifier; the downstream object identifier comprising precursor data; at least one desired downstream performance parameter related to the chemical product; downstream historical data; and wherein the set of downstream control settings is usable for manufacturing the chemical product at the downstream industrial plant. The present teachings also relate to a system, a use and a software product.