|
Multi-Phase and Multi-Stage Batch Process Analysis and Control
Batch processes have always been difficult to analyse and
control because there are so many variables changing at once
and so many quite different sets of activities taking place
in sequence. Users have not been able to directly compare
the many tens or hundreds of process variables and quality
results across batches in a meaningful way let alone the
reasons for the differences in performance of two or more
apparently identical reactors. Process control has been limited to forcing the trajectory of a
single variable, such as reactor temperature, to follow the
same trajectory as that in a ‘golden’ batch.
That’s now at an end. Over the last three years working with
some of our leading customers we have extended both CVE and
CPM to analyse and control Multi-Stage and Multi-Phase batch processes.
CVE can analyse multi-stage processes allowing you to link
from end-of-batch product qualities, for many batches
simultaneously, back to what was happening in an individual
phase in the first stage of a
batch.
CPM follows a trajectory tube composed of many variables and
of constantly-changing size depending on the interactions
between the variables and the present position of the
process within the tube.
CPM uses the well-proven “no maths” Operating
Envelope technology of Geometric Process Control to model
each phase of a batch given a selection of good batches.
Operating Advice is given to the operator in open-loop but
since the same software is used for both batch and
continuous processes, closed-loop control is already available
for use if
and when required. How many batches are needed to build a
model? This is an important question for those who
frequently introduce new products. We answered the question
in a project with a pharmaceutical customer by rebuilding
the model with successively fewer batches and running the
same test data through it watching for the alarm rate to
rise sharply. The answer was 6 batches if the manufacturing
conditions were chosen using Design of Experiments methods
and 16 if they were chosen arbitrarily.
Best of
all, there is no maths so the models are easy to build and
even easier to maintain. No math or programming skills are
required so the costs are an order of magnitude less than
some other methods. This means you can afford to apply
Multi-Phase Batch Process Control not only to your main
products and processes but to many of your minor products
and processes too.
Contact us for a webinar if Batch Analysis and/or control is
of interest to you at enquiries@curvaceous.com
|
