In the K-Project "Industrial Methods for Process Analytical Chemistry - From Measurement Technologies to Information Systems" new process analytical measurement techniques shall be realised. The measured data will be used for the optimization of process-modeling and will enable self-sufficient and autonomus control and optimize production processes in process control systems.
K-Project Industrial Methods for Process Analytical Chemistry
Facts and Figures
- Runtime: 4 years (01.09.2014 - 31.08.2018)
- Funding program: COMET (administered by FFG)
- Sponsors: Governments of Austria (BMDW, BMVIT); Federal State of Upper Austria & Lower Austria
- Project partners: 11 Company partners; 8 Scientific partners
- Consortium leader: RECENDT GmbH
- Project structure: 5 sub-projects
Whether you produce medicals, mineral oil products or beer: In all chemical and biochemical processes you need to know what is momentarily going on in your process, in the reactors, in order to get information about the process. In many cases this means to interrupt the process for taking a sample - which may not always be easy. Besides accuracy, also speed of measurement plays an important role. The problem is, that often it takes hours to have the results available. If such a result shows any defects then, this could, in the worst case, mean that the entire production is unusable.
Inline Process analytical technologies avoid these problems: By immediate and regulatory intervention shorter process times are possible. Hence also the quality of the product can be measured at all stages of the process. A further advantage of process analysis is, that it helps companies to save raw materials and energy as well as to reduce waste. Moreover health and environmental hazards can be avoided, through the elimination of potentially hazardous taking of samples.
Process analysis on the one hand helps companies to save costs and on the other hand contributes to the competitiveness for the industrial location Austria.
- Generation of knowledge on chemical production processes through novel analysis, multivariate data analysis, computational fluid dynamics, simulation and mechanistic modeling.
- Development of advanced optical and MEMS based sensor systems for ultra-sensitive, fast and spatially resolved measurement of the chemical and physical properties of fluids, solids and multi-phase samples.
- Transfer of methodological approaches to industrial partners, for use in different - but similar - production processes.
Goals / Mission
- Applicable process analytics for the industrial production in various industrial sectors
- New measurement technologies to gain valid information from the processes
- Analysis on an elemental and molecular level
- Description of condition with matematical models
- Useful application of mathematical models in the industry (Computational Model Life-Cycle Management - CMLCM)
- Tools for improved process understanding
- Knowledge generation and transfer to the industry
- Process optimization by modern analytical methods
The project is organised in form of 5 sub-projects, with 3 of them being executed by the scientific partners in close collaboration with the company partners (3 multifirm-projects). The other 2 sub-projects are called strategic projects and their scope is mainly scientific.
- Multifirm-Project 1: Development of novel measurement technologies for process analytics
As a broad fundament for future needs in process analytics, novel measurement methods, focusing on industrial-suited on-line implementation, will be developed. This includes methods, such as Laser-Induced Break-down Spectroscopy (LIBS), Mid-infrared Quantum Cascade Lasers (QCL) and Micro Electro-Mechanical Systems (MEMS).
- Multifirm-Project 2: Characterization and in-depth understanding of multi-phase processes
The goal of MP2 is the development of suitable characterization methods in order to gain in-depth understanding of chemical processes accompanied with theoretical and numerical process modelling approaches. Modern measurement technologies will provide, e.g., 3D chemical information of industrial processes. This task will be supported by advanced simulation methods, such as Computational Fluid Dynamics (CFD).
- Multifirm-Project 3: Monitoring & control of target parameters in industrial processes
In the sub-project MP3 methods are developed for the involved companies, in order to be able to better monitor parameters in production process. Proven measurement technologies (e.g. near-infrared spectroscopy) build the basis for continuous in-line monitoring of target parameters. Based on this, new modelling concepts will be developed with regard to applicability and transferability to industrial processes.
- Strategic Project 1: Advanced strategies for information mining and knowledge generation
Within the strategic project SP1 generic approaches on how chemical processes can be described and monitored will be investigated. A focus herein will be the introduction of suitable quality parameters for chemometric models and generic concepts for their easy adaption to changing process environments. Computational Model Life Cycle Management (CMLCM) methods and Chemometric Model Environments (CME) as suitable software eco-systems will be developed to accomplish theses tasks.
- Strategic Project 2: Advancing spectroscopy for the analysis and characterization of materials
In SP2 trend-setting spectroscopy-based analysis methods will be developed. This includes: PEIM (Photothermal Expansion Imaging), THz (Terahertz) spectroscopic imaging, LIBS (Laser-Induced Break-down Spectroscopy), NMR (Nuclear Magnetic Resonance) Spectroscopy, MIR (Mid-Infrared) Spectroscopy and MEMS-based miniaturized viscosity sensors. These technologies have promising advantages for upcoming industrial applications.
Each of the sub-projects is coordinated by a Project Manager (staff-members of the scientific partners) and overviewed by a Key Researcher. The overall organisational head for PAC is the consortium-leader RECENDT.
The so-called Board is a platform where all partners can discuss scientific and programme relevant issues. Voting rights are granted to the consortium leader, three company partners, and three scientific partners.
3 sources of financing
The funding for the projects within PAC comes from 3 sources:
one part is the in-kind - contribution from the scientific partners,
a major part of the costs is funded by the company partners, who contribute in form of cash and in-kind,
and an other major part is provided by public funding from the governments of Austria (BMVIT, BMDW) and the Federal States of Upper Austria and Lower Austria.
⇒ Brau Union Österreich AG
⇒ EXPUTEC GmbH
⇒ Kelheim Fibres GmbH
⇒ Keysight Technologies GmbH
⇒ Kraiburg Austria GmbH & Co. KG
⇒ Lenzing AG
⇒ Metadynea Austria GmbH
⇒ Patheon Austria GmbH & Co KG
⇒ Sandoz GmbH
⇒ voestalpine Stahl GmbH
⇒ Johannes Kepler Universität Linz, Fuzzy Logic Laboratorium Linz / Hagenberg
⇒ Johannes Kepler Universität Linz, Institut für Angewandte Physik
⇒ Johannes Kepler Universität Linz, Institut für Mikroelektronik und Mikrosensorik
⇒ Kompetenzzentrum Holz
⇒ RECENDT - Research Center for Non-Destructive Testing GmbH
⇒ Software Competence Center Hagenberg
⇒ Technische Universität Wien, Institut für Verfahrenstechnik, Umwelttechnik und Technische Biowissenschaften
⇒ Technische Universität Wien, Institut für Chemische Technologien und Analytik