PROCESS ANALYTICAL TECHNOLOGY

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PROCESS ANALYTICAL TECHNOLOGY

• WHAT IS IT AND WHY IS IT IMPORTANT
• M Koch
• Center for Process Analytical Chemistry (CPAC)
• University of Washington

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ANALYTICAL SCIENCES

• SPECTROSCOPY
• CHROMATOGRAPHY
• ELEMENTAL ANALYSIS
• MICROSCOPY
• THERMAL
• POLYMER CHARACTERIZATION
• PROCESS ANALYSIS

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Real-time Data Acquisition . . .

• . . . provides researchers with a video of a
  chemical process.
• Deliverables
• Composition
• Unknown Identification
• Reaction Pathways Kinetics
• Chemical Topography
• Emission Monitoring
• Process Hardware Integrity
• Reactive Chemical Issues
• On-line Feasibility Studies

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REAL TIME ANALYSIS IS NEEDED IN MORE THAN JUST
THE PRODUCTION PROCESS

• DISCOVERY
• DEVELOPMENT
• PROCESS
• PROCESS OPTIMIZATION
• PRODUCT DEVELOPMENT

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On-line Measurements Questions

• What kind of instrumentation is best suited?
• Where in the process should one measure?
• What kind of models should be used (on
  raw data, transformed data, compressed data)?

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REVOLUTIONARY ADVANCES THAT ARE AFFECTING
CHEMICAL MEASUREMENTS

• MEASUREMENT INFORMATION PROCESSING
• MINIATURIZATION
• ENGINEERED MATERIALS
• ELECTRO-OPTICS

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• Advances in Microtechnology.
• Electronics
• computers, communications
• MEMS
• microfluidics, microoptics, bulk micromachining
• Nanotechnology
• new materials and interface control

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WITH NEW DIRECTIONSIN INDUSTRY
? GLOBALIZATION OF BUSINESSES ? CONSOLIDATION OF
INDUSTRIES ? CONSTRICTED RESOURCES
PARTNERING IS NEEDED
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PARTNERING
? WITHIN AN ORGANIZATION ? ACROSS INDUSTRY ?
INDUSTRY - UNIVERSITY ? INDUSTRY -
GOVERNMENT - UNIVERSITY
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NATIONAL INITIATIVES

• Vision 2020 Roadmaps
• Advanced Technology Programs
• Green Chemistry
• PAT
• Micro-sensors

• DOE / OIT
• DOC / NIST
• EPA / GCI
• FDA
• DOD / DARPA

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CENTER FOR PROCESS ANALYTICAL CHEMISTRY
UNIVERSITY OF WASHINGTON,
SEATTLE
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CPAC is a Consortium of Industrial Sponsors,
National Laboratories and Government Agencies
? Established in 1984, the Objective of the
Center is to Address Challenges in Real-Time and
Continuous Process Monitoring and Control
? Provides a Forum for Multidisciplinary
Participation in Process Analytical Technology
Definition, Creation, and Utilization
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CPAC Activities

• Semiannual Sponsor Meetings
• Graduate Education
• Summer Institute
• Industry Segment Meetings
• Technical Workshops
• Visiting Scientist Program
• Pittcon, IFPAC, mTAS
• FDA - PAT

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BENEFITS OF CONSORTIA MEMBERSHIP
New Technology
Peer Communication
Students
Deliverables
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PEER COMMUNICATION
? BENCHMARKING ? CLEARING HOUSE ? FOCUS GROUPS
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Sponsor Focus Groups
? Oil Petrochemicals ? Chemicals Materials ?
Food Consumer Products ? Bio Tech /
Pharmaceuticals ? National Labs Agencies ?
Instrument Companies
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CPAC Industrial Sponsors
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CPAC Government Sponsors

• National Institute of Standards Technology
• Pacific Northwest National Labs
• Westinghouse Savannah River Co.

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Core Research Areas
? Chemometrics ? Sensors ? Spectroscopy /
Imaging ? Chromatography ? MicroFlow Analysis ?
Process Control
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•  
• Sensors Projects
• Grating Light Reflection Spectroscopy
•  
• High Precision Reflectometer
•  
• Vapochromic Detection and Identification of
  Volatile Organic Compounds
• Advanced Surface Plasmon Resonance Sensors
•  
• In-Situ Evaluation of Physical Sensor Health
  and Output Signal Validity
• Dynamic Surface Tension Detector

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Spectroscopy/Imaging Projects Evaluating
Raman Spectroscopy to Improve Process Monitoring
and Materials Characterization Development
and Application of On-Line Particle Analyzers
Non-destructive Measurement of Moisture
Distribution with Fringing Electric Field Sensors
Application of MRI for Analysis
of Mixing   Development of a Micro NMR
System   Ultrasonic Sensor for Viscosity and
Microstructural Measurements
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CHEMOMETRIC PROJECTS

• Chemometrics for Smart Sensors
•  
• Novel Classification Tools Combining Data
  Mining and Statistical Inferencing Techniques
• New Approaches to Transfer and Maintenance of
  Multivariate Calibrations
•  
• Incorporating Raw Material Variation into
  Process Chemometric Models
•  

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Multidisciplinary
? Chemistry ? Chemical Engineering ? Electrical
Engineering ? Bioengineering ? Applied Physics ?
Forestry ? Mechanical Engineering ? Food Science
Engineering ? Health Sciences
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OTHER UNIVERSITY PARTNERING
University of Arkansas University of
Alberta Arizona State University University of
California Davis Clarkson University University
of Colorado University of Delaware University of
Michigan University of Minnesota Texas Tech
University
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INDUSTRY NEEDS

• ? MIXING EFFICIENCY
• ? CLEANING VALIDATION
• ? PARTICLE SIZING
• ? CHEMICAL COMPOSITION (molecular, spatial)
• ? COATING CONSISTENCY
• ? VAPOR CHARACTERIZATION
• ? VISCOSITY / RHEOMETRICS
• MOISTURE CONCENTRATION
• BIOASSAY

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CPAC STRATEGIC PLATFORMS

• ? SURFACE AND INTERFACIAL CHARACTERIZATION AND
  CONTROL
• MULTICOMPONENT MATERIALS CHARACTERIZATION AND
  CONTROL
• VERSATILE MICROANALYTICAL SYSTEMS
• ? PROCESS MONITORING, MODELING AND CONTROL

PROBLEMS
SYSTEMS
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CPAC INITIATIVES AND PLATFORMS

• NEW SAMPLING AND SENSOR INITIATIVE (NeSSI)
• CONNECTIVITY INTIATIVE (ConnI)
• INSTRUMENTATION FOR MICRO REACTORS PLATFORM
• FERMENTATION MONITORING AND CONTROL PLATFORM
  (FermI)
• CHEMOMETRICS ON-LINE INITIATIVE (COPA)
• RAW MATERIAL QUALITY RELATED TO FINAL PRODUCT
  PROPERTIES