Automated process monitoring

The creation and analysis of process flow sheets has become much easier because of the availabihty of automated systems to draw and revise them. The goal of the use of the flow sheet as the input for process simulation and for process control is likely to be achieved reasonably soon. The use of interactive graphic displays for process monitoring and control is pervasive today. 

HPLC is extremely useful in monitoring and optimizing industrial processes. Conventional process monitors measure only bulk properties, such as the temperature and pressure of a reactor, while HPLC permits continuous realtime monitoring of consumption of starting materials, product composition, and impurity profile. There are a number of new initiatives relevant to HPLC for process monitoring, including sample preparation, automation, miniaturization, and specialized detectors. 

Figure A2.1 Waters ProMonix On-Line HPLC analyzer. The upper compartment door contains a keypad for programming and operation of the analyzer. The upper window allows viewing of indicator lights and a liquid crystal display that provides the operator with analyzer interface, programmed parameters, and instrument status results. The lower chamber contains the pumps, valves, injector, and detector(s) required for the chromatographic separation. The sample conditioning plate for online process monitoring is to the right of the analyzer. This is a typical process HPLC. (From Cotter, R.L. and Li, J.B., Lab Rob Autom., 1, 251,1989. With permission of VCH Publishers.)...

This chapter provides a complementary perspective to that provided by Kramer and Mah (1994). Whereas they emphasize the statistical aspects of the three primary process monitoring tasks, data rectification, fault detection, and fault diagnosis, we focus on the theory, development, and performance of approaches that combine data analysis and data interpretation into an automated mechanism via feature extraction and label assignment. 

Figure 4.20 Schematic of the FDEMS sensor smart system for monitoring quality and for expert automated process control...

The technical development is still very rapid and addresses the growing need within process monitoring. The current trend includes further improvement of instrument design for smaller and more rugged equipment, integration into automated analytical systems and miniaturisation for multiple installations and portability. 

Process monitoring poses two additional challenges compared to these automated fluidic separation methods. First, methodology for automated sample preparation must be developed, and second, the entire sample preparation-separation-detection system must be developed to operate on-line or at-site under unattended computer control, including sample transport through all the steps. Sample preparation is particularly critical for nuclear-waste and nuclear-process streams due to the complexity of the sample matrix and the uncontrolled valence states of several of the potential analytes. 

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