- Yield Improvement
- Quality Improvement
- Waste Reduction
- Statistical Process Control
- Statistical Quality Control
- Design of Experiments
Chemical Process Improvement
A large percentage of chemical process problems can be traced to excessive variation somewhere in the process.
The first step in diagnosing and treating such problems is often implementing statistical process control (SPC, SQC). This usually results in better yields, better quality, smoother operations and, therefore, lower costs. Proven statistical tools will help us move through your process in a systematic manner, improving results (or confirming that you have a well-controlled process) at each step along the way.
Special statistical techniques, called Experimental Design or Design of Experiments (DOE), can reveal the most significant factors in your processes. The most important factors revealed by this tool are often hidden or intertwined with other factors and are often not known to those most familiar with the process. These factors can be adjusted to optimum values, leading to further improvements in yields and quality.
Beyond applying these statistical tools to your chemical process, they can and should be extended to your measurement systems and analytical methods. Quality improvements made this way do not cost - THEY PAY. Less waste, less rework, more product right the first time = higher yields, lower costs.
Tuning up your chemical process in this way can sometimes result in capacity increases of 10-30% or more in the same equipment, depending on the details of your process and equipment.
I can bring these powerful tools to your chemical process and help you run your process better and more efficiently.
Chemical Process Troubleshooting
Have you grown to accept some problem in your chemical plant that you could really do without? Is there a troublesome buildup on a piece of equipment? Is there foaming, frothing and carryover in a vessel? Is there a problem filtering a product? Do you not meet specifications part of the time? Is there a discrepancy between a process instrument and an analytical result? You don't have to live with these.
When you call or email, we will begin a dialog about your problem to determine its scope and how we might arrive at solutions. For process issues, I will visit your site, examine your process with a new pair of eyes and try to see things in ways you and your people have not been able to. My training and experience combine to bring solutions to problems others have not found. I can zero in on one reaction intermediate in one vessel or step back and consider a multi-step process as a whole. Years of R&D and years of plant experience make me conversant with chemists, chemical engineers, other engineering disciplines, analytical labs and operating technicians.
Let's start solving your chemical process problem today.
