[...]... will have dramatic effects on the entire plant, which may even have to be scrapped Planning errors made further up in Process Development From the Initial Idea to the Chemical Production Plant G Herbert Vogel Copyright ª 2005 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31089-4 16 2 The Chemical Production Plant and its Components Fig 2-2 Pyramid structure of process development Without a functional... 1.2 The Production Structure of the Chemical Industry Fig 1-6 Comparison between bulk and fine chemicals with regard to turnover and the development time of the corresponding process [Metivier 2000] gaining customers In contrast, the actual chemical production of the active substance is of only background importance The required precursors can be purchased from suppliers, and the production of the. .. Process Development 4.1 4.2 4.2.1 4.2.1.1 4.2.1.2 4.2.1.3 4.3 4.4 4.5 4.5.1 4.5.1.1 4.5.1.2 4.5.1.3 4.5.1.4 4.5.2 Process Development as an Iterative Process 281 Drawing up an Initial Version of the Process 284 Tools used in Drawing up the Initial Version of the Process 287 Data Banks 287 Simulation Programs 288 Expert Systems 292 Checking the Individual Steps 294 The Microplant: The Link between the. .. sufficient to examine the coarse structure of the production costs Thus, each item in Table 1-2 can be analysed individually and the Fig 1-1 Market capital of major chemical companies [Mayer-Galow 2000] Process Development From the Initial Idea to the Chemical Production Plant G Herbert Vogel Copyright ª 2005 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31089-4 3 4 1 Introduction Tab 1-1 Growth of the. .. profitability) The way in which chemical companies organize their research varies and depends on the product portfolio [Harrer 1999, Eidt 1997] Mostly it involves a mixture of the two extremes: pure centralized research on the one hand, and decentralized research (research exclusivelyin the company sectors) on the other [Hanny 1984] ¨ 1.3 The Task of Process Development The task of process development is to extrapolate... extrapolate a chemical reaction discovered and researched in the laboratory to an industrial scale, taking into consideration the economic, safety, ecological, and juristic boundary conditions [Harnisch 1984, Semel 1997, Kussi 2000] The starting point is the laboratory apparatus, and the outcome of development is the production plant; in between, process development is re- 11 12 1 Introduction quired The following... Brainstorming Discussion 66 Features 635 Brainwriting-pool Ideas Delphi Heuristic principles Bionics Synectics BBB methods Semantic intuition Morphological box Morphological Taublau? Sequential morphology Problem solving tree Progressive abstraction K-J-methods Hypothese s matrix Relevance tree 2 The Chemical Production Plant and its Components Process Development From the Initial Idea to the Chemical Production. .. structure of a chemical plant Around the production plant itself with starting material preparation, the reactor, and product workup are a series of other auxilliary units without which operation would not be possible Like a living organism, the total chemical plant is more than the sum of its individual units (organs in the former, units in the latter) [GVC VDI 1997] A properly functioning chemical plant requires... (production- independent) Depreciation Other costs R Production costs total system optimized The competive advantage better now refers not only to availability and product quality, but also to the environmental compatibility of the process [Gartner 2000], and the quality assurance concept, delivery time, and exclusivity of the ¨ supplier, etc 1.2 The Production Structure of the Chemical Industry If the. .. 1995] Figure 2-1 shows the most important units of a chemical plant Since more than 85 % of all reactions carried out industrially today require a catalyst [Romanov 1999], the catalyst can be regarded as the true core of the plant [Misono 1999] The development of the chemical industry is largely detetined by the development and introduction of new cataytic processes In 1995 the market value of all .