Chemical Process Simplification: Improving Productivity and Sustainability -- Contents -- Preface -- 1 Process Simplification: Basic Guidelines -- Application Areas -- References -- 2 Process Solutions -- Examples of Problem Solving -- Mass Balance -- Monitoring Plant Operations -- Filter Feed Pump -- Ester Manufacturing Process -- Simplification of a Product Solution Process -- Process "On Stream Time" -- Inventory Management and Process Repeatability -- Sampling and Size -- Antioxidant Production -- Novolac Resin -- Alkyd Resins -- Paint Making -- Continuous-Process Latex Polymer -- Waste Paint -- Wastewater Treatment -- Electroplating Chemicals -- Specialty Surfactant Manufacture -- Decanter -- Active Pharmaceutical Ingredients -- API Intermediates and Pollution -- Solving Process Problems -- Maintaining Pump Prime -- Problem -- Degas the Ammonia -- Take out Torque -- Problem -- Slowly Add Fine Powder -- Stop Solvent Losses -- Problem -- Cut Back the Mixing Time -- Choose a Pump Wisely -- Problem -- Try a Rotary Disk Pump -- Know When the End is Near -- Problem -- Use an Inline Viscosity Measuring Device -- Vanquish Material Variations -- Problem -- Choose Monitoring Point Carefully -- Fend off Reboiler Fouling -- Problem -- Remove the Fatty Oil First -- Prevent Heat Exchanger Plugging -- Problem -- Recycle Concentrated Solution -- Making Sense of Temperature Sensing -- Problem -- Poor Mixing -- Boost the Reliability of a Solvent Supply Pump -- Problem -- Use Eccentric Reducers -- Uncovering the Cause of Solid Buildup -- Problem -- Look at the Material Balance -- Consider Options for Automation -- Problem -- Automation can also Boost Morale -- Sticky Valve -- Problem -- Focus on Heat-Tracing Failure -- Quick Fix Needed! -- Problem -- Eventually, Do a Redesign -- Clarify a Clogged Caustic Conundrum -- Problem -- Try Recirculation.

Succeed through Thick and Thin -- Problem -- Maintain the Temperature -- Quell a Quality-Control Confrontation -- Problem -- Improve the Design -- Get out of the Soup -- Problem -- Use an Eductor -- KAYO a Cascade Control Complication -- Problem -- Redesign the Process -- Use of Azeotrope to Improve a Process -- Problem -- Alternate Process -- Use of Heat Exchanger in the Manufacture of Coatings -- References -- 3 Commonalities of Businesses -- Products Produced by Reactions -- Examples -- Simplification Strategy -- Amines and Other Products -- Emulsion Polymerization -- Formulated Products -- Method of Production -- Surface Coating Manufacturing -- Architectural Coatings -- Continuous Paint Processing -- Cosmetic Ingredients -- Equipment Commonalities -- Tanks, Reactors, and Vats -- Dispersers -- Similarities in Coatings -- Use of Architectural Coatings in Paper Manufacture -- Surplus Paint in Other Applications -- Ink-Jet Printing for Cheaper Solar Cells -- References -- 4 Laboratory Process Development -- Laboratory Development -- Mass Balance -- Chemicals Produced by Reaction -- Examples -- Considerations for the Development of a Continuous Process -- Solvent Selection -- Solvent Separation -- Phase Separation -- Azeotropic Distillation -- Kinetics -- Chemical Blending Operation -- References -- 5 Mass and Heat Balance -- Mass-Balance Uses -- Mass Balance for Blended Products -- Mass Balance for Reactive Processes -- Examples -- USP 7,227,024 -- USP 6,875,893 and 7,057,069 -- Heat Balance -- Financial Value of Mass and Heat Balance -- References -- 6 Reaction Kinetics -- Reaction Rate and Variables -- Concentration -- Physical State -- Temperature -- Heat of Reaction -- Order and/or Method of Addition -- Rate of Additon -- Other Parameters -- Applications -- Diazotization -- Reactant as a Solvent -- Other Considerations.

Production of Benzimidazole Compound -- Use of Physical and Thermodynamic Properties -- Equipment -- References -- 7 Physical Properties -- Physical State -- Density -- Melting/Freezing Point -- Boiling Point -- Azeotrope Characteristics -- Solubility -- Heat of Reaction -- Heat Capacity -- Viscosity -- Combined Value of Physical Properties -- Evaluate Alternate Routes -- References -- 8 Combination of Heat, Mass Balance, and Physical Properties -- Technical Operating Manual -- Process Description -- Unit Charge and Material Recovery Sheet -- Raw Materials Specification and Material Safety Data Sheets (MSDS) -- Process Chemistry -- Heat and Mass Balance -- Process Conditions and Effects of Variables -- Equipment Description and Process and Instrumentation Diagram -- Suggested Operating Procedure -- Laboratory Synthesis Procedure -- Additional Critical Notes -- Analytical Methods -- Thermodynamic and Physical Properties Data -- Troubleshooting Guide -- Process Design Manual -- References -- 9 Cross-Fertilization of Technologies -- Regulatory Challenge and Creative Competition -- Home-Repair Products in Food Packaging -- Specialty Chemicals vs. Active Pharmaceutical Ingredients -- Liquid Blending Processes -- Labeling -- Hot-Melt Extrusions -- Miniaturization/Size reduction -- Alternate Energy -- References -- 10 Scale-up to Commercialization -- Reaction Scale-Up/Commercialization -- Process Outline -- Laboratory Process Review -- Alternative Process Stoichiometry -- Other Process Options -- Potential Continuous Process -- Commercialization of Fluorochemical Products -- Monomer Laboratory Preparation -- Monomer Scale-Up -- Polymer Laboratory Preparation -- Polymer Scale-Up -- Polymer Derivatives Laboratory Preparation -- Polymer Derivative Scale-Up -- Blending Scale-Up -- Scale-up Information Benefits -- References.

Appendix A: Ideas and Observations from the Author -- Appendix B: Related Articles by the Author -- Index.