SPIRE 1 2014 Integrated Process Control Title: Robust and...

PROPAT PUBLIC Deliverable 9.1

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SPIRE 1 – 2014 – Integrated Process Control

Title: Robust and affordable process control technologies for improving standards and optimising industrial operations

Acronym: ProPAT Grant Agreement No: 637232

Deliverable 9.1 Knowledge Transfer & Training Programme and Materials

Associated WP WP9 Knowledge Transfer & Training

Associated Tasks T9.1

Due Date 2016-12-31 (M24)

Date Delivered 2018-10-02 (M44)

Prepared by (Lead Partner)

DECHEMA

Partners involved All

Authors

Linus Schulz, Alexis Bazzanella, DECHEMA Georgios Chalkias, IRIS Ana Maria De Juan Capdevila, UB Joan Ferré, URV Rubaiya Hussain, ICFO Uula Kantojärvi, SPECTRAL

Dissemination Level Public

Ref. Ares(2018)5270592 - 14/10/2018


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© European Communities, 2018.

The information and views set out in this publication are those of the author(s) and do not necessarily

reflect the official opinion of the European Communities. Neither the European Union institutions and

bodies nor any person acting on their behalf may be held responsible for the use which may be made

of the information contained therein.


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Table of Contents

Executive Summary ................................................................................................................... 4

1. Introduction .......................................................................................................................... 5

2. Identification of priority technology aspects for training activities ................................. 6

2.1. NIR for real-time in-process (physico)chemical characterization ............................. 6

2.2. ProG for real-time in-process particle size determination ........................................ 7

2.3. Chemometric and data fusion models.......................................................................... 7

2.4. The use of PATBox software ......................................................................................... 7

3. Training programme ............................................................................................................ 8

4. Training materials .............................................................................................................. 10

5. Annex 1 Workshop programmes ....................................................................................... 12

6. Annex 2 Training Materials ............................................................................................... 16

6.1. Educative posters on ProPAT technical topics .......................................................... 16

6.2. Educative presentations and training lectures ......................................................... 29

6.3. Specific training material on statistical process control .......................................... 48


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Executive Summary

This deliverable compiles the training programme and training materials that have been

developed and prepared during the ProPAT project. A number of technology topics have been

identified by the consortium, on which fundamental skills are mandatory for the implementation

of advanced process control strategies in the process industries. ProPAT has thereby understood

the need to join forces with other related SPIRE projects developing complementary PAT

solutions as the training needs as well as target audiences of these projects are identical. The

focus of the ProPAT training activities has therefore been put on joint workshops with these

related projects. Main events for training of interested persons from academia and relevant

industries were two SPIRE-workshops on “Tackling the future of plant operation” in Frankfurt

(25 January 2017) and Barcelona (13+14 December 2017), the ProPAT contributions to the 4th

European Conference on Process Analytics and Control Technology in Potsdam, Germany ((10-

12 May 2017) and a Smart Sensors workshop in Frankfurt (to take place 2+3 October 2018).


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1. Introduction

The ProPAT work package (WP) 9 “Knowledge Transfer & Training” comprises two consecutive

tasks:

Task 9.1 Preparation of the Knowledge Transfer & Training Programme & Materials

Task 9.2 Execution of the Knowledge Transfer and Training Programme

This deliverable 9.1 “Knowledge Transfer & Training Programme and Materials” reports on the

activities within task 9.1. Task 9.1 aimed at the organization of at least 4 knowledge transfer and

training sessions to be delivered to the technical, operational and managerial staff of the

participating process industries in order to systematically transfer to them the knowledge in the

use of the project results at relevant points along the work plan. In addition, the preparation of

external sessions aimed at the European SPIRE community in close collaboration with the SPIRE

PPP was envisioned. For all training sessions, appropriate training materials had to be

developed. Accordingly, D9.1 describes the programming of corresponding sessions and the

developed training materials.

The actual execution and assessment of these training activities, subject to task 9.2 will be

reported in D9.2.


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2. Identification of priority technology aspects for training activities

The ProPAT project aims at developing an integrated process control approach embedding a

novel monitoring system based on low cost analysers combined with smart sensors for

monitoring of critical control parameters in real time. Key processes in the minerals, ceramics,

non-ferrous metals, and chemical process industries are addressed. A versatile Global Control

System Platform developed in ProPAT will allow seamless management, acquisition processing

and mining of the data from the sensors and analysers for closed loop control of the process or

for decision support.

Accordingly, the ProPAT consortium has identified a number of priority technology fields which

should be subject of targeted training towards key audiences in the process industries. The

training activities and corresponding materials have been designed to support the target sectors

of the SPIRE community to overcome major barriers of expertise in relation to the

implementation of PAT and QbD in industry. These technology fields are described

subsequently, together with a description of an appropriate training approach in the respective

areas.

2.1. NIR for real-time in-process (physico)chemical characterization

Spectral Engines spectral sensors enable a material sensing technology that is especially suitable

for molecular spectroscopy. The sensors can effectively be used to measure the chemical

composition of materials that are composed at least partially of molecules, meaning that

typically O-H, C-H, N-H, or C-C type chemical bonds are present. What makes the Spectral

Engines spectral sensors unique from other near-infrared spectrometers is their compact size,

mass production suitability, efficiency, ow price point, durability, robustness, modular design,

and ease of integration.

Application testing is simple, as most non-transparent solid materials can be measured with

diffuse reflection by simply shining light and collecting the reflected, partially absorbed light

from the samples. For transparent materials the transmission mode can be used, by measuring

light as it travels directly through a material. The sensors measure only the spectra directly, and

the quality or quantity parameters need to be calibrated for the sensors. So, in order to measure

the fat content of milk, samples with known quantity of milk need to be available for

measurements. Once the calibration data, both the spectra and compositional data, are

available, it can be possible to relate variation in the spectra to variations in the samples.

Chemometrics is what enables the spectral sensor to transform into a milk sensor, or something

else that is relevant for the end-user.


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2.2. ProG for real-time in-process particle size determination

ProG is a compact and cost effective granulometer for online particle size monitoring in

industrial applications. The device is designed for liquid suspension, dry and wet flow and is

capable of measuring particle size range from 0 µm to 150 µm. ProG is made from commercial-

of-the-shelf components which reduces the price by one order of magnitude compared to the

commercial particle size analysers. Due to its small size and lower price, ProG also offers high

integrability in atline/online powder production monitoring applications.

The enduser will require a short training in the device operation and user interface management

which includes a) load/save projects and data management b) configurable options to specific

PSD plots (Volume[%], Number, etc..) and desired values of the size percentiles, c) calibration of

the device, d) and periodic maintenance of the measurement windows.

Specific training procedures for integrators will be needed during the integration in industry

plants mainly focused in the sampling adjusting the working concentration range of the ProG

system and in the enclosure, which has to have an ingress protection allowing dust and water

isolation. An add-on IP65 enclosure is recommended in this case.

2.3. Chemometric and data fusion models

Chemometric models are used in ProPAT to translate instrumental signals into chemical

information that can be used to make process control decisions. The most relevant developed

models have been applied to nearinfrared (NIR) spectra to predict acid value and viscosity in real

time during the production of polyester, and moisture content during the drying of a

pharmaceutical product. They have also been used to detect process-end point and critical point

detection in the polymerisation process for the mentioned processes.

Divulgative training materials have been prepared to illustrate the uses of the chemometric

models (see posters presented and oral communications presented at workshops related to

SPIRE and other international conferences related to chemometrics and PAT fields).

Technical training material is available in our institutions and could be adapted for those

industries that have implemented ProPAT and need to understand the mathematical support of

chemometric models in order to develop themselves their own models. Such a training must be

in-company and has to be prepared focusing on their specific control needs.

General training on chemometric procedures for process understanding, modeling and control

could be envisioned for the general industrial community under the form of dedicated

workshops or short courses.

2.4. The use of PATBox software

PATBOX is a robust and versatile PAT integration and data management platform to facilitate

seamless integration (not only of the ProPAT analyzers and sensors, but all commercially


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available systems), provide the connectivity management, interface with users and other

business systems, and complete data management at a higher level. PATBOX consists of (i) data

acquisition layer, (ii) data processing layer, (iii) data mining layer, (iv) data management system,

and (v) User Interface. The platform architecture has been designed so that the computational

load of the data acquisition layer is divided into sub-systems named Gateways. This feature gives

the system the capacity of being resized according to the process needs up to a quantity of 256

Gateways or sensor nodes, where each node manages up to 4 analyzers. The Data Processing

and Data Mining layers can be dynamically implemented by loading external files of

chemometric and process control models, giving the system a high adaptability to a vast quantity

of processes and model maintenance capacity. The Data Management System is flexible and

allows the users to save their processes in a local server or directly to the Cloud. Finally, multiple

information obtained from different analyzers and sensors and from the process analysis itself,

can be followed in real-time in a user friendly interface.

PATBox system is accompanied by a user manual (D5.3) that is continuously updated as the

software is being further developed. The GUI has been designed to be simple and straight-

forward, maximizing software stability and robustness while minimizing the learning curve.

Experienced PAT and analytical software users can master the software in less than one week

through self-learning based on the manual. In addition to this, IRIS provides a one-on-one

consultancy and training on the software that takes 1 or 2 working days (based on user

experience) and can be performed on-site or remotely.

3. Training programme

The original workplan anticipated four training session at the facilities of individual industrial

partners and additional training activities towards the SPIRE community. Contacts and exchange

with related SPIRE projects early on showed, that a more efficient training programme would be

delivered by organising training workshops jointly with these projects for two main reasons:

a combined training on technology aspects and related case studies from the various

projects would shed light on complementary aspects and provide a more holistic view

and convincing storyline on challenges and opportunities of advanced process control;

joint training activities would deliver content and knowledge to a much larger

stakeholder group, including both industrial corporates and other partners involved in

the projects as well as external audiences from the SPIRE community, thereby creating

a stronger awareness and maximized impact.

For this reason, the ProPAT training programme focused on delivering the basic skills on the

topics described in chapter 2 jointly with other relevant SPIRE projects in the area of process

control. The related projects identified as ideal partners were:

CONSENS (www.consens-spire.eu), developing novel sensors and integrated process control

techniques for continuous processes

DISIRE (www.spire2030.eu/disire), integrating properties of raw materials or product flows in

an inline measuring system

http://www.spire2030.eu/disire


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iCspec (www.icspec.eu), fast in-line multi-component monitoring of gas composition for

process control of technical gases

RECOBA (www.spire2030.eu/recoba), Cross-sectorial real-time sensing, advanced control

andoptimisation of batch processes saving energy and raw materials

All of the above mentioned projects share the need for the same fundamental skills in the area

of sensors and process analytical tools, process control, modelling and data mining and

therefore had a common interest in training the consortium partners project-internally as well

as external stakeholders representing future users of advanced process control systems. In these

projects combined, 17 major corporations from diverse sectors of process industry have been

represented with more than 40 technology companies and with research institutes and

universities.

Two workshops have specifically been organized as joint events by DECHEMA:

Tackling the future of plant operation – How to integrate online data-analytics, process

control, and PAT for optimal plant operation (Frankfurt, 25 January 2017); jointly with the

project CONSENS

Tackling the future of plant operation - Jointly towards a digital process industry (Barcelona,

13-14 December 2017); jointly with CONSENS, DISIRE, iCspec and RECOBA

The programmes of these two events are provided in Annex 1.

Two other events have been used (rsp. are anticipated) to deliver educative presentations and

to directly interact with stakeholders on ProPAT results:

The 4th European Conference on Process Analytics and Control Technology in Potsdam,

Germany ((10-12 May 2017), including a plenary lecture by ProPAT and Consens on

“Integrated Process Control – SPIRE Projects with High Impact for Process Industry” and a

joint exhibition with five other SPIRE projects, presenting results

The 2-day workshop “Smart Sensors - mechanistic and data driven modelling” at DECHEMA

in Frankfurt, 1-2 October 2018, at which a keynote on “Softsensor applications to industrial

processes monitoring, control and end-point detection” will be delivered by the University

of Barcelona and URV, explaining the chemometrics and data fusion models prepared in the

project.

ProPAT partners have also contributed to other events with educative lectures and posters.

These lectures and posters represent ready to use training materials that address the main

technological areas of ProPAT and also provide case studies that can be covered in training

courses. The respective material is provided in Annex 2.

Specific training activities on ProPAT results, in particular training on the use of the PATBox

software was hampered by the late availability of these results. An online training tool has to be

provided by the end of the project, which allows scalable training of future users of the PATBox

software. Training activities in this respect will be part of the ProPAT exploitation strategy as

potential customers will be addressed.

http://www.icspec.eu/

http://www.spire2030.eu/recoba


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4. Training materials

For all events presented in chapter 3, presentations and posters have been prepared and are

provided as training material in this deliverable. A dedicated set of training material statistical

process control has been compiled by UB. An overview on the topics covered and materials

provided are summarized in Table 1.

Table 1: Overview on ProPAT training materials

Posters

Characterisation of particle size distribution in process monitoring

PATBox: Global Process Control Platform

Compact and cost effective online granulometer for particle size

monitoring in industrial applications

Decision support by process monitoring and statistical process

control

Validation of online particle sizing sensor for process control

Quality parameter monitoring and end-point detection in polyester

production process within NIR spectroscopy and multivariate analysis

Moisture monitoring and process end-point detection in fluidized bed

drying of pharmaceutical granules with NIR spectroscopy and

multivariate analysis

Data fusion workflow for process monitoring and control

Decision support by process monitoring and statistical process control

Data fusion strategies for NIR-based batch process control and end-

point detection

Monitoring and control of saturated polyester resins production

process with NIR spectroscopy and multivariate statistical process

control strategies

ProPAT: Robust and affordable process control technologies for

improving standards and optimising industrial operations

Presentations

ProPAT concept, overview and case studies

On-line and data fusion strategies for NIR-based industrial batch

process monitoring and control; incl. gasoline quality control case,

process modelling, data fusion strategies, on-line process control and

MSPC strategies

Alignment-free multivariate statistical process control for online

monitoring of batch evolution, incl. pharmaceutical granules and


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gasoline distillation case studies, process modelling, and MSCP for on-

line monitoring of batch process evolution

Complete set of dedicated training lecture on statistical process

control incl. fundamentals and tools


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5. Annex 1 Workshop programmes


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13.-14.12.2017, TACKLING THE FUTURE OF PLANT OPERATION -JOINTLY TOWARDS A DIGITAL

PROCESS INDUSTRY, Barcelona (Spain)

Programme Wednesday 13.12.2017

09:00 Welcome address

09:10 Overview of the workshop Day 1 – organizational details

09:15 Key note on the digital strategy of P&G Andre Convents, P&G

10:00

Overview of projects funded under SPIRE-01-2014 Integrated Process Control on projects CONSENS: Manuel Pereira Remelhe, Bayer AG, Germany ProPAT: Yorgos Chalkias, IRIS, Spain RECOBA: Omar Naeem, BASF SE, Germany DISIRE: George Nikolakopoulos, Luleå Uni of Technology, Sweden iCspec: Rainer Strzoda, Siemens AG, Germany


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11:00 Coffee break and networking

11:30

Highlights & Case studies 1 Already producing or still calibrating? - Online NMR Spectroscopy as Smart Field Device Michael Maiwald, BAM NIR control of polymer processing Frans L. Muller - University of Leeds Plantwide control of modularized production plants Sebastian Engell, TU Dortmund

Resource efficient liquid steelmaking – Process modeling and real-time sensing for control of melt temperature Bernd Kleimt, VDEh-Betriebsforschungsinstitut

13:00 Lunch break

14:00

Highlights & Case studies 2 On-line process model for silicon refining – An operator support system based on nonlinear model predictive control Kjetil Hildal, Elkem PAT and digitalization for paving the way to Industry 4.0 Alejandro Rosales - IRIS

Image-based diagnosis tool for combustion improvements Carlos Herce, CIRCE (Research Centre for Energy Resources and Consumption) The Highway from Big Data Analytics to Advanced Process Control Andreas Krüger; atlan-tec Systems GmbH Real-time gas composition measurement – a prerequisite for efficient process control Rainer Strzoda, Siemens AG

16:00 Coffee break and networking

16:30

Panel discussion SPIRE towards post H2020 Àngels Orduña Cao, Executive Director A.SPIRE aisbl Digitalization Manufacturing – Impact on Industry, Society and Economy


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08:30 Welcome address & wrap-up of day 1

Review of the workshop day 2 – organizational details

08:50 Parallel workshop sessions, 1st round

10:00 Parallel workshop sessions, 2nd round

11:10 Parallel workshop sessions, 3rd round

Guided discussions on various topics incl. educative poster presentations on novel technologies.

Topics that will be offered in all rounds:

1. Chemical composition sensors

2. Rheology, fouling and particle size sensors

3. Process modelling and simulation

4. Closed loop process control

5. Data analytics for process, quality and asset monitoring

6. Data and tool integration - future vison

7. Case studies

8. Aspects of sensor development

12:10 Lunch break

13:00 B2B brokerage Targeted networking in structured bilateral meetings

15:30 Wrap-up poster sessions

16:00 Final remarks

16:15 End of meeting

16:45 Harald Peters, BFI

Andre Convents, P&G Martin Winter, Cefic

17:30 End of 1st day

Thursday 14.12.2017


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6. Annex 2 Training Materials

6.1. Educative posters on ProPAT technical topics

Presented at: TACKLING THE FUTURE OF PLANT OPERATION, Frankfurt (Germany)

and TACKLING THE FUTURE OF PLANT OPERATION, Barcelona (Spain)


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Presented at: TACKLING THE FUTURE OF PLANT OPERATION, Barcelona (Spain)


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Moisture monitoring and process end-point detection in fluidizes bed drying of

pharmaceutical granules with NIR spectroscopy and multivariate analysis


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Presented at: TACKLING THE FUTURE OF PLANT OPERATION, Barcelona (Spain) and

17th Chemometrics in Analytical Chemistry, 2018, Halifax, Canada


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Presented at: 9th Colloquium Chemiometricum Mediterraneum, 2017, Arles, France


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Presented at: EuroPACT 2017, Potsdam (Germany)


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6.2. Educative presentations and training lectures


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Presented at: EuroPACT 2017, Potsdam, Germany


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Presented at: EuroPACT 2017, Potsdam, Germany


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Presentation at: 17th Chemometrics in Analytical Chemistry, 2018, Halifax, Canada


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6.3. Specific training material on statistical process control


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