WO2020152235A1

WO2020152235A1 - Modular process control system for a chemical process

Info

Publication number: WO2020152235A1
Application number: PCT/EP2020/051551
Authority: WO
Inventors: Andreas Mueller; Michael Dejmek; Peter Welter; Florian Huber
Original assignee: Hte Gmbh The High Throughput Experimentation Company
Priority date: 2019-01-25
Filing date: 2020-01-23
Publication date: 2020-07-30
Also published as: EP3914385A1

Abstract

The invention relates to a modular process control system (1a) and to a method for controlling said process control system for chemical processes. The process control system has a control unit (05), a process unit (01), an external module (03, 04) and a logistics module (02, 02', 02"). The logistics module is designed to accommodate a reactant E, a product P, an intermediate product Z and/or a reactor R (16, 16', 16", 16''') and to transport same to or from the process unit and/or the module. The process unit is designed to receive E, Z and/or R from the logistics module, to accommodate R and to carry out a chemical process to produce P or Z. The logistics module is further designed to accommodate the P or Z produced by the process unit and/or to accommodate R and to transport same. The module is designed to accommodate E, P, Z and/or R from the logistics module or to deliver same thereto. The control unit is designed to receive data from the logistics module, the process unit or the module, to calculate an optimised process flow and, based on said optimised process flow, to control the logistics module, the process unit and the module.

Description

Modular process control system for a chemical process

Background of the Invention

The invention relates to a device and a method for carrying out chemical processes, in particular chemical research processes, by means of flexibly arranged system components. In particular, the invention relates to a modular process control system, a method for controlling this process control system and a computer-readable medium.

Complex systems are mostly used to design chemical processes efficiently and to manufacture chemical products efficiently. The individual components of this entire process, such as the storage of the starting materials, intermediate products or products, the analysis of the intermediate products or products or the implementation of the process itself, are often carried out by piped systems. Furthermore, manual work, such as assembly, is often performed in the analysis of the products and the process. Furthermore, a large number of sensors and / or complex analytical measuring devices, which are required for controlling or regulating the process, are installed on each process unit which carries out a chemical process. These disadvantages are to be at least partially eliminated by the following invention.

Description of the invention

It is an object of the invention to flexibly design and further optimize a process flow of a chemical process, and to further automate it.

This object is achieved by the subject matter of the independent claims. Embodiments and developments can be found in the dependent claims, the description and the figures.

The invention relates to a process control system and a method for improving chemical processes and in particular chemical research processes, the process control system having a plurality of system components and a central control unit. The system components include at least one process unit, at least one external module, preferably several external modules, and at least one logistics module.

A first aspect of the invention relates to a modular process control system for chemical

Processes, especially for chemical research processes. The modular process control system has a central control unit, at least one process unit, at least one external one Module and at least one logistics module. The logistics module is set up to receive an educt, a product, an intermediate product and / or a reactor and to transport it to or from the process unit and / or the external module. The process unit is set up to receive the starting material, the intermediate product and / or the reactor from the logistics module, to take up the reactor and to carry out a chemical process so that the product or the intermediate product is produced. The logistics module is also set up to receive and transport the product or intermediate product generated by the process unit and / or the reactor. The external module is set up to take up or deliver the starting material, the product, the intermediate product and / or the reactor from the logistics module. The central control unit is set up to receive data from the logistics module, the process unit or the external module, one

Calculate the process flow and control the logistics module, the process unit and the external module based on this process flow. The process control system is characterized in that the logistics module is autonomous and physically separate from the central control unit, the process unit and the external module.

In other words, a chemical process, especially a chemical one

Research process through the use of logistics modules to make them more flexible, dynamic, efficient, space-saving and cost-efficient. Furthermore, the chemical process can be automated further by using the logistics module. The logistics module can do this for goods or substances such as Transport starting materials, products or intermediate products, or reactors between the various system components of the modular process control system. The logistics module can advantageously be controlled by a central control unit, in which data or information from the other system components (e.g. the process unit and the external module) also converge. So that can

Logistics module serve to decouple the chemical process, products and

To store intermediate products temporarily, not to exceed a critical quantity of substance (e.g. due to the risk of explosion) at the process unit, to adapt the production process flexibly to the current circumstances or to take samples and transport them to an analysis device. It should be noted that the control unit can calculate an optimized process flow based on the received data from the logistics module, the process unit or the external module and can accordingly control the system components. Here, the control unit can optimize the process flow according to various criteria, for example an optimization can take place with regard to the production time, the production costs, the use of materials or the energy consumption. Furthermore, the control unit can reschedule or adapt the process if this is based on the received data appears necessary. In other words, the modular process control system allows a chemical process to be rescheduled flexibly.

The external module can be arranged decoupled from the process unit. This means that the external module can be located at a certain spatial distance from the process unit, but can also be arranged in an adjacent environment. The external module can in particular take on tasks that are not in the foreground of the chemical process, such as the analysis of samples or the storage of starting materials, products, intermediate products or reactors.

Furthermore, the external module can be in an adjacent environment to the process unit, but the external module is not physically connected to the process unit or has no structural connection to the process unit. It should be noted that the external module can be a storage module or an analysis module, for example, which allows a time connection to the process. This time connection can be within a normal test period, for example within a few hours, days or even several weeks.

The logistics module can cause a flow of material between the individual system components that is independent of structural connecting elements, which allows the direct chronological sequence of individual process steps that is normally used in process engineering units to be decoupled. The logistics module can act like a valve for the material flow with the additional advantage that the time sequence in the process can be changed without piping the process lines. It should be noted that several logistics modules can be used, in particular if several external modules or process units can be used in the modular process control system, between the external modules and the process unit (s) several logistics modules can be used.

The logistics module can be a movable unit that has at least one transverse mobility (i.e. mobility in the horizontal plane). Furthermore, the logistics module can have a gripping arm with a gripping means. The logistics module can also clean the reactor of the process unit using the gripper arm. This can

be provided in particular in a batch reactor. The logistics module can be an autonomous unit which has maneuverability, is movable and can be handled by

Can make objects, test samples or mounts with test samples. The

Logistics module can create an effective link between the different

Manufacture system components and the process unit. The logistics module can also be connected to the central program unit, preferably by means of a wireless connection, so that the logistics module can transmit data to the central control unit and can receive commands from the central control unit. The term autonomous units means that the logistics module has a physical decoupling from other units.

Furthermore, it should be noted that the gripper arm can be designed both as a horizontal and as a vertical articulated arm robot, the latter form being the preferred. Furthermore, it should be noted that sensors can be integrated in the gripper or its fingers which allow detection, analogous to the human fingers, of distance, heat, cold, pressure, force etc. and in a further form even as a human hand with five Fingers can be designed.

The data exchanged between the logistics module, the process unit and / or the external module and the central control unit can include movement data or navigation data, loading data or status data of the logistics module, process parameters, such as e.g. Temperature, pressure, throughput, production quantity, reaction speed or quantity of substance, data of the process unit or inventory data or analysis results of the external module. In other words, the control unit can control the logistics module and its path within the process. The analysis data can relate, for example, to the quality, the amount, the temperature or the purity of the sample.

The logistics module and the resulting flexible design of the process can always be advantageous if a further analysis or an adaptation of the process is necessary, for example if a further or new sample is required for a further test. Conventionally, due to the fixed piping, only a limited flexibility within a chemical process is possible. The logistics module can fetch a new educt or intermediate product from the storage module if the central control unit determines that this is necessary for the chemical process. This means that the amount of explosive, flammable or toxic educts or intermediate products that are stored in the production hall or laboratory can be expanded without causing problems under occupational safety and health law. In other words, the amount of substance can easily be increased by the logistics module by adding a container, e.g. a cartridge with which the corresponding substance in the system is simply exchanged as soon as it is used up.

Furthermore, the analysis following the process can be set in a new chronological (priority) order depending on test results from other tests, for example in order to reduce the test time or to reorganize the process itself. The actual reaction in the process unit can also follow Processes for stock preparation, such as stock separation, stock dilution, stock cleaning or stock applications, are structurally separate from the reaction process. This is possible even if the various sub-processes are structurally separate from one another, since here too the logistics module can put them in a (also new) chronological and logical sequence.

The free material connection of the system components thus resembles the wireless data connection and facilitates free control of a process flow (and reorganization of the process if necessary), which identifies the module character of the process identically in the form of control modules (activities), each of which is a process unit or a control external module, which in turn can be connected to one another via the logistics module. The time sequence in the process flow control can be freely defined regardless of structural restrictions, which allows maximum flexibility.

The logistics module can ground-based, in the form of ^AGV's (Autonomous Guided Vehicle) or trucks, or not ground-based, in the form of drones be. Such drones, for example, move along defined tracks along the ceiling of the production hall or the laboratory and thus resemble rail-bound transport systems, but do not have their limitations like the fixed transport sequence.

In other words, a modular process control system for carrying out chemical processes or chemical research experiments is described here. This modular process control system can have continuous system components and non-continuous system components. The continuous system components and non-continuous system components can be integrated in associated modules or units. A non-continuous system component can be arranged in an external module. The individual system components are connected to each other by the logistics module. The feedback between the external module and the process unit can take place via the central control unit. The central control unit can have a hierarchically arranged control structure so that the modular process control system can be mapped well and easily.

A chemical process within the scope of this disclosure can in particular be a catalytic process in the presence of a solid catalyst. In one embodiment of the invention, the process unit comprises a device for carrying out High throughput research experiments. For this purpose, several reactors or series-coupled reactors can in particular be arranged in parallel.

The analysis of the sample of the process unit by the external module, here an analysis module, can deliver a result data set. This result data record can be transmitted to the central control unit. In a further embodiment, however, this result data record can also be used by an external user, such as a customer, by means of a cloud, e.g. be made available on the Internet. Furthermore, the external user can have the option of evaluating the result data record and using the evaluation to guide the central control unit to change or adapt the process or the course of the process. In other words, you can intervene in the process and in particular in the control of the logistics module from the outside in order to adapt it "live" to the current conditions.

The analysis module can in turn consist of a nitrogen / sulfur analysis module or a gas chromatography module (GC analysis), a sensor module, e.g. a balance, an infrared sensor (IR), a rheometer or a tensile strength device, a dilution or distillation device to prepare the nitrogen / sulfur analysis or GC analysis and / or an additive manufacturing device (3D printer) to prepare the train - Tear resistance measurement passed.

The logistics module can thus create a fast, flexible, decoupled, dynamic system.

It should be noted that the process control system can also be referred to as a process control system or as a modular production system.

According to one embodiment of the invention, the process unit has a reaction space which receives the reactor. In the reaction space, gaseous and / or liquid material flows are brought into contact, preferably in the presence of a solid catalyst or a catalyst dissolved in the material flows, for the purpose of material conversion or separation. The reactor is a boiler reactor, a pressure vessel reactor, a stirred tank reactor, a

Fluidized bed reactor or a tubular reactor. Furthermore, the reactor can also be a sequence of several reactors or further process engineering process units. Furthermore, it should be noted that the reactor can also be designed as a membrane reactor or as an ebullated bed or can be in combination with these reactors. According to a further embodiment of the invention, the process unit has a plurality of reaction spaces, which are preferably arranged parallel to one another. Thus, several different reactions can be carried out in parallel or the same reaction can also be carried out in parallel in order to increase the production quantity. More preferably, the reaction spaces arranged in parallel partially consist of several reaction spaces connected in series.

According to one embodiment of the invention, the reaction space of the process unit has a volume between 0.1-5000 ml, preferably a volume between 1-2500 ml.

According to one embodiment of the invention, the reactor has a catalyst. This catalyst can be arranged, for example, within a tubular reactor and a gas stream can flow through it in the reaction chamber of the process unit. Furthermore, the catalyst and / or the reactor including the catalyst can be added

Manufacturing processes (3D printing), such as laser sintering, are produced. Thus, catalysts with different particle sizes or from different

Materials used in the reactor. Additive manufacturing enables a free three-dimensional structure to be achieved within the catalytic converter. Furthermore, material samples can be produced in 3D printing for material testing, for example corrosion tests or physical separation tests with different membranes or electrochemically active substances. In the latter case, an electrical potential is still applied to each reactor to support the reaction.

According to a further embodiment of the invention, the catalyst has a volume between 0.5-500 ml, preferably a volume between 0.75-250 ml and more

more preferably a volume between 1 - 100 ml.

According to one embodiment of the invention, the external module has a device for mass determination, dilution and / or analysis. The logistics module is set up to take a sample from the process unit and to the device for

Transport mass determination, dilution and / or analysis. The device for mass determination, dilution and / or analysis is set up to measure, dilute and / or analyze the sample and to send or transmit the result of this measurement, dilution and / or analysis to the central control unit. The central control unit is set up to control the process unit, device for dilution and / or analysis based on the result of the measurement, the dilution and / or the analysis. Furthermore, the central control unit can control based on this result further optimize the chemical process so that the highest possible quality, a short time or a small amount of material is used.

The process unit can generate process data on relevant process parameters such as pressure, temperature, flow rates, electrical measurement values to qualify the chemical reaction and online analysis data. The process data can then be transmitted to the central control unit. The process unit can generate samples or test samples. The samples can be stored in a receptacle, such as a container. The receptacles filled with samples can first be stored in the area of the process unit, e.g. in a sample holder. The receiving containers filled with samples or a part of the receiving containers filled with samples can then be picked up by the logistics module and transported to the external analysis module. The external analysis module can analyze the supplied samples. The data generated during the analysis or the results can be communicated to the central control unit or can be transmitted to it.

The central control unit in turn carries out an evaluation of the data obtained during the analysis, in particular with regard to the process parameters of the process unit. The evaluation by the central control unit can be a comparison of actual and target values. On the basis of the results obtained in the evaluation, the central control unit can adjust process parameters or, based on this, the central control unit can further optimize the process.

With the described modular process control system, the equipment of the process unit can be simplified in terms of measurement technology compared to conventional process plants, since sensors that are otherwise directly connected to the material flow can also be connected to the material flow via the logistics module. One application is the weighing of the samples after sampling. With the weighing, a material balance of the chemical process is possible, which makes statements, for example, about the turnover of the insert components with a specific catalyst. This scale is therefore an external module and does not have to be installed in every process unit, but can be used by several process units. Another application is the dilution of the test samples before the actual characterization in the analysis module. The test samples are brought into the condition necessary for the characterization by the dilution. This dilution step can be carried out in a separate sample preparation module. The sample preparation can include several work steps. The sample preparation module can be used by several process modules as well as analysis modules. The Sample preparation module is connected to the other modules via a logistics module.

According to one embodiment of the invention, the external module from the group consisting of a mass determination device, an analysis device, a measuring device, a sensor, a distillation device, a dilution device, a further process unit, a reactor store, a storage for sample containers, one

Barcode labeling device, a liquid storage, a solid storage, a

Eduktlager, a product warehouse and / or a device for additive manufacturing selected.

In a preferred embodiment, the modular process control system has a storage module as a system component. A storage module can include different types of stored starting materials, products, intermediate products, reactors or catalysts. The storage module can have a storage module for liquids, a storage module for solids and / or a storage module for reactors. In addition, the storage module can also have a synthesis module, preferably the synthesis module is a device for additive manufacturing, i. a 3D printer. For example, the device for additive manufacturing can be used to produce a tensile test specimen, in particular if a polymer is produced in a batch reactor and is subsequently printed in a specimen.

According to a further embodiment of the invention, the reactor and / or the catalyst is produced by the additive manufacturing device.

With the synthesis module of the storage module, reactors made of different materials can be printed and then stored in the storage module. In addition, it is also possible to print catalysts which are made up of different base materials, which vary in layers or which also consist of different materials within a layer. These printed components can then be stored in the storage module for solids. For example, the test task of the process can consist of evaluating different catalysts.

By choosing suitable materials, the corrosion resistance of the reactors can be adjusted so that the reactors are suitable for the respective process. In this case, all reactors consist of the same mixture of materials. However, the material mixture can also be composed such that all reactors have different materials. In this case, the test task can be to test the reactors themselves, for example their chemical compatibility with the product in the reactor. According to one embodiment of the invention, the logistics module is an industrial truck, a drone, a truck or a rail vehicle. Furthermore, it should be noted that the logistics module itself can already have a mass determination device in order to carry out a weighing. The logistics module can be localized, for example, by means of conductor loops which are introduced into the ground, but the logistics module can also be localized via satellite navigation, such as GPS. Localization methods using pseudo satellites are also possible, so that precise localization and navigation within a building is possible. A laser surface scanner integrated in the logistics module can also be used for localization using a mapping process.

According to one embodiment of the invention, the starting material, the product and / or the

Intermediate product in a cartridge container. The logistics module is accordingly set up to pick up and transport the container. So you can too

Liquids, hazardous substances and / or explosive substances can be transported easily and safely. Furthermore, the containers can also be stacked and / or handled more easily in the storage module. In other words, the storage unit can provide receptacles for the container.

According to a further embodiment of the invention, the data exchange between the logistics module, the process unit, the external module and the central control unit, and the control of the logistics module, the process unit and the external module takes place wirelessly.

The data exchange between the individual system components (process unit, external module and logistics module) and the central control unit can take place wirelessly, over the air. The wireless transmission or reception of the data can be done via Bluetooth, WLAN (e.g. WLAN 802.11 a / b / g / n / ac or WLAN 802.1 1 p), ZigBee or WiMax or also by means of cellular radio systems such as GPRS, UMTS, 3G, LTE, 4G or 5G. Other transmission protocols can also be used. The protocols mentioned offer the advantage of the standardization that has already taken place.

According to one embodiment of the invention, the modular process control system comprises several logistics modules, several process units and several external modules. The central one

The control unit is set up to control the transport by means of the multiple logistics modules between the multiple process units and / or the multiple external modules, and the central control unit is set up to do the modular based on the received data of the logistics modules, the process units or the external modules Optimize process control system. In other words, the described modular process control system can be flexibly expanded and it can have a large number of system components, all of which are controlled by the central control unit. This shows another advantage of the logistics modules, as they can be used flexibly and dynamically between the large number of system components and the individual system components can also be flexibly connected to one another.

According to one embodiment of the invention, the central control unit also has a database and an interface. The interface is in turn set up to process the data received by the central control unit of the logistics module, the process unit and / or the external module. Furthermore, the interface enables one

Remote access, for example by a customer.

The underlying control architecture of the modular process control system can be hierarchical. Starting with the level of the process control technology (PLT) to the recipe sequence control (RAS) to the database, the number of individual pieces of information can decrease, while the information density can increase. In other words: At the PLT level, there is a query of material states (pressure p, temperature T, quantity, etc.). This information can be filtered in the transition to the level of the recipe sequence control, in information that is used for process control and information that is used to describe the substance. These substance states can be translated into descriptions of the process at the database level. In particular with the help of balance calculations and reaction kinetics, in order to subsequently trigger decisions based on the material states that influence the further course of the process. These material states can be reflected back to the level of the PCT, where they are taken into account in a control loop (p, T, amount, etc.).

Another control level - asset management - can be included if there are multiple process units or linked process units. The asset management can then coordinate the chronological sequence in which the process units are operated with one or more logistics modules and can also query the availability of upstream or downstream system components, for example the individual external modules. For example, a process unit with a recipe sequence control and a process control system (RAS + PLT (1)) reports a sample analysis to the asset management. This then checks the readiness of the downstream analysis unit (eg gas chromatography) to take samples to be measured. Then proceeded the logistics module to the process unit, takes the samples there and transports them to the analysis unit and equips them with the sample. Fleet management, for example, coordinates the logistics module. This fleet management can be in direct contact with the asset management. Asset management can also be used to plan the utilization of the process units and / or the external modules through order planning in production or in the laboratory. For this purpose, it can check the data traffic between the process units and the central control unit and reports an availability for new orders if, for example, the data traffic fails. The latter can be used as an indication that the process unit is underutilized. Depending on the degree of expansion of the control level, very complex sequences of effects and causes can be triggered if calculation algorithms (machine learning) are included in this level, for example for the detection of upcoming system problems in the near future by evaluating long-term measured process data.

This may require a connection to the central control unit or an interface, which does not have to be in the direct vicinity of the process unit, but is also connected to the process unit via remote access or cloud access. Such a cloud access can be realized with a user (customer) who has proprietary information that should only be used for billing and data compression in this procedure, but should not leave the user's proprietary environment. Access to the process control of the chemical process via the cloud can then also allow the user remote control of the process (remote control) within defined security limits for the process unit on the basis of this proprietary information. This gives the user more direct process control and improves their data protection from competitors.

Cloud access can also be used to offer additional services (cloud services) that cannot be provided by the user in the form of the following work packages: "Machine learning" based on existing historical user data and from this developing specifications for new test variants that Calculation of reaction kinetics on the basis of sales measurements, computer simulations of the temperature distribution in the reactors on the basis of the calculated reaction kinetics and material flows (hot-spot simulation), statistically cleverly chosen parameter ranges as a specification for new test plans (Design of Experiments).

The cloud access can be a control unit or an interface to the central control unit. This cloud access can be available for a variety of chemical processes, but each user can only use the chemical processes that have been approved for them view and adjust. Furthermore, the cloud access can have several control units, which are distributed over different locations (worldwide). Cloud access can be, for example, a server that can be reached via the Internet or another network.

In a preferred embodiment, the interface is designed to report the utilization of the modular process control system to an order manager and to release it

Display research capacity.

In a further, even more preferred embodiment, the interface is designed to enable the exchange of test results and further calculations.

Another aspect of the invention relates to a method for controlling a modular

Process control system for chemical processes, especially chemical research processes. The process has the following steps:

- Receiving data from a logistics module, a process unit and / or an external module;

- Evaluation of the received data by a central control unit;

- Calculating, by the central control unit, a process flow based on the received data;

- Controlling the logistics module, the process unit and / or the external module based on the calculated process flow in order to obtain a chemical process.

The method for improving chemical processes can include the configuration of system components, a selection and compilation of system components taking place which then carry out the implementation of integrated work processes. The system components can be configured via the central control unit.

It should be noted that the steps of the method can also be carried out in a different order or simultaneously. Furthermore, there can also be a longer period of time between individual steps.

Another aspect of the invention relates to a computer-readable medium on which a

Program element that, when on a central control unit of a modular

Process control system is executed, the modular process control system instructs to carry out the steps of the above and below described method is stored. Further features, advantages and possible uses of the invention result from the following description of the exemplary embodiments and the figures.

The figures are schematic and not to scale. Are in the following

Description of the figures given the same reference numerals, they designate the same or similar elements.

Brief description of the figures

1 shows a schematic illustration of the modular process control system according to an embodiment of the invention.

2 shows a further schematic illustration of the modular process control system with two logistics modules according to an embodiment of the invention.

Fig. 3 shows a schematic representation of the individual system components of the

Modular process control system, which is shown in Fig. 2, according to an embodiment of the invention.

Fig. 4 shows a schematic representation of the different control levels of the

modular process control system according to an embodiment of the invention.

5 shows a schematic according to a further embodiment of the invention

Presentation of the modular process control system, which is connected to different production processes via a cloud server.

6 shows an abstract flow and control diagram of the modular process control system according to an embodiment of the invention.

7 shows a cloud server, which is connected to a plurality of process control systems, according to an embodiment of the invention.

8 shows a flowchart for a method for controlling a modular

Process control system according to an embodiment of the invention.

Detailed description of embodiments 1 shows a schematic illustration of the modular process control system 1a. The modular process control system 1 a has a process unit 01, a logistics module 02, a first external module 03, which is configured here as an analysis module 03, a second external module 04, which is configured here as a storage module 04, and a central control unit 05. The wireless connection between the logistics module 02 and the central control unit 05 is shown in FIG. 1 by means of a dashed line. Thus, between the

Logistics module 02 and the central control unit 05 data can be exchanged. It should be noted that the central control unit 05 can also be connected wirelessly to the external modules 03, 04 and the process unit 01. The exchanged data can in particular the loading state, the position or the current route of the

Concern logistics module 02. It should be noted that the process unit 01 can also exchange data relating to its process parameters, such as temperature, pressure or quantity of substance, with the central control unit 05, but also data relating to the state of a reactor or the replacement of a reactor, the parallel operation of several reaction rooms or the manufactured product or intermediate. The external modules 03, 04 can also exchange data with the central control unit 05; these can, for example, relate to inventory data for a storage module, the free capacities in a storage or the manufacture of a catalytic converter. Furthermore, the data of the external module 03, 04 can include analysis data, sensor data or control data for a dilution device or a

Distillation device.

The process unit 01 can produce a product or a further intermediate product from at least one starting material and / or an intermediate product by means of a chemical reaction. Furthermore, in order to check the quality of this manufactured product or intermediate product and / or to control the process unit 01, the process unit 01 can derive samples 12. Advantageously, these samples 12 can be placed in a container, e.g. a container or a cartridge.

The first external module 03 in Fig. 1 is an analysis module 03, which in turn consists of a nitrogen / sulfur analysis module or a gas chromatography module 31 (GC analysis), a sensor module 32, e.g. a balance, an infrared sensor (IR), a rheometer or a tensile strength device, a dilution or distillation device 33 and / or an additive manufacturing device 34 (3D printer) can exist.

The second external module 04 is a storage module 04 in FIG. 1, in which substances such as starting materials, products or intermediate products or reactors can be stored. For this purpose, the storage module 04 can have a storage for liquids 41, a storage for solids 42 and a storage for reactors 43 exhibit. Furthermore, the storage module 04 can also be a synthesis module 44, such as one

Device for additive manufacturing. Thus the storage module 04 itself

Manufacture reactors or catalysts for the reactors in an additive manufacturing process in order to then use them in the process unit in a chemical process.

The logistics module 02 can take up substances such as starting materials, products or intermediate products, reactors or a sample of the process unit and transport them between the storage module 04, the analysis module 03 and the process unit 01 or exchange them between them. Since the data of the individual system components of the modular

Process control system 1 a are each sent to the central control unit 05, this central control unit 1 a can in turn control the respective system components. For example, the logistics module 02 can transport an educt and a reactor from the storage unit 04 to the process unit 01. Furthermore, the logistics module 02 can transport a sample 12 from the process unit 01 to the analysis module 03, which analyzes the sample 12 and in turn transmits or sends the data of this analysis to the central control unit 05. Based on the data of the analysis, the latter can adapt the control of the process unit 01 or instruct the logistics module 02 to transport a new reactor or further starting materials to the process unit 01.

Through the central control by the central control unit 05 and through the use of logistics modules 02 instead of fixed piping, the process flow can be made more flexible and the logistics modules 02 can simultaneously serve as storage and decoupling between the individual system components of the modular process control system 1a. Furthermore, the use of analysis modules 03 can thus be reduced, since an analysis module 03 does not have to be provided directly on each process unit 01, but this analysis module 03 can be arranged centrally for a plurality of process units 01. Furthermore, the central control unit 05 can ensure maximum utilization of the analysis module 03. Furthermore, the central control unit 05 can optimize the process flow between the individual system components, so that the resulting chemical process is characterized, for example, by a minimal use of time, a minimal use of costs, a minimum use of materials, a minimum use of energy, maximum production or maximum quality of the resulting products or.

Distinguishes intermediate products. In Fig. 1, the logistics module 02 is shown as an industrial truck, but it can

Logistics module 02 can also be a drone or a truck that transports goods between different locations.

2 shows a further schematic illustration of the modular process control system 1 a with two logistics modules 02 ″, 02 “, which substances or reactors between the individual ones

Transport system components of the modular process control system 1 a. Furthermore, it can be seen in FIG. 2, by means of the dashed line, that each system component, that is to say that

Storage module 04, analysis module 03, process unit 01 and logistics modules 02 ″, 02 “are connected to central control unit 05 in order to send data to it and to be controlled by it. In particular, there is a wireless connection between the

Logistics modules 02 ', 02 "and the central control unit 05 can be recognized via antennas 25.

It can also be seen in FIG. 2 that the process unit 01 has a reaction space which can accommodate one or more reactors 16 ″, 16 ″, 16 ″ ”. Thus, the

Process unit 01 perform several processes in parallel. It should be noted that a sample 12 can be taken from each reactor 16 ', 16 ", 16", which can then be analyzed by the analysis module 03. Furthermore, the process unit 01 can

Process control 15 to control the process unit 01, the

Process controller 15 in turn receives or receives its instructions from central control unit 05. This process control typically consists of one

Recipe sequence control (RAS) and a downstream process control system (PLT). Of

Furthermore, the process unit 01 can have a liquid container 13 in order to store liquids directly on the process unit 01 and to be able to introduce them into the chemical process.

2 also shows a detailed illustration of the logistics modules 02 ″, 02 “, these have a body 21, a gripper arm 22 with a gripper 23 and an antenna 25 for wireless communication. The gripper arm 22 with the gripper 23 can reactors or substances, e.g. in a container or cartridge, pick up and transport. Furthermore, the logistics modules 02 ″, 02 “can accommodate a holder in which several reactors are held or several different containers with different substances.

With regard to the logistics module 02, 02 ', 02 “, it should also be noted that a collaborative robot is preferably used as the logistics module. The logistics module 02, 02 ', 02 "comprises a body 21 and one or more gripping arms 22 which, depending on the embodiment, have one or more gripping tools

or grippers 23 are equipped. The grippers 23 can preferably be replaced. The gripper arm 22 has one or more sensors. In a preferred embodiment, a camera is integrated in the gripping arm 22. The camera enables visual inspections, sound, image and film recordings as well as

Image processing and image recognition. It is further preferred that the body 21 of the logistics module with an energy supply unit - in the form of a battery or

Accumulator is equipped. Furthermore, the energy supply unit can also be used as

Fuel cell and be configured as a capacitor (super-cap) as an electrical energy store. The energy supply unit serves to supply energy to the logistics module 02, 02 ', 02 ”and the gripping arm 22. In a further embodiment, both the gripping arm 22 and the body 21 of the logistics module have their own energy supply unit. This has the advantage that the gripper arm 22 can be operated in stationary arrangements completely independently of the logistics module or the body 21.

In one embodiment, the logistics module 02, 02 ″, 02 “with power or

Torque sensors in the joints equipped that can perceive touches and stop movements if there is contact with a body that is not part of the process. The sensitivity of the individual sensors is adjustable and can be varied. In a further preferred embodiment, the logistics module 02, 02 ', 02 "has a distance sensor such as a laser scanner that the body can perceive even before touching it. With the help of the laser scanner, the possible

Traversing areas as well as fixed obstacles in a floor are recorded and processed into a map of the floor. With the help of an optical camera, patterns can also be recorded and evaluated using algorithms for image recognition

Execution of certain actions such as positioning in front of a measuring device. The gripping arm 22 preferably has a plurality of axes of rotation. In a preferred embodiment, the gripping arm is designed for handling payloads in the range from 1 g - 12000 g, preferably 10 - 10000 g. The range of the logistics module 02, 02 ', 02 “is preferably in the range from 0.5 to 100 meters, the weight of the logistics module is in the range from 5 to 150 kg, preferably in the range from 10 to 100 kg, more preferably in the range from 15-85 kg. The base area of the logistics module 02, 02, 02, has a diameter in the range of 300-1000 mm, further preferably in the range of 400-900 mm. The

Independent mobility of the logistics module 02, 02 ', 02 "is of particular advantage, as this enables the logistics module 02, 02', 02" to integrate external modules that are located in another room and / or on another floor as the process unit. In this case, for example, an elevator or a stairlift can also be used as aids, which are operated independently by the logistics module 02, 02 ', 02 ". In a preferred embodiment, the logistics module 02, 02 ', 02 ”is moved in that it is equipped with wheels under a drive device. In a further embodiment, the logistics module (02, 02 ', 02 “) can be moved in connection with a running rail. In yet another embodiment, the logistics module 02, 02 ', 02 "has movable legs, with the aid of which it can move step by step. In a further embodiment, which is also preferred, the logistics module 02, 02 ', 02 "is able to manage the steps independently by step-by-step movement.

The first logistics module 02 'transfers the sample containers 12' to the analysis module 03 and the second logistics module 02 "transports reactors 16", 16 "" from the storage module 04 or from storage for solids 42 to the process unit 01. Furthermore, FIG. 2 shows that the storage module 04, the process unit 01, the analysis module 03 and the logistics modules 02 ',

02 ”are connected to the central control unit 05.

FIG. 3 shows a schematic illustration of the individual system components of the modular process control system which is shown in FIG. 2. 3 shows the connections to the central control unit 05 in the form of wireless connections. This can be seen in particular from the antenna 25 of the logistics module 02 '.

4 shows the various control levels t1 of the modular process control system. The control levels t1 of the modular process control system are hierarchical. This is illustrated by the triangle. The process unit 01, the external modules 03, 04 and the logistics modules 02 ″, 02 “each have their own control, the central one

Control unit 05 is the parent of the individual units. The logistics modules 02 ', 02 "connect the material flow, the storage and the analysis between the process unit 01 and the external modules 03, 04, thus the logistics modules 02', 02" are shown as the lowest hierarchical level, since these are the easiest and easiest to influence are. A flexible, automated and dynamic process control by the central control unit 05 can be ensured by means of these different control levels t1.

5 shows a schematic representation of the modular process control system, which is connected to different production processes P1, P2, P3 via a cloud server s1. In other words, a cloud server s1 can be superordinated to the central control unit, to which the central control unit transmits its data or part of its data. Thus, several central control units from different can be accessed via the cloud server s1 Production processes P1, P2, P3 and their respective control levels t1 can be accessed. The respective central control unit can also transmit only a defined part of its data to the cloud server s1, for example via an interface, so that the actual chemical process cannot be disrupted by the cloud server s1.

6 shows an abstract flow and control diagram of the modular process control system according to an embodiment of the invention. The individual tasks of the modular process control system are divided according to their task. A "Fleet Management" can control the logistics units, conveyor belts and other transport facilities. "Asset management" can control the individual processes of the process unit, the analysis unit and additive manufacturing. This enables a task-related separation of individual processes or sub-processes. The asset management can control the process control technology (PLT) and the recipe sequence control (RAS) as well as the analysis of samples from this process. The data of the process control technology and the recipe sequence control as well as the analysis can be transferred to a database. Based on this data, the asset management can control the process control technology and the recipe sequence control. In addition, asset management can guide fleet management the appropriate

Correctly coordinate and control transport equipment. The data of the asset

Managements in turn form the basis for order planning.

Fig. 7 shows a cloud server s1, which is connected to several process control systems. This means that several different modular modules can be used via the cloud server s1

Process control systems are monitored or influenced. Furthermore, the individual modular process control systems can be accessed via a cloud server s1, so that a user does not have to be on site. Furthermore, cloud services can be offered via the cloud server s1, for example process data and analysis data can be exchanged directly with the customer via the cloud server and the customer receives the data about his chemical process in real time.

8 shows a flowchart for a method for controlling a modular

Process control system for chemical processes, especially chemical research processes. In step S1, data from a logistics module, a process unit and / or an external module are received by a central control unit. This data can

In particular, movement data of the logistics module, process parameters of the process unit or analysis and inventory data of the external module. The central control unit can then evaluate the received data in step S2. Based on the evaluation of the data, the central control unit can in step S3 an optimized process flow of the calculate chemical process performed by the modular process control system. Furthermore, in step S4, the central control unit can control the logistics module, the process unit and / or the external module based on the calculated optimized process flow in order to obtain an optimized chemical process.

Reference list

1a Modular process control system

01 Process unit that carries out a chemical process

12, 12 ',. . . Sample from the process unit in a container

13 liquid container

15 Process control

16, 16 ', ... reactor, tubular reactor, boiler reactor, stirred tank reactor,

Pressure vessel reactor

02, 02 ',. . . Logistics module (shown here as an industrial truck)

21 Corpus of the logistics module

22 gripper arm

23 grippers

25 Wireless connection of the logistics module to the central control unit 03 External module (here external analysis modules)

31 Nitrogen / sulfur analysis, GC analysis

32 sensor, at least one from the group Libra, IR sensor, tensile strength analysis, rheometer

33 Dilution or distillation device

34 device for additive manufacturing (3D printer)

04 External module (here storage module)

41 bearings for liquids

42 bearings for solids

43 bearings for reactors

44 synthesis module, preferably with a device for additive

production

05 central control unit

t1 hierarchical levels of the control of the modular control system s1 Central control unit as a cloud computing system

P1 production process 1

P2 production process 2

P3 production process 3

S1 to S4 process steps 1 to 4

Claims

1. Modular process control system (1 a) for chemical processes, in particular chemical research processes, comprising:

- a central control unit (05);

- a process unit (01);

- an external module (03, 04); and

- a logistics module (02, 02 ‘, 02“),

wherein the logistics module (02) is set up to provide an educt, a product

To take the intermediate product and / or a reactor (16, 16 ', 16', 16 '') and to transport it to or from the process unit (01) and / or the external module (03, 04),

wherein the process unit (01) is set up to receive the starting material, the intermediate product and / or the reactor (16, 16 ', 16 ", 16" ") from the logistics module (02, 02', 02"), the reactor (16, 16 ', 16 ", 16'") and carry out a chemical process so that the product or the intermediate product arises,

wherein the logistics module (02, 02 ', 02 ") is set up to receive and transport the product or intermediate product generated by the process unit (01) and / or the reactor (16, 16", 16 ", 16" "),

wherein the external module (03, 04) is set up to receive the starting material, the product, the intermediate product and / or the reactor (16, 16 ', 16 ", 16'") from the logistics module (02, 02 ', 02 " ) record or deliver to this,

the central control unit (05) being set up to receive data from the logistics module (02, 02 ', 02 "), the process unit (01) or the external module (03, 04), to calculate a process flow and based on this Process flow to control the logistics module (02, 02 ', 02 “), the process unit (01) and the external module (03, 03), characterized in that

the logistics module (02) is autonomous and physically separate from the central control unit (05), the process unit (01) and the external module (03, 04).

2. Modular process control system (1 a) according to claim 1,

wherein the process unit (01) has a reaction space which receives the reactor (16, 16 ″, 16 ″, 16 ″ “), the reactor (16, 16 ″, 16 ″, 16 ″“) a boiler reactor

Pressure vessel reactor, a stirred tank reactor, a fluidized bed reactor, a tubular reactor or a sequence of several reactors or other process engineering process units.

3. Modular process control system (1 a) according to claim 1 or 2, wherein the process unit (01) has a plurality of reaction spaces, which are preferably arranged parallel to one another, which are more preferably in one

Combination are arranged parallel and serial to each other.

4. Modular process control system (1 a) according to claim 2 or 3,

wherein the reaction space of the process unit (01) has a volume between 0.1 - 5000 ml, preferably a volume between 1 - 2500 ml.

5. Modular process control system (1 a) according to one of the preceding claims,

wherein the reactor (16, 16 ″, 16 ″, 16 ″ “) has a catalyst,

6. Modular process control system (1 a) according to claim 5,

wherein the catalyst has a volume between 0.5-500 ml, preferably a volume between 0.75-250 ml and more preferably a volume between 1-100 ml.

7. Modular process control system (1 a) according to one of the preceding claims,

wherein the external module (03, 04) has a device for mass determination, dilution and / or analysis and the logistics module (02, 02 ', 02 ") is set up to take a sample (12, 12') from the process unit (01 ) to be removed and transported to the device for mass determination, dilution and / or analysis,

wherein the devices for mass determination, dilution and / or analysis are set up to measure, dilute and / or analyze the sample (12, 12 ') and the result of this measurement, dilution and / or analysis to the central control unit (05 ) to send

wherein the central control unit (05) is set up to control the process unit (01), the device for dilution and / or analysis based on the result of the measurement, the dilution and / or the analysis.

8. Modular process control system (1 a) according to one of the preceding claims,

the plurality of external modules (03, 04) from the group consisting of one

Mass determination device, an analysis device, a measuring device, a sensor, a distillation device, a dilution device, another

Process unit, a reactor warehouse, a warehouse for sample containers, one

Barcode labeling device, a liquid storage, a solid storage, a

Eduktlager, a product warehouse and / or a device for additive manufacturing is selected.

9. Modular process control system (1 a) according to claim 8,

wherein the reactor (16, 16 ″, 16 ″, 16 ″ “) and / or the catalyst is produced by the additive manufacturing device.

10. Modular process control system (1 a) according to one of the preceding claims,

wherein the logistics module (02, 02 ‘, 02“) is an industrial truck, a drone

Truck or a rail vehicle.

1 1. Modular process control system (1 a) according to one of the preceding claims,

the starting material, the product and / or the intermediate product being in a container, and the logistics module (02, 02 ″, 02 “) being set up to receive and transport the container.

12. Modular process control system (1 a) according to one of the preceding claims,

the data exchange between the logistics module (02, 02 ', 02 "), the process unit (01), the external module (03, 04) and the central control unit (05), and the control of the logistics module (02, 02', 02 “), The process unit (01) and the external module (03, 04) takes place wirelessly.

13. Modular process control system (1 a) according to one of the preceding claims, comprising a plurality of logistics modules (02, 02 ', 02 "), a number of process units (01) and a number of external modules (03, 04),

the central control unit (05) being set up to control the transport by means of the plurality of logistics modules (02, 02 ', 02 ") between the plurality of process units (01) and / or the plurality of external modules (03, 04), and wherein the central control unit (05) is set up to optimize the modular process control system (1a) based on the data received from the logistics modules (02, 02 ', 02 "), the process units (01) or the external modules (03, 04).

14. Modular process control system (1 a) according to one of the preceding claims,

wherein the central control unit (05) further has a database and an interface, the interface being set up to receive the data of the logistics module (02, 02 ', 02 "), the process unit (01) and / or the external module (03, 04),

whereby the interface enables remote access.

15. Modular process control system (1 a) according to claim 14, wherein the interface is designed to report the utilization of the modular process control system to an order management and to indicate free research capacity.

16. Modular process control system (1 a) according to claim 14 or 15, wherein the interface is designed to exchange test results and more

Allow calculations.

17. A method for controlling a modular process control system according to one of claims 1 to 14 for chemical processes, in particular chemical research processes, with the

Steps:

- Receiving (S1) data from a logistics module, a process unit and / or an external module;

- Evaluation (S2) of the received data by a central control unit;

- Calculating (S3), by the central control unit, a process flow based on the received data;

- Controlling (S4) the logistics module, the process unit and / or the external module, based on the calculated process flow, in order to obtain a chemical process.

18. Computer-readable medium on which a program element, which, when it is executed on a central control unit of a modular process control system, guides the modular process control system to carry out the steps of the method according to claim 17, is stored.