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The services of the Premium Service "Batch to Conti" are mainly suitable for:

• Production processes in the chemical and pharmaceutical industries
• Optimization of chemical reactions and processes

They are particularly advantageous for:

• Development of processes whose starting materials are only available in small quantities
• Fast, highly exothermic reactions (examples: organometallic reactions with Grignard compounds, butyl lithium or complex metal hydrides)
• Reactions with unstable intermediates
• Reactions taking place in classical batch or semi-batch mode at very low temperatures (‑30 °C and lower)
• Reactions with unsatisfactory selectivities and/or yields
• Reactions with problematical or even impossible scale-up
• Particularly safety-relevant reactions

The fine and special chemicals industries, as well as the pharmaceutical industry, are traditionally dominated by batch and semi-batch processes. However, continuous developments in the chemical reaction technology sector mean that continuous modes have become increasingly attractive in the meantime. In particular, the increase in product selectivity and yield as well as improvements in energy efficiency are important arguments with many production procedures for transferring from batch to continuous mode.

With the Premium Service "Batch to Conti", Siemens offers customers from the chemical and pharmaceutical industries comprehensive services for optimization of their production processes through conversion of conventional batch or semi-batch processes to continuous mode. The services have a modular structure, and extend from pure consulting through experimental investigations up to rebuilding of plants.

The Premium Service "Batch to Conti" consists of three modules which build upon each other and which can be ordered individually:

Module 1:
Determination of batch-to-continuous optimization potential through analysis by experts

• One-day workshop to analyze the chemical synthesis processes
• Participants: Siemens experts and representatives of the client with profound knowledge of the process
• Pre-definition of workshop details between client and contractor, e.g. discussion of the chemical processes and visiting of the existing production plant
• Qualitative evaluation of the optimization potential with consideration of possible energy savings, expected increase in product yield, required investment, scale-up possibilities, and safety aspects
• Result: Workshop documentation with qualitative evaluation of the batch-to-continuous potential, and specific recommendations for further actions

Module 2:
Preparation of a feasibility study

• One-week feasibility study for detailed, project-based process analysis with qualitative and quantitative evaluation of the benefits of process optimization
• Participants: Siemens experts and representatives of the client
• Experimental investigation of the optimization potential determined in Module 1 by means of laboratory tests
• Individual targets are, e.g.:
  • Increase in yield and space/time turnover
  • Integration of several reaction stages in one equipment
• Inclusive services:
  • Project-specific adaptation of the continuous laboratory system for the tests (max. 2 days in the laboratory)
  • Production of a test plan and agreement with the client
  • Carrying out of tests (4 days in the laboratory)
  • Processing and documentation of test results
• Extra services (separate charge):
  • Analysis of test samples: agreement on analytical methods between client and contractor; billing of analyses carried out by Siemens according to actual requirement
• Result: Feasibility study, consisting of documentation on trials, qualitative and quantitative evaluation of the optimization potential (Return on Investment), and specific recommendations for implementation

Module 3:
Implementation of the produced feasibility study

• Implementation of knowledge gained in Modules 1 and 2 in a specific project
• Content is the subject of an individual agreement between client and contractor
• Basis for the individual agreement is a project-specific quotation provided by Siemens as the contractor
• Inquiries for production of a quotation should be directed to the address specified under "Further information"

Note:
The modules of the Premium Service "Batch to Conti" do not include any traveling expenses. Traveling expenses from the Hoechst Industrial Estate, Frankfurt am Main, Germany, will be invoiced separately.

• Increase in selectivity and yield
• Saving of up to 80% of energy costs
• Constantly high product quality
• Small space requirements of production plants allows decentralization of production and shortening of transport paths
• Increased safety through plant enclosure and short standstill
• Reduction of scale-up risks, even with extremely fast and highly exothermic reactions
• High space/time yields as result of low reactor volumes and shorter times for heating, cooling, filling, and emptying
• Reduction in number of individual process steps
• Process development, engineering and plant construction from a full-line supplier

These advantages are largely independent of the plant size and the production capacity. The difference they make primarily depends on the industrial characteristic of the process.

Siemens AG
Industry Sector
Industry Automation Division
Industrial Automation Systems

Hoechst Industrial Estate, Building K801
D-65926 Frankfurt

Phone: +49 69 305 305 69

E-mail: team-ec.industry@siemens.com

Additional information is available on the Internet at:

http://www.siemens.de/ec