【Weekly Topic】Production Technology: What aspects should be considered in the development of chemical products? 2011.06.19~06.26

Points to note: ① The product area must rely on health for long-term growth； ②Contents related to chemical processes, chemical engineering processes, and process control ； Regarding the second point mentioned above, the details are as follows: 1. Chemical processes: Chemical processes refer to chemical engineering technologies or chemical production techniques, namely the methods and processes by which raw materials are transformed into products through chemical reactions, including all measures taken to achieve this transformation. Chemical production processes can generally be summarized into three main steps: Raw material processing: To bring the raw materials into a state suitable for chemical reactions, various pre-treatment procedures—such as purification, concentration, mixing, emulsification, or pulverization (for solid raw materials)—are required depending on the specific circumstances. Chemical reaction: This is the key step in production. The pretreated raw materials are reacted under certain conditions such as temperature and pressure to achieve the desired reaction conversion rate and yield. There are various types of reactions, through which the desired product or its mixture is obtained via chemical reactions. Product refinement: The mixture obtained through chemical reactions is separated to remove by-products or impurities, in order to obtain a product that meets the specified composition requirements. 2. Chemical processes: Chemical processes is an engineering discipline that studies the common laws governing the chemical and physical processes occurring in the production activities of the chemical industry and other process industries. These industries start with basic raw materials such as oil, coal, natural gas, salt, limestone, other ores, as well as food, timber, water, air, etc. By employing chemical or physical processes, they alter the composition, properties, and state of these materials to turn them into a variety of high-value products. The so-called “process industries” such as chemical, petrochemical, metallurgical, and pharmaceutical industries generally involve a series of physical or chemical processing steps; this series of steps is referred to as a process. The process needs to be carried out by the equipment. Process equipment must meet the requirements of the process. Chemical engineering includes unit operations, chemical reaction engineering, transport processes, chemical thermodynamics, chemical systems engineering, process dynamics, and chemical process control. Unit operations: The physical processes involved in the production of various chemical products can be reduced to a limited number of basic processes, such as fluid transfer, heat exchange (heating and cooling), distillation, absorption, evaporation, extraction, crystallization, drying, etc. These basic processes are called unit operations. Research on unit operations yields common results that can be used to guide the production of various products and the design of chemical processing equipment. Chemical reaction engineering: Chemical reactions are a core aspect of chemical production; they determine the yield of products and have a significant impact on production costs. Nevertheless, in the early stages, its complexity hindered any systematic study of it. It was not until the mid-20th century that, based on research findings in unit operations and transport processes, several common problems were identified in various reaction processes such as oxidation, reduction, nitration, and sulfonation; these include backmixing within reactors, mass and heat transfer within the reaction phase, mass and heat transfer outside the reaction phase, and reactor stability. The study of these problems, as well as their various effects on reaction kinetics, has given rise to a new branch of science known as chemical reaction engineering, thereby enriching and developing the content and methods of chemical engineering. Transfer process: It is the common foundation of unit operations and reaction engineering. The physical processes that occur in various unit operation equipment and reaction vessels are nothing more than three types of transfer: momentum transfer, heat transfer, and mass transfer. For example, fluid transport based on momentum transfer, gas flow distribution in reactors ； Heat exchange operations based on heat transfer, the removal of polymerization heat from polymerization reactors ； Absorption operations based on mass transfer, diffusion of reactants and products within the catalyst, etc. In some processes, two or more types of transfer phenomena occur simultaneously, such as moisture addition and removal in gases. As a branch of chemical engineering, transport phenomena focuses on studying the rates of these three types of transport and their interrelationships, thereby linking together phenomena that are essentially similar but exhibit different forms. Chemical thermodynamics: It also serves as the theoretical foundation for unit operations and reaction engineering, studying the direction and limits of transfer processes, and providing the basic data needed for process analysis and design. Therefore, the sub-disciplines of chemical engineering can also be divided into two levels: unit operations and reaction engineering are more directly geared toward industrial practice, while transport processes and chemical engineering thermodynamics primarily serve to support the former two sub-disciplines from a fundamental research perspective. These two levels enable a close integration of theory and practice. Chemical process engineering: Since the various process units in chemical processes influence and restrict one another, it is necessary to consider the chemical process as an integrated system and establish the concept of overall optimization. As a result, the discipline of systems engineering developed rapidly within chemical engineering, achieving significant results and giving rise to chemical engineering systems engineering. It is the product of combining systems engineering methods with the two disciplinary branches of unit operations and chemical reaction engineering. Process dynamic characteristics: To maintain rational and optimized operations, process dynamic characteristics are also an important aspect of chemical engineering. The subjects of study in chemical engineering are usually very complex, as evidenced by the complexity of the processes themselves: these involve both chemical and physical aspects, and these aspects often occur simultaneously and influence each other. Complexity of the material system: it contains both fluids (gases and liquids) and solids, with multiple phases often coexisting. Fluid properties can vary significantly, such as low viscosity and high viscosity, as well as Newtonian and non-Newtonian behavior. Sometimes, significant changes in physical properties occur during the process, such as the transition of the reactant system from low viscosity to high viscosity during polymerization. The complexity of boundaries in fluid flow: The varying geometries of equipment such as trays, impellers, and baffles, as well as the diverse shapes of fillers like catalysts and packing materials, result in complex flow boundaries that are difficult to determine and describe. Chemical process control: also known as process control, it is an abbreviation for the automatic control of chemical production processes. Chemical process control primarily deals with the application of control theory in chemical production processes, including the analysis, design, and on-site implementation and operation of various automation systems. It does not encompass purely theoretical research or the design and manufacturing of instruments. The biggest difference between chemical process control and general chemical methods is dynamics and feedback. Classical control theory was developed starting from the premise of describing systems using linear differential equations with constant coefficients. Classical control theory is limited to dealing with single-variable control systems. Modern control theory uses matrix equations that can represent systems of differential equations to describe them, and expresses various new control criteria in functional form; thus, system analysis and design can be carried out through rigorous mathematical operations. When the system is designed to satisfy an extreme value (maximum or minimum) of a control criterion, what is known as optimal control is obtained. Since modern control theory overcomes and compensates for many shortcomings of classical control theory, and can be applied to multivariable systems, it has found extensive application in chemical process control. Control applications: In well-established production processes, chemical process control is an effective means of improving yield and quality, saving raw materials and energy, reducing labor intensity, and cutting labor costs. In recent years, mathematical modeling methods have been used to explore and promote the application of modern control theory in the control of chemical processes. Numerous projects have focused on computer-based control and scheduling management, some of which have been successful, leading to significant improvements in both the technical level of production and its economic efficiency.

Science and technology are the primary driving force for progress, but to truly fulfill this role, they must move beyond the laboratory and be transformed into real productive forces. Only in this way can they create value for society and bring wealth to enterprises. The transition of fine chemical products from laboratory-scale technologies to industrial production techniques is not merely a process of scaling up; it is rather a complex transformation involving equipment, manufacturing processes, as well as the skills of personnel and management standards. In terms of the manufacturing process alone, there are also certain differences between the actual chamber process and the large-scale production process. Therefore, in the process of developing new products, in addition to conducting comprehensive and systematic research on process conditions such as temperature, time, pressure, and the use of catalysts, it is also essential to carry out simulation tests on industrial production equipment, the competence of personnel, and management levels. From the perspective of the transformation process in chemical engineering, the biggest challenge in converting laboratory techniques into production technologies often lies not in the process itself, but rather in the differences between laboratory conditions and production conditions – differences that are sometimes overlooked. Whether in terms of hardware or software, there are significant differences between laboratories and manufacturing enterprises. If the various technical parameters obtained in laboratories are applied directly in large-scale industrial production without being adjusted to take into account the actual conditions of those enterprises, it will surely cause problems in the process of technology transfer, and may even lead to the failure of such transfer. Therefore, to ensure the smooth transition of technology, attention and research should be paid to the following differences. 1. Stability of the process: The stability of the process is very important for manufacturing enterprises. In large-scale industrial production, the equipment is quite large; reaction vessels can weigh from a few tons to over ten tons or even hundreds of tons. From an economic perspective, the cost of a single batch of material used in such processes ranges from hundreds of thousands to millions of yuan, so there can be no room for mistakes, as this could result in severe financial losses for the company. From an environmental perspective, the chemical industry differs from other industries. Several or even dozens of chemical raw materials are simultaneously introduced into a reactor; if the desired substances are not produced, these materials become waste, which is very difficult to recycle. The reaction mixture is also hard to handle, potentially causing significant environmental pollution. Therefore, special attention must be paid to the stability of the process. However, to address the issue of process stability during the conversion process, attention should be paid to the following areas of research. 1.1 Strengthen research on intermediate detection methods and standards. Rigorous intermediate detection methods and quality standards for determining compliance are essential to ensure the safe and smooth progress of production. The development process of new products takes place in the laboratory. In the initial stage, various methods such as liquid chromatography-mass spectrometry, gas chromatography-mass spectrometry, infrared spectroscopy, ultraviolet spectroscopy, and elemental analysis are used to analyze the structure in order to determine whether the resulting product meets the requirements. Once this is confirmed, during the process development phase, less attention is paid to studying the intrinsic quality of the intermediate products for various reasons; judgment is mainly based on experience and observation of reaction phenomena. Some do have testing methods, but they are very crude, involving only simple qualitative assessments such as spot testing, color, and crystal form to make judgments; as a result, there are several issues in large-scale production: one of them is the significant variation among personnel. In a laboratory, one person usually handles a certain portion of the work alone; however, in large-scale production, it’s impossible for one person to do everything—it requires multiple people working together. Second, there are significant differences in equipment conditions. Phenomena that can be observed in the laboratory are difficult to observe directly in large-scale production, and the control of various parameters is not as stable. Third, there are significant differences in the environment. The laboratory is a relatively enclosed environment, whereas large-scale production takes place in an open environment where conditions such as air humidity and temperature vary greatly. As a result, there are significant differences between batches. There are no strict testing methods or standards to control the quality of intermediates, which makes it difficult to decide what materials to use next, often leading to failures in subsequent steps. Therefore, during the new product development process, every intermediate in the research process should be treated as a product. It is necessary to thoroughly study its analytical and testing methods and establish strict quality standards to ensure the safe and smooth progress of production. 1.2 Permissible range of reaction temperature In chemical synthesis processes, we all know that temperature is one of the important factors affecting chemical reactions. Temperature control is a crucial operating condition, as it directly influences various aspects such as the reaction rate, yield, side reactions, and energy consumption. In the process of product development and research, we regard the reaction temperature as a key parameter to be studied in great detail. We determine the optimal reaction temperature and present it as a crucial condition for the reaction. However, we must also fully consider the various complexities faced by manufacturing enterprises; for instance, one such factor is the time required for heating up and cooling down. In the laboratory, due to the small size of the reaction vessels and the fast heat transfer rate of glass, it is generally possible to meet the requirements within a few minutes to at most a dozen minutes. However, in large-scale production, it takes much longer – sometimes even several hours – to achieve the same results. The second is the precision of temperature control. In the laboratory, the temperature can be easily controlled; especially with the advent of advanced equipment and technologies, the precision of temperature control can reach a few tenths of a degree. However, this is difficult in large-scale industrial production, as achieving a precision of within plus or minus 5°C is already quite challenging. Therefore, while studying the optimal temperature for the process, we must thoroughly examine the impact of temperature variations on the reaction, especially in those cases where the reaction temperature has a serious effect on safe production. For example, in reaction systems that contain both concentrated sulfuric acid and acetonitrile, these two substances can undergo uncontrolled and violent reactions at certain temperatures, leading to safety accidents. We must take into account the actual conditions of the enterprise and keep the temperature within an absolutely safe range. Providing enterprises with practical optimal temperatures may result in slight differences compared to those stated in research reports, and this can also have an impact on the yield; however, by minimizing such effects and keeping everything within acceptable limits for safe production, it is recommended to specify reaction temperatures as ranges of degrees, and to avoid using expressions such as ‘at certain degrees’, ‘below a certain degree’, or ‘above a certain degree’ in process reports. 1.3 Adjustment of pH value: In chemical synthesis processes, pH value adjustment is frequently used; it not only affects the yield of the product but also its quality. In enterprises, pH value adjustment is currently done manually, relying on experience and individual judgment; due to differences among individuals, the results of such adjustments vary considerably. In fact, during the process of process research, adjustments are also made manually, with very little use of instruments. The difference is that in process research, after dozens or even hundreds of trials, a wealth of experience regarding both successes and failures is accumulated; this results in high adjustment stability, though not necessarily high accuracy. Therefore, instruments should be utilized to eliminate individual differences among people and minimize the impact of errors on the process conversion. 1.4 Determination of reaction time In chemical synthesis processes, reaction time is an important operational parameter; it directly affects a range of issues such as the yield of the product and energy consumption. In the process of product development and research, we regard reaction time as a key parameter to be studied in depth, so as to determine the optimal reaction time. In industrial plants, the equipment is large-scale and the methods of heating or cooling are relatively limited, which results in longer overall processing times. For most synthesis processes, the longer the time, the higher the yield, up to the point where reaction equilibrium is reached ； However, for a few synthesis processes, an extended time leads to reduced yields, increased side reactions, and lower product quality. For such synthesis processes, it is necessary to fully take into account the actual conditions of the enterprise during product development, and make adjustments and modifications by simulating the actual conditions of industrial production. 1.5 The impact of moisture on the synthesis process: In chemical synthesis processes, it is important to note that moisture has a significant effect on the chemical synthesis. In the new product development process, we pay great attention to absolutely anhydrous reactions involving sodium metal, lithium amide, sodium hydride, etc., requiring that they be carried out under nitrogen protection; however, we pay insufficient attention to reactions using ordinary non-aqueous solvents. In the laboratory, the reaction flasks and other containers used are usually washed or dried naturally or by heating. The humidity of the air is the same as that in the atmosphere; as long as the moisture content of the solvent and raw materials meets the required standards, the impact of moisture on the reaction is generally not noticeable. In industrial enterprises, the dryness levels of the reactor vessels and their connecting pipes, as well as various equipment, vary significantly; moreover, the humidity of the air in the workshops is much higher than that in laboratories. Therefore, it is necessary to take these factors into full consideration through simulation tests, and establish appropriate conditions based on different reactions to ensure the smooth progress of technology transfer. However, it is not possible to require all reactions to be as absolutely anhydrous as possible, as that would increase the production costs for enterprises. 2 Recycling of solvents Organic solvents are essential for chemical synthesis reactions. The production of a new product involves the use of anywhere from a few to dozens or even hundreds of chemical raw materials. Aside from a few that form new substances, most of these materials remain in their original form or as by-products, and determining how to deal with them poses a significant challenge for companies. During the development of new products and new processes, they often go unnoticed due to their small usage amounts. But in enterprises, hundreds or even thousands of tons of these by-products are generated each year; failing to deal with them results in waste and increases production costs ； On the other hand, it will cause severe pollution to the environment. To address this issue, it is necessary, during the rigorous product development process and especially in the later stages of product development, once a mature chemical synthesis process has been established, to conduct thorough analysis of the waste materials generated at each stage of the chemical reactions. These waste materials should be processed accordingly based on their characteristics; as for those that cannot be recycled, whether through combustion or burial, safety assessments must be carried out to ensure the safety of personnel and the environment. This approach helps guide companies in carrying out safe production practices, thereby preventing environmental pollution caused by the manufacture and use of new products and new processes from the very beginning. 3 Wastewater treatment: In the production process of each new product, it is more or less inevitable to encounter wastewater issues. Wastewater treatment is currently the biggest technical challenge faced by enterprises. Whether through chemical methods, enzymatic methods, or adsorption methods, it remains very difficult to effectively address wastewater issues despite the significant investment of human resources, materials, and financial resources. The main reason is the wide variety of chemical substances; it is impossible to completely address them using just one or a few methods. This requires us to analyze the causes of wastewater generation as well as the composition of pollutants in the water, and to collect and treat them in a categorized manner. During the research on chemical synthesis processes, we analyze the components of the wastewater and pollutants generated. On one hand, water is treated as the most expensive organic solvent, and every effort is made to minimize its usage ； On the other hand, by classifying and collecting pollutants according to their composition and treating them effectively, practical wastewater treatment solutions are provided for enterprises, thereby eliminating their concerns. In short, the research and development of chemical synthesis processes are quite challenging, requiring significant investment in terms of human resources, materials, and financial resources. The outcomes of such development efforts are aimed at enabling companies to achieve higher economic growth and ensuring their sustainable development. The only way to realize one’s own value is to quickly transform those achievements into productive forces, serving the enterprise and benefiting society. For various reasons, on the one hand, companies are striving to develop new products, while on the other hand, research institutions have accumulated results that cannot be transferred. At its core, the issue is not price; rather, it is the aforementioned reasons that lead to various problems during the process of technology transfer. A considerable amount of research output remains unfinished, causing significant losses for companies and leading them to feel fearful of new innovations. In fact, solving the above problems is not difficult; as long as, during the process of process research, close ties are established between the laboratory and the enterprise, and slight attention is paid to the differences, all problems can be resolved smoothly

1. The economic and social benefits of the product. 2. The method of waste disposal for the product. 3. Product quality. 4. Safety and stability of the production process. 5. The ease of implementing the product production plan.

Do what you can. Independent innovation, cooperation, introduction, and so on.

Pay attention to the following aspects: 1. Practicality 2. Market prospects 3. Investment 4. R&D cycle 5. The advancement of R&D technology 6. Whether the technical capabilities are sufficient

　When choosing the direction for new product development, companies should consider the following points: (1) Consider the nature and purpose of the product. Before developing new products, it is necessary to thoroughly examine the technical level, performance, and applications of similar products as well as corresponding alternatives, in order to ensure that the newly developed products are advanced or innovative, and to prevent them from being phased out by the market from the very day they are introduced. 　　(2) Consider price and sales volume. Serialized products have low production costs, allowing them to be sold at lower prices to increase sales volume; however, their monotony may also affect sales volume. Therefore, the relationship between serialized and diversified products, as well as prices and sales, needs to be determined through research and investigation. 　　(3) Fully consider the speed and direction of changes in consumer demand. As people’s material living standards improve, consumers’ demands are becoming more diverse and changing at a rapid pace. Developing a new product takes some time, and this time must be shorter than the period during which consumer demand changes in order to have a market and achieve economic benefits. 　　(4) The ability of a company’s product innovation to meet market demands. The four companies that once represented China’s telecommunications industry – Giant Dragon, Great Tang, ZTE, and Huawei – faced similar market opportunities and started off on a similar footing. However, after three to four years, Huawei and ZTE took the lead, while Giant Dragon almost withdrew from the telecommunications market. The most crucial factor determining the gap between these four companies is the ability of their products to incorporate product and technological innovations. 　　(5) Building up the enterprise’s technical capabilities and product development team. It is important to choose the right approach when a company develops new products. With the right choices that suit the actual conditions of the enterprise, risks can be reduced and success is more likely to be achieved. Generally, there are four methods: the original method, the imported method, the combined method, and the improved method. 　　1. Original approach. In the long run, the most fundamental way for companies to develop new products is through self-design and self-development, that is, the so-called original approach. Developing new products in this way facilitates product updates and the creation of a technological advantage for the company, as well as enhancing product competitiveness. To develop products independently, a company needs to have a strong R&D team, a solid technical foundation, and a scientific and efficient product development process. 　　2. Introduction method. Technology introduction is a common method for developing new products. By adopting this approach, companies can quickly master the manufacturing techniques for new products, reduce development costs and the effort required, thereby gaining time and narrowing the gap with other companies. However, the introduction of technology is not conducive to establishing a company’s technological advantages or to the upgrading of its products. 　　3. Improvement methods. This approach involves developing new products based on the company’s existing products, by making changes to their performance, altering their design, or expanding their uses to meet the needs of users. By using this approach, it is possible to rely on the company’s existing equipment and technical capabilities, resulting in low development costs and a high chance of success. However, relying on improved methods for developing new products over the long term can affect the speed of a company’s development. 　　4. Combination method. The integration approach is a combination of innovation and introduction.

Are the raw materials readily available? Is the manufacturing process mature? Is there an oversupply in the industry? Is there a large profit margin? Are there prospects for expanding the supply chain further?

1. Stability of the process: The stability of the process is very important for manufacturing enterprises. In large-scale industrial production, the equipment is quite large; reaction vessels can weigh from a few tons to over ten tons or even hundreds of tons. From an economic perspective, the cost of a single batch of material used in such processes ranges from hundreds of thousands to millions of yuan, so there can be no room for mistakes, as this could result in severe financial losses for the company. From an environmental perspective, the chemical industry differs from other industries. Several or even dozens of chemical raw materials are simultaneously introduced into a reactor; if the desired substances are not produced, these materials become waste, which is very difficult to recycle. The reaction mixture is also hard to handle, potentially causing significant environmental pollution. Therefore, special attention must be paid to the stability of the process. However, to address the issue of process stability during the conversion process, attention should be paid to the following areas of research. 1.1 Strengthen research on intermediate detection methods and standards. Rigorous intermediate detection methods and quality standards for determining compliance are essential to ensure the safe and smooth progress of production. The development process of new products takes place in the laboratory. In the initial stage, various methods such as liquid chromatography-mass spectrometry, gas chromatography-mass spectrometry, infrared spectroscopy, ultraviolet spectroscopy, and elemental analysis are used to analyze the structure in order to determine whether the resulting product meets the requirements. Once this is confirmed, during the process development phase, less attention is paid to studying the intrinsic quality of the intermediate products for various reasons; judgment is mainly based on experience and observation of reaction phenomena. Some do have testing methods, but they are very crude, involving only simple qualitative assessments such as spot testing, color, and crystal form to make judgments; as a result, there are several issues in large-scale production: one of them is the significant variation among personnel. In a laboratory, one person usually handles a certain portion of the work alone; however, in large-scale production, it’s impossible for one person to do everything—it requires multiple people working together. Second, there are significant differences in equipment conditions. Phenomena that can be observed in the laboratory are difficult to observe directly in large-scale production, and the control of various parameters is not as stable. Third, there are significant differences in the environment. The laboratory is a relatively enclosed environment, whereas large-scale production takes place in an open environment where conditions such as air humidity and temperature vary greatly. As a result, there are significant differences between batches. There are no strict testing methods or standards to control the quality of intermediates, which makes it difficult to decide what materials to use next, often leading to failures in subsequent steps. Therefore, during the new product development process, every intermediate in the research process should be treated as a product. It is necessary to thoroughly study its analytical and testing methods and establish strict quality standards to ensure the safe and smooth progress of production. 1.2 Permissible range of reaction temperature In chemical synthesis processes, we all know that temperature is one of the important factors affecting chemical reactions. Temperature control is a crucial operating condition, as it directly influences various aspects such as the reaction rate, yield, side reactions, and energy consumption. In the process of product development and research, we regard the reaction temperature as a key parameter to be studied in great detail. We determine the optimal reaction temperature and present it as a crucial condition for the reaction. However, we must also fully consider the various complexities faced by manufacturing enterprises; for instance, one such factor is the time required for heating up and cooling down. In the laboratory, due to the small size of the reaction vessels and the fast heat transfer rate of glass, it is generally possible to meet the requirements within a few minutes to at most a dozen minutes. However, in large-scale production, it takes much longer – sometimes even several hours – to achieve the same results. The second is the precision of temperature control. In the laboratory, the temperature can be easily controlled; especially with the advent of advanced equipment and technologies, the precision of temperature control can reach a few tenths of a degree. However, this is difficult in large-scale industrial production, as achieving a precision of within plus or minus 5°C is already quite challenging. Therefore, while studying the optimal temperature for the process, we must thoroughly examine the impact of temperature variations on the reaction, especially those reaction temperatures that have a serious effect on safe production. For example, in a reaction system containing concentrated sulfuric acid and acetonitrile, these two substances can undergo uncontrolled and violent reactions at certain temperatures, leading to safety accidents. We must take into account the actual conditions of the enterprise and keep the temperature within an absolutely safe range. Providing enterprises with practical optimal temperatures may result in slight differences compared to those stated in research reports, and this can also have an impact on the yield; however, by minimizing such effects and keeping everything within acceptable limits for safe production, it is recommended to specify reaction temperatures as ranges of degrees, and to avoid using expressions such as ‘at certain degrees’, ‘below a certain degree’, or ‘above a certain degree’ in process reports. 1.3 Adjustment of pH value: In chemical synthesis processes, pH value adjustment is frequently used; it not only affects the yield of the product but also its quality. In enterprises, pH value adjustment is currently done manually, relying on experience and individual judgment; due to differences among individuals, the results of such adjustments vary considerably. In fact, during the process of process research, adjustments are also made manually, with very little use of instruments. The difference is that in process research, after dozens or even hundreds of trials, a wealth of experience regarding both successes and failures is accumulated; this results in high adjustment stability, though not necessarily high accuracy. Therefore, instruments should be utilized to eliminate individual differences among people and minimize the impact of errors on the process conversion. 1.4 Determination of reaction time In chemical synthesis processes, reaction time is an important operational parameter; it directly affects a range of issues such as the yield of the product and energy consumption. In the process of product development and research, we regard reaction time as a key parameter to be studied in depth, so as to determine the optimal reaction time. In industrial plants, the equipment is large-scale and the methods of heating or cooling are relatively limited, which results in longer overall processing times. For most synthesis processes, the longer the time, the higher the yield, up to the point where reaction equilibrium is reached ； However, for a few synthesis processes, an extended time leads to reduced yields, increased side reactions, and lower product quality. For such synthesis processes, it is necessary to fully take into account the actual conditions of the enterprise during product development, and make adjustments and modifications by simulating the actual conditions of industrial production. 1.5 The impact of moisture on the synthesis process: In chemical synthesis processes, it is important to note that moisture has a significant effect on the chemical synthesis. In the new product development process, we pay great attention to absolutely anhydrous reactions involving sodium metal, lithium amide, sodium hydride, etc., requiring that they be carried out under nitrogen protection; however, we pay insufficient attention to reactions using ordinary non-aqueous solvents. In the laboratory, the reaction flasks and other containers used are usually washed or dried naturally or by heating. The humidity of the air is the same as that in the atmosphere; as long as the moisture content of the solvent and raw materials meets the required standards, the impact of moisture on the reaction is generally not noticeable. In industrial enterprises, the dryness levels of the reactor vessels and their connecting pipes, as well as various equipment, vary significantly; moreover, the humidity of the air in the workshops is much higher than that in laboratories. Therefore, it is necessary to take these factors into full consideration through simulation tests, and establish appropriate conditions based on different reactions to ensure the smooth progress of technology transfer. However, it is not possible to require all reactions to be as absolutely anhydrous as possible, as that would increase the production costs for enterprises. 2 Recycling of solvents Organic solvents are essential for chemical synthesis reactions. The production of a new product involves the use of anywhere from a few to dozens or even hundreds of chemical raw materials. Aside from a few that form new substances, most of these materials remain in their original form or as by-products, and determining how to deal with them poses a significant challenge for companies. During the development of new products and new processes, they often go unnoticed due to their small usage amounts. But in enterprises, hundreds or even thousands of tons of these by-products are generated each year; failing to deal with them results in waste and increases production costs ； On the other hand, it will cause severe pollution to the environment. To address this issue, it is necessary, during the rigorous product development process and especially in the later stages of product development, once a mature chemical synthesis process has been established, to conduct thorough analysis of the waste materials generated at each stage of the chemical reactions. These waste materials should be processed accordingly based on their characteristics; as for those that cannot be recycled, whether through combustion or burial, safety assessments must be carried out to ensure the safety of personnel and the environment. This approach helps guide companies in carrying out safe production practices, thereby preventing environmental pollution caused by the manufacture and use of new products and new processes from the very beginning. 3 Wastewater treatment: In the production process of each new product, it is more or less inevitable to encounter wastewater issues. Wastewater treatment is currently the biggest technical challenge faced by enterprises. Whether through chemical methods, enzymatic methods, or adsorption methods, it remains very difficult to effectively address wastewater issues despite the significant investment of human resources, materials, and financial resources. The main reason is the wide variety of chemical substances; it is impossible to completely address them using just one or a few methods. This requires us to analyze the causes of wastewater generation as well as the composition of pollutants in the water, and to collect and treat them in a categorized manner. During the research on chemical synthesis processes, we analyze the components of the wastewater and pollutants generated. On one hand, water is treated as the most expensive organic solvent, and every effort is made to minimize its usage ； On the other hand, by classifying and collecting pollutants according to their composition and treating them effectively, practical wastewater treatment solutions are provided for enterprises, thereby eliminating their concerns. In short, the research and development of chemical synthesis processes are quite challenging, requiring significant investment in terms of human resources, materials, and financial resources. The outcomes of such development efforts are aimed at enabling companies to achieve higher economic growth and ensuring their sustainable development. The only way to realize one’s own value is to quickly transform those achievements into productive forces, serving the enterprise and benefiting society. For various reasons, on the one hand, companies are striving to develop new products, while on the other hand, research institutions have accumulated results that cannot be transferred. At its core, the issue is not price; rather, it is the aforementioned reasons that lead to various problems during the process of technology transfer. A considerable amount of research output remains unfinished, causing significant losses for companies and leading them to feel fearful of new innovations. In fact, solving the above problems is not difficult; as long as, during the process of process research, close ties are established between the laboratory and the enterprise, and slight attention is paid to the differences, all issues can be resolved smoothly. 1. Chemical Process: A chemical process refers to chemical engineering technology or chemical production technology, meaning the methods and processes by which raw materials are transformed into products through chemical reactions, including all measures taken to achieve this transformation. Chemical production processes can generally be summarized into three main steps: Raw material processing: To bring the raw materials into a state suitable for chemical reactions, various pre-treatment procedures—such as purification, concentration, mixing, emulsification, or pulverization (for solid raw materials)—are required depending on the specific circumstances. Chemical reaction: This is the key step in production. The pretreated raw materials are reacted under certain conditions such as temperature and pressure to achieve the desired reaction conversion rate and yield. There are various types of reactions, through which the desired product or its mixture is obtained via chemical reactions. Product refinement: The mixture obtained through chemical reactions is separated to remove by-products or impurities, in order to obtain a product that meets the specified composition requirements. 2. Chemical processes: Chemical processes is an engineering discipline that studies the common laws governing the chemical and physical processes occurring in the production activities of the chemical industry and other process industries. These industries start with basic raw materials such as oil, coal, natural gas, salt, limestone, other ores, as well as food, timber, water, air, etc. By employing chemical or physical processes, they alter the composition, properties, and state of these materials to turn them into a variety of high-value products. The so-called “process industries” such as chemical, petrochemical, metallurgical, and pharmaceutical industries generally involve a series of physical or chemical processing steps; this series of steps is referred to as a process. The process needs to be carried out by the equipment. Process equipment must meet the requirements of the process. Chemical engineering includes unit operations, chemical reaction engineering, transport processes, chemical thermodynamics, chemical systems engineering, process dynamics, and chemical process control. Unit operations: The physical processes involved in the production of various chemical products can be reduced to a limited number of basic processes, such as fluid transfer, heat exchange (heating and cooling), distillation, absorption, evaporation, extraction, crystallization, drying, etc. These basic processes are called unit operations. Research on unit operations yields common results that can be used to guide the production of various products and the design of chemical processing equipment. Chemical reaction engineering: Chemical reactions are a core aspect of chemical production; they determine the yield of products and have a significant impact on production costs. Nevertheless, in the early stages, its complexity hindered any systematic study of it. It was not until the mid-20th century that, based on research findings in unit operations and transport processes, several common problems were identified in various reaction processes such as oxidation, reduction, nitration, and sulfonation; these include backmixing within reactors, mass and heat transfer within the reaction phase, mass and heat transfer outside the reaction phase, and reactor stability. The study of these problems, as well as their various effects on reaction kinetics, has given rise to a new branch of science known as chemical reaction engineering, thereby enriching and developing the content and methods of chemical engineering. Transfer process: It is the common foundation of unit operations and reaction engineering. The physical processes that occur in various unit operation equipment and reaction vessels are nothing more than three types of transfer: momentum transfer, heat transfer, and mass transfer. For example, fluid transport based on momentum transfer, gas flow distribution in reactors ； Heat exchange operations based on heat transfer, the removal of polymerization heat from polymerization reactors ； Absorption operations based on mass transfer, diffusion of reactants and products within the catalyst, etc. In some processes, two or more types of transfer phenomena occur simultaneously, such as moisture addition and removal in gases. As a branch of chemical engineering, transport phenomena focuses on studying the rates of these three types of transport and their interrelationships, thereby linking together phenomena that are essentially similar but exhibit different forms. Chemical thermodynamics: It also serves as the theoretical foundation for unit operations and reaction engineering, studying the direction and limits of transfer processes, and providing the basic data needed for process analysis and design. Therefore, the sub-disciplines of chemical engineering can also be divided into two levels: unit operations and reaction engineering are more directly geared toward industrial practice, while transport processes and chemical engineering thermodynamics primarily serve to support the former two sub-disciplines from a fundamental research perspective. These two levels enable a close integration of theory and practice. Chemical process engineering: Since the various process units in chemical processes influence and restrict one another, it is necessary to consider the chemical process as an integrated system and establish the concept of overall optimization. As a result, the discipline of systems engineering developed rapidly within chemical engineering, achieving significant results and giving rise to chemical engineering systems engineering. It is the product of combining systems engineering methods with the two disciplinary branches of unit operations and chemical reaction engineering. Process dynamic characteristics: To maintain rational and optimized operations, process dynamic characteristics are also an important aspect of chemical engineering. The subjects of study in chemical engineering are usually very complex, as evidenced by the complexity of the processes themselves: these involve both chemical and physical aspects, and these aspects often occur simultaneously and influence each other. Complexity of the material system: it contains both fluids (gases and liquids) and solids, with multiple phases often coexisting. Fluid properties can vary significantly, such as low viscosity and high viscosity, as well as Newtonian and non-Newtonian behavior. Sometimes, significant changes in physical properties occur during the process, such as the transition of the reactant system from low viscosity to high viscosity during polymerization. The complexity of boundaries in fluid flow: The varying geometries of equipment such as trays, impellers, and baffles, as well as the diverse shapes of fillers like catalysts and packing materials, result in complex flow boundaries that are difficult to determine and describe. Chemical process control: also known as process control, it is an abbreviation for the automatic control of chemical production processes. Chemical process control primarily deals with the application of control theory in chemical production processes, including the analysis, design, and on-site implementation and operation of various automation systems. It does not encompass purely theoretical research or the design and manufacturing of instruments. The biggest difference between chemical process control and general chemical methods is dynamics and feedback. Classical control theory was developed starting from the premise of describing systems using linear differential equations with constant coefficients. Classical control theory is limited to dealing with single-variable control systems. Modern control theory uses matrix equations that can represent systems of differential equations to describe them, and expresses various new control criteria in functional form; thus, system analysis and design can be carried out through rigorous mathematical operations. When the system is designed to satisfy an extreme value (maximum or minimum) of a control criterion, what is known as optimal control is obtained. Since modern control theory overcomes and compensates for many shortcomings of classical control theory, and can be applied to multivariable systems, it has found extensive application in chemical process control. Control applications: In well-established production processes, chemical process control is an effective means of improving yield and quality, saving raw materials and energy, reducing labor intensity, and cutting labor costs. In recent years, mathematical modeling methods have been used to explore and promote the application of modern control theory in the control of chemical processes. Many projects have focused on research in computer-based control and scheduling management, and some of these have been successful, leading to significant improvements in both the technical level of production and its economic efficiency

The main focus is on ensuring proper personal protection, preparing for the experiments, and using statistical methods to determine the experimental ratios

1. Stability of the process: The stability of the process is very important for manufacturing enterprises. In large-scale industrial production, the equipment is quite large; reaction vessels can weigh from a few tons to over ten tons or even hundreds of tons. From an economic perspective, the cost of a single batch of material used in such processes ranges from hundreds of thousands to millions of yuan, so there can be no room for mistakes, as this could result in severe financial losses for the company. From an environmental perspective, the chemical industry differs from other industries. Several or even dozens of chemical raw materials are simultaneously introduced into a reactor; if the desired substances are not produced, these materials become waste, which is very difficult to recycle. The reaction mixture is also hard to handle, potentially causing significant environmental pollution. Therefore, special attention must be paid to the stability of the process. However, to address the issue of process stability during the conversion process, attention should be paid to the following areas of research. 1.1 Strengthen research on intermediate detection methods and standards. Rigorous intermediate detection methods and quality standards for determining compliance are essential to ensure the safe and smooth progress of production. The development process of new products takes place in the laboratory. In the initial stage, various methods such as liquid chromatography-mass spectrometry, gas chromatography-mass spectrometry, infrared spectroscopy, ultraviolet spectroscopy, and elemental analysis are used to analyze the structure in order to determine whether the resulting product meets the requirements. Once this is confirmed, during the process development phase, less attention is paid to studying the intrinsic quality of the intermediate products for various reasons; judgment is mainly based on experience and observation of reaction phenomena. Some do have testing methods, but they are very crude, involving only simple qualitative assessments such as spot testing, color, and crystal form to make judgments; as a result, there are several issues in large-scale production: one of them is the significant variation among personnel. In a laboratory, one person usually handles a certain portion of the work alone; however, in large-scale production, it’s impossible for one person to do everything—it requires multiple people working together. Second, there are significant differences in equipment conditions. Phenomena that can be observed in the laboratory are difficult to observe directly in large-scale production, and the control of various parameters is not as stable. Third, there are significant differences in the environment. The laboratory is a relatively enclosed environment, whereas large-scale production takes place in an open environment where conditions such as air humidity and temperature vary greatly. As a result, there are significant differences between batches. There are no strict testing methods or standards to control the quality of intermediates, which makes it difficult to decide what materials to use next, often leading to failures in subsequent steps. Therefore, during the new product development process, every intermediate in the research process should be treated as a product. It is necessary to thoroughly study its analytical and testing methods and establish strict quality standards to ensure the safe and smooth progress of production. 1.2 Permissible range of reaction temperature In chemical synthesis processes, we all know that temperature is one of the important factors affecting chemical reactions. Temperature control is a crucial operating condition, as it directly influences various aspects such as the reaction rate, yield, side reactions, and energy consumption. In the process of product development and research, we regard the reaction temperature as a key parameter to be studied in great detail. We determine the optimal reaction temperature and present it as a crucial condition for the reaction. However, we must also fully consider the various complexities faced by manufacturing enterprises; for instance, one such factor is the time required for heating up and cooling down. In the laboratory, due to the small size of the reaction vessels and the fast heat transfer rate of glass, it is generally possible to meet the requirements within a few minutes to at most a dozen minutes. However, in large-scale production, it takes much longer – sometimes even several hours – to achieve the same results. The second is the precision of temperature control. In the laboratory, the temperature can be easily controlled; especially with the advent of advanced equipment and technologies, the precision of temperature control can reach a few tenths of a degree. However, this is difficult in large-scale industrial production, as achieving a precision of within plus or minus 5°C is already quite challenging. Therefore, while studying the optimal temperature for the process, we must thoroughly examine the impact of temperature variations on the reaction, especially those reaction temperatures that have a serious effect on safe production. For example, in a reaction system containing concentrated sulfuric acid and acetonitrile, these two substances can undergo uncontrolled and violent reactions at certain temperatures, leading to safety accidents. We must take into account the actual conditions of the enterprise and keep the temperature within an absolutely safe range. Providing enterprises with practical optimal temperatures may result in slight differences compared to those stated in research reports, and this can also have an impact on the yield; however, by minimizing such effects and keeping everything within acceptable limits for safe production, it is recommended to specify reaction temperatures as ranges of degrees, and to avoid using expressions such as ‘at certain degrees’, ‘below a certain degree’, or ‘above a certain degree’ in process reports. 1.3 Adjustment of pH value: In chemical synthesis processes, pH value adjustment is frequently used; it not only affects the yield of the product but also its quality. In enterprises, pH value adjustment is currently done manually, relying on experience and individual judgment; due to differences among individuals, the results of such adjustments vary considerably. In fact, during the process of process research, adjustments are also made manually, with very little use of instruments. The difference is that in process research, after dozens or even hundreds of trials, a wealth of experience regarding both successes and failures is accumulated; this results in high adjustment stability, though not necessarily high accuracy. Therefore, instruments should be utilized to eliminate individual differences among people and minimize the impact of errors on the process conversion. 1.4 Determination of reaction time In chemical synthesis processes, reaction time is an important operational parameter; it directly affects a range of issues such as the yield of the product and energy consumption. In the process of product development and research, we regard reaction time as a key parameter to be studied in depth, so as to determine the optimal reaction time. In industrial plants, the equipment is large-scale and the methods of heating or cooling are relatively limited, which results in longer overall processing times. For most synthesis processes, the longer the time, the higher the yield, up to the point where reaction equilibrium is reached ； However, for a few synthesis processes, an extended time leads to reduced yields, increased side reactions, and lower product quality. For such synthesis processes, it is necessary to fully take into account the actual conditions of the enterprise during product development, and make adjustments and modifications by simulating the actual conditions of industrial production. 1.5 The impact of moisture on the synthesis process: In chemical synthesis processes, it is important to note that moisture has a significant effect on the chemical synthesis. In the new product development process, we pay great attention to absolutely anhydrous reactions involving sodium metal, lithium amide, sodium hydride, etc., requiring that they be carried out under nitrogen protection; however, we pay insufficient attention to reactions using ordinary non-aqueous solvents. In the laboratory, the reaction flasks and other containers used are usually washed or dried naturally or by heating. The humidity of the air is the same as that in the atmosphere; as long as the moisture content of the solvent and raw materials meets the required standards, the impact of moisture on the reaction is generally not noticeable. In industrial enterprises, the dryness levels of the reactor vessels and their connecting pipes, as well as various equipment, vary significantly; moreover, the humidity of the air in the workshops is much higher than that in laboratories. Therefore, it is necessary to take these factors into full consideration through simulation tests, and establish appropriate conditions based on different reactions to ensure the smooth progress of technology transfer. However, it is not possible to require all reactions to be as absolutely anhydrous as possible, as that would increase the production costs for enterprises. 2 Recycling of solvents Organic solvents are essential for chemical synthesis reactions. The production of a new product involves the use of anywhere from a few to dozens or even hundreds of chemical raw materials. Aside from a few that form new substances, most of these materials remain in their original form or as by-products, and determining how to deal with them poses a significant challenge for companies. During the development of new products and new processes, they often go unnoticed due to their small usage amounts. But in enterprises, hundreds or even thousands of tons of these by-products are generated each year; failing to deal with them results in waste and increases production costs ； On the other hand, it will cause severe pollution to the environment. To address this issue, it is necessary, during the rigorous product development process and especially in the later stages of product development, once a mature chemical synthesis process has been established, to conduct thorough analysis of the waste materials generated at each stage of the chemical reactions. These waste materials should be processed accordingly based on their characteristics; as for those that cannot be recycled, whether through combustion or burial, safety assessments must be carried out to ensure the safety of personnel and the environment. This approach helps guide companies in carrying out safe production practices, thereby preventing environmental pollution caused by the manufacture and use of new products and new processes from the very beginning. 3 Wastewater treatment: In the production process of each new product, it is more or less inevitable to encounter wastewater issues. Wastewater treatment is currently the biggest technical challenge faced by enterprises. Whether through chemical methods, enzymatic methods, or adsorption methods, it remains very difficult to effectively address wastewater issues despite the significant investment of human resources, materials, and financial resources. The main reason is the wide variety of chemical substances; it is impossible to completely address them using just one or a few methods. This requires us to analyze the causes of wastewater generation as well as the composition of pollutants in the water, and to collect and treat them in a categorized manner. During the research on chemical synthesis processes, we analyze the components of the wastewater and pollutants generated. On one hand, water is treated as the most expensive organic solvent, and every effort is made to minimize its usage ； On the other hand, by classifying and collecting pollutants according to their composition and treating them effectively, practical wastewater treatment solutions are provided for enterprises, thereby eliminating their concerns. In short, the research and development of chemical synthesis processes are quite challenging, requiring significant investment in terms of human resources, materials, and financial resources. The outcomes of such development efforts are aimed at enabling companies to achieve higher economic growth and ensuring their sustainable development. The only way to realize one’s own value is to quickly transform those achievements into productive forces, serving the enterprise and benefiting society. For various reasons, on the one hand, companies are striving to develop new products, while on the other hand, research institutions have accumulated results that cannot be transferred. At its core, the issue is not price; rather, it is the aforementioned reasons that lead to various problems during the process of technology transfer. A considerable amount of research output remains unfinished, causing significant losses for companies and leading them to feel fearful of new innovations. In fact, solving the above problems is not difficult; as long as, during the process of process research, close ties are established between the laboratory and the enterprise, and slight attention is paid to the differences, all problems can be resolved smoothly