(43b) Maximizing Process Efficiency without Capital Investment: A Lubrizol Case Study

Optimization is a fundamental aspect of process development, aiming to enhance efficiency, product quality, and sustainability in existing processes. While step change improvements can be made by investing in new technologies, there are often unrealized efficiency gains in the existing process that can be realized with a systematic approach.

This presentation will focus on a case study in process optimization with the stringent constraint of zero capital expenditure. The purpose of the optimization is to increase throughput in a capacity-constrained system to meet internal demand for a key intermediate in Lubrizol’s fuel additives business. Achieving this growth will avoid costly premiums from purchasing the equivalent material externally and make Lubrizol’s additives more cost competitive in the market.

The optimization began with a Design of Experiments to systematically explore interactions between key process variables. Statistical analysis was employed to identify the ideal conditions that maximized performance and validated in lab-scale experiments designed to mimic production conditions. Following completion of a PFMEA, the process was then delivered to the plant for trial and implementation.

Through this work, the optimization was able to deliver an initial 10% increase to yield on a per batch basis. These improvements will enable savings upwards of $400,00 per annum, purely through adjustments in formulation and process variables. Overall, this case study highlights the potential for substantial gains without the need for capital expenditure, underscoring the importance of a data-driven approach in process development.