(185a) Intensification of Lubrizol Additive Production: Optimization and Scale-up Using Batch and Continuous Flow Technologies

This presentation explores a transformative approach to producing one of Lubrizol’s additives through the development of an intensified “one-pot process” in batch mode. This new process aims to enhance operational efficiency, reduce manufacturing costs, and increase production capacity.

The current manufacturing workflow involves three independent production steps across multiple tolling facilities and Lubrizol sites in the United States. This workflow requires the addition and subsequent removal of a stabilizing feed to facilitate product shipping between locations – these iterative steps add significant time and cost. Our project focused on optimizing the existing process by redesigning the synthetic route, consolidating production at a single site, reducing labor and overhead (L&O) costs per metric ton, and shortening cycle times.

Key advancements include the use of a high-pressure autoclave reactor equipped with Fourier-transform infrared (FTIR) technology to optimize reaction conditions such as temperature, stoichiometry, and reaction time. Insights gained from the FTIR-enabled batch process allowed us to achieve the desired product specifications with reduced CAPEX and OPEX. Furthermore, the gained knowledge led to the development of a continuous flow reactor, which promises a sustainable, scalable production pathway and supports future growth through the deployment of modular chemical process intensification (MCPI) units.

Attendees will gain insight into practical steps and technological innovations that achieved a cost-effective, high-yield process for this additive, aligning with the industry’s focus on reducing production costs while advancing sustainability. This work showcases a quick-win optimization strategy with minimal CAPEX, laying the groundwork for scalability and efficient use of resources in chemical manufacturing.