Batch-to-Continuous Processing: Risk Aversion and Value Analysis

Continuous processing is known to hold many potential advantages over batch processing - from a clean-sheet design perspective - but what happens when a batch process is already established in production? There are two key aspects to evaluating continuous process implementation into existing production schemes – risk aversion and value analysis. The first deals with the dreaded ‘unknown’ – the very practical “if it isn’t broken, don’t fix it” mentality that can exist from the production floor all the way up to the executive leadership. The second deals with assigning a dollar value to not just the productivity benefits of continuous processing but also the less-tangible benefits of quality and new operating latitude that is not possible in batch processing. Ultimately, this talk aims to provide a high-level framework for process engineers to construct value propositions for continuous process implementation as well as to provide new optimization criterion for process development.