Identifying Parameter Modifications to Enable Industrial Processes to Become More Tolerant to Changes in the Availability and Composition of Materials

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a computer-implemented method and system for making industrial processes more flexible and tolerant to changes in the input material's availability or composition. By running simulations that vary both incoming materials and process operation parameters, the system identifies which process parameters should be modified to maintain product quality, even when input conditions change. The approach uses clustering and statistical analysis of simulated outcomes to pinpoint specific adjustable parameters, enabling the process to adapt to fluctuations without requiring a complete process re-design.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing plants adjusting to changing supplies of raw materials due to supply chain disruptions or market shifts.
• Chemical processing facilities integrating recycled or alternative materials into their production lines.
• Food processing plants optimizing recipes or process settings based on varying qualities of agricultural inputs.
• Pharmaceutical production adapting batch parameters for variations in active ingredient composition.
• Power generation adapting operational settings based on fuel composition or quality variability (e.g., switching between coal, gas, or biomass).
• Recycling plants optimizing sorting, cleaning, or processing parameters based on mixed waste streams.

BenefitsContent extracted from patent full text and abstract with AI.

• Enhances operational flexibility by allowing industrial processes to tolerate wider variations in input materials.
• Reduces need for full system re-design when introducing new or alternative raw materials, saving cost and time.
• Minimizes production downtime and waste caused by unanticipated material fluctuations.
• Automates identification of key process parameters to adjust, supporting faster and more informed operator decisions.
• Potentially enables use of more sustainable, recycled, or locally available materials.
• Optimizes process efficiency, product quality, and resource usage under varying conditions.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

A computer-implemented method identifies an operation parameter of an industrial process as a candidate for modification so that the process can continue even of the material at the input of the process changes. In simulation instances, the computer receives representations of the material and of operation parameters and provides a representation of the would-be product. The computer classifies the instances into first and second quality classes. The computer continues by clustering—separated by parameters—the instances according to parameter attributes and according to the first and second quality classes. The computer repeats the simulation with variations that are related to significant differences, and identifies the candidate for modification.