AI is a hot topic, so it’s no surprise that we can expect more automation and AI integration in chemical manufacturing in the near future.
Even now, a large portion of the chemical manufacturing process is automated. Along with this, the process is becoming more cost-effective, efficient, and environmentally-friendly. Sustainable chemical manufacturing is, reassuringly, amongst the long-term goals and standard practices in the chemical industry.
Continue reading to find out what we think is the future of the chemical industry.
In this post:
Modern chemical manufacturing
Although there are many overlaps, chemical manufacturing can currently be generally grouped into six main categories:
- Agricultural chemicals (agrochemicals) – these include chemicals like fertilisers, insecticides, herbicides, fungicides, antibiotics, and plant-growth hormones. The modern way of manufacturing these chemicals relies on the use of catalysts and high temperatures and pressures, such as in the Haber process.
- Basic chemicals – also known as basic commodity chemicals, basic chemicals are typically produced in bulk and sold to other chemical manufacturers. They are mainly used as precursors, ingredients, and as reagents. Examples of basic chemicals are sulphuric acid, nitric acid, and chlorine.
- Petrochemicals – these are mainly the fossil fuels we use in vehicles and to generate electric power. The petrochemical industry is focused on refining raw petroleum (crude oil) into useful and cleaner fuels with higher octane rates, such as gasoline and diesel. The process of refining crude oil is mainly distillation.
- Speciality chemicals – unlike basic chemicals, speciality chemicals are produced in much smaller volumes. They have added value because of the more complex processes they undergo, but they are not yet finished products, and other companies need to process them further. They are used in a wide range of products, such as advanced polymers, adhesives, and paints.
- Consumer products – these are finished products that are meant to be used by end-users, i.e. consumers or the general public. They are not meant to be used by other companies or industries to manufacture other products. Consumer products include cosmetics, plastic bottles, drinks, soaps, detergents, and processed food. Basic chemicals and specialty chemicals are used to produce these products. The main process used is the modifications/reactions of specialty and basic chemicals to synthesise new chemicals.
- Pharmaceuticals – these are also meant to be used or consumed by the general public. However, some pharmaceutical products are also used in laboratories for research and in hospitals. These include medicines, antibiotics, vaccines, and chemicals for medical devices. The main process used is the chemical synthesis of organic chemicals with biological and pharmacological effects.
Modern chemical manufacturing combines various methods and processes, which vary depending on the intended end product. However, all processes used are typically repetitive and require high precision.
That means a lot of automation, with some human intervention for quality control. This is especially true for mass produced chemicals with fixed formulations. Expert chemists would mainly be involved in the research and development of new chemicals and methods, but once these are established, automation comes into its own.
Innovations in the chemical industry
Information technology and automation are now an integral part of the chemical industry, used throughout the various steps in chemical manufacturing. This could include formulating ingredients, monitoring and controlling reactions, and removing waste byproducts. To some extent (and this is increasing), AI is also part of the process – more on that in the section below.
Except for research and development, quality control, and maintenance, almost all aspects of chemical manufacturing can now be automated.
Artificial intelligence (AI) in chemistry
Artificial intelligence is disrupting many industries, and the chemical industry is no exception. For example (scarily), an AI algorithm was able to come up with more than 40,000 chemical weapons in just six hours. Imagine how long it would take a team of scientists to formulate the same number of chemical weapons. And although these chemicals the AI came up with haven’t been tested, the formulations theoretically appear to be legitimate.
Similar AI algorithms can solve many problems in chemistry and chemical manufacturing through large data and machine learning. But there is a learning curve that needs to be honed and tested. Although the technology is already here, it probably can’t easily be implemented. Chemical manufacturers would need to look into retrofitting or replacing existing machines and methods.
The role of big data
AI technology relies on big data to properly implement efficient chemical manufacturing that is cost-effective, efficient, and environmentally-friendly.
In the context of manufacturing, big data is a large collection of interrelated information from the various aspects of production in real time. It’s usually gathered from sensors in the manufacturing plant, which can be anything from pressure to temperature sensors.
The data is then fed to a computer, which makes correction algorithms in real-time. This is made possible by the Internet of Things, which connects machines, sensors, and computers. Along with it might be blockchain and cloud systems that decentralise data collection, storage, and analytics.
This might sound futuristic, but it’s happening right now in manufacturing facilities across the world.
Advancing green chemistry
The problems we’re facing now because of climate change are serious enough that governments and corporations are making extra effort to implement greener alternatives.
The chemical industry is amongst those that are responding to the challenge of making their operations more environmentally-friendly. That’s why green chemistry was developed.
Green chemistry is governed by twelve principles, but its overall aim is to make chemical manufacturing and chemistry in general environmentally sustainable by eliminating or reducing harmful chemicals.
This can be done by finding new chemical pathways to desired results. The idea was initially developed as a response to the US Pollution Prevention Act of 1990. Green chemistry covers all the steps in the life cycle of a product, from design to disposal.
Sustainable chemical manufacturing
Sustainable chemical manufacturing is not only about eliminating the pollution after the manufacture of chemical products.
It begins from choosing feedstocks, or raw materials. For example, instead of using feedstocks just once and throwing away the excess as well as intermediate byproducts, you can practise atom economy, which is about maximising every atom in the feedstock.
Regulations affecting chemical production
International treaties and national laws are influenced by the need to achieve sustainable chemical manufacturing, and are primarily influenced by the scientific consensus on climate change.
Climate change can rewrite the geological and geopolitical maps of the world, and can cause famine, wars, and collapse of governments. One significant binding international treaty is the Kyoto Protocol, which requires European Union countries and other industrial countries that ratified the treaty such as the US to reduce carbon dioxide and other greenhouse gases emissions by 5.2% lower than the 1990 levels. The treaty came into force on 16 February 2005 and it is currently ratified by 192 parties.
New regulations in chemical production
In most industrialised countries, chemical manufacturers are required to provide Safety Data Sheets (SDS) for hazardous chemical products. These include the formulation, toxicity, flammability, and safety precautions.
However, since Brexit, the UK has loosened the regulations and reduced the number of chemical products that require SDS.
Future challenges in chemical manufacturing
Aside from the changing regulations, the chemical manufacturing industry faces possible disruptions in the supply chain. Many raw materials are getting more expensive and harder to obtain.
There’s also the problem of using non-renewable energy sources and finding ways to use renewable or perpetual sources. On top of that is the need for more sustainable manufacturing methods. The international pressures of climate change and unstable weather are serious threats. Manufacturing companies now have to navigate through large amounts of data, new regulations, complex supply chains, and the question of becoming more sustainable just to maintain their competitiveness.
Navigating cost, efficiency & environmental impact
Many chemical manufacturing companies will need to retrofit their facilities and invest in new equipment. They also have to improve their methods and hire new experts in green chemistry.
These all entail additional cost, but hopefully will result in cost-efficiency and enhanced production capabilities in the long run – as well as being more environmentally sustainable. The paradigms of best industrial practices are changing towards large data, automation, and artificial intelligence.
Educational & skill requirements for future chemists
Advanced post-graduate degrees and fellowships in chemistry will still be necessary moving forwards – if not more critical as we navigate the new world of AI, green and sustainable chemistry, and big data. That also means that current research chemists also need to update their knowledge on the latest technological trends.
They’ll also need to broaden their horizons, improving on soft skills in approaching problems from multiple angles. For example, solving the problem of greenhouse emissions isn’t only a technical chemical problem; it’s also a matter of political will amongst policymakers. Chemists may have to learn to be more vocal on environmental issues by improving their public communication skills.
Conclusion
There are wonderful prospects for the future of chemical manufacturing. However, there are also many challenges to overcome. It’s both a matter of economic competition and creating a sustainable future. The use of AI, the Internet of Things, and big data have significant potential to improve the way in which chemicals will be made in the future.
