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1 An Introduction to Chemical Product Design 1

1.1 What Is Chcmical Product Design？ 1

1.2 Why Chemical Product Design Is Important 3

Changes in the Chemical Industry 3

Changes in Employment 5

1.3 Changes in Corporate Culture 6

Corporate Organization 7

Corporate Strategy 8

1.4 The Product Design Procedure 8

How the Procedure Organizes this Book 9

Limitations of the Procedure 9

1.5 Conclusions 11

2 Needs 13

2.1 Customer Needs 13

Interviewing Customers 13

Interpreting Customer Needs 15

Example 2.1-1. Better Thermopane Windows 16

Example 2.1-2. Alternative Fluids for Deicing Airplanes 18

Example 2.1-3. “Smart” Labels 20

2.2 Consumer Products 22

Consumer Assessments 23

Consumer versus Instrumental Assessments 24

Example 2.2-1. Tasty Chocolate 25

Example 2.2-2. The Consumer Attribute “Viscosity” 26

2.3 Converting Needs to Specifications 27

Example 2.3-1. Muffler Design 28

Example 2.3-2. Water Purification for the Traveler 29

Example 2.3-3. Preventing Explosions in High-Performance Batteries 30

2.4 Revising Product Specifications 33

Example 2.4-1. Deicing Winter Roads 34

Example 2.4-2. Scrubbing Nitrogen from Natural Gas 38

2.5 Conclusions and the First Gate 41

3 Ideas 43

3.1 Human Sources of Ideas 44

Sources of Ideas 44

Collecting the Ideas 45

Problem Solving Styles 46

Examples of Unsorted Ideas 48

3.2 Chemical Sources of Ideas 49

Natural Product Screening 52

Random Molecular Assembly 54

Combinatorial Chemistry 55

Example 3.2-1. Fuel Cell Catalysis 57

3.3 Sorting the Ideas 57

Getting Started 58

“The Material Will Tell You” 58

Example 3.3-1. Adhesives for Wet Metal 60

Example 3.3-2. Reusable Laundry Detergents 61

Example 3.3-3. Pollution Preventing Ink 63

3.4 Screening the Ideas 64

Strategies for Idea Screening 65

Improving the Idea Screening Process 66

Example 3.4-1. Home Oxygen Supply 68

Example 3.4-2. High-Level Radioactive Waste 69

3.5 Conclusions and the Second Gate 73

4 Selection 75

4.1 Selection Using Thermodynamics 76

Ingredient Substitutions 76

Substitutions in Consumer Products 77

Ingredient Improvements 79

Example 4.1-1. A Better Skin Lotion 80

Example 4.1-2. A Pollution Preventing Ink 81

Example 4.1-3. Antibiotic Purification 81

4.2 Selection Using Kinetics 82

Chemical Kinetics 82

Heat and Mass Transfer Coefficients 84

Example 4.2-1. A Device that Allows Wine to Breathe 85

Example 4.2-2. A Perfect Coffee Cup 87

4.3 Less Objective Criteria 90

When to Make Subjective Judgments 91

How to Make Subjective Judgments 92

Why We Use Selection Matrices 93

Example 4.3-1. Monarchy Substitution 94

Example 4.3-2. The Home Ventilator 94

4.4 Risk in Product Selection 102

Risk Assessment 103

Risk Management 105

Example 4.4-1. Power for Isolated Homes 107

Example 4.4-2. Taking Water out of Milk at the Farm 109

4.5 Conclusions and the Third Gate 114

5 Product Manufacture 116

5.1 Intellectual Property 117

Patents and Trade Secrets 118

What Can Be Patented 120

Requirements for Patents 120

Example 5.1-1. The Invention of the Windsurfer 123

5.2 Supplying Missing Information 123

Reaction Path Strategies 124

Example 5.2-1. Synthesis of the Tranquilizer， Phenoglycodol 125

Example 5.2-2. Sterically Hindered Amines for CO2 Removal from Gases 125

Example 5.2-3. Silver Bullets for Zebra Mussels 127

5.3 Final Specifications 128

Product Structure 129

Central Product Attributes 130

Chemical Triggers 130

Example 5.3-1. Freon-Free Foam 131

Example 5.3-2. Better Blood Oxygenators 134

5.4 Microstructured Products 137

Thermodynamics 139

Colloid Stability 141

Rheology and Mixing 144

Example 5.4-1. Destabilizing Latex Paint 146

Example 5.4-2. Making More Ice Cream 147

5.5 Device Manufacture 148

Thermodynamics 148

Enzyme Kinetics 150

Example 5.5-1. An Electrode for Measuring Dodecyl Sulfate 151

Example 5.5-2. Designing an Osmotic Pump 152

5.6 Conclusions 154

6 Specialty Chemical Manufacture 156

6.1 First Steps Toward Production 157

Extending Laboratory Results 158

Reaction Engineering 160

Example 6.1-1. Penicillin Modification 160

Example 6.1-2. Etching a Photoresist 161

6.2 Separations 162

Heuristics for Separations 163

The Most Useful Separations 166

Example 6.2-1. Penicillin Purification 176

6.3 Spccialty Scale-Up 177

Reactor Scale-Up 178

Separation Scale-Up 181

Example 6.3-1. Reacting Suspended Steroids 185

Example 6.3-2. Scaling Up a Lincomycin Adsorption 185

6.4 Conclusions 187

7 Economic Concerns 189

7.1 Product versus Process Design 190

Commodity Products 191

Specialty Products 192

7.2 Process Economics 193

A Hierarchy of Process Design 193

Economic Potential 196

Capital Requirements 198

7.3 Economics for Products 200

Cash Flow Without the Time Value of Money 202

Cash Flow Including the Time Value of Money 204

Time To Market 206

Example 7.3-1. The Economics of Scottish Mussel Farming 207

7.4 Conclusions and the Fourth Gate 208

Problems 211

Index 227

Products Index 229