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1 An Introduction to Chemical Product Design1

1.1 What Is Chcmical Product Design？1

1.2 Why Chemical Product Design Is Important3

Changes in the Chemical Industry3

Changes in Employment5

1.3 Changes in Corporate Culture6

Corporate Organization7

Corporate Strategy8

1.4 The Product Design Procedure8

How the Procedure Organizes this Book9

Limitations of the Procedure9

1.5 Conclusions11

2 Needs13

2.1 Customer Needs13

Interviewing Customers13

Interpreting Customer Needs15

Example 2.1-1. Better Thermopane Windows16

Example 2.1-2. Alternative Fluids for Deicing Airplanes18

Example 2.1-3. “Smart” Labels20

2.2 Consumer Products22

Consumer Assessments23

Consumer versus Instrumental Assessments24

Example 2.2-1. Tasty Chocolate25

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

2.3 Converting Needs to Specifications27

Example 2.3-1. Muffler Design28

Example 2.3-2. Water Purification for the Traveler29

Example 2.3-3. Preventing Explosions in High-Performance Batteries30

2.4 Revising Product Specifications33

Example 2.4-1. Deicing Winter Roads34

Example 2.4-2. Scrubbing Nitrogen from Natural Gas38

2.5 Conclusions and the First Gate41

3 Ideas43

3.1 Human Sources of Ideas44

Sources of Ideas44

Collecting the Ideas45

Problem Solving Styles46

Examples of Unsorted Ideas48

3.2 Chemical Sources of Ideas49

Natural Product Screening52

Random Molecular Assembly54

Combinatorial Chemistry55

Example 3.2-1. Fuel Cell Catalysis57

3.3 Sorting the Ideas57

Getting Started58

“The Material Will Tell You”58

Example 3.3-1. Adhesives for Wet Metal60

Example 3.3-2. Reusable Laundry Detergents61

Example 3.3-3. Pollution Preventing Ink63

3.4 Screening the Ideas64

Strategies for Idea Screening65

Improving the Idea Screening Process66

Example 3.4-1. Home Oxygen Supply68

Example 3.4-2. High-Level Radioactive Waste69

3.5 Conclusions and the Second Gate73

4 Selection75

4.1 Selection Using Thermodynamics76

Ingredient Substitutions76

Substitutions in Consumer Products77

Ingredient Improvements79

Example 4.1-1. A Better Skin Lotion80

Example 4.1-2. A Pollution Preventing Ink81

Example 4.1-3. Antibiotic Purification81

4.2 Selection Using Kinetics82

Chemical Kinetics82

Heat and Mass Transfer Coefficients84

Example 4.2-1. A Device that Allows Wine to Breathe85

Example 4.2-2. A Perfect Coffee Cup87

4.3 Less Objective Criteria90

When to Make Subjective Judgments91

How to Make Subjective Judgments92

Why We Use Selection Matrices93

Example 4.3-1. Monarchy Substitution94

Example 4.3-2. The Home Ventilator94

4.4 Risk in Product Selection102

Risk Assessment103

Risk Management105

Example 4.4-1. Power for Isolated Homes107

Example 4.4-2. Taking Water out of Milk at the Farm109

4.5 Conclusions and the Third Gate114

5 Product Manufacture116

5.1 Intellectual Property117

Patents and Trade Secrets118

What Can Be Patented120

Requirements for Patents120

Example 5.1-1. The Invention of the Windsurfer123

5.2 Supplying Missing Information123

Reaction Path Strategies124

Example 5.2-1. Synthesis of the Tranquilizer， Phenoglycodol125

Example 5.2-2. Sterically Hindered Amines for CO2 Removal from Gases125

Example 5.2-3. Silver Bullets for Zebra Mussels127

5.3 Final Specifications128

Product Structure129

Central Product Attributes130

Chemical Triggers130

Example 5.3-1. Freon-Free Foam131

Example 5.3-2. Better Blood Oxygenators134

5.4 Microstructured Products137

Thermodynamics139

Colloid Stability141

Rheology and Mixing144

Example 5.4-1. Destabilizing Latex Paint146

Example 5.4-2. Making More Ice Cream147

5.5 Device Manufacture148

Thermodynamics148

Enzyme Kinetics150

Example 5.5-1. An Electrode for Measuring Dodecyl Sulfate151

Example 5.5-2. Designing an Osmotic Pump152

5.6 Conclusions154

6 Specialty Chemical Manufacture156

6.1 First Steps Toward Production157

Extending Laboratory Results158

Reaction Engineering160

Example 6.1-1. Penicillin Modification160

Example 6.1-2. Etching a Photoresist161

6.2 Separations162

Heuristics for Separations163

The Most Useful Separations166

Example 6.2-1. Penicillin Purification176

6.3 Spccialty Scale-Up177

Reactor Scale-Up178

Separation Scale-Up181

Example 6.3-1. Reacting Suspended Steroids185

Example 6.3-2. Scaling Up a Lincomycin Adsorption185

6.4 Conclusions187

7 Economic Concerns189

7.1 Product versus Process Design190

Commodity Products191

Specialty Products192

7.2 Process Economics193

A Hierarchy of Process Design193

Economic Potential196

Capital Requirements198

7.3 Economics for Products200

Cash Flow Without the Time Value of Money202

Cash Flow Including the Time Value of Money204

Time To Market206

Example 7.3-1. The Economics of Scottish Mussel Farming207

7.4 Conclusions and the Fourth Gate208

Problems211

Index227

Products Index229