Workman, Jerome, Jr., Veltkamp, David J., Doherty, Steve, Anderson, Brian B., Creasy, Ken E., Koch, Mel, Tatera, James F., Robinson, Alex L., Bond, Leonard, Burgess, Lloyd W., Bokerman, Gary N., Ullman, Alan H., Darsey, Gary P., Mozayeni, Foad, Bamberger, Judith Ann, and Greenwood, Margaret Stautberg
This review of process analytical chemistry is an update to the previous review on this subject published in 1995 (A2). The time period covered for this review includes publications written or published from late 1994 until early 1999, with the addition of a few classic references pointing to background information critical to an understanding of a specific topic area. These older references have been critically included as established fundamental works. New topics covered in this review not previously treated as separate subjects in past reviews include sampling systems, imaging (via optical spectroscopy), and ultrasonic analysis. The individual review subjects are organized into their most obvious subsection. The purpose of this review is to include the more critical work from each topic area in brief summaries, rather than as protracted abstracts. For this review, an expanded definition of the eras for the implementation of process analyzers has been included. The earlier definition for process analyzers was encompassed by the terms off-line, at-line, on-line, in-line, and noninvasive (A1, A2). A more expanded descriptive list of applicable process analyzer conditions, or eras, as extracted from the various titles of published research papers, includes (in alphabetical order) the following: airborne, at-line, automatic/automated, fieldable, hyperspectral, imaging/image analysis, in situ, in-line, near-line, noninvasive/nondestructive, on-line, open path, portable/hand-held, process monitoring/production control, quality control/quality assurance, quality monitoring, rapid, real-time, and remote. These types or eras for process analyzers are included under each review topic. Analytical chemistry is a key component of measurement science that plays a valuable role in supporting the characterization of products resulting from research, product and process development, and manufacturing. Process analytical chemistry is now an established field of Analytical Chemistry, as evidenced by the growing number of publications, by sections of symposiums (e.g., FACSS, Pittsburgh Conference, ACS meetings, etc.), and by dedicated meetings such as IFPAC. The field of process analytical chemistry has developed over the past 50 years due to the growing appreciation for having process data gathered close to the production operation. This has occurred for a variety of reasons including rime and cost savings, sampling concerns, sample transport, process efficiency, and safety. These reasons contributed to process efficiency and improved process control. With the globalization of industries, productivity and quality have added to the need for effective process control while minimizing the environmental impact. This approach requires a certain level of dedication and resources from the corresponding internal research operations within the organization. This has become more difficult recently as a result of cost reduction activities driven by corporate re-engineering and subsequent resource reduction of research, production maintenance, and plant instrumentation groups. To be most meaningful, process measurement science must tie into the needs in the engineering disciplines related to process control. There is a strong need for cross discipline appreciation, understanding, and cooperation in order to effectively incorporate the new developments in analytical measurement science with the advances in process modeling, monitoring, and control. These new developments are facilitated by continued improvements in the computer-related fields (semiconductor, automation, software, etc.). An important step is not only to incorporate these computer-related developments into analytical instrumentation but to explore these computing advances for ideas in microinstrumentation. Traditional laboratory-based analytical instrumentation, as well as the process analytical technologies described in this review, will be evaluated as to whether there is value to process control in pursuing them at the microscale. There will be advantages in ruggedness, replication, and subsequent cost where multiple units are desired for useful implementation. In addition, nontraditional measurement and characterization techniques (such as imaging, acoustics, thermal, and rheology approaches) will take on additional importance. This is due to global interest in marketing, technical service and development, and sales of products where the measurement and prediction of final product properties becomes key to a successful business. Although process measurements have traditionally included temperature, pressure, and flow rate, more efficiency can be added to processes by measuring composition or structural properties in a manner allowing real-time control during a manufacturing process. This review considers the essential elements to this compositional measurement scheme. These key aspects for process analytical chemistry include chemometrics and process control algorithms, sensors, optical spectroscopy, chromatography, mass spectrometry, flow injection analysis and automated wet chemical methods, ultrasonic analysis, NMR, and other techniques.