by Emily Newton
Understanding and analyzing chemical processing trends can help decision-makers respond to changing market conditions, become early adopters of advanced technologies and more. Here are four factors shaping chemical engineering innovation and streamlining internal processes.
1. Artificial Intelligence
Artificial intelligence has moved from a relatively niche technology to one that has shaped many industries and positively changed workflows. Many people are interested in how it could benefit chemical processing plants.
To understand how AI is pioneering chemical engineering and catching leaders’ interest, one can examine a 2024 McKinsey & Company study. Respondents mentioned chemical process innovation and AI-assisted chemical discovery as the two areas with the most potential for near-term growth.
Additionally, 42% of those polled intended to invest from $101-500 million in AI chemical discovery, with another 17% planning to put even more toward that aim. Even so, many respondents reported numerous challenges, such as a lack of technical expertise and issues with technological maturity, that hindered their goals.
However, those obstacles have not stopped numerous developments that contribute to chemical engineering innovation. One example is a machine learning framework that evaluates the knowledge and reasoning of large language models used for chemical-related tasks. The machine learning algorithms compare the tool’s results with the insights of human chemists.
It works based on a carefully selected assortment of 7,000 question-answer pairs encompassing chemical science topics. This resource could be vital for chemical professionals interested in applying AI to their work who want to scrutinize the relevant large language models first. Recent examples have shown this type of artificial intelligence can often perform well on specific tasks, but it has notable shortcomings. People must know what those are before they can feel confident about applying them to potentially critical tasks.
2. Augmented Reality
Augmented reality has experienced increased usage rates throughout the process industries because it combines virtual elements with real-world features. Imagine if a technician could see a checklist on a surface directly in front of them, guiding them through different parts of their task. AR makes that possible by improving training, quality control and more.
It also supports chemical plant maintenance. Much of the industry’s equipment is complex and could be overwhelming to a new machine technician. However, an AR app might highlight or label individual components, giving people valuable context and confidence.
Although AR tools may not replace specialists who must come to a facility to make urgent repairs, they could provide the additional information needed to help on-site employees walk through basic troubleshooting steps or confirm which parts are faulty versus working well.
AR is among notable chemical processing trends because it supports people through various workflows, enabling better productivity and fewer errors. Since chemical plant mistakes can be costly or worse, reducing them is essential for making operations more effective and efficient.
3. Sustainability Improvements
Chemical plant executives are exploring many options to make their operations as sustainable as possible. Sometimes, that means buying or selling used processing equipment rather than purchasing it new or discarding it once a company no longer needs it. Products that are well-maintained, newer and have spare parts available generally bring higher resale values than their counterparts. Becoming more conscious of equipment purchases and selling options is one widely accessible way for chemical industry leaders to practice better sustainability.
People are also prioritizing sustainability through chemical engineering innovation. In one case, a researcher will combine quantum computing and artificial intelligence to find new, sustainable chemical process designs. This approach analyzes aspects such as reactions, separations, and mixing to find new structural combinations that help people identify and utilize different chemical processes.
Those working on this project also hope the technologies will show chemical professionals which processes are most energy-efficient, environmentally friendly and appropriate for facilities’ existing infrastructure. This work has recently gained momentum with a $240,000 grant but is also getting noticed due to its applicability to real, current issues.
Elsewhere, groundbreaking pilot projects are underway to explore greener ethylene production methods. The work centers on improved methods of breaking apart its molecules or “cracking” it since current techniques require burning fossil fuels to heat huge furnaces.
Several efforts involve using electricity to facilitate the cracking. Several efforts involve using electricity to facilitate the cracking. These are yet to be widespread, but some people familiar with them believe these alternatives could collectively represent a chemical engineering innovation that is better for the planet. Some companies are building demonstration models of electricity-powered furnaces, moving those options closer to real-world deployment.
Statistics indicate 90% of ethylene plants’ CO2 emissions come from cracking. Improving that step could make a big difference, especially if producers use clean energy sources.
4. Digitalization and the Internet of Things
Internet of Things sensors are part of prominent chemical processing trends because of their versatility. Specialized hardware gives plant leaders unprecedented visibility over each process and every individualized step. Such insights provide better quality control and details about overall resource usage.
IoT sensors also support worker safety. They can detect abnormal temperatures, chemical concentrations or other potential hazards, warning individuals to evacuate the area or take other preventive measures to avoid accidents. Although chemicals have numerous valuable uses in the modern world, people must always understand their associated risks.
For example, up to 20,000 cases of pesticide poisoning occur annually among agricultural workers in the United States. Because of the quantities and concentrations involved, those working at the plants producing those chemicals are often at even greater risks. However, IoT sensors can detect minute changes that humans may not notice until it is too late and they are in danger.
IoT products also accelerate chemical processing trends involving digitalization. Many decision-makers recognize the value of seeing real-time data flows or using remote-enabled dashboards to tweak processes. Investing in digital advancements supports those goals, and the Internet of Things is a significant part of many leaders’ plans.
One study showed how 80% of chemical industry respondents would use digitalization to develop new products and services. The IoT can support them in those aims by helping them track supply chain activities or internal processes. The same research found 60% of those polled said digitalization applied to supply chain planning has heavily impacted them over the past several years.
Since the IoT and digitalization are some of the broader chemical processing trends mentioned here, leaders must analyze the best ways to apply them in their facilities to optimize the results.
An Exciting Future for Chemical Processing
The areas discussed above are among those attracting the most interest and investment from chemical industry professionals. Remaining aware of further progress in these and related aspects will help workers respond to changes affecting their work and processes.
