Rigid to Resilient: The Transformative Power of Tolerant Process Design and Operation.

Existing productions are efficient but rigid.

Adapting to a changing economic landscape requires integrating tolerance into designs and operations, boosting resilience and readiness for a circular economy.

As the world moves away from a linear and fossil-based economy, it’s becoming clear that our industrial processes are not ready for this change towards the dynamic environment of a circular economy: The existing production processes, while highly efficient, show rigidity and inflexibility as a downside. To adapt and thrive in this new economic landscape, it’s essential to develop and integrate tolerance into our process designs and operations.

Explore our workflow for adapting chemical processes to this new paradigm, emphasizing virtual stress tests and mitigation strategies shown for a case study of a waste-to-methanol process’s tolerance to variable feedstock compositions.

Tolerant processes

are key for the green transition—flexible, resilient, and capable to operate in dynamic environments.

Virtual stress tests

An innovative tool that simulates dynamic conditions, ensuring your chemical processes ready for any future challenge.

Reveal cause-effect chains

Implementing tolerance in processes involves understanding the cause-effect relationship between dynamic input conditions and processes

Integrating Process Tolerance

Process tolerance isn't just for new designs; it's a versatile approach that can be integrated at the early stages of process development or ingeniously retrofitted into existing systems, enhancing their adaptability and resilience.

Optimizing a Chemical Process Through Tolerant Process Design & Operation

The benefits of including tolerant process designand control strategies in a chemical processdevelopment is demonstrated through awaste-to-methanol process. Here, the focus of theprocess tolerance analysis is on maximizingfeedstock utilization and ensuring the highestpossible operational reliability of the plant, whileconsistently meeting product quality standards.


various potential feedstock compositions investigated


achieved plant availability within product specifications

In a rapidly evolving competitive landscape, as highlighted in our recent market studies Sustainable Aviation Fuel and Methanol with a market outlook 2030, the necessity for flexible process design becomes evident.

The industry faces dynamic markets where adaptability is key to quickly respond to changing demands and technologies, like the ones shown in our article Process and Catalytic Systems for Sustainable Aviation Fuel Production.

Dr.-Ing. Maximilian Hungsberg

Technology Expert

Committed to driving industry evolution, I strive to empower clients with cutting-edge solutions for the production of renewable fuels and chemicals, seamlessly merging economic viability with environmental responsibility.

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