TECHNOLOGY VISION The U.S. Chemical Industry AMERICAN CHEMICAL SOCIETY AMERICAN INSTITUTE OF CHEMICAL ENGINEERS CHEMICAL MANUFACTURERS ASSOCIATION COUNCIL FOR CHEMICAL RESEARCH SYNTHETIC ORGANIC CHEMICAL MANUFACTURERS ASSOCIATION Copyright © December 1996 by The American Chemical Society, American Institute of Chemical Engineers, The Chemical Manufacturers Association, The Council for Chemical Research, and The Synthetic Organic Chemical Manufacturers Association A full, printed version of this report can be obtained from American Chemical Society Department of Government Relations and Science Policy 1155 16th Street, NW Washington, DC 20036 (202) 452-8917 http://www.acs.org TECHNOLOGY VISION 2020 THE U.S. CHEMICAL INDUSTRY* The U.S. chemical industry . leads the world in technology development, manufacturing, and profitability. The U.S. chemical industry . is responsible for breakthroughs in R&D that enhance the quality of life worldwide by improving energy use, transportation, food, health, housing, and environmental stewardship. The U.S. chemical industry . leads the world in creating innovative process and product technologies that allow it to meet the evolving needs of its customers. The U.S. chemical industry . sets the world standard for excellence of manufacturing operations that protect worker health, safety, and the environment. The U.S. chemical industry . is welcomed by communities worldwide because the industry is a responsible neighbor who protects environmental quality, improves economic well-being, and promotes a higher quality of life. The U.S. chemical industry . sets the standard in the manufacturing sector for efficient use of energy and raw materials. The U.S. chemical industry . works in seamless partnerships with academe and government, creating "virtual" laboratories for originating and developing innovative technologies. The U.S. chemical industry . promotes sustainable development by investing in technology that protects the environment and stimulates industrial growth while balancing economic needs with financial constraints. *U.S. chemical industry is defined as U.S.-based production and R&D TABLE OF CONTENTS Foreword .............................................................................. 5 Acknowledgments ....................................................................... 7 Executive Summary .................................................................. 9 1. Introduction to the Chemical Industry and Its Contributions to U.S. Society ................... 15 2. Business Issues Facing the U.S Chemical Industry ....................................... 17 3. Role of Technology ................................................................. 19 The Path Toward Technology Vision 2020: Technical Issues ............................... 22 4. New Chemical Science and Engineering Technology ..................................... 23 The Three Areas of Chemical Science ................................................... 23 Chemical Synthesis ............................................................... 23 Bioprocesses and Biotechnology .................................................... 25 Materials Technology ............................................................. 27 Enabling Technologies ................................................................ 30 Process Science and Engineering Technology .......................................... 30 Chemical Measurement ........................................................... 32 Computational Technologies ........................................................ 34 5. Supply Chain Management ........................................................... 39 6. Information Systems ................................................................ 43 Information Systems in the Chemical Industry from Three Perspectives .......................... 43 Infrastructure and Open Systems .................................................... 43 Business and Enterprise Management ................................................ 45 Product and Process Design and Development ......................................... 47 Computers in Manufacturing ........................................................... 50 Manufacturing and Operations ...................................................... 50 Computers in Plant Engineering and Construction ....................................... 55 7. Manufacturing and Operations ........................................................ 57 Customer Focus ................................................................. 57 Production Capability ............................................................. 58 Information and Process Control ..................................................... 59 Building New Plants .............................................................. 60 Supplier Relationships ............................................................. 60 Global Operations ................................................................ 61 Conclusion ........................................................................ 65 Contributors ........................................................................... 67 Vision 2020 Workshop Participants ......................................................... 72 4 FOREWORD In 1994, technical and business leaders in the U.S. chemical industry1 began a study on the factors affecting the competitiveness of the industry in a rapidly changing business environment and set out to develop a vision for its future. The work focused on needs in research and development (R&D) capabilities, which are directly linked to growth and competitive advantage. This study was also stimulated by a request from the White House Office of Science and Technology Policy for industry advice on how the U.S. government could better allocate R&D funding to advance the manufacturing base of the U.S. economy. Since then, more than 200 technical and business leaders have investigated the challenges confronting the chemical industry today. (A list of the contributors is on page 67.) The results of this work, contained in Technology Vision 2020, emphasize opportunities for advancement in R&D capabilities. Participants concluded that the growth and competitive advantage of our industry depend upon individual and collaborative efforts of industry, government, and academe to improve the nation’s R&D enterprise. To assemble these conclusions and recommendations, staff and members of the American Chemical Society (ACS), Chemical Manufacturers Association (CMA), American Institute of Chemical Engineers (AIChE), Council for Chemical Research (CCR), and Synthetic Organic Chemical Manufacturers Association (SOCMA) formed the Technology and Manufacturing Competitiveness Task Group (TMCTG). The charter of the TMCTG was to • provide technology vision and establish technical priorities in areas critical to improving the chemical industry’s competitiveness; • develop recommendations to strengthen cooperation among industry, government, and academe; and • provide direction for continuous improvement and step change technology. Over the course of several months, the TMCTG convened 36 formal working meetings and 20 technical sessions to review and establish consensus on requirements within the chemical industry. The task group also polled senior management on the industry’s business needs, seeking to link technical recommendations to pressing business issues. Four technical disciplines were selected as crucial to the progress of the chemical industry. They are • new chemical science and engineering technology, • supply chain management, • information systems, and • manufacturing and operations. 1 This report does not focus on the needs of the pharmaceutical industry, but rather examines the chemical industry as the supplier and user of basic chemicals. 5 In addition to the technical work groups, a study group was put together to research existing concepts of sustainable development, such as those developed by the President’s Council on Sustainable Development and the International Council of Chemical Associations (ICCA). The study group provided these concepts to members of the technical groups as major considerations in their future-oriented technology recommendations. A second study group also reviewed ideas for partnerships among industry, government, and academe. The group concluded that in this age of reorganization, the synergy of collaboration often has a ’’multiplier effect’’ on our nation’s pool of talent, equipment, and capital available for R&D. The conclusions of the four technical and two study groups were reviewed at a public workshop in May 1995 hosted by the TMCTG and attended by 120 leaders from industry, government, and academe. Final recommendations and conclusions are contained in Technology Vision 2020. Technology Vision 2020 is a call to action, innovation, and change. The body of this report outlines the current state of the industry, a vision for tomorrow, and the technical advances needed to make this vision a reality. The vision, like the industry, will evolve as the industry faces new realities and challenges. Technology Vision 2020 is the first step of a continuous journey—one that will see the U.S. chemical industry continue as a global leader in the next century. We thank you, the reader, for considering our report and are grateful for the outstanding professional contributions of our many working members and reviewers. Sincerely, Members of the Steering Committee John Oleson, Dow Corning Victoria