Application of Taguchi Method of Experimental Design for Chemical Process Optimisation: A Case Study

Abstract

This case study is one of the distinctive researches which highlight the factor ratings and process optimisation through Taguchi design. This research has been conducted with a special reference to chemical plants in India. The objective of the present study was to establish optimal setting of four factors, viz., ( i) temperature (°C), ( ii) percentage of chemical (Borex), ( iii) pH and ( iv) time (Hrs). The present study was conducted to ensure optimisation of two response variables which were ( i) Loss-on-Ignition (LoI) (lower the better) and ( ii) chemical Borate content (higher the better). The unique 10 step methodology was adopted for arriving at optimal setting of four factors. Validation of optimal settings has been done by comparing actual values (means and signal to noise [S/N] ratios) for optimal setting with predicted values (means and S/N ratios). The results show that the Taguchi parameter design improves the response variables ( i) LoI (lower is better) and ( ii) chemical Borate content (higher is better), as the Taguchi L9 experiment resulted in lower LoI (less than 15 per cent) and high Borate percentage of chemical (greater than 45 per cent). The optimisation of response variables has ensured breakthrough improvement in the manufacturing process of Zinc Borate. The result underlines effectiveness of Taguchi optimisation technique.