A chemical company had just started production of a new product in its new batch process. After some initial tests, it was found that increasing the yield and decreasing the variation in the viscosity were necessary for a successful product. The batches were run in nine-day campaigns with two batches made each day. Holding tanks were available for raw materials with capacities for enough materials for 18 batches. There were four reactors in the unit that could be used for the new product.

Viscosity was measured in the laboratory using a composite sample from each batch. Yield was calculated through a material balance for each batch. The operators in the unit identified a number of factors that could affect either yield or viscosity:

Factor Levels

(maximum range for operation)

Reactor A, B, C, or D Reactor temperature 150 to 270 (°C)

Reaction time 6 to 8 (h)

Raw material supplier Quality, A-1, Discount Agitation rate 100 to 150 (rpm)

Distillation time 2 to 4 (h)

Catalyst concentration 6 to 12 (percent)

Plan an experiment for this process with the following constraints:

1. Learn something about each potential factor.

2. Complete the experiment during the next campaign of the product of interest.

3. Develop the experimental pattern, blocking, replication, and randomization for the study. Complete an experimental design planning form.