text: The microprocess design philosophy has been largely envisioned by historical analysis of the role that component miniaturization has played in the information technology industry.  It is the evolution of the miniaturization of computer hardware that has enabled the thinking about process miniaturization, in the chemical engineering design context.  Rather than the traditional design objective as “scale-up” of processing to one centralized large processing plant (e.g. the mainframe), one can envision achieving the economic objectives using a “scale-out” philosophy (e.g. multiple microcomputers).
  Electrical and electronic devices have always played an important role in chemical process plant automation.  However, initially, simple thermometers such as those containing mercury, and pressure gauges which were completely mechanical in nature were used to monitor process conditions (such as the temperature, pressure and level in a chemical reactor).  Process conditions were adjusted based largely on a human operator's heuristic knowledge of the process behavior.  Even with electronic automation installed, many process still require substantial operator interaction, particularly during the start-up phase of the process, or during deployment of a new technology.
  Process control of the future will involve the widespread utilization of intelligent sensors, and mass-produced intelligent miniaturized devices such as programmable logic controllers that communicate wirelessly to process actuators.  Since these devices will be miniaturized to reduce manufacturing cost, this enables the devices to be embedded in structures so that they become invisible to the casual observer.  The cost of such sensors will likely be reduced to a point where they either "function or don't function".  When that cost threshold has been reached, the repair procedure will be to disable the sensor, and to actuate a redundant working sensor.  In otherwords, entire complex control systems will become so low cost, that repair will not be economically viable.
  The intelligence of the process will be developed using process simulation models based on scientific fundamentals.  Heuristic rules will be programmed into the micro-controllers, which will largely eliminate the need for constant monitoring by human heuristic knowledge of the process behavior. Process which can automatically self-optimize through advanced algorithms developed by microprocess engineers will be embedded, and only accessible to the knowledge-owner.  This will enable the construction of large networks of autonomous microprocesses.