{"schema_version":1,"experiment_id":"eoa_inverse_innovation_exp09_archetype_breadth150_20260804","research_id":"eoa_inverse_innovation_exp09_light_prior_art_20260804","cell_id":"controlled_reentry__chemistry_materials","search_lanes":{"direct_problem_and_intervention":{"queries":["fed-batch polymerization restart after thermal runaway monomer feed staged restart","semi-batch polymerization runaway feed interruption restart reaction calorimetry","polymerization reactor emergency shutdown restart monomer feed interlock"],"source_ids":["SRC1","SRC2","SRC4"],"no_result_note":null},"synonyms_and_historical_terms":{"queries":["semibatch emulsion polymerization sudden inhibition monomer accumulation feedback control","polymerisation runaway reactant addition loss of agitation cooling failure","gas phase polymerization processing interruption idling transitional restart conditions"],"source_ids":["SRC1","SRC2","SRC4"],"no_result_note":null},"products_practices_and_standards":{"queries":["model predictive control emulsion polymerization monomer dosing cooling capacity pressure constraints","official chemical reaction hazard testing polymerisation runaway feed interlock restart","CCPS DIERS polymerization runaway feed shutoff cooling agitation"],"source_ids":["SRC2","SRC3","SRC4"],"no_result_note":null},"component_combination":{"queries":["adaptive feed control reaction calorimetry heat generation cooling capacity semibatch reactor","staged reactant feed temperature pressure rollback calorimeter","polymerization reactor restart transitional monomer feed temperature pressure"],"source_ids":["SRC1","SRC3","SRC4"],"no_result_note":null}},"sources":[{"source_id":"SRC1","title":"On-line control of a semibatch emulsion polymerization reactor based on calorimetry","publisher":"AIChE Journal / Wiley","url":"https://aiche.onlinelibrary.wiley.com/doi/abs/10.1002/aic.690430420","source_type":"PRIMARY_RESEARCH","claims_supported":["Online calorimetry was used for real-time feedback control of monomer feeding in semibatch emulsion copolymerization.","After deliberately inducing sudden reaction inhibition, feedback control avoided monomer accumulation and the associated potential for thermal runaway.","The work demonstrates response-based adjustment of polymerization feed under uncertain reaction activity, closely overlapping the proposal's feedback-governed premise."]},{"source_id":"SRC2","title":"Reaction / Product testing","publisher":"Health and Safety Executive (UK)","url":"https://www.hse.gov.uk/comah/sragtech/techmeasreaction.htm","source_type":"OFFICIAL_GUIDANCE","claims_supported":["Thermal runaway occurs when reaction heat generation exceeds heat loss and can produce catastrophic overpressure.","For batch and semibatch reactors, hazard assessment should consider cooling failure, loss of agitation, reactant addition rate, and reactant temperature.","Reaction-hazard testing should define safe temperature, cooling, and addition-time limits together with required relief, quench, trip, and containment measures."]},{"source_id":"SRC3","title":"Model predictive control of emulsion polymerization processes","publisher":"Cybernetica AS","url":"https://cybernetica.no/cybe_case/emulsion/","source_type":"FIRST_PARTY_PRODUCT","claims_supported":["A commercial model-predictive-control application adjusts monomer and initiator dosing together with reactor heating and cooling.","The system constrains monomer-feed maximization using available cooling capacity, pressure, quality, and safety limits.","Online parameter adaptation accounts for deviations in reaction heat and varying cooling capacity, and the product includes fault-detection functionality."]},{"source_id":"SRC4","title":"WO2024137204A1 — Gas phase polymerization reactor restart","publisher":"World Intellectual Property Organization / Google Patents","url":"https://patents.google.com/patent/WO2024137204A1/en","source_type":"OTHER","claims_supported":["The patent describes stopping catalyst and monomer addition after a processing interruption, idling the polymerization zone, and restarting under transitional polymerization conditions.","Restart may use reduced or varying feed rates and intermediate temperature and pressure conditions before adjustment to normal operating conditions.","This is direct polymer-reactor restart prior art, although it concerns a gas-phase fluidized-bed process after an ancillary-system interruption rather than a jacket-cooled fed-batch reactor recovering from a heat excursion."]}],"problem_evidence":{"status":"SUPPORTED","finding":"The hazardous mechanism is plainly visible. Official guidance identifies reactant-addition rate, cooling failure, and loss of agitation as material semibatch-runaway scenarios, while primary polymerization research demonstrates that sudden inhibition can cause monomer accumulation requiring feedback control to avoid potential runaway. Commercial control practice also treats reaction heat, cooling capacity, pressure, and monomer feed as coupled variables. The sources do not establish how often a second excursion occurs specifically after a feed trip, but they support the proposal's causal problem.","source_ids":["SRC1","SRC2","SRC3"]},"closest_prior_art":[{"name":"Calorimetry-based feedback control after sudden polymerization inhibition","source_ids":["SRC1"],"overlap":"Detects changed polymerization behavior online and controls feed to prevent monomer accumulation and potential runaway after an induced disturbance.","remaining_difference":"It does not disclose a post-thermal-trip recovery state, predefined probe stages and observation windows, separate advance and rollback thresholds with hysteresis, or automatic re-isolation after a failed reentry probe."},{"name":"Cooling- and pressure-constrained model-predictive monomer-feed control","source_ids":["SRC3"],"overlap":"Continuously adapts monomer dosing to observed and predicted reaction heat while respecting cooling-capacity, pressure, and safety constraints and detecting faults.","remaining_difference":"It is an ongoing production controller, not a disclosed trip-recovery protocol based on reversible, discrete load-bearing probes and mandatory return to an approved safe state."},{"name":"Transitional polymerization-reactor restart after interruption","source_ids":["SRC4"],"overlap":"Stops monomer and catalyst feeds, maintains an idled protected condition, and restores polymerization using transitional feed, temperature, and pressure conditions before returning to normal operation.","remaining_difference":"It addresses gas-phase reactor restart after ancillary-system interruption and does not disclose response-gated probe stages following a heat excursion, cooling-headroom tests, sensor-agreement criteria, hysteretic advancement, or automatic rollback on adverse slopes."}],"prior_art_disposition":"ADJACENT_PRIOR_ART","contrastive_claim_remaining":"For a jacket-cooled fed-batch polymerization specifically recovering from a thermal-excursion feed trip, feed restoration is implemented as discrete, predefined live-monomer probes whose expansion is contingent on sustained acceptable temperature and pressure slopes, jacket response, spatial sensor agreement, and demonstrated cooling reserve across separate advance and rollback thresholds, with automatic feed re-isolation on any failed stage. The retained art separately shows feedback dosing after inhibition, continuously constrained polymerization control, and transitional restart, but not this complete post-excursion sequence.","contrastive_claim_falsifier":"The remaining contrast would be falsified by a prior patent, publication, vendor implementation, standard, or operating procedure that applies substantially the same discrete probe-and-observe stages, multivariable cooling-headroom criteria, hysteretic advancement and retreat, and automatic feed re-isolation to post-excursion polymerization restart. It would also be experimentally falsified if delayed heat release, spatial hot spots, or cumulative monomer inventory make early probe success non-discriminating, or if rollback cannot arrest renewed acceleration.","gates":{"adequate_source_search":{"status":"PASS","rationale":"The bounded search covered direct proposal language, older semibatch and inhibition terminology, official reaction-hazard practice, commercial polymerization control, patents concerning polymer-reactor shutdown and restart, and combinations of calorimetry, constrained dosing, cooling capacity, pressure, and rollback concepts. Four opened sources from four publisher entities include primary research, official guidance, and a first-party implementation. This is sufficient for a coarse screen, not an exhaustive patent or literature review.","source_ids":["SRC1","SRC2","SRC3","SRC4"]},"supported_problem":{"status":"PASS","rationale":"Primary research and official guidance support the linked hazards of reaction inhibition or accumulation, renewed reactant addition, deficient mixing or cooling, excessive heat generation, and pressure escalation in semibatch polymerization.","source_ids":["SRC1","SRC2","SRC3"]},"distinct_testable_claim":{"status":"PASS","rationale":"Although the component ideas are established, the remaining post-excursion claim is narrowly specified by discrete probes, fixed observation windows, multiple response signals, cooling reserve, hysteretic stage decisions, and automatic rollback. Documentary discovery or matched calorimetry can falsify it.","source_ids":["SRC1","SRC3","SRC4"]},"bounded_next_test":{"status":"PASS","rationale":"A smallest-approved, shielded reaction-calorimetry comparison between the approved baseline restart and one frozen staged-reentry protocol is bounded. It can measure peak temperature and pressure, heat-removal demand, accumulation, sensor divergence, signal delay, and whether feed isolation arrests renewed acceleration. The result would not authorize production-scale use.","source_ids":["SRC1","SRC2"]},"no_obvious_safety_or_authority_stop":{"status":"PASS","rationale":"There is no categorical stop to the limited laboratory study if a competent process-safety authority approves the chemistry, scale, containment, thresholds, and safe-state procedure. Existing agitation, cooling, instrumentation, interlocks, relief, quench, and containment protections must remain independent and operative; production trials and interlock bypasses remain excluded.","source_ids":["SRC2"]}},"screen_survival":true,"world_novelty_boundary":"This four-source bounded web screen establishes only coarse researchability and an adjacent-prior-art disposition. It does not establish world novelty, patentability, freedom to operate, market size, expert acceptance, production-scale safety, or realized value. A fuller search of patents, process-control literature, safety-instrumented-system standards, vendor documentation, and confidential industry procedures could reveal a substantial collision."}