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2016/17 Taught Postgraduate Module Catalogue

CAPE5903M Manufacturing

30 creditsClass Size: 25

Module manager: Dr RA Bourne
Email: r.a.bourne@leeds.ac.uk

Taught: 1 Sep to 31 Aug View Timetable

Year running 2016/17

Pre-requisite qualifications

BEng/MEng, BSc/MChem in relevant engineering or science discipline

Module replaces

CAPE5921M Particle Product Processing Project

This module is not approved as an Elective

Module summary

Formulated products in agrochemicals, catalysts, coatings, fine chemicals, foods, healthcare, home and personal care and pharmaceuticals industries are complex particulate products are worth 25B£ to the UK economy. These highly-structured multiphase products contain particulates, often modified by the adsorption of additives to increase product stability and enhance the efficacy and delivery of 'active' ingredients. In this module students will use SCAPE and iPRD labscale and pilot scale processing facilities in an intensive training activity. Students will observe and experience issues associated with operation of large batch-scaled particulate processes. This will illustrate product manufacturing scale-up issues encountered in industry, and set the scene for the tasks required in this module. Using standard commercial products as a baseline, we will require the students (working in small teams) to synthesise and manufacture analogous particle based chemical products at various lab-scales. They will also gain experience of larger 20 L batch reactors. In a second phase of the module, the student teams will be asked to deliver a process flowsheet (or flowsheets) and associated costing for the manufacturing of these products at a relevant industrial scale. Environmental sustainability and waste issues with product manufacture will also be explored. The students will select and justify appropriate equipment for the process they have selected – this will need to be linked to the properties of the material to be manufactured. They will then undertake appropriate design calculations and modelling for the scale-up. The assignments in this module will be supported by a series of taught lectures and focused workshops on key skills; such as scale-up theory, mass & energy balances, chemical kinetics, design of experiments, powder mixing and rheology. The taught components will be led by a combination of our industry-experienced academic staff and key external providers (e.g. PSE, Sellafield).The work requires students to link key concepts from process chemistry, chemical technology and engineering science in the area of drug discovery, process development, engineering operations and plant design.

Objectives

At the end of the module the student should:
Specific objectives:
- have an overview and understanding of the concepts surrounding pharmaceutical, personal care and fine chemical development and manufacturing;
- understand the concepts of fundamental process chemistry, chemical technology and engineering science underpinning product innovation, process development, engineering operations and plant design together with basic regulatory issues;
- be capable of executing a process design.

Transferable skills objectives:
- have designed complex communications;
- have experience with pilot scale process development.

Learning outcomes
On completion of this module, participants should have:
Specific outcomes:
- Knowledge of research and development of fine chemical, personal care and pharmaceutical manufacture.
- Knowledge underpinning the design and operation of chemical and pharmaceutical research, development and manufacture.
- Knowledge of the plant design principles and methods, e.g. engineering design skills, mass/energy balances.
- Knowledge of whole systems analysis and sustainability issues in chemical manufacture.

Transferable skills:
- Engineering project management skills.
- 'Should-cost' analyses.
- Training of fundamental engineering design and practice.

Skills outcomes
As part of this module, the students will have the opportunity to learn a number of transferable skills which are key to the delivery of good outcomes.

These include:
- Critical evaluation of the literature, including literature search and retrieval;
- Methodologies associated with design and analysis during projects;
- Option selection strategies;
- Reasoning and problem solving;
- Skills in communication and targeting the audience;
- Professionals skills and attitudes;
- Teamwork;
- Keep an accurate, formal record of meetings and research performed.


Syllabus

Introduction to scale-up processing
The taught components of this module will enhance students understanding of the processing and manufacture of complex particle products:

- Principles of engineering scale-up; including, dimensional analysis, example scale-up problems, use of experimental data correlation and scale-up of batch mixing systems.
-Engineering mass balances and chemical kinetics.
-Design of experiments and sweet spot analysis in chemical processes.
-HAZard and Operability analysis of engineering units
-Rheology of complex particulate fluids
-Powder processing and mixing

These taught components will be combined with significant laboratory practical work and group project design (see below).

Processing design and development to pilot scale
Using standard commercial products as the basis for the key assignment task, students will design and execute a process recipe for batch-scale production of an analogous particulate chemical product, to introduce the concepts of chemical manufacture and scale-up analysis. Students will be required to evaluate the process at a small scale, and, working together with plant personnel, accommodate the process into one or more of the several larger batch scale processing units that are available in iPRD and SCAPE, as well as a number of smaller labscale processing equipment (e.g. spray drying, granulation, tabletting). Students must firstly manufacture their products and secondly test their performance against other leading brands. Additionally, students will complete a pilot-scale batch crystallisation (~20 L) at iPRD to observe and experience issues associated with operation of such large processing equipment.

Processing design manufacturing scale
The designed process and scale up experience forms the basis of the major assessment task, the design of a process flowsheet (or flowsheets) and associated costing for the manufacturing of this product at a given (industrial) scale. The students will select and justify appropriate equipment for the process they have selected – this will need to be linked to the properties of the material to be manufactured. They will also link their design to their own small-scale manufacture. They will then undertake appropriate design calculations and modelling for the scale-up. They will also consider HSE concerns (Health, Safety and Environment) and be required to use a full-systems perspective to understand sustainability and waste issues with their product manufacture.

The assignments in this module will be supported by a series of focused workshops on key skills such as flowsheeting, process modelling, product formulation and whole process analysis. These workshops will be led by a combination of our industry-experienced academic staff and key external providers (e.g. PSE, Sellafield).

Transferrable skills: communication and independence
Working with an academic mentor, operating as the project manager, small teams of CDT students (4 or 5) will be required to design and execute the technology transfer of their process to a team of industrial/academic people. The students will decide what information is needed and where they will access this (lectures, seminars, web, books, and journals).

Teaching methods

Delivery typeNumberLength hoursStudent hours
Workshop102.0020.00
Technical Training27.0014.00
Lecture102.0020.00
Lecture112.0022.00
Tutorial101.0010.00
Private study hours214.00
Total Contact hours86.00
Total hours (100hr per 10 credits)300.00

Private study

Students will need to prepare for the various elements of the project, including background reading and literature review, and up skilling on software packages. The individual and team elements of the accommodation document and the tech transfer package will require preparation.

Opportunities for Formative Feedback

Working with an academic mentor, operating as the project sponsor (less direction), small teams of CDT students (2-4) will report weekly to discuss what information is needed, where they will access this (lectures/seminars/web/books/journals) and plan experimental work required to support their process design. These meetings will be minuted by the students. The VLE diary provides a monitoring tool across the programme and will be discussed at quarterly meetings with senior CDT staff.

Methods of assessment


Coursework
Assessment typeNotes% of formal assessment
AssignmentH & S Assignment7.50
In-course AssessmentQuiz20.00
ReportIndividual element of Pilot Scale Manufacturing and Processing Report10.00
Group ProjectPilot Scale Manufacturing and Processing Report (including lab-scale)40.00
PortfolioPresentation - Technical transfer communication of the Manufacturing Flowsheet Report10.00
Self/Peer AssessmentTeam Evaluation12.50
Total percentage (Assessment Coursework)100.00

Normally resits will be assessed by the same methodology as the first attempt, unless otherwise stated

Reading list

There is no reading list for this module

Last updated: 11/10/2017

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