John Blacker
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Transcript John Blacker
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What is iPRD?
Founded in 2008 at the University of Leeds
Established to support chemical companies of all sizes by providing
solutions for product and process development.
Research focus driven entirely by challenges in chemical manufacturing
Developing technologies to improve products and product manufacture:
Robustness
Process Efficiency (throughput, waste, energy)
Quality Control
Environmental & worker safety issues
Product Cost
Sustainability (raw materials, supply chain)
Working with a diverse range of industries:
Construction
Agrochemical
Waste Recovery
Dyes & Pigments (textiles)
Personal Care
Electronics
Mineral Products
Energy & Renewables
Pharmaceutical
Security Printing
Automotive
Fine & Speciality Chemicals
Management Team
John Blacker
• Professor of Process Chemistry
• 19 year’s experience in the fine
chemicals industry (ICI)
• Technical Director at Piramal
Healthcare.
• Research interests include catalysis
• Inventor on 25 patents
Frans Muller
• Prof. of Chem. Process Engineering
• 17 year’s experience in industrial product
development (AZ, Syngenta)
• Focused on the interaction between
process and equipment
• Expert in Scale up, mixing, modelling
and computer simulation.
Steve Marsden
Kevin Roberts
• Professor of Organic Chemistry
• >30 industrial research collaborations
• Secondment in the speciality chemicals
industry examining the challenges in
technology transfer between
Universities & industry.
• Brotherton Professor of Chemical
Engineering
• World expert in the formation and
processing of crystalline solids
• Application in Process R&D (PAT)
• Industrial Fellowship at AstraZeneca
Chris Rayner
Philip Kocienski FRS
• Professor of Organic Chemistry
• >20 years experience of working with
a wide range of industries (pharma,
cosmetics & power generators!)
• Director of 3 chemistry-based SMEs
(pigmentation, carbon capture)
• Professor of Organic Chemistry
• New methodology for the synthesis
of biologically active targets
• >30 years consulting experience with
pharmaceutical and agrochemical
industries
Integration of Expertise at iPRD
Expertise at Leeds throughout the product development process
Industrial R&D uses integrated teams of chemists and chemical engineers
to solve problems in a holistic manner
iPRD working model reflects the industrial approach
Concept/
candidate
Route
design
Process
design
Synthetic chemistry
Catalysis
Isolation
design
Formulation
design
Separation sci/eng
Crystallisation
Physical organic chem.
Reaction engineering
Particle Science
Product
Expertise
Chemistry
and Process
Catalysis
Process
Engineering
Crystallisation/
Particle Science
Formulation
Process Laboratory
Industry-standard development and scale-up facilities and procedures
£4.8m investment by Yorkshire Forward/EU (ERDF)
650m2 refurbished laboratory space
Unique facility in academia worldwide
− non-aqueous solvent handling capabilities
Projects executed by industrially-experienced scientists
Dedicated laboratory manager and technician
On-site mechanical and electrical workshops
Safety training for all staff and students
Access to all University analytical facilities
Specialist services provided by professional partners:
iPOS (Agilent Centre of Excellence): http://www-old.hud.ac.uk/ipos/
ParticlesCIC (Particle Characterisation): http://particlescic.org/
Batch Manufacture
Remotely-controlled 20 and 50 L reactors with:
− 5 L addition vessel
− 20 L distillate receiver
− 1 m2 condenser
− variable speed agitator motor
− pitched bladed agitator
ATEX rated (temperature, gas apparatus)
Operational temperature range: -20 to 160 oC
Integrated PAT:
− Temperature sensors (Tr, Tj, condenser, BOV)
− Coolant flow meters for vessel jackets and condensers
− Rotation sensors on agitator to monitor agitation rate
− Reaction monitoring via IR, pH and conductivity probes
− FBRM (LasenTech) probe for crystallisation monitoring
Flow Manufacture
Flow Reactors
Syrris-Afrika Microreactor
2*800ml high pressure cascade CSTR
Variable residence time static mixer 40-200ml/min
Oscillating baffled reactor
High pressure fixed-bed catalyst flow reactor
Semi-continuous microwave
Mercury-lamp photoreactor
Flow Work-up and isolation
Continuous liq-liq extraction
Lab-scale thin film evaporator
Short-path continuous distillation
Rotary drum filter
Process Development Technologies
Specialist equipment available to aid all aspects of process development:
•
•
•
•
•
Small-scale parallel reactors (solubility/reaction screening)
Continuous reaction and work-up assessment
High pressure reaction vessels
Calorimetry and Process Safety
Crystallisation and Isolation Development
1 0 0 μm
100m
Current Projects
• TSB
Immobilised Catalyst Project for purer, lower cost products in more intensive process
iPRD, AstraZeneca, Pfizer, Reaxa, Cambridge Uni
• TSB
Mild, selective extraction of chemicals from seaweed
iPRD, Böd Ayre Products, Critical Processes, The Body Shop, Independent
Cosmetic Advice, Higgins Consultancy
• IMI/EU Green Chemistry for the 21st Century
20 academic and industry collaborators across Europe including Durham, York,
Manchester, Leeds
• TSB
Control of crystal growth for integrated primary and secondary manufacturing
iPRD, AstraZeneca, Pfizer, Syngenta, Avantium
• TSB
Mild, selective extraction of chemicals from fruit
iPRD, Critical Processes, Higgins Consultancy
• EPSRC Phosgene-free synthesis of isocyanates for fine chemicals
iPRD, Pfizer
Avoiding going through the mill
Pharmaceuticals/agrochemicals are typically isolated as large crystals of
variable size (primary manufacture)
Processing to the appropriate size for formulation by milling, granulation,
or micronisation (secondary manufacture) is energy intensive & wasteful
Leeds technology facilitates real-time measurement of crystal growth
TSB High Value Manufacturing award - £1.6m project (£590k @ Leeds)
with Syngenta, Pfizer, AstraZeneca, Avantium to investigate effects of
crystal growth modifiers on control of crystal size
Aim: avoid secondary manufacture (safer, cheaper, more active products)
1 0 0 μm
1.6
1.5
run 5
1.5
140
1.53 > S nuc > 1.56
Turbidity on-set
Supersaturation [-]
1.10 < S grow < 1.14
100
1.2
1.1
140
S profiles
120
120
80
1
60
1.3
100
Supersaturation [-]
1.3
1.4
S profile
Temperature [°C], Sol. Trans. [%]
1.4
160
1.34 < S grow < 1.38
160
run 4
1.2
Turbidity on-set
1.1
80
1.18 > S nuc > 1.14
1
60
0.9
Temperature [°C], Sol. Trans. [%]
1.6
0.9
40
0.8
40
T profile
0.8
20
0.7
T profiles
.
20
0.7
0.6
300
400
500
600
700
Time [min]
800
900
0
1000
100 μm
0.6
300
.
400
500
600
700
Time [min]
800
900
0
1000
100m
Industry Offering
Strategic process and manufacture related R&D using
Leeds and other expertise, public-private funding via
individual or collaboratively funded projects
Contract work in process development, testing and small
scale manufacture
Students trained in process R&D
Professional development courses
Industrial Club
Consultancy and advisory service
Our Research and Consultancy Services include:
Process Design
Process
Understanding
Process
Measurement
Physical &
Chemical
Analysis
Technology
Design
Process
Optimisation
Bulk Manufacture
Data Analysis
Renewable
Feedstocks
Product
Isolation
Continuous
Processing
Materials
Safety Analysis
Catalysis
Green
Chemistry
Scale-Up Risk
Assessment
Understanding
Impurities
Waste
Stream
Reduction &
Recycling
PAT
Process
Understanding
Improving Energy
Efficiency
Understanding
Bulk Properties
Process
Modelling
Reaction
Screening
Contract & Consultancy Services
iPRD has an excellent track record of delivering high quality contract
research and consultancy projects
All services tailored to meet client’s commercial needs
Contracts managed by University KT professionals (confidentiality, IP)
Our experts have a diverse skill set but a common focus:
application of research expertise to commercial business situations
iPRD Industrial Club
iPRD hosts two meetings per year
Brainstorm cross-industry challenges
Identify potential areas for collaboration
Showcase iPRD projects and activities
Annual Research Symposium
Symposium topics:
Green Chemistry
Crystallisation
Intensive Processing
Process Optimisation
Process Modelling (March 2012)
Current Members:
Bakhu
Pfizer
YPT
ChiralQuest
AstraZeneca
Escubed
Syngenta
Lonza
DyeCat
BromChem
GSK
Scientific Update
Dr Reddys
DeDietrich
Get Involved in Training Scientists for Process Industries
Joint Chemistry/Chemical Engineering activity
High quality students recruited from both disciplines
Unique courses to Leeds University
Student bursaries from EPSRC and Industry (£3.5k)
Title
Duration
MSc in Chemical Process Research and Development
One year
Integrated MSc and PhD (Centre for Doctoral Training) in Chemical
Process Research and Development
Four Years
Course Material:
Industry-led lectures and workshops
Industry-sponsored laboratory projects for student training
Use of large scale laboratories where appropriate (25 and 50 L reactors)
MSc in Pharmaceutical Process Engineering also available
Summary:
What is iPRD?
Research Facilities and Infrastructure
Working with the Chemical and Chemical-Using Industries
Strategic Process and Manufacturing-Related R&D
Research Collaborations
iPRD Industrial Club
Student Training and Professional Development
Knowledge Transfer Partnerships
Contract Research and Consultancy Services
Acknowledgements:
Prof. John Blacker, Prof. Steve Marsden, Prof. Kevin Roberts, Prof. Xue Wang,
Prof. Jonathan Williams, ERDF, Yorkshire Forward, EPSRC, TSB