Process Development Division Area 12B -Pilot Plants

AIChE 2006 Fall Meeting San Francisco, CA Monday 11/13/2006 6:30-7:30 PM Hilton (Union Square 11 – 4th floor)

AGENDA

 Introductions  Mission Statement Review  Area Leadership   Programming Review (2006 - 2008) Future Programming Topics – Open Forum  Current Action Items  New Business  Area 12b Leadership Roles

Mission Statement

The Pilot Plant Area is a forum for active interchange of ideas and for the continual improvement of Pilot Plant contributions to quality research and effective scale-up. AIChE programming, benchmarking, operation reviews, and extensive networking form the backbone of the Area activities.

Area 12B Leadership Elections



Chair:

Joe Powell

,

Shell



Chair-Elect:

Dan Pintar

, UOP



Activities Chair:

Adam Whalley,

Zeton



Past Chair:

David Edwards

, Zeton

Programming….

Spring 2006 (Orlando, FL)



Pilot Plant Success Stories

 Chair : David Edwards  Vice-Chair : Raymond Rooks  4-Session Mini-Topical for 12A & SEF: Sustainability in Practice  Joe Powell, chair  Book to be drafted

Programming….

Fall 2006 (San Francisco, CA)

Pilot Plants Mini-Topical: Pilot Plant Design and Optimization Chairs: Dan Pintar, Joe Powell

 Unit Operations : Scale Up and Scale-down in Pilot Plants 

Joe Powell, Osman Aboul-Nasr

 Pilot Plants in the Food and Consumer Products Industries 

Marc Privitera, David Reeder

 Strategies in Biopharmaceutical Scale-up & Pilot Plants 

Nihal Tugcu (15b), Adam Whalley (12b)

 Poster Session : Pictures of Pilot Plants and University Unit Operation Labs 

John Corn

Monday, 13 November 2006: 8:30 AM-11:00 AM Union Square 25 (Hilton San Francisco) Topical 5: Pilot Plant Design and Optimization (T5) #52 - Unit Operations: Scale up and Scale-down in Pilot Plants (T5002) Chair:

Joseph B. Powell

CoChair:

Osman Aboul-Nasr

CoSponsor(s):

Pilot Plants (12b) 8:30 AM 8:35 AM 52a

Donald J. Glatz

, Wendy Parker 9:00 AM 52b Production Plants Jonathan H. Worstell,

David S. Brown

Introductory Remarks Pilot Plant Testing Results in Successful Liquid-Liquid Extraction Scale-up Pilot Plant Politics: Scaling up from Small Pilot Plants to Commercial 9:25 AM 52c

Joseph B. Powell

9:50 AM 52d Laboratory Scale to Commercial Scale

Jonathan H. Worstell

Reactor Scale-down for Pilot Plant, Bench Scale, and Multi-Throughput Units Scaling Two Phase Batch and Semi-Batch Chemical Processes from 10:15 AM 52e Development of an Adsorption Model Using Aspen Custom Modeler as a Troubleshooting and Optimization Tool for Plant Processes

Salvador Aldrett

, Jonathan H. Worstell 10:40 AM Concluding Remarks

Monday, 13 November 2006: 3:15 PM-5:45 PM Union Square 25 (Hilton San Francisco) Topical 5: Pilot Plant Design and Optimization (T5) #151 – Strategies in Biopharmaceutical Scale-up & Pilot Plants (T5003) Chair:

Nihal Tugcu

CoChair: CoSponsor(s):

Pilot Plants (12b) Pharmaceuticals (See also Topical 2) (15b) Topical 2: Discover, Development and Delivery of Medicines (T2) 3:15 PM

Part 1

Adam Whalley Introductory Remarks 3:20 PM 151a Therapeutic Antibody Manufacturing Cell Culture Scale-up and Technology Transfer for 12,000 L-Scale

John Fann

, John Ponzo, Ziran Sun, Seshu Tummala, Clara Teijido, Min Wan, George Avgerinos 3:41 PM 151b Strategy to Fit a Downstream Purification Platform for an Early Stage Development, Therapeutic Protein into an Existing Pilot Plant

Francis M. Torres

, Nguyen V. Ly 4:02 PM 151c Technology Transfer

Charles Siletti

, Demetri P. Petrides The Role of Process Modeling in Bioprocess Development and 4:23 PM 151e Multi-Dimensional Model for Prediction and Scale-up of Lyophilization

Pavol Rajniak

, Jiri Placek, Joseph Schaller, Rajiv Mahajan, Rey Chern 4:44 PM 151f

James Y. Oldshue

Scale up of Fluid Mixing Parameters in Bio-Pharmaceutical Processes 5:05 PM 151g From Petrochemicals to Pharmaceuticals: Rapid Scale-up of Penicillin by an Academia-Industry Consortium Including Shell Development Company during World War II

Joseph B. Powell

Monday, 13 November 2006: 6:30 PM-9:00 PM Grand Ballroom B (Hilton San Francisco) Topical 5: Pilot Plant Design and Optimization (T5) #161 - Pictures of Pilot Plants and University Unit Operation Labs (T5001)

A picture is worth a 1000 words... for some of us, that is. One can also use a picture to help focus a discussion on pilot plant operations and undergaraduate engineering laboratory education. The aim of this poster session is to allow lively small group discussions and to help inform a cohort of laboratory directors and workers about pilot plant systems and/or University Unit Operations Labs.

Chair:

161a Pilot Plant for Distillation and Extraction Testing

Donald J. Glatz

, Lori Mason 161b John Corn

Jeanette Beard

Pilot Plants for the Chemical Process Industry (2) The Ohio State University -- Chem Engr Ug Teaching Lab 161c

John Corn

161d

Marina Miletic

Unit Operations at the University of Illinois Urbana-Champaign 161e

Joseph B. Powell

Scale down: Unusual "Pilot Plants" and Unit Ops 161f The Undergraduate Laboratories at University of Notre Dame

Salma Saddawi, Special, Profess

161g

Annette A. Johnston

Abbott Laboratories Fermentation and Separation Pilot Plants

Tuesday, 14 November 2006: 8:30 AM-11:00 AM Van Ness (Hilton San Francisco) Topical 5: Pilot Plant Design and Optimization (T5) #198 - Pilot Plants in the Food and Consumer Products Industries (T5000)

Pilot plants as normally thought of in the chemical industry, but there are similar needs in the Food and Consumer Products Industries. This session will seek to present pilot plant and process development examples from this important industry segment.

Chair:

Marc Privitera

CoChair:

David Reeder

CoSponsor(s):

Pilot Plants (12b) 8:30 AM 8:35 AM 198a

Mike J. Doll

, Jonathan H. Worstell 9:00 AM 198b

Gregg M. Willie

9:25 AM 198c

Richard Hess

9:50 AM 198d Cycle Time

Jonathan H. Worstell

Introductory Remarks Pilot Plants: Scaling down from Commercial Production Plants Unique Pilot Plant Capabilities in the Canadian Prairie Food and Chemical Pilot Plants – What Are the Differences?

Using Pilot Plants Creatively to Reduce Product Development 10:15 AM Demands 198e

Joseph B. Powell

10:40 AM Re-Use of Pilot Plants to Meet Consumer Products Feedstock Concluding Remarks

Programming….

Spring 2007 (Houston, TX)   Tools and Best Practices in Pilot Plants  Chair : Joe Powell (Shell)   Co-Chair : David Attride (Eastman) Call for papers open until Nov. 30 SUSTAINABLE Manufacturing  Chair : Joe Powell (Shell)  Co-Chair : Benson Pair (KBR)   Co-sponsor SEF & 12d Call for papers open until Nov. 30

Programming….

   

Fall 2007 (Salt Lake City, UT)

Solids Handling in Pilot Plants  Bruce Hook (Dow)  Vice Chair: Joe Powell (Shell) Careers in Pilot Plants   Chair : Dan Pintar (UOP) Vice-Chair : Salvador Aldrett (Shell) Alternative-Fuel Pilot Plants & Process Development  Chair: David Reeder (Cargill)  Vice-Chair: Lissa Morgenthaler-Jones (LiveFuels) Mixing in Pilot Plants Co-Sponsored by NAMF (Group 6)  Chair: David Dickey (Mix Tech)  Vice-Chair: Tony Cartolano (Air Products)

Fall 2007 or 2008+ (TBA)



Pharmaceutical Pilot Plants

(tentative) – Chair: Brent Nielsen (Bristol-Myers Squibb) – Co-Chair: Elizabeth Spiteri (Bristol-Myers Squibb) – Possible multiple sessions (4 – topical)

Programming….

Spring 2008 (New Orleans, LA)

   Current Challenges in Pilot Plant Operation  Chair: Bob Duggal (Afton); or Cawas Cooper or Tony Cartolano (Air Products).

 Co-Chair: Adam Whalley (Zeton) Process Chemistry and Catalysis in Pilot Plants (ACS overlap)  Chair: Joe Powell (Shell)  Co-Chair: David Attride (Eastman) Gasification & pyrolysis pilot plants  Chair: David Edwards (Zeton)  Co-Chair: Dan Pintar (UOP)

Programming….

Fall 2008 (Philadelphia, PA)

Session topics or topical conference to be chosen to coincide with AIChE’s centenary celebrations

 Pilot Plant Centenary Celebration Topical: David Edwards (Zeton) / Jean Tom (Bristol-Myers Squibb) = topical chairs – Instrumentation and control  Chair: David Edwards; Co-chair (TBA?) – Pharmaceuticals (chiral catalysis, separations)  Chair: Jeam Tom; Co-chair (TBA?) – Reaction engineering / reactor design  Chair (TBA?; Sue Degaleesan- Shell?); Co-Chair (TBA?) – Pilot Plants through History? Pictures; How technology has changed.

 Chair: TBA?

 Co-Chair: TBA?

 Consider Rich Palluzi short course? ½-day course? Part of topical

Programming….

Spring 2009 (Location TBA)



Shortcut Methodology in Pilot Plants

 Chair : Joe Powell, Shell  Co-Chair : Dan Pintar, UOP 

Heavy oil upgrading, hydrotreating & refining pilot plants

 Adam Whalley (Zeton)  Dan Pintar (UOP)

Programming….

Fall 2009 (Location TBA)

 Biotech and Biopharma Pilot Plants  Misti Ushio (Merck 12b), Vice Chair (15c)  Pilot Plant Metrics and Productivity  Chair, Vice Chair (TBA)

Potential Session Topics...

             Analytical techniques/devices for pilot plants Pharmaceutical pilot plants - regulations and environmental challenges Process safety management in pilot plants Bio-informatics/Bio-technology  Generic drugs and related topics  Bio-processing  Bio-tech Pilot Plants Polymer Processing in Pilot Plants Syngas Pilot Plants Contract Pilot Plants (contracting either as a supplier of pilot plant services or a client) Constructability issues for Pilot Plants Careers in Pilot Plants Microbiological and Cleanliness Challenges in Pilot Plants Internal & Contract Vs. Toll Pilot Plants Novel reaction techniques in Pilot Plants (e.g. microwave) Pilot Plant metrics and productivity

Potential Session Topics

             Miniaturization of Pilot Plants Cost-Driven Pilot Plants (Funding) Process Control and Data Acquisition in Pilot Plants Marketing of Pilot Plants (internal see next topic or External for purposes of contracting services) Time-to-Market Successful Pilot Plant Design Pilot Plant Productivity (Metrics used to define equipment/personnel/reliability) Pilot Plants as Part of the Corporate Structure/Organization Optimum Sizing of Pilot Plants Internal or Contract Pilot Plants ?

Pilot Plant Tools and Techniques Pilot Plant Equipment Selection Use of Computer Simulation to Support Pilot Plant Design and Operation

Current Action Items

 Oversee Chemical Process Development Web Forum and Vendor Area (DE)…hosted on www.eng-tips.com

 Opportunities for courses include ASME and Univ. of Wisconsin continuing education. No interest in developing AIChE sponsored course at this time.  Publish Pilot Plant Benchmarking results in CEP (JBP / BD) ongoing

New Business

 Solicit session chairs and co-chairs for 2007-09 (done)   Vote: Adam Whalley (Zeton) elected as 12b activities chair Possible Process Development or Pilot Plant Best Practices Edited Book (Wiley):  Publish pilot plant benchmarking first  forward chapter proposal to [email protected]

if interested.

Area 12b Leadership Roles

Area 12b Past Chair

The Area 12b Past Chair oversees the handover of action items and responsibilities to the incoming Area 12b Chair, and supports and advises the Area 12b Chair during his/her two year term as necessary.

Area 12b Leadership Roles

Area 12b Chair

The Area 12b Chair leads all Area 12b activities, and has overall responsibility for ensuring all phases of programming for Area 12b.

 Automatically assumes Area Chair position at the

beginning

of the annual (Fall) meeting in odd years after serving as Chair-Elect for two years.

 Is responsible for selection of technical session topics in coordination with the Division Programming chair, and for finding chairs and co-chairs for these sessions.

Area 12b Leadership Roles

Area 12b Chair Cont’d.

 Coordinates and helps session chairs in organizing sessions and meeting deadlines.

 Develops the Area in accordance with the Area Mission Statement.

 Holds Area meetings at least once a year at the Annual or Spring Meeting.

 Holds an Area election at the Steering Committee meeting upon

leaving

office for the incoming Activities Chair position before handing over responsibilities to the Chair-Elect.

 Provides leadership and management for the Area.

Area 12b Leadership Roles

Area 12b Chair-Elect

The Area 12b Chair-Elect prepares for the office of Chair by assisting the Area 12b Chair during his/her two year term.

 Deputizes for the Area 12b Chair in the Chair's absence or inability to serve.

 Automatically assumes the position of Area 12b Chair at the beginning of the annual (Fall) meeting in odd years after serving for two years as Area 12b Chair-Elect.  Formulates long-term plans and strategic activities for the Area in accordance with the Area Mission Statement.  Assist session chairs and co-chairs with finding presenters for 12b sessions.

Area 12b Leadership Roles

Area 12b Activities Chair

The Area 12b Activities Chair prepares for the office of Chair-Elect during his/her two year term. This position requires no prior experience in AIChE/PD Division or Area matters.

 Is recruited by the outgoing Area 12b Chair-Elect, and is elected to office during Area Elections at the annual (Fall) meeting in odd years.

 Automatically assumes the position of Area 12b Chair Elect at the annual (Fall) meeting in odd years after serving for two years as Area 12b Activities Chair.  Assist session chairs and co-chairs with finding presenters for 12b sessions.