Process Development Division Area 12B -Pilot Plants

1. 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)

2. 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

3. 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.

4. Area 12B Leadership Elections • Chair: Joe Powell, Shell • Chair-Elect: Dan Pintar, UOP • Activities Chair: Adam Whalley, Zeton • Past Chair: David Edwards, Zeton

5. 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

6. 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

7. 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 AMIntroductory Remarks 8:35 AM52aPilot Plant Testing Results in Successful Liquid-Liquid Extraction Scale-upDonald J. Glatz, Wendy Parker 9:00 AM52bPilot Plant Politics: Scaling up from Small Pilot Plants to Commercial Production PlantsJonathan H. Worstell, David S. Brown 9:25 AM52cReactor Scale-down for Pilot Plant, Bench Scale, and Multi-Throughput UnitsJoseph B. Powell 9:50 AM52dScaling Two Phase Batch and Semi-Batch Chemical Processes from Laboratory Scale to Commercial ScaleJonathan H. Worstell 10:15 AM52eDevelopment of an Adsorption Model Using Aspen Custom Modeler as a Troubleshooting and Optimization Tool for Plant ProcessesSalvador Aldrett, Jonathan H. Worstell 10:40 AMConcluding Remarks

8. 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: Adam Whalley CoSponsor(s): Pilot Plants (12b)Pharmaceuticals (See also Topical 2) (15b)Topical 2: Discover, Development and Delivery of Medicines (T2) 3:15 PM   Introductory Remarks Part 1 3:20 PM 151a Cell Culture Scale-up and Technology Transfer for 12,000 L-Scale Therapeutic Antibody ManufacturingJohn 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 PlantFrancis M. Torres, Nguyen V. Ly 4:02 PM 151c The Role of Process Modeling in Bioprocess Development and Technology TransferCharles Siletti, Demetri P. Petrides 4:23 PM 151e Multi-Dimensional Model for Prediction and Scale-up of LyophilizationPavol Rajniak, Jiri Placek, Joseph Schaller, Rajiv Mahajan, Rey Chern 4:44 PM 151f Scale up of Fluid Mixing Parameters in Bio-Pharmaceutical ProcessesJames Y. Oldshue 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 IIJoseph B. Powell

9. 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:John Corn 161aPilot Plant for Distillation and Extraction TestingDonald J. Glatz, Lori Mason 161bPilot Plants for the Chemical Process Industry (2)Jeanette Beard 161cThe Ohio State University -- Chem Engr Ug Teaching LabJohn Corn 161dUnit Operations at the University of Illinois Urbana-ChampaignMarina Miletic 161eScale down: Unusual "Pilot Plants" and Unit OpsJoseph B. Powell 161fThe Undergraduate Laboratories at University of Notre DameSalma Saddawi, Special, Profess 161gAbbott Laboratories Fermentation and Separation Pilot PlantsAnnette A. Johnston

10. 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 AMIntroductory Remarks 8:35 AM198aPilot Plants: Scaling down from Commercial Production PlantsMike J. Doll, Jonathan H. Worstell 9:00 AM198bUnique Pilot Plant Capabilities in the Canadian PrairieGregg M. Willie 9:25 AM198cFood and Chemical Pilot Plants – What Are the Differences?Richard Hess 9:50 AM198dUsing Pilot Plants Creatively to Reduce Product Development Cycle TimeJonathan H. Worstell 10:15 AM198eRe-Use of Pilot Plants to Meet Consumer Products Feedstock DemandsJoseph B. Powell 10:40 AMConcluding Remarks

11. 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

12. 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)

13. 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)

14. 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)

15. 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

16. 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)

17. 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)

18. 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

19. 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

20. 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

21. 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 Joe.Powell@Shell.com if interested.

22. 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.

23. 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.

24. 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.

25. 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.

26. 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.