Introducing the…
AIChE
Process Development Division
Bob Duggal
Ethyl Corporation
Agenda
Background & History
 Structure and Current Leadership
 Recent Programs & Activities, Future
Programs
 Benefits to Division Members
 How to Get Involved
 Q&A, Remarks
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Effective Process Development
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New product or process ideas
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Superior process research and innovation
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Detailed pilot plant scale-up
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Thorough technology transfer
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Quality manufacturing leading to successful
commercialization and business results
Background & History…
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Pilot Plants Area 12A started in 1984 within the
“Engineering Division”
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Forum for pilot plant engineers & managers
Industrial focus with some academic participation
Programmed 1-2 sessions in AIChE National Meetings
Was the most active group within Engineering
In mid-1990’s, scope broadened to other areas
– Benchmarking, networking, industry-university collaborations, etc.
– Need for broader forum on industrial process development
emerged
– High level of interest from industrial participants at AIChE National
Meetings
…Background & History
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Expansion of Pilot Plants Area initiated in 1996-1997 by a core
group
Proposed name change of “Engineering Division” to “Process
Development Division”
Proposed new structure covering key elements of process
development
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12A Process Research & Innovation
12B Pilot Plants
12C Technology Transfer
12D Manufacturing
Permanent Division Status granted by AIChE CTOC in 2002
Process Development Division
Vision and Goals
Our vision is to provide leadership in the development of
the next-generation technologies for process development
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Promote programming and presentations of process
development topics at the Spring and Annual Meetings of the
Institute, and at the Process Development Symposium
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Promote the interchange of ideas, concepts and history of
process development in various aspects, from theory to
hardware
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Provide a continuous forum for communication, sharing ideas,
learning new concepts and benchmarking
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Promote networking and communication among those involved
in process development
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Promote the teaching of process development, thereby
improving interactions between industry and academia
Process Development Division
Structure
Current Leadership (2001-2003)
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Chair: John E. Corn (Consultant; Professor at Ohio State University)
Chair-Elect: Christine Seymour (Pfizer)
Treasurer: Jean Bender (Genentech)
Programming Chair: Raymond Rooks (Dow)
Membership Chair: Ramesh Rameswaran (Lyondell)
Newsletter Editor: Nicolette Modes (Abbott)
Webmaster: Jack Vinson (Pfizer)
Awards Committee Chair: Glen Wheeler (Alkermes)
International Liaison: Kamlesh Bhatia (DuPont)
Process Development Symposium Chair: Cawas Cooper (Air Products)
Special Projects: Ka M. Ng (Hong Kong UST)
12a Cheryl Teich (Rohm & Haas), Yinlun Huang (Wayne State), Lionel O’Young
(CWB Technology)
12b A. (Bob) Duggal (Ethyl), David Edwards (Zeton), Joe Powell (Shell)
12c John F. Peragine (Bristol-Myers Squibb), Annette Johnston (Abbott), Osman
Aboul-Nasr (Fluor)
12d John Battler (Consultant), Helen Lou (Lamar), Stephanie Sullivan (Merck)
Process Research & Innovation
Mission and Goals
Area 12A:
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Foster process innovation by applying Chemical
Engineering principles to the synthesis of novel
operations for new product manufacture and step
changes in existing technology.
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The PR&I area will be a meeting ground for diverse
academic and industrial practitioners of Process
Innovation.
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Its programming and activities will explore the
components of successful process innovation, and
distribute this shared knowledge to the Institute
membership.
Pilot Plants
Mission and Goals
Area 12A:
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.
Technology Transfer
Mission and Goals
Area 12C:
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Provide a forum to share and build on
technology transfer (TT) principles and
experiences of professional colleagues from
different disciplines.
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Generate ideas to develop TT work
processes aimed at extracting value from
internal and external technology for speedy
and cost effective commercialization of new
processes and products.
Manufacturing
Mission and Goals
Area 12D:
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Provide programming to enhance the
professional development of AIChE members
and industry colleagues who affect
manufacturing process improvements.
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Expand in scope to include other aspects of
manufacturing technology and secure active
participation from a greater breadth of the
ChE population. Maintain strong ties with
internal and external groups.
PDD Membership Trend
565
600
500
353
400
300
200
138
100
0
2000-2001
2001-2002
2002-2003
Programs & Activities:
Past & Future
Technical Sessions at National AIChE
Meetings
 Process Development Symposiums
 Group Planning Meetings
 Group Dinners
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Process Research & Innovation
Recent Programming Sessions
Area 12A:
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2003 Annual Meeting, San Francisco:
Topical Conference: Process Research and Innovation
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– Innovation in Pharmaceutical and Biotechnology
Development and Manufacturing
– Innovation in Green Chemistry and Sustainable Process
Development
– Selling Innovation in the Traditional CPI
– Process Innovation as a Route to Shorter Time to Market
– Innovation in Green Chemistry and Sustainable Process
Development - Measuring it and Making it Happen
2003 Spring Meeting, New Orleans
– The Role of Innovation in Extending the Life of Mature
Products
Session Papers:
Selling & Implementing Innovation in the Traditional CPI
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Implementing a High-value Novel Technology in
Petrochemical Setup
The Road to Innovation --- Contingency Cost
Reduction
A One-Step, Greener Process for Adipic Acid
Promoting Innovation with Advanced Knowledge
Management
Microfluidic Chips: A New Platform for Performing
Chemical Analysis of Drilling Fluid
McPIPE- Passively Heated Subsea Flowline
Process Research & Innovation
Future Programming Sessions
Area 12A:
2004 Annual Meeting, Austin:
Topical Conference: 21st Century Process Development Tools
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– From the university to the factory - successful
collaborations in innovation
– Innovation in Consumer Products
– Industrial Preparative Chromatography
– Innovative Design Methodologies
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2004 Spring Meeting, New Orleans
– Innovation in Fuel Processing
Pilot Plants
Recent Programming Sessions
Area 12A:
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2003 Annual Meeting, San Francisco:
Topical Conference: Pilot Plants in Process Development
– The Role of Pilot Plants in Process Development
– Pilot Plants: The Uniqueness of Small Scale
– Traditional and Novel Pilot Plant Reactors
– Key Factors in Successful Pilot Plant Design and Operation
– Pharmaceutical Pilot Plants
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2003 Spring Meeting, New Orleans
– New Trends and Best Practices in Pilot Plant I and II
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2002 Annual Meeting, Indianapolis
– Piloting for Process Intensification and Miniaturization
Session Papers:
The Role of Pilot Plants in Process Development
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Pilot Plants: A New World, A New Mission
Pilot Plants in Process Development
Changes in the Operation and Use of Pilot
Plant for Support of Refining
Pilot Plants in a Changing Industry
Environment
The Changing World of Pilot Plants
The New Pharmaceutical Pilot Plant
Pilot Plants
Future Programming
Area 12A:
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2004 Annual Meeting, Austin:
– Bioreactor Pilot Plants
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Elegant Experimental Methodology in Pilot Plants
Membrane Process Design and Scale-up Considerations
Pilot Plant Benchmarking Study Results
R&D Management Topical 3: Six Sigma Usage in the CPI
2004 Spring Meeting, New Orleans
– Mixing in Pilot Plants
Pilot Plants
Other Activities …
Area 12A:
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Pilot Plant Benchmarking
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Discussion Forum on Pilot Plants
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Pilot Plant Tours
Benchmarking Objectives
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Compile “best” practices and “norms” in
areas of interest to Pilot Plant group
– Survey members from a cross section of CPI
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Disseminate results
– In a way that members and organizations can
benchmark effectively with
– In a format that does not raise competitive issues
Benchmarking Topics
Business objectives for pilot plants
 Staffing for construction and operation
of Pilot Plants
 Pilot Plant Automation
 EH&S Issues/Consideration in Pilot
Plants
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Project Timeline
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Finalize topics - Complete
Finalize questionnaires – 4Q 2002
– Drafted by team members with input from Area 12B
– Multiple choice format with area for comments
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Circulate for responses – 2Q 2003
– Team chose to send to PDD membership to obtain a
representative cross section of CPI, representing major
industry sections
– 22 Respondents to date
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Compile responses – 3-4Q 2003
– Analyze by industry section/demographic
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Present at next AIChE/PDD Event
– Austin 2004
– Full session with 4 papers and discussion format
Technology Transfer
Recent Programming Sessions
Area 12C:
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2002 Annual Meeting, Indianapolis
– Commercialization of Separation Unit Operations
– Pharmaceuticals: Rapid Process Development
and Manufacture
2003 Spring Meeting, New Orleans
– Analytical Technology Transfer: The Good, the
Bad and the Ugly
Manufacturing
Recent Programming Sessions
Area 12D:
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2002 Spring Meeting, New Orleans
– Process Improvements in Existing Processes I
– Implementing Innovation in the Manufacturing
Setting
– Process Improvements in Existing Processes II
2002 Annual Meeting, Indianapolis
– PHA/HAZOPS for New Systems and Processes in
Manufacturing
– Pharmaceuticals: Rapid Process Development
and Manufacture
2003 Spring Meeting, New Orleans
– Case Studies and Lesson Learned
Manufacturing
Future Programming
Area 12D:
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2004 Annual Meeting, Austin:
– Spend Capital or Toll it
– Technical Project Management
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2004 Spring Meeting, New Orleans
– Case Studies and Lesson Learned
– Environmental Challenges in
Manufacturing
– Engineering Issues in Security of High
Hazard Facilities
PD Symposium:
“Accelerating Process Development for Growth”
June 2003, Poconos, PA
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Batch Process Development for
Pharmaceuticals & Specialty/Fine Chemicals
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Continuous Process Development for
Petro/Commodity Chemicals
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Visionary Talks and Panel Discussion
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Table-Top Displays
Batch Session
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“An Integrated Development Approach to API
Process R&D”
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“Process Development for the 21st Century
Pharmaceutical Industry”
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“Notes on Process Development: Pharmaceutical
Intermediates and APIs” - Ed Paul
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“Pick the Best Route: We Need It Tomorrow”!
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“Successful Chemical Process Development:
Profitable Specialty Chemical Products Using
Winning Work Practices”
Continuous Session
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“Recent Advances in the Application of Molecular
Sieve Catalysts for the Commercial Production of
Aromatics”
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“Development of Catalyst Impregnation Processes”
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“Using Physical Property Models to Accelerate
Process and Product Development”
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“Flow Visualization and Modeling of Opaque
Multiphase Flow Reactors”
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“Accelerating Process Development for Growth”
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“Dinosaurs to Small Furry Animals- The Evolution of
Process Development Methodology”
Visionary Talks
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Dr. Arthur Andrews
VP Process R&D, Merck
“Chemical Process Development for Pharmaceuticals Challenges, Opportunities, and Future Directions”
Dr. Kenneth Kem
VP Chemicals Technology, Air Products
“Use Process Innovation to Remodel Performance Products
Businesses”
Dr. Frits Dautzenberg
VP Technology Development, ABB Lummus
“Accelerating Innovation in Process Development”
Table Top Displays (partial list)
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Chemstations, Inc.
CWB Technology
HEL
Lasentec
Mettler Toledo AutoChem
Molecular Knowledge Systems, Inc.
Remspec Corp.
Xytel Corp.
Zeton Inc.
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ChemEngine
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2004 Process Development Symposium
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“Working Right on the Right Thing”
– June 20-23, 2004; Chicago
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Topics
– Technology and Knowledge
– Pilot Plants
– Modeling And Optimization as a Tool for Effective
Process Development
– Laboratory Tools for Effective Process
Development
– Working Right for the Future
Division Awards
Process Development Practice Award
(Spring) sponsored by Zeton
 Excellence in Process Development
Research Award (Fall) sponsored by
Pharmacia (Pfizer)
 The Process Development Division
Student Paper Award (Fall) sponsored
by Lilly
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Long Range Plan
2001
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2003
2004
2005
2006
2007
General
Start Soliciting Funds
Develop Targets for Fund Raising
Web Page Upgrades
Provide Free Ad Space for Universities
Process Development Benchmarking
Pilot Plant Benchmarking
Review Programming Strategy
Review Organization
Topical Programming
Membership Committee
Develop plans to increase membership
Develop Membership Targets
Alliances
-- American Chemical Society
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Process Development Symposium
Campaign to increase membership
More industry participation
Start Web PD Qtrly Publication
Elect Editor for Web Publication
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Start Student/Education
How to Provide PD Education?
-- Provide Design Probs/Solutions
-- Coordinate Seminar Sessions
Initiate Student Award
Division Focus
Initiate Division Membership Fees
Recruit Newsletter Editor
Start Division Newsletter
Increase Programming
Actively seek Industrial Sponsorship
Membership Survey
Financial Plan
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Benefits to Division Members
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Professional Development
Opportunities for Networking
Benchmarking Resources
Recognition
News and Information
Professional Development
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Attend Division sponsored activities
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Technical sessions at AIChE meetings
Process development symposiums
Topical conferences
Short courses
Develop leadership and organizational skills
by participating in Division activities
Networking
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Interact with peers from industry and
academia at group dinners and mixers
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Develop relationships for mentoring and
career development
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Access a comprehensive membership list of
peers active in Process Technology
Benchmarking
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Best practices in Process Technology
– Round table & panel discussions on specific topics
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Plant, pilot plant & laboratory tours
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Consortia sponsorships (future)
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Centers of excellence (future)
Recognition
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Annual Division sponsored award for
outstanding contributions to the field of
Process Technology
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Certificates/plaques recognizing service to
the Division
News and Information
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Division web-site
 www.pd-aiche.org
 Programming
information
– Past, current and future events
 Discussion groups (future)
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Semi-annual newsletter
How to Get Involved
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At AIChE National Meetings in the Spring & Fall
– Attend our Program Sessions
– Come to Area Meetings
– Join us at the Group dinner and other social
events
– Chair/Vice-Chair a session
Nominate a colleague for PD Awards
Join the PD Division when you renew your
annual AIChE Membership