Introducing the

1
Introducing theAIChE Process Development
Division

• Bob Duggal
• Ethyl Corporation

2
Agenda

• Background History
• Structure and Current Leadership
• Recent Programs Activities, Future Programs
• Benefits to Division Members
• How to Get Involved
• QA, Remarks

3
Effective Process Development

• New product or process ideas
• Superior process research and innovation
• Detailed pilot plant scale-up
• Thorough technology transfer
• Quality manufacturing leading to successful
  commercialization and business results

4
Background History

• Pilot Plants Area 12A started in 1984 within the
  Engineering Division
• 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-1990s, 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

5
Background History

• 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
• 12A Process Research Innovation
• 12B Pilot Plants
• 12C Technology Transfer
• 12D Manufacturing
• Permanent Division Status granted by AIChE CTOC
  in 2002

6
Process Development DivisionVision and Goals
Our vision is to provide leadership in the
development of the next-generation technologies
for process development

• Promote programming and presentations of process
  development topics at the Spring and Annual
  Meetings of the Institute, and at the Process
  Development Symposium
• Promote the interchange of ideas, concepts and
  history of process development in various
  aspects, from theory to hardware
• Provide a continuous forum for communication,
  sharing ideas, learning new concepts and
  benchmarking
• Promote networking and communication among those
  involved in process development
• Promote the teaching of process development,
  thereby improving interactions between industry
  and academia

7
Process Development Division Structure
8
Current Leadership (2001-2003)

• 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 OYoung (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)

9
Area 12A Process Research InnovationMission
and Goals

• Foster process innovation by applying Chemical
  Engineering principles to the synthesis of novel
  operations for new product manufacture and step
  changes in existing technology.
• The PRI area will be a meeting ground for
  diverse academic and industrial practitioners of
  Process Innovation.
• Its programming and activities will explore the
  components of successful process innovation, and
  distribute this shared knowledge to the Institute
  membership.

10
Area 12A Pilot PlantsMission and Goals

• 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.

11
Area 12C Technology TransferMission and Goals

• Provide a forum to share and build on technology
  transfer (TT) principles and experiences of
  professional colleagues from different
  disciplines.
• 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.

12
Area 12D ManufacturingMission and Goals

• Provide programming to enhance the professional
  development of AIChE members and industry
  colleagues who affect manufacturing process
  improvements.
• 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.

13
PDD Membership Trend
14
Programs ActivitiesPast Future

• Technical Sessions at National AIChE Meetings
• Process Development Symposiums
• Group Planning Meetings
• Group Dinners

15
Area 12A Process Research InnovationRecent
Programming Sessions

• 2003 Annual Meeting, San Francisco
• Topical Conference Process Research and
  Innovation
• 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

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Session PapersSelling Implementing Innovation
in the Traditional CPI

• 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

17
Area 12A Process Research InnovationFuture
Programming Sessions

• 2004 Annual Meeting, Austin
• Topical Conference 21st Century Process
  Development Tools
• From the university to the factory - successful
  collaborations in innovation
• Innovation in Consumer Products
• Industrial Preparative Chromatography
• Innovative Design Methodologies
• 2004 Spring Meeting, New Orleans
• Innovation in Fuel Processing

18
Area 12A Pilot PlantsRecent Programming Sessions

• 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
• 2003 Spring Meeting, New Orleans
• New Trends and Best Practices in Pilot Plant I
  and II
• 2002 Annual Meeting, Indianapolis
• Piloting for Process Intensification and
  Miniaturization

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Session PapersThe Role of Pilot Plants in
Process Development

• 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

20
Area 12A Pilot PlantsFuture Programming

• 2004 Annual Meeting, Austin
• Bioreactor Pilot Plants
• Elegant Experimental Methodology in Pilot Plants
• Membrane Process Design and Scale-up
  Considerations
• Pilot Plant Benchmarking Study Results
• RD Management Topical 3 Six Sigma Usage in the
  CPI
• 2004 Spring Meeting, New Orleans
• Mixing in Pilot Plants

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Area 12A Pilot PlantsOther Activities

• Pilot Plant Benchmarking
• Discussion Forum on Pilot Plants
• Pilot Plant Tours

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Benchmarking Objectives

• Compile best practices and norms in areas of
  interest to Pilot Plant group
• Survey members from a cross section of CPI
• Disseminate results
• In a way that members and organizations can
  benchmark effectively with
• In a format that does not raise competitive
  issues

23
Benchmarking Topics

• Business objectives for pilot plants
• Staffing for construction and operation of Pilot
  Plants
• Pilot Plant Automation
• EHS Issues/Consideration in Pilot Plants

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Project Timeline

• Finalize topics - Complete
• Finalize questionnaires 4Q 2002
• Drafted by team members with input from Area 12B
• Multiple choice format with area for comments
• 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
• Compile responses 3-4Q 2003
• Analyze by industry section/demographic
• Present at next AIChE/PDD Event
• Austin 2004
• Full session with 4 papers and discussion format

25
Area 12C Technology TransferRecent Programming
Sessions

• 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

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Area 12D Manufacturing Recent Programming
Sessions

• 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

27
Area 12D Manufacturing Future Programming

• 2004 Annual Meeting, Austin
• Spend Capital or Toll it
• Technical Project Management
• 2004 Spring Meeting, New Orleans
• Case Studies and Lesson Learned
• Environmental Challenges in Manufacturing
• Engineering Issues in Security of High Hazard
  Facilities

28
PD SymposiumAccelerating Process Development
for GrowthJune 2003, Poconos, PA

• Batch Process Development for Pharmaceuticals
  Specialty/Fine Chemicals
• Continuous Process Development for
  Petro/Commodity Chemicals
• Visionary Talks and Panel Discussion
• Table-Top Displays

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Batch Session

• An Integrated Development Approach to API
  Process RD
• Process Development for the 21st Century
  Pharmaceutical Industry
• Notes on Process Development Pharmaceutical
  Intermediates and APIs - Ed Paul
• Pick the Best Route We Need It Tomorrow!
• Successful Chemical Process Development
  Profitable Specialty Chemical Products Using
  Winning Work Practices

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Continuous Session

• Recent Advances in the Application of Molecular
  Sieve Catalysts for the Commercial Production of
  Aromatics
• Development of Catalyst Impregnation Processes
• Using Physical Property Models to Accelerate
  Process and Product Development
• Flow Visualization and Modeling of Opaque
  Multiphase Flow Reactors
• Accelerating Process Development for Growth
• Dinosaurs to Small Furry Animals- The Evolution
  of Process Development Methodology

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Visionary Talks

• Dr. Arthur Andrews
• VP Process RD, 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

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Table Top Displays (partial list)

• Chemstations, Inc.
• CWB Technology
• HEL
• Lasentec
• Mettler Toledo AutoChem
• Molecular Knowledge Systems, Inc.
• Remspec Corp.
• Xytel Corp.
• Zeton Inc.
• ChemEngine

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2004 Process Development Symposium

• Working Right on the Right Thing
• June 20-23, 2004 Chicago
• 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

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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
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Benefits to Division Members

• Professional Development
• Opportunities for Networking
• Benchmarking Resources
• Recognition
• News and Information

37
Professional Development

• Attend Division sponsored activities
• Technical sessions at AIChE meetings
• Process development symposiums
• Topical conferences
• Short courses
• Develop leadership and organizational skills by
  participating in Division activities

38
Networking

• Interact with peers from industry and academia at
  group dinners and mixers
• Develop relationships for mentoring and career
  development
• Access a comprehensive membership list of peers
  active in Process Technology

39
Benchmarking

• Best practices in Process Technology
• Round table panel discussions on specific
  topics
• Plant, pilot plant laboratory tours
• Consortia sponsorships (future)
• Centers of excellence (future)

40
Recognition

• Annual Division sponsored award for outstanding
  contributions to the field of Process Technology
• Certificates/plaques recognizing service to the
  Division

41
News and Information

• Division web-site
• www.pd-aiche.org
• Programming information
• Past, current and future events
• Discussion groups (future)
• Semi-annual newsletter

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How to Get Involved

• 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