The module allows a student to develop knowledge and skills in the design, operation and optimization of batch chemical and biochemical processing plants. They will be able to apply the principles of batch process engineering in single batch unit operation as well as in an integral batch plant design project. As the professional field has significantly embraced the use of industry-standard batch process simulation software, as the students will translate and elaborate theoretical (bio)chemical concepts in DynoChem (single batch unit operations) and SuperPro Designer (full batch and hybid batch/continuous process simulator) including techno-economic and life cycle analysis.

Generic scheduling approaches, applied to single batch reaction and separation process unit operations including batch and cycle times, critical path analysis. Impact of equipment, bottlenecks as well as those in operators, feedstock supply, utilities availability. Batch and fed-batch (bio)reaction process design principles; fed-batch profiles and impact on yield and selectivity of common reaction schemes (parallel, consecutive, fermentation). Selection and sequencing of batch product separations operations such as but not limited to crystallization, ion exchange chromatography and membrane processes. Product isolation (purification) including cascade processes. Equipment dimensions, scale-up, and operating conditions. Flowsheeting for semi-continuous and discrete operations. Campaign operation and scheduling. Multiple product batch processes. Impact of transfer policies, intermediate storage, inventory design of feedstocks, buffer and eluent solutions and operational management. Process control, optimisation and modelling for unsteady state reaction processes. Use of industry-standard batch equipment (DynoChem) and process (SuperProDesigner) simulation software. Process and product quality control and compliance. Selected case studies from relevant process industries such as (bio)pharma, chemicals and specialities, food and fed (ingredients and consumer products.. Single batch unit operations and full batch process design assignments.

On successful completion of this module students should be able to: • Recognise the differences between batch and continuous processes and understand and distinguish between multiproduct and multipurpose batch plants, flowshop (same process routing) and jobshop (individual process routing). • Present different concepts of scheduling and rescheduling for batch processes capacity and efficiency improvement. • Show competency in the design and operation of batch reaction systems for the production of chemicals and biochemicals. • Identify appropriate methods for product isolation in batch processing operations. • Tabulate the various models and techniques available for batch process control. • Show practical skills in the use of industry-standard batch process simulation software. • Develop, present and discuss a batch unit operation and full process design.

On successful completion of this module students should be able to: • Develop a deep appreciation for the complexity of batch processes, recognizing the unique challenges posed by the intermittent nature of operations and the need for specialized approaches in comparison to continuous processes. • Demonstrate a commitment to understanding and differentiating between various batch processes, including multiproduct and multipurpose batch plants, flowshop, and jobshop, recognizing the diversity in industrial applications. • Recognize and value the importance of efficiency improvement in batch processes, understanding that optimal scheduling, rescheduling, and design contribute to increased productivity and resource utilization. • Cultivate intrinsic motivation for exploring and presenting different concepts of scheduling and rescheduling for batch processes, recognizing the potential for innovation in enhancing capacity and operational efficiency. • Develop a profound appreciation for the practical application of industry-standard batch process simulation software, understanding its role in enhancing design, optimization, and decision-making in batch processes.

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This module will be taught through lecturing mode and tutorial. Student need to actively participate a number of dedicated computer labs using the DynoChem and SuperProDesigner software during the semester, elaborating a number of assignments. Batch Process Engineering with a strong focus on impact of scheduling and quantitative predictions on techno-economic performance and sustainability is among the base tools in the toolbox of the (bio)process developers. Main research developments are on novel (bio)catalysts and production organisms and novel materials that assist purification; these will be touched upon in the lectures and identification of opportunities for (bio)chemical process improvement are integral part of the later assignments. Students will be stimulated to design with 'the end in mind' (optimal delivery at commercial scale), and explore where gaps an opportunities for those research improvements are. Another line of current research development is the use of automated flowsheet generation using AI systems (Industry 4.0 and 5.0) and control/optimization using neural networks instead of mechanistic models, but this is only being explored by advanced industries.