The module allows a student to develop knowledge and skills in the design, operation and optimisation of bioprocess plants for the whole range of circular and sustainable bio-based commodity and speciality chemical, pharmaceutical, food and feed, fuels and environmental industries. Global industries in this domain are developing rapidly to include advanced biologics for cell and gene therapy and towards cultured meat and alternative proteins in the food domain. New industries have a strong focus on improved techno-economic performance and sustainability and will challenge the (best of the base) tools in the toolbox of the (bio)process developers. Conventional bio-based sectors can be increasingly found in use for other renewables, especially increased electrification from wind and solar. Successful students will be able to integrate the principles of (bio)process engineering from single unit operation towards an integral plant design, in a sustainable and renewables context. The professional field has significantly embraced the use of industry-standard process simulation software, and thus the students will elaborate and translate theoretical (bio)chemical concepts in industry standard software such SuperPro Designer (full batch and hybrid batch/continuous process simulator) including techno-economic and life cycle analysis. The bioprocess design project will also serve as a smooth entry to the 3rd semester full-time research project, again ideally with an industry partner.

A. Introduction and General Overview of Bioprocess Engineering & Design Generic approaches in bioprocess design, especially those related to the common (fed) batch and other dynamic/hybrid reaction and separation process unit operations process. Refresh of relevant process dynamics and scheduling (including batch and cycle times, critical path analysis). Impact of equipment, bottlenecks including biobased ones such as seasonal variation and feedstock supply chains, centralised scaled-up versus distributed manufacturing. B. Quick Review of Biobased Reaction and Separation Unit Operations Batch and fed-batch (bio)reaction process design principles based on metabolic flux analysis and biochemical principles; fed-batch profiles and impact on yield and selectivity of common reaction schemes (parallel, consecutive, fermentation). Selection and sequencing of relevant separation operations such as but not limited to crystallisation, ion exchange chromatography and membrane processes. Product isolation (purification) including cascade processes. Equipment dimensions, scale-up, and operating conditions. C. Design and evaluation of integral biobased processes Integral bioprocess design project to synthesize prior knowledge (see prerequisite modules) in the framework of a relevant and challenging bioprocess concept into a credible and robust bioprocess design. Ideally this is done with an industry partner from (bio)pharma, chemicals and specialities, fuels, food and feed (ingredients) and consumer products' industries, to ensure constructive-critical feedback and pragmatic considerations. As a side-product it leads to an infusion of advanced insight into Irish bioprocess industries.

On successful completion of this module, students will be able to: • Integrate advanced biochemical and metabolic flux concepts and products into a meaningful, robust and sustainable bioprocess design. • Formulate and present strategies and scenarios for bioprocess improvement, from a technological, economic and environmental perspective . • Show competency in critical/constructive review of conventional and advanced bioprocess designs for a broad variety of industrial sectors, • Develop, present and discuss a full process design, while demonstrating good insight in the fundamentals and engineering aspects of the underlying unit operations.

On successful completion of this module, students will be able to: • Develop a deep appreciation for the opportunities, challenges and limitations in the application of biobased processes, recognising the unique challenges posed by the biological nature of operations and the need for specialised approaches in comparison to conventional and non-biobased processes. • Demonstrate a commitment to understanding and differentiating between various biobased processes, including multiproduct and multipurpose plants, recognising the diversity in industrial applications. • Recognise and value the importance of efficiency improvement in bioprocesses that are often dynamic in nature, understanding that optimal scheduling, feed profiles, rescheduling, and design contribute to increased productivity and resource utilisation. • Cultivate intrinsic motivation for exploring and presenting different concepts of scheduling and rescheduling for circular Biobased processes, recognising the potential for innovation in enhancing capacity and operational efficiency. • Develop a profound appreciation for the practical application of industry-standard Biobased process simulation software, understanding its role in enhancing design, optimisation, and decision-making in batch processes.

On successful completion of this module, students will be able to: • Show practical skills in the use of industry-standard biobased process simulation software.

This module will be taught over the semester through lecturing mode, computer labs, group tutorial meetings and a bioprocess design assignment. Students will be stimulated to design with 'the end in mind' (optimal delivery at commercial scale), and explore where gaps and opportunities for those research improvements are. Current research development in the use of automated flow-sheet generation using AI systems (Industry 4.0 and 5.0) and control/optimisation using neural networks instead of mechanistic models, requiring advanced AI capabilities and software tools will be touched upon in the alter part of the module. By engaging in group problem-based and authentic learning experiences that are industrially contextualised, students will also further develop their UL Graduate Attributes.