In this research project, systematic studies of polymer-assisted flocculation and dewatering behaviour of colloidal gibbsite (y-Al(OH)3) dispersions, together with polymeric flocculant structure-mediated interfacial chemistry and particle interactions, have been performed. Clear links between flocculation performance, interfacial chemistry, particle interactions, dispersion settling rate and sediment consolidation were established for improved dewaterability.

In this research project, systematic studies of polymer-assisted flocculation and dewatering behaviour of colloidal gibbsite (y-Al(OH)3) dispersions, together with polymeric flocculant structure-mediated interfacial chemistry and particle interactions, have been performed. Clear links between flocculation performance, interfacial chemistry, particle interactions, dispersion settling rate and sediment consolidation were established for improved dewaterability.

<div>Liquid desiccant air dehumidification (LDAD) is a promising substitute for the conventional dehumidification systems that use mechanical cooling. However, the LDAD system shares a little market because of its high installation cost, carryover problem, and severe corrosion problem caused by the conventional liquid desiccant. The research reported in this thesis aimed to address these challenges by applying membrane technology and ionic liquid desiccants (ILDs) in LDAD. The membrane technology uses semi-permeable materials to separate the air and liquid desiccants, therefore, the solution droplets cannot enter into the air stream to corrode the metal piping and degrade the air quality. The ILDs are synthesized salts in the liquid phase, with a large dehumidification capacity but no corrosion problems. In order to study the applicability and performance of these two technologies, both experimental and modeling investigations were made as follows.</div><div>In the study, experimental researches and existing models on the membrane-based LDAD (MLDAD) was extensively reviewed with respects of the characteristics of liquid desiccants and membranes, the module design, the performance assessment and comparison, as well as the modeling methods for MLDAD.</div><div>A small-scale prototype of the MLDAD was tested by using ILD in controlled conditions to characterize its performance in Oak Ridge National Lab. The preliminary experimental results indicated that the MLDAD was able to dehumidify the air and the ILD could be regenerated at 40 ºC temperature. However, the latent effectiveness is relatively lower compared with conventional LDAD systems, and the current design was prone to leakage, especially under the conditions of high air and solution flow rates.</div><div>To improve the dehumidification performance of our MLDAD prototype, the two-dimensional numerical heat and mass transfer models were developed for both porous and nonporous membranes based on the microstructure of the membrane material. The finite element method was used to solve the equations in MATLAB. The models for porous and nonporous membranes were validated by the experimental data available from literature and our performance test, respectively. The validated models were able to predict the performance of the MLDAD module and conduct parametric studies to identify the optimal material selection, design, and operation of the MLDAD.</div><div><br></div>

<div> Here, the quartz crystal microbalance with dissipation monitoring (QCM-D) is employed to explore the interaction of the various free oxidant species with condensed PA model membranes in order to improve our understanding of how the interaction with these species affects rates of membrane chlorination and alter membrane structure. Molecular-scale mass uptake and changes in the dissipative nature of the of the model membranes as measured by the QCM is correlated to performance changes in interfacially polymerized PA reverse osmosis (RO) membranes. Leveraging newly gained insights from these measured interactions, new strategies are explored to improve flux and chlorine resistance using novel membrane structure and chemistry.<br></div>

This diploma thesis deals with the effectiveness of separation technologies for water treatment. The first theoretical part mentions types of pollution that can be found in surface water. Furthermore, the interparticle interactions affecting the stability of colloidal dispersions are discussed. The following is a description of the principle, procedure, mechanisms of coagulation and factors influencing this process. The chapter dealing with types of water treatment is followed by a more detailed description of the individual separation technologies used in the water treatment plants. The important passage in the theoretical part is the description of materials and reagents used in laboratory experiments. The coagulants nanoiron and sodium water glass are characterized, as well as Bayoxide E33, CFH 0818, FILTRASORB 100 activated charcoal and DORSILIT silicate sand. The experimental part of the thesis analyses the jar test procedure. The flocculation tester intended for the jar test was used for laboratory coagulation using nanoiron and sodium water glass. The effectiveness of selected coagulants in the removal of turbidity from water during sedimentation of flakes produced in reaction vessels was investigated. In addition, the effectiveness of individual filtering materials in the removal of turbidity from water containing nanoiron/sodium water glass was investigated. In the end, the results of laboratory tests are compared and evaluated, including photos taken during experiments.

<p>Cutting greenhouse gas emissions to as close to zero as possible, or ”net-zero”, may be the biggest sustainability goal to be achieved in the next 30 years. While chemical engineering evolved against the backdrop of an abundant supply of fossil resources for chemical production and energy, renewable energy resources such as solar and wind will find more usage in the future. This thesis work develops new concepts, methods and algorithms to identify and synthesize process schemes to address multiple aspects towards sustainable chemical and energy systems. Shale gas can serve as both energy resource and chemical feedstock for the transition period towards a sustainable economy, and has the potential to be a carbon source for the long term. The past two decades have seen increasing natural gas flaring and venting due to the lack of transforming or transportation infrastructure in emerging shale gas producing regions. To reduce carbon emission and wastage of shale resources, an innovative process hierarchy is identified for the valorization of natural gas liquids from shale gas at medium to small scale near the wellhead. This paradigm shift fundamentally changes the sequencing of various separation and reaction steps and results in dramatically simplified and intensified process flowsheets. The resulting processes could achieve over 20% lower capital with a higher recovery of products. Historically, heat energy is supplied to chemical plants by burning fossil resources. However, in future, with the emphasis on greenhouse gas reduction, renewable energy resources will find more usage. Renewable electricity from photovoltaic and wind has now become competitive with the electricity from fossil resources. Therefore, a major challenge for chemical engineering processes is how to use renewable electricity efficiently within a chemical plant and eliminate any carbon dioxide release from chemical plants. We introduce several decarbonization flowsheets for the process to first convert natural gas liquids (NGLs) to  mainly ethylene in an energy intensive dehydrogenation reactor and subsequent conversion of ethylene into value-added and easy-to-transport liquid fuels. </p> <p><br></p> <p>Molecular separations are needed across many types of industries, including oil and gas, food, pharmaceutical, and chemical industries. In a chemical plant, 40%–60% of energy and capital cost is tied to separation processes. For widespread use of membrane-based processes for high recovery and purity products from gaseous and liquid mixtures on an industrial scale, availability of models that allow the use of membrane cascades at their optimal operating modes is desirable towards sustainable separation systems. This will also enable proper comparison of membrane performance vis-a-vis other competing separation technologies. However, such a model for multicomponent fluid separation has been missing from the literature. We have developed an MINLP global optimization algorithm that guarantees the identification of minimum power consumption of multicomponent membrane cascades. The proposed optimization algorithm is implemented in GAMS and is demonstrated to have the capability to solve up to 4-component and 5-stage membrane cascades via BARON solver, which is significantly more advantageous than the state-of-the-art processes. The model is currently being further developed to include optimization of total cost including capital. Such a model holds the promise to be useful for the development in implementation of energy-efficient separation plants with least carbon footprint. This thesis work also addresses important topics in separation including dividing wall columns and water desalination. </p>

<p>  </p> <p>Crystallization is a purity and particle control unit operation commonly used in industries such as pharmaceuticals, agrochemicals, and energetics. Often, the active ingredient’s crystal mean size, polymorphic form, morphology, and distribution can impact the critical quality attributes of the final product. The active ingredient typically goes through a series of process development iterations to optimize and scale-up production to reach production scale. Guided by the FDA, the paradigm shift towards continuous processing and crystallization has shown benefits in introducing cheaper and greener technologies and relieving drawbacks of batch processing. To achieve successful batch scale-up or robust continuous crystallization design, process intensification of unit operations, crystallization techniques, and utilizing data driven approaches are effective in designing optimal process parameters and achieving target quality attributes. </p> <p>In this thesis, a collection or toolbox of various process intensification techniques was developed to aid in control, optimization, and digitalization of crystallization processes. The first technique involves developing a novel control algorithm to control agrochemical crystals of high aspect ratio to improve the efficiency of downstream processes (filtration, washing, and drying). The second technique involves the further improvement of the first technique through digitalization of the crystallization process to perform simulated optimization and obtain a more nominal operating profile while reducing material consumption and experimentation time. The third method involves developing a calibration procedure and framework for in-line video microscopy. After a quick calibration, the in-line video microscopy can provide accurate real-time measurements to allow for future control capabilities and improve data scarcity in crystallization processes. The last technique addresses the need for polymorphic control and process longevity for continuous tubular crystallizers. Through a sequential stirred tank and tubular crystallizer experimental setup, the control of polymorphism, particle mean size, and size distribution were characterized. Each part of this thesis highlights the importance and benefits of process intensification by creating a wholistic process intensification framework coupled with novel equipment, array of PAT tools, feedback control, and model-based digital design.</p>

<p>Crystallization is a key solid-liquid separation and purification technique used in pharmaceutical industry. Some of the critical quality attributes (CQAs) of a product from crystallization process include crystal size distribution (CSD), purity, polymorphic form, morphology, etc. Different size and polymorphs of a drug substance may have different dissolution profiles and different bioavailability, which can have adverse effect on human health. Therefore, it is important to design and control crystallization process to meet product CQAs. In recent years, drug substances are becoming more complex, often being heat sensitive, which may limit the temperature that can be used in the crystallization step. Consequently, the traditional cooling only crystallization may not be well suited to recover the high value drug substances. For these systems, antisolvent crystallization is typically employed to improve the yield. On the other hand, the solvent composition can significantly impact the polymorphic outcome. Therefore, designing combined cooling and antisolvent crystallization (CCAC) processes to solve the challenges of active pharmaceutical ingredient (API) crystallization in a highly regulated environment is a complex engineering problem. </p> <p>With rising energy costs and intense price competition from generic pharmaceutical companies, the pharmaceutical industry is looking for ways to reduce the cost of manufacturing via process intensification (PI). This thesis focuses on different PI techniques for CCAC of drug substances. Continuous or smart manufacturing is gaining popularity due to its potential to lower the cost of manufacturing while maintaining consistent quality. Continuous crystallization is an important link in the continuous manufacturing process. The first part of the thesis shows PI of a commercial drug substance, Atorvastatin calcium (ASC) for target polymorph development via continuous CCAC using an oscillatory baffled crystallizer (OBC). An existing batch CCAC process for ASC was compared with the continuous CCAC in OBC and it was found the continuous process 30-fold more productive compared to the batch process. An array of process analytical technology (PAT) tools was used in this work to assess key process parameters that affect the polymorphic outcome and CSD. The desired narrower CSD product was obtained in the OBC compared to that from a batch crystallizer.</p> <p>The next part of the thesis focused on model-based PI technique for efficient determination of crystallization kinetics of a polymorphic system in CCAC. A novel experimental design was proposed which significantly reduced the number of experiments required to determine crystallization kinetics in a CCAC process. The kinetic parameters were validated, and a validated polymorphic model was used to perform an in-silico design of experiment (DoE) to develop a design space that can be used to identify operating conditions to achieve a desired crystal size and polymorphic form. </p> <p>The final part of the thesis combines the experimental and model-based approach for designing a continuous CCAC process for ASC in a cascade of Coflore agitated cell reactor (ACR) and three-stage mixed suspension mixed product removal (MSMPR). A combined artificial neural network (ANN) and principal component analysis (PCA) method was used to calibrate an ultraviolet (UV) probe which was used to monitor ASC solute concentration in the cascade process. The crystallization kinetic parameters were estimated in ACR and MSMPR which was used to build a digital model of the cascade process. The digital model was then used to obtain a design space with different temperature profile in the three-stage MSMPR that yielded narrow CSD of ASC form I. Overall, this thesis demonstrates the benefits of applying PI in the CCAC of drug substances using a holistic approach including novel equipment, application of an array of PAT tools, and model-based digital design to achieve desired CQAs of the product.</p>

<p>Particle suspensions in viscoelastic fluids (e.g., polymeric fluids, liquid crystalline solutions, gels) are ubiquitous in industrial processes and in biology. In such fluids, particles often acquire lift forces that push them to preferential streamlines in the flow domain. This lift force depends greatly on the fluid’s rheology, and plays a vital role in many applications such as particle separations in microfluidic devices, particle rinsing on silicon wafers, and particle resuspension in enhanced oil recovery. Previous studies have provided understanding on how fluid rheology affects the motion of spherical particles in simple viscoelastic fluid flows such as shear flows. However, the combined effect of more complex flow profiles and particle shape is still under-explored. The main contribution of this thesis is to: (a) provide understanding on the migration and rotation dynamics of an arbitrary-shaped particle in complex flows of a viscoelastic fluid, and (b) develop guidelines for designing such suspensions for general applications.</p> <p><br></p> <p>In the first part of the thesis, we develop theories based on the second-order fluid (SOF) constitutive model to provide solutions for the polymeric force and torque on an arbitrary-shaped solid particle under a general quadratic flow field. When the first and second normal stress coefficients satisfy  <strong>Ψ</strong>₁  = −2 <strong>Ψ</strong> ₂ (corotational limit), the fluid viscoelasticity modifies only the fluid pressure and we provide exact solutions to the polymer force and torque on the particle. For a general SOF with  <strong>Ψ</strong> ₁ ≠  −2 <strong>Ψ</strong> ₂, fluid viscoelasticity modifies the shear stresses, and we provide a procedure for numerical solutions. General scaling laws are also identified to quantify the polymeric lift based on different particle shapes and orientation. We find that the particle migration speed is directly proportional to the length the particle spans in the shear gradient direction (L_sg), and that polymeric torques lead to unique orientation behavior under flow.</p> <p><br></p> <p>Secondly, we investigate the migration and rotational behavior of prolate and oblate spheroids in various viscoelastic, pressure-driven flows. In a 2-D slit flow, fluid viscoelasticity causes prolate particles to transition to a log-rolling motion where the particles orient perpendicular to the flow-flow gradient plane. This behavior leads to a slower overall migration speed (i.e., lift) of prolate particles towards the flow centerline compared to spherical particles of the same volume. In a circular tube flow, prolate particles align their long axis along the flow direction due to the extra polymer torque generated by the velocity curvature in all radial directions. Again, this effect causes prolate particles to migrate slower to the flow centerline than spheres of the same volume. For oblate particles, we quantify their long-time orientation and find that they migrate slower than spheres of the same volume, but exhibit larger migration speeds than prolate particles. Lastly, we examine the effect of normal stress ratio ? <strong>α</strong>  = <strong>Ψ</strong> ₂ /<strong>Ψ</strong>₁on the particle motion and find that this parameter only quantitatively impacts the particle migration velocity but has negligible effect on the rotational dynamics. We therefore can utilize the exact solution derived under the corotational limit (?<strong>α</strong> = −1/2) for a quick and reasonable prediction on the particle dynamics.</p> <p><br></p> <p>We next experimentally investigate the migration behavior of spheroidal particles in microfluidic systems and draw comparisons to our theoretical predictions. A dilute suspension of prolate/oblate microparticles in a density-matched 8% aqueous polyvinylpyrrolidone (PVP) solution is used as the model suspension system. Using brightfield microscopy, we qualitatively confirm our theoretical predictions for flow Deborah numbers 0 < De < 0.1 – i.e., that spherical particles show faster migration speed than prolate and oblate particles of the same volume in tube flows.</p> <p><br></p> <p>We finally design a holographic imaging method to capture the 3-D position and orientation of dynamic microparticles in microfluidic flow. We adopt in-line holography setup and propose a straightforward hologram reconstruction method to extract the 3-D position and orientation of a non-spherical particle. The method utilizes image moment to locate the particle and localize the detection region. We detect the particle position in the depth direction by quantifying the image sharpness at different depth position, and uses principal component analysis (PCA) to detect the orientation of the particle. For a semi-transparent particle that produces complex diffraction patterns, a mask based on the image moment information can be utilized during the image sharpness process to better resolve the particle position.</p> <p><br></p> <p>In the last part of this thesis, we conclude our work and discuss the future research perspectives. We also comment on the possible application of current work to various fields of research and industrial processes.</p> <p><br></p>

<p>  </p> <p>In the pharmaceutical industry, special care must be taken by companies to guarantee high quality medications that are free from byproducts and impurities. The development process involves various considerations including solvent selection, solubility screening, unit operation selection, environmental, and health impact evaluations. Traditionally, pharmaceutical manufacturing consisted of large, centralized facilities to meet pharmaceutical demands; however, there has been a recent shift toward distributed manufacturing. With distributed manufacturing platforms, rapidly changing supply chain needs can be met regionally in addition to supplying small-volume medications and personalized medicines to hospitals and pharmacies. To produce quality pharmaceuticals, distributed manufacturing platforms should integrate digital design, novel unit operations, and process analytical technology (PAT) tools for quality monitoring and control. In this dissertation, a process design and development framework is proposed and implemented for a small-scale pharmaceutical manufacturing platform: MiniPharm.</p> <p>Various approaches to process design are detailed in this dissertation, which include heuristic-based and digital or simulation-based design. For heuristic-based design, the knowledge of the researchers was utilized to provide unit operation evaluation and screening of process alternatives. In cases when unit operations were highly complex, digital or simulation-based design was utilized to conduct sensitivity analyses and simulation-based design of experiments. With the implementation of simulation-based design, material and time needs were reduced while gaining knowledge about the system. The integration of various unit operations comes with increased understanding of start-up dynamics and operational constraints. What was found to be the most successful approach was the combination of heuristics and digital design to combine researcher knowledge and experience with the information gained from process modeling and simulation to create process alternatives that utilized system dynamics to reach desired process outcomes. </p> <p>Additionally, MiniPharm was used for process model development at the small-scale. Various software packages have been made commercially available that focus on production scale; however, models for small-scale operations are not typically implemented in these packages. Models for unit operations were fit with collected experimental data to estimate model parameters for small-scale synthesis, liquid-liquid extraction, and crystallization unit operations. The models were implemented to better capture the heat and mass transfer of the milli-fluidic scale platform, which consist of unit operations housed within microchannels. MATLAB was utilized for estimation of parameters such as kinetic rate constants and overall mass transfer coefficients. These parameters were used for design space determination and process disturbance simulation. The exploration of the impact of various process parameters on quality attributes helps researchers gain a deeper understanding about the manufacturing process and helps to demonstrate how to control the process. </p> <p>An important aspect of MiniPharm is the process development progress that has been demonstrated. With the construction of a modular and reconfigurable platform, various process alternatives can now be experimentally validated. The integration of unit operations operated at a decreased scale makes MiniPharm an example of process intensification. The implementation of integrated unit operations decreases handling time of intermediates and reduces the overall footprint for manufacturing. Designed to allow for increased flexibility of operation, perfluoroalkoxy alkane (PFA) tubing was used for synthesis and purification. With PFA tubing clean in place procedures can be implemented using continuous solvent flow or the low cost, PFA tubing can be replaced. The modular nature of the platform also allows for the investigation of individual unit operations for performance evaluation. </p> <p>Finally, a novel continuous solvent switch distillation unit operation was designed and constructed along with customized reactor and crystallizers for process alternative screening for the synthesis and purification of two compounds: Diphenhydramine hydrochloride and Lomustine. Diphenhydramine hydrochloride is a low-value, high volume allergy medication commonly found in Benadryl and Lomustine is a high-value, low volume cancer medication used to treat glioblastoma and Hodgkin Lymphoma. The production of the compounds demonstrated the flexibility of the manufacturing platform to produce both a generic and a specialty medication. A versatile platform is needed for distributed manufacturing because of quickly changing supply chain needs. Overall, this dissertation successfully demonstrates the process design, development, and simulation for small-scale manufacturing.</p>