Postgraduate Diploma/Msc Pharmaceutical and Chemical Process Technology

Student Handbook

Postgraduate Diploma/MSc Pharmaceutical and Chemical Process Technology

Contents

Programme details

Aims and Objectives

Programme Structure

Overview of Modules

In-Course Assessment

Course journal list

Course management

Guidance to student

Welcome

On behalf of the Programme Committee I would like to welcome you onto this programme. This programme is designed to provide you with the necessary knowledge and skills to operate effectively in chemical and pharmaceutical production processes and to contribute significantly to your continuing professional development in the chemical and pharmaceutical sectors.

The programme is managed by the School of Chemical and Pharmaceutical Sciences, Faculty of Science, DIT, Kevin St. and the full-time staff teaching on this programme are from the School of Chemical and Pharmaceutical Sciences and the School of Control Systems and Electrical Engineering.

The programme will take place in the Faculty of Science, DIT, Kevin St.

This course handbook is designed as a useful reference for you as you participate in this programme. Further details can be found in the Programme Documentation Parts A/B.

Chairperson Programme Committee
Programme details

Staff

Membership of Programme Team.
Paul Ashall, Lecturer in Chemical and Pharmaceutical Technology
Hassan Ali, Lecturer in Chemical Technology
Gavin Duffy, Lecturer in Process Control and Separation Processes

Peter Kavanagh, Lecturer in Chemical Technology

Anne Greene, Lecturer in Process Validation and Pharmaceutical Technology

Claire McDonnell, Lecturer in Chemical Development

Fiona O’Sullivan, Lecturer in Process Validation and Pharmaceutical Technology

Membership of the Programme Committee
The proposed Programme Committee (subject to nomination by the Head of School) will be as follows:
Dr. D. McCormackHead of School
Dr. M.B.Foley
Dr. H. Ali
Mr. P.AshallProgramme Director

Mr. Gavin Duffy

Student Rep.

Programme Tutors
P. Ashall, G. Duffy, H. Ali, C. McDonnell, A. Greene

Aims and Objectives

The overall aim of this programme is to provide education at postgraduate level in aspects of chemical and pharmaceutical process and production technology which are of relevance to scientists, engineers and other professions who operate in the chemical and pharmaceutical industry and related sectors, particularly in the production, process and chemical development areas.

General programme objectives include:

(i)To provide a programme which allows graduates to develop the necessary knowledge and skills to integrate quickly into the industrial environment and to operate effectively in production processes.

(ii)To present to the student a body of knowledge, practical, technical and theoretical, that is relevant to the needs of industry in the area of chemical and pharmaceutical process technology and related topics

(iii)To provide a unique opportunity for personnel already employed in industry to obtain a highly relevant postgraduate qualification over two or more years on a part-time basis

(iv)Provision of high quality industrially relevant education and training by experts from academia and industry

(v)The teaching of proposed modules and related topics designed to enhance the knowledge and skills of students in these areas

(vi)To provide a broad programme consistent with the graduate intake and programme objectives

(vii)Provision of appropriate assessments and assignments to promote, reinforce and test learning

(viii)To deliver modules and topics suitable for continuing professional development

(ix)To deliver a programme which will enable graduates to outline design requirements for process plant and to work effectively with engineers and other professions as part of a process/chemical development team

(x)To deliver a programme which will enable graduates to work effectively with engineers and other professions in solving plant operating problems

(xi)To enhance the students ability to exploit work-based learning and self-directed learning

(xii)To develop research skills

(xiii)To develop transferable (key professional) skills.

Programme Structure

The lecture programme is divided into twelve taught modules. Each module also comprises of assessment elements such as written examinations, case studies, design exercises, essays, laboratory practicals etc. The project is completed in Semester five of the part time programme. In-course assignments will be in the form of laboratory practical assignments, case studies, design exercises, individual and team assignments, problem sets and essays. These assignments are designed to build upon, and give practical expression to, the material covered in the lecture programme.

Programme delivery is by lectures, case studies, seminars, laboratory based practical exercises and tutorials/problem solving sessions.

Students are expected to build on the framework of material delivered at lectures etc by directed self-study from recommended textbooks, review articles and journals.

Programme Delivery Structure (part time programme)

/ Duration / Lectures/wk (ave.)
Semester 1 (Yr 1) / 13 weeks / 6 hours
Semester 2 (Yr 1) / 13 weeks / 6 hours
Semester 1 (Yr 2) / 13 weeks / 6 hours
Semester 2 (Yr 2) / 13 weeks / 6 hours

Semester 1(Yr 3) Project By arrangement with Programme Committee and Employer

The laboratory practical programme consists of a number of experiments (refer to module descriptors). A laboratory manual will be issued to students. Students are required to comply with laboratory safety rules.

List of Modules

Module / Code / Title
1 / CPPT9001 / Pharmaceutical processes – basic principles
2 / CPPT9002 / Heat transfer and fluids
3 / CPPT9003 / Mass transfer applications in pharmaceutical processes
4 / CPPT9004 / Reactor design and separation processes I
5 / CPPT9005 / Separation processes II
6 / CPPT9006 / Material handling and drying
7 / CPPT9007 / Process control
8 / CPPT9008 / Process utilities et al
9 / CPPT9009 / Process design and development
10 / CPPT9010 / Facility design and operation
11 / CPPT9011 / Management aspects of pharmaceutical production
12 / CPPT9012 / Regulatory aspects, GMP and process validation
13 / CPPT9013 / Project

Detailed Programme Structure

Module / Delivery
Method / Student
ContactHours / Student Self Learning (hr) / Assessment Mode / Total Student Workload (hr) / ECTS
1
CPPT
9001 / Lecture / 24 / 76 / Assignment
Written examination / 100 / 5
2
CPPT
9002 / Lecture / 24 / 76 / Assignment
Written examination / 100 / 5
3
CPPT
9003 / Lecture / 24 / 76 / Assignment / 100 / 5
4
CPPT
9004 / Lecture / 24 / 76 / Assignment
Written examination / 100 / 5
5
CPPT
9005 / Lecture / 24 / 76 / Assignment
Written examination / 100 / 5
6
CPPT
9006 / Lecture / 24 / 76 / Assignment / 100 / 5
7
CPPT
9007 / Lecture / 24 / 76 / Assignment
Written examination / 100 / 5
8
CPPT
9008 / Lecture / 24 / 76 / Assignment / 100 / 5
9
CPPT
9009 / Lecture / 24 / 76 / Assignment / 100 / 5
10
CPPT
9010 / Lecture / 24 / 76 / Assignment / 100 / 5
11
CPPT
9011 / Lecture / 24 / 76 / Assignment / 100 / 5
12
CPPT
9012 / Lecture / 24 / 76 / Assignment / 100 / 5
Project
CPPT
9013 / Industry/ work Based / Thesis / 600 / 30
TOTAL / 1800 / 90

The current structure has 13 modules (12 taught modules and a project module). Modules include a laboratory element and laboratory based practical work which will be assessed in-course. Modules are assessed by assignment and written examination. Module 13 is assessed by dissertation.

Module 13 comprises of an industrial/work based project.

The project allows the student the opportunity to undertake a detailed study of a topic relevant to industry. Projects are normally performed at the place of employment. The standard expected for the final body of work is appropriate for a taught Master's degree and should include an amount of originality. The final report must be in a typed, bound form with typical length of 15,000 to 20,000 words (not including appendices etc.).

Projects for part-time students are normally proposed by the student in consultation with their employer.

All project proposals must include the aims and objectives of the project, the research methodology and the expected outcomes.

Overview of Modules

The content of taught modules and topics/subjects may vary from time to time. The syllabuses presented here are only a guide as to the subject material and content delivered in the programme and the time allocated to particular topics.

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9001 / Pharmaceutical Processes

Module author: Gavin Duffy/Paul Ashall/Hassan Ali

Module Description:

Thismodule introduces the student to chemical and pharmaceutical processes, the unit operations they typically consist of and how mass and energy are accounted for on an overall basis throughout a typical process.

Module aim

The module is aimed at those who have no prior knowledge of chemical and pharmaceutical production processes. The objective of the module is to introduce the student to the overall analysis of chemical and pharmaceutical processes by mass and energy balance. A simple pharmaceutical process such as the production of aspirin is used as a case study. The basic principles and techniques of mass and energy balances are appliedto this type of process.

Learning Outcomes:

On completion of this module the learner will be able to:

Describe the fundamental principles of operation of chemical and pharmaceutical processes
Explain the principles of mass and energy balance
Apply the techniques of mass and energy balance to chemical and pharmaceutical processes
Develop a comprehensive process flow diagram for a pharmaceutical process

Learning and Teaching Methods:
Lecture, case-study, tutorial

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9001 / Pharmaceutical Processes

Module content:

Lectures

Types of process.
Primary and secondary pharmaceutical processing.
Routes
Process operations
Process equipment
Process descriptions
Flowsheets (PFD and P&ID)
Batch record sheets, batch cycles
Characteristics of chemical processes
Operating aspects of chemical processes
Types of chemical process.
General mass balance equation. Balances on continuous processes and batch processes.
Mass balance techniques and calculations. Balances on multiple unit processes. Recycle and bypass streams.
Balances on processes involving chemical reaction.
Non-steady state mass balances.
Application in process development and scale-up.
Forms of energy. Closed systems and open systems. Energy balance procedures.
Mechanical energy balances.
Enthalpy balances. Balances on processes involving chemical reaction.
Importance in chemical processes.

Laboratory

There are no laboratory practicals associated with this module

Module Assessment

Assignment 50%

End of module written examination 50%

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9001 / Pharmaceutical Processes

Essential Reading:

Chemical Process Technology, J.A.Moulijn et al, Wiley, 2001

Elementary Principles of Chemical Processes, R.M.Felder and R.W.Rousseau, John Wiley and Sons, 3rd edition, 2000

Unit Operations in Chemical Engineering, W. McCabe, J. Smith and P. Harriott, McGraw-Hill,

6th edition, 2001

Supplemental Reading:

Pharmaceuticals Vol. 1 – 4, Ed.J.McGuire, 2002, Wiley VCH

Ullmans Encyclopedia of Industrial Chemistry, 6th edition, Wiley – VCH, 2000

Kirk-Othmer Encyclopedia of Chemical Technology, 4th edition, John Wiley, 1998

Thermodynamics of Chemical Processes, G.J.Price, OUP, 1998

Pharmaceutical Production, B. Bennett & G. Cole, IChemE, 2003

Chemical Process Technology, J.A.Moulijn et al, Wiley, 2001

Elementary Principles of Chemical Processes, R.M.Felder and R.W.Rousseau, John Wiley and Sons, 3rd edition, 2000

Unit Operations in Chemical Engineering, W. McCabe, J. Smith and P. Harriott,

Chemical Engineering: Volume1 J. M. Coulson, J. F. Richardson et al,

Butterworth-Heinemann,

6th edition, 1999

Perrys Chemical Engineers Handbook, R. H. Perry and D. W. Green, 7th edition, McGraw Hill, 1997

Engineering Thermodynamics, G. Rogers and Y. Mayhew, 4th edition, Longman, 1992

CRC Handbook of Chemistry and Physics

Concepts of Chemical Engineering for Chemists, Ed. SJR Simons, RSC, 2007

Web references, journals and other:

Pharmaceutical Technology Europe

Journal of Organic Process Research and Development

Chemical Engineering Progress

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9001 / Pharmaceutical Processes

Further Details:

This module is delivered by staff of the School of Chemical and Pharmaceutical Sciences.

24 contact hours

Date of Academic Council approval ………………………….

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9002 / Heat transfer and fluid flow

Module author: Gavin Duffy/Paul Ashall/Hassan Ali

Module Description:

This module is concerned with the principles of heat transfer and fluid flow in pharmaceutical processes. Both these topics are fundamental to the operation of all process steps such as reaction, distillation, drying, filtration units, centrifugation and crystallisation as well as to heat transfer and fluid flow equipment such as heat exchangers and pumps.

Module aim

To introduce the students to the basic concepts of heat transfer and fluid flow

To introduce the fundamental principles of heat transfer in chemical and pharmaceutical processes.

To enable students to make simple design calculations and to specify heat transfer equipment.

To introduce the basic principles and techniques of fluid flow in chemical and pharmaceutical processes and to apply these principles and techniques to industrial chemical and pharmaceutical processes.

Learning Outcomes:

On completion of this module, the learner will be able to…………….

Explain the fundamental principles of heat transfer in chemical and pharmaceutical processes
Carry out design calculations for heat transfer processes
Specify heat transfer equipment
Explain the principles of fluid flow in chemical and pharmaceutical processes

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9002 / Heat transfer and fluid flow

Perform design calculations on fluid flow systems
Specify components for fluid flow systems
Understand the principles of fluid mixing and apply these concepts to mixing problems

Learning and Teaching Methods:
Lecture, case-studies, tutorial, practical

Module content:

Lectures

Mechanisms for heat transfer.
Fourier equation. Steady state conduction. Thermal conductivity.
Conduction through planar and cylindrical surfaces.
Natural and forced convection.
Boundary layer concept.
Heat transfer coefficient, h. Overall heat transfer coefficient, U.
Expressions for U. Thin walled tube approximation.
Calculation of h.
Simple double tube heat exchanger. Co-current and counter current flow. Temperature profiles.
LMTD
Fouling factors, hd.
Q = UAθlmtd
Energy balance. Q = mcpΔT
Heat exchange equipment and heat transfer fluids.
Types of fluids

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9002 / Heat transfer and fluid flow

Basic equation of fluid flow
Flow in pipes and channels
Flow of compressible and incompressible fluids
Flowof multiphase mixtures
Flow and pressure measurement
Mechanical energy balance
Pumps, blowers, fans
Principles and application of mixing

Laboratory (2)

Heat Exchanger
Fluid flow measurement and pressure drop in a fluid flow system

Module Assessment

Assignment and laboratory 50%

End of module written examination 50%

Essential Reading:

Introduction to Heat Transfer, F.P, Incropera et al, 4th edition, John Wiley, 2002

Unit Operations in Chemical Engineering, W. McCabe, J. Smith and P. Harriott, McGraw-Hill, 6th edition, 2001

Chemical Engineering: Volume1, J. M. Coulson, J. F. Richardson et al, Butterworth-Heinemann, 6th edition, 1999

Chemical Process Technology, J.A.Moulijn et al, Wiley, 2001

Elementary Principles of Chemical Processes, R.M.Felder and R.W.Rousseau, John Wiley and Sons, 3rd edition, 2000

Introduction to Heat Transfer, F.P, Incropera et al, 4th edition, John Wiley, 2002

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9002 / Heat transfer and fluid flow

Supplemental Reading:

Heat Transfer (OxfordUniversity Primers), R.H.S.Winterton, OxfordUniversity Press, 1997

Two Phase Flow and Heat Transfer, P.B.Whalley, OUP, 1997

Radiation Heat Transfer, H.Jones, OUP, 2000

Perrys Chemical Engineers Handbook, R. H. Perry and D. W. Green, 7th edition, McGraw Hill, 1997

Engineering Thermodynamics, G. Rogers and Y. Mayhew, 4th edition, Longman, 1992

Thermodynamics of Chemical Processes, G.J.Price, OUP, 1998

Chemical Engineering: Volume1,J. M. Coulson, J. F. Richardson et al,Butterworth-Heinemann,6th edition, 1999

CRC Handbook of Chemistry and Physics

Web references, journals and other:

Pharmaceutical Technology Europe

Chemical Engineering Progress

Further Details:

This module is delivered by staff of the School of Chemical and Pharmaceutical Sciences.

24 contact hours

Date of Academic Council approval ………………………….

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9003 / Mass transfer applications

Module author: Gavin Duffy/Paul Ashall/Hassan Ali

Module Description:

The principles of mass transfer and its wide applications to different unit operations in the pharmaceutical industry are introduced and advanced in this module. Distillation is just one example of a mass transfer process that is widely used in this industry. The underlying principles of distillation are also covered in this module as well as the design of continuous and batch columns. Absorption of gases is also covered in this module as it is a common mass transfer application in the pharmaceutical industry.

Module aim

To introduce the basic principles of mass transfer and to apply these principles to chemical and pharmaceutical production processes

To understand the differences in physical properties of components that are exploited in separation by distillation.

To understand the process of distillation of a binary mixture.

To be familiar with the different components of distillation equipment.

To understand how to size a continuous column using the McCabe-Thiele graphical method.

To explain the operation of a batch column.

To explain the design and operation of an absorption column.

Learning Outcomes:

On completion of this module, the learner will be able to…………….

Define the basic principles of mass transfer as applied to chemicaland pharmaceutical processes

Dublin Institute of Technology

Pre-Requisite Modules code(s) / Co-Requisite Modules code(s) / ECTS
Credits / Module Code / Module Title
None / CPPT9001-9012 / 5 / CPPT9003 / Mass transfer applications

Explain the underlying principles of separation by distillation
Develop vapour liquid equilibrium data
Explain the operation of a distillation column and the importance of reflux and other operating parameters
Derive the operating lines for a continuous column
Apply the McCabe Thiele graphical design method
Carry out a mass balance on and design a batch distillation column
Size a distillation system
Compare constant and variable reflux in a batch column
Design an absorption process

Learning and Teaching Methods:
Lecture, case-studies, tutorial, practical