Modeling and Analyzing Batch Processes for Pharmaceuticals

Course Id:  EPD101   |   Duration:  2.00 day(s)   |   CEUs Awarded:  1.4   |   Level:  Intermediate


Course Objective

Learn how to model and analyze batch data for pharmaceutical, agrochemical, biotech, and specialty chemical processes. Become proficient and self-sufficient in batch process modeling to rapidly evaluate new synthesis routes and develop cost estimates with limited data, and to build an equipment and material database. Create text recipes to simulate batch and pharmaceutical operations. Scale-up lab-scale recipes to pilot-scale, then to full-scale. Perform environmental analysis and vapor emissions calculations.Perform multi-batch campaign study.

Course Overview

Identify the concepts required to model and analyze batch pharmaceutical, agrochemical, biotech, and specialty chemical processes. Become proficient and self-sufficient in batch process modeling so that you can immediately generate business benefits for your organization.

Benefits

This course will show you how to:

  • Rapidly evaluate new synthesis routes and develop cost estimates with limited data
  • Build an equipment and material database
  • Create text recipes to simulate batch and pharmaceutical operations
  • Scale-up lab-scale recipes to pilot-scale, then to full-scale
  • Perform de-bottlenecking studies for existing batch processes and plan capacity expansions
  • Perform environmental analysis and vapor emissions calculations
  • Perform multi-batch campaign study

Audience

  • Chemists and chemical engineers working in R&D or in the laboratory environment
  • Engineers involved in process design and engineering functions
  • Environmental group who needs to ensure the regulatory requirements are met
  • Industrial engineers who deal with the production aspects of manufacturing process

Approach

  • Instruction on basic topics
  • Discussion about the general approach and the key elements for successful use of Aspen Batch Process Developer
  • Demonstrations of features
  • Instructor-guided exercises
  • Hands-on workshops that apply learned concepts

Prerequisites

A background in industrial chemistry or in chemical engineering.

Subsequent Courses

  • EAP202 Modeling Batch Processes using Aspen Plus
  • EAP201 Aspen Plus: Physical Properties for Process Engineers

Class Schedule

Class Agenda

EPD101: Modeling and Analyzing Batch Processes for Pharmaceuticals

Introducing Aspen Batch Processes

  • Identify and explain the capabilities, usage and key features of the Aspen Batch Process Developer application
Concepts in Batch Process Developer
  • Identify and explain the concepts and terminology associated with Aspen Batch Process Developer
  • Recognize how concepts and terminology relate to Aspen Batch Process Developer application
Graphical User Interface (GUI)
  • Identify and explain the basic graphical user interface for Aspen Batch Process Developer
  • Create an example process to develop a working knowledge of Aspen Batch Process Developer
  • Demonstrate how to modify a text recipe
  • Identify and explain the operational input specifications that may be included in a simulation
  • Review and interpret simulation results
Early Cost Assessments
  • Identify and explain how the Route Selection function is used for cost analysis and route selection in the early development stage
  • Demonstrate the Route Selection User Interface 
  • Interpret the Route Selection result display
Defining Facility and Equipment
  • Identify and explain how to create a facility and enter equipment data
  • Describe the available Equipment Catalog resources 
  • Demonstrate how to create a facility and define the equipment unit using Aspen Batch Process Developer
  • Workshop:  Define Facility and Equipment
Defining Materials and Utilities
  • Recognize the databanks and physical property parameters used by Aspen Batch Process Developer 
  • Demonstrate how to add pure components, predefined mixtures and utilities to a project
  • Workshop: Define Materials and Utilities
Defining Chemical Reactions
  • Identify the reaction types supported in Aspen Batch Process Developer
  • Demonstrate how to specify and use chemical reactions in Aspen Batch Process Developer methods
  • Explain the parameters (Dielectric Constant, Ion Radius) used by different methods
Models and Operations
  • Discuss the various operation categories and models
  • Review some commonly used operations and models in the Aspen Batch Process Developer
Developing Batch Process Developer Project
  • Identify and explain how to build a complete Aspen Batch Process Developer project from scratch 
  • Recognize the basic inputs to build a project: Equipment, Materials, Reactions and Text recipe
  • Workshops: Simulate ACC Production 
    • Implement Enhancements for ACC Production Workshop
    • Manipulate ACC Production File 
Preferences and Default Settings
  • Identify and explain the preferences and default settings for a project: customizing calendar, units, vapor emission methods etc.
  • Demonstrate how to import/export preferences, steps, and other data
File Management 
  • Identify and explain how to manage project files in Aspen Batch Process Developer
Recipe Scaling
  • Identify and explain how a step recipe can be scaled using various criteria: 
  • Scaling to the maximum batch size in the size limiting equipment or selected equipment
  • Scaling to the minimum batch size in the limiting equipment or selected equipment (based on the minimum stirred volume requirement of a vessel)
  • Scaling to a specific batch size of an key intermediate
  • Scaling to a multiple of the current batch size
  • Workshop: Perform Recipe Scaling
Production Plan
  • Identify and explain how to setup and simulate a campaign using Aspen Batch Process Developer
  • Demonstrate how to create and modify a production plan
  • Workshop: Create Production Plan
Charge and Recycle 
  • Generate an Aspen Plus properties definition Identify and explain charge operations, feed basis and recycle
  • Demonstrate how to setup a simulation with a recycle stream 
  • Workshop: Model Recycle Stream
Heat Transfer Models 
  • Discuss and review heat transfer models
  • Review examples of Shortcut and U-based Heat Transfer
  • Workshop: Use Different Heat Transfer Models
Vapor Emission and Waste Categorization 
  • Identify and explain vapor emission models used in Aspen Batch Process Developer
  • Demonstrate how to define emission paths and control devices
  • Identify and explain waste categorization
  • Demonstrate how to define waste streams
  • Workshop: Perform Vapor Emission Calculations
Optional Topic: Operating Instructions 
  • Demonstrate how to create operating instruction templates
  • Demonstrate how to automatically generate operating instructions from text recipes
Optional Topic: Property Constant Estimation 
  • Identify and explain the pure component property constant estimation
  • Demonstrate how to define molecular structure
  • Review and interpret property estimation results 
  • Workshop: Estimate property constants for a given compound 
Optional Topic: Advanced Reactor Modeling (Aspen Plus Dynamics) 
  • Identify and explain the Aspen Plus Dynamics interface for rigorous batch reactor simulation
  • Demonstrate how to simulate different types of reactions using the rigorous AD Kinetic Reactor model
  • Workshop: Simulate a given process using the rigorous AD Kinetic Reactor model
Optional Topic: Automation 
  • Identify and explain Aspen Batch Process Developer as an automation server 
  • Explain how to use VBA in Aspen Batch Process Developer   
Optional Topic: Special Applications
  • Biotech Operations

Aspen Technology, Inc. awards Continuing Education Units (CEUs) for training classes conducted by our organization. One CEU is granted for every 10 hours of class participation.