Learning objectives
At the end of the course, participants will have an in-depth understanding of the characteristics and structure of the modern chemical industry, strategies for designing and managing chemical processes, regulations related to chemical substances, industrial separation processes, risk analysis methods in chemical processes, and approaches to managing intellectual capital and industrial property (Knowledge and understanding). They will also have developed awareness of the state of the art in integrating emerging technologies into synthesis, which are radically transforming the role of industrial chemists.
Participants will be able to understand how an industrial chemical process is conducted and identify the optimal parameters for its management. They will also be capable of theorizing possible improvements for specific chemical processes. They will contribute to the scale-up and technological transfer from the laboratory level to pilot and industrial scales. In general, those completing the course will be able to address professional challenges, conduct critical evaluations, and propose specific solutions. Additionally, they will have the skills to retrieve chemical information by consulting databases, including patent databases (Applying knowledge and understanding).
Participants completing the course will be able to evaluate the economic and safety aspects of processes, as well as those related to products and materials. They will identify optimal procedures and technologies for product purification, assess the need to apply regulations and authorizations for chemical products and formulations, and critically choose the most suitable production technologies. They will also develop skills for effectively managing intellectual property. In general, they will critically assess their knowledge and abilities, analyze the timing and dynamics of chemical reactions, and adapt to diverse working environments and topics. Furthermore, they will be capable of forming judgments on significant scientific and ethical issues (Making judgements).
Participants will acquire the ability to communicate effectively, both orally and in writing, using technical and specialized language. This will enable them to engage with chemists, chemical engineers, and other industry experts, as well as to convey complex concepts in a language understandable to non-specialists. They will be able to collaborate with others and work in teams on multidisciplinary projects while also being capable of working independently, planning objectives, timelines, and methodologies. Additionally, they will be prepared to conduct training and experimental teaching activities for undergraduate students (Communication skills).
Those attending the course will develop critical analysis skills to optimize chemical processes based on experimental results. They will strengthen logical reasoning abilities and connect the various topics covered in the course with each other and with the fundamental disciplines of industrial chemistry. They will be capable of autonomous learning, addressing new scientific topics or professional challenges, and staying up to date by consulting sector-specific databases, including patent databases (Learning skills).
Prerequisites
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Course unit content
Part 1: Development and Management of Industrial Chemical Processes - Prof. Nicola Della Ca’ (3 ECTS)
- Characteristics and Structure of Modern Chemical Industry: Features of industrial chemical production and factors influencing the type of chemical process. Product lifecycle and added value. Priorities in process design and factors driving their evolution. Practical examples of the evolution of chemical processes.
- Strategies for Process Design and Management: Guidelines for process scale-up development. Analysis of factors influencing the scale-up of a process. Types of industrial reactors (dedicated plants, multi-product plants, multi-purpose plants). Strategies for selecting synthetic routes, raw materials, and solvents in the industrial production of a chemical compound.
- Separation Processes in Industry: Extractions, crystallizations, distillations. Classification based on the separating agent and impact on overall economic costs. Degrees of freedom in design and management. Selection strategies depending on the type of industrial process. Separation factors.
- Intellectual Capital and Industrial Property: Fundamental principles in managing intellectual capital and industrial property. Invention & Patent: basic concepts. Industrial Property Code (IPC) and European Patent Convention (EPC). Patentability requirements. Blocking and selection patents. Product and use patents. Patentability vs. Freedom to Operate.
- Regulatory and Authorization Procedures for Chemical Products (REACH).
- Risk Analysis in Chemical Processes: Hazard and Operability Study (Hazop). Assessment of the consequences of accidental events. Risk management.
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Part 2: Emerging Technologies - Prof. Luca Capaldo (3 ECTS)
- Flow Chemistry: General principles of flow chemistry. Types of reactors and their anatomy: Plug Flow Reactor (PFR) and Continuous Stirred-Tank Reactor (CSTR). Strategies for scaling up fine chemical synthesis: numbering-up and sizing-up. Heterogeneous reactions in flow: managing systems containing liquids, gases, and solids. Multistep synthesis.
- Photochemistry in Flow: General introduction to photochemistry and photocatalysis. Advantages of conducting photochemical reactions in flow. Examples of synthetic photochemistry applications for industrial synthesis.
- Electrochemistry in Flow: General introduction to electrochemistry and electrocatalysis. Advantages of conducting electrochemical reactions in flow. Examples of synthetic electrochemistry applications for industrial synthesis.
- Mechanochemistry: General introduction to mechanochemistry. Various reactors (ball milling, twin-screw extruder, planetary mill). Examples of synthetic mechanochemistry applications for industrial synthesis. Introduction to photomechanochemistry.
- High-Throughput Experimentation, Machine Learning & Automation: Definition of HTE, ML, and automation and their integration. Interaction between ML and chemistry: various algorithms and their functions. Library generation through HTE (reaction discovery & hit discovery): illustrations of different HTE setups for electrochemistry, photochemistry, and mechanochemistry. Examples of automation integration in chemical laboratories.
Full programme
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Bibliography
1) CHEMCAL PROCESS TECHNOLOGY, J.A. Moulijn, M.Makkee, A.E. van Diepen, Wiley , IBSN 0-471-63062-4
2) INDUSTRIAL ORGANIC CHEMICALS (2nd Ed), H.A. Wittcoff, B.G. Reuben, J.S. Plotkin, Wiley, ISBN 0-471-44385-9
3) PRODUCT AND PROCESS DESIGN PRINCIPLES: SYNTHESIS ANALYSIS AND EVALUATION, W.D. Seider, J. D. Seader, Daniel R. Lewin, Wiley, ISBN: 978-0-471-21663-6
4) Darvas, Ferenc, Hessel, Volker and Dorman, György. Volume 1 Flow Chemistry – Fundamentals, Berlin, Boston: De Gruyter, 2014.
5) Darvas, Ferenc, Dormán, György, Hessel, Volker and Ley, Steven V. Volume 2 Flow Chemistry – Applications, Berlin, Boston: De Gruyter, 2021.
Teaching methods
The lessons (48 hours, 6 ECTS) will be conducted in person, using PowerPoint presentations. The course may also include one or more seminars by experts from the industrial sector, which will be promptly communicated to students. The slides used during the lessons will be uploaded weekly to the Elly platform. Additional materials to supplement the slides will also be made available on Elly. To download the slides, students must register for the online course. The slides are considered an integral part of the teaching material. Non-attending students are reminded to regularly check the available teaching materials and the instructions provided by the lecturers through the Elly platform. The lecturers are available by appointment (email: nicola.dellaca@unipr.it; luca.capaldo@unipr.it) for further clarifications.
Assessment methods and criteria
Assessment is conducted through an oral examination (in person), aimed at verifying the acquisition of the expected knowledge and skills for the two course components. The exam will assess the understanding of the topics covered, as well as the ability to critically argue and establish connections between concepts. Strong synthesis skills, the use of accurate technical language, and effective communication will be positively evaluated. The final grade is calculated as the average of the scores obtained for each component. Honors are awarded in cases where the maximum score is achieved in both parts, along with a demonstrated mastery of the disciplinary lexicon.
Exam dates can be consulted on the ESSE3 portal.
Other information
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2030 agenda goals for sustainable development
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