Expertise

In this position, the research activities are centered around optimizing gas-solid processes using small particles (< 30 µm) under centrifugal fields, with a specific focus on pharmaceutical applications such as drying active pharmaceutical ingredients (API). As a postdoctoral researcher, my concrete research activities will include: Simulation Studies and Computational Analysis: Conduct advanced simulations to optimize the design and performance of the fluidized bed system for small particle handling, building on the data and insights gained during the patent development. These simulations will focus on heat and mass transfer efficiencies, pressure drop, and the behavior of particles in centrifugal fields. Perform computational fluid dynamics (CFD) studies to optimize the scale-up strategy for the fluidized bed system, ensuring it can handle both lab-scale and potential industrial-scale operations. Prototype Development: Collaborate in the design and construction of a lab-scale prototype for the fluidized bed apparatus. The goal is to build a system that can handle the unique challenges of small particle fluidization under centrifugal fields. Work on sourcing and integrating the necessary components for the prototype, ensuring that each component supports the desired operational conditions (temperature, pressure, particle velocity, etc.). Experimental Testing and Validation: Carry out real-life experiments to test the drying efficiency of the fluidized bed system on APIs. These experiments will focus on assessing how well the system removes residual solvents and compares with conventional drying methods. Benchmark the drying results with published data to validate the system’s performance in terms of heat transfer, solvent removal efficiency, and process scalability. Thermodynamic and Kinetic Analyses: Conduct studies on the thermodynamics and kinetics of solvent removal during the drying process, to optimize the operating parameters (temperature, airflow, centrifugal forces) for maximum efficiency. Analyze the energy consumption of the process to ensure that it is competitive with existing technologies. Market Application Analysis: Alongside technical development, assess the potential commercial applications, particularly in pharmaceutical drying. Explore fallback options in the chemical industry, focusing on applications such as extending the lifetime of FCC catalysts.

Technique

As a researcher working on the IOF-POC CREATE project, I will employ various research techniques to carry out my expertise and services effectively. Here’s a detailed explanation of the research techniques I will use: 1. Computational Fluid Dynamics (CFD) Simulations I will use advanced CFD tools such as OpenFOAM to model the fluidized bed system with small particles. This involves simulating particle behavior, pressure drop, heat transfer, and fluid flow under centrifugal forces. By doing so, I can predict the system's performance and optimize the prototype design. 2. Thermodynamic and Kinetic Analysis I will analyze the thermodynamic properties and kinetic processes involved in the drying of active pharmaceutical ingredients (API). This includes studying energy consumption, heat transfer rates, and phase changes during solvent evaporation, helping to optimize drying conditions. 3. Prototype Development The design and development of a lab-scale prototype are key. Using engineering techniques such as CAD (Computer-Aided Design) and rapid prototyping tools, I will collaborate with engineers to physically construct the fluidized bed apparatus and optimize it for small particle fluidization under centrifugal forces. 4. Experimental Testing and Data Collection Conducting real-life drying experiments with APIs is crucial. I will set up laboratory-scale tests to measure drying efficiency, solvent removal rates, and energy usage, using techniques like gravimetric analysis and thermogravimetric analysis (TGA). The collected data will be benchmarked against published drying results. 5. Statistical Analysis and Process Optimization To validate the experimental results, I will use statistical analysis techniques such as regression analysis, design of experiments (DOE), and response surface methodology (RSM) to optimize operating conditions and improve process efficiency. 6. Patent and Intellectual Property (IP) Analysis Given that the project involves a patent (PCT/EP2022/055011), I will need to perform IP analysis to protect the intellectual property, ensuring that the developed technology is commercially viable and legally secure. 7. Market Feasibility Studies Conduct market research to evaluate potential industrial applications, particularly in the pharmaceutical sector and the chemical process industry. Feasibility studies will involve analyzing the market demand for API drying technologies and alternative applications in sectors like FCC catalysts. By applying these techniques, I can comprehensively address the project's research objectives, from simulation and prototype development to experimental testing and commercialization efforts.

Users

The expertise and services provided through this project, particularly on fluidized bed technology and its applications in pharmaceutical and chemical industries, can benefit a wide range of users. Below are the target groups: Pharmaceutical Companies: Companies involved in the production of active pharmaceutical ingredients (APIs) can benefit from the fluidized bed technology to optimize their drying processes and improve solvent removal efficiency. This technology is particularly valuable for increasing the quality of drug formulations and enhancing production efficiency. Chemical Process Industries: Firms in the chemical industry, especially those working with fluid catalytic cracking (FCC) processes, can use this expertise to enhance catalyst performance and reduce operational costs by improving the lifetime of catalysts through optimized fluidized bed designs. Energy and Environmental Engineering Firms: Companies focused on improving energy efficiency and reducing environmental impacts can utilize this technology to optimize gas-solid processes, leading to improved heat transfer and lower energy consumption. Research and Development (R&D) Departments: R&D teams in both academic and industrial settings involved in process engineering, chemical engineering, and pharmaceutical development can make use of this expertise to develop new processes, conduct experimental testing, and optimize fluidized bed technologies for various applications. Universities and Research Institutes: Academic researchers interested in advanced gas-solid interactions, thermodynamic analysis, and fluidized bed systems can collaborate or utilize this expertise for both basic and applied research projects, including developing new patents and scaling up from lab to industrial applications. Government Agencies and Regulatory Bodies: Public sector entities focused on technology transfer, innovation in pharmaceutical manufacturing, and environmental regulation can benefit from this technology in ensuring efficient, scalable, and environmentally friendly processes.

Keywords

Fluid models, Experimental study, Cfd simulation, Multiphase flow

The University of Antwerp is powering the electrification of chemical processes In addition to the well known research groups such as PLASMANT (Plasma Lab for Applications in Sustainability and Medicine - Antwerp), and ELCAT (Applied Electrochemistry & Catalysis), the University of Antwerp is now offering an additional engineering expertise to ensure the smooth deployment of energy efficient power-to-heat chemical processes.​ At ElectrifHy, we are offering an engineering expertise to ensure the smooth deployment of energy-efficient power-to-heat chemical processes. This unit, related to BlueApp, is dedicated to chemical reactor design (CFD and engineering models, from packed, [electrothermal] fluidized and simulated moving beds), prototyping and experimental characterization of heat & mass transfer of electrified processes (ohmic and induction heating, and the use of electrical field to enhance chemical conversion). It’s mission is to design and test electrified chemical reactors based on the power-to-heat concepts (e.g., induction, ohmic, shock-wave), provide guidelines for their scale-up, improve their energy efficiencies, elaborate temperature control strategies, as well as developing modular approaches to deal with the fluctuating nature of renewable electricity. In terms of applications, we cover both the production of value-added chemicals and hydrogen (e-cracking of green ammonia, biogas conversion, electrified steam methane reforming, methane pyrolysis, and [non-]oxidative coupling of methane), to its storage in Liquid Organic Hydrogen Carriers (LOHC), solids (hydrates), and chemical carriers, focusing on the release of H2 and its purification.

Technique

The lab of Professor Patrice Perreault is equipped for the moment with a Sievert apparatus for hydrogen storage in solids (up to 100 bar, from -50 °C to 200 °C), a 300 mL Parr autoclave reactor, as well as various fluidized beds and swirling fluidized bed reactors, and centrifugal reactors for dehydrogenation experiments from Liquid Organic Hydrogen Carriers (LOHC). His hydrogen lab is also equipped with a Quadrupole Mass spectrometer, and a TCD detector for binary gas mixtures. In addition, as a professor in a Flemish University, he has access to the powerful Vlaams Supercomputer Centrum (VSC) for computational studies. As part of his research on process intensification of multiphase turbulent reacting flows and shape/topology optimisation, he will use OpenFoam coupled to Sandia National Laboratories Dakota optimisation toolbox (constrained shape optimisation with CFD). Being jointly responsible for the University of Antwerp pre-incubator for sustainable chemistry and materials “Blue App” (https://www.blueapp.eu/), Professor Perreault will soon start to buy/design/assemble all the tools required for the demonstration of valorisation projects (prototypes) and state of the art equipment.

Users

Chemical reactors are ubiquitous and form the core of industrial plants. Proper construction and operation of these reactors is essential for every processing plant, poorly designed reactors result in energy losses and unwanted by-products. The generation of these by-products then need further purification steps, which have a further inherent energy loss and possible emissions of pollutants to the environment. The petrochemical industry and post-consumer plastic companies could benefit from my expertise in chemical reactor design and chemical reaction engineering in general. Researchers lacking a strong engineering background or process intensification could also benefit.

Keywords

Computational fluid dynamics, Fluidized bed reactor, Process optimization, Carbon dioxide, Chemical process, Hydrogen storage, Packed bed reactor, Process intensification, Flow reactor