THESIS
2006
xxv, 184 leaves : ill. ; 30 cm
Abstract
The chemical processing industries have shifted their attention from commodity chemicals to high-value-added specialty chemicals in recent decades. Specialty chemicals always serve as major ingredients in consumer products such as pharmaceuticals, cosmetics, and agricultural products. The manufacture of specialty chemicals can generally be divided into three stages: reaction and natural product isolation, separation and purification, and product development. Besides the compositions and purity as required for commodity chemicals, more product requirements have to be met for specialty chemicals or consumer products. For example, the disintegration rate is important to control the rate of release of active pharmaceutical ingredients in pharmaceutical tablets. The additional product requi...[
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The chemical processing industries have shifted their attention from commodity chemicals to high-value-added specialty chemicals in recent decades. Specialty chemicals always serve as major ingredients in consumer products such as pharmaceuticals, cosmetics, and agricultural products. The manufacture of specialty chemicals can generally be divided into three stages: reaction and natural product isolation, separation and purification, and product development. Besides the compositions and purity as required for commodity chemicals, more product requirements have to be met for specialty chemicals or consumer products. For example, the disintegration rate is important to control the rate of release of active pharmaceutical ingredients in pharmaceutical tablets. The additional product requirements to specialty chemicals and consumer products pose extra challenges to the process and increase process complexity. Together with an urging need to shorten time to market, it is crucially important to have procedures and frameworks to develop the manufacturing process of specialty chemicals effectively.
In response to such challenges, a systematic framework is developed for the development of specialty chemicals processes. Systematic procedures of selected processes in the last two stages of the development process are studied, including chromatography-crystallization hybrid separation process, granulation process, and solid dosage forms production. Fractionation policies of chromatographic effluents and flowsheet synthesis for each fraction are identified for the hybrid process. An iterative procedure is presented to identify the formulation and operating conditions for a granulation process such that granules with the desired attributes are produced. For solid dosage forms production, a procedure involving product quality factors identification, excipients and equipment selections, and flowsheeet synthesis is developed to produce pharmaceutical tablets and capsules processes effectively. Together with the systematic procedures, common tools such as design heuristics, experiments, shortcut models, and simulations are also included to assist the decision making process in developing specialty chemicals processes.
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