The Fine Chemical Process R&D group of Prof. L.A. Hulshof, working in the area of Applied Organic Chemistry, aims at the realization of a methodology for faster fine chemical process research and development (process architecture). Such expertise serves fine chemical industrial needs.

Fine chemical batch process design suffers from major handicaps. Yet until recently, the chemical engineer and the mainstream chemical industry have viewed batch processing as unfashionable or even primitive compared to large scale, continuous processing. Batch process design is poorly served with design tools and methodologies when compared with continuous processing. The published literature on batch process design, particularly that originating from the academic world, is seldom of use in practical situations. Interest in universities often fails to address issues of importance to manufacturers. It is clear that the ultimate objective of automatic design of batch processes will not be achieved soon. Our group intends to reduce these handicaps.

The main research equipment consists of a mini-plant batch reactor and a reaction calorimeter (Mettler Toledo). The reactor is controlled by a PLC, a special computer that monitors physical data (batch history) and secures optimal process and safety conditions. In 2005 a continuous-flow microwave reactor for heterogeneous systems has been installed.

Work is in progress on methodology development for a fast scale-up of fine chemical processes, scale-up of different types of reactions, e.g. reductions and oxidations, also substitutions, additions and eliminations, and process design of relevant fine chemical processes. Scale-up and process architectures are investigated with a combination of semi-empirical statistical methods and known or new scale-up rules for batch-reactors and additional generic multi-process equipment. This research occurs in collaboration with synthetic organic chemistry (Prof. E.W. Meijer and Dr. J.A.J.M. Vekemans), process technology (Dr. J. Meuldijk and Prof. J.C. Schouten) and catalysis (Prof. D. Vogt).

Prof.dr. L.A. Hulshof gives a course on 'Challenges in the Fine Chemicals Industry: Integration of Chemistry and Process Technology' each year. TWAiO’s and other students are invited to join these lectures on Process Research and Development of Fine Chemicals. This course is not compulsory, but to those who are interested. The lectures will be held every Monday at 13.30 – 15.30 h. starting from early January till May (about 24 hours in total), location: SIXMA room, STO 4.91.

A more elaborate description of these courses is given below.

After about 1 year of research, at least another 10 years are needed before the research on a fine chemical can be put into practice. After this explorative research phase and before the plant design, research has to be performed in the field of selectivity, optimization of chemistry, technology, economics, process development and scale-up, competitive analysis and QESH (quality, environment, safety and health) -aspects. Timing and results ('performance') in process development and scale-up are hard to estimate in practice. In particular, pressure of time makes it more difficult to maintain the traditional methodology and way of thinking. The course will deal with the possibilities of improving the performance in the fine chemicals industry by means of solved practical problems in scale-up (so called '(non)-flyers'). These problems will give lower yields and loss in quality at first. After some changes and adjustments, results similar or better to those in the laboratory are obtained. These (non)-flyers will help to get insight into the ideal concept of the future fine chemicals plant.

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