Chemical Engineering October 2013 - 12

CHEMENTATOR
Control particle size and morphology with this technique
L
actose has been widely used as a pharmaceutical
excipient, where the size and
morphology of the particles of lactose significantly
affect the functionality of the resultant
drug product. Lactose particles produced by
various methods exhibit various morphologies,
such as spherical amorphous particles,
or lactose crystals with tomahawk or sharp
and fine morphology. To date, however, there
is no report in which a single process can be
manipulated to produce both types of morphology,
according to a team from Monash
University (Melbourne, Australia; www.monash.edu.au).
Together with colleagues from
Xiamen University (Xiamen) and Soochow
University (Suzhou, both China), the team
has developed a technique, called antisolvent
vapor precipitation (AVP), which can be controlled
to produce ultra-fine lactose particles
of uniform size, with spiky crystalline morphology
or spherical amorphous morphology.
The method is expected to improve the
efficiency of powder pulmonary-drug delivery,
as for example in the case of asthma
inhalers. With current inhaler designs, a
large portion of medication propelled into
a patient's throat remains there, and only
a fraction reaches the lower regions of the
lungs, says team member Meng Wai Woo, of
Monash's Dept. of Chemical Engineering.
The underlying principle of the technique
is liquid antisolvent precipitation.
However, instead of large bulk liquid, the
AVP technique introduces a single aqueous
droplet with dissolved lactose into a
stream of convective ethanol vapor. Precipitation
is induced when the ethanol is
absorbed into the droplet at a different degree
and rate of oversaturation.
The researchers have been exploring
the possibility of producing precipitated
particles from atomized droplets in spray
systems. They found that the AVP method
enables hundreds of 1-3-µm size excipient
particles to be produced from a single, relatively
large droplet (about 1,200 µm). The
team is now testing its method on another
dairy product (whey) and on protein-based
medicines. It is also building a demonstration
unit to be completed later this year.
Scaleup for a CO2 mineralization process
A
Purifying aromatics
Last month, BASF's Catalyst
Div. (Iselin, N.J.; www.catalysts.
basf.com) introduced F-24X,
the company's newest catalyst
and adsorbent for aromatic
purification. F-24-X - a drop-in
replacement for its predecessor
F-24 - is said to improve
process economics through extended
life and shorten startup
time through lower moisture.
The catalyst is used in fixedbed
columns for the purification
of benzene, xylenes, cumene,
kerosene, jet fuel and other
petrochemical and petroleum
process streams.
pilot plant will be established at the
University of Newcastle (Newcastle,
Australia; www.newcastle.edu.au) to test
a new technology for the sequestration of
CO2 through mineral carbonation - the
reaction with magnesium silicate minerals,
such as serpentine, to form mineral carbonates.
Mineral carbonation mimics and accelerates
the Earth's natural carbon-sink
mechanism by combining CO2 with lowgrade
minerals to create inert carbonates
similar to antacids and baking soda. In the
mineral carbonation process, basic rock such
as serpentinite is mined, crushed, heated
and then mixed with water and pressurized
with CO2 to speed up the natural carbonation
reaction, which forms stable magnesium
carbonate powder and sand.
The project will be carried out by Mineral
Carbonation International (MCi), a joint
venture of Newcastle Innovation (the University
of Newcastle's technology transfer
company); Orica Ltd. (formerly ICI Australia;
Melbourne; www.orica.com); and a
private investor, the GreenMag Group. The
four-year project - funded by the Australian
and New South Wales governments
and Orica - will be carried out by a multidisciplinary
team of researchers led by
Orica's Geoff Brent, and professors Bogdan
Dlugogorski and Eric Kennedy of the University
of Newcastle.
Mineral carbonation as a route to sequester
CO2 has been proposed as early as 1990.
The Albany Research Center (ARC; Albany,
Ore.) has demonstrated the technically feasible
routes for mineral carbonation based
on high-pressure aqueous systems. However,
according to Brent, the economic viability of
these processes has not yet been established.
Brent says the ARC did not consider pretreatment
via direct thermal activation in a
fuel-fired furnace, nor did it include any heat
recovery from the exothermic carbonation reaction,
both of which could offer significant
reduction in net processing costs. Improvements
in reaction rates and conversions, as
well as optimization of energy utilization via
process integration are required, says Brent.
MCi's project will develop a process for
direct gas-fired thermal activation of serpentinite
ore followed by supercritical carbonation
using the ARC process. The project
team says the direct use of thermal heat,
coupled to partial dehydroxylation and the
use of lower CO2-intensive fuel presents a
practical, cost-effective option for serpentine
activation.
12 CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2013
Textile catalyst support
A technique for immobilizing
organic catalysts onto textiles
has been developed by researchers
at the Max-Planck
Institüt für Kohlenforschung
(Mülhein an der Ruhr; www.
kofo.mpi.de), in collaboration
with colleagues at the German
Textile Research Center
(Krefeld, both Germany) and
Sungkyunkwan University
(Suwon, South Korea). Such
functionalized textiles are
expected to eliminate the separation
step needed for reactions
involving homogeneous
catalysts, in which the organic
acids are normally used in the
dissolved state.
The catalytic textiles are
made by attaching the catalyst
to nylon fibers, followed by irradiation
with ultraviolet light for
5 min. The fibers can then be
interwoven to form a fabric. The
fabric is said to provide a larger
surface area compared to alternative
immobilization supports,
such as plastic spheres or foils.
Three different organic catalysts
were tested: dimethylaminopyridine
(DMPA; a base), a
sulfonic acid, and a catalyst that
acts as both acid and a base.
All three catalysts converted
around 90% of the substrates
into the desired products. The
amphoteric catalyst - important
for performing chiral reactions
- also achieved an optical
purity of more than 95%.
Hard metal
A new hard metal and a process
for manufacturing it have
been developed by VTT Technical
Research Center of Finland
(Continues on p. 14)
http://www.catalysts http://www.basf.com http://www.mo http://nash.edu.au http://kofo.mpi.de http://www.newcastle.edu.au http://www.orica.com http://WWW.CHE.COM

Chemical Engineering October 2013

Table of Contents for the Digital Edition of Chemical Engineering October 2013

Contents
Chemical Engineering October 2013 - Cover1
Chemical Engineering October 2013 - Cover2
Chemical Engineering October 2013 - Contents
Chemical Engineering October 2013 - 2
Chemical Engineering October 2013 - 3
Chemical Engineering October 2013 - 4
Chemical Engineering October 2013 - 5
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