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The Pilot Plant Real Book, by Francis X. McConville, is a unique and highly practical new handbook for R&D chemists, chemical engineers, technicians, and students. Bridging the gap between chemistry and engineering, it is designed for process R&D, kilo-lab and pilot plant personnel, and is packed with information for the safe and effective scale-up of new processes.
The revised and expanded 2nd edition is richly illustrated with over 200 distinctive charts, graphs, figures and data tables, and contains countless tips and techniques, an exhaustive index, bibliography and recommended reading list. 320 pages, 8.5 x 11 inches, two-color, robust lay-flat binding.
Francis X. McConville has over 35 years of experience in the chemical and
related industries, including process development and scale-up, with
expertise in asymmetric crystallization, biocatalytic conversion and
fermentation as well as traditional chemical synthetic methods. He is perhaps
process development personnel, which he wrote and self-published in 2006.
Mr. McConville spent 14 years as a process engineer at Sepracor, Inc. where he helped develop cost-effective processes for numerous pharmaceutical actives and intermediates. He was a key member of the technology transfer and scale-up teams for the company's collaborations in Asia, Europe and North America. He was educated at Worcester Polytechnic Institute, from which he holds Masters degrees in both Biotechnology and Chemical Engineering, as well as a Bachelor's degree in Chemistry. This varied background allows him to bring a unique and valuable mix of skills to his work. He now works as a consultant and training instructor and lives with his family in Worcester, Massachusetts. See his
A brief description of the contents:
? Properties of common solvents, gases, reagents, buffers, and heat transfer fluids...
azeotropes, boiling point relationships, flammability, pKa, solubility and chemical compatibility tables... conversions and mathematical formulae...
?Clear, concise monographs on heat transfer, temperature control, agitation, distillation, extraction, crystallization, filtration and drying... reactors, TCU's, chillers, motors, pumps, electricity,
intrinsic safety and process control...
?Safe practices for handling of flammable solvents, compressed gases, toxic substances and electrical equipment... hazardous materials classifications, selection of personal protective equipment...
?The role of the pilot plant in chemical development, guidelines for developing scalable reactions, process safety screening, Haz-Ops, cGMP, tips for maximizing efficiency and getting the most
out of process scale-up... and much more...
TABLE OF CONTENTS
Chapter 1 - The Pilot Plant
The Role of the Pilot Plant 1-2
Major Factors in Scale-Up 1-3
12 Things to Do During Process Scale-Up 1-6
12 Things to Avoid During Process Scale-Up 1-7
Developing Scalable Reactions 1-8
The Role of Calorimetry and Process Safety Screening 1-11
The Haz-Op 1-12
The Batch Checklist 1-14
The Process Flow Diagram 1-15
The Batch Record 1-16
The Campaign Report 1-17
Notes on GMP 1-18
Chapter 2 - Equipment and Operations
The Pilot Plant Equipment Train 2-2
Notes on Equipment Selection, Installation and Maintenance 2-3
Reactors 2-4
Vessel Agitation 2-8
Charging Raw Materials 2-11
Reaction Control 2-13
Sampling for Reaction Monitoring 2-15
Workup 2-16
Partition Coefficient and Extraction Efficiency 2-17
Polish Filtration / Decolorization / Water Removal 2-18
Batch Distillation 2-19
Crystallization 2-21
Product Isolation 2-24
Filtration Scale-Up 2-27
Product Drying 2-29
Scrubbers 2-33
Reactor and Equipment Cleaning 2-34
Chapter 3 - Liquid Handling Introduction and Terminology 3-2
Pump Sizing and Selection 3-4
Pump Installation and Operation 3-5
Rotary Pump Troubleshooting Guide 3-6
Major Pump Types 3-7
Diaphragm Pump Troubleshooting Guide 3-8
Peristaltic Pump Tubing Sizing and Flowrate Guides 3-13
Pipe, Drawn Tube and Fittings 3-14
Flanges and Gaskets 3-19
Valves 3-21
Hose and Hose Fittings 3-23
Liquid Velocity and Pressure Effects 3-24
Viscosity Effects 3-26
Standard O-Ring Size Chart 3-28
Rubber Stopper Sizes 3-29
Ground Glass Joint Sizes 3-29
Capacity of Liquid Storage Tanks 3-30
Storage Drum and Shuttle Data 3-32
Chapter 4 - Heat Transfer
Heat Transfer in Stirred Tank Reactors 4-2
Typical Batch Cooling Profiles 4-4
Reactor Heat Transfer Coefficients 4-5
Experimental Determination of Heat Transfer Coefficient 4-7
Heat Exchanger Fundamentals 4-8
Example Heat Exchanger Problem 4-9
Chart for Estimating Log Mean Temperature Difference 4-10 Temperature Control Units 4-11
System Start-up and Operation 4-12
Tips on Using Heat Transfer Fluids in TCUs 4-13
Heat Transfer Fluid Selection 4-14
Specific Heat of Various Heat Transfer Fluids vs. Temperature 4-15
Useful Temperature Ranges and Properties of Commercial HTF抯4-16 Notes on the Use of Glycol HTFs 4-18
Specific Gravity of Aqueous Glycol Solutions 4-19
Freezing Points of Aqueous Glycol Solutions 4-20
Boiling Points of Aqueous Glycol Solutions 4-21
Specific Heats of Aqueous Glycol Solutions 4-22
Viscosity of Aqueous Ethylene Glycol Solutions 4-23
Freezing Points of Brines 4-24
Steam Pressure vs. Temperature 4-25
Notes on Process Chillers 4-26
Approximate Chiller Capacity 4-28
Effect of Condenser Cooling Water Temperature 4-28
Chapter 5 - Electricity and Istrumentation Notes on Electrical Safety 5-2
Electric Power Basics 5-3
Wire Data 5-4
Standard Resistor Color Code 5-5
Tips on Making Electrical Connections 5-5
Receptacle Data 5-6
Electrical Enclosure Data 5-7
Hazardous Location Classifications for Electrical Equipment 5-8 Intrinsically Safe Equipment 5-10
Electric Motors 5-11
Motor Nameplate Data 5-11
Typical Current Draw of Induction Motors 5-12
Common Types of Motor Enclosures 5-13
Electric Motor Troubleshooting Guide 5-14
Standard NEMA Motor Frame Sizes 5-14
Temperature Measurement 5-15
The 4-20 mA Transmitter 5-17
Pressure Measurement 5-18
Flow Measurement 5-20
Level Measurement 5-22
pH Measurement and Control 5-24
Notes on Process Control 5-26
Analog vs. Digital Control Networks 5-27
Understanding PID Controllers 5-28
Chapter 6 - Solvents
Notes on the Safe Handling of Solvents 6-2
NFPA Solvent Flammability Classifications 6-2
Relative Flammability Hazard of Selected Solvents 6-3
Notes on Solvent Selection 6-4
Some Solvents Useful for Crystallization 6-4
Notes on Solvent Properties Table 6-5
Solvent Properties Table 6-6
Solubility Map of Common Solvents 6-16
Effect of Temperature on Specific Volume 6-17
Enthalpy of Vaporization vs. Boiling Point 6-18
Effect of Temperature on Enthalpy of Vaporization 6-19
Effect of Temperature on Viscosity 6-20
Effect of Temperature on Specific Heat 6-21
Reduced Pressure Boiling Points for Some Common Solvents 6-22 Chart for Estimating Boiling Point vs. Pressure 6-23
Chart for Estimating Vapor Pressure at Elevated Temperatures 6-24 Notes on Distillation and Azeotropes 6-25
Effect of Pressure on Azeotrope Composition 6-26
Water Azeotropes of Some Common Solvents 6-27
Binary Azeotropes of Some Common Solvents 6-28
Ternary Water-Containing Azeotropes of Some Common Solvents 6-40 Solvents Limited for Pharmaceutical Use 6-44
Common Types of Denatured Ethanol 6-44
Important Temperature Dependent Properties of Water 6-45
Common Water Purification Methods 6-47
Process Water Quality Specifications 6-47
Water Conductivity and Resistivity 6-48
Chapter 7 - Compressed Gases
Notes on the Safe Handling of Compressed Gases 7-2
Special Precautions for Gaseous Hydrogen 7-3
Precautions for Cryogenic Liquids 7-3
Estimating Partial-Cylinder Contents 7-3
Common Gas Cylinder Types and Specifications 7-4
Typical Gas Cylinder Markings 7-4
Cylinder Valve Outlet Connections for Common Gases 7-6 Recommended Torque Values for CGA Outlet Connections 7-7
CGA Fitting Specifications 7-8
Metering Gases 7-9
Heating Gas Cylinders Safely 7-9
Care and Use of Gas Pressure Regulators 7-10
Physical Properties of Gases 7-11
Properties of Some Cryogenic Liquids 7-12
Gas Leak Detection 7-13
Properties of Air 7-14
Dew Point vs. Relative Humidity 7-15
Compressed Air Systems 7-16
Compressor Horsepower Requirements 7-17
Typical Compressed Air Usage Rates 7-17
Compressed Air Tank Capacity 7-18
Equivalent Cubic Feet of Compressed Air 7-18
Air Flow Through Pipes and Tubes 7-19
Pressure Drop Through Fittings for Air, Steam, or Gases 7-19
Air Flow Through Orifices 7-20
Vacuum Systems 7-21
Chapter 8- Chemical Data
Periodic Table of the Elements 8-2
Properties of Commercial Acids and Bases 8-3
pH of Common Acid and Base Solutions 8-3
Recipes for Dilute Acid/Base Solutions 8-4
pKa of Acids, Bases and Buffers 8-6
Properties and Preparation of Buffer Solutions 8-8
Some Useful Buffer Systems 8-9
Some NBS Standardized Buffers 8-9
pH Range of Some Acid-Base Color Indicators 8-9
Aqueous Solubility 8-10
General Water Solubility Rules for Inorganic Compounds 8-10
United States Pharmacopeia Definitions of Solubility 8-10
Aqueous Solubility of Selected Inorganic Compounds 8-11
Aqueous Solubility of Selected Organic Compounds 8-12
Effect of Temperature on Aqueous Solubility of Selected Compounds 8-13 Heat of Solution 8-14
Solution Density 8-15
Density of Selected Aqueous Inorganic Solutions 8-16
SpecificGravity and Density Scales 8-17
Comparison of Various Concentration Scales 8-17
Grades of Chemical Purity 8-18
Drying Agents for Solvents and Solutions 8-18
Names of Ions 8-19
Functional Groups in Organic Chemistry 8-19
Some Common Acronyms Used in Organic Chemistry 8-20
Some Common Types of Organic Reactions 8-21
Chapter 9 - Chemical Safety and Hygiene General Notes on the Safe Handling of Chemicals 9-2
The Chemical Hygiene Plan 9-3
Material Safety Data Sheets 9-4
Classification of Hazardous Substances 9-5
Toxicity and Health 9-6
Fire Safety 9-6
Fire Extinguishers 9-7
Chemical Labeling 9-8
List of Incompatible Chemicals 9-9
Waste Effluent Disposal 9-10
Eye and Face Protection 9-12
Hearing Protection 9-12
Hand Protection 9-13
Glove Selection Guide 9-13
Respiratory Protection 9-16
Chapter 10 - Material Selection Properties of Common Elastomers 10-2
Properties of Common Fluoropolymers 10-3
Properties of Common Plastics 10-4
U.S. Plastics Recycling Symbols 10-4
Properties of Common Metals 10-5
Corrosion 10-6
Relative Corrosion Resistance of Various Materials 10-6
Corrosion Units Conversion Factors 10-7
Galvanic Series of Metals 10-7
Properties and Corrosion of Glass 10-8
Effect of pH on Glass Corrosion Rate 10-8
Substances Know to Attack Borosilicate Glass 10-8
Corrosion of Borosilicate Glass by Acids 10-9
Corrosion of Borosilicate Glass by Bases 10-9 MaterialsCompatibility Table 10-10
Substances Known to Attack 316 Stainless Steel 10-28 Substances Known to Attack Hastelloy C-276 10-28
Substances Known to Attack Tantalum Metal 10-28
Chapter 11 - Miscellaneous
Unit Conversion Factors 11-2
Comparison of Unit Systems 11-4
Mathematical and Physical Constants 11-5
Useful Mathematical Relationships 11-5
Exponents and Logarithms 11-5
Polynomials 11-5
Geometric Formulas 11-6
Trigonometry 11-7
Continuous Stirred Tank Dilution Effects (Feed and Bleed) 11-7 Calculations for Asymmetric Crystallizations 11-7 Temperature Conversion Diagram 11-8
Pressure Conversion Diagram 11-9
Vacuum Conversion Diagram 11-10
Useful Cold Mixtures for the Laboratory 11-11
Decimal Equivalents of Fractions of an Inch 11-11
Standard Sieve Specifications 11-12
Mill Grade Wire Cloth Specifications 11-12
Industry-Related Acronyms and Abbreviations 11-13