• Offered for Year: 2026/27

• Module Leader(s): Professor Adam Harvey
• Lecturer: Professor Jonathan Lee, Dr Evangelos Papaioannou, Professor Kamelia Boodhoo, Dr Fernando Russo Abegao, Dr Vladimir Zivkovic, Dr Richard Law

• Owning School: Engineering
• Teaching Location: Newcastle City Campus

Semesters

Your programme is made up of credits, the total differs on programme to programme.

Aims

This module aims to provide an overview of approaches available to improve the efficiency of chemical processes. This includes catalysis and process intensification.

Part I:

Process Intensification deals with novel, radically different technologies which have the potential to revolutionize the way chemical plants are designed and operated. The ultimate aim of Process Intensification methods is to reduce the size of process plants by orders of magnitude. Other typical benefits stemming from this reduction in size include:

Enhanced safety,
Reduced environmental footprint,
Improved product quality,
More responsive processing.

All of these advantages are discussed and exemplified by case studies within the module.

This module will:

- Provide an understanding of the concept of Process Intensification and of the application of a variety of intensification techniques to numerous applications;

- Provide an understanding of basic operating principles of a variety of intensified process equipment such as spinning disc reactors, rotary packed beds, oscillatory baffled reactors, compact heat exchangers and micro-reactors;

- Allow students to be apply knowledge to unit operation design, and evaluate the resultant designs;

- Allow students to analyse systems for opportunities for PI/new technologies.



Part II:



Catalysis is ubiquitous in the chemical industry and responsible for almost all chemicals produced at scale in some way, with heterogenous catalysis playing a particular important role. Part II of this module aims to make students familiar with principles of heterogenous catalysis science, from basic principles of catalysis, mass transfer, adsorption and reaction phenomena, to catalyst preparation and characterisation methods.



Additionally, students will learn how heterogenous catalysts are applied to the chemical processes of the future to contribute to a net zero and circular economy, including biomass and CO2 conversion processes, key green chemistry applications, and more traditional catalytic chemistries that will play an active role in such applications.

Outline Of Syllabus

Part I: Process Intensification

Definition of Process Intensification (PI). Origin of PI. Benefits of PI. Methods of achieving PI in general, with specific examples/case studies. Barriers and opportunities. Target industries.

Oscillatory baffled reactor (OBR). Description & operating principles. History. Explanation of niche applications. Design. Case studies.

Spinning disc reactor (SDR): Operating principle and development of models for thin film flow on rotating disc. Examples of application of SDR to a range of processes.

Rotary packed bed (RPBs): Operating principle of rotating contactors. Development of models for counter-current multiphase flow in rotating systems. Examples of the application of multiphase contactors.

Compact heat exchangers (CHE): Definition of CHEs. Construction and main properties. Applications. Basic design procedures. Examples.

Micro-reactors: Description and operating principles. Heat transfer, mass transfer and mixing applications.


Part II: Heterogenous Catalysis:


Principles of catalysis and heterogenous catalysis;

Physisorption and chemisorption at different types of solid surfaces, electronic effects, poisoning and promotion;

Kinetics and Transport Processes in heterogeneous catalysis;

Catalyst performance metrics: catalyst structure relationships and relationships with volcano plots, and activity and selectivity maps;

Preparation, activation and regeneration of heterogenous catalysts;

Catalyst characterisation techniques;

Heterogenous catalyst applications to net zero and circular processes:

Thermochemical waste and biomass valorisation: Gasification, cracking, reforming and Fisher-Tropsch;

Biofuels and platform molecules: Acid and base catalysts: hydrolysis, dehydration and transesterification;

Chemicals and fine chemicals from renewable platform molecules: selective oxidation, hydrogenation and dehydrogenation;

CO2 conversion catalysis.

Teaching Methods

Teaching Activities

Jointly Taught With

Teaching Rationale And Relationship

Basic concepts are introduced and developed in lectures, and reinforced by tutorials on each section of the course. Case studies from lecturers’ own research reinforce the material developed throughout. Tutorial classes are used to develop problem solving skills including design and case studies of technology applications.

Assessment Methods

The format of resits will be determined by the Board of Examiners

Exams

Other Assessment

Assessment Rationale And Relationship

The examination will test knowledge acquired and also problem solving in a timed environment. The examination will cover the process intensification section of the course (AHEP4 M2-5, M7).

The presentation will assess students’ ability to apply knowledge and skills to an open-ended problem related to catalysis, and defend their solution (AHEP4 M1-5, M7, M16-17).

Reading Lists

• CME8415's Reading List

Timetable

• Timetable Website: www.ncl.ac.uk/timetable/
• CME8415's Timetable