Particulate operations in the pharmaceutical and fertilizer industries

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The proposed research program focuses on particulate manufacturing processes with long term general objectives to improve our understanding of these important processes and to develop and implement methods that can be used for monitoring online and in real time. This will lead to increased efficiency through optimization and better control to ensure that the final products achieve desired specifications. The proposal focuses on two projects, one with applications in the pharmaceutical industry and the other in the fertilizer industry: (i) investigation of coating of pharmaceutical pellets and (ii) investigation of biochar granulation. Pharmaceutical pellets can be coated to create modified release rates and then packed into capsules to form a multiple unit dosage form that is taken orally. This relatively new dosage form has advantages over conventional tablets, but its manufacture is more complicated, time-consuming and expensive. Combined with being a relatively new dosage form, this means that pellet coating has not yet been extensively studied including any research on developing online and real time monitoring methods. One of the objectives of this project is to develop a passive acoustic emission monitoring method for fluidized bed coating of pellets. The goal of pyrolysis of agricultural wastes or residues is usually to produce bio-oil. Biochar is the solid by-product of pyrolysis. Biochar has been proven to amend soil by reducing nutrient leaching, increasing water retention and increasing microbial activity. In addition, biochar addition to soils could provide effective carbon sequestration. Biochar is a very fine powder that is difficult to handle and would be blown away if applied to soils without modifications. One of the objectives of this project is to investigate wet drum granulation of biochar to create a form that would be easier to handle and apply effectively to the soil. The proposed research will provide training for two PhD, two MESc and five summer students. The pharmaceutical industry remains a strong sector of the Canadian economy. The students that will be trained through the proposed research will thus graduate with the skills necessary to make an important contribution to this industry and to the economic well-being of Canada. The global demand for agricultural commodities is increasing and there is a need to find effective carbon sequestration methods to mitigate climate change. Students involved in the proposed research on biochar granulation have a fantastic opportunity to provide a unique solution to significant global problems and help to position Canada as a world leader in agriculture and climate change strategy. The proposed research has anticipated impact for both the pharmaceutical and agricultural industries. Many will develop a mental illness at some point in their lives. Drugs taken as coated pellets packed into capsules have many benefits for treating mental illnesses. Their manufacture, however, is complex. The development of passive acoustic emission monitoring of fluidized bed coating of pellets will significantly improve manufacturing of this multiple unit dosage form and therefore have the potential to positively impact the lives of many Canadians. The granulation of biochar to add to soils has a three significant benefits: (i) the pyrolysis of agricultural wastes or residues that produces the biochar also has bio-oil as a product that can be used as a fuel or fuel additive, (ii) enhanced biochar granules amend the soil and provide necessary nutrients for plant growth with plants absorbing atmospheric carbon through photosynthesis, (iii) biochar applied to soils is an effective carbon sequestration strategy.