Annual Review of Chemical and Biomolecular Engineering - Volume 8, 2017

John J. McKetta, Jr. is a foundational figure in chemical engineering education and energy policy in the United States. An authority on the thermodynamic properties of hydrocarbons and an energy adviser to several US presidents, McKetta helped to educate and mentor thousands of students at the University of Texas at Austin for over 40 years, many of whom became leading figures in the energy and petrochemical industries, as well as in academia. As dean of the College of Engineering, McKetta helped to establish a bioengineering program, which later became the Biomedical Engineering Department, at the University of Texas at Austin, and was a tireless advocate for excellence and a focus on the student. At age 100, McKetta recalls the challenges and opportunities he faced in childhood, his memories of the emergence of petrochemical engineering, and his views on chemical engineering education and the people it has impacted in the United States over the past 100 years.

Cells are bombarded by extrinsic signals that dynamically change in time and space. Such dynamic variations can exert profound effects on behaviors, including cellular signaling, organismal development, stem cell differentiation, normal tissue function, and disease processes such as cancer. Although classical genetic tools are well suited to introduce binary perturbations, new approaches have been necessary to investigate how dynamic signal variation may regulate cell behavior. This fundamental question is increasingly being addressed with optogenetics, a field focused on engineering and harnessing light-sensitive proteins to interface with cellular signaling pathways. Channelrhodopsins initially defined optogenetics; however, through recent use of light-responsive proteins with myriad spectral and functional properties, practical applications of optogenetics currently encompass cell signaling, subcellular localization, and gene regulation. Now, important questions regarding signal integration within branch points of signaling networks, asymmetric cell responses to spatially restricted signals, and effects of signal dosage versus duration can be addressed. This review summarizes emerging technologies and applications within the expanding field of optogenetics.

A new generation of catalysts is needed to meet society's energy and resource requirements. Current catalyst synthesis does not fully achieve optimum control of composition, size, and structure. Atomic layer deposition (ALD) is an emerging technique that allows for synthesis of highly controlled catalysts in the form of films, nanoparticles, and single sites. The addition of ALD coatings can also be used to introduce promoters and improve the stability of traditional catalysts. Evolving research shows promise for applying ALD to understand catalytically active sites and create next-generation catalysts using advanced 3D nanostructures.

Big data analytics is the journey to turn data into insights for more informed business and operational decisions. As the chemical engineering community is collecting more data (volume) from different sources (variety), this journey becomes more challenging in terms of using the right data and the right tools (analytics) to make the right decisions in real time (velocity). This article highlights recent big data advancements in five industries, including chemicals, energy, semiconductors, pharmaceuticals, and food, and then discusses technical, platform, and culture challenges. To reach the next milestone in multiplying successes to the enterprise level, government, academia, and industry need to collaboratively focus on workforce development and innovation.

Bacterial infections remain a major public health concern. However, broad-spectrum antibiotics largely target redundant mechanisms of bacterial survival and lead to gained resistance owing to microbial evolution. New methods are needed to attack bacterial infections, and we have only begun to seek out nature's vast arsenal of antimicrobial weapons. Enzymes offer one such weapon, and their diversity has been exploited to kill bacteria selectively through unique targets, particularly in bacterial cell walls, as well as nonselectively through generation of bactericidal molecules. In both approaches, microbial resistance has largely been absent, which bodes well for its potential use in human therapeutics. Furthermore, enzyme stabilization through conjugation to nanoscale materials and incorporation into polymeric composites enable their use on surfaces to endow them with antimicrobial properties. Here, we highlight the use of enzymes as antimicrobial agents, including applications that may prove effective in new therapeutics and through control of key societal infrastructures.

With technological advancement of thermocatalytic processes for valorizing renewable biomass carbon, development of effective separation technologies for selective recovery of bioproducts from complex reaction media and their purification becomes essential. The high thermal sensitivity of biomass intermediates and their low volatility and high reactivity, along with the use of dilute solutions, make the bioproducts separations energy intensive and expensive. Novel separation techniques, including solvent extraction in biphasic systems and reactive adsorption using zeolite and carbon sorbents, membranes, and chromatography, have been developed. In parallel with experimental efforts, multiscale simulations have been reported for predicting solvent selection and adsorption separation. We discuss various separations that are potentially valuable to future biorefineries and the factors controlling separation performance. Particular emphasis is given to current gaps and opportunities for future development.

Nonnative protein aggregation is the process by which otherwise folded, monomeric proteins are converted to stable aggregates composed of protein chains that have undergone some degree of unfolding. Often, a conformational change is needed to allow certain sequences of amino acids—so-called aggregation-prone regions (APRs)—to form stable interprotein contacts such as β-sheet structures. In addition to APRs that are needed to stabilize aggregates, other factors or driving forces are also important in inducing aggregation in practice. This review focuses first on the overall process and mechanistic drivers for nonnative aggregation, followed by a more detailed summary of the factors currently thought to be important for determining which amino acid sequences most greatly stabilize nonnative protein aggregates, as well as a survey of many of the existing algorithms that are publicly available to attempt to predict APRs. Challenges with experimental validation of predicted APRs for proteins are briefly discussed.

The brewing of beer is an ancient biotechnology, the unit processes of which have not changed in hundreds of years. Equally, scientific study within the brewing industry not only has ensured that modern beer making is highly controlled, leading to highly consistent, high-quality, healthful beverages, but also has informed many other fermentation-based industries.

Microneedle patches (MNPs) contain arrays of solid needles measuring hundreds of microns in length that deliver drugs and vaccines into skin in a painless, easy-to-use manner. Optimal MNP design balances multiple interdependent parameters that determine mechanical strength, skin-insertion reliability, drug delivery efficiency, painlessness, manufacturability, and other features of MNPs that affect their performance. MNPs can be made by adapting various microfabrication technologies for delivery of small-molecule drugs, biologics, and vaccines targeted to the skin, which can have pharmacokinetic and immunologic advantages. A small number of human clinical trials, as well as a large and growing market for MNP products for cosmetics, indicate that MNPs can be used safely, efficaciously, and with strong patient acceptance. More advanced clinical trials and commercial-scale manufacturing will facilitate development of MNPs to realize their potential to dramatically increase patient access to otherwise-injectable drugs and to improve drug performance via skin delivery.

Nanomanufacturing—the fabrication of macroscopic products from well-defined nanoscale building blocks—in a truly scalable and versatile manner is still far from our current reality. Here, we describe the barriers to large-scale nanomanufacturing and identify routes to overcome them. We argue for nanomanufacturing systems consisting of an iterative sequence of synthesis/assembly and separation/sorting unit operations, analogous to those used in chemicals manufacturing. In addition to performance and economic considerations, phenomena unique to the nanoscale must guide the design of each unit operation and the overall process flow. We identify and discuss four key nanomanufacturing process design needs: (a) appropriately selected process break points, (b) synthesis techniques appropriate for large-scale manufacturing, (c) new structure- and property-based separations, and (d) advances in stabilization and packaging.

This review aims to illustrate the diversity of measurements that can be made using magnetic resonance techniques, which have the potential to provide insights into chemical engineering systems that cannot readily be achieved using any other method. Perhaps the most notable advantage in using magnetic resonance methods is that both chemistry and transport can be followed in three dimensions, in optically opaque systems, and without the need for tracers to be introduced into the system. Here we focus on hydrodynamics and, in particular, applications to rheology, pipe flow, and fixed-bed and gas-solid fluidized bed reactors. With increasing development of industrially relevant sample environments and undersampling data acquisition strategies that can reduce acquisition times to <1 s, magnetic resonance is finding increasing application in chemical engineering research.

This article first reviews recent developments in process synthesis and discusses some of the major challenges in the theory and practice in this area. Next, the article reviews key concepts in optimization-based conceptual design, namely superstructure representations, multilevel models, optimization methods, and modeling environments. A brief review of the synthesis of major subsystems and flowsheets is presented. Finally, the article closes with a critical assessment and future research challenges for the process synthesis area.

The past two decades have witnessed a rapid development of microreactors. A substantial number of reactions have been tested in microchemical systems, revealing the advantages of controlled residence time, enhanced transport efficiency, high product yield, and inherent safety. This review defines the microchemical system and describes its components and applications as well as the basic structures of micromixers. We focus on mixing, flow dynamics, and mass and heat transfer in microreactors along with three strategies for scaling up microreactors: parallel numbering-up, consecutive numbering-up, and scale-out. We also propose a possible methodology to design microchemical systems. Finally, we provide a summary and future prospects.

The present review deals with recent advances in the rapidly growing field of aerogel research and technology. The major focus of the review lies in approaches that allow tailoring of aerogel properties to meet application-driven requirements. The decisive properties of aerogels are discussed with regard to existing and potential application areas. Various tailoring strategies, such as modulation of the pore structure, coating, surface modification, and post-treatment, are illustrated by results of the last decade. In view of commercialization of aerogel-based products, a panorama of current industrial aerogel suppliers is given, along with a discussion of possible alternative sources for raw materials and precursors. Finally, growing points and perspectives of the aerogel field are summarized.

Algal oil as an alternative to fossil fuel has attracted attention since the 1940s, when it was discovered that many microalgae species can produce large amounts of lipids. Economics and energy security were the motivational factors for a spurt in algae research during the 1970s, 1990s, and early 2000s. Whenever crude prices declined, research on algae stopped. The scenario today is different. Even given low and volatile crude prices ($30–$50/barrel), interest in algae continues all over the world. Algae, with their cure-all characteristics, have the potential to provide sustainable solutions to problems in the energy-food-climate nexus. However, after years of effort, there are no signs of algae-to-biofuel technology being commercialized. This article critically reviews past work; summarizes the current status of the technology; and based on the lessons learned, provides a balanced perspective on a potential path toward commercialization of algae-to-oil technology.

Modular chemical process intensification can dramatically improve energy and process efficiencies of chemical processes through enhanced mass and heat transfer, application of external force fields, enhanced driving forces, and combinations of different unit operations, such as reaction and separation, in single-process equipment. These dramatic improvements lead to several benefits such as compactness or small footprint, energy and cost savings, enhanced safety, less waste production, and higher product quality. Because of these benefits, process intensification can play a major role in industrial and manufacturing sectors, including chemical, pulp and paper, energy, critical materials, and water treatment, among others. This article provides an overview of process intensification, including definitions, principles, tools, and possible applications, with the objective to contribute to the future development and potential applications of modular chemical process intensification in industrial and manufacturing sectors. Drivers and barriers contributing to the advancement of process intensification technologies are discussed.

Phase behavior and thermophysical properties of mixtures of carbon dioxide with various other substances are very important for the design and operation of carbon capture and storage (CCS) processes. The available empirical data are reviewed, together with some models for the calculation of these properties. The systems considered in detail are, first, mixtures of carbon dioxide, water, and salts; second, carbon dioxide–rich nonelectrolyte mixtures; and third, mixtures of carbon dioxide with water and amines. The empirical data and the plethora of available models permit the estimation of key fluid properties required in the design and operation of CCS processes. The engineering community would benefit from the further development, and delivery in convenient form, of a small number of these models sufficient to encompass the component slate and operating conditions of CCS processes.

The application of statistics in pharmaceutical process research and development has evolved significantly over the past decades, motivated in part by the introduction of the Quality by Design paradigm, a landmark change in regulatory expectations for the level of scientific understanding associated with the manufacturing process. Today, statistical methods are increasingly applied to accelerate the characterization and optimization of new drugs created via numerous unit operations well known to the chemical engineering discipline. We offer here a review of the maturity in the implementation of design of experiment techniques, the increased incorporation of latent variable methods in process and material characterization, and the adoption of Bayesian methodology for process risk assessment.

Although too small to be seen with the human eye, atmospheric particulate matter has major impacts on the world around us, from our health to global climate. Understanding the sources, properties, and transformations of these particles in the atmosphere is among the major challenges in air quality and climate research today. Significant progress has been made over the past two decades in understanding atmospheric aerosol chemistry and its connections to climate. Advances in technology for characterizing aerosol chemical composition and physical properties have enabled rapid discovery in this area. This article reviews fundamental concepts and recent developments surrounding ambient aerosols, their chemical composition and sources, light-absorbing aerosols, aerosols and cloud formation, and aerosol-based solar radiation management (also known as solar geoengineering).