The movement of solid-liquid suspensions in pipes and vessels is a generic complex problem which is commercially challenging and technically important. Industrial applications are numerous, e.g. chemicals, consumer goods, food, pharmaceuticals, oil, mining, river engineering, construction, power generation, biotechnology and biomedical. Despite such large markets, industrial practice and processes are neither efficient nor optimal because of a severe lack of fundamental understanding of these flows. Such flows involve complex phenomena on a wide range of scales as flow conduits generally vary from the micron scale to the centimetre scale, and vessels vary from the millilitre scale to the cubic metre scale. Flows may be turbulent or viscous and the carrier fluid may exhibit complex non-Newtonian rheology. Particles occur in various shapes, sizes, densities, bulk and surface properties which exacerbates the complexity of the problem. The design of processes for conveying or processing solid-liquid suspensions requires information about particle behaviour such as particle trajectory, radial migration across streamlines, particle velocity distribution, and solids distribution. There are, however, huge practical difficulties in imaging solid-liquid flows and measuring local fluid and solid velocities, since little of the available instrumentation is applicable. Mixtures of practical interest are often concentrated and opaque so that flow visualisation is impossible, and particles may be deformable, breakable or prone to aggregation. Such complex phenomena are presently difficult to predict. They have hampered fundamental research and the development of rigorous holistic modelling strategies and, as a result, work has generally followed a piecemeal empirical approach. This proposal will use a multiscale approach to study the flow of solid-liquid suspensions including fluids of complex non-Newtonian rheology and particles with complex properties: (i) experimentally via a unique and accurate Lagrangian technique of positron emission particle tracking, which can measure local 3-D phase velocities as well as phase distribution in opaque systems; and (ii) by developing and validating novel modelling approaches to predict such flows including detailed interactions between particles, fluid and walls. A number of advanced modelling techniques will be used including principally the Discrete Element Method (DEM), Computational Fluid Dynamics (CFD), Smooth Particle Hydrodynamics (SPH), Lattice Boltzmann Method (LBM) and Coarse-Grained Molecular Dynamics (CGMD). None of these methodologies on its own, however, is able to effectively model these complex flows as they all enjoy strengths as well as weaknesses. We will, therefore, exploit the strengths of each technique by assembling these methods in an efficient hybrid fashion to produce an integrated multiscale modular framework to be made available free of charge within the unique and well-known open source code DL_MESO. Thus, we will evaluate the best hybrid approaches and develop a paradigm for modelling these complex flows by mapping the model hybrids against flow characteristics. The use of a hybrid modelling methodology and a multiscale approach to include concentrated turbulent flows, fluids of non-Newtonian rheology, particles of complex shapes and properties will produce a quantum leap advance in the modelling of these complex flows. In the medium to long-term, the findings from this work should improve the competitiveness of the UK solid-liquid processing technologies. Our industrial and academic partners, however, will be able to draw immediate benefits through engagement with the project.

The proposal seeks funds to renew and refresh the Centre for Doctoral Training in Formulation Engineering based in Chemical Engineering at Birmingham. The Centre was first funded by EPSRC in 2001, and was renewed in 2008. In 2011, on its 10th anniversary, the Centre received one of the Diamond Jubilee Queen's Anniversary Prizes, for 'new technologies and leadership in formulation engineering in support of UK manufacturing'. The scheme is an Engineeering Doctoral Centre; students are embedded in their sponsoring company and carry out industry-focused research. Formulation Engineering is the study of the manufacture of products that are structured at the micro-scale, and whose properties depend on this structure. In this it differs from conventional chemical engineering. Examples include foods, home and personal care products, catalysts, ceramics and agrichemicals. In all of these material formulation and microstructure control the physical and chemical properties that are essential to its function. The structure determines how molecules are delivered or perceived - for example, in foods delivery is of flavour molecules to the mouth and nose, and of nutritional benefit to the GI tract, whilst in home and personal care delivery is to skin or to clothes to be cleaned, and in catalysis it is delivery of molecules to and from the active site. Different industry sectors are thus underpinned by the same engineering science. We have built partnerships with a series of companies each of whom is world-class in its own field, such as P&G, Kraft/Mondelez, Unilever, Johnson Matthey, Imerys, Pepsico and Rolls Royce, each of which has written letters of support that confirm the value of the programme and that they will continue to support the EngD. Research Engineers work within their sponsoring companies and return to the University for training courses that develop the concepts of formulation engineering as well as teaching personal and management skills; a three day conference is held every year at which staff from the different companies interact and hear presentations on all of the projects. Outputs from the Centre have been published in high-impact journals and conferences, IP agreements are in place with each sponsoring company to ensure both commercial confidentiality and that key aspects of the work are published. Currently there are 50 ongoing projects, and of the Centre's graduates, all are employed and more than 85% have found employment in formulation companies. EPSRC funds are requested to support 8 projects/year for 5 years, together with the salary of the Deputy Director who works to link the University, the sponsors and the researchers and is critical to ensure that the projects run efficiently and the cohorts interact well. Two projects/year will be funded by the University (which will also support a lecturer, total >£1 million over the life of the programme) and through other sources such as the 1851 Exhibition fund, which is currently funding 3 projects. EPSRC funding will leverage at least £3 million of direct industry contributions and £8 million of in-kind support, as noted in the supporting letters. EPSRC funding of £4,155,480 will enable a programme with total costs of more than £17 million to operate, an EPSRC contribution of 24% to the whole programme.

This application requests funds to continue and develop the EngD in Formulation Engineering which has been supported by EPSRC since 2001. The EngD was developed in response to the needs of the modern process industries. Classical process engineering is concerned with processing materials, such as petrochemicals, which can be described in thermodynamic terms. However, modern process engineering is increasingly concerned with production of materials whose structure (micro- to nano- scale) and chemistry is complex and a function of the processing it has received. For optimal performance the process must be designed concurrently with the product, as to extract commercial value requires reliable and rapid scale-up. Examples include: foods, pharmaceuticals, paints, catalysts and fuel cell electrodes, structured ceramics, thin films, cosmetics, detergents and agrochemicals. In all of these, material formulation and microstructure controls the physical and chemical properties that are essential to its function. The Centre exploits the fact that the science within these industry sectors is common and built around designing processes to generate microstructure:(i) To optimise molecular delivery: for example, there is commonality between food, personal care and pharmaceuticals; in all of these sectors molecular delivery of actives is critical (in foods, to the stomach and GI tract, to the skin in personal care, throughout the body for the pharmaceutical industry);(ii) To control structure in-process: for example, fuel cell elements and catalysts require a structure which allows efficient passage of critical molecules over wide ranges of temperature and pressure; identical issues are faced in the manufacture of structured ceramics for investment casting;(iii) Using processes with appropriate scale and defined scale-up rules: the need is to create processes which can efficiently manufacture these products with minimal waste and changeover losses.The research issues that affect widely different industry sectors are thus the same: the need is to understand the processing that results in optimal nano- to microstructure and thus optimal effect. Products are either structured solids, soft solids or structured liquids, with properties that are highly process-dependent. To make these products efficiently requires combined understanding of their chemistry, processing and materials science. Research in this area has direct industrial benefits because of the sensitivity of the products to their processes of manufacture, and is of significant value to the UK as demonstrated by our current industry base, which includes a significant number of FMCG (Fast Moving Consumer Goods) companies in which product innovation is especially rapid and consumer focused. The need for, and the added value of, the EngD Centre is thus to bring together different industries and industry sectors to form a coherent underpinning research programme in Formulation Engineering. We have letters of support from 19 companies including (i) large companies who have already shown their support through multiple REs (including Unilever, P+G, Rolls Royce, Imerys, Johnson Matthey, Cadbury and Boots), (ii) companies new to the Centre who have been attracted by our research skills and industry base (including Bayer, Akzo Nobel, BASF, Fonterra (NZ), Bristol Myers Squibb and Pepsico).

A vital challenge for modern engineering is the modelling of the multiscale complex particle-liquid flows at the heart of numerous industrial and physiological processes. Industries dependent on such flows include food, chemicals, consumer goods, pharmaceuticals, oil, mining, river engineering, construction, power generation, biotechnology and medicine. Despite this large range of application areas, industrial practice and processes and clinical practice are neither efficient nor optimal because of a lack of fundamental understanding of the complex, multiscale phenomena involved. Flows may be turbulent or viscous and the carrier fluid may exhibit complex non-Newtonian rheology. Particles have various shapes, sizes, densities, bulk and surface properties. The ability to understand multiscale particle-liquid flows and predict them reliably would offer tremendous economic, scientific and societal benefits to the UK. Our fundamental understanding has so far been restricted by huge practical difficulties in imaging such flows and measuring their local properties. Mixtures of practical interest are often concentrated and opaque so that optical flow visualisation is impossible. We propose to overcome this problem using the technique of positron emission particle tracking (PEPT) which relies on radiation that penetrates opaque materials. We will advance the fundamental physics of multiscale particle-liquid flows in engineering and physiology through an exceptional experimental and theoretical effort, delivering a step change in our ability to image, model, analyse, and predict these flows. We will develop: (i) unique transformative Lagrangian PEPT diagnostic methodology for engineering and physiological flows; and (ii) innovative Lagrangian theories for the analysis of the phenomena uncovered by our measurements. The University of Birmingham Positron Imaging Centre, where the PEPT technique was invented, is unique in the world in its use of positron-emitting radioactive tracers to study engineering processes. In PEPT, a single radiolabelled particle is used as a flow follower and tracked through positron detection. Thus, each component in a multiphase particle-liquid flow can be labelled and its behaviour observed. Compared with leading optical laser techniques (e.g. LDV, PIV), PEPT has the enormous and unique advantage that it can image opaque fluids, and fluids inside opaque apparatus and the human body. To make the most of this and image fast, complex multiphase and multiscale flows in aqueous systems, improved tracking sensitivity and accuracy, dedicated new radiotracers and simultaneous tracking of multiple tracers must be developed, and new theoretical frameworks must be devised to analyse and interpret the data. By delivering this, we will enable multiscale complex particle-liquid flows to be studied with unprecedented detail and resolution in regimes and configurations hitherto inaccessible to any available technique. The benefits will be far-reaching since the range of applications of PEPT in engineering and medicine is extremely wide. This multidisciplinary Programme harnesses the synergy between world-leading centres at Birmingham (chemical engineering, physics), Edinburgh (applied maths) and King's College London (PET chemistry, biomedical engineering) to develop unique PEPT diagnostic tools, and to study experimentally and theoretically outstanding multiscale multiphase flow problems which can only be tackled by these tools. The advances of the Programme include: a novel microPEPT device designed to image microscale flows, and a novel medical PEPT validated in small animals for translation to humans. The investigators' combined strengths and the accompanying wide-ranging industrial collaborations, will ensure that this Programme leads to a paradigm-shift in complex multiphase flow research.

Formulation engineering is concerned with the manufacture and use of microstructured materials, whose usefulness depends on their microstructure. For example, the taste, texture and shine of chocolate depends on the cocoa butter being in the right crystal form - when chocolate is heated and cooled its microstructure changes to the unsightly and less edible 'bloomed' form. Formulated products are widespread, and include foods, pharmaceuticals, paints, catalysts, structured ceramics, thin films, cosmetics, detergents and agrochemicals, with a total value of £180 bn per year. In all of these, material formulation and microstructure control the physical and chemical properties that are essential to the product function. The research issues that affect different industry sectors are common: the need is to understand the processing that results in optimal nano- to micro structure and thus product effect. Products are mostly complex soft materials; structured solids, soft solids or structured liquids, with highly process-dependent properties. The CDT fits into Priority Theme 2 of the EPSRC call: Design and Manufacture of Complex Soft Material Products. The vision for the CDT is to be a world-leading provider of research and training addressing the manufacture of formulated products. The UK is internationally-leading in formulation, with many research and manufacturing sites of national and multinational companies, but the subject is interdisciplinary and thus is not taught in many first degree courses. A CDT is thus needed to support this industry sector and to develop future leaders in formation engineering. The existing CDT in Formulation Engineering has received to date > £6.5 million in industry cash, has graduated >75 students and has 46 currently registered. The CDT has led the field; the new National Formulation Centre at CPI was created in 2016, and we work closely with them. The strategy of the new Centre has been co-created with industry: the CDT will develop interdisciplinary research projects in the sustainable manufacture of the next generation of formulated products, with focus in two areas (i) Manufacturing and Manufacturability of New Materials for New Markets 'M4', generating understanding to create sustainable routes to formulated products, and (ii) 'Towards 4.0rmulation': using modern data handling and manufacturing methods ('Industry 4.0') in formulation. We have more than 25 letters from companies offering studentships and >£9 million of support. The research of the Centre will be carried out in collaboration with a range of industry partners: our strategy is to work with companies that are are world-leading in a number of areas; foods (PepsiCo, Mondelez, Unilever), HPC (P+G, Unilever), fine chemicals (Johnson Matthey, Innospec), pharma (AstraZeneca, Bristol Myers Squibb) and aerospace (Rolls-Royce). This structure maximises the synergy possible through working with non-competing groups. We will carry out at least 50 collaborative projects with industry, most of which will be EngD projects in which students are embedded within industrial companies, and return to the University for training courses. This gives excellent training to the students in industrial research; in addition to carrying out a research project of industrial value, students gain experience of industry, present their work at internal and external meetings and receive training in responsible research methods and in the interdisciplinary science and engineering that underpin this critical industry sector.