Date post: | 20-Jun-2015 |
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RECYCLE SOLUTIONS
Reduce E-Factor for Pharma Intermediates by 90%
Nitesh H. MehtaFounder DirectorNewreka Green Synth Technologies Pvt. Ltd.Mumbai, India
Two roadblocks in implementing GC
Concept of Industrial Green Chemistry
Enviropreneur – possible model to accelerate implementation of GC
Newreka as an Enviropreneur
Case Study
Opportunities in Industrial Green Chemistry
Agenda
Universities:1. Limitations to
Customize, Scale-up & Commercialize
2. Limitations to Market their Innovations
Industry:1. Profit Driven Approach2. Limitation to approach
& define their problems3. Mindset of not investing
on Green R&D
Common Man & Society:
1. Lack of Awareness2. Mindset of not investing
on Education & Research
Govt. Bodies & NGO’s:1. Formulations of practical
policies.2. Carrot & Stick Approach3. Limitations of paperwork
& bureaucracy
Roadblocks in Implementation of GC
This is the only World that exists.
We keep hearing:
GC in Real World Practice,Real World Case Studies of GC,GC implementation in Real World, etc…..
There is no other world. Then why specifically say “Real World” ??
Real World ??
Roadblocks in Implementation of GC
World of Chemists, Chemical Engineers, Academicians, Researchers & Scientists:
new fields or areas like Nano complex mechanisms fascinating instruments publications awards …….etc.
May be: to distinguish it from our individual worlds
Roadblocks in Implementation of GC
World of an Industrialist, CEO, MD, or VP running a company:
sales, turnover profitability quarterly, yearly targets share value accountable to stakeholders …….etc.
None of these “worlds” is a problem.
Roadblocks in Implementation of GC
Problem starts, when these become the ultimate objective, instead of larger causes like:
reducing environmental footprint of industry making our industry competitive safety of shopfloor operators drugs being available at affordable prices clean water for all biodegradable/recyclable consumer products energy conservation, optimizing utilization …….etc
Roadblocks in Implementation of GC
Industrial A bigger cause (beyond us)Green = +Chemistry Green Chemistry Commercialized
or Commercially viable+
Quality of Air, Water & Soil impacted at ground
level
Concept of Industrial Green Chemistry
Universities:1. Limitations to
Customize, Scale-up & Commercialize
2. Limitations to Market their Innovations
Industry:1. Profit Driven Approach2. Limitation to approach
& define their problems3. Mindset of not investing
on Green R&D
Common Man & Society:
1. Lack of Awareness2. Mindset of not investing
on Education & Research
Govt. Bodies & NGO’s:1. Limitations of
paperwork & bureaucracy
2. Carrot & Stick Approach
Enviropreneurs
“Enviropreneurs” - A Possible Bridge
Enviropreneurs = Environment + Entrepreneurs
Enviropreneurs :
Their View : Environment is an Asset not a Problem.
Their Qualities : “Passion” of an Environmentalist & “Spirit of Adventure” of an Entrepreneur.
Their Business Model : Long Term Sustainable Solutions
Their Goals : Make Money & also Produce benefits for the Environment
“Enviropreneurs”
Founders Team of Technocrats from IIT Bombay passionate about Nature
Foundation Principles of Green Chemistry, Green Engineering & Enviropreneurship
Knowledge Base & Over 40,000 experiments conducted by
Experience a dedicated team of 50 Chemists & Chemical Engineers.
Service Customized & Sustainable Solutions to
reduce E-FACTOR*
* E-FACTOR = kgs waste generated per kg product
Newreka as an Enviropreneur
All Unit Processes use H2O / Solvent as a Reaction Medium or Extraction Medium
Reduction, Condensation, Nitration, Diazotization, Hydrolysis, Methylation, etc.
Use is spread across all Industrial Sectors Pharma, Dyes, Pigments, Specialty & Fine Chemicals, Agro, etc.
High Volume Products generate huge quantities of waste
like H-Acid, DASDA, Paracetamol, Phenylephrine, Pigment CPC, Violet23, Pendimethylene..
Focus: Reducing E-FACTOR (Recycle of Aqueous & Solvent Effluent Streams)
Solvents61%
Water31%
Reactants & other
reagents8%
Solvent & Water contribute more than 90% of the Reaction Mass
Source Data: ACS GCI Pharmaceutical Roundtable benchmarking exercise 2007
Average composition of Effluents will be similar.
Recycle of Water & Solvent can take care of 90% of problem.
Average Composition of Reaction Mass
SOURCE: REACTION MEDIUM EXTRACTION
MEDIUM
After Process
AQUEOUS STREAM SOLVENT STREAM(acidic, neutral, or alkaline)
Raw Finished Organic Inorganic
Materials Product Impurities Impurities
Effluent Streams in Chemical Industry
AQUEOUS STREAMS SOLVENT STREAMS (acidic, neutral, alkaline)
Raw Finished Organic Inorganic
Materials Product Impurities Impurities
selectively removed
“RCatTM
” (customized proprietary catalytic formulation for Recycle @
Source) selectively & effectively removes undesired org. & inorg.
impurities such that the streams can be recycled back in the process.
Concept behind our Recycle Solutions
Industry Pharmaceutical
Customer One of the fastest growing Pharma Company in India
Product Anti – Retroviral (or Anti – Aids) Drug
Application prevents transfer of virus from mother to child
Our Context Enable our customer to supply drug to patients at affordable price so that our next generation is not contaminated with the virus
Convert entire API/Drug synthesis Green
Case Study
CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS
E-Factor 67 61 42 4
Effluent 4020 TPA 3660 TPA 1680 TPA 240 TPA Total = 9600 TPA(for 60TPA plant) (32,000 kgs per day)
GREEN CHEMISTRY SOLUTION BY NEWREKA
E-Factor 6 6 1 4
Effluent 360 TPA 360 TPA 60 TPA 240 TPA Total = 1020 TPA
Stage IIIChlorination
Stage IVReduction
Stage VStage IINitration
Stage IDiazo. & Hydrolysis
Stage VI
Stage IINitration
Stage IIIChlorination
Stage IVReduction
Stage IDiazo &Hydrolysis
Stage VIStage V
Case Study: Reducing E-Factor & Improving Yield
CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS
Th. Yield 1.01 1.41 1.12 0.826 = Overall Yield 1.317
Yield 0.80 0.53 1.05 0.73 = Actual Yield 0.325 (25% of Th.)
GREEN CHEMISTRY BASED PROCESS
Th. Yield 1.01 1.41 1.12 0.826
Yield 0.95 1.38 1.10 0.79 = Actual Yield 1.140 (86% of Th.)
250% Improvement in Yield
Stage IIIChlorination
Stage IVReduction
Stage VStage IINitration
Stage IDiazo. & Hydrolysis
Stage VI
Stage IINitration
Stage IIIChlorination
Stage IVReduction
Stage IDiazo &Hydrolysis
Stage VIStage V
Case Study: Improving Yield & Reducing E-Factor
Stage I : Diazotization - Hydrolysis
20% higher yield (higher conversion & selectivity, recycle of aq. acidic stream)
Decreased fresh water consumption in process by recycle of ML.
Elimination of one of the solvents from the process.
Replacing a Class I solvent with a safer solvent.
Stage II : Nitration
163% higher yield (higher conversion & selectivity, recycle of aq. stream).
Decreased fresh water consumption in process by recycle of ML.
Replacing a Class I solvent with a safer solvent.
Stage III : Chlorination
16% higher yield (increased conversion & selectivity).
Decreased fresh water consumption in process by recycle aq. acidic stream.
Replaced one solvent with another which is more effective & much safer to handle.
Recovery & reuse of some of the raw materials.
Stage IV : Reduction
23% higher yield (increased conversion & selectivity).
Eliminated use of two solvents from the process by using Water as the reaction & extraction medium
Decreased fresh water consumption in process by recycle of neutral ML.
Safer process since solvents are eliminated & high pressure reaction replaced by atmospheric pressure process.
Impact of Recycle Solution
Impact:
Industrial Green Chemistry based Solution impacted:-
1. Economics (RMC down by 40%)
2. Environment (E-Factor down by 90%)
3. Safety (H2, Ni, Chloroform, EDC, MeOH avoided)
The solution saved USD 125,000 per month.
Enhanced Quality was a Bonus.
Industries: Pharma, Dyes, Pigment, Agro, etc.
e.g. Pharma – 1 billion kgs per annum of Drugs
Products: huge volumes & huge E-Factors
Chemistries: Friedel Craft, Sulphonations, etc.
Effluent Streams: Solid, Liquid, Gaseous
Developing GC Tools: platform technologies
Opportunities in Industrial GC
Opportunities for Industrial GC
• Organized by • GCNC (Indian chapter of ACS-GCI)
• Newreka
• Supported by• Centre for GC&E at Yale
• Warner Babcock Institute of GC
• Department of S&T, Govt. of India
• Media Partners• Royal Society of Chemistry (RSC)
• DMG Worldmedia
• Chemical Industry Digest
Thank You
&
Wish all of You a
“Greener Future”from
Team Newreka