recycle solution - reduce e-factor for pharma intermediates by 90%

RECYCLE SOLUTIONS

Reduce E-Factor for Pharma Intermediates by 90%

Nitesh H. MehtaFounder DirectorNewreka Green Synth Technologies Pvt. Ltd.Mumbai, India

nitesh.mehta@newreka.co.in

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