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Recycle Solution - Reduce E-Factor for Pharma Intermediates by 90%

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Reduce E-Factor for Pharma Intermediates by 90%

Reduce E-Factor for Pharma Intermediates by 90%

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  • 1. RECYCLE SOLUTIONS Reduce E-Factor for Pharma Intermediates by 90% Nitesh H. Mehta Founder Director Newreka Green Synth Technologies Pvt. Ltd. Mumbai, India [email_address]
  • 2.
      • 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
  • 3.
    • Universities:
    • Limitations to Customize, Scale-up & Commercialize
    • Limitations to Market their Innovations
    • Industry:
    • Profit Driven Approach
    • Limitation to approach & define their problems
    • Mindset of not investing on Green R&D
    • Common Man & Society:
    • Lack of Awareness
    • Mindset of not investing on Education & Research
    • Govt. Bodies & NGO’s:
    • Formulations of practical policies.
    • Carrot & Stick Approach
    • Limitations of paperwork & bureaucracy
    Roadblocks in Implementation of GC
  • 4. 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
  • 5.
    • 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
  • 6.
    • 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
  • 7.
    • 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
  • 8. 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
  • 9.
    • Universities:
    • Limitations to Customize, Scale-up & Commercialize
    • Limitations to Market their Innovations
    • Industry:
    • Profit Driven Approach
    • Limitation to approach & define their problems
    • Mindset of not investing on Green R&D
    • Common Man & Society:
    • Lack of Awareness
    • Mindset of not investing on Education & Research
    • Govt. Bodies & NGO’s:
    • Limitations of paperwork & bureaucracy
    • Carrot & Stick Approach
    Enviropreneurs “ Enviropreneurs” - A Possible Bridge
  • 10.
    • Enviropreneurs = Enviro nment + Entre preneurs
    • 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”
  • 11. 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
  • 12.
    • All Unit Processes use H 2 O / 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)
  • 13. 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
  • 14. 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
  • 15. AQUEOUS STREAMS SOLVENT STREAMS (acidic, neutral, alkaline) Raw Finished Organic Inorganic Materials Product Impurities Impurities selectively removed “ RCat TM ” (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
  • 16. 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
  • 17. 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 Case Study: Reducing E-Factor & Improving Yield Stage III Chlorination Stage IV Reduction Stage V Stage II Nitration Stage I Diazo. & Hydrolysis Stage VI Stage II Nitration Stage III Chlorination Stage IV Reduction Stage I Diazo & Hydrolysis Stage VI Stage V
  • 18. 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 Case Study: Improving Yield & Reducing E-Factor Stage III Chlorination Stage IV Reduction Stage V Stage II Nitration Stage I Diazo. & Hydrolysis Stage VI Stage II Nitration Stage III Chlorination Stage IV Reduction Stage I Diazo & Hydrolysis Stage VI Stage V
  • 19. 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.
  • 20. 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.
  • 21. 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.
  • 22. 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.
  • 23. Impact of Recycle Solution
    • Impact:
    • Industrial Green Chemistry based Solution impacted:-
        • Economics (RMC down by 40%)
        • Environment (E-Factor down by 90%)
        • Safety (H 2 , Ni, Chloroform, EDC, MeOH avoided)
    • The solution saved USD 125,000 per month.
    • Enhanced Quality was a Bonus.
  • 24.
    • 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
  • 25.
    • 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
    Opportunities for Industrial GC
  • 26. Thank You & Wish all of You a “ Greener Future” from Team Newreka