"Recycle@Source - An Effective Alternative to End of the Pipe Treatment" a presentation on implementing Green Chemistry by Mr. Nitesh Mehta from Newreka (http://bit.ly/datnAG) on a phone seminar to The Great Lakes Green Chemistry Network.

1. Recycle@Source :An effective
TM
alternative to End of the
Pipe Treatment
Nitesh H. Mehta
Founder Director
Newreka Green-Synth Technologies Pvt. Ltd.
Mumbai, India
nitesh.mehta@newreka.co.in
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2. Flow
 “Recycle” – context & scope of this presentation
 E-Factor & magnitude of challenge
 Why “End of the Pipe Treatment”?
 Recycle@Source
 A Case Study
 Advantages of Recycle@Source
 Green Chemistry in India
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3. “Recycle” – context & scope
 “Recycle” – widely use terminology
 plastics, cans, paper, e-waste, sewage, etc.
 Context in this presentation
 liquid effluents generated by process industry
 Scope of this presentation
 pharma, specialty & fine chemicals industry
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4. “E-Factor” – magnitude of challenge
 Why Pharma, Specialty & fine chemicals industry?
Source: R A Sheldon
Sector E - Factor Product Tonnage
Oil Refining ≤ 0.1 106 - 108
Bulk Chemicals 1–5 104 – 106
Fine Chemicals 5 – 50+ 102 – 104
Pharmaceuticals 25 – 100+ 10 - 103
E - Factor or Environmental Impact Factor (defined as kgs of waste / kg of product)
 Magnitude of challenge?
 Approx. 1 bn kgs of API being manufactured every year
 Effluents generated by pharma industry per year = 25 to 100 bn kgs
 All industry sectors together, effluents per year = ?? (unimaginable)
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5. “E-Factor” – magnitude of challenge
Basis: 1MT of Chemical Intermediate = 10,000 lit of liquid effluents
(assuming a very conservative E-Factor of 10)
1lit of liquid effluent (high COD, BOD & toxic sub.) has potential to
contaminate = approx. 1000 lit of clean water in rivers, lakes, etc.
1 normal human being consumes = approx. 100 lits water / day
1MT of Chem. Intermediate = 100,000 peoples water security at stake
10’s of millions of tons of Chemical Intermediates we make every year
= ???? Serious impact on the water security of all humans
Need to explore ways to accelerate implementation of
Green Chemistry & Green Engineering.
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6. Why “End of the Pipe Treatment?”
Nature of Pharma & Specialty Chemical manufacturing:
• Complex molecules & multi-step synthesis
• Chemistry Intensive processes
• Stringent quality & regulatory requirements
The above leads to High E - Factor or Environmental Impact Factor
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7. Why “End of the Pipe Treatment?”
Step 1 Step 2 Step 3 Step 4
Intermediate or
2 - 3 Raw Materials
Finished Product
Reaction Medium Step 1
Effluents
Extraction Medium Reaction & Extraction
Medium
By-products
Organic Impurities
Inorganic Impurities
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8. Why “End of the Pipe Treatment?”
Step 1 Step 2 Step 3 Step 4
Effluent 1: Effluent 2: Effluent 3: Effluent 4:
4 - 5 different 4 - 5 different 4 - 5 different 4 - 5 different
chemicals chemicals chemicals chemicals
Cocktail of 20 - 25
different chemicals
Impossible
to
No option except separate,
Effluent Treatment Plant or recover or
Incineration recycle
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9. Why “End of the Pipe Treatment?”
Impact: huge threat to water bodies & human health
 Quantity – 25 to 100 bn kgs per annum only from Pharma
 Outcome – converting one kind of effluent in to other
 Toxicity – not fully known (Ecotoxicity data available for less than 1%
of human pharmaceuticals…Ref: journal “Regulatory
Toxicology & Pharmacology, April’2004)”
 Degradation – very slow, impact unknown after degradation
Examples:
 Feb 2009, Pharma Zone in Central India – River water sample
analyzed by a professor from Sweden. This supposedly treated water
was a soup of 21 different APIs.
 2007, River in China – effluent from a contraceptive manufacturing
plant contained 10 times of Oestrogen required to collapse fish
population.
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10. Recycle@Source
TM
Solvent & Water contribute more than 90% of the Reaction Mass
Reactants
& other
reagents
8%
Water
31% Solvents
61%
Source Data: ACS GCI Pharmaceutical Roundtable benchmarking exercise 2007
Most cases, average composition of Effluents will be close to
composition of reaction & extraction medium.
Recycle of reaction & extraction medium can take care of 90% of
effluent problems.
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11. Recycle@Source
TM
Step 1 Step 2 Step 3 Step 4
2 - 3 Raw Materials Finished Product
Reaction Medium Step 1 Effluents
Extraction Medium Reaction & Extraction
Medium
By-products
Organic Impurities
Inorganic Impurities
TM 11
Recycle@Source

12. A Case Study
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/Drugs synthesis in to Green
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13. A Case Study – Impact on E-Factor
CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS
Stage I
Diazo. & Stage II Stage III Stage IV Stage V Stage VI
Hydrolysis Nitration Chlorination Reduction
E-Factor 32 38 28 4 Effluent
1920 TPA 2280 TPA 1680 TPA 240 TPA Total = 6120 TPA
(for 60TPA plant) (20,000 kgs per day)
GREEN CHEMISTRY SOLUTION BY NEWREKA
Stage I
Diazo & Stage II Stage III Stage IV Stage V Stage VI
Hydrolysis Nitration Chlorination Reduction
E-Factor 6 6 1 4
Effluent 360 TPA 360 TPA 60 TPA 240 TPA Total = 1020 TPA
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14. A Case Study – Impact on Yield
CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS
Stage I
Diazo. & Stage II Stage III Stage IV Stage V Stage VI
Hydrolysis Nitration Chlorination Reduction
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
Stage I
Diazo & Stage II Stage III Stage IV Stage V Stage VI
Hydrolysis Nitration Chlorination Reduction
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 14

15. Advantages of Recycle@Source
 Preventive approach vis-à-vis remedial approach
 Profit center based approach vis-à-vis cost center
based approach
 Positively impacts triple bottom line of
 Profit
 People
 Planet (Environment & Energy)
 Enhanced yields, lower raw material consumption, lower
E-Factor, lower effluent treatment costs, enhanced
productivity
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16. Green Chemistry in India
• Academics : Researchers, scientists and students are pursuing the emerging
frontiers of Green chemistry like Bio Transformation, Nanocatalysis,
Nanotechnology, Micro reactors, renewable feedstock etc for cutting edge
research.
• Indian government's Department of Science and Technology has set up a
Green Chemistry task force to promote green chemistry in research and in
university curricula from the undergraduate through post-graduate levels.
• Green Chemistry Network Centre, India organizes various seminars and
workshops to create awareness and promote Green Chemistry in India.
• Green Chemistry Network Centre India has also established a green chemistry
awards program to recognize and promote work in the field.
• Industries like Dr . Reddy’s Laboratories, Tata Innovation Centre , etc have taken up Green
chemistry based research and Innovations & driving GC within the organizations.
• Start up companies offering services/ solutions based on Green chemistry have started
showing up.
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17. Key Roadblock in Implementation of GC
Universities: Industry:
1. Limitations to 1. Profit Driven Approach
Customize, Scale-up & 2. Limitation to approach
Commercialize & define their problems
2. Limitations to Market 3. Mindset of not investing
their Innovations on Green R&D
Govt. Bodies & NGO’s: Common Man &
1. Formulations of practical Society:
policies. 1. Lack of Awareness
2. Carrot & Stick Approach 2. Mindset of not investing
3. Limitations of paperwork on Education &
& bureaucracy Research
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18. Attempt to bridge the gap
Universities: Industry:
1. Limitations to 1. Profit Driven Approach
Customize, Scale-up & 2. Limitation to approach
Commercialize & define their problems
2. Limitations to Market 3. Mindset of not investing
their Innovations Industrial on Green R&D
Green
Chemistry
World
(IGCW) Common Man &
Govt. Bodies & NGO’s: Society:
1. Limitations of 1. Lack of Awareness
paperwork & 2. Mindset of not investing
bureaucracy on Education &
2. Carrot & Stick Research
Approach
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19. IGCW- a global platform for:
IGCW Expo: Showcasing innovations in industrializing GC&E
technologies
Partners Case-study Presentations: Sharing emerging &
innovative technologies in the Industrial world of GC&E
IGCW Innovators’ Award: Recognizing & Felicitating GC&E
Initiatives
Exploring A,B,C of GC&E: Customized one day seminars
for Scientists & engineers
e - learning GC&E concepts & practices for various
stakeholders
e - Connecting GC&E community through online
networking
platform
Shaping future: GC&Ewww.industrialgreenche
training workshops for Teachers and
Students m.com
Organizer: Green ChemisTree 19
Foundation

20. Thank You
&
Wish all of You a
“Greener Future”
from
Team Newreka
Contact
Email : nitesh.mehta@newreka.co.in
Web : www.newreka.co.in
Phone : +91 22 2879 1235
Fax : +91 22 28794790
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