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Green Chemistry in Real World Practices - Pharmaceutical Industry Experience
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Green Chemistry in Real World Practice
Case Study from Pharmaceutical Industry
Nitesh H. MehtaFounder DirectorNewreka Green Synth Technologies Pvt. Ltd.Mumbai, India
nitesh.mehta@newreka.co.in
sharing context – a possible context for all
status of effluents in Pharma Industry
application of Green Chemistry
brief background about Newreka
a case study
opportunities
Agenda
This is the only World that exists.
Real World ??
There is no other world. Then why specifically say “Real World” ??
Green Chemistry in Real World Practice
World of Chemists, Chemical Engineers, Researchers & Scientists:
new fields or areas like Nano complex mechanisms fascinating instruments publications …….etc.
May be: to distinguish it from our individual worlds
Green Chemistry in Real World Practice
None of the above is a problem.
Problem starts, when these become the ultimate objective, instead of larger causes like:
reducing environmental footprint of industry making our industry competitive v/s china safety of shopfloor operators drugs being available at affordable prices clean water for all biodegradable/recyclable consumer products energy conservation, optimizing utilitzation …….etc
Green Chemistry in Real World Practice
World of Chemists, Chemical Engineers, Researchers & Scientists:
new fields or areas complex mechanisms fascinating instruments publications …….etc.
Green Chemistry in Real World Practice
A possible Context to operate from:
All the above are tools or resources, useful for the purpose of serving society, our nation & our world to make it a better place to live.
E - Factor for Manufacturing Sectors
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
Source: R A Sheldon
E - Factor = Total waste generated per kg of Product
E - Factor for Pharmaceutical Sector
Stage Average E - Factor
Pre Clinical 185 kg Material Use / kg API
Phase I 123 kg Material Use / kg API
Phase II 117 kg Material Use / kg API
Phase III 96 kg Material Use / kg API
Commercial 45 kg Material Use / kg API
Source Data: ACS GCI Pharmaceutical Roundtable benchmarking exercise 2007
Pharmaceutical Ind. annually makes 1bn kgs drugs
When to implement “Green Chemistry”?
Pre Clinical No. of molecules very high
Phase I No. of molecules still highVolumes involved very low
Phase II Limited No. of moleculesVolumes increased
Phase III No. of molecules further shortlistedVolumes further increased (kgs to ton)
Commercial DMF FiledVolumes high (tens of tons)
Phase II & Phase III : Right time to start exploring “Green Chemistry” based processes.Will ensure next generation drugs are manufactured through Green Processes.
When to implement “Green Chemistry”?
Potential Generics : molecules going off - patent in next 5 years
processes being used are “Synthetic Chemistry” based
same as was filed in DMF during launch (high E – Factor)
volumes expected to increase after patent expiry ( effluents )
price expected to crash after patent expiry (pressure on costing)
Generics : patents already expired
processes being used are “Synthetic Chemistry” based
mostly same as was filed in DMF during launch (high E – Factor)
volumes are high (huge quantities of effluents)
high competition (pressure on costing)
Potential Generics & Generics : ideal cases to start exploring “Green Chemistry” based processes.
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 : Brief Introduction
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
Industry Pharmaceutical
Customer One of the fastest growing Pharma Companyin 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 Green
Case Study
CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS
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
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
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 III : 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.
Inside the larger context of serving our society, our nation & our Real World, there are following opportunities for us:
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 for all of us
Opportunities for all of us
Our world needs Chemists & Chemical Engineers operating from larger context of :
“Making a Difference to the world through their work”.
Thank You
&
Wish all of You a
“Greener Future”from
Team Newreka
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