Solutions for Greener Processes - IGCW 2019...Ms. Megha Shanbhag – Business Development Manager Founded in 2000 by technocrats from IIT-Bombay Engaged in developing, customizing

Solutions

for Greener Processes

Mrs. Ashwini Gunnal Kothe – R & D Manager

Ms. Megha Shanbhag – Business Development Manager

Founded in 2000 by technocrats from IIT-Bombay

Engaged in developing, customizing and commercializing GC&E based technologies in the chemical industry

Core competence – Nitro to Amine reduction

Registered as a not-for-profit in 2009

Accelerates the implementation of GC&E in the chemical industry

Industrial Green Chemistry World – A GCF initiative

1. Reality of our processes, plants and streams

2. Newreka’s Platform Technologies

3. Case studies, Advantages, Conclusion

4. How can we work together?

Reality of our processes,

plants and streams

Step 1 Step 2 Step 3 Step 4

Step 1 2 - 3 Raw Materials

Reaction Medium &

Extraction Medium

Intermediate/Product

Effluents

Reaction & Extraction Medium Intermediate/Product By-products Organic Impurities Inorganic Impurities

Realities of our processes, plants and streams

Manufacturing Site

Mfg. Block for

Campaign

Products

Mfg. Block for

Dedicated

Products

Dedicated

Product

Step 1 Step 2 Step 3

Product 1 Product 2 Product 3

Step 1 Step 2 Step 3

Step 1 Step 2 Step 3 Step 4

Step 1 Step 2

Realities of our processes, plants and streams

Each effluent stream has its own

Physical properties

Chemical composition

Volume

Characteristics

Toxicity & hazard

What we end up with: Multiple effluent streams, each of different volume and characteristics

Realities of our processes, plants and streams

Effluent stream from

dedicated products Effluent stream

from product 1

Effluent stream

from product 2

Effluent stream

from product 3

Cocktail of 40 - 50

different chemicals

End-of-the-pipe Treatment (primary & secondary treatment, triple effect

evaporator, incineration, solid waste disposal sites, land

fill, etc.)

Our Environment

Impossible

to

separate,

recover or

recycle

Realities of our processes, plants and streams

E-Factor = Kg of waste generated/Kg of final product

Sector Avg. global production

(bn kg)

Avg. no of steps

Avg. E-Factor

Avg. Aqueous E-Factor

Avg. vol. of liquid effluent

(bn lt)

Avg. COD (lacs)

Toxicity

Pharma 1 7+ 50+ 30-40% 15-20 3-4 V. high

Fine Chem

2 3+ 25+ 60-70% 30-35 2-3 High

R. A. Sheldon, Consider the Environmental Quotient, Chemtech,. March 1994, 38-47

Above figures are indicative only

Liquid Effluents

ETP and CETP

Conversion of waste from one form to another

Cost-centric approach (Capital investment, space and energy intensive)

Waste of resources due to valuable chemicals being incinerated/disposed off

Zero Liquid Discharge

Purify and recycle all the wastewater produced

Industrial Ecology

Waste from one process becomes input for another process

Realities of our processes, plants and streams

Green chemistry-based approach • Resource-efficient • Inherently safer design of molecules, materials, products and processes

Newreka’s is one such green chemistry tool

Realities of our processes, plants and streams

Step 1 Step 2 Step 3 Step 4

2 - 3 Raw Materials

Reaction Medium

Extraction Medium

Finished Product

Effluents Step 1

Reaction & Extraction

Medium

By-products

Organic Impurities

Inorganic Impurities

Recycle@SourceTM

Realities of our processes, plants and streams

Proven Platform

Technologies and Case

Studies

Newreka Reduction Technology (NRT)

Nitro to Amine

Dinitro to Diamine

Nitroso to Amine

Oxime to Amine

Newreka Recycle Solution (NRS)

Acidic Effluent Stream

Neutral Effluent Stream

Alkaline Effluent Stream

Solvent Effluent Stream

Proven Platform Technologies and Case Studies

Making Molecules Green

Product: Pharma Intermediate (Anti-Aids Drug)

No. of Steps: Four

Existing E-Factor: 175 (i.e. 175kgs waste/kg product)

Making Chemistry Green

Product: Pharma Intermediate (Anti-Aids Drug)

Chemistry: Reduction

Conventional Technology: Catalytic Hydrogenation

Making Streams Green

Product: Pharma Intermediate (Decongestant Drug)

Stream: Acidic stream from Diazotization-Hydrolysis

Existing Disposal Method: Neutralization & incineration

Proven Platform Technologies and Case Studies

Case Study: Making Molecule Green

CONVENTIONAL SYNTHETIC CHEMISTRY PROCESS

Stage I Diazo. & Hydrolysis

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 II Nitration

Stage III Chlorination

Stage IV Reduction

Stage V Stage VI

Stage I Diazo. & Hydrolysis

Stage II Nitration

Stage III Chlorination

Stage IV Reduction

Stage V Stage VI

E-Factor 6 6 1 4 Effluent 360 TPA 360 TPA 60 TPA 240 TPA Total = 1020 TPA

Case Study: Making Chemistry Green

Chemistry with Core Competence Reduction

Functional Groups reduced Nitro to Amine

Dinitro to Diamine

Nitroso to Amine

Oxime to Amine

Conventional Technologies Catalytic Hydrogenation (Raney Ni, Pd/C)

replaced Metal-Acid reductions (Iron or Zn/HCl)

Hydrazine Hydrate

Sodium Sulphide reductions

Extraordinary results a. no dehalogenation in halogen

substituted substrates

b. selective reduction of nitro group in presence of other competing groups

c. freedom from poisoning in sulphur substituted substrates

Newreka Reduction Technology

Basis of Newreka Reduction Technology (NRT)

Based on the concept of Hydrogen Transfer Catalysis (HTC) using Iron

based reducing agent

Salient Features of NRT

a. Mild operating conditions (atm. pressure, temperature < 100oC, pH - 5

to 7)

b. Reaction Medium - Usually Water (no solvent required in reduction in

most cases)

c. No acids or alkali used in process

d. Safe reducing agent (avoids use of pyrophoric catalyst like Raney Ni)

e. High surface area of reducing agent

Case Study : Making Chemistry Green

Unit Process : Reduction Conventional Technology

Feedback from customer: Recycling mother liquor for over 2 years now.

Over 800 batches (at times on campaign basis)

Just make-up for Water loss (saved millions of lit of fresh water)

Amine Quality – 99%+ on HPLC, 10% Yield improvement

Case Study: Newreka Reduction Technology (NRT)

Patented

Technolog

y

NRT: Amine soluble at Alkaline pH

NRT: Amine soluble in Immiscible Solvent

NRT: Amine soluble in Miscible Solvent

1. Water as “Reaction Medium”

2. Atm. Pr., Nominal pH & Temp

3. Neutral ML Recycled 25 times

4. 95% of Theoretical Yield

5. White to Off-White Amine

6. Freedom from Solvents

7. Energy efficient

8. Safe Raw Materials, No Acids or Alkali

1. Solvent as “Reaction Medium”

2. High Pressure

3. Effluent containing Organics both

Solvents & Amine

4. 85% of Theoretical Yield

5. Brown Colored Amine

6. 2 Solvents used

7. Energy Intensive process

8. Hazardous Raw Materials like Raney Ni

& Hydrogen Gas

A Comparison of Conventional Technology & NRT

Case Study : Newreka Reduction Technology (NRT)

Unit Process : Diazotisation Conventional Technology

Case Study : Making Streams Green

Unit Process : Diazotization Newreka Recycle Solution (NRS)TM

Case Study : Making Streams Green

1. Recycle of ”Reaction Medium” 75 times

2. 50% Savings in Sulphuric Acid

3. Freedom from CuSO4 and Acetic Acid

4. 95% of Theoretical Yield

5. Yellow Colored Product

6. Water as Extraction Medium, Freedom from Solvent

7. Energy efficient

1. Highly Acidic Liquid Effluent

2. Sulphuric Acid – 2 Times

3. Use of CuSO4 & Acetic Acid which don’t participate

4. 70% of Theoretical Yield

5. Brown Colored Product

6. Solvent as Extraction Medium

7. Energy Intensive process

A Comparison of Conventional Technology & NRS

Case Study : Making Streams Green

Pharma Industry – Multiple products, multi-step process & each process generates a different type of effluent stream

Multiple effluent streams with widely differing quantities & characteristics

Our molecules are complex, very less idea about their environmental consequences

Concern for not Recycling – completely valid

Can explore Recycle@SourceTM in early stage pharma synthesis

Volumes of intermediates (hence effluents) usually high

Usually involves chemistries which inherently create pollution

Non DMF steps

Less Regulatory constraints

Easier to get customer’s approval

Conclusions

How can we work together?

Core competence

Nitro to Amine reduction

Diazotization

Nitration

Business Work Flow

Identification and Initiation

Invention and Innovation

Implementation and Industrialization

How can we work together?

1. Identification and Initiation

Sign a Confidentiality Agreement

Understand customer’s requirements

Submit a detailed proposal

Sign a Commercial Agreement

How can we work together?

2. Invention and Innovation

Begin the R&D process based on specific customer expectations

Demonstration of technology by our lab demo team at customer’s lab

Demonstration of process by our plant demo team at customer’s plant

How can we work together?

3. Implementation and Industrialization

Supply our customized, consistent quality catalytic formulations, G-Cat and R-Cat

Ongoing customer service & technical support: trouble shooting and optimization

How can we work together?

Prefeasibility Study

Exploratory research for new domains and chemistries

Reduced risk for both organizations

Commencement of full-fledged project in case of positive results

Core capabilities Recycle of

Neutral effluent streams

Acidic effluent streams

Alkaline effluent streams

Solvent effluent streams

How can we work together?

Visit our EXPO stalls #37 and #38

[email protected]

[email protected] Ph.: +91-022-28791275 +91-022-28791835 Fax: +91-022-28794790 www.newreka.co.in

Thank you