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

nitesh.mehta@newreka.co.in

Recycle@SourceTM:An effective alternative to End of the Pipe Treatment

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“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

Flow

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“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

“Recycle” – context & scope

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Why Pharma, Specialty & fine chemicals industry?

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)

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” – magnitude of challenge

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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.

“E-Factor” – magnitude of challenge

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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

Why “End of the Pipe Treatment?”

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Step 1 Step 2 Step 3 Step 4

2 - 3 Raw Materials

Reaction Medium

Extraction Medium

Intermediate or Finished Product

EffluentsStep 1

Reaction & Extraction MediumBy-productsOrganic ImpuritiesInorganic Impurities

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Why “End of the Pipe Treatment?”

Step 1 Step 2 Step 3 Step 4

Effluent 1: 4 - 5 different chemicals

No option except Effluent Treatment Plant or

Incineration

Cocktail of 20 - 25 different chemicals

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Why “End of the Pipe Treatment?”

Impossible to

separate, recover or

recycle

Effluent 2: 4 - 5 different chemicals

Effluent 3: 4 - 5 different chemicals

Effluent 4: 4 - 5 different chemicals

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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Why “End of the Pipe Treatment?”

Recycle@SourceTM

Solvents61%

Water31%

Reactants & other reagents

8%

Solvent & Water contribute more than 90% of the Reaction Mass

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.

Source Data: ACS GCI Pharmaceutical Roundtable benchmarking exercise 2007

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Step 1 Step 2 Step 3 Step 4

2 - 3 Raw Materials

Reaction Medium

Extraction Medium

Finished Product

EffluentsStep 1

Reaction & Extraction MediumBy-productsOrganic ImpuritiesInorganic Impurities

Recycle@SourceTM

Recycle@SourceTM

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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

A Case Study

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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

A Case Study – Impact on E-Factor

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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

A Case Study – Impact on Yield

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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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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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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

Key Roadblock in Implementation of GC

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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

Industrial Green

Chemistry World(IGCW)

Attempt to bridge the gap

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Partners

Organizer: Green ChemisTree Foundation

IGCW Expo: Showcasing innovations in industrializing GC&E technologies

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&E training workshops for Teachers and Students

IGCW- a global platform for:

www.industrialgreenchem.com

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Thank You

&

Wish all of You a

“Greener Future”from

Team Newreka

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ContactEmail : nitesh.mehta@newreka.co.inWeb : www.newreka.co.inPhone : +91 22 2879 1235Fax : +91 22 28794790