the role of flow chemistry in sustainable chemical ... · •low chemistry f provides new paradigm...
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![Page 1: The role of flow chemistry in sustainable chemical ... · •low chemistry F provides new paradigm for fine chemical manufacture •Key benefits – Better process control (less waste)](https://reader034.vdocuments.us/reader034/viewer/2022050513/5f9d9867f3bbe17df54384d2/html5/thumbnails/1.jpg)
The role of flow chemistry in
sustainable chemical manufacturing
John Tsanaktsidis| Chief Research Consultant
22 November 2014
MANUFACTURING FLAGSHIP
WASTECH International Summit & Expo , 21-22 November 2014 Mahatma Mandir, Gandhinagar, Gujarat, India
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Agenda
• CSIRO
• The global chemical economy
• Conventional Batch Manufacture
• Continuous flow processing – Flow Chemistry
• Case studies
• Summary & conclusion
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CSIRO – Delivers solutions through Flagships
Commonwealth Scientific and Industrial Research Organisation
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CSIRO – Impact through Innovation
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CSIRO – Our partners are local and global
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Chemical manufacturing is a global business
• The chemical industry is global, and
• underpins the modern world economy
• Uses existing (oil, natural gas, water, metals, & minerals) and renewable
(crops) raw materials to produce >140,000 products
• Represents a $4.12 trillion (2010) global enterprise*
– growing by ~3% pa
* UNEP report, Global Chemical Outlook 2012
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Conventional batch manufacture of chemicals
• Batch processing
– mainstay of fine chemical & pharmaceutical industries
• Capital & labour intensive
– high capital, operation & maintenance costs
• Waste intensive
– 5-100+ kg of chemical wastes per kilogram of fine chemicals & pharmaceuticals produced
• Safety issues
– high risk of exposure, runaway reactions, catastrophic events....
Discovery Development Pilot scale Batch manufacturing scale
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However, ....
“The chemical sector has long been viewed by wider society as being ‘dirty’; ....”
Green Chem., 2012, 14, 38
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175 times, and then....
T2 Laboratories, Florida
• Production of fuel additive - methylcyclopentadienyl manganese tricarbonyl
• Catastrophic thermal runaway lead to Plant destruction!
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So how do we do it better?
• Better chemical processes
• Higher yields
• Fewer by-products
• Less waste
• Shorter processing times
• Smaller plant footprint
• Lower plant & operating costs
• Safer processes & processing
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Process intensification
• Deep understanding of the underlying chemistry
• Use of intensive reactor technologies
• Transition from batch to continuous processing
• Modular plug & play approach
• mix of process technologies (batch & continuous)
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Flow chemistry
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5 - 40mL reactor volume; up to 250 oC; up to hundreds of grams per day
Flow reactors – Laboratory scale
Vapourtec R2/R4 Uniqsis FlowSyn
CRD Polar Bear
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Flow reactors – Pilot and industrial scale
CRD Shell and Tube reactor
100mL- 2L, up to 250 oC & 30bar, up to hundreds of kilograms per day
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Chemtrix MR260 plate reactor
100mL+, up to 250 oC & 20bar, multi-kilograms per day
Chanel dimensions 2.0 x 2.0mm
Flow reactors – Pilot and industrial scale
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Flow chemistry – Critical process parameters
Reaction Temperature
Residence Time (in flow reactor)
Concentration (stoichiometry)
Pressure
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Flow chemistry – Key attributes & benefits
• Better process control
• higher product yields & purities,
• shorter processing times,
• less waste generation
• Easily (infinitely) scalable
• Temporal relationship, not spacial
– Scale = Total Flow Rate x Time
• Smaller physical footprint
• Reduced capital, operating & maintenance costs - reduced energy usage
• Inherently safer
• Lower risk of catastrophic events & exposure
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Case study 1: Production of a pharmaceutical
Pilot-scale API manufacture
Reaction time: 2 min in flow vs 2days in batch Yield: ~100% increase over batch process Purity: cleaner crude product � simpler purification Throughput: Flexible; infinitely scalable Plant costs: About 1/10th the cost of a batch plant
John Tsanaktsidis, unpublished data
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Case study 2: Synthesis of a photochromic dye
• 9 step synthesis ; 8 steps done in in flow (1kg scale)
Mark York, unpublished data
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Case Study 3: Fine chemicals from refined sugars
Carbohydrate
g/10 mL (conc.)
Solvent T (ºC) Flow Rate (mL/min)
RT (min)
Yield (%)
Sucrose (10g) 1.0 (0.29 m) DCE 130 5 + 5 1 61
D-glucose 0.2 (0.11 m) DCE 120 1 + 1 5 58
D-fructose (10g) 1.0 (0.56 m) CH2Cl2 100 5 + 5 1 79
M. Brasholz, K. von Kaenel, C. H. Hornung, S. Saubern, J. Tsanaktsidis, Green Chemistry, 2011, 13, 1114
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Case Study 4: Polymer synthesis
before thermolysis after thermolysis
Christian Hornung , unpublished data
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Summary & conclusions
• Sustainable chemical manufacturing is essential!
• Competitive advantage
• Reduced environmental footprint
• Flow chemistry provides new paradigm for fine chemical manufacture
• Key benefits
– Better process control (less waste)
– Infinite scalability
– Small physical footprint
– Better safety
• Take home
• Fine chemicals can be manufactured at scale, with better quality outcomes (yield, purity), at lower cost, & with better safety.
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CSIRO MANUFACTURING FLAGSHIP
Thank you
Dr John Tsanaktsidis
Chief Research Consultant