Process Optimization Center Concept Solution Providers

Size: px

Start display at page:

Download "Process Optimization Center Concept Solution Providers"

Bryce Ryan
5 years ago
Views:

1 MATRIC Europa Life Changing Innovation Process Optimization Center Concept Solution Providers Giorgio Borghi MD MATRIC Europa Cortona September 2010

2 WHY FLOW CHEMISTRY? MAIN ADVANTAGES OF FLOW CHEMISTRY: YIELD & SELECTIVITY INCREASE. MORE EFFECTIVE PROCESS CONTROL. MORE UNIFORM PRODUCT QUALITY. REDUCED NUMBER OF «TOUCHES». INCREASED SAFETY. ELIMINATE INTERMEDIATE STORAGE (FOOTPRINT, CAPITAL). FACILITATE «REACH» COMPLIANCE. ALL OF WHICH RESULT IN REDUCED COSTS.

3 WHY MICROFLOW CHEMISTRY? Reactor type Temperature Residence Time Yield Flask, 0,5 l -40 C 0,5 h 88% : Production (stirred vessel, 6m³) -20 C 5 h 72% Microreactor (lab) -10 C < 10 s 95% 5 Minireactors (production) -10 C < 10 s 92% Early Industrial Production Unit at Merck in Gernsheim, Improved solvent use - Reduced energy consumption - Reduced capital, less space - GREENER PROCESSING Flexible production SHORTER TIME TO MARKET. EXTENSION OF PATENT LIFE. Courtesy H. Wurziger, Merck KGaA

4 MANY DIFFERENT TYPES OF MICROREACTORS ALREADY EXIST CORNING SAS (F) IMM (D) TNO (NL) CHEMTRIX (UK, NL) AM TECHNOLOGY (UK) VAPOURTEC (UK) LITTLE THINGS FACTORY (D).

6 MODULE LIBRARY

7 Gen I Gen II scale out Stacking scale out Gen III scale out Gen I, II, III Production banks

8 BARRIERS TO SHORT TERM ADVANCES IN MICRO-CONTINUOUS PROCESSING REASONS CITED BY PHARMA COMPANIES FOR RELUCTANCE TO INTRODUCE NEW MICROTECHNOLOGIES NEED TO UNDERTAKE RE REGISTRATION PROCEDURES WITH AUTHORITIES DUE TO PROCESS CHANGE LACK OF INTEREST DUE TO SUNK CAPITAL SITUATION OUTSOURCING WITH TRADITIONAL CMO s LACK OF INTERNAL KNOW HOW RELUCTANCE TO ENGAGE CRO s (FEAR OF IP LOSS) LACK OF HUMAN AND CAPITAL RESOURCES FOR RESEARCH AND DEVELOPMENT MOST NEW PLANTS BASED ON MICROPROCESSING ARE BEING ESTABLISHED IN THE FAR EAST AND INDIA

9 EXPLORE THE CONCEPT OF AN INDEPENDENT REGIONAL PROCESS OPTIMIZATION RESOURCE CENTER THAT WILL HAVE PROVIDE ACCESS TO THE DEVELOPMENT OF NEW TECHNOLOGY FROM: UNIVERSITIES INDUSTRIAL CONSORTIA NATIONAL LABORATORIES RESEARCH INSTITUTES VENDOR COMPANIES

10 MATRIC Europa MISSION: Independent innovation organization servicing European and International manufacturers Focus on Chemical, Energy and Environmental Technologies API and specialty chemicals manufacture Green chemistry Alternative energy and energy efficiency Pollution control Unique Capabilities and Impacts Process Innovation Process Integration Process Intensification Basing its commercial viability on contract work and development of Intellectual Property Built on successful business model from United States

MATRIC - MIDDLE ATLANTIC TECHNOLOGY, RESEARCH AND INNOVATION CENTER MATRIC is non profit research and development corporation formed in 2004 Reinvest earnings in new research Offices in throughout

11 MATRIC - MIDDLE ATLANTIC TECHNOLOGY, RESEARCH AND INNOVATION CENTER MATRIC is non profit research and development corporation formed in 2004 Reinvest earnings in new research Offices in throughout the USA Research and engineering staff of over PhD level researchers 25+ average years of experience 2 members of National Academy of Engineering MATRIC has a focus on developing Intellectual Property for commercial and industrial customers Significant portfolio of over 100 projects and a variety of customers Large industrial customers (Chevron, Exxon, Dow, UOP) Small innovation companies (BEST Energies, DNP, Novamer) Government agencies (Energy, Defense, NASA, EPA) MATRIC was formed from the downsizing of over 2000 research scientists and engineers located at the Union Carbide Tech Center, South Charleston, WV from

12 MATRIC S THREE STEP APPROACH TO TECHNOLOGY COMMERCIALIZATION 1. Do the necessary research, development and engineering to define the technology, process or product. 2. Develop an intellectual property (IP) package which defines the technology, process or product, and if warranted, develop and carry out a patent strategy. 3. Either start up a new company to carry out the commercialization or license the IP, receiving royalties for its use. Two licenses and 12 companies started using MATRIC intellectual property

13 MATRIC GREEN CHEMISTRY ACTIVITIES DEVELOPED A CONTINUOUS BIODIESEL PROCESS THAT CAN USE CRUDE CORN OIL AS WELL AS CRUDE SOYBEAN OIL Developed a process to produce isosorbide from corn Developed new technology for refining fermentation ethanol that decreased energy usage by 40 percent Developed a process to produce a fermentation based deicer Made major improvements in the production of green polymers for two different companies Developed a low cost green solvent for coke production from coal for the steel industry Developed a biodegradable slide release agent for prevention of coal adhering to the sides of rail cars Solved some difficult solids handling and processing problems for a company with a large scale cellulose to ethanol pilot plant DEVELOPED A NEW BULLET PROOF PLASTIC THAT CAN REPLACE POLYCARBONATE DEVELOPED A PROCESS FOR TREATING GAS WELL WATER Developed Se removal technology for surface water DEVELOPING AL AND HG REMOVAL TECHNOLOGIES FOR SURFACE WATERS CO/CO2 utilization to make novel green polymers Anaerobic digestion of farm wastes to produce energy and value added products (Bioplex) Algae based fuels and products Inherent safety improvements in manufacture of highly reactive intermediates Olefins production from natural gas Use of oxy fuels for co production of power & chemicals Novel technology approaches for CO2 and SOx capture Biomass to gasoline Ethanol to more efficient fuels & specialty chemicals Novel biobased routes to acrylate products

14 MATRIC Europa located in the Insubria BioPark at Gerenzano Former multi national pharmaceutical research complex outside of Milan Available chemical and biological laboratories Utilizing technology developed at MATRIC, CPAC and other research centers

15 AFR evaluation tool: flexible with capability all the way to pilot scale

16 CURRENT GERENZANO LABORATORY REACTOR SET UP A1 A2 Reactor Block A Standard Reactor Blocks A + B : 1 SJI 2 SJH 6 RTH A3 A4 Reactor Block B A5

17 Corning LFR LFR = Low Flow Reactor

21 Research and Engineering Enterprise Supporting Processes Ability to offer innovation from laboratory discovery through operation of full scale production MATRIC Europa 21

technology (PAT) for pharmaceuticals and fine chemicals MATRIC Europa s labs in

22 Summary MATRIC Europa has access to a depth of expertise in process development at all scales Special focus will be on the use of microreactors and process analytical technology (PAT) for pharmaceuticals and fine chemicals MATRIC Europa s labs in Gerenzano offer the ability to test new chemistries and processes quickly and efficiently

23 Key Partnerships Engineering Organizations Research Universities, Institutes and Consortia Vendor Companies MATRIC Title Europa Provincial and National Government Agencies Trade Associations European Union Government LEVERAGING THE FULL CAPABILITIES OF MATRIC AND CPAC IN THE US MATRIC Europa 23

24 REACTORS AND PAT ARE ONLY PART OF THE STORY: PROCESS INTENSIFICATION REQUIRES THE INTEGRATION OF REACTORS, SEPARATION TECHNOLOGY AND ANALYTICAL TECHNOLOGY.

25 Thank you MATRIC Europa c/o Biopark Insubrias via Roberto Lepetit Gerenzano (VA), Italy contact: Europa.asp

Europa. Special Board Meeting March 20, Life-Changing Research and Innovation. Keith Pauley x81

Europa. Special Board Meeting March 20, Life-Changing Research and Innovation. Keith Pauley x81 Special Board Meeting March 20, 2009 Life-Changing Research and Innovation Keith Pauley Keith.Pauley@matricresearch.com 800-611-2296 x81 Chemical and Environmental Technologies Health and Life Sciences