Continuous Crystallisation and Manufacture

Transcription

1 Continuous Crystallisation and Manufacture Professor Xiong-Wei Ni, BSc, PhD, CEng, CSci, FIChemE, FRSC Founder and Technical Director Cammo Place, Edinburgh EH4 8EN, UK Achema 18 th June 2015

2 Structure 1. Background on crystallisation science and technology ( Why do we flow? ) 2. NiTech continuous crystalliser ( How do we flow? ) 3. Cases of continuous crystallisation ( What does flow deliver? ) 4. Key messages to take away

3 1. Background on crystallisation Scientific parameters Solubility Supersaturation Metastable Zone Width Nucleation mechanism & rate Growth mechanism & rate Product Crystal size and shape Morphology Purity Environmental parameters Concentration Temperature Cooling profile Mixing Solvent/additives Seeding Functionality (materials) Bio-availability (drugs) Surface activity (catalysts) Texture (foods)

4 Science of a cooling crystallisation Crystallisation pathway Concentration Supersolubility Labile Metastable Zone (MSZW) Solubility Under-saturated Supersolubility is thermodynamically not found and kinetically not well defined, depending on: Temperature profile Rate of generating supersaturation Solution history impurities Fluid dynamics Temperature Scale dependent parameter Ulrich & Strege, J. of Crystal Growth, Vol.237, p , 2002

5 How could the crystallisation environment affect the science?

6 MSZW ( o C) Crystallisation environment how mixing is generated and how intensive OBC (2007) 45g/L 0.5 C/min STC Liang (2002) 45g/L 0.5 C/min STC Liang (2002) 45g/L 0.5 C/min no vortex 5 Stirring vs. oscillating Power Dissipation (W m -3 ) Cooling crystallisation of L-glutamic acid

7 What do the data tell us? Crystallisation environment in terms of global and local mixing intensity affects MSZW, nucleation and growth Crystallisation environment in terms of how mixing being generated also influences crystallisation science

8 Crystallisation/manufacturing environment lab Uniform mixing/ Kinetic controlled regimes e.g. 30 mins pilot full scale Non uniform mixing/ Mass transfer controlled e.g. >30 hrs Crystallisation environment changes and gets worse with increasing scales

9 Industrial batch crystallisation Mixing gradient Concentration gradient supersaturtion gradient polymorph Concentration C MSZW Inconsistent morphology Wide size distribution Difficult to filter T Temperature Temperature MSZW and nucleation Polymorph gradient Crystallisation path & growth & size

10 Detail from an 1850 drawing of the London sugar refineries of Messrs. Fairrie and Co showing a copper crystallising pan for sugar. The worker to the right of the pan is holding a mallet that was used to bang on the pan to induce nucleation of the crystallisation process Book of Joel Is crystallisation science the dark science?

11 Science Solubility Supersaturation Metastable Zone Width Nucleation mechanism & rate Growth mechanism & rate Product Crystal size and shape Morphology Purity Environment Concentration Temperature Cooling profile Mixing Solvent/additives Seeding Functionality (materials) Bio-availability (drugs) Surface activity (catalysts) Texture (foods) It is the environment that prevents learnt crystallisation science to be executed in all scales!!

12 How could we improve crystallisation environment? How could we create a reactor system that allows kinetic controlled reaction times to be performed at lab scale as well as full scale?

13 The basis for continuous From the viewpoint of fluid mechanics i) consistent product quality can only be achieved in plug flows; ii) it is very rare to obtain plug flow conditions in batch STR! iii) Plug flow conditions can only be attained in continuous operation.

14 How to achieve plug flow a) Using a series of CSTRs.. Plug flow is achieved when the number of CSTRs approaches to infinite Conclusions: a) significant increase in inventory, running and capital costs b) far from plug flow

15 b) Employ a tubular reactor with or without inserts Operating a tubular reactor at turbulent flow regime in order to obtain near to plug flow Conclusion: a) significant high flow rates, leading to very long reactor and large capital costs b) very short residence time

16 Evolution of Manufacturing Technology for Chemicals Industry c present Little has changed in 450 years The stirred tank reactor is the normal approach for mixing, reaction, crystallisation and manufacture Particular challenges around the scale-up of processes Expensive, poor control over quality

17 2. NiTech Crystalliser

18 Demonstration of radial mixing Real system 3-D CFD simulation Re o = 1250 (x o = 4 mm, f = 1 Hz)

19 NiTech Continuous Crystalliser Conductivity probes Tracer Oscillation liquid Out No. of CSTR = 550 for a RT of 60 mins E ~ m 2 s -1 Probe meters away from injection Probe meters away from injection Probe meters away from injection

20 Heat Transfer on Scale-Up Volume (m 3 ) Area (m 2 ) Area / unit Volume (m 2 /m 3 ) Typical 90 litre STR Typical 6500 litre STR Typical 72m long 100mm diameter NiTech Reactor NiTech Crystalliser has larger specific surface area for heat transfer

21 Key differences from traditional tubular devices on the market Mixing is not controlled by net flow Plug flow achieved at laminar flows Good with solids Excellent heat & mass transfers No concentration gradients

22 Temp (oc) Temp (oc) Control over cooling profile oC Flow Rate L/min Cooling Rate 6.5oC/min y = x R 2 = y = x R 2 = y = x R 2 = y = x R 2 = y = x R 2 = Time (min) oc Flow Rate 0.3 L/min Cooling Rate 2.0 oc/min y = x R 2 = y = x y = x R 2 = R 2 = y = x R 2 = y = x R 2 = Time (min) Any cooling profile, e.g. linear, parabolic, non-continuous, stepwise and etc, can be obtained along NiTech Crystalliser Any lab monitoring tools can directly be implemented along NiTech Crystalliser without modification

23 Design and Operation a) Cooling crystallisation b) Anti-solvent crystallisation

24 a) A cooling crystallisation of API Conditions: Starting temperature (T start ) = 50 0 C Saturation temperature (T sat ) = 40 0 C End temperature (T exit ) = 10 0 C Seeding temperature (T seed ) = 39 0 C Maximum supercooling (or MSZW) = 3 0 C Crystallisation time = (50 40)C 10 C/min C 1 C/min = = 31 mins The minimization of mass/heat transfer constraints allows the straightforward and simple design of crystallisation processes

25 The layout and operation of a cooling crystallisation Seed Tank 20 C 30 C 10 C 4 5 Net flow velocity = Length Crystallisation time 20 m = =0.011 m/s 31 mins 39 C 3 40 C Collecting Tank Concentration Seeding Volumetric flow rate = 7.85x10-5 m 2 x m/s = 51.8 ml/min (Re = 110) 50 C Feed Tank Water Tank Temperature Successful running for 8 hrs until the seed tank has emptied

26 b) An antisolvent crystallisation to generate seeds API + solvent (IPA) antisolvent is water solvent flow rate antisolvent flow rate residence time initial supersaturation ratio, S run ml/min ml/min min A B C D E Solubility curve of API in IPA/water at 298 K

27 The layout and operation of an antisolvent crystallisation Continuously operated for 6.25 hrs until the feed tanks have emptied.

28 3. Applications Handling solids

29 Crystallisation The residence time in the NiTech Crystalliser translates to 12 minutes, compared to a batch cycle time of 9 hours 40 mins, demonstrating a significant potential improvement in throughput relative to a batch manufacturing facility. Organic Process Research & Development, 2009, 13,

30 Filtration index for a fine chemical product Concentration NiTech Crystalliser delivered Product characteristics/performance Consistent filtration index of 25 Temperature STC NiTech Crystalliser

31 crystal moisture contents of API NiTech Crystalliser STC Moisture content: 50% 73% Crystallisation achieved in 1/8 th of the time

32 Filtration time (min) Fractionation of edible oils Two stage cooling (17 and 0.3 o C/min) Consistent IV achieved Significant reduction of crystallisation time Improved filtration time Process Time (min) Benchmark T05C T08C T10C T11C T12C T13C T14C T16C

33 CMAC Mission: To establish a demand led, world class centre for continuous manufacturing research delivering impact across 3 key areas: products, processes and operation Industry: 3m (CMAC membership 3 tier 1 + tier 2s) EPSRC Centre: 9.1m (EPSRC, industry, HEIs) EPSRC Doctoral Training 6.9m (EPSRC, industry, HEIs) Scottish Funding Council / HEIs SPIRIT 1.5M (initial seed) HEIs general:.5m Strathclyde TIC Project: ~ 4M 2 TSB Collaborative R+D projects: 1.75m European IMI Project OrBiTo : 0.5M Euro EPSRC ICT 5 Year Platform 4m UK RPIF CAPEX 32M April 2014 TOTAL 84m AWL

34 Could reactions be intensified in such a plug flow reactor?

35 Manufacture of a pharmaceutical API involving a liquid-solid slurry with gas NiTech Reactor gives consistent gas absorption rate resulting in consistent product Reaction time reduced from >60 mins to 2 mins NiTech Solutions, 2008

36 We met Genzyme in July 2005, the full scale production including the approval of FDA started April 2007 Continuous API Manufacture The world s largest patentprotected continuous pharma API plant is at Genzyme, now Sanofi, in Haverhill, where NiTech continuous reactor is used as part of key synthesis step handling three phases since April Reactor volume reduced by 99.6% against traditional approach of 2 off 150 m 3 STRs

37 The paradigm of continuous processing Lab scale Process time, e.g. 30 mins Full scale Overall process time, e.g.30 mins Enabling intrinsic reaction times to be performed in lab/pilot/full scales, shrinking scale up process and plant size Enabling direct use of any lab scale monitoring/pat tools, hence knowledge/knowhow learnt from batch to full scale

38 Phases Applications Reactions Liquid-Solid-Gas Carbonation NiTech Tubular Reactor Liquid-Liquid-Solid Hyaluronic Acid Blending /Formulation Liquid-Solid Liquid-Liquid Acetylation Basification Liquid-Solid-Gas Hydrogenation NiTech Continuous Reactor Liquid-Solid Wetting Diazotisation Cyclisation Drug Encapsulation Acetylation Bromination Enzymatic reactions Polymer dissolution Liquid-Liquid Polymerisation Transesterification Hydration of Nitrile Amide Boranation Nitration Liquid-Gas Oxidation Hydroformylation Liquid-Liquid Separation In-Line phase separation NiTech Continuous Crystalliser Liquid-Solid Crystallisation L-Glutamic Acid Pharma APIs Liquid-Liquid-Solid Fractionation NiTech Solutions Ltd, 2010 Palm/Sunflower oil

39 Limitations of NiTech reactors and crystallisers Specific density of particles should generally be lower than 1.5, e.g. copper acetate, or lead are too heavy (depending on particle size) Particle concentration should generally be lower than 25% (general pharma operation is 5~10%) Viscosity of the main phase should generally be lower than 300 cp Gas concentration should generally be lower than 10%

40 Processing Slow Reacting, Non-Aqueous and Viscous Materials Under Pressure Incremental Flowrate (L/min) Total Flowrate (L/min) Residence Time (min) Tube Length (m) Heat Up A st adding B nd adding B rd adding B th adding B Adding oil & cooling Total

41 4. Key messages to take away STR/CSTR has been the work horse over 450 years, NiTech crystalliser is the only real challenger to STR/CSTR in the R&D and manufacturing spaces NiTech Crystalliser and Reactor work well with solids NiTech Reactor allows reactions with their intrinsic reaction times to be performed in lab/pilot/full scales, facilitating smooth scale up operation Any lab scale monitoring tools can directly be fitted along NiTech Crystalliser without modification, enabling direct use of knowledge/knowhow learnt from batch to full scale

42 Come to visit us Hall 9.2, F47 Any question?