Newreka’s Recycle@SourceTM Solution : A New Preventive Paradigm based on Green Chemistry Approach

Aim : Reduction of E-Factor* by recycling at source of reaction-processes’ aqueous streams (*E-Factor= Kgs of waste generated in manufacturing per kg of product)

Applicable : To the chemistry-intensive sectors such as Pharma API and its intermediates (E-Factor > 50) and fine chemicals – dyes, pigments, agro chemicals and their intermediates – (E Factor > 25)

Mechanism :

  • The aqueous stream from each reaction is recycled locally at reactor level, instead of mixing the streams from various reactions across the plant, doing a primary treatment to send it to ETP/CETP
  • Individual aqueous streams are processed and purified with Newreka’s customized proprietary catalytic formulation “R-Cat” (Recycle Cat) which selectively prevents organic and inorganic impurities from building up in the recycle loops
  • This purified stream is then recycled as reaction/extraction medium back to the same chemical process step where it originally came from. Hence the name Recycle@SourceTM Solution

Advantages and Benefits :

  • Quality : Consistent quality of product is retained over many many recycle loops
  • Quantity : Due to recycle of soluble product in aqueous stream, the overall conversion is enhanced with each recycle
  • Productivity : Overall productivity is improved by 10 to 20%
  • Environment : Aqueous effluent load minimized by 80%, thereby preventing treatment cost
  • Safety : “R-Cat” is inherently safe and easy to handle
  • Economics : 5 to 10% increase in overall profitability

Case Study : Recycle@SourceTM Solution applied to a 60 TPA Pharma Intermediate Plant:

Click here to read customer feedback

Products that can benefit :

  Pharma API and
Intermediates
  Albendazole, Omeprazole, Itraconazole,   Triclabendazole,
Nevirapine, Retigabine, Quetiapine, Domperidone,
Dronedarone, Darunavir, Dabigatran, Sildenafil Citrate,   Paracetamol For more, click here.
  Fine Chemicals (Dyes,
pigments, agro   chemical, specialty
chemicals and their   Intermediates)
  H-Acid, FC-Acid, DASDA, MPDSA, OAPSA, ADAPSA, PABA,
DABA, C-Acid, Violet-23, PABZ

  Dichloroaniline, Meta Bromoaniline, 5-amino orthotoluedine
P-aminophenol, Dichloroaminophenol, OAP, PPD

Reduction chemistry made profit-centric by Newreka’s Platform Technology #1

Chemistry : Aromatic Nitro to Amine reduction

Applicable : When the nitro and amine are both soluble in water

‘Greener’ alternative to conventional approach :

  • The nitro is reduced in the presence of Newreka’s proprietary catalysts “G-Cat” and “R-Cat”
  • The spent G-Cat is filtered out and the rest is sent to a crystallizer and centrifuge from where the amine is taken out
  • The mother liquor is treated with R-Cat to remove organic and inorganic impurities and then recycled into the processpatent technology IP 242146

Advantages :

  Economics   -   Increase profitability by over 5% through a Profit-Centric   approach
  Quality   -   High Purity, low Impurity profile while integrating   Recycle@SourceTM  Solutions
  Quantity   -   High selectivity leading to increase in yield by 5-10%
  Productivity   -   Reduce process batch time by 30%
  Environment   -   Minimize liquid effluents by 80%
  Safety   -   Freedom from high pressure, incidental hazards, pyrophoricity,   acidic and alkaline conditions
  Energy   -   Minimize energy consumption by 20%

Products that can benefit from this technology :

  Nitro   CAS no   Amine   CAS no
  4-nitrophenol   100-02-7   4-aminophenol   123-30-8
  2-nitrophenol   88-75-5   2-aminophenol   95-55-6
  2-chloro-3-nitro-4- methyl   pyridine   23056-39-5   2-chloro-3-amino-4-   methyl pyridine   133627-45-9
  4-nitroso meta cresol   615-01-0   4-amino meta cresol   2835-99-6
  1,3-dimethyl-5-nitroso
  uracil
  6632-68-4   Theophiline   58-08-2

Successfully Industrialized :

  • In over 5 API & API Intermediate manufacturing companies having E-Factor of more than 50 (E-Factor = Kg Waste /Kg Product)
  • 10+ Fine Chemicals Industry (Agro, Dyes, Pigments & its intermediate manufacturers)- with E-Factor of more than 25

Case-study :

More than 800 successful Recycle loops set up for an API Intermediate. click here to read customer feedback.