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Process Development & Plant Concept

Process Development and Plant Concept for a Continuous Hydrogenation Plant

Mobile and efficient hydrogenation is a well-known target. In a feasibility study, Microinnova demonstrated that compact plants for polymer hydrogenation are possible. The target was to develop a concept for a mobile hydrogenation plant with a manufacturing capacity of more than 1 ton per hour. Feasibility studies in the labs of Microinnova translated a  process suitable for this kind of application. The key element to do this was the process intensification of the hydrogenation reaction. The lab team was able to demonstrate a process with reaction times of minutes instead of hours, as is the case in conventional processes. The development team was very proud to have been able to present this success for viscous raw materials. 

Microinnova demonstrated that compact plants for polymer hydrogenation are possible. The target was to develop a concept for a mobile hydrogenation plant with a manufacturing capacity of more than 1 ton per hour. Feasibility studies in the labs of Microinnova translated a  process suitable for this kind of application. The key element to do this was the process intensification of the hydrogenation reaction.

 

Environmental & Economic Impact of solvent-free Continuous API Manufacturing of Rufinamide

In the pharma and fine chemical industries, the development of continuous flow technologies is a process intensification step of primary importance towards the manufacturing of high‐quality products, while reducing the environmental impact and cost of production. The sustainability and profitability of a process can be measured through life cycle assessment and cost evaluation. However, when applied to emerging technologies based on flow chemistry, these need to be performed at different stages of the process development in order to limit the uncertainties arising from the scale‐up, and hence providing high‐fidelity projections of environmental impacts and costs at larger scales.

Therefore, we perform an assessment at two different scales of production, lab and mini pilot plant scale, with the aim of quantifying the uncertainties of the assessment related to the scale‐up, identifying the hotspots of the system, and hence providing guidelines for the further steps of process development. One such process that was successfully optimized using this process was the synthesis of Rufinamide. Importantly, in this case, the identification and implementation of effective solvent free conditions was evaluated at a pilot scale for the first time.

We present the first time a solvent-free continuous flow synthesis of the active pharmaceutical ingredient (API) Rufinamide is evaluated at pilot plant scale. This publication elaborates on the elevated sustainability and profitability and the resulting relevance for the pharma and fine chemical industries. This case study presents how process intensification can move sustainability and profitability of API manufacturing to a significantly improved level by means of continuous manufacturing.

 

Continuous Precipitation increases the Safety Level of a Manufacturing Plant 

Starting point for the project was an accident at the site of one of Microinnova’s customers. A powder explosion in a milling step had caused significant damage. Therefore, Microinnova’s target was to avoid the milling step in the manufacturing process and develop a flow chemistry process for the precipitation application, reaching the necessary particle size in the precipitation without the milling step. By influencing the nucleation and the particle growth by means of continuous manufacturing we were able to cut out the milling step, since the continuous process already delivered the desired particle size. In this process intensification of precipitation project Microinnova delivered a continuous lab plant for lab pilot tests. 

Microinnova’s target was to avoid the milling step in the manufacturing process and develop a flow chemistry process for the precipitation application, reaching the necessary particle size in the precipitation without the milling step. By influencing the nucleation and the particle growth by means of continuous manufacturing we were able to cut out the milling step, since the continuous process already delivered the desired particle size. In this process intensification of precipitation project Microinnova delivered a continuous lab plant for lab pilot tests.