Nanofiltration-Enabled In Situ Solvent and Reagent Recycle for Sustainable Continuous-Flow Synthesis

Tamas Fodi, Christos Didaskalou, Jozsef Kupai, Gyorgy T. Balogh, P. Huszthy, Gyorgy Szekely

Research output: Contribution to journalArticle

46 Citations (Scopus)

Abstract

Solvent usage in the pharmaceutical sector accounts for as much as 90 % of the overall mass during manufacturing processes. Consequently, solvent consumption poses significant costs and environmental burdens. Continuous processing, in particular continuous-flow reactors, have great potential for the sustainable production of pharmaceuticals but subsequent downstream processing remains challenging. Separation processes for concentrating and purifying chemicals can account for as much as 80 % of the total manufacturing costs. In this work, a nanofiltration unit was coupled to a continuous-flow rector for in situ solvent and reagent recycling. The nanofiltration unit is straightforward to implement and simple to control during continuous operation. The hybrid process operated continuously over six weeks, recycling about 90 % of the solvent and reagent. Consequently, the E-factor and the carbon footprint were reduced by 91 % and 19 %, respectively. Moreover, the nanofiltration unit led to a solution of the product eleven times more concentrated than the reaction mixture and increased the purity from 52.4 % to 91.5 %. The boundaries for process conditions were investigated to facilitate implementation of the methodology by the pharmaceutical sector.

Original languageEnglish
Pages (from-to)3435-3444
Number of pages10
JournalChemSusChem
Volume10
Issue number17
DOIs
Publication statusPublished - Jan 1 2017

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Nanofiltration
Drug products
drug
Recycling
manufacturing
recycling
Pharmaceutical Preparations
Carbon footprint
carbon footprint
Processing
cost
Costs
methodology
in situ

Keywords

  • catalytic membrane reactors
  • continuous processes
  • flow reactors
  • membranes
  • Michael Addition

ASJC Scopus subject areas

  • Environmental Chemistry
  • Chemical Engineering(all)
  • Materials Science(all)
  • Energy(all)

Cite this

Nanofiltration-Enabled In Situ Solvent and Reagent Recycle for Sustainable Continuous-Flow Synthesis. / Fodi, Tamas; Didaskalou, Christos; Kupai, Jozsef; Balogh, Gyorgy T.; Huszthy, P.; Szekely, Gyorgy.

In: ChemSusChem, Vol. 10, No. 17, 01.01.2017, p. 3435-3444.

Research output: Contribution to journalArticle

Fodi, Tamas ; Didaskalou, Christos ; Kupai, Jozsef ; Balogh, Gyorgy T. ; Huszthy, P. ; Szekely, Gyorgy. / Nanofiltration-Enabled In Situ Solvent and Reagent Recycle for Sustainable Continuous-Flow Synthesis. In: ChemSusChem. 2017 ; Vol. 10, No. 17. pp. 3435-3444.
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