Environmental analysis of the life cycle emissions of 2-methyl tetrahydrofuran solvent manufactured from renewable resources.

An environmental analysis has been conducted to determine the cradle to gate life cycle emissions to manufacture the green solvent, 2-methyl tetrahydrofuran. The solvent is considered a greener chemical since it can be manufactured from renewable resources with a lower life cycle footprint. Analyses have been performed using different methods to show greenness in both its production and industrial use. This solvent can potentially be substituted for other ether and chlorinated solvents commonly used in organometallic and biphasic reactions steps in pharmaceutical and fine chemical syntheses. The 2-methyl tetrahydrofuran made from renewable agricultural by-products is marketed by Penn A Kem under the name ecoMeTHF™. The starting material, 2-furfuraldehyde (furfural), is produced from corn cob waste by converting the available pentosans by acid hydrolysis. An evaluation of each step in the process was necessary to determine the overall life cycle and specific CO2 emissions for each raw material/intermediate produced. Allocation of credits for CO2 from the incineration of solvents made from renewable feedstocks significantly reduced the overall carbon footprint. Using this approach, the overall life cycle emissions for production of 1 kg of ecoMeTHF™ were determined to be 0.191 kg, including 0.150 kg of CO2. Life cycle emissions generated from raw material manufacture represents the majority of the overall environmental impact. Our evaluation shows that using 2-methyl tetrahydrofuran in an industrial scenario results in a 97% reduction in emissions, when compared to typically used solvents such as tetrahydrofuran, made through a conventional chemical route.

Life cycle analysis of solvent reduction in pharmaceutical synthesis using continuous adsorption for palladium removal.

The life cycle emissions associated with the reduction of wastes from an adsorption process to remove palladium complexes in drug manufacture have been evaluated. The study assessed a green improvement to a process step in an active pharmaceutical ingredient synthesis where palladium catalyst is removed from a reaction mixture. The greener process uses a continuous adsorption system, composed of a more efficient adsorbent, consuming less organic solvent and rinse water, which results in less waste disposal. The newer process is also more energy and cost efficient from an operational perspective. There is a 94% reduction in the carbon footprint of the new process when compared to the current operation.

Strategic Optimization of the Flushing Operations in Lubricant Manufacturing and Packaging Facilities.

Commercial lubricant industries use a complex pipeline network for the sequential processing of thousands of unique products annually. Flushing is conducted between changeovers to ensure the integrity of each production batch. An upcoming product is used for cleaning the residues of the previous batch, resulting in the formation of a commingled/mixed oil that does not match the specifications of either of the two batches. The existing operations are based on the operator's experience and trial and error. After a selected flush time, the samples are tested for their viscosity to determine the success of a flush. The approach results in long downtime, the generation of large commingled oil volumes, and huge economic losses. Hence, to overcome the drawback, our work introduces a solution strategy for systematically optimizing flushing operations and making more informed decisions to improve the resource-management footprint of these industries. We use the American Petroleum Institute-Technical Data Book (API-TDB) blending correlations for calculating the mixture viscosities in real-time. The blending correlations are combined with our first-principles models and validated against well-designed experimental data from the partnered lubricant facility. Next, we formulate an optimal control problem for predicting the optimum flushing times. We solve the problem using two solution techniques viz. Pontryagin's maximum principle and discrete-time nonlinear programming. The results from both approaches are compared with well-designed experimental data, and the economic and environmental significance are discussed. The results illustrate that with the application of a discrete-time nonlinear programming solution approach, the flushing can be conducted at a customized flow rate, and the necessary flushing volume can be reduced to over 30% as compared to the trial-and-error mode of operation.

Efficient UV Filter Solubilizers Prevent Recrystallization Favoring Accurate and Safe Sun Protection.

Sun protection is a global concern, and maximizing sunscreen stability and efficacy depends partially on the prevention of UV filters recrystallization. We aimed to study the efficacy of hydrophobic solubilizers in preventing the recrystallization of solid hydrophobic UV filters in predissolutions, sunscreen formulations, and during simulated human use. Recrystallization of UV filters induced by ultrasonication, temperature variation, or simulated human application was analyzed by different methods. Maximum solubility of UV filters in solubilizers was determined. Surprisingly, the best solubilizer was not necessarily the best solvent to prevent recrystallization, suggesting there are different forces controlling these phenomena. Hydrophobic solubilizers tend to perform better than ethanol in predissolutions, but the presence of other components in final products may change their performance. Results suggest that some UV filters tend to form liquid clusters, which may behave as crystals and affect the desired even distribution of UV filters on the skin. UV filters were also found to respond differently to Hansen Solubility Parameters. Scanning electron microscopy supports the fact that recrystallization upon sunscreen application is an issue to be tested during development. A timesaving method to predict recrystallization of UV filters in clear systems was developed and is presented as a tool to enhance the efficacy of sunscreens.

Pervaporation study for the dehydration of tetrahydrofuran-water mixtures by polymeric and ceramic membranes.

Pervaporation technology can effectively separate a tetrahydrofuran (THF) solvent-water waste stream at an azeotropic concentration. The performance of a Sulzer 2210 polyvinyl alcohol (PVA) membrane and a Pervatech BV silica membrane were studied, as the operating variables feed temperature and permeate pressure, were varied. The silica membrane was found to exhibit a flux of almost double that of the PVA membrane, but both membranes had comparable separation ability in purifying the solvent-water mixture. At benchmark feed conditions of 96 wt% THF and 4 wt% water, 50 degrees C and 10 torr permeate pressure, the silica membrane flux was 0.276 kg/m(2)hr and selectivity was 365. For both membranes, flux was found to increase at an exponential rate as the feed temperature increased from 20 to 60 degrees C. The flux through the silica membrane increases at a 6% faster rate than the PVA membrane. Flux decreased as permeate pressure was increased from 5 to 25 torr for both membranes. The amount of water in the permeate decreased exponentially as the permeate pressure was increased, but increased linearly with increasing temperature. Optimum conditions for flux and selectivity are at low permeate pressure and high feed temperature. When a small amount of salt is added to the feed solution, an increase in flux is observed. Overall models for flux and permeate concentration were created from the experimental data. The models were used to predict scale-up performance in separating an azeotropic feed waste to produce dehydrated THF solvent for reuse and a permeate stream with a dilute THF concentration.