Efficiency

Enzymes that improve the production of Atorvastatin calcium, an essential building block of Lipitor. Atorvastatin calcium is produced through hydroxynitrile (HN). This conventional process yields less than 50% and requires hydrogen bromide (a hazardous chemical). Codexis introduces a new enzymatic pathway that consists of three bioengineered enzymes that reduce the original process to two steps. This new process by Codexis® works in mild conditions and produces significantly higher yields. It also reduces environmental and health hazards by producing fewer byproducts and waste.

Four-step synthetic route for ibuprofen production. This company's four-step synthetic route is an alternative to the traditional six-step synthetic route. This new process has 90% atom efficiency compared to the original process with less than 40% atom efficiency. Using anhydrous hydrogen fluoride as a solvent and catalyst reduces the volume of generated waste and increases the reaction's selectivity. Anhydrous hydrogen can also be recovered and reused with 99.9% efficiency.

Improved synthesis of aprepitant, the active ingredient in Emend® — a drug that combats chemotherapy-induced nausea and vomiting. This new process assembles aprepitant in 3 highly atom-economical steps (compared to the traditional 6 steps) and nearly doubles the yield. Compared with the first-generation synthesis, this new route eliminates sodium cyanide, dimethyl titanocene, and gaseous ammonia. This new process also requires only 20% of the raw materials and water used in the original process, eliminating approximately 41,000 gallons of waste per 1,000 pounds of aprepitant.

Improved synthesis of Prevymis™, a prescription medicine that helps prevent cytomegalovirus (CMV) infection and disease in adults who have received bone marrow transplants. This antiviral drug uses an improved chemical catalyst, increases the overall yield by 60%, reduces the PMI by 73%, reduces raw material costs by 93%, and reduces water usage by 90%. Merk claims this synthesis will result in the elimination of over 15,000 MT of waste over its lifetime. It should also decrease the product's carbon footprint and water usage by 89% and 90%, respectively.

Membrane separation process in solvent lube dewaxing. Conventional solvent lube dewaxing processes are energy-intensive due to the need for refrigeration. This new process uses an exclusive polymeric membrane material to separate up to half of the dewaxing solvents from the solvent mixture, reducing the need for distillation, cooling, and refrigeration. This reduced waste generation and VOC emissions. The process increases the yield of lubricants while decreasing by-product generation, virgin material extraction, and equipment.

Long-lasting synthetic oils. Conventional oils are not long-lasting, which generates waste oil. Frequently disposing of large quantities of oil is hazardous to human health and the environment due to its composition of lead, nickel, and other heavy metals. AMSOIL's long-lasting oil extends its lifespan to 11 times longer than conventional oils; pairing this oil with an oil analysis program can further extend its life span. AMSOIL achieves this by removing impurities and allowing molecules to slip more easily over one another, reducing energy lost to friction and maximizing fuel economy.

Polyester polyols based on rPET and other recycled components. Resinate® is a product line that uses recycled and renewable materials for high-performance applications in coating, adhesives, and foams. The product, Resinate® EP1000-5.6, is based on rPET (recycled PET) and other recycled components, resulting in 66% recycled content. Resinate® C2051-50 is a modified polyol for the coatings marketplace and contains 50% renewable content. 

Synthesis of simvastatin with a biocatalyst. Simvastatin is a drug used to treat high blood pressure and cholesterol. The conventional synthesis of this drug is not atom-economic (<70% original mass) and utilizes toxic feedstocks. This new process from Professor Tang and his research group at UCLA uses a biocatalyst for regioselective acylation with safer and cheaper reagents in a high-yield, single-step process. 

Solid catalyst alkylation process for the production of alkylate. Alkylate is a clean fuel component of gasoline. Traditional production methods use toxic liquid acid technologies that require post-treatment. Using the Alkystar catalyst, AlkyClean is a more efficeint alkylate production process that increases reaction speed and reduces environmental hazards by eliminating the need for liquid acids.

Natural ester dielectric fluid. PCBs were traditionally used as fluid insulators in transformers and were eventually banned due to their high toxicity. PCBs were then replaced with petroleum-based mineral oil. Unfortunately, mineral oil is highly flammable and has a low affinity for water. Additionally, other insulator materials within transformers are made of cellulose. Thus, water inside the transformers was mostly absorbed by the cellulose-based insulator materials, catalyzing their degradation and reducing the lifetime of the transformers.