Hazard Reduction

Synthesis of surfactants from cellulosic material through a biocatalyzed process. This novel process for the synthesis of surfactants does not require large amounts of energy nor organic solvents. This technology can decrease carbon dioxide emissions and reduce deforestation from palm plantations. Conventional surfact production is based on petrochemicals and seed oils, such as palm oil. Surfactant synthesis involves highly hazardous compounds to human health and the environment. 

Two synthetic routes for the production of thermal polyaspartic acid. TPA is a non-toxic, biodegradable, and cost-effective polymer with applications in many industrial processes, such as agriculture, water treatment, detergent, and oil and gas industries. TPA functions as a more sustainable alternative to conventional polyacrylic acids (PAC). The first route for the synthesis of TPA consists of a solventless solid-state-polymerization-reaction that transforms the aspartic acid monomor into polysuccinimide, eliminating the use of organic solvents.

General purpose non-orthophthalate plasticizer. Phthalate esters are used in conventional plasticizers and are hazardous to the environment and human health due to their toxicity and volatility. Eastman Chemical Company developed a non-orthophtalate plasticizer with equal or superior performance to convention orthophthalate plasticizers. Features of this plasticizer include good performance properties, excellent low-temperature flexibility, resistance to extraction by soapy water, and excellent non-migration properties.

Polylactic acid (PLA) made from greenhouse gases. This process transforms greenhouse gases into PLA by using agricultural crops to sequester carbon and transform it to simple plant sugars through photosynthesis. The plants are milled to extract glucose as starch. Enzymes are then added to convert the glucose to dextrose via hydrolysis. Microorganisms then ferment the dextrose into lactic acid. Lactic acid is converted to lactide and lactide is polymerized into Ingeo™ PLA by opening the lactide ring and linking them together to form a long polylactide polymer chain.

Non-phthalate plasticizer for flexible PVC. While flexible PVC is less dependent on raw fossil materials, significant ingredients in its production are plasticizers. Conventional plasticizers are made of phthalate esters, which carry health concerns. Prevalen™ is plasticizer made of pentaerythritol tetravalerate (PETV). This novel plasticizer has excellent processing properties, high plasticizing efficiency, exceptional UV resistance, low volatility and smoke. It is also produced using less finite raw materials than conventional plasticizers.

Fully compostable packaging. This technology emulates the properties and functionality of conventional plastic such as polyethylene and polypropylene, while being made from a blend of fully compostable polymers. This packaging demonstrates excellent optical, mechanical, and barrier properties (high transparency, printability, high sealing strength, high impact, and high barrier). The packaging is certified home or industrial compostable. The laminates and labels of the packaging are also compostable.

Merck Research Laboratories redesigned the manufacturing process for Zerbaxa™, a drug used to treat gram-negative bacterial infections resistant to conventional antibiotics. Ceftolozane sulfate is a key ingredient of the drug. Unfortunately, existing processes for its production require hazardous chemicals, a high process mass index, long cycle times, and low yields. Merck developed a sustainable second-generation manufacturing route.