Reduced Number of Process Steps

Reduces number of process steps required. p-hydroxyphenylglycine (esp. Recordati process), L-lysine... 

Dr Adam Harvey at Newcastle University (Harvey, 2006) is examining the use of oscillatory baffle reactors as components to intensify the production of biodiesel fuels. The research at Newcastle University uses rapeseed oil as the feedstock, the atfiaction being generally that it is a renewable energy source, it reduces CO2 emissions and pollution and it attracts tax relief in the UK at present. The range of PI projects in this area include a portable plant, solid catalysts (which allow a reduced number of process steps compared to liquid catalysts), the development of a reactive extraction process direct from the oilseeds, examination of cold flow properties and the production of biodiesel from algae. 

The ideal control on the structural and textural properties of perovskite-type oxides can be better achieved by exploiting aerosol spray synthesis methods to prepare highly dispersed and nanostructured materials from metal salt precursors. High-specific-surface-area (above 20m /g) crystalline perovskite-type oxides can be then obtained, which are suitable for a variety of applications. A major advantage of spray methods is that the material is directiy processed from the precursor solution with a reduced number of processing steps during powder synthesis (one-step approach), thus making them ideally suited for... 

As discussed in Sections 14.2 and 14.3, a critical difference between batch and continuous processes lies in equipment utilization. The complexity (or simplicity) of synthesis and isolation is a critical factor in determining whether a whole process is viable for switching from B2C. Given that it takes an average of eight synthetic steps to produce an API from raw materials [51], it is clear that the average API manufacturing process is probably too complex in its current form. Reduction in the number of process steps for a continuous process will, to a first approximation, reduce the plant costs pro rata. 

As a rule it is best to avoid separation steps, such as extraction, that involve the addition of a compound not already present. The reason for this rule is that extra processing steps will be required to recover the foreign compound so it can be reused. This means it is a costly operation. Whenever possible the number of processing steps should be reduced, not increased. 

One of the most widely used methods to improve overall process efficiency is to reduce the number of steps and unit operations in a synthetic route. This is more commonly known as telescoping. This can lead to more efficient, less wasteful processes that require fewer solvents because of the smaller number of steps. An example of this technique was illustrated earlier in Section 3.1.6, where the process optimization of the sertraline (Zoloft ) production process by Pfizer was described. In this case the number of process steps (unit operations) was reduced from 3 to 1, which led to huge savings due to higher productivity, fewer inputs, and less waste generation [18]. 

The economic benefits alone are also driving the adoption of biotechnology. BASF has reduced the production process for Vitamin B2 from eight steps to one through biotechnology, while DSM s bioroute for Cephalexin has also substantially reduced the number of process steps. These examples and those of dozens of pharmaceutical intermediates demonstrate that cost savings of 50 percent and more are not unlikely. The savings may come directly from lower variable costs, but also from reduced capital expenditures for simpler production assets, or from reduced scale and therefore lower risk, transportation costs, and/or overcapacity. 

Regarding the improvement of overall economy of ABS and HIPS-production the polymerization of BD in the presence of styrene monomer is particularly worth mentioning (Sect. 3.3) [581-590]. By the implementation of this technology the total number of process steps and overall process complexity would be considerably reduced. In particular, the isolation of BR from the polymer solution and the drying and baling of BR at the end of the finishing process could be avoided. In addition, the preparation of BR solu-... 

A growing interest in direct compression formulas has developed, mainly for economic reasons. The number of processing steps has been reduced, and the availability of many direct compression materials allows for a simplified tablet formulation. Direct compression formulations require blending only therefore, lakes and other pigments are used because the elimination... 

Process economics clearly need improvements both on the process side and in the performance of the catalysts. Both aims are best satisfied by increasing conversions and selectivities and by reducing the number of process steps. These improvements tend to minimize the amounts of capital, raw materials and energy needed. 

Reducing the number of process steps by activation of simpler raw materials (e.g., alkanes)... 

Modified knee presses up to a nominal force of 6300 kN are employed to extrude the valve tappets. The output capacity is 25-40 parts per minute. As a result of the near-net-shape process, the material is utilized to a higher extent—about 80%. The sizes of slot width and hole diameter are delivered at an accuracy ready for installation, whereas the outer diameter is pressed at IT quality 9-10 ready for grinding. The number of process steps and part manufacturing time were reduced. 

Solvent free techniques also reduce the number of processing steps and eliminate the time-consuming drying step. Also, there is no need to handle potentially dangerous solvents, resulting in the absence of residual solvents in the final formulation. 

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