(20a) Implementation of Process Intensification and Flow Chemistry

The presentation will highlight selected examples from current industrial development activities at Bayer Technology Services covering innovative chemical route selection, introduction of special technologies, scale-up and small scale manufacturing enabled by process intensification.

Process intensification and flow chemistry are opportunities to open novel pathways in process design and engineering. These step changes can significantly improve efficiency and safety in chemical and pharmaceutical synthesis and reduce capital expenditure. Continuous processes can yield value chemicals at higher efficiency and lower manufacturing costs or even allow the access to new or tricky molecules. A number of highly innovative approaches and protocols are currently being developed in both industry and academia. The presentation will highlight selected examples from current development activities at the Bayer Group. The examples will cover innovative route selection, introduction of special technologies, micro structured equipment design as well as scale-up and modularized approaches. The examples will illustrate the methodology of intensified continuous process and product development demonstrating how novel routes can be indentified and what the benefits and hurdles from a process and manufacturing point of view can be. The presentation will illustrate how scale up effort and time to market can be reduced when moving from “lab chemistry” to pilot and production scale. As reduction of manufacturing costs is becoming increasingly important for the production of even high-value chemicals such as API it will be discussed how routes and technologies can be assessed at a very early stage of development and what the impact of novel processing conditions and continuous manufacturing can be.