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Computer Aided Methods & Tools For Separation & Purification of Fine Chemical & Pharmaceutical Products
Computer Aided Methods & Tools For Separation & Purification of Fine Chemical & Pharmaceutical Products
1. Introduction
The fine chemicals, agrochemicals, food and pharmaceutical industries need a
different set of processes and have different operational constraints than processes
producing bulk chemicals. For example, they usually involve batch operations (low
production rates) and usually handle chemicals that are temperature sensitive, difficult
to separate (because of isomers), and have high purity requirements. Also, at the initial
discovery step, the required processing steps need to be configured and tested very
rapidly and at the final (clinical) trials, they need to be reliable and efficient. Computeraided tools can provide significant savings in time and resources if reliable models for
product-process evaluation were available and could be used in an integrated manner.
The objective of this paper is a) to present a set of integrated computer-aided
methods and tools that are particularly suitable for application in the synthesis, design
and analysis of the separation-purification steps related to the production of high-value
chemical products; b) to highlight the application of the developed methods and tools
through a set of industrial case studies. The methods and tools include a large database
containing pure component data of chemicals, solubility data of typical chemical
products, azeotropic data of chemicals and many more. If the data for a chemical is
incomplete, a property model program package is available to generate reliable data to
fill out the needed missing properties. A unique feature of the property prediction
method is its ability to predict missing model parameters from molecular structural
information, without the need for additional experimental data [ 1] and is therefore able
to handle a very wide range of compounds and isomers. Also, the azeotrope database
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includes an analysis tool that helps to identify azeotropic systems for which solventbased separation is necessary and azeotropic systems for which it is not necessary. A
solvent selection tool [2], integrated to the system, then finds the most appropriate
solvents for the desired separation. The same is true for solid-liquid separations
involving solution crystallization [3] and liquid-liquid extraction. In all these cases, the
sequence of operations needed to achieve the desired separation/purification is
identified through generic model-based tools (solubility model creation, generation of
saturation curves, sequencing of operations, etc.) that can handle the complex mixture
behavior of fine chemicals and pharmaceutical chemicals. The generated
synthesis/design alternatives for the separation/purification steps are verified through an
integrated modelling system [4] that can be configured to simulate various types of
batch/continuous operations. Finally, a chemical system pre-analysis tool has been
developed to identify the types of operation needed to achieve the desired separation or
purification [5]. For example, should the separation/purification be achieved through
batch distillation or short-path evaporation or pervaporation, if a vapor-liquid separation
is feasible? Also, when should crystallization be used and under what conditions?
Should solvents (and/or anti-solvents) be introduced?
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point and normal melting point of the API, it is possible to use the ProCAMD tool
within ICAS [6] to identify solvents that are partially miscible in water, forms low
boiling azeotropes with water, dissolves the API and has boiling points between 3 5 0 420 K and melting point lower than 250 K. Using ICAS-utility and ICAS-sim, the
removal of water from the API solution has been verified.
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s e q u e n c e o f p u r i f i c a t i o n s t e p s d e s i g n e d to m a t c h t h e d e s i r e d p r o d u c t p u r i t y . M o r e
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4. C o n c l u s i o n s
B e c a u s e o f t h e n a t u r e o f t h e p r o b l e m s in t h e h i g h - v a l u e c h e m i c a l p r o d u c t s
sector (new chemicals, process reliability, reliable product performance and complex
phenomena),
models play a very important role and provide the basis for a wide range
of computer aided tools. In this respect, the paper highlights the important issues with
r e s p e c t to t h e i n t e g r a t e d a p p r o a c h as w e l l as t h e n e e d f o r a f l e x i b l e m o d e l - b a s e d
framework, the appropriate modelling tools, the importance and need for property
models, and the need for performance models for evaluation of processes and products.
F o r t h e i n t e g r a t i o n o f m e t h o d s a n d t o o l s to w o r k , r e l a t i o n s h i p s b e t w e e n t h e d a t a - f l o w ,
p r o b l e m t y p e s a n d m e t h o d s / t o o l s n e e d to b e p r o p e r l y e s t a b l i s h e d . C u r r e n t a n d f u t u r e
w o r k is d e v e l o p i n g a c o l l e c t i o n o f c a s e s t u d i e s o f w i d e r s c o p e a n d s i g n i f i c a n c e .
References
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T h e o r y & Practice, C A C E - 1 2 , Elsevier Science b.v., The Netherlands, 2002.
[3] A. Karunanithi, L. E. K. Achenie, R. Gani, C h e m Eng Science, 61 (2006) 1243-1256.
[4] M . S a l e s - C r u z , R. Gani, in D y n a m i c M o d e l D e v e l o p m e n t , Eds. S.P. A s p r e y and S. Macchietto,
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