Role of Process Development in Successful Commercialization of Speciality Chemicals - A Case Study

摘要

Process development work was carried out for the production of rubber adhesion promoter, for steel belted radial tyres, using n-Propyl Carbamate, Cymel Resin and Acrylamide. Critical processes variables were evaluated for different phases of the process. Solvent screening was carried out and experimental work conducted using IsoPropyle Alchohol, Toulene and Methanol, finally selecting a methanol based process. It has advantages such as good solvent, inexpensive and water soluble. The selection of suitable solvent was based on the properties such as economical and environmentally acceptable, miscible with both water and product and boiling point above 70°C (reaction is carried out at 85°C) but below 100°C (so that the solvent could be stripped off leaving water containing residual organics as bottoms). Material balance at a large scale was carried out. Small scale laboratory (1 Liter) studies were carried out to investigate fundamental research concept. Additional experiments were carried out in an engineering laboratory. For reaction phase, this setup included a 1 Liter resin flask equipped with baffles and set of turbine blades. Temperature was controlled with an external oil bath. Three runs were carried out at 22 Liter scale for the preparation of product for characterization of product. Further runs were carried out in the pilot plant of 60 Gallon capacity for market development. Semi works plant of 200 Gallon capacity was used to produce the product for the selected customers. A total of 3 batches were produced in the Semi works area of 200 gallon scale. The pilot plant investigation results are summarized in the following table & meet all product specifications.