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Chen Y, Kotamarthy L, Dan A, Sampat C, Bhalode P, Singh R, Glasser BJ, Ramachandran R, Ierapetritou M. Optimization of key energy and performance metrics for drug product manufacturing. Int J Pharm 2023; 631:122487. [PMID: 36521636 DOI: 10.1016/j.ijpharm.2022.122487] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/15/2022] [Revised: 12/02/2022] [Accepted: 12/07/2022] [Indexed: 12/15/2022]
Abstract
During the development of pharmaceutical manufacturing processes, detailed systems-based analysis and optimization are required to control and regulate critical quality attributes within specific ranges, to maintain product performance. As discussions on carbon footprint, sustainability, and energy efficiency are gaining prominence, the development and utilization of these concepts in pharmaceutical manufacturing are seldom reported, which limits the potential of pharmaceutical industry in maximizing key energy and performance metrics. Based on an integrated modeling and techno-economic analysis framework previously developed by the authors (Sampat et al., 2022), this study presents the development of a combined sensitivity analysis and optimization approach to minimize energy consumption while maintaining product quality and meeting operational constraints in a pharmaceutical process. The optimal input process conditions identified were validated against experiments and good agreement resulted between simulated and experimental data. The results also allowed for a comparison of the capital and operational costs for batch and continuous manufacturing schemes under nominal and optimized conditions. Using the nominal batch operations as a basis, the optimized batch operation results in a 71.7% reduction of energy consumption, whereas the optimized continuous case results in an energy saving of 83.3%.
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Affiliation(s)
- Yingjie Chen
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, US
| | - Lalith Kotamarthy
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Ashley Dan
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Chaitanya Sampat
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Pooja Bhalode
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, US
| | - Ravendra Singh
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Benjamin J Glasser
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Rohit Ramachandran
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, US
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, US.
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2
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Mackey J, Grover D, Pruneda G, Zenk E, Nagy ZK. Continuous Extraction of 2-Chloroethyl isocyanate for 1-(2-chloroethyl)-3-cyclohexylurea Purification. CHEMICAL ENGINEERING AND PROCESSING = GENIE DES PROCEDES = VERFAHRENSTECHNIK 2023; 183:109225. [PMID: 38179340 PMCID: PMC10765575 DOI: 10.1016/j.cep.2022.109225] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/06/2024]
Abstract
This study details the development of simulation-aided design, development, and successful operation of a continuous liquid-liquid extraction platform made with 1.5 mm tubing for the extraction of 2-chloroethyl isocyanate, an important reagent in the synthesis of cancer drugs. Preliminary solvent screening was carried out with partition coefficient calculations to determine solvents of interest. Next, batch and flow extraction experiments of 2-chloroethyl isocyanate in 2-methyl tetrahydrofuran and water were conducted to estimate extraction parameters. Following parameter estimation, experimental and model values for KLa were determined in the range of 1.13×10-3 to 36.0×10-3 s-1. Simulations of the extraction of 2-chloroethyl isocyanate were found to agree with experimental data resulting in a maximum efficiency of 77% and percent extraction of 69% for the continuous platform. Finally, model selection and discrimination was implemented for design space generation with experimental and model determined KLa values to guide lab-scale operation.
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Affiliation(s)
- Jaron Mackey
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907
| | - Devna Grover
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907
| | - Gabriella Pruneda
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907
| | - Eva Zenk
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907
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3
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Diab S, Christodoulou C, Taylor G, Rushworth P. Mathematical Modeling and Optimization to Inform Impurity Control in an Industrial Active Pharmaceutical Ingredient Manufacturing Process. Org Process Res Dev 2022. [DOI: 10.1021/acs.oprd.2c00208] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Samir Diab
- GlaxoSmithKline (GSK), Park Road, Ware SG12 0DP, United Kingdom
| | | | - George Taylor
- GlaxoSmithKline (GSK), Gunnels Wood Road, Stevenage SG1 2NY, United Kingdom
| | - Philip Rushworth
- GlaxoSmithKline (GSK), Gunnels Wood Road, Stevenage SG1 2NY, United Kingdom
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4
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Labarta JA, Olaya MM, Marcilla AF. What does the
NRTL
model look like? Determination of boundaries for different fluid phase equilibrium regions. AIChE J 2022. [DOI: 10.1002/aic.17805] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Juan A. Labarta
- Department of Chemical Engineering & Institute of Chemical Process Engineering University of Alicante, PO 99 Alicante Spain
| | - María M. Olaya
- Department of Chemical Engineering & Institute of Chemical Process Engineering University of Alicante, PO 99 Alicante Spain
| | - Antonio F. Marcilla
- Department of Chemical Engineering & Institute of Chemical Process Engineering University of Alicante, PO 99 Alicante Spain
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5
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Pan DT, Yan WC, Luo ZH. Solid-liquid equilibrium of 3,3-dilauryl thiodipropionate/lauryl alcohol in melt crystallization and model based process design. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2021.117209] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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6
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Application of a System Model for Continuous Manufacturing of an Active Pharmaceutical Ingredient in an Industrial Environment. J Pharm Innov 2022. [DOI: 10.1007/s12247-021-09609-7] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/02/2022]
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7
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Roche P, Jones RC, Glennon B, Donnellan P. Development of a continuous evaporation system for an
API
solution stream prior to crystallization. AIChE J 2021. [DOI: 10.1002/aic.17377] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Phillip Roche
- School of Chemical & Bioprocess Engineering Univerty College Dublin Dublin Ireland
| | - Roderick C. Jones
- School of Chemical & Bioprocess Engineering Univerty College Dublin Dublin Ireland
| | - Brian Glennon
- School of Chemical & Bioprocess Engineering Univerty College Dublin Dublin Ireland
| | - Philip Donnellan
- School of Chemical & Bioprocess Engineering Univerty College Dublin Dublin Ireland
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8
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Diab S, Raiyat M, Gerogiorgis DI. Flow synthesis kinetics for lomustine, an anti-cancer active pharmaceutical ingredient. REACT CHEM ENG 2021. [DOI: 10.1039/d1re00184a] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
Abstract
An original reaction mechanism and kinetic parameter estimation has been achieved for lomustine, an anti-cancer active pharmaceutical ingredient (API).
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Affiliation(s)
- Samir Diab
- Institute for Materials and Processes (IMP), School of Engineering, University of Edinburgh, The King's Buildings, Edinburgh, EH9 3FB, Scotland, UK
| | - Mateen Raiyat
- Institute for Materials and Processes (IMP), School of Engineering, University of Edinburgh, The King's Buildings, Edinburgh, EH9 3FB, Scotland, UK
| | - Dimitrios I. Gerogiorgis
- Institute for Materials and Processes (IMP), School of Engineering, University of Edinburgh, The King's Buildings, Edinburgh, EH9 3FB, Scotland, UK
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Diab S, Gerogiorgis DI. No More Than Three: Technoeconomic Mixed Integer Nonlinear Programming Optimization of Mixed Suspension, Mixed Product Removal Crystallizer Cascades for Melitracen, an Antidepressant API. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c03535] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Samir Diab
- Institute for Materials and Processes (IMP), School of Engineering, University of Edinburgh, The Kings Buildings, Edinburgh EH9 3FB, Scotland, U.K
| | - Dimitrios I. Gerogiorgis
- Institute for Materials and Processes (IMP), School of Engineering, University of Edinburgh, The Kings Buildings, Edinburgh EH9 3FB, Scotland, U.K
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10
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Integration of graphical approaches into optimization-based design of multistage liquid extraction. Comput Chem Eng 2020. [DOI: 10.1016/j.compchemeng.2020.107126] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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Diab S, Gerogiorgis DI. Design Space Identification and Visualization for Continuous Pharmaceutical Manufacturing. Pharmaceutics 2020; 12:E235. [PMID: 32151096 PMCID: PMC7150984 DOI: 10.3390/pharmaceutics12030235] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2020] [Revised: 03/02/2020] [Accepted: 03/03/2020] [Indexed: 11/16/2022] Open
Abstract
Progress in continuous flow chemistry over the past two decades has facilitated significant developments in the flow synthesis of a wide variety of Active Pharmaceutical Ingredients (APIs), the foundation of Continuous Pharmaceutical Manufacturing (CPM), which has gained interest for its potential to reduce material usage, energy and costs and the ability to access novel processing windows that would be otherwise hazardous if operated via traditional batch techniques. Design space investigation of manufacturing processes is a useful task in elucidating attainable regions of process performance and product quality attributes that can allow insight into process design and optimization prior to costly experimental campaigns and pilot plant studies. This study discusses recent demonstrations from the literature on design space investigation and visualization for continuous API production and highlights attainable regions of recoveries, material efficiencies, flowsheet complexity and cost components for upstream (reaction + separation) via modeling, simulation and nonlinear optimization, providing insight into optimal CPM operation.
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Affiliation(s)
| | - Dimitrios I. Gerogiorgis
- School of Engineering, Institute for Materials and Processes (IMP), University of Edinburgh, The King’s Buildings, Edinburgh EH9 3FB, Scotland, UK;
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