Detail
Merck Research Laboratories is being recognized for redesigning the manufacturing of the antibiotic ZerbaxaTM. Key to the redesign is a crystallization-based purification process that reduces the process mass index by 75%, reduces raw material costs by 50%, and increases the overall yield by more than 50%. Merck estimates that the new process will save approximately 3.7 million gallons of water annually and reduce the carbon footprint and energy usage by 50% and 38%, respectively.
Summary of Technology:
Ceftolozane sulfate is the cephalosporin antibiotic component of ZerbaxaTM used to treat gram-negative bacterial infections that have become resistant to conventional antibiotics, especially urinary tract and intra-abdominal infections. The existing manufacturing process for ceftolozane sulfate was comprised of three stages and included the use of hazardous chemicals, an unacceptably high process mass index, long cycle times, and low yields.
Merck achieved innovations in both synthetic chemistry and process development leading to a truly sustainable second generation (Gen 2) manufacturing route to ceftolozane sulfate. Key to the development of a sustainable process was crystallization-based purification, the invention of which dispelled the traditional belief that chromatography was the only method capable of purifying β-lactam antibiotics.
This discovery of the sustainable crystallization-based purification process led to a revolutionary new process that reduces the process mass index by 75%, reduces raw material costs by 50%, and increases the overall yield by more than 50%. Merck estimates that the new process will save approximately 3.7 million gallons of water annually, which equals enough drinking water for approximately 21,000 people per year. In addition, life-cycle assessment data shows that the new process is expected to reduce environmental impact by decreasing the carbon footprint and energy usage by 50% and 38%, respectively.
This patented process was successfully implemented, demonstrated, filed, and approved in the US and EU in 2018, and is currently being used on commercial scale to manufacture ceftolozane sulfate for ZerbaxaTM.
WSI is being recognized for developing TRUpathTM, a successful alternative to traditional commercial laundering technologies that use harsh and harmful chemicals. TRUpathTM uses more biodegradable surfactants and eliminates phosphates from wash formulas.
Summary of Technology:
Commercial laundering traditionally has utilized harsh and harmful chemicals such as sodium hydroxide, sodium or potassium phosphates, and nonylphenol ethoxylate-based surfactants. Phosphates in detergents can lead to freshwater algal blooms that are toxic to other aquatic organisms and which deplete oxygen in waterways. Nonylphenols are endocrine disruptors that accumulate in sewage sludge, river sediments, and groundwater.
WSI’s TRUpathTM technology provides successful alternatives that overall are readily biodegradable and less toxic to the environment. TRUpathTM utilizes a nonylphenol ethoxylate-free detergent that substitutes more readily biodegradable, linear chain alcohol ethoxylates. TRUpathTM also utilizes an EDTA- and phosphate-free builder and an enzyme-based booster. Additionally, the TRUpathTM process works at colder temperatures than traditional laundry formulations, which reduces energy consumption and decreases cycle time, meaning fewer machine hours.
WSI’s TRUpathTM technology was commercialized in 2018. The use of this laundry system has displaced nearly 30 million pounds of nonylphenol ethoxylate-based detergents. Additionally, the TRUpathTM detergent has prevented the discharge of petroleum hydrocarbons into wastewater by approximately 200,000 lbs/yr and reduced overall laundry wastewater discharge by more than 1.3 million lbs/yr. Removing phosphates from the laundry builder has reduced phosphate discharge into the environment via wastewater by 1.5 million lbs/yr, and removing EDTA has reduced EDTA discharge by 104,000 lbs/yr. Additionally, annual use of natural gas is reduced nationwide by greater than 5.1 million therms, and 545 million gallons of water are saved annually.
Kalion, Inc., in partnership with the Massachusetts Institute of Technology, is being recognized for commercializing the first microbial fermentation process to produce glucaric acid, which offers the possibility of replacing environmentally polluting chemicals with a bio-degradable, non-toxic, sugar-derived product. Kalion is initially using it as a corrosion inhibitor for water treatment plants.
Summary of Technology:
The production of glucaric acid by fermentation has been long sought technology due to the harsh, toxic and non-selective nature of traditional chemical approaches. Glucaric acid as a product also offers the possibility of replacing environmentally polluting chemicals such as phosphate with a bio-degradable, non-toxic, sugar derived product. Glucaric acid’s potential was highlighted in a 2004 Department of Energy report where it was ranked among the Top Valued Added Chemicals from Biomass. Its potential has never been realized due to challenges in the safe and economical production of the chemical.
Kalion, Inc. is commercializing the first microbial fermentation process that produces glucaric acid. Kalion uses a novel biosynthetic pathway, expressed in E. coli, consisting of three enzymes from disparate organisms: myo-inositol-1-phosphate synthase (INO1), myo-inositol oxygenase (MIOX), and uronate dehydrogenase (udh). Expressing the MIOX and udh genes (but not INO1) allows for the conversion of myo-inositol to glucaric acid, thus by-passing central metabolism and resulting in yields approaching 100%. Expression of the complete pathway, to include INO1, allows for production of glucaric acid from glucose via the key cellular intermediate glucose-6-phosphate.
Kalion’s fermentation process solves the challenges of traditional chemical approaches and enables the production of high-purity, low-cost glucaric acid. End uses for glucaric acid now possible include water treatment, additives for polymer formulations, excipients for active pharmaceutical ingredients, chelants for the detergent industry, concrete admixtures, and corrosion inhibitors for road salt.
Kalion is initially focused on the use of glucaric acid as a corrosion inhibitor in water treatment applications, which would/will replace phosphate-based treatment programs. Phosphate point sources from water treatment waste water are well-known environmental pollutants for aquatic ecosystems. Glucaric acid, in contrast, degrades in a benign fashion and can be used effectively in water systems without restriction. At full-scale production, glucaric acid can serve as a complete substitute for phosphate in water treatment. This is one of several billion-dollar addressable markets for glucaric acid. Kalion’s fermentation-based approach enables glucaric acid, created through this green chemistry approach, to reach its full potential envisioned in the Top Value Added Chemicals Report.
Prof. Sanjoy Banerjee, City College of New York and City University of New York Energy Institute, in partnership with Urban Electric Power, Inc., Sandia National Laboratories, Brookhaven National Laboratory, and the Energy Storage Research Program in the Department of Energy Office of Electricity Urban Electric Power, Inc., is being recognized for creating large-scale zinc-manganese oxide batteries that can be recharged thousands of times without the typical decrease in the length of the battery’s life-time. These batteries do not have some of the limitations of lithium-ion and lead-acid batteries, and they use materials that are abundant and common in existing supply chains.
Summary of Technology:
Zinc (Zn) and manganese dioxide (MnO2) are electrochemical energy storage materials with high energy density, low cost, and established safety characteristics as demonstrated by the widespread use of alkaline primary batteries. Zn and MnO2 are readily available with an abundant domestic supply in the U.S. and Canada. These materials are key components of primary (non-rechargeable) alkaline batteries that presently dominate the disposable battery market. Transforming this technology into a grid-scale rechargeable system would enable a revolutionary, low cost, green technology able to meet critical U.S. electrical grid needs. But the traditional chemistries used in primary alkaline batteries lead to irreversible degradation of the electroactive components that has made them unsuitable for the thousands of charge/discharge cycles desired for rechargeable grid-scale energy storage systems.
The City University of New York - Energy Institute (CUNY-EI) has achieved a recent breakthrough utilizing chemical dopants, such as copper ions, to stabilize the MnO2 cathodes in these batteries by allowing them to be recharged thousands of times without degradation of capacity. In parallel, progress has been made in structuring and stabilizing Zn anodes with electrode and electrolyte additives that allow full utilization of the battery capacity while mitigating problems that degrade Zn-anode lifetime, such as dendrite formation, shape change and passivation. The resulting batteries feature energy densities approaching 200Wh/L and lifecycle CO2 emissions comparable to those of lead acid batteries. The batteries also do not have the temperature limitations of lithium-ion and lead-acid batteries. They do have an aqueous chemistry, are non-flammable, and use materials that are abundant and already in use in existing supply chains.
Urban Electric Power built a pilot scale manufacturing plant in Pearl River, NY, and is commercializing the battery technology developed at the CUNY-EI. When manufactured at high volume production, the batteries can be produced for <$50/kWh, enabling the expansion of renewable energy generation and significantly contributing to the reduction of CO2 generated. For example, storing 20% of the energy generated by renewables allows the plant to use those renewables for base load generation, typically the minimum power supplied at a continuous rate, further displacing traditional electricity generation. This translates to an additional reduction of 0.4 G Tons of CO2 per year.
Source: EPA.gov 【Return】
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