Breakthrough PTC Process Screening & Development
Program
Goal -
Rapid Expert Screening of
Breakthrough High-Performance PTC Process
PTC Organics applies highly-specialized expertise in
Phase-Transfer Catalysis to innovate and evaluate proof-of-concept for
breakthrough high-performance low-cost PTC processes.
Innovation, performance and time are of the essence. PTC Organics
determines proof-of-concept typically within 1 month of laboratory
evaluation by PTC Organics’ dedicated PTC experts. PTC Organics
typically delivers all three of "the big three":
[1] high performance breakthrough evaluation
[2] fast
[3] cost effective
Once proof-of-concept is established, the customer
can [1] take the process in-house for further development or [2]
contract with PTC Organics to perform "PTC Development" to
achieve a high-performance PTC process ready for scale-up.
When to Consider Breakthrough PTC Process
Screening
- Route selection
- Early stage process development
- Major process improvement, cost reduction program (e.g., Six
Sigma) or other strong driving force for breakthrough
performance for cases in which the PTC Cost Savings
Program (licensing) is not available
Initiating the Project
A project is initiated when the customer provides a "Project
Description" under secrecy agreement (click for sample
form and hypothetical example). The Project Description is a
rather simple form which includes drawings of the specific molecular
structures of the product and reactants for a specific chemical
reaction and a summary of the desired Performance Targets for the
reaction. The customer optionally (preferably) attaches background
information about the reaction and process constraints for the
project. It is usually the case that the integration of PTC Organics’
expertise with the background project expertise of the customer’s
chemists and engineers leads to the most efficient use of development
resources while enhancing the probability of success. Such an initial
discussion is highly recommended prior to starting the laboratory
program.
Breakthrough PTC Process Screening in PTC Organics’ Laboratory
PTC Organics dedicates its best efforts, highly specialized
expertise in Phase-Transfer Catalysis and laboratory resources to
design, redesign and execute an experimental program in PTC Organics’
laboratory, including highly specialized PTC techniques, to determine
proof-of-concept and promising results for the PTC process option. In
order to determine proof-of-concept, Breakthrough PTC Process
Screening typically focuses on the 3 to 5 parameters which are most
likely to be responsible for most of the behavior of the PTC system
(out of a possible 14 factors) while applying highly specialized PTC
techniques for these factors and defining the ranges for the
parameters in which high performance is most likely to be achieved.
PTC Screening Report
At the end of Breakthrough PTC Process Screening, PTC Organics
composes a PTC Screening Report. The report describes the procedures,
results and rationale for the design of the experimental program. The
report provides analysis of the results and ramifications as measured
against the pre-defined Performance Targets. The report also includes
a critique of selected relevant PTC literature. Overall, the PTC
Screening Report provides an excellent basis for making decisions
justified by data, rationale and the best PTC expertise available with
cost-effective investment of resources.
Terms of Breakthrough PTC Process Screening
Breakthrough PTC Process Screening is provided at a flat fee which
includes experimental programs designed and executed in PTC Organics’
laboratory and the PTC Screening Report. More specifically, the flat
fee includes all internal expertise of PTC Organics’ experts, all
lab work, written reports, one initial and one final meeting at PTC
Organics’ site, waste disposal, supplies, analytical (GC, HPLC, Karl
Fischer and other wet methods are included; does not include GC-MS,
LC-MS or NMR) and all other routine lab activities. Chemicals which
cost $20 per kg or less including commercially available
phase-transfer catalysts, routine solvents and routine chemicals are
included. Raw materials, analytical samples, analytical methods and
MSDS’s are provided by the customer. Certain chemistries are not
performed by PTC Organics, such as work with controlled substances,
high potency materials (LD50 oral-rat < 1 mg/kg)
phosgene and lower mercaptans. Most other chemistries are acceptable,
including work with cyanide, azide, epichlorohydrin, dimethyl sulfate,
acrylonitrile, benzyl chloride, allyl chloride, PCl3,
fluoride and most standard organic and inorganic chemicals. Special
capital items, travel to the customer site, additional face-to-face
meetings and other non-routine items are not included. In practice, it
is rare that any additional fees are incurred beyond the flat fee.
Optional - PTC Development in PTC Organics’ Laboratory
If proof-of-concept is achieved during Breakthrough PTC Process
Screening, the customer can request PTC Development by PTC Organics
which is focused on developing a high-performance PTC process ready
for scale-up. The duration of the project and process parameters
evaluated are specific to each process and generally include: identity
of the phase-transfer catalyst, solvent, hydration factors, identity
of base (this is often the key parameter when relevant), effects of
anion & leaving group, co-catalyst, agitation, concentrations
& mole ratios, temperature and order & rate of addition. The
results monitored are specific to each process and generally include:
conversion rate (kinetic profile), selectivity (especially for
water-sensitive reactants & products) and isolated yield &
product assay (if the customer chooses to invest in developing
separation/work-up procedures). A detailed Development Report is
issued at the end of PTC Development. Scale-up should not be performed
before conducting a formal comprehensive safety and environmental
review (hazop analysis, etc.).
