PowerPoint Presentation · 8 Need for Innovation and Development chemistry to be Sustainable...

"Green Chemistry for Agro Chemicals Industry Sector"

Sustainability trends in Agrochemical Innovation and Research

IGCW2019

2

Syngenta Biosciences Pvt. Ltd. (SBPL): Our Purpose

IGCW2019 - IIT Mumbai PUBLIC 16/17 Oct 2019

To be a Centre of Excellence in Organic and Analytical Chemistry and

contribute significantly to the innovation process in Syngenta Crop

Protection Research while adhering to highest standards of Health,

Safety and Environment

3

Topics of Discussion:

● Introduction to Agrochemical Research and Agrochemicals

● Green Chemistry – Area of Focus

● SBPL journey of Sustainable R & D

- Lean Impact

- Reach Impact

- Technology Impact


4

Pesticides

USE OF PESTICIDES – TYPES OF PRODUCTS

❖ Pesticides used in different settings: -

✓ AgriculturaL

✓ Veterinary

✓ Domestic

✓ Institutional

❖ Formulations: liquid, gel, paste, chalk, powder, granules, pellets, baits...

❖ Concentrations: from 2% to 80% of active ingredient

❖ Containers: glass, plastic or metal flasks, bottles, drums,

traps, plastic bags or paper bags....

Fungicides Rodenticides

Wood preservatives

Pesticides

PESTICIDES – CLASSIFICATION BY USE

Insecticides Herbicides

Fumigants

Insect repellents

Chemicals designed to kill, reduce or repel pests

Insects Weeds MouldsRats, mice,

moles


5

4

Pesticides

PESTICIDES – RISKS AND BENEFITS

RISKS

❖Toxic to humans

❖Impact on environment

and ecosystems

BENEFITS

❖Crop protection

❖Food preservation

❖Material preservation

❖Disease control


6

What to look for in a new lead compound

⚫ Does it have the right kind of activity?

➢ In vitro

➢ In vivo

➢ Spectrum (selectivity)

➢ Potency

⚫ Structure

➢ Novelty

➢ Amenable to modification

➢ No potential toxicity alerts (alkylating groups, Michael acceptors, etc)

⚫ Is the mode of action new?


7

Pesticides

ORIGIN, TRANSPORT AND FATE

Distribution routes and "receptor" organisms for pesticides

used in agriculture

Air

Sediment

Target

Pest

Surface

water

Soil

Ground

water

-Crops

-Soil organisms

-Applicators

-Bystanders

-Wildlife

Humans

Wildlife

Plants

Cattle

Crops

Aquatic

organisms

Terrestrial

organism

Sediment

organism

1

1

2

3

5

4

6

7

1. Emission

2. Drift

3. Deposition

4. Sedimentation

5. Leaching

6. Drainage

7. Volatilization

A

.Laborde

Application

Spray

Granulate

Or

Seed

Treatment


8

Need for Innovation and Development chemistry to be Sustainable


Compound with given

physico-chemical propertiesPlant with his defence system

Nature, sun, humans

?

http://www.icone-gif.com/gif/nature/fleurs/fleurs-gif-022.gif

http://www.icone-gif.com/gif/meteo/nuages/nuage-gif-001.gif

http://www.icone-gif.com/gif/meteo/pluies/pluie-gif-002.gif

9 IGCW2019 - IIT Mumbai PUBLIC 16/17 Oct 2019

The 17 sustainable development goals (SDGs) to transform our world: - 2030

GOAL 1: No Poverty

GOAL 2: Zero Hunger

GOAL 3: Good Health and Well-being

GOAL 4: Quality Education

GOAL 5: Gender Equality

GOAL 6: Clean Water and Sanitation

GOAL 7: Affordable and Clean Energy

GOAL 8: Decent Work and Economic Growth

GOAL 9: Industry, Innovation and Infrastructure

GOAL 10: Reduced Inequality

GOAL 11: Sustainable Cities and Communities

GOAL 12: Responsible Consumption and Production

GOAL 13: Climate Action

GOAL 14: Life Below Water

GOAL 15: Life on Land

GOAL 16: Peace and Justice Strong Institutions

GOAL 17: Partnerships to achieve the Goal

https://www.un.org/development/desa/disabilities/?page_id=6226&preview=true

http://www.un.org/development/desa/disabilities/envision2030-goal2.html
















10

What is Green Chemistry?

Innovation aimed at design, development, and implementation

chemical products, reactions, and processes that …

❑ minimize hazardous substances

❑ develop Processes are inherently safe

❑ reduce waste and environmental footprint,

❑ improve efficiency and economics

Noyori - “…green chemistry is not just a catchphrase. It is an

indispensable principle of chemical research that will sustain our civilized society in the twenty-first century and

further into the future.”R. Noyori, Synthesizing our future, Nature Chemistry, 2009,

1, 5-6.


11

ThroughoutDevelopment

Green Chemistry Innovation to motivate internal and external waste & cost reduction

EarlyDevelopment

Establish the “ideal synthesis route” to enable maximum future process greenness with respect to co-produced waste

LateDevelopment

Optimize the “ideal synthesis route” with respect to Life Cycle Assessment

Drug Discovery

PreclinicalPhase1 Clinical

Phase2 Clinical

Phase3 Clinical

FDAReview

ManufactureOngoing Research

GreenSustainable Chemistry



- Adding value sustainably

http://reference/sites/brandlearn/en/Pages/Wordmark.aspx

13

Did you know?

We know of 7 000 plant species in the

world that are edible, but over 50% of

our plant-derived calories come

from only 3 species:

Corn Wheat Rice


14

Did you know?

Due to drought and desertification each

year 12 million hectares of soil are lost

(23 hectares/minute!),

where 20 million tons

of grain could have

been grown


15

Did you know?

Without fungicides, yields of most fruits and vegetables would fall by 50–90%, making fresh produce unaffordable

to many


16

Who we are

One of the world’s leading agriculture

companies helping to safely feed the world

while taking care of the planet.

● Aiming to improve the sustainability, quality

and safety of agriculture with world class

science and innovative crop solutions

● Enabling millions of farmers around the

world to make better use of limited

agricultural resources through the use of our

technologies

● Committed to improving farm productivity,

rescuing land from degradation, enhancing

biodiversity and revitalizing rural

communities through partnerships,

collaboration and The Good Growth Plan


90countries

104production and

supply sites

120research and

development sites

28,000employees

17

Soybean

Cereals

Corn

Diverse field crops

Rice

Specialty crops

Sugar cane

Vegetables and flowers

Supporting key crops with Crop Protection and Seeds offers

78%

22%


$13.5bn revenue in 2018

>50% emerging markets

Broad, innovative portfolio

Crop Protection, Seedcare, Pest

Control, Seeds, Biotechnology

Traits, Digital

18

870 million people

go to bed hungry

We are committed to finding better ways to safely feed the world sustainably

Every day the

world’s population

increases by

200,000

By 2050, 5bn people

will live with water

scarcity – agriculture

uses 70% of fresh

water

Agriculture produces

30% of greenhouse

gases and 40% of

soil is degraded


19

Adding value sustainably

As a business serving the agricultural industry, we help farmers safely feed a fast-growing world population. But there’s more: we aim to lead in sustainability.

The Good Growth Plan is not only driving the way we add value to a sustainable agriculture system; it’s measuring the results, so we can quantify the difference we make.


Learn more at

www.goodgrowthplan.com


More health

Less poverty

More biodiversity

Less degradation

More food

Less waste

One planet. Six commitments.

Make crops

more efficient

Increase average productivity

of the world’s major crops by

20% without using more land,

water or inputs

Rescue more

farmland

Improve the

fertility of 10

million hectares

of farmland on

the brink of

degradation

Look after every worker

Strive for fair

labor conditions

throughout our

entire supply

chain network

Empower smallholders

Reach 20 million

smallholders

and enable them

to increase

productivity

by 50%

Help biodiversity

flourish

Enhance

biodiversity on

5 million

hectares of

farmland

Help people stay safe

Train 20 million

farm workers on

labor safety,

especially in

developing

countries

The Good Growth Plan

We’ve made six commitments to help grow more food using fewer resources,

while protecting nature, and at the same time helping people in rural communities

live better lives


In 2018, we measured

input efficiency changes

for 3,759 reference and

benchmark farms for 20

crops in 39 countries

Since 2014, we have

benefited 10.8 million

hectares of farmland

through soil conservation

practices

In 2018, we have covered 99.6% of our suppliers in our sustainability and fair labor programs

In 2018, we have

reached 19.5 million

smallholders through

training and sales

Since 2014, we have

benefited 6.4 million

hectares of farmland

through biodiversity

enhancing practices

Since 2014, we have

trained 33.8 million

people on safe use

The Good Growth Plan in 2018 – turning the commitments into tangible achievements

22

Keeping our commitments relevant to society

Our six Good Growth Plan commitments help us quantify

how we contribute to the Sustainable Development Goals

set out in the United Nations Agenda 2030.


23

SBPL Research Journey –Focus on Green and Sustainable chemistries


25

2006-2010

2011-2016

2016-2019

5S

➢ Infrastructure Phase-1

➢ Global HSE Policy

➢ Basic Resource Planning

➢ Functional SOP’s

➢ Basic Financial and Resource Planning

➢ Infrastructure Phase-2

➢Sorting-Shining Phase of Lean Initiated

across functions on site including

➢Waster area,

➢ Stores

➢ Infrastructure

➢Engineering services

➢Laboratories

➢ Initiated metrics Based Monitoring Systems

➢Advanced Financial and Resource Planning

➢ Integrated SOP’s for Site

➢Standardisation-Sustain aspects of Lean

➢Auditing and Gap analysis for HSE and

Laboratories

➢Sustaining Good Practices on site across

functions

➢Advanced Financial and Resource Planning

➢Metrics based data collection, improvement

plan and implementation

➢ Implementation of Globally Recommended

Best Pracitces for Engineering Standards

SBPL Journey Towards Sustainability


26

➢ INTIATIVES TAKEN

➢ SORTING OF PROCESSESS AND WAYS OF WORKING

➢ SORTING OF EQUIPMENTS FOR BETTER USE OF INFRASTRUCUTRE

➢ ACTIONS PLANNED WERE TO DISCARD/DONATE TO CLEAR THE WORK

AREA AND INCLUDES ITEMS SUCH AS

➢ EQUIPMENTS

➢ DOCUMENTS

➢ CHEMICALS

➢ GLASSWARE

SBPL Sustainability INITIATIVES:


27

Period April-Aug-2013 Jan-14 March-14 June-14 Desired

Time Required (Minutes) 25 14 6 4 2

Lean (5S) Initiative to Reduce Time for Setting up of Reaction

June-2014 :

➢ Audit (by team of 2 members)

➢ Retrospective Data Collection

Key Changes:

➢ Rearranged lab storage (more space)

➢ Introduced new ways for storage

➢ Modified SOP for washing

➢ Combined order of better quality glassware

➢ Organized regular audit (Behaviors)



28

➢ Equipments and materials not in regular use are stored in

designated areas

➢ Undesired Ways of Working were made Redundant

➢ Relevant Ways of Working were Refined

➢ Work areas were equipped with required items including

➢ EQUIPMENTS

➢ DOCUMENTS

➢ CHEMICALS

➢ GLASSWARE

Sustainability INITIATIVES AT SBPL


29

➢ FOLLOWING BEST PRACTICES TO MAINTAIN THE FACILITIES

INCLUDING

➢ ENGINEERING MAINTENANCE POLICY AND STANDARDS

➢ SITE INTRASTUCURE MATURITY MODEL

➢ SCHEDULED AMC F

➢ SCHEDULED FACILITY MANAGEMENT INCLUDING HOUSEKEEPING

➢ STREAMLINED WAYS OF WORKING AND IMPLEMENTED

STREAMLINED PROCESSESS UNIFORMLY ON SITE

➢ APPROPRIATE RESOURCES ALLOCATED FOR THE INITIATIVES



30

➢ RESOURCE PLANNING AND MANAGEMENT ACROSS FUNCTIONS

➢ SITE SOP’S AND DOCUEMENTATION

➢ MATERIAL MANAGEMENT ON SITE

➢ BENCH MARKED AGAINST GLOBAL GOOD PRACTICES IN THE

FORM OF POLICIES, CODE OF PRACTICES, STANDARDS ETC..

➢ VISUAL MANAGEMENT OF VARIOUS ACITIVIES ON SITE WERE

INSTALLED



31

➢ Regular AUDITING, REPORTING AND RESOURCE ALLOCATION FOR

ACTIONABLE ITEMS

➢ REGULAR TOWN HALLS WITH EMPLOYEES FOR TRAINING AND

AWARENESS

➢ INITIATIVES TO REDUCE WASTE GENERATED FROM SITE

THROUGH VARIOUS PROGRAMS: REMOVE, REDUCE, RECYCLE

➢ METRICS BASED DATA MONITORING OF ALL ACTIVITIES ON SITE

FOR SUSTAINING EFFICIENCY

➢ PROCESSES TO SUSTAIN CHANGE MANAGEMENT



32

Value Creation for Customers

➢ Quality, Quantity and Timely Delivery

➢ >95 % Success Rate in Project Deliverables

➢ Lean Initiatives in Sourcing – Financial saving

➢ Inventory Management - Reduction in ware house space

➢ WOW in lab has reduced failure in advanced stage – impact on reworking and waste generation

Value Creation for Site and Employees

➢ More organised work space

➢ Appreciation from local and statutory Bodies

➢ Empowering employees through various forums

➢ Scientific and technical

➢ Soft skill training

➢ Engagement events for site culture development

➢ More than doubled the productivity of scientist

➢ Improved HSE statistics

IMPACT OF 5S INITIATIVES IN SBPL


33

Financial Budget No

of P

roje

cts

Value Creation at R&T

IMPACT OF 5S INITIATIVES IN SBPL


35

Continued use of many polar aprotic solvents, and amides in particular, is likely to be restricted under

Reach, because of concerns about their reproductive toxicity. ‘NMP [N-methyl-2-pyrrolidone], DMF

[dimethylformamide] and DMAc [dimethylacetamide] have been workhorses of industry for a long time, but

their days are numbered, except maybe for some very specialist applications

The “REACH” ImpactRegistration, Evaluation, Authorisation and Restriction of Chemicals


36

The health, safety and environmental spotlight is now

falling squarely on many of the solvents chemists take for

granted. A number of widely used ones are now facing

restrictions, if not outright bans, because of toxicity and

environmental concerns. What is being done to make

solvents safer and more sustainable?

Recycling and using new, greener solvents can make

chemical processes more sustainable

‘Industry has been chasing greener solvents for at least

20 years, but Reach [the EU regulations on registration,

evaluation, authorisation and restriction of chemicals] is

really forcing their hands,’ says James Clark, director of

the Green Chemistry Centre at the University of York, UK.

‘


37

Initiatives Towards Sustainability: Solvent Selection


Recommended

(or preferred)

to be tested first in a screening exercise, if

of course there is no chemical

incompatibility in the process conditions

Problematic

can be used in the lab or in the Kilolab, but

their implementation in the pilot plant or at

the production scale will require specific

measures, or significant energy

consumption

Hazardousstrong constraints on scale-up. Substitution

during process development is a priority

Highly

hazardous

Solvents to be avoided, even in the

laboratory

Four Classes of Solvent

What is a green solvent?

Physical and chemical

properties, toxicity,

environmental and safety

aspects and many more

parameters to be taken into

account…

Green Chem. 2007, 9, 927–934

Green Chem. 2016, 18, 288-296

Energy it takes to

produce 1kg of

solvent

Energy saved vs

(making new) by

recycling

Energy saved vs

(making new) by

incinerating

https://pubs.rsc.org/en/content/articlelanding/2007/gc/b617536h#!divAbstract

https://pubs.rsc.org/en/content/articlelanding/2007/gc/b617536h#!divAbstract

38

Initiatives Towards Sustainability: Solvent Minimization


Reduction of Solvent

➢ Process Driven: Validation, Consistency and Scale up

➢ Reuse: Solvents in a campaign

➢ Reduce: Process initiatives, alternate purifications

➢ Recycling: Recycle

Reduction of Solvent

➢ Reduced Risks, Enhanced Safety

➢ 75 % Reduction in Solvent Costs over 2 years

➢ 50 % in sourcing

➢ 25 % in waste management

39

Initiatives Towards Sustainability: Solvent Selection


➢ 2 % Reduction in Hazardous solvent

➢ 1.5 % Increase in Recommended solvent


Chemical Process Development

41

Batch and flow

● Classic way to do chemistry.

● Reagents are loaded into the reactor, mixed and

left to react.

● The products is collected at the end, after the

reaction has been completed and worked-up.

.


DOI: 10.1021/acs.oprd.5b00325Org. Process Res. Dev. 2016, 20, 2−25

Reaction

Mixture

>5mm

Reagent A Reagent

B

Reagent A

Reaction

Mixture

~100µm

Reagent B

Key factors:

- Concentration

- Mixing

- Temperature

- Reaction time

Key factors:

- Residence time (flow rates)

- Mixing

- Pressure

- Temperature

42

Advantages of implementing Flow solution at an early development stage

Introducing continuous flow at this point enables

• use of specific types of reactions that are very difficult to accommodate with the traditional batch

process.

• Applying continuous flow in early phase development also allows greater control over the reaction

• it also makes it possible to start building a process that can be commercially viable from the outset,

reducing the potential multiple iterations of a development cycle as the compound progresses from

phase to phase.

• The ability to optimise the process from the outset is a major advantage as it means that the best route

can be used, rather than one best suited to a batch operation.

• With continuous flow, all routes can be explored to find the most appropriate synthesis that can then be

progressed through all the different stapes of development.

• continuous flow offers a process that is scalable from the beginning, allowing the manufacture of a few

hundred grams or perhaps a kilogram of a compound, and this can be quickly increased to larger

quantities of material for a later phase, by increasing the scale of the equipment, or by extending the

processing time. This scale up can be done multiple times through to commercial quantities, as opposed

to batch manufacturing,

SCALE-UP (Pilot plant trials)-Transfer to Manufacturing/life

cycle management

Discovery Chemistry

Lead compound

Process Development – piloting

Flow chemistry

SCALE-UP (Pilot plant trials)-Transfer to Manufacturing/life

cycle management

Discovery Chemistry

Lead compound

Process Development – piloting

•-Optimization (change conditions and parameters)

•-Minor change of route / intermediate

•-Cheaper / more efficient reagents (new to market)

•-Environmentally-friendly reagents and effluent

•considerations

•-Yield / concentration improvement

•-Statistical methods

Chemical Process Development: 3-6 years



WASTE MANAGEMENT FOR SUSTAINABILITY

44

WASTE MANAGEMENT FOR SUSTAINABILITY


45

Thank You!


PowerPoint Presentation · 8 Need for Innovation and Development chemistry to be Sustainable...

Documents

Transcript of PowerPoint Presentation · 8 Need for Innovation and Development chemistry to be Sustainable...