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A process for the commercial production of a family of Warwick-invented organometallic catalysts has been developed and patented by Johnson Matthey (JM). The catalysts — which have been sold internationally to several fine chemical and pharmaceutical companies in kilogram quantities, capable of producing tonnes of product — are in widespread industrial use for synthesis and scale-up. Other companies have protected, and are marketing, similar `copycat' catalysts. JM continues to work in collaboration with Warwick Chemistry on the next generation of catalysts.
Studies into the deactivation and regeneration of heteropoly acid catalysts, which took place in the group of Professor Ivan Kozhevnikov at Liverpool University since 1996, resulted in the large-scale industrial application of these catalysts in BP's process for the synthesis of the widely used solvent ethyl acetate, thus making significant economic and environmental impact. This process, trademarked AVADA (for AdVanced Acetates by Direct Addition of acetic acid to ethylene), was launched in 2001 at Hull, UK, on a scale of 220,000 tonnes p.a., then the world's largest ethyl acetate production plant. The impact continued through the REF period from 2008 to 2013. In October 2011, the AVADA process produced 56% of the ethyl acetate in Europe (245,000 tonnes p.a. production capacity and $340m p.a. factory gate value), being the second largest in the world after the Zhenjiang 270,000 tonnes p.a. ethyl acetate plant in China. Over the REF period, the AVADA process produced 1.2 million tonnes of ethyl acetate worth $1.7 billion. The AVADA process makes ethyl acetate with 100% atom efficiency, avoiding the use of ethanol as an intermediate. It beats conventional processes in environmental friendliness by reducing energy consumption by 20% and feedstock losses by 35%, thus removing more than 100,000 tonnes p.a. of wastewater stream. At the heart of the AVADA process is a highly efficient heteropoly acid catalyst that is responsible for its superior performance. Implementation of measures improving catalyst stability and resistance to coking, which originated from collaboration between the Kozhevnikov group and BP Chemicals, prevented otherwise fast catalyst deactivation to create an economically viable process.
Research carried out by Malcolm Green's group in the UOA led to the spin-out of Oxford Catalysts Ltd. A large part of the company's technology is based on Green's transition-metal catalysis research, which has enabled them to develop a highly efficient Fischer-Tropsch (FT) catalyst to convert natural gas to liquid hydrocarbons. In 2010, Oxford Catalysts Group (now Velocys) demonstrated the world's first smaller-scale, modular gas-to-liquids and biomass-to-liquids FT plants which made use of the catalyst for the efficient conversion of low-value or waste gas to liquid hydrocarbon fuels. Since then, orders worth £ 8M have been taken and the company has been selected to provide FT technology for 4 commercial projects. From 2008 - 2012, the company raised over £ 60M, achieved revenue of £ 30M and now employs around 90 people.
Research at UEA over a 20 year period in the area of olefin polymerisation catalysis has had significant economic impact through:
This research project, carried out at the University of Derby, was used to develop an engine performance monitoring system and a data optimisation method for engine management systems for Land Rover. The project delivered two pieces of software developed for data modelling and optimisation with respect to the engine test bed. This has significantly reduced the engine test time on the test bed by up to 30%, reduced the cost of each engine test and provided optimum engine operation parameters to the Engine Control Unit (ECU), which has resulted in lower emissions and improved fuel economy. The project was started in 2000 and completed in 2008. However the outcomes of the research and developed software tools are still used by the Land Rover engine test group.
Using powertrain system models arising from QUB research Wrightbus Ltd developed an advanced eco-friendly hybrid diesel-electric bus which won the New Bus for London contract worth £230M supplying 600 buses to Transport for London (commencing August 2012).
Demonstrating highly significant economic and environmental impacts the bus has twice the fuel economy of a standard diesel and emits less than half the CO2 and NOx. The full fleet reduces annual CO2 emissions in London by 230,000 tonnes, improving air quality and reducing greenhouse gases.
The company continues to develop the technology in new hybrid vehicles reaching worldwide, including USA, Hong Kong, Singapore and China.
Implementing measures that can maintain, as well as improve air quality is a constant challenge faced by local authorities, especially in metropolitan cities. The AVERT, EPSRC/DTI link project, led by Samuel and Morrey of Oxford Brookes University, were tasked at identifying and proposing a new strategy to limit the amount of pollutants from vehicles dynamically using remote sensing and telematics. Firstly, it established the magnitude of real-world emission levels from modern passenger vehicles using a newly developed drive-cycle. Secondly, it demonstrated a broad framework and limitations for using existing on-board computer diagnostic systems (OBD) and remote sensing schemes for the identification of gross polluting vehicles. Finally, it provided a strategy for controlling the vehicle to meet air pollution requirements. The outcomes had direct impact on Government policy on "Cars of the Future", roadside emission monitoring, and the business strategies for both the Go-Ahead Group and Oxonica Ltd.
Cardiff University, through developing and patenting a commercially viable synthetic route to a catalyst, has enabled the application of a new process, the Alpha Process, for the production of methyl methacrylate (MMA), a key commodity precursor to Perspex. The Alpha Process has had economic and environmental impacts.
Lucite International, the world's leading MMA producer, has invested in major Alpha Process production facilities in Singapore and Saudi Arabia, benefitting from a production route which is more efficient, more reliable and cheaper than conventional routes.
The Alpha Process also brings environmental benefits, as it does not rely on the use of corrosive and toxic feedstocks, such as hydrogen cyanide, which are associated with conventional MMA processes.
The selection of ligand(s) for the transition metal complexes that are frequently employed as catalysts for the production of fine chemicals is a key activity ultimately governing the financial viability of the process. Traditionally, the method for discovery of ligands with the appropriate balance of cost and efficiency has been achieved empirically via screening. This Impact Case Study reports on the development of a novel methodology for the qualitative and quantitative analysis and prediction of the effect of ligand structure on the catalytic activity of late-transition metals. It has been applied in process and discovery chemistry in pharmaceutical and agrochemical industries in the UK (and beyond). The analysis allows rapid, and therefore cost efficient, identification of ligands and catalysts with the potential to bypass intellectual property issues.