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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.
Research at UEA over a 20 year period in the area of olefin polymerisation catalysis has had significant economic impact through:
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.
Fluorescent ligand technologies developed by Professor Hill and Dr Briddon in the Pharmacology research group, in collaboration with Professor Kellam in the School of Pharmacy, permitted biophysical analysis of G-protein coupled receptors (GPCRs) at the individual cell and molecule level for the first time. The technologies have been commercialised through the spin-out business, CellAura Technologies (and their distributors Abcam, Sigma-Aldrich and others), generating revenues and making the products available to researchers and drug discovery communities worldwide. Custom product developments with global pharmaceutical companies and drug screening reagent providers have generated further partnership revenues and technology benefits. Nottingham-trained researchers are now employed worldwide, broadening the technology's impacts.
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 by the School of Pharmacy has underpinned the development of fluorescent ligand probes that have opened-up new pathways in drug discovery. These ligands have been commercialised through the formation of the spin-out company CellAura Technologies Ltd, and have been made globally available through a number of distributer agreements. Customers include pharmaceutical companies (e.g. Pfizer, AstraZeneca), drug discovery biotechs (e.g. Addex, Heptares) and drug discovery technology providers (e.g. CisBio). These ligands provide alternatives to the use of radio-ligands, giving more informative and safer solutions for industrial drug discovery. This has, for example, enabled: a new direction in G protein-coupled receptor research at Novartis Pharmaceuticals UK Ltd; validation of Promega Corporation's new drug-binding assay; and superior performance in the establishment of cell lines at inSCREENex GmbH.
Cranfield's work on ethylene supplemented storage is now exploited in the supply chains to major supermarkets in the UK, including Waitrose and Tesco, reducing waste and avoiding volatility in supply for fresh food products such as onions and potatoes. By prolonging storage life by up to six weeks it is also having a positive impact on the UK's self-sufficiency in these products, displacing imports from overseas.
Complementary work has also led to commercial ethylene scrubbing technologies for packaging, which typically save around 50% of in-store waste and add two days to the product life for a range of fruit and vegetables. Such packing is now in use in most mainstream UK supermarkets, and in the USA where it has created a new export market for the manufacturer.
The growth and performance of Biofocus Galapagos Argenta (BGA) and Pulmagen Therapeutics (PT) are underpinned by research from the Imperial-based TeknoMed project that started in 1997. BGA was formed in 2010 through the acquisition of Argenta Discovery (AD) by Biofocus Galapagos for €16.5 million and is one of the world's largest drug discovery service organisations with 390 plus employees and turnover of €135 million [section 5, A]. PT was formed as a separate company to own the complete AD drug pipeline. It develops new medicines to treat asthma, cystic fibrosis and allergic diseases. In 2011 BGA signed agreements with PT for an initial £6million fee and with Genentech for £21.5million.
Catalysis is a major UK industry strength and wealth generator for the UK economy. Research carried out in the group of Professor Matthew Davidson in the Department of Chemistry at the University of Bath resulted in the development of titanium and zirconium alkoxide catalysts for use in three industrial polymerisation processes and patented by the UK companies ICI Synetix and Johnson Matthey. Patents have recently also been acquired by the Indian multinational Dorf Ketal and filed by the Dutch multinational Corbion Purac. The research has resulted in the adoption of new catalysts in industry leading to increased turnover, onward dissemination and implementation of the Bath intellectual property. It has also generated £4.6M from sale of intellectual property and an increase in generated sales of new, sustainable titanium catalysts that replace heavy metals such as tin, antimony and mercury in major industrial processes. The intellectual property and process developments have been implemented globally in the poly(ethylene terephthalate) (PET) and poly(urethane) (PU) plastics markets, worth $23B and $33B, respectively, in 2010.
Globally there are estimated to be 60 million cars produced each year. These all require catalysts that need testing to meet stringent emissions legislation. Catagen Ltd, a spin-out from Queen's University has developed a product for testing motor vehicle catalysts that is 85% cheaper to operate than traditional methods and represents a 98% reduction in CO2 emission from testing and an 80% reduction in energy input.
Major global customers including GM motors and Fiat have adopted this revolutionary patent protected technology and international sales growth has been recognised, winning an all- Ireland business award for BEST High Growth Company 2012