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The pioneering work of Steven Ley on polymer-supported reagents and continuous-flow reaction technology has helped change the way we achieve cleaner chemical processes. The concepts and techniques invented in Cambridge allow more sustainable processes to be developed, with concomitant reduction in purification steps, shorter reaction times and diminished solvent usage. The work has led to a spin-out company (Reaxa), seeded the creation of a number of other companies, and resulted in the development of several devices for continuous flow synthesis that are now commercially available via Mettler-Toledo (USA) and Cambridge Reactor Design (UK). This technology is having an impact in industry, with continuous flow processing increasingly being used for full-scale commercial production.
Plaxica is a spin-out from, and based, at Imperial College London with economic, societal and environmental impacts. Launched in 2008, Plaxica is a process technology licensing business which is tackling the barriers that currently prevent a wider acceptance of bioplastics; specifically improving properties, decreasing cost and using non-food feedstocks to manufacture the biopolymer poly(lactic acid), PLA. Plaxica's technology uses sustainable feedstocks to produce PLA using more energy-efficient processes, to produce a strong, high-quality polymer, the result of which is a low-cost, environmentally-friendly biopolymer for use in applications including textiles, packaging, and automobile parts. In the REF period Plaxica has raised £10m from investors such as Imperial Innovations, Invesco Perpetual and NESTA Investments. The market pull for biorenewable materials from consumers is strong and the EU predicts that PLA will substitute >10% of the existing market for petrochemical polymers and forecasts a market >$15b [A].
University of Huddersfield research in physical organic chemistry has delivered economic, industrial and societal benefits. It has led to process improvements in chemical manufacturing, most notably in the optimisation of the synthesis of antisense oligonucleotides and in the use of liquid ammonia as a solvent. It has also led to the development of new inhibitors of bacterial β-lactamases for use as antibacterials. The research team's expertise has been reflected in the success of IPOS (Innovative Physical Organic Solutions), a unit established in 2006 to carry out research in process and other areas of chemistry for the chemical industry. IPOS expanded significantly from 2009 to 2013 and has now collaborated with more than 150 companies, many of them based in Yorkshire/Humberside where regeneration is critically dependent on the success of new, non-traditional, high-technology firms and industries. Through these collaborative projects, IPOS has contributed to the growth and prosperity of both regional and national industry.
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.
Research at Warwick by Professor David Haddleton's team led to the discovery of a new family of catalysts for living radical polymerisation. A spin-out company, Warwick Effect Polymers Ltd (WEP), was established to develop this research and received a total of £3.77M investment. Supplemented by income from contracts, and operating in purpose-built laboratories on the Warwick Science Park, WEP employed 10-15 people and spent £3.0M over the REF2014 period developing a substantial patent portfolio. WEP's commercial success and intellectual property in polymer therapeutics and nanomedicine led to its acquisition by PolyTherics Ltd in 2012.
The unique application of combinatorial chemistry in materials science at Southampton has directly underpinned the success of University spin-out, Ilika Technologies. Since 2008, the breadth of applications of the research has allowed Ilika:
Between 2008 and 2012, Ilika enjoyed considerable growth, doubling employment to 35 staff, increasing turnover by approximately 25% annually, and floating on the AIM with a market capitalisation of £18.7 million.
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.
The technology in this impact study is based on organofunctionalised silica materials that can address market needs for high purity in compounds that underpin many areas of the pharma, electronic and medical sectors as well as the recovery of limited resources such as precious metals that are used in diverse industries. Since the launch of the product portfolio in 2006, the materials have become embedded in purification or recovery steps in commercial production processes of leading mining (South Africa), pharmaceutical (UK) and petrochemical (Germany) companies and make a significant impact on the business of these companies as well as limiting waste of limited resources.
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.
Labelled compounds form an essential part of drug discovery and development within the pharmaceutical industry. Novel iridium catalysts, developed by Kerr at WestCHEM since 2008, have introduced a step-change in the ability to label pharmaceutical candidate compounds with radioactive (tritium) or non-radioactive (deuterium) isotopes.
The catalysts are applicable to specific types of compounds that comprise approximately one-third of all drug candidates. Advantages of the catalysts include greater efficacy (less catalyst needed and higher yield of labelled product, giving cost savings), greater speed (efficiency savings), and a significant decrease in radioactive waste compared with previous methods (environmental and safety benefits).
Even since 2008, their adoption within the pharmaceutical industry has been extremely rapid; e.g., the multinational pharmaceutical company AstraZeneca now applies the Kerr methodology to 90% of their relevant candidate compounds. Additional impact has been achieved by Strem Chemicals who have been manufacturing and marketing the catalysts worldwide since October 2012. Even in that very short period, multiple sales have been made on three continents providing economic benefit to the company.