Aarti Industries is a knowledge-driven Company. Aarti presently has three R&D centers; two, located in Dombivali and Vapi, focus on R&D initiatives for Pharmaceutical APIs, and the other, located in Vapi, on Chemicals. Another 50,000 sq ft R&D and Innovation Complex, which will house 150 scientists and engineers, is in the works. The complex will double Aarti’s R&D capabilities and focus on development of newer and niche value-added products and process chemistries, and improving product quality and process yields of existing products, forward integration for downstream products, among others. The complex is planned to comprise of an R&D centre, a scale-up facility, an Innovation Center, and dedicated labs for Process Safety, Effluent Treatment and Flow Chemistry, among others.

SYNTHESIS CAPABILITY

Aarti has a state-of-the-art R&D Center with the latest laboratory reactors equipped to carry out various types of reactions:

Reactions at atmospheric pressure

Atmospheric reactions are carried out in jacketed glass reactors. The reactors are equipped to measure and control process parameters precisely. This has enabled Aarti to apply Design of Experiment during process intensification. It also uses PAT tools such as react-IR and online particle size to monitor the progress of reaction and take critical decisions. This reduces the incidence of manual errors and produces reliable results.

Reactions at high pressure

A dedicated high pressure section has been developed with ballast proof walls. The reactors are controlled by DCS to avoid any exposure to research personnel. Further, software-controlled gas feeding, temperature control, cooling, and liquid feeding has been employed to obtain reliable data. This allows a thorough analysis of abnormal thermochemical activity in the process.

Workup

The laboratory is equipped with lab scale modules for various types of workup equipments used in the plant, including Buchner Funnels, Nutsche Filter, and Centrifuge Filter. Also, rotavapors are used for solvent recovery.

Distillation

Aarti frequently employs distillation employed as a purification step. So, Aarti has procured a sophisticated distillation apparatus that can achieve separation of compounds with boiling point difference of around 1 °C. This setup provides flexibility to change theoretical plates and reflux ratios. Lab data helps in scaling up and designing pilot and plant-scale distillation setup.

Parallel Reactors

Parallel reactors are being used for high throughput screening of reaction parameters and process optimization using statistical design of experiments.

Photochemistry

Aarti’s capabilities include carrying out photochemical reactions in the batch reactors.

EXPERTISE IN SPECIFIC CHEMISTRY

  1. Alkylation
  2. Acetylation
  3. Amino Acid Esterification
  4. Ammonolysis
  5. Aldol Condensation
  6. Asymmetric Hydrogenation
  7. Butyl Lithium Reaction
  8. Balz-Schiemann Reaction
  9. Boron Chemistry
  10. Cynation
  11. Chlorination
  12. Cyclocondensation
  13. Condensation
  14. Chichibabin Reaction
  15. Chiral Chemistry (Implementation of enzymatic technology)
  16. Diazzotization
  17. Denitrochlorination
  18. Diborane Reduction
  19. Darzens Glycidic Ester Condensation
  20. Dieckmann Cyclization
  21. Ethylation
  22. Epoxidation
  23. Friedel Crafts Reaction
  24. Flow reactor technology at commercial scale
  25. Grignard's Reaction
  26. Hydrogenation
  27. Halex (Fluorination)
  28. Hetero Diels Alder Reaction
  29. Kolbe's Reaction
  30. Knoevenagel Reaction
  31. Methoxylation
  32. Meerwein-Pondorf-Verley Reduction
  33. Michael Addition
  34. Negishi Reaction
  35. Nitration
  36. Oppenauer Oxidation
  37. Phosphorylation
  38. Silylation
  39. Sandmeyer Reaction
  40. Suzuki Coupling
  41. Swern Oxidation
  42. Sulphonation
  43. Skraup Reaction
  44. Steroid Chemistry
  45. Triphosgene Reactions
  46. Ullamann Reaction
  47. Witting Reaction
  48. Willegrodt Reaction

FLOW CHEMISTRY

Aarti is a manufacturing solution provider for chemical syntheses of various kinds. Aarti uses flow chemistry to increase the safety of the process . There are several advantages this process has over traditional batch chemistry

EFFICIENT

  • Higher yield and purity
  • In-situ analytical evaluation of reactions
  • Better process control
  • Shorter time to commercial launch

FLEXIBLE

  • Different chemistries/ reactors on one instrument
  • Less restrictions on minimum fill volumes
  • Scaling out by adding units in parallel

SAFE

  • Excellent heat transfer
  • Low reactor volume and hold up time
  • In-situ generation and consumption of dangerous compounds

Aarti is equiped with several flow
instruments from different vendors:

  • R Series Vapour Tec (Vapourtec)
  • Chemtrix
  • Syrris
  • Amar (Lab to plant)

ANALYTICAL CAPABILITY

Aarti’s analytical team employs procedures like gravimetric, volumetric, colorimetric and potentiometric for chemical testing in the wet lab. Using these, the team obtains quantitative and qualitative information relating to elements in a sample.


Chemical composition analysis utilizes a combination of techniques that can cover a wide range of applications. These determine chemical quality, identity, composition and impurities, with molecular structure elucidation and chemical structure confirmation.


Chemical trace analysis is often complex. Aarti’s trace chemical testing capabilities include trace metals analysis and organic compound detection up to trace and ultra-trace ranges, even for complex sample matrices.


ICP Spectrometers perform trace element analysis, detecting the full spectrum of elements. These machines have detection limits in the parts per million range for many metals, and even parts per trillion for a few.


Chemical residues testing includes analysis, detection and identification of residues and this expertise is regularly deployed to solve industry problems.


ORGANIC ANALYSIS

  • Separation and quantitative analysis of trace-level complex organic mixtures and compounds
  • Gas chromatography/mass spectrometry (GC/MS)
  • Gas chromatography/electron capture device for PCB analysis (GC-ECD)
  • High Performance Liquid Chromatography/mass spectrometry (UP/HP-LC/MS)
  • Autosampler, Headspace
  • Infrared Spectroscopy (IR)
  • UV-Vis Spectroscopy

CORROSION TESTING

The analytical laboratory also performs testing on metals to determine susceptibility to corrosion. The list of services provided for corrosion testing include accelerated intergranular corrosion, passivation, humidity, salt spray and salt fog methods performed according to ASTM and industry standards.

INORGANIC ANALYSIS

  • Wet-chemical and instrumental methods for elemental, compositional and isotopic analysis of solid and liquid samples. Analysis can be done on radioactive samples
  • Ion chromatography (IC)
  • Inductively coupled plasma/atomic emission spectrometry (ICP/AES)
  • Inductively coupled plasma/mass spectrometry (ICP/MS) with dynamic reaction cell (DRC)
  • Thermal ionization mass spectrometry (TIMS)
  • Carbon, sulphur LECO analysis
  • Autotitration
  • Cold vapor atomic absorption mercury analysis
  • pH, cyanides, mercury, conductivity, reactive sulphides
  • Particle Size Distribution Determination
  • Total inorganic analysis by Muffle Furnace

PHYSICAL PROPERTIES TESTING AND MEASUREMENT

  • Physical properties testing is done by latest equipment in the industry by trained scientists
  • This helps in process scale up, plant design and process safety analysis
  • Melting point / boiling point
  • Vapor pressure
  • Flashpoint
  • Calorific value of coal

PROCESS SAFETY ANALYSIS

The four major hazards in chemical processing are:

  1. Chemical reaction hazards
  2. Fire and explosion hazards
  3. Health hazards
  4. Environmental hazards

At the R&D stage, Aarti has defined philosophies and procedures to be followed when designing a safe chemical reaction process. These concentrate on the hazards that may be generated during the chemical reaction.

The three major chemical reaction hazards are:

  1. The thermal instability of reactants, reactant mixtures and products(including any intermediates, potential contaminants and by-products)
  2. Exothermic reactions which raise the temperature to produce decomposition reactions or violent boiling
  3. Gas evolution

A dedicated team and laboratory has been developed with following equipments for fledged process safety analysis:
Thermal Screening Unit - TSU(HEL)
Reaction Calorimeter - RC1(Mettler)
Advance Reactive System Screening Tool - ARSST(Fauske & associate) under planning
Hazop, studies are being carried during R&D process development to design inherently safe procedures.

Chemical Information management

Aarti has developed a central database of MSDS involving all the chemicals being used at our sites. This online database is readily accessible to all employees.

Effluent study

Aarti is planning to setup a dedicated ETP division with an aim to reduce the effluent load and treat it in an economic and environment friendly way.