Robinsons Brothers, a leading UK manufacturer of specialty chemicals serving the pharmaceutical, agrochemical, and specialty chemical sectors, is seeking innovative solutions to reduce nickel catalyst consumption in hydrogenation processes through the implementation of an effective recycling or reuse system. This initiative aligns with Robinsons Brothers’ sustainability objectives and aims to deliver significant cost savings while maintaining product quality and compliance with industry standards. Given the pyrophoric nature of nickel catalysts, the challenge also addresses safety considerations, environmental impact, and asset utilisation, alongside improving material and resource efficiency. The process involves high-pressure and high-temperature conditions, requiring robust and reliable solutions.
Background
Robinsons Brothers has over 150 years of experience in specialty chemical manufacturing, including catalytic hydrogenation at scale. Nickel catalysts are routinely used in their hydrogenation reactions and represent a substantial material cost. The current process is a high temperature(150-300°C), high pressure (20-100 bar) hydrogenation of an unsaturated heterocycle to the corresponding saturated heterocycle, widely used in agrochemical and pharmaceutical applications.
At the end of the reaction, the catalyst is removed from the crude product by filtration prior to final purification. Owing to the pyrophoric nature of the catalyst, it is not re-used and instead sent directly for disposal/ refining. Laboratory trials have demonstrated that these catalysts can be reused up to eight times without any decline in performance. Robinsons Brothers have not tested beyond the eight cycles, however it isassumed that the activity will extend further.
As an ISO14001-certified company committed to sustainability, Robinson Brothers views catalyst recycling as a strategic priority to reduce reliance on critical raw materials and improve environmental performance. Previous attempts to implement a recycling system at production scale proved challenging due to the pyrophoric nature of the recovered catalyst. Finding a solution was resource-intensive and constrained by limited engineering capacity. The re-use of the catalyst will significantly reduce the required inventory and manufacturing costs.
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Entrants to this competition must be established businesses, academic institutions, start-ups, SMEs, or individual entrepreneurs. They must be UK based or have the intention to set up a UK base.
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The company aims to reduce catalyst consumption by up to 80% through the introduction of a robust recycling process to improve resource efficiency, reduce resource (people) time, increase asset utilisation and improve safety (due to pyrophoric nature). Laboratory trials have demonstrated that these catalysts can be reused without any decline in performance, but this currently cannot be achieved at larger scale.
Any solution should maintain catalyst performance and product quality while minimising the burden on internal resources. Ultimately, the goal is to create a system that is both economically viable and environmentally sustainable. Robinsons Brothers are open to hearing from a variety of different solutions, preferably at TRL 5-6 so it can be used at 30L pilot scale, but are also open to earlier stage solutions. A preference would be solutions that would allow the retention of the catalyst within the system or handling in a closed loop. Other ideas could include engineered handling systems, new catalysts including biocatalysts and new chemistries.
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Full functional, operating and technical details are available from the Innovation Exchange site. The below is a brief summary.
The current process involves hydrogenation using nickel catalysts in an autoclave, and laboratory trials show minimal catalyst deactivation with up to eight successful reuse cycles. Despite this, the company has not yet established a scalable reuse or recycling system for production environments. The reaction product is discharged as a slurry of liquid containing the pyrophoric catalyst solid and handled outside of the reactor. Developing a reuse or recycling system requires consideration of purity standards, contamination risks, and compliance with safety regulations. The solution should be practical and cost-effective.
Solutions must be:
- capable of integration into existing hydrogenation workflows requiring minimal disruption to current operations. While temporary shutdowns of individual autoclaves for phased implementation may be feasible, the preference is to minimise any operational interruptions wherever possible
- compliant with chemical manufacturing safety and environmental regulations.
- at least scalable for validation in a 30L autoclave operating at 150–300°C and 20–100 bar, which serves as Robinsons Brothers pilot scale for hydrogenation.
suitable for operation within an ATEX, Zone 1 hazardous environment on a low tier COMAH site
For full functional, operating and technical details, visit the Innovation Exchange site.
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The following are out of scope:
- Solutions that increase the risk to site safety including the manual handling risk to operators due to the pyrophoric nature.
- Solutions that increase operator exposure to toxic nickel catalyst.
- Methods that increase hazardous waste or environmental impact associated with catalyst use.
- Solutions that contaminate the products with excessive water.
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For solutions closer to market, Robinsons Brothers are looking for a 2yr Return on Investment (ROI) based on the volumes of catalyst detailed above and the potential savings on any solution provided. However, if external grant funding or Innovation loans are available then longer payback periods may be considered.
When evaluating solutions, the lowering of OPEX cost/ annum of the catalyst will be seen as more important than the cost/ kg of a catalyst.
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Successful applicants will be given an opportunity to pitch to Robinsons Brothers. Selected solutions will be trialled by Robinsons Brothers with potential for further adoption if trials are successful. Robinsons Brothers can also provide in-situ process testing of a new catalyst during operation.
The solution has potential to be deployed across mutiple reactors and products at their site
The benefits package for a successful applicant may also include:
- Support from Innovate UK Business Connect
- Support in the development of a prototype or pilot
- Technical support
- Invitation to attend or present at Innovate UK Business Connect events
- A potential business collaboration
- Investor introductions (if investment isrequired)
- Support if any Innovate or similar competitions are relevant.
For full information, including technical and functional details and IP/commercial licensing, see the Innovation Exchange site at the link below.