Traditional pharmaceutical manufacturing is based on a complex supply chain that is vulnerable to spikes in demand and interruptions. Continuous pharmaceutical production in compact modules is a potential solution that allows for drug manufacturing when and where it is needed with significantly shorter lead times. As part of the Pharmacy on Demand (PoD) initiative, we demonstrate the potential for end-to-end manufacturing of multiple drug substances in reconfigurable devices, under common industrial constraints, and within a challenging manufacturing time frame. A new set of refrigerator-sized modules was constructed for the synthesis, isolation, and formulation of several drugs, with focus on achieving high manufacturing throughputs, and allowing for the production of pharmaceutical tablets. Their operation is demonstrated with the synthesis and formulation of USP-compliant tablets of diazepam, diphenhydramine hydrochloride, and ciprofloxacin hydrochloride, as well as liquid formulations of lidocaine hydrochloride and atropine sulfate.

The economic, environmental, and energetic performance of direct air capture (DAC) processes based on solid sorbents depends significantly on ambient air conditions and the availability of renewable resources. High ambient temperature or low humidity leads to higher energy consumption and lower CO 2 productivity; lack of renewable resources may make the direct air capture process not viable. With this work, we investigated how the performance of sorbent-based direct air capture plants varies when changing ambient conditions and how the system should be optimally designed and operated to match the time-dependent variations. To this end, we formulated a new modeling framework, where thermodynamic modeling of adsorption processes is bridged to mixed integer linear optimization via a portable linear model of DAC. The process is based on a vacuum-temperature swing cycle, whose performance was obtained with a ratebased thermodynamic model at varying ambient conditions for an exemplary sorbent representative of different amine-functionalized materials. The optimal design and operation were investigated for (i) a stand-alone DAC system installed at three different geographical locations and (ii) a DAC system embedded in a multi-energy hub aimed at supplying the DAC energy demand from renewable resources. We found that DAC performance is optimal when the process can adjust the operating variables according to the weather profile and when CO 2 can be produced flexibly over time, for example, by adopting a buffer storage tank. Other operation strategies are suboptimal but might require less sophisticated control systems. Moreover, the results suggest that capturing costs are significantly smaller in cold and humid conditions. This conclusion holds for both the stand-alone and the integrated DAC systems. However, for the latter, cold and humid conditions are favorable only when abundant renewable energy is available and can be supplied at low costs, for example, via wind farms. These conclusions remain true over a wide range of technical and cost assumptions.

A Mg–Al oxide obtained by thermal activation of a hydrotalcite and extruded with bentonite enables the continuous manufacture of glycerol carbonate from glycerol and urea owing to its strong Lewis basicity and resistance to leaching.