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From Petrochemicals to Pharmaceuticals: Rapid Scale-up of Penicillin by an Academia-Industry Consortium Including Shell Development Company during World War II

Joseph B. Powell, Chemical Process Technology, Shell Global Solutions US Inc., Westhollow Technology Center, P. O. Box 1380, Houston, TX 77251-1380

Most have heard the story of accidental discovery of penicillin by Alexander Flemming in a discarded culture (Petri) dish left in a window in his lab at St. Mary's Hospital, London. The chance observance (1928) is a well-noted example of “serendipity” in research. The discovery went nowhere, however until Flemming's 1929 publication was remembered in 1938 by Howard Florey and Ernst B. Chain at Oxford, who developed a method to extract and purify the first “antibiotic”. Initial production at the start of World War II used buckets, bathtubs, milk bottles, and any number of items resembling a common laboratory synthesis flask. Needless to say, this did not meet the wartime demand. A top-secret project was initiated in the US in mid-1943 via a consortium of industry and academic partners, including Shell Development Company, to scale up production. This led to rapid development of a 100-m3 mechanically stirred bioreactor, the first of its kind. Scale-up and production was sufficient to provide the full supply needed to support the Allies D-Day invasion of Normandy one year later (1944). This achievement ranks as one of the great success stories in chemical engineering and process development.