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Green chemistry and engineering tools
Principles to praxis
Green Business Options for
Textile, Chemicals & Pharmaceutical Sectors
19th & 20th March, 2016
A KnowGenix presentation
KnowGenix
KnowGenix
GCE: Reflections & lessons learnt
Waste valorisation: Promise & prospects
New directions: IOTs & Manufacturing technologies
… a commercially viable practice…. driven by regulation and
customer space driven innovations…
• GC: Science based, non regulatory and economically driven
• DfE: Moving GC praxis to sustainable products for the market
place
• GC Metrics: enabling monitoring and evaluation of outcomes
..Commercially viable sustainable products, created a new
culture of innovation, enhanced resource optimization and led to
businesses now embracing GCE protocols and praxis into their
business planning… evolving since 1970s…
Sustainability in chemical enterprise
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Sustainability : Evolution
Tangibles from GCE practice
Bottom Line Top Line
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New products
New markets
Differentiation
Revenue growth
Newer IP
Brand image
Higher CSR indices
Optimal
• Cap. Utilisn
• Energy/water use
• Inventory costs
• Product yield
• Quality
• Overhead costs
New opportunities USD 98.5 Bn [2020]
Cost savings
USD 65.5 Bn [ 2020 ]
Source: Pike Research, 2015
Energy/fuels
Designer biomass, eco-efficient OFC, bio
materials for solar and wind energy systems,
Li–Ion batteries
Sensor networks, recyclable products, energy
devices, safer electronic chemicals
Transportation
Infrastructure
ICT
Healthcare
Self healing aids, biomarkers, customized
cosmetics; novel diagnostics, designer
prosthesis
Fuel cells, bioplastics, lightweight polymers,
recyclable green tyres, compact batteries
Performance coatings, bio-cleaners, asphalt
binders, cement additives, adhesives, colorants
Economics of GCE: New Opportunities
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Leveraging GCT platforms GCE tools
Resource management Energy/water/solvent/inputs efficiency
Valorization of wastes Industrial, agriculture, fruit, vegetable process wastes
Economics of GCE: Cost savings
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GCT platforms
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Products to markets
Product redesign: Saquinavir, Aprepitant, (S)- Metolachlor, Sertraline
P-Phenylenediamine, Citral, Lazabemide, 1-Menthol
Valorisation: High value products from steel mills flue gases, other
industrial processes, Carbondioxide/ Biowastes to fine chemicals
Process intensification: Pigments, APIs, organic Intermediate, Polymers,
Methylacetate, Hydrogen peroxide etc etc
Biocatalysis: Simvastatin, Atorvastatin, Pregabalin, Sitagliptin
PI
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Intensified processes
Source: Eastman Chemicals
Water as a green solvent?
Volatile vs involatile solvents? Ionic liquids
Making choices hazardous reagent Vs low waste route?
Bio based value chain Vs Fossil fuel chain?
Waste minimisation Vs Value added by-product
Catalytic vs Reagents? Depletion
Bio process vs chemocatalytic process?
Food or non food crops?
Lessons learnt
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Lessons leant Trade off in designing greener processes
Hazardous Vs Low waste, low energy
On site
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Source: ACS
A&W principles : Rallying point for lowering chemical hazards through
chemistry based model
Peterson Myers principles : Toxicology, EDs became central to GC debate
– Reducing toxicity by design
– Poor track record of chemical substitutions – lack of insights into ED
Key directives
• Tiered protocol for endocrine disruptors (TiPED)
• a design phase tool for ED free chemicals
• links GC with environmental health sciences
• Framework for strategic sustainable development ( FSSD)
• enabling multidisciplinary approach
• strategic mapping of sustainability solutions
Carcinogens were the buzz words of 90s Endocrine disruptors are the buzz words today
Lessons learnt : 12 GC Postulates
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Newer and complex heteroaromatic chemistries
New green chemistry metrics of different categories (mass, energy, safety,
ecotoxicity, etc.) needed
Multiple metrics to provide precise data.
Solvent/water intensity, Ecoscale, Stoichiometric factor, Toxic Release
Inventory (TRI); Life Cycle Metrics; Energy Metrics, Renewability metrics,
Recyclability metrics, and Degradation potential metrics….
CHEM21 Green Metrics
•Alternatives for a number of key transformations (e.g. amidation, C–X bond
formation and C–H activation)
•Utilising a wide range of chemical, biocatalysis and synthetic biology
techniques
•Assessing and determining the efficacy of the new reactions or
methodologies developed against the existing chemistries
Lessons leant: Green Metrics
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Lessons learnt: GCE Priorities
At a strategy level
Eco-efficient products
Energy efficiency
Emission reduction
Waste reduction
Reduction of GHG
Inherently safer products/
processes
Novel pathways, reagents
Catalysis, Biocatalysis
Bio transformations
Reactor design /
engineering
Process intensification
New activations
At a R&T level
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Optimising our raw material usage
Using solvent guides
Using the right GCE metrics and tools
Integrating GCE protocols at the process design stage
Using green chemistry / engineering softwares
Benchmarking our products/processes
Regularly auditing energy, water, solvent, raw material , waste streams , vent gases
Adopting best practices in alignment with industry norms
Identifying and assessing our visible and invisible cost structures due wastes
Meeting our client expectations in –eco efficient products and services
We aware of thermochemical hazards of our processes
Are we ?..
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Waste valorisation : Prospects and challenges
Fruit/ veg
processing
Veg. Oil
processing
Flue gases Carbondioxide, CO, PA vent gases, etc etc
Waste valorization
Industrial
By-products
Agriculture
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Recovery of chemicals and solvents
(Pharmaceuticals, dyestuffs, coatings, fragrance
industry wastes)
Palm oil, castor oil. Olive oil mills processing
wastes
Polymers from bagggase, nutrients from dairy
wastes
Orange peel and potato processing
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Valorization of synthetic wastes
• NOX in Nitric acid plant to sodium nitrite
• Aluminumchloride in FC to polyaluminum chloride, a coagulant
• Alpha methylstyrene from phenol plant
• m/p diethylbenezne to divinyl benzenes
• Waste bottom from Isophorone to fragrance products
• Toluene/C9 aromatics to xylenes
• Phthalic anhydride vent gases to fumaric acid
• Lean copper and nickel ores using reactive solvent extraction
many more examples from India…
Bayer
Evonik
BASF/ RTI/
Universities
LanzaTec
Carbon capture technologies (coal fired plants)
Carbondioxide to fuels
Polyether polyols
Polyurethane from waste carbondioxide
Zinc catalysed – BMS.BTS, Univ. Aachen
Carbon capture models using designer adsorbents
to produce chemical feedstock
Valorization of Carbondioxide
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Ethanol and derivatives from steel mill flue gases
(CO) using gas fermentation technology
Valorization of biowastes
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Bio-waste valorization : Status
Fastest growing sector in EU. APAC
Technologies: Commercial status
Sources: Agri, Food, Fruit, Veg, Dairy, OM etc
Sourcing: Varied models
Key sourcing hubs
India, Sub Saharan Africa, APAC, EU, Brazil
Market status: Diverse products commercialized
Sustainability protocols key driver
India: High resource, huge opportunity
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High end fine chemicals
High value products
Speciality
Antioxidants, antimicrobial agents, vitamins, flavors,
dietary fibres
Health ingredients: carotenoids and phytoestrigens
Bio : surfactants, polymers, specialities, monomers
Macromolecules
Cellulose, starch, lipids, proteins, plant enzymes
Polysacchharides
Oligosaccharides: mono, di and non digestible
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Indian opportunities
Orange: D-limonene,pectin,Alpha-terpineol
Tomato: Lycophene, tocopherols, enzymes
Coffee beans: Proteins, amino acid, Pol.Sach
Potatoes: Proteins, biosurfactants etc
Tea : Tannic acids, flavonoids, caffeine
Dairy: Antioxidants, amino acids
Olive Oil Mill: Amino acids, proteins etc
Glycerol: Bio lubricants, fuel additives, SA
Biosurfactants: Sweet potato, sorghum, distillery, cassava,
starch, pomace, rice husk, oil refining wastes etc etc – many
Indian sources
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Waste orange peel
Supercritical
CO2
Microwave
treatment Liquid CO2
Limonene a-Terpineol HMF Pectin
Biocatalysis
Bio-ethanol p-Cymene
p-Cymene
sulfonic acid
p-Cresol &
acetone
p-a-dimethyl
styrene
Fermentable sugars
Food
additive Porous
carbonaceo
us material
High value chemicals from orange peels
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Key determinants Sourcing
Competitive access, supply reliability, logistics, Supply contracts, pricing etc
Technology
Chemical, biotransformation, separation
Extraction: SC, solvent, enzymatic
Advanced pre treatment, refining techniques
Quality determination/characterization methods
Integrated/intensified model
Quality
Consistency, toxic components, composition
Residual pesticides
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Biowaste valorisation roadmap
Opportunity and risk analysis
Technology access and integration
Skilled bioprocess personnel
R&D: Product/process design, infrastructure
Q/C: Characterization, instrumentation
Sourcing models, SCM strategies
Market strategies, access, alliances
National/State biowaste valorisation strategy
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Waste valorisation technologies are yet to mature.
Enzymatic, fermentation and extraction technologies
sub-optimal to deal with diverse range of wastes
Evaluation of wastes depends on accurate analysis of the
composition of wastes, toxic components and the proportion of
diverse functional ingredients present
The key to effective valorisation of wastes to value-added
chemicals and polymers goes beyond technology to that of
competitive access, quality and characterisation of wastes
Research is needed on stability and interactions of
phytochemicals with other food ingredients during processing
and storage
Lessons learnt: Waste valorisation
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New Directions
IOTs & manufacturing technologies
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ACS 6 Enablers: Future manufacturing platforms Process Intensification
• New advances in intensified processes: flow reactors, hybrid systems, reactive
separations
rationalise material, energy, and safety parameters
Active Analytical Devices
• assure reliability of inputs, conditions, and outputs to match engineering and
operating specifications
• precise knowledge of manufacturing parameters in real time
better productivity, profitability, safety and product quality
Advanced Separation Processes
• Advancements in materials (e.g., membranes) and processes (e.g., membrane-
reactors).
• Advancing chromatography (a mainstay in analytical work) for improved
product purity
• Ionic liquids for cleaner, more energy-efficient and precise separation
Energy efficient, high precision manufacturing
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New Energy Activations
• Photochemical (lowering dissociation time)
• Microwave ( improving energy efficiency)
• Ultrasonic ( precise measurement of energy transfer/usage) and
• Electron beam energy ( developing semiconductors)
large scale efficiencies, product reliability and manufacturing flexibility.
Computational Modeling:
• Increasing computing power to analyze massive data sets
• Provide visualization and integrate finite-element analysis with
biological, chemical, thermal and mechanical modeling.
improve economics, avoiding costly downtime, retrofits or failures.
Automation, Robotics, Computing, and Intelligent Systems
• Integration of computational and mechanical systems
• New automation and intelligent systems for continuous monitoring and
feedback
sustainable manufacturing in diverse fine and speciality chemical plants
ACS 6 Enablers: Future manufacturing Platforms
Introspections
Insights
Initiatives
2025 2015
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“where is every molecule going in your plant?”
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Physical
Source: Modified Roland Berger
Digital platforms driven by IOTs to shape future of sustainable manufacturing
Source: KnowGenix
