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Leveraging GCE for sustainable chemical manufacturing
Learning outcomes
IGCW 2015
4-6 December 2015, Mumbai
A KnowGenix presentation
KnowGenix
Characteristics
• Multiproduct, multisegment, multilocation
• An enterprise with a global footprint in 70 odd countries
• Migration of markets, labor, manufacturing,
Structural shifts
• Feedstocks, R&D, technology platforms, manufacturing,
markets, EHS and SC management
• Asset recapitalization continued; ownership pattern
changed; portfolios rationalized; R&D pipelines slowed
• Customers consolidated; specialties commoditized
• New regulations; products banned; aware consumers
• Managing complexities became the norm
KnowGenix
Landscape in transition
Global presence
Multiple technologies
Margin driven growth
Competitive feedstocks
Innovation (mega trends)
Sustainability capability
Regional presence
Niche technologies
Customer driven growth
Competitive delivery
Innovation (Customer)
Customer sustainability
Hybrid companies Niche companies
KnowGenix
Landscape in transition
Global mega trends sets new engagement rules
• Sustainability mandates influenced business agenda
• Investments in GCE tools, metrics, standards
• Focus on segment specific sustainability standards
• Risk management of portfolios (mega trend driven)
• Enhanced regulatory response capability
• Value creation models that embed EES-S components
industry explored, evaluated and experimented with diverse
innovation models
Landscape in transition
KnowGenix
Leveraging GCT platforms GCE tools
Bio-based products Synthetic biology
Resource management Energy efficiency
Valorization of biowastes Industrial, agriculture, fruit, vegetable process wastes
KnowGenix
Reflections
Biocatalysis: Simvastatin, Atorvastatin, Pregabalin, Sitagliptin
Product redesign: Saquinavir, Aprepitant, (S)- Metolachlor
PI: Pigments, API intermediates, Viagra Intermediate etc
GCE to markets
KnowGenix
Insulation foams, reflector coatings,
detergent enzymes (energy reduction)
Light weighting polymers (fuel efficiency)
Fluorescent lights (GHG reduction)
Energy devices (energy optimization)
Advanced materials (fuel efficiency)
Novel Bio- materials (Energy/ GHG
reduction)
Healthcare
Food
Housing
Transportation
Infrastructure
Climate change driven EE innovations
KnowGenix
Onsite EE: New EE products; Enabling customer EE
Climate protection products – high cost, high risk game
New tools for sector specific energy efficiency
Energy/fuelsDesigner biomass, eco-efficient OFC, bio materials
for solar and wind energy systems, Li–Ion batteries
Climate change driven opportunities
Transportation
Infrastructure
ICT
Healthcare
KnowGenix
Sensor networks, recyclable products, energy devices,
safer electronic chemicals
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
Synthetic biology (complex yet to mature)
Thermochemical conversion (mature, scalable)
Algae based (nascent, early stage failures)
Bio based products
Medicine Food
Sitagliptin
(Merck/Codexis)
Cephalexin
(DSM)
Antitrypsin
(Intrexon)
Artemisnin
(Amyris)
Valencene/
Nooktatone
(Isobionics/D
SM, Allylix)
Vanillin/resve
ratrol
(Evolva)
Vetivone
(Allylix)
D-lactic acid
(Myriant)
Butanediol
( BioAmber,
Genomatica)
Adipic acid
(Verdezyne)
Succinic acid
(BioAmber, etc
Farnesene
(Amyris/Kurar
ay)
PHA
(Metabolix)
Isoprene
(Amyris,
Genencor etc )
PBS
(BioAmber)
Fuels
Isobutanol
(Gevo)
Algal oils
(Solazyme)
Butanol
(Butamax/Dup
ont)
Algal biofuels
(Syn.Genom)
Chemicals Materials
www.synbioproject.org
KnowGenix
Learning outcomes
“GC Postulates – no rocket science, any chemist could have written it”
“Experience to pedagogic structures”
“GC innovation that does not find market acceptance is irrelevant”
“Causality – ability to predict cause and effect”
Dr. John C Warner, 4 Dec 2015, IGCW 2015, Mumbai
Hydrogen economy, fuel cells, cellulosic ethanol. algae?
Reliable, inexpensive and limitless energy!!
Buckyballs- new form of carbon – designer and highly symmetrical molecular form of carbon systems with very limited application!
Graphenes – the wunderkind of materials??
Areas needing scrutiny
• Biofuels/materials/chemicals
• Algae based fuels
• Carbon dioxide capture
Learning outcomes
High hype, low delivery business ?
KnowGenix
Key impacts:
• Attracting investments into GC
• Low credibility due sub optimal assessment
• Devalued IP
• Waste of research dollars
• Difference between subset of discoveries that offer viable and
practical solutions and that which offer only possibilities
• Innovation is defined by the market place and not the scientific
community
Chemical engineers must focus on practical solutions, AIChE, Aug 2013, Vol
59. No 8 Banholzer W F and Jones ME
Learning outcomes
KnowGenix
Solvents
• Water as a green solvent?
• Volatile vs involatile solvents
Ionic liquids as a green solvent? negative impact of preparation, separation and toxicity, biodegradability
Replacement of a hazardous chemical with a bad one
Bio based value chain – sustainable ?
Waste minimisation Vs value added by-product
Biofeedstocks: Food vs Fuel vs Feed debate
Food or non food crops?
• Which crops use land more sustainably and more efficiently?
• Which technologies offer most efficient and sustainable use of land/ biomass?
Food crops use land efficiently: Emphasis on food crops – risk diversification ?
Learning outcomes
KnowGenix
A&W principles : Rallying point for lowering chemical hazards through
chemistry based model; became the criteria for USEPA award, GC journal
Peterson Myers principles : Toxicology, EDs became central to GC debate
– New toxicology tools for designing safer chemicals
– Poor track record of chemical substitutions – lack of insights into ED and its relevance
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
Learning outcomes: 12 GC Postulates
GC, a powerful sustainability tool, is one among diverse narratives inthe dialogic process involving chemistry and sustainability
KnowGenix
The need for validated and reliable green metrics has become
very critical in design and development of greener product and
processes with ever increasing false claims of greenness
Development of green chemistry metrics poses challenges as
newer and complex heteroaromatic chemistries continue to
dominate new product development
In the background of complex molecules being developed no
single metric, in isolation can adjudge the ‘greenness’ of a
process. We need multiple metrics to provide precise data before
processes can be validated
Learning outcomes: Metrics/tools
KnowGenix
Biocatalytic technologies are yet on learning curve and issues related to validation, productivity, selectivity and more importantly consistency in formulation and limited substrate options need closer attention.
Enzymatic processes could be a key alternative to chemical synthesis for diverse commercially important reactions like esterification, transesterification etc
Directed evolution processes and genetically engineered modification of microorganisms for tailor-made enzymes will form the basis of several sustainable processes??
Actualisation of prospects based on future advances in high-throughput screening, fermentation technology and biocatalyst immobilization
Learning outcomes: Biotransformations
KnowGenix
Biowaste valorisation technologies are yet to mature.
Enzymatic, fermentation and extraction technologies
sub- optimal to deal with diverse range of wastes
Evaluation of food industry 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 containing proteins,
sugars and lipids to value-added chemicals and polymers goes
beyond technology to that of competitive access, quality and
characterisation.
Research is needed on stability and interactions of
phytochemicals with other food ingredients during processing
and storage.
Learning outcomes: Biowaste valorisation
KnowGenix
• It is ironical that major catastrophes have driven key advances in
science, technology, legal systems, social care, public health
administration and regulations at international levels
• The uncertainties prevalent in chemical manufacturing pose
serious questions about our understanding of newer chemistries
and pathways; dynamics of thermal runaway reactions;
mechanism of formation of intermediate products, and expertise
in managing the consequences of TRs
• Three decades after Bhopal, if we still need chemical
catastrophes to drive advances in science, technology, legal,
health and social care policies etc, it is indeed a sad reflection of
progressive technology driven societies !
Learning outcomes: Process safety
KnowGenix
• Sustainability ethics, communication, interlocution
• Philosophy of technology and regulatory frameworks
• Guiding principles of chemical sustainability
• Design and development of green tools/metrics
• Process economics
• Toxicology: EDs, POPs
• Rational design of safer products
• Feedstocks management
• Product engineering (formulation engineering)
• Design of Inherently safer processes
• Pedagogy: STS, innovation, IDM
Focus on R&D/Manufacturing insulated from broader sustainability /Innovation skills
Learning outcomes: GC education gaps
KnowGenix
90s to now
Flexible to rigid innovation structures
Company specific to collaborative innovations
Product/process to non-technical innovations
Coupling and decoupling of R&D and innovation cells
Segment specific innovation models
Innovative products are orphaned at high costs
Innovation tunnel misaligned with market space
Attracting investments for concept to proof of concept
“Banned” products to “regrettable” replacements
Learning outcomes : Innovation
KnowGenix
high risk, slow return, unpredictable game
Rajagopal R, 1992 Clean technology development – the ultimate solution?: Norsk geogr, Tulsskr. Vol. 46, 193 197 Oslo ISSN 0029-1951…
“solutions to contemporary industrial and environmental problems lie not in
just designing and selling a new technology .. but in being able to predict the consequences of such technological changes in terms of cost benefit ratio: socio-economic imbalances, local market forces that control the production outputs, potential environmental and health effects…..”
“The search for newer alternatives in terms of pollution reduction should not be at the cost of inherent community and work place safety. Important issues such as the toxicity level of new materials and products and the level of safety control systems required would ultimately be the deciding factors in clean technology promotion”
“The development of clean technology has to be preceded by a thorough scrutiny of the various choices in terms of resources required for the various alternatives. Furthermore, the prediction of environmental, social and economic consequences as a result of the choices made is essential
“It is vital that the new environmentally benign technologies that are developed globally are not subjected to types of restrictions such as patent laws, regulations and barriers in technology transfer.”
Moving back in time.. 1992.. from Blindern, Oslo
Clean chemistries/technologies was the buzz word ‘84-’97.. Green chemistry since ‘98
KnowGenix
CCE : reshaped by SynBio, MolBio, etc.
Regulatory/business pressures: “where is every molecule going in your/my plant?”
Future chemical enterprises will demand a new breed of C&CEs- trained to operate in the interphases of several disciplines; also act as • resource managers• value creators • interlocutors
Future landscape
Change: radical & catastrophic will happen in shorter cycles
KnowGenix
Thanks for your attention
Appreciate your feedback at [email protected]
while seeking corrections to an existing bad option
let us not create a worse option