increasing profitability with green chemistry (chemspec asia'14, bangkok)
TRANSCRIPT
Increasing profitability with Green Chemistry
Nitesh H. MehtaGreen ChemisTree FoundationMumbai, India
www.industrialgreenchem.com
Realities of Chemical Industry – Past, Present & Future
Magnitude of environmental challenge & its impact
Approaches to address our environmental challenges
Distinguishing “Green Chemistry”
Strategies to implement Green Chemistry
Increasing Profitability with Green Chemistry: Case Study of Recycle@SourceTM Solution
Potential Impact of a Green Chemistry Solution
Barriers to implement Green Chemistry
Conclusions
Flow
• Population Explosion
• Last two decades, nature of expansion:
mostly linear expansion of volumes
linear expansion of hardware
linear expansion of batch size
linear expansion of labour
linear expansion of effluent treatment facilities
• Developing countries like India, China, etc – outsourcing hub for
manufacturing activities & hence environmental load on us is higher
Increase in Demand
Need for expansionExpanded Capacities
Realities of Chemical Industry: Past
In the last two decades, direction of innovation:
enhancing productivity & better material handling
enhancing quality
expanding & improving effluent treatment methods
Drivers for innovation: Cost Quality Productivity
Recent signals from nature:
Earthquakes Cyclones Floods, Diseases, etc…
Impact on ENVIRONMENT???
Realities of Chemical Industry: Present
Our practices UNSUSTAINABLE
Probable Future
Environmental Norms – more stringent, more regulatory pressure
Common man’s awareness about their rights – expand
Customer’s / End User’s demand for “Green” products – increase
Water – crisis
Energy – short supply
Managing Eco. & Environmental Competitiveness – big challenge
raw material prices going up
labor, power & overheads going up
effluent treatment costs going up
selling prices going down
Chemical Industry – tough times ahead (from the perspective of environment), unless we intervene & do something different.
Realities of Chemical Industry: Future
Magnitude of environmental challenge
Industry Sector
Production (bn
kg)
No. of Steps
E-Factor (Ref: R.
Sheldon)
Aqueous E-Factor
Vol. of Liq. Eff. (bn lits)
No. of tankers
(mn)
COD (lacs)
Toxicity
Pharma 0.75 - 1 7+ 50 - 100 20% 15 1.5 1.5 - 2 Very High
Agro 1 - 1.5 5+ 40 - 60 25% 15 1.5 1 - 1.5 Very High
Pigment 1.5 - 2 4+ 30 - 50 30% 20 2.0 0.5 - 1Medium
High
Dyes 2 – 2.5 3+ 20 - 30 35% 20 2.0 0.25 - 0.5 High
Total volume of liquid effluents (world) = around 70 bn lits/year
= 7 million trucks/year
Indian Market 20 – 30 % of global
Total volume of liquid effluent (India) = 15 - 20 bn lits/year
= 1.5 – 2.0 million trucks/year
= 4,000 trucks/day
Total Organic Mass in effluents (India) = 875,000 TPA (avg. COD = 50K)
Impact: huge threat to water bodies & human health
Quantity : approx. 50 - 70 bn kgs of liquid effluents include solid & gaseous effluents include all wastes from all other sectors (mining, steel, power,…..)
Practice : End-of-pipe-treatment (converting one kind of effluent in to other)
Issue : Toxicity not fully known (Ecotoxicity data available for less than 1% of human pharmaceuticals…Ref: journal “Regulatory
Toxicology Pharmacology, April’2004)”
Degradation : very slow, impact unknown after degradation
Impact on Economics
Direct Cost : loss of solvent, raw material & finished product, loss of utilities, treatment cost, higher overheads, loss of business…
Indirect Cost : unreliable supplies, loss of credibility in market, anxiety, etc.
Impact
Approaches to deal with environmental challenges
What is Green Chemistry?
a science
a philosophy
an attitude
a new domain or branch of chemistry
“greener” way of doing the same chemistry
Way we look at Green Chemistry:
an approach
a way of thinking
place to come from while designing or working on a product or process
Distinguishing Green Chemistry
Definition of Green Chemistry:
Chemistry & chemical engineering to design chemical products & processes that
reduce or eliminate the use or generation of hazardous substances while
producing high quality products through safe and efficient manufacturing
processes.
- “Green Chemistry” as defined by Green Chemistry Research & Dev. Act of 2005
Definition of Green Engineering:
Green Engineering is the development and commercialization of industrial
processes that are economically feasible and reduce the risk to human health &
environment.
Distinguishing Green Chemistry
12 Principles of Green Chemistry
Prevent waste
Design safer chemicals and products
Design less hazardous chemical syntheses
Use renewable feedstocks
Use catalysts, not stoichiometric reagents
Avoid chemical derivatives
Maximize atom economy
Use safer solvents and reaction conditions
Increase energy efficiency
Design chemicals and products to degrade after use
Analyze in real time to prevent pollution
Minimize the potential for accidents
- Environmental Protection Agency, USA
12 Principles of Green Engineering
Inherent Rather Than Circumstantial
Prevention Instead of Treatment
Design for Separation
Maximize Efficiency
Output-Pulled Versus Input-Pushed
Conserve Complexity
Durability Rather Than Immortality
Meet Need, Minimize Excess
Minimize Material Diversity
Integrate Material and Energy Flows
Design for Commercial "Afterlife"
Renewable Rather Than Depleting
- Anastas P.T. & Zimmerman J. B., “Design through twelve principles of Green Engineering”, Env. Sci. Tech. 2003, 37 (5), 94A – 101A
Distinguishing Green Chemistry
Some common myths about Green Chemistry: Its expensive, not worth it
it is theory, doesn’t work in real life
it takes long time to develop & implement
it’s a cost center (biggest myth)
GreenChemistry
Performance
Safety & Environment Cost/Economics
Distinguishing Green Chemistry
Where to start from? Basis of selection?
Green Chemistry Metrices: may start with effluent stream with highest E-Factor, PMI, or any other matrices
Toxicity
Internal Competency
Cost pressures
Regulatory pressures
Demand from customer
Resources available
Management’s priority
Ready availability of a particular technology in market place
Strategies for implementation of Green Chemistry
Short term
e.g. Immediate, workable solution (reduce COD or reduce effluent load by recycling)
Medium term
e.g. Process Intensification of Unit Processes & Unit Operations (Greener catalyst, etc)
Long term
e.g. Paradigm shift in Engineering like micro reactors
Very Long term
e.g. designing new route of synthesis starting from renewable feedstock, using Biomimicry
Strategies for implementation of Green Chemistry
Short term
Time : 1 to 2 years Resources: very low Risk: very low
Medium term
Time: 2 to 4 years Resources : low to medium Risk: low to medium
Long term
Time: 4 to 8 years Resources: high Risk: high
Very Long term
Time : 8 to 16 years Resources: very high Risk: very high
Strategies for implementation of Green Chemistry
Case Study 1:
Developed & commercialized by Newreka Team
Running successfully as commercial scale at a Pharma Company – 3 years
Transformed the was chemistry done to a “Greener Way”
Also, used our concept of Recycle@SourceTM to recycle aqueous stream
Case Study 2:
Developed by Newreka Team, patented & under commercialization
Most polluting dye intermediate called H-Acid
Using the concept of Recycle@SourceTM
Increasing Profitability with Green Chemistry: Case Studies
Step 1 Step 2 Step 3 Step 4
Step 1
2 - 3 Raw Materials
Reaction Medium
Extraction Medium
Intermediate/Product
Effluents
Reaction & Extraction MediumIntermediate/ProductBy-productsOrganic ImpuritiesInorganic Impurities
Reality of our processes
Reality of our processes
Step 1 Step 2 Step 3 Step 4
4 - 5 different chemicals
4 - 5 different chemicals
4 - 5 different chemicals
4 - 5 different chemicals
No option except Effluent Treatment Plant or
Incineration
Cocktail of 15 - 25 different chemicals
Impossible to separate, recover or
recycle
Manufacturing Site
Reality of our plants
Mfg. Block for Campaign Products
Mfg. Block for Dedicated Products
Dedicated Product
Step 1 Step 2 Step 3
Product 1 Product 2 Product 3
Step 1 Step 2 Step 3
Step 1 Step 2 Step 3 Step 4
Step 1 Step 2
Each effluent stream has its own:
• Physical properties• colour, pH, temperature
• Chemical composition• organics, inorganics
• Volume
• Characteristics• COD, BOD, TDS, etc.
• Toxicity & hazard
What we have is:
• multiple effluent streams with widely differing quantities & characteristics
Reality of our effluent streams
Current industrial practice
Effluent stream from dedicated products
Effluent stream from product 1
Effluent stream from product 2
Effluent stream from product 2
Cocktail of 40 - 50 different chemicals
End-of-the-pipe Treatment (primary & secondary treatment, triple effect evaporator,
incineration, solid waste disposal sites, land fill, etc.)
Our Environment
Step 1 Step 2 Step 3 Step 4
2 - 3 Raw Materials
Reaction Medium
Extraction Medium
Finished Product
EffluentsStep 1
Reaction & Extraction MediumProduct/IntermediateOrganic ImpuritiesInorganic Impurities
Recycle@SourceTM
Recycle@SourceTM Solution: Concept
AQUEOUS EFFLEUNT STREAMS SOLVENT STREAMS
(acidic, neutral, alkaline)
Raw Finished Organic Inorganic
Materials Product Impurities Impurities
Recycled back to process selectively removed
“RCatTM
” (customized proprietary catalytic formulation for Recycle @ Source)
selectively & effectively removes undesired org. & inorg. impurities such
that the streams can be recycled back in the process.
Recycle@SourceTM Solution: Concept
Conventional Technology: High pressure catalytic hydrogenation with Raney Ni
Chemistry: Nitro to Amine Reduction
Recycle@SourceTM Solution: Case Study 1
Feedback from customer: Recycling mother liquor for over 3 years now. Over 800 batches (at times on campaign basis) Just make-up for Water loss (saved millions of lit of fresh water) Amine Quality – 99%+ on HPLC, 10% Yield improvement
Recycle@SourceTM Solution: Case Study 1
Impact:
• Increase in profitability:
1. Yield improved by 10%
2. Batch Times reduced – 20% Higher productivity
3. Two solvents eliminated
4. Energy savings – distillation & purification avoided
5. Effluent treatment cost reduced (E-Factor down by 90%)
6. Safer process (H2, Ni, Chloroform, EDC, MeOH avoided)
• Customer got breakeven on their investment in < 3 months.
• Enhanced Quality is a Bonus.
26
Recycle@SourceTM Solution: Case Study 1
H – Acid (1-Amino-3-Hydroxy Naphthalene 3,6 Disulphonic Acid):
One of the oldest & biggest volume Dye Intermediates (goes mainly in to Black Dyes)
High volume product (India alone makes over 20,000 TPA)
Known in the industry for it’s high E-Factor (over 50 kgs waste / kg H-Acid)
Uses mostly conventional technologies
Theoretical yield 2.4 kgs H-Acid/kg naphthalene, Industry yield is 1.28 (53%)
Last innovation happened 5 years back – solvent based Fusion, yield increased from
1.1 to 1.28
Lot of efforts put in by private companies, government bodies, academic & research
institution to change the process & reduce E-Factor
Recycle@SourceTM Solution: Case Study 2
Fusion & Evaporation
Isolation Vessel
CENTRIFUGE
AmineMethanolCaustic
Acidic Mother Liquor
H-Acid
Representative diagram of Conventional Process
Dilute Sulphuric Acid
CharacteristicsColour Deep RedpH 1.5 - 2.0COD 150,000TDS 15 - 20%Toxicity Not Known
Recycle@SourceTM Solution: Case Study 2
Fusion & Evaporation
Isolation Vessel
CENTRIFUGE
AmineMethanolCaustic
Acidic Mother Liquor
Storage Vessel
Mother Liquor Recycle
H-Acid
More than 25 recycles
E-Factor = 90% Patented TechnologyYield = 10%
RCat Treatment
Recyle CatTM
FilterFilter
Spent RCat
Representative diagram to explain the concept of Recycle@SourceTM solution as applied to H-Acid
Recycle@SourceTM Solution: Case Study 2
Batch No.Product Colour
Product Appearance
H-Acid Obtained (gm)
Product Purity
FreshOff white to Light Pink
Powder 59 > 80.0%
Recycle 1Off white to Light Pink
Powder 62 > 80.0%
Recycle 2 Off white to Light Pink
Powder 63 > 80.0%
Recycle 3Off white to Light Pink
Powder 65 > 80.0%
Recycle 4Off white to Light Pink
Powder 65 > 80.0%
Recycle 5Off white to Light Pink
Powder 65 > 80.0%
Product Characterization & Impact on Yield (Basis: 90 gm batch size)
Recycle@SourceTM Solution: Case Study 2
In the face of challenges that chemical industries face today, like:
market competition, further shrinking of already “thin margins”, tighter environmental
regulations, lower level of permissible discharge, tough stance of government & regulatory
bodies, volatile market & fluctuating raw material & finished product prices
Benefits of Recycle@SourceTM Solutions:
Freedom from treatment of huge quantities of effluents
Lower effluent treatment cost
Enhanced yields & productivity
Lower cost of production
Saving of time & energy which otherwise goes in dealing with regulatory bodies
Wide applicability – diverse industry sectors, wide range of reactions
Benefits of Recycle@SourceTM Solutions
Impact of Recycle@SourceTM Solutions that are ready with Newreka:
Total Impact on environment : effluent discharge to environment & fresh
water consumption of industry reduced by over 50,000 MT per month.
Potential Impact of a Green Chemistry Solution
No. ProductTotal
Production in (TPM)
E-Factor * (kgs
waste/kg product)
Effluent QualityMinimum No. of Recycles
Effluent quantity before & after implementing NRS (litres per month)
before after
1 Nevirapine 20 4 Mixture of solvents 500+ 80,000 0
2 Sildenafil Citrate 25 14 Neutral effluent 25 3,50,000 14,000
3 Omeprazole 50 8 Highly alkaline effluent 10 4,00,000 40,000
4 Albendazole 100 8 Highly alkaline effluent 25 8,00,000 32,000
5 Quietiapine 20 6 Neutral effluent 10 1,20,000 12,000
6 H-Acid 2000 26 Acidic effluent 15 5,20,00,000 35,00,000
7 OAPSA 75 13 Acidic effluent 15 9,75,000 65,000
8 FC Acid 50 10 Acidic effluent 15 5,00,000 33,000
9 4-ADAPSA 40 10 Acidic effluent 15 4,00,000 26,000
10m-Phenylene Diamine Sulphonic Acid (MPDSA)
100 5 Acidic effluent 15 5,00,000 33,000
Inertia to New Paradigm against the gravity of existing paradigm
Technical Barriers: no ecosystem for knowledge-based entrepreneurship
Seed capital & funding barriers
IP Barriers: protecting IP
Market Barriers: awareness, business model
Human Barriers: Inertia to change, culture, language
Scale-up Barriers: same result in lab as in plant, availability of plant, risk
Barriers created by “Old Nexus”
Regulatory Barriers: changes in DMF, FDA & Customer approvals
Financial Barriers: working capital for growth
Barriers to implementation of Green Chemistry
Human Barriers inertia to change from old paradigm to New Paradigm
decades of shop-floor experience becomes barrier instead of resource
Scale-up Barriers want to see same result in lab as that expected in plant availability of plant to take trials with new technology risk of scale-up – who will bear?
Market Barriers Lack of awareness about potential of Green Chemistry tool box
Some myths like it’s expensive, it will increase cost, etc
IP Barriers challenge to protect IP
little respect for IP in the industry – no hesitation in copying idea
Key Barriers to implementation of Green Chemistry
The question now, is no longer – Whether Green Chemistry or not? The question now is – How can we develop & implement Green Chemistry?
Each of us have a role to play here – Academic & research institutes, Students, Industry, Government & Regulatory bodies, Financial Institutions, etc
Academic & Research Institutes – working on real, relevant & critical environmental challenges faced by the Industry
Industry: Start wherever you want to or can. But let’s START. Create short term & long term strategy to implement Green Chemistry & Green Engineering in to operations.
Government & Regulatory Bodies – Facilitate, incentives to those taking risk
Shift from a cost centre approach to a profit-centric approach.
Environmental challenges are opportunities to make PROFITS
Conclusions
Magnitude of Environment Challenges
Magnitude of Environment Challenges
ScaleScale
UrgencyUrgency
? ??
?? ?
Green Chemistry : Our key challenge
Universities:1. Limitations to
Customize, Scale-up & Commercialize
2. Limitations to Market their Innovations
Industry:1. Profit Driven Approach2. Limitation to approach
& define their problems3. Mindset of not investing
on Green R&D
Common Man & Society:
1. Lack of Awareness2. Mindset of not investing
on Education & Research
Govt. Bodies & NGO’s:1. Formulations of practical
policies.2. Carrot & Stick Approach3. Limitations of paperwork
& bureaucracy
Key Roadblock in Implementation of GC
Universities:1. Limitations to
Customize, Scale-up & Commercialize
2. Limitations to Market their Innovations
Industry:1. Profit Driven Approach2. Limitation to approach
& define their problems3. Mindset of not investing
on Green R&D
Common Man & Society:
1. Lack of Awareness2. Mindset of not investing
on Education & Research
Govt. Bodies & NGO’s:1. Limitations of paperwork
& bureaucracy2. Carrot & Stick Approach
Industrial Green
Chemistry World
(IGCW)
Attempt to bridge the gap
MNC or Large or Small Organization: Partner with us & express your commitment to Sustainability by being a Sponsor & share your initiatives
Working on Green Chemistry: Present your case study & be a speaker
Exhibit your “Green” Products & Services: Exhibit your Green Chemistry or Green Engineering based product, technology or services
Apply for an Award: Apply for an award under various categories
Participate in IGCW’2013 Symposium: Opportunity to meet pioneers and senior scientists from the field of Green Chemistry & Engineering
IGCW2013: Invite you to be a stakeholder
www.industrialgreenchem.com
Event: IGCW2013 – Convention & Ecosystem
Date: 6, 7 & 8 December’13
Venue: Hotel Renaissance & Conventional Center, Powai, Mumbai
For more details and to participate, please contact: [email protected]
Thank you
For resources on Green Chemistry Please visit
& Green Engineering: www.industrialgreenchem.com