www.greenchemistry.net. atom efficiency in the manufacture of chemicals industryproduct tonnagekg...

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Atom Efficiency in the Manufacture of Chemicals

Industry Product tonnage Kg by-products / Kg product

Oil refining 106 - 108 < 0.1

Bulk chemicals 104 - 106 1 - 5

Fine chemicals 102 - 104 5 - 50+

Pharmaceuticals 10 - 103 25 - 100+

Most chemical reactions make more waste than product!

… note the recent statement from the GSK CEO…we need morepeople willing to challenge the “accepted limits”


Pressures on the Chemical Industry Across the Lifecycle


4

IntroductionWhat is Green Chemistry?

• Green chemistry is the design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances

• Discovery and application of new chemistry/technology leading to prevention/reduction of environmental, health and safety impacts at source

ReducingReducing

MaterialsEnergy

Cost

Non-renewables

Risk &Hazard

Waste


Green Chemistry is about turning a waste into a product and a cost into a profit


Waste is tomorrows resource

We have converted virgin resources to waste and we now need to encourage the greater use of

chemically rich waste as a resource


Food supply chain residues

sugars

phenols

collagen

starchnatural dyes

chitosan

cellulose

pectin

hemicellulose

waxes

films

bio-adhesives

hydrogels

natural chelants

bio-solvents

chemical monomers

nanocomposites

bio-surfactants

PVC replacements

Liquid fuels

cosmetic waxes

solid fuels

hydrophobes

lignin


• Research

• Industry collaboration

• Education, including development of teaching and promotional materials

• Networking with all chemical stakeholders

Activity Areas

The Centre’s Activities can be groups into 4 areas:


Natural SolventsScience Leader Dr Andrew Hunt

We are interested in supercritical and liquid carbon dioxide as an extraction, fractionation and

reaction medium with projects covering areas such as the extraction of waxes from agricultural

and food waste for personal care (and other) applications, and the synthesis of flavour and aroma molecules using in-situ biocatalysis.

Funding comes from the University, METRC and industry. We have excellent supercritical fluid

extraction facilities and access to scale-up facilities.


InorganicPetroleum Biomass

Conventional+

Neoteric(e.g. IonicLiquids)

‘Natural’ solvents

CO2 + Water

EthanolEthyl acetateEthyl lactate

Glycerol2-MeTHF

Solvents

Greener Solvents


1110 20 30 40

100

50

75

25

100

oC

MPa

Terpenoids

Lipids

Alkaloids

Sterol monoglycosides

Phenolics

Polyphenols

Carotenoids

Lipids & Waxes

Sterols

Diterpenes

Phospholipids

O

OH OH

OH

O

Case Study 1Extraction with Super-critical CO2


ExtractablesExtractables…….……….…Eco-waxes

Wheat strawScCO2 extraction

Wax products

Cosmetic Products

Lignocellulose

- Strawboard

- Garden Mulch

- Pulp & Paper

-Bioethanol -Electricity

Health Products

Semiochemicals

Renewable resource+CO2 extraction = EU “natural”


Renewable MaterialsScience Leader Dr Avtar Matharu

For us this means the physical and chemical modification of natural abundant materials and especially polysaccharides. Projects include

Starbons (new carbonaceous materials derived from starch), new “bio-boards” made entirely of

green and sustainable components, novel switchable adhesives, new intumescent flame

retardants, and PVC replacements.

Funding comes from industry, EPSRC, DEFRA and TSB. The area is supported by state-of-the-art thermal analysis, infrared spectroscopy and

extrusion equipment.


Recyclable

Materials……

Switchable adhesives for carpet tiles (InterfaceFlor)

Diverting millions of Kg pa from landfill


Clean Synthesis and Platform Molecules

Science Leader Dr Simon Breeden

Very much our root area with interests covering the use of solid catalysts and alternative solvents to

“green” reactions.

Recently we have become especially interested in doing clean synthesis starting from molecules and

mixtures derived from biomass (eg using fermentation broths).

We have funding in this area from industry, EPSRC, METRC, and GSK.


Microwave Chemistry

Science Leader Dr Duncan MacQuarrie

This brings together our long-standing interest in microwave-assisted chemistry with our more

recent interest in the conversion of biomass (eg forestry and agricultural wastes, food waste, etc) to

useful products. With substantial funding from ERDF, Carbon Trust, METRC and industry we are

starting major new projects on fast pyrolysis for the production of liquid fuels, high calorific value

chars and chemical intermediates.

A major part of this is the design and build of new continuous microwave processors, with the final

semi-scale prototype to be located outside the GCC.


Advantages of MW Heating

•Rapid internal heating

•Uniform heating

•Instant control

•Acceleration of reaction rate

•Selective interaction with active groups


Biomass

Microwave processor

Energy

ExtractedExtractedoiloil

ExtractedExtractedoiloil

Pyrolysis Pyrolysis OilOil

Pyrolysis Pyrolysis OilOil

CharCharCharChar

Wide range offeedstock

+ = Wide range ofproducts

Flexibility of Microwave Parameters

(time, temperature, power)

Low temperature

Microwave Processing of Biomass


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Microwave Processing of BiomassRape Seed Example

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www.greenchemistry.netwww.greenchemistry.net21

Biomass PretreatmentBiomass Pretreatment

Supercritical COSupercritical CO22 extraction extractionSupercritical COSupercritical CO22 extraction extraction

FermentationFermentation

Microwave Microwave processingprocessingMicrowave Microwave processingprocessing

Ammonia fibre explosion

Ammonia fibre explosion

StarbonisationStarbonisationStarbonisationStarbonisation

Higher value products

Higher value products


[email protected]

Industry

Networking

Education

www.greenchemistry.net

Any questions?

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