green chemistry
DESCRIPTION
The design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances. Green Chemistry moves our consideration of how to deal with environmental, health and safety problems from the circumstantial to the intrinsic.TRANSCRIPT
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Green Chemistry Building HSE Performance into Products
Dr Rajendra R PatelMicrochem Research Services
Bangalore INDIA
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Green Chemistry - Building HSE Performance into Products
Topics
• What is Green Chemistry?
• Why apply Green Chemistry?
• How is this done?
• Examples & References
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Green Chemistry - Building HSE Performance into Products
The design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances
GREEN CHEMISTRY
What is Green Chemistry?
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Green Chemistry - Building HSE Performance into Products
Green Chemistry moves our consideration of how to deal with environmental, health and safety problems from the circumstantial to the intrinsic.
What is Green Chemistry?
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Green Chemistry - Building HSE Performance into Products
IntrinsicCircumstantial
• use hazardous chemicals• generate hazardous materials
• protective and reactive systems• permits• reporting• training• waste handling, disposition• public information/accountability• consequences of use/misuse• liability
• inherently safer design• reduced hazardous materials
• molecular design for reduced toxicity• reduced potential to manifest hazard• safety from accidents or terrorism• less regulatory burden• minimize potential community impact• decreased resource drain• lower impact from use/misuse
Added Costs! Fewer Costs!
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Green Chemistry - Building HSE Performance into Products
What is Green Chemistry?
Examples -
• Plastics that serve their purpose, yet biodegrade
• Cleaning agent that is effective, and is non-toxic
• Biological conversion of raw materials to a product
• Highly selective pesticide that does not persist
• Biodiesel production and use
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Green Chemistry - Building HSE Performance into Products
• Increased understanding of the molecular basis of hazard.
• Physical, toxicological, and global hazards.
• Moving from descriptive toxicology to mechanistic toxicology.
• Treating hazard as simply another physical/chemical property.
Current State of Science
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Green Chemistry - Building HSE Performance into Products
12 Principles of Green Chemistry
1. Prevention
2. Atom Economy
3. Less Hazardous Chemical Syntheses
4. Designing Safer Chemicals
5. Safer Solvents and Auxiliaries
6. Design for Energy Efficiency
7. Use of Renewable Feedstocks
8. Reduce Derivatives
9. Catalysis
10. Design for Degradation
11. Real-time analysis for Pollution Prevention
12. Inherently Safer Chemistry for Accident Prevention
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Green Chemistry - Building HSE Performance into Products
Why apply Green Chemistry?
HSE Benefits
• lower impact on natural resources
• second lever to reduce riskRisk = f(hazard, exposure)
Business Benefits
• lower production costs
• reduced asset risk
• public perception & expectations
• investor relations
State-of-the-Art in HSE issue management
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Green Chemistry - Building HSE Performance into Products
Why apply Green Chemistry?
“IPPC presumes the use of preventative techniques before any consideration of end-of-pipe control techniques.”
European IPPC BureauReference Document on Best Available Techniques in the Large Volume Organic Chemical IndustryFebruary 2002
“The Congress hereby declares it to be the national policy of the United States that pollution should be prevented or reduced at the source whenever feasible...”
US Pollution Prevention Act of 1990
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Green Chemistry - Building HSE Performance into Products
“Business is going to get significantly more profitable through the application of green chemistry. Proactive companies are finding the theme ‘good for business’ to be credible and real.
Paul V. TeboVice President, DuPont
“Green Chemistry can return as much as 53% on capital, compared with a negative 16% when improvements are mandated by law.”
William S. StavropoulosChairman of the Board, Dow Chemical
Why apply Green Chemistry?
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Green Chemistry - Building HSE Performance into Products
Define Desired State/Establish Expectations
Review, ID issues, provide
input
Tools, options, alternatives available
– make good decisions
Measure Progress, Capture
Successes, Take Credit
Fill the toolbox
Develop Chemical Process
How is this done?
Process for Implementation
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Green Chemistry - Building HSE Performance into Products
Resource Use
Impact
Resource Use
Impact Impact
How is this done?
Resource Use
RawMaterial
Production
Material Management
Production Product In Use
Distribution
Suppliers Manufacture/Distribution Customers
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Green Chemistry - Building HSE Performance into Products
Incremental• apply best current science• optimize through substitution, selection, technology,
etc.• quantity, quantity, quantity
Two Modes of Improvement• Step-change• Incremental
Step-change• unique and breakthrough chemistries• application of new technologies• different “kinds” of products meeting same
need
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Green Chemistry - Building HSE Performance into Products
Tools for Chemists
• Solvent selection guides
• Acid/Base selection guides
• Materials lists
• Comparative measures - “greenness scorecard”
• Safety screens
• EPA’s Green Chemistry Expert System- Synthetic Methodology Assessment for Reduction Techniques (SMART) - Green Synthetic Reactions - Designing Safer Chemicals - Green Solvents/Reaction Conditions - Green Chemistry References
• Alternatives
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Green Chemistry - Building HSE Performance into Products
Measure Progress, Capture Successes
mass of wastemass of product
e Factor =
RME =Reaction mass efficiency
mass of product x 100mass of reactants in process
FW of product x 100∑ FW of all reactants in reaction
Atom economy =
mass of wastemass of product
Projected burden = x projected annual production
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Green Chemistry - Building HSE Performance into Products
Active Pharmaceutical AMaterial Use/kg Product
0
50
100
150
200
250
300
350
400
450
SR08/1999 SR07/2002 SR02/2004
This improvement represents 6,000,000 kg less material use per year at full scale production.
Measure Progress, Capture Successes
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Green Chemistry - Building HSE Performance into Products
Measure Progress, Capture Successes
TRI- US EPA Toxics Release Inventory Listed
0
5
10
15
20
25
30
35
40
45
SM1, Step 1 SM1, Step 2 SM2, Step 1 SM2, Step 2 SM2, Step 3 Step 1 Step 2
TRI Use Water Use All Other Use
Development Compound “B” Material Use by Stepkg material use/kg API
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Green Chemistry - Building HSE Performance into Products
To Consider...
• company strategy
• culture
• geographical differences
• available resources
• substituting one problem for another
• weighing alternatives – apples & oranges
• moving issue instead of eliminating it
Individual Situation
Unexpected Consequences
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Green Chemistry - Building HSE Performance into Products
Examples -
Adipic Acid Synthesis
Contributes 1% anthropogenic NOx/year
Ni-Al2O3
370-800 psi Co / O2
120-140 psi
O
+OH
Cu / NH4VO3
HNO3 HO2CCO2H + N2O
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Green Chemistry - Building HSE Performance into Products
Examples -
No nitrous oxide generated
Renewable feedstock replaces petroleum-based feedstock
O
OH
OH
OH
OH
OH
E. coli
D-glucose
OH
OH
CO2H
O
3-dehydroshikimate
E. coli
HO2C
CO2H
cis, cis-muconic acid
Pt / H2
50 psi HO2CCO2H
Adipic Acid Synthesis
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Green Chemistry - Building HSE Performance into Products
Practical Application of a Biocatalyst in Pharmaceutical Manufacturing
Roughly 34,000 liters of solvent and 300 kg of chromium waste were eliminated for every 100 kg of medicine produced.
The new protocol was developed by combining innovations from chemistry, microbiology, and engineering.
The new synthesis begins with a biocatalytic reduction to an optically pure intermediate using a yeast- Zygosaccharomyces rouxii - in a novel three-phase reaction design replacing chemical reduction.
Eli Lilly and Company – 1999 Presidential Green Chemistry Challenge Award Winner
Examples -
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Green Chemistry - Building HSE Performance into Products
Presidential Green Chemistry Challenge Awards
Summary of 2005 Award Recipients
Alternative Synthetic Pathways Award Archer Daniels Midland Company - Novozymes NovaLipid™: Low Trans Fats and Oils Produced by Enzymatic Interesterification of Vegetable Oils Using Lipozyme®
Alternative Synthetic Pathways Award Merck & Co., Inc. A Redesigned, Efficient Synthesis of Aprepitant, the Active Ingredient in Emend®: A New Therapy for Chemotherapy-Induced Emesis
Alternative Solvents and Reaction Conditions Award BASF Corporation A UV-Curable, One-Component, Low-VOC Refinish Primer: Driving Eco-Efficiency Improvements
Designing Safer Chemical Award Archer Daniels Midland Company Archer RC™: A Nonvolatile, Reactive Coalescent for the Reduction of VOCs in Latex Paints
Small Business Award Metabolix, Inc. Producing Nature’s Plastics Using Biotechnology.
Academic Award Prof. Robin D. Rogers; The University of Alabama A Platform Strategy Using Ionic Liquids to Dissolve and Process Cellulose for Advanced New Materials.
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Green Chemistry - Building HSE Performance into Products
Thank youThank you