green chemistry

24
1 Green Chemistry Building HSE Performance into Products Dr Rajendra R Patel Microchem Research Services Bangalore INDIA

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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.

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Page 1: Green Chemistry

1

Green Chemistry Building HSE Performance into Products

Dr Rajendra R PatelMicrochem Research Services

Bangalore INDIA

Page 2: Green Chemistry

2

Green Chemistry - Building HSE Performance into Products

Topics

• What is Green Chemistry?

• Why apply Green Chemistry?

• How is this done?

• Examples & References

Page 3: Green Chemistry

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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?

Page 4: 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?

Page 5: 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

Page 8: Green Chemistry

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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

Page 10: Green Chemistry

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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

Page 14: Green Chemistry

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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