increasing profitability with green chemistry

7/29/2019 Increasing Profitability With Green Chemistry

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Increasing profitability with GreenChemistry

Nitesh H. Mehta

Green ChemisTree Foundation

Mumbai, India

www.industrialgreenchem.com

[email protected]


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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


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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 ofeffluent 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


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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


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Probable Future

Environmental Normsmore stringent, more regulatory pressure

Common mans awareness about their rights expand

Customers / End Users demand for Green products increase

Watercrisis

Energyshort supply

Managing Eco. & Environmental Competitivenessbig 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


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Magnitude of environmental challenge

Industry

Sector

Product

ion(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)


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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 than1% of human pharmaceuticalsRef: journal Regulatory

Toxicology Pharmacology,April2004)

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


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Central Effluent TreatmentPlant (CETP)

- Capital intensive

- Cost centric approach

- Ineffective same treatment towide variety of effluents

End-of-the-pipe Treatment(ETP)

- Capital intensive

- Cost centric approach

- Converts one type of effluent into another

Industrial Ecology

- Low value creation- Logistics & capacity mismatch

issues

- Doesnt address problem atsource level

Green Chemistry

- Address problem at source level

- Profit centric approach, high valuecreation

- Less capital intensive

Economics &

Environmental

Footprint

Approaches to deal with environmental challenges


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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



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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.



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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



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Some common myths about Green Chemistry:

Its expensive, not worth it

it is theory, doesnt work in real life

it takes long time to develop & implement

its a cost center (biggest myth)

GreenChemistry

Performance

Safety & Environment Cost/Economics



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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

Managements priority

Ready availability of a particular technology in market place

Strategies for implementation of Green Chemistry


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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 fromrenewable feedstock, using

Biomimicry



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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: highRisk: high

Very Long term

Time : 8 to 16 years

Resources: very highRisk: very high



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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 GreenerWay

Also, used ourconcept 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


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Step 1 Step 2 Step 3 Step 4

Step 1

2 - 3 Raw Materials

Reaction Medium

Extraction Medium

Intermediate/Product

Effluents

Reaction & Extraction

Medium

Intermediate/Product

By-products

Organic Impurities

Inorganic Impurities

Reality of our processes


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Reality of our processes


4 - 5 different

chemicals

4 - 5 different

chemicals

4 - 5 different

chemicals4 - 5 different

chemicals

No option except

Effluent Treatment Plant or

Incineration

Cocktail of 15 - 25

different chemicals

Impossible

to separate,

recover or

recycle


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Manufacturing Site

Reality of our plants

Mfg. Block for

Campaign

Products

Mfg. Block for

Dedicated

Products

DedicatedProduct

Step 1 Step 2 Step 3

Product 1 Product 2 Product 3

Step 1 Step 2 Step 3


Step 1 Step 2


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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


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Current industrial practice

Effluent stream from

dedicated productsEffluent 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


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2 - 3 Raw Materials

Reaction Medium

Extraction Medium

Finished Product

EffluentsStep 1

Reaction & Extraction

MediumProduct/Intermediate

Organic Impurities

Inorganic Impurities

Recycle@SourceTM

Recycle@SourceTM

Solution: Concept


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AQUEOUS EFFLEUNT STREAMS SOLVENT STREAMS(acidic, neutral, alkaline)

Raw Finished Organic InorganicMaterials 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


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Conventional Technology: High pressure catalytic hydrogenation with Raney Ni

Chemistry: Nitro to Amine Reduction

Recycle@SourceTM

Solution: Case Study 1


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Feedback from customer: Recycling mother liquor forover 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



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Impact:

Increase in profitability:

1. Yield improved by 10%

2. Batch Times reduced 20% Higher productivity

3. Two solvents eliminated4. 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



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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 over20,000 TPA)

Known in the industry for its high E-Factor (over50 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



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Fusion &

EvaporationIsolation

Vessel

CENTRIFUGE

Amine

Methanol

Caustic

Acidic Mother Liquor

H-Acid

Representative diagram of Conventional Process

Dilute

Sulphuric Acid

CharacteristicsColour Deep Red

pH 1.5 - 2.0

COD 150,000

TDS 15 - 20%

Toxicity Not Known

Recycle@SourceTM



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Fusion &

EvaporationIsolation

Vessel

CENTRIFUGE

AmineMethanol

Caustic

Acidic Mother Liquor

Storage

Vessel

Mother Liquor Recycle

H-Acid

More than 25 recycles

E-Factor = 90%

Patented TechnologyYield = 10%

RCatTreatment

Recyle CatTM

Filter

Spent

RCat

Representative diagram to explain the concept ofRecycle@SourceTM

solution as applied to H-Acid

Recycle@SourceTM



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Batch No.Product

Colour

Product

Appearance

H-Acid

Obtained (gm)

Product

Purity

FreshOff white to

Light PinkPowder 59 > 80.0%

Recycle 1 Off white toLight Pink

Powder 62 > 80.0%

Recycle 2Off white to




Recycle 4Off white toLight Pink

Powder 65 > 80.0%



Product Characterization & Impact on Yield (Basis: 90 gm batch size)

Recycle@SourceTM



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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 ofRecycle@SourceTMSolutions


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Impact ofRecycle@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. Product

Total

Production

in (TPM)

E-Factor *

(kgs

waste/kg

product)

Effluent Quality

Minimum

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

10

m-Phenylene

Diamine

Sulphonic Acid

(MPDSA)

100 5 Acidic effluent 15 5,00,000 33,000


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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


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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 its 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


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The question now, is no longerWhether Green Chemistry or not?

The question now isHow can we develop & implement Green Chemistry?

Each of us have a role to play hereAcademic & research institutes, Students,

Industry, Government & Regulatory bodies, Financial Institutions, etc

Academic & Research Institutesworking on real, relevant & critical environmental

challenges faced by the Industry

Industry: Start wherever you want to or can. But lets START.Create short

term & long term strategy to implement Green Chemistry & Green Engineering

in to operations.

Government & Regulatory BodiesFacilitate, incentives to those taking risk

Shift from a cost centre approach to a profit-centric approach.

Environmental challenges are opportunities to make PROFITS

Conclusions


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Magnitude ofEnvironment

Challenges

Scale

Urgency

???

???

Green Chemistry : Our key challenge


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Universities:1. Limitations to

Customize, Scale-up &

Commercialize

2. Limitations to Market

their Innovations

Industry:1. Profit Driven Approach

2. Limitation to approach

& define their problems

3. Mindset of not investing

on Green R&D

Common Man &

Society:1. Lack of Awareness


on Education &

Research

Govt. Bodies & NGOs:

1. Formulations of practicalpolicies.

2. Carrot & Stick Approach

3. Limitations of paperwork

& bureaucracy

Key Roadblock in Implementation of GC


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Universities:1. Limitations to

Customize, Scale-up &

Commercialize

2. Limitations to Market

their Innovations

Industry:1. Profit Driven Approach

2. Limitation to approach

& define their problems


on Green R&D

Common Man &

Society:1. Lack of Awareness


on Education &

Research

Govt. Bodies & NGOs:1. Limitations of

paperwork &

bureaucracy

2. Carrot & Stick

Approach

Industr ial

Green

Chemistry

World

(IGCW)

Attempt to bridge the gap


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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 GreenEngineering based product, technology or services

Apply for an Award:Apply for an award under various categories

Participate in IGCW2013 Symposium:Opportunity to meet pioneers and seniorscientists 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 December13

Venue: Hotel Renaissance & Conventional Center, Powai, Mumbai

For more details and to participate, please contact: [email protected]


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Thank you

For resources on Green Chemistry Please visit

& Green Engineering: www.industrialgreenchem.com

increasing profitability with green chemistry

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