magic processes & plants€¦ · for faster lab to market innovation. some key principles •...
TRANSCRIPT
MAGIC ProcesTransform Manufacturing
Vivek VChemical Engineering & Pr
National ChemPune Pune
National Chemic
Create Innovations & Knowledge
sses & Plantsg of Specialty Chemicals
V. Ranaderocess Development Division
mical Laboratory 411008 411008
al Laboratory 2011
base to Solve Relevant Problems
Outline
S i lt h i l• Specialty chemicals– Key requirements/ drivers
Challenges/ technology p– Challenges/ technology p
• MAGIC processes and pMAGIC processes and p– Key attributes– Realizing MAGIC in practi
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ea g G C p act
• Summary & path forwar
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mic
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ab©
Nat
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l
splatformsplatforms
plantsplants
icece
rd
Specialty Chemicals
Characterized by low volu• Characterized by low voluprice, sold on performanc
• Key sub-sectors– Catalysts– Textile chemicals– Textile chemicals– Water treatment chemicals– Adhesives and sealants
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– Leather chemicals– Detergents & surfactants
Paper chemicals
Che
mic
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ab – Paper chemicals– Electronic chemicals– Biomarkers
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– API
umes niche applications highumes, niche applications, high ce specifications
– Paints, pigments and colorants– Flavors and fragrances
Foundry chemicals– Foundry chemicals– Rubber chemicals – Photographic/reprographicPhotographic/reprographic
chemicals– Printing inks
dd f l– Additives for polymers– Construction chemicals– Oil field chemicalsOil field chemicals– Cosmetics
Indian Specialty Chem
C t t 15• Current turnover: ~ 15– Expected to grow at doub
economy like Indiaeconomy like India
• Turnover will cross 75
• Need significant techno
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1 addition turnover of 6
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mic
al L
ab©
Nat
iona
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micals Sector
50000 C50000 Croresble the rate of GDP in emerging
50000 Crores by 2022y
logy inputs to create 600000 Crores!
Growth Potential
Gl b li ti f b i• Globalization of busines• Shifting manufacturing• Growing concerns for s
– Catch up with and exceedt i bilitsustainability
• Changing customer expd hi
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1 demographics– Address unmet needs & n
developing nation (capac
Che
mic
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ab developing nation (capac
• Rapid market fluctuatioIndustry consolidation
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nal • Industry consolidation
ss geographiessustainabilityd the global benchmarks on
pectations driven by new
newer demands of rapidly ity/ quality)ity/ quality)
ns/ cycles
Key Drivers for Growt
L t ti /• Low cost operation/ ma
• Develop better process p pquality
• Provide systems solutio• Provide systems solutio
• Develop new application
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• Develop new products ton unmet needs of cust
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on unmet needs of cust
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th
f t ianufacturing
technologies/ product g p
nsns
ns for existing products
to create new market based tomertomer
Indian Specialty Chem
• Business issues• Business issues– Fragmented capacity; low cap– Threat of horizontal transfer o
due to commoditization of pro– Difficulties in identifying new g– Lack of deep pockets to sustaiLack of deep pockets to sustai
supplier/ manufacturing entity
• Technological issues
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1 • Technological issues– Cost of new product introducti– Relative unfamiliarity with cata
conventional engineering prac
Che
mic
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ab conventional engineering prac– Limited in house technology d– Innovation deficit; few process
serious issues of talent retenti
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nal serious issues of talent retenti
– Increasing regulatory (environ
micals: Challenges
ital/ technology intensityof technology/ quicker erosion of margins oductsgrowth platforms in business cycles; branded as low costin business cycles; branded as low cost y; managing supply chain of raw materials
ions/ cost of raw materials & energyalytic processes/ different reactors; ticesticesevelopment strengthses based on proprietary knowledge/ IP; on/ flighton/ flight
nment, health and safety) frameworks
Possible Ways to Ove
• Improve productivity an• Improve productivity anproducts; Adjust with racycles; Reduce time tocycles; Reduce time to – Multiple products from th– Improve functionalities –Improve functionalities – Flexible & multi-purpose – Focus on formulated prod
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p– Products with unique raw– Process intensification &
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– Use continuous processes– Computational modeling
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Science, Technology &
rcome Challenges
nd develop innovativend develop innovative apid market fluctuations/ marketmarket
he same facilitiesnew marketsnew marketsplantsducts
w material advantagescompact plantssfor faster lab to market
& Innovation
Some Key Principles
• Use catalysts not stoich• Use catalysts, not stoich• Use better (& safer) sol
conditionsconditions • Design syntheses so tha
maximum proportion ofmaximum proportion of• Prevent waste, leave no• Design safer (non-toxic)
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1 • Design safer (non toxic)• Maximize energy efficie• Use multi-functional & i
Che
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ab • Use multi functional & iequipment
• Real-time monitoring an
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nal Real time monitoring an
hiometric reagentshiometric reagentsvents and reaction
at the final product contains f the starting materialsf the starting materialso waste to treat or clean up) chemicals and products) chemicals and productsncy & effectivenessntensified processntensified process
nd process controlnd process control
Key Technology Platf
Ch i t• Chemistry– Catalysis (replace reagen
Improved solvents (super– Improved solvents (super– Other tools like chiral swi
encapsulation, Suzuki couencapsulation, Suzuki couand so on
• Chemical engineering &
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1 • Chemical engineering &– Batch to continuous, mult– Micro-reactors new react
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Micro reactors, new react– Novel separation platform– Computational modeling,
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nal p g,
CSIR - National Che
forms
t based processes)rcritical media ionic liquids)rcritical media, ionic liquids)tches / single enantiomers, micro-upling, metathesis, click chemistryupling, metathesis, click chemistry
& process intensification& process intensificationtifunctional reactorstors and mixerstors and mixers
mssimulation & visualization
emical Laboratory
CSIR
CSIR’ i i• CSIR’s mission– To provide scientific indu
economic environmentaleconomic, environmentalpeople of India.
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hem
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Lab
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Total No. of Laboratories/Institu
strial R&D that maximizes the and societal benefits for the and societal benefits for the
NPL, CRRI, IGIB, NISCAIR, NISTADS
CEERI
CSIOCDRI, CIMAP, IITR, NBRI
NEIST
IMT CBRIIIP
IHBTIIIM
CIMFR
NIO
CSMCRI CGCRI
NCL
AMPRI
NEERI
NML
IMMT
CMERI
IICB
Physical SciencesChemical SciencesBiological Sciences
CCMBIICTNGRI
SERCCLRI
CECRI
NIIST
NAL
CFTRI
o og ca Sc e cesEngineering SciencesInformation Sciences
utes: 37 Outreach Centres: 39
CSIR Today: Played K
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Lab
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Key Role
CSIR Vision: New CSIR
P i hi h t• Pursue science which sttechnology that enablesand nurture trans discipand nurture trans-discipcatalyzing inclusive econpeople of Indiapeople of India– Establish science & engin– Provide innovative techno
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Provide innovative techno– Harness open innovation – Encourage science based
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mic
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g– Realize socio-economic tr
intervention
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R for New India
t i f l b l i ttrives for global impact, s innovation-driven industry plinary leadership therebyplinary leadership thereby nomic development for the
neering leadershipology solutionsology solutionsand crowd sourcing entrepreneurship p pransformation through S&T
N CSIR f New CSIR for New India
National Chemical La
NCL’ i i• NCL’s mission– To further knowledge in t
for the benefit of the peofor the benefit of the peo
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Lab
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aboratory
the chemical sciences and apply it opleople.
• Knowledge creation, g ,capability building, PhD researchK h t h l• Knowhow, technology, innovations
• Research servicesResearch services, consulting, technical support
• Establish & nurture resource centers
NCL Eras: Lab to Mar
Basic chemicals; Dye st
Agrochemic
Pharmaceuticals; Fine che
Import subs;
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1 Import subs;
R h i I di Gl
Che
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ab Research services; India – GlPatenting; Global tech trans
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PartnershipInnovatio
ket
tuffs (1950s)
cals; Organic chemicals (1960s)
emicals (1970s)
Catalysis; Tissue culture Catalysis; Tissue culture (1980s)
l b l R&D h b lobal R&D hub; sfer (1990s/early 2000s)
p models; Entrepreneurship; on networks (mid/late 2000s/ 2010s)
National Chemical La
Create innovations and kn• Create innovations and knquality of life via contribu– Create value through innovaCreate value through innova
infringing processes and scicomplex processes
• Capabilities– Strong process chemistry/ p
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1 – Competence in homogeneo– Process intensification, reac
S ti i
Che
mic
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ab – Separation sciences– Strong domain knowledge i
advanced process control st
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Close association with i
aboratory
nowledge base to enhancenowledge base to enhance utions to key industry sectorsations IP development of non-ations, IP, development of nonience based understanding of
process design and engineering skillsous and heterogeneous catalysisctor engineering & scale-up
n process modeling, simulation, trategies and flow modelingg g
industry/ a credible partner
Process Intensificatio
Fi t i i iti ti• First in initiating researcIndia
Established first of its kin– Established first of its kinreactors’ at NCL
– Equipment manufacturesEquipment manufactures
• Complemented consorti
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1 center of excellence (Co– Development of new proc
Che
mic
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ab devices– Convert batch processes
Intensify processes to ach
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nal – Intensify processes to ach
plants
on at NCL
h i t ich on micro-reactors in
d industry consortium on ‘microd industry consortium on ‘micro
to usersto users
ium with CSIR funded oE) on micro reactorscess equipment/ multifunctional
to continuous oneshieve compact & multi purposehieve compact & multi-purpose
MAGIC Plants & Proce
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Lab
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esses
Modular
AGile
IntensifiedIntensified
Continuous
M for Modular
M d l l t• Modular plants– Designed as interchangea
equipment with pre-definequipment with pre defin– Reduce field work/ reduc– Facilitate shorter scheduleFacilitate shorter schedule
testing– Enhance flexibility/ reloca
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• Need to develop& b
Che
mic
al L
ab – New & better connectors– Intensified & compact rea
New concepts in modular
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nal – New concepts in modular
– Standardization and inter
able modules containing groups of ned interfaces to utilities etcned interfaces to utilities etc.e time from lab to practicees, compact design & rigorouses, compact design & rigorous
ation
actorsrizingrizing roperability policies
AG for Agile
A ilit• Agility– Ability to change process
market needs and to manmarket needs and to man– Demands re-configurable
• Dynamic plant layouty p y
• Need to develop
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1 – New & multifunctional pro– New design paradigms: r
parameters instead of po
Che
mic
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ab parameters instead of poCombinatorial methods todesign variables and proc
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g p– Use of wireless technolog
plants quickly in response to nufacture new productsnufacture new productse process and plant designs
ocess equipmentanges of the values of the design int values as input parameters;int values as input parameters; o scan the domain consisting of cess functionsgies as enabler in plants
I for Intensified
• Enhanced transport rate• Enhanced transport rate– Very large surface area to
interactions– Fast mixing/ heat transfe– Precise control on residen
• Small reaction volumes– Low inventories/ safer op
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1 Low inventories/ safer op– Ability to withstand extre
Che
mic
al L
ab • Possibility of integratingseparations on single pl
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eseso volume ratio/ interfacial
r/ mass transfernce time distribution
perationsperationsme conditions
g multiple reactions/ latform
C for Continuous
C t & l i t• Compact & low inventor– Safer operations, lower fo
• Consistency in product q– Better control on selectivBetter control on selectiv– Better atom efficiency
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• Optimal use of utilities– More efficient
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mic
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• Better process control
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ryoot print
qualityityity
Drivers for MAGIC
• Enhanced quality and sa• Enhanced quality and saenvironmental impact– Modular and agile (ability to co
minimum down time & off spe– Lower E factor, carbon & wate
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Lab
From
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PissAICh
afety at reduced cost andafety at reduced cost and
onduct several product campaigns with ec products)er footprints, hazards (green)
Calabrese and Calabrese and savini (2011) hE J, 57, 828
MAGIC Plant: Scientif
• Early stage reaction en• Early stage reaction en– Selected reaction platfor
• New concepts & design
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1 • New concepts & designequipment/ process con– Delivering materials and
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gplace (manipulate design
• Understand, quantify &
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– Corrosion/ erosion/ cloggswitching products/ reco
fic Challenges
gineering analysis:gineering analysis: ms (chemistry/ reaction kinetics)
ns for intensified processns for intensified process ntrolenergy at right time and at right gy g g
n & process control strategies)
& manage other issues:ging/ maintenance/ cleaning/ onfiguration
Indus Magic©Indus MagicInnovate, Develop & Up Scale Modular, Agile, Intensified & Continuous Processes & Plants
• Magically transform Indindustryy
ProchemPro
chem
Reaction
MAGIC (AGile, In
& ContReaction
MAGIC (AGile, In
& Cont
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1 Reaction kinetics &
engineering
& Contpl
Reaction kinetics &
engineering
& Contpl
Che
mic
al L
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• Likely project partners (
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– ICC, sector specific indus– NCL, IICT, NIIST, CSMCR
New Age Specialties
dian specialty chemicals
ocess mistryocess mistry
Process
(Modular,ntensified tinuous) Process
(Modular,ntensified tinuous) Process
intensification & synthesis
tinuous) ant
Process intensification
& synthesis
tinuous) ant
(industry, CSIR, others)try consortiums
RI, NEIST + CEERI, CMERI
Indus MAGIC E
Conventional wayh b hBatch or semi-batch processes
Stirred reactorsLess flexible plants, clumsy cleaning
Use of stoichiometric reagentsGenerate significant waste per unit product
Large water foot print
Use hazardous solventsReactions limited by transport limitations
Separate unit operations: reactors,
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Separate unit operations: reactors, separations
Cabled process instrumentation & control
Che
mic
al L
ab©
Nat
iona
l
nhance Productivity & Profitability
Indus MAGIC wayContinuous processes
Compact, intensified reactorsModular, agile and reconfigurable plantsUse of catalysts & catalytic processes
Intensified processes/ operation to maximize atom efficiency
Reduced water foot print via water recycle and reuse
Conduct reactions in water/ benign solventsReactions at intrinsic rates without any
transport limitations Integrated processes with multi-functionalIntegrated processes with multi functional
reactors/ process equipmentWireless process instrumentation & control/
new paradigms for process optimization
Indus MAGIC Approac
• Establish focused research• Establish focused research – Continuous reactors & process
processes by catalytic process– Reduce, reuse & recycle
• Establish industry consortiu– Include industry representative
consortium
bl h ‘ G C l ’ f
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1 • Establish ‘MAGIC Plant’ facito specialty chemicals indus
Che
mic
al L
ab • Associate large number of f– Formulate final year projects a
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• License technologies, createventures & globally leading
ch
programs on work packagesprograms on work packagesses, separations, replace reagent based es, use benign solvents …
um to involve industrieses in the management board of
l d klity to demonstrate key concepts stry
final year ChE studentsaround Indus MAGIC theme
e new entrepreneurs, start-up specialty chemical industry
Pre-project of Indus M
I iti t d j t f• Initiated pre-project of – Reposition research focus
iCPs©
– Focus on developing inte
Develop Intensified & Continuous Processes for Specialty Chemicals
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p gand plants
• Associated industry consor• Associate large number of
Che
mic
al L
ab • Associate large number of
– Develop multifunctional p• Compact modular reactors
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nal p
like helical coils, diodes, m
www.indusmagic.org will b
MAGIC
I d MAGIC t NCLIndus MAGIC at NCLs on MAGIC concepts
nsified & continuous processes p
rtiumf BE project students for pre screeningf BE project students for pre-screening
processess: assembled using a few basic devices g
mixers
be launched soon
Realizing MAGIC Proc
w
ates
al
©
ICC & othconw
ays/
new
arke
ts
mis
ing
s fr
om
othe
r
al c
andi
daen
t/ in
itia
Sch
olar
hola
r© conN
ew w ma
on o
f pr
omes
/ in
puts
CPI/
ICC/
oso
urce
s
f po
tent
iaev
elop
me
via
Indu
s
us S
ch
zed
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Eval
uati
proc
esse
Indu
s C s
fica
tion
of
proc
ess
dcr
eeni
ng v
Indu
ecen
tral
izct
urin
g
Che
mic
al L
ab
Iden
tif
for
p sc Indu
n ti
me/
dm
anuf
ac
Currently
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nal
Just
in
y
Indus MAGIC w
cesses & Plants
her industry ntacts
Li i /
ntacts
Licensing/ Commercialization/ Spinout companies
iCPs©
p p
©us CPI©
8 members
will be initiated under 12th five year plan
Summary
Realizing next phase of g• Realizing next phase of gspecialty chemicals requ
Innovations in process int– Innovations in process intengineering: iCPs/ Indus
– Proactive participation of p p– Harnessing large number
students: Indus Scholar
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1 • Will be agents of transform
• Significant potential to tr
Che
mic
al L
ab • Significant potential to trchemical industry by parother CSIR chemical clus
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nal other CSIR chemical clus
growth & leadership ingrowth & leadership in iretensification & reactortensification & reactor MAGIC industry: Indus CPIy
r of young chemical engineers/
mation in the coming years
ransform Indian specialtyransform Indian specialty rtnering with CSIR – NCL and ster laboratoriesster laboratories
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Specialty Chemicals M
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From Burgess et al. (2003), Europe
Market
an Management Journal, 20(2), 199–212