Leveraging GCE for sustainable chemical manufacturing

Learning outcomes

IGCW 2015

4-6 December 2015, Mumbai

A KnowGenix presentation

KnowGenix

Landscape

Introspections

Learning outcomes

Landscape in transition

Characteristics

• Multiproduct, multisegment, multilocation

• An enterprise with a global footprint in 70 odd countries

• Migration of markets, labor, manufacturing,

Structural shifts

• Feedstocks, R&D, technology platforms, manufacturing,

markets, EHS and SC management

• Asset recapitalization continued; ownership pattern

changed; portfolios rationalized; R&D pipelines slowed

• Customers consolidated; specialties commoditized

• New regulations; products banned; aware consumers

• Managing complexities became the norm

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Landscape in transition

Global presence

Multiple technologies

Margin driven growth

Competitive feedstocks

Innovation (mega trends)

Sustainability capability

Regional presence

Niche technologies

Customer driven growth

Competitive delivery

Innovation (Customer)

Customer sustainability

Hybrid companies Niche companies

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Landscape in transition

Global mega trends sets new engagement rules

• Sustainability mandates influenced business agenda

• Investments in GCE tools, metrics, standards

• Focus on segment specific sustainability standards

• Risk management of portfolios (mega trend driven)

• Enhanced regulatory response capability

• Value creation models that embed EES-S components

industry explored, evaluated and experimented with diverse

innovation models

Landscape in transition

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Introspections

Leveraging GCT platforms GCE tools

Bio-based products Synthetic biology

Resource management Energy efficiency

Valorization of biowastes Industrial, agriculture, fruit, vegetable process wastes

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Reflections

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GCT platforms

Biocatalysis: Simvastatin, Atorvastatin, Pregabalin, Sitagliptin

Product redesign: Saquinavir, Aprepitant, (S)- Metolachlor

PI: Pigments, API intermediates, Viagra Intermediate etc

GCE to markets

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Insulation foams, reflector coatings,

detergent enzymes (energy reduction)

Light weighting polymers (fuel efficiency)

Fluorescent lights (GHG reduction)

Energy devices (energy optimization)

Advanced materials (fuel efficiency)

Novel Bio- materials (Energy/ GHG

reduction)

Healthcare

Food

Housing

Transportation

Infrastructure

Climate change driven EE innovations

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Onsite EE: New EE products; Enabling customer EE

Climate protection products – high cost, high risk game

New tools for sector specific energy efficiency

Energy/fuelsDesigner biomass, eco-efficient OFC, bio materials

for solar and wind energy systems, Li–Ion batteries

Climate change driven opportunities

Transportation

Infrastructure

ICT

Healthcare

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Sensor networks, recyclable products, energy devices,

safer electronic chemicals

Self healing aids, biomarkers, customized cosmetics,

Novel diagnostics, designer prosthesis

Fuel cells, bioplastics, lightweight polymers,

recyclable green tyres, compact batteries

Performance coatings, bio-cleaners, asphalt binders,

cement additives, adhesives, colorants

Valorization of biowastes

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Synthetic biology (complex yet to mature)

Thermochemical conversion (mature, scalable)

Algae based (nascent, early stage failures)

Bio based products

Medicine Food

Sitagliptin

(Merck/Codexis)

Cephalexin

(DSM)

Antitrypsin

(Intrexon)

Artemisnin

(Amyris)

Valencene/

Nooktatone

(Isobionics/D

SM, Allylix)

Vanillin/resve

ratrol

(Evolva)

Vetivone

(Allylix)

D-lactic acid

(Myriant)

Butanediol

( BioAmber,

Genomatica)

Adipic acid

(Verdezyne)

Succinic acid

(BioAmber, etc

Farnesene

(Amyris/Kurar

ay)

PHA

(Metabolix)

Isoprene

(Amyris,

Genencor etc )

PBS

(BioAmber)

Fuels

Isobutanol

(Gevo)

Algal oils

(Solazyme)

Butanol

(Butamax/Dup

ont)

Algal biofuels

(Syn.Genom)

Chemicals Materials

www.synbioproject.org

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Learning outcomes

“GC Postulates – no rocket science, any chemist could have written it”

“Experience to pedagogic structures”

“GC innovation that does not find market acceptance is irrelevant”

“Causality – ability to predict cause and effect”

Dr. John C Warner, 4 Dec 2015, IGCW 2015, Mumbai

Hydrogen economy, fuel cells, cellulosic ethanol. algae?

Reliable, inexpensive and limitless energy!!

Buckyballs- new form of carbon – designer and highly symmetrical molecular form of carbon systems with very limited application!

Graphenes – the wunderkind of materials??

Areas needing scrutiny

• Biofuels/materials/chemicals

• Algae based fuels

• Carbon dioxide capture

Learning outcomes

High hype, low delivery business ?

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Key impacts:

• Attracting investments into GC

• Low credibility due sub optimal assessment

• Devalued IP

• Waste of research dollars

• Difference between subset of discoveries that offer viable and

practical solutions and that which offer only possibilities

• Innovation is defined by the market place and not the scientific

community

Chemical engineers must focus on practical solutions, AIChE, Aug 2013, Vol

59. No 8 Banholzer W F and Jones ME

Learning outcomes

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Solvents

• Water as a green solvent?

• Volatile vs involatile solvents

Ionic liquids as a green solvent? negative impact of preparation, separation and toxicity, biodegradability

Replacement of a hazardous chemical with a bad one

Bio based value chain – sustainable ?

Waste minimisation Vs value added by-product

Biofeedstocks: Food vs Fuel vs Feed debate

Food or non food crops?

• Which crops use land more sustainably and more efficiently?

• Which technologies offer most efficient and sustainable use of land/ biomass?

Food crops use land efficiently: Emphasis on food crops – risk diversification ?

Learning outcomes

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A&W principles : Rallying point for lowering chemical hazards through

chemistry based model; became the criteria for USEPA award, GC journal

Peterson Myers principles : Toxicology, EDs became central to GC debate

– New toxicology tools for designing safer chemicals

– Poor track record of chemical substitutions – lack of insights into ED and its relevance

Key directives

• Tiered protocol for endocrine disruptors (TiPED)

• a design phase tool for ED free chemicals

• links GC with environmental health sciences

• Framework for strategic sustainable development ( FSSD)

• enabling multidisciplinary approach

• strategic mapping of sustainability solutions

Carcinogens were the buzz words of 90s Endocrine disruptors are the buzz words today

Learning outcomes: 12 GC Postulates

GC, a powerful sustainability tool, is one among diverse narratives inthe dialogic process involving chemistry and sustainability

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The need for validated and reliable green metrics has become

very critical in design and development of greener product and

processes with ever increasing false claims of greenness

Development of green chemistry metrics poses challenges as

newer and complex heteroaromatic chemistries continue to

dominate new product development

In the background of complex molecules being developed no

single metric, in isolation can adjudge the ‘greenness’ of a

process. We need multiple metrics to provide precise data before

processes can be validated

Learning outcomes: Metrics/tools

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Biocatalytic technologies are yet on learning curve and issues related to validation, productivity, selectivity and more importantly consistency in formulation and limited substrate options need closer attention.

Enzymatic processes could be a key alternative to chemical synthesis for diverse commercially important reactions like esterification, transesterification etc

Directed evolution processes and genetically engineered modification of microorganisms for tailor-made enzymes will form the basis of several sustainable processes??

Actualisation of prospects based on future advances in high-throughput screening, fermentation technology and biocatalyst immobilization

Learning outcomes: Biotransformations

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Biowaste valorisation technologies are yet to mature.

Enzymatic, fermentation and extraction technologies

sub- optimal to deal with diverse range of wastes

Evaluation of food industry wastes depends on accurate analysis

of the composition of wastes, toxic components and the

proportion of diverse functional ingredients present.

The key to effective valorisation of wastes containing proteins,

sugars and lipids to value-added chemicals and polymers goes

beyond technology to that of competitive access, quality and

characterisation.

Research is needed on stability and interactions of

phytochemicals with other food ingredients during processing

and storage.

Learning outcomes: Biowaste valorisation

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• It is ironical that major catastrophes have driven key advances in

science, technology, legal systems, social care, public health

administration and regulations at international levels

• The uncertainties prevalent in chemical manufacturing pose

serious questions about our understanding of newer chemistries

and pathways; dynamics of thermal runaway reactions;

mechanism of formation of intermediate products, and expertise

in managing the consequences of TRs

• Three decades after Bhopal, if we still need chemical

catastrophes to drive advances in science, technology, legal,

health and social care policies etc, it is indeed a sad reflection of

progressive technology driven societies !

Learning outcomes: Process safety

KnowGenix

• Sustainability ethics, communication, interlocution

• Philosophy of technology and regulatory frameworks

• Guiding principles of chemical sustainability

• Design and development of green tools/metrics

• Process economics

• Toxicology: EDs, POPs

• Rational design of safer products

• Feedstocks management

• Product engineering (formulation engineering)

• Design of Inherently safer processes

• Pedagogy: STS, innovation, IDM

Focus on R&D/Manufacturing insulated from broader sustainability /Innovation skills

Learning outcomes: GC education gaps

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90s to now

Flexible to rigid innovation structures

Company specific to collaborative innovations

Product/process to non-technical innovations

Coupling and decoupling of R&D and innovation cells

Segment specific innovation models

Innovative products are orphaned at high costs

Innovation tunnel misaligned with market space

Attracting investments for concept to proof of concept

“Banned” products to “regrettable” replacements

Learning outcomes : Innovation

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high risk, slow return, unpredictable game

Rajagopal R, 1992 Clean technology development – the ultimate solution?: Norsk geogr, Tulsskr. Vol. 46, 193 197 Oslo ISSN 0029-1951…

“solutions to contemporary industrial and environmental problems lie not in

just designing and selling a new technology .. but in being able to predict the consequences of such technological changes in terms of cost benefit ratio: socio-economic imbalances, local market forces that control the production outputs, potential environmental and health effects…..”

“The search for newer alternatives in terms of pollution reduction should not be at the cost of inherent community and work place safety. Important issues such as the toxicity level of new materials and products and the level of safety control systems required would ultimately be the deciding factors in clean technology promotion”

“The development of clean technology has to be preceded by a thorough scrutiny of the various choices in terms of resources required for the various alternatives. Furthermore, the prediction of environmental, social and economic consequences as a result of the choices made is essential

“It is vital that the new environmentally benign technologies that are developed globally are not subjected to types of restrictions such as patent laws, regulations and barriers in technology transfer.”

Moving back in time.. 1992.. from Blindern, Oslo

Clean chemistries/technologies was the buzz word ‘84-’97.. Green chemistry since ‘98

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KnowGenix

CCE : reshaped by SynBio, MolBio, etc.

Regulatory/business pressures: “where is every molecule going in your/my plant?”

Future chemical enterprises will demand a new breed of C&CEs- trained to operate in the interphases of several disciplines; also act as • resource managers• value creators • interlocutors

Future landscape

Change: radical & catastrophic will happen in shorter cycles

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Thanks for your attention

Appreciate your feedback at strategy@knowgenix.com

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