recycle@sourcetm solution: a platform technology in … presentation/mr... · in the green...
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Recycle@SourceTM Solution: a platform technology
in the Green Chemistry tool box
Nitesh H. Mehta Newreka Green Synth Technologies Pvt. Ltd. Mumbai, India [email protected]
E-Factor in Specialty & Fine Chemicals Industry
Impact of High E-Factor
Reality of our processes, plants & effluents
Current Industrial practice
Recycle@SourceTM Solutions: Concept
Case Studies
Benefits of Recycle@SourceTM Solutions
Flow
Source: R A Sheldon
E-Factor (Environmental Impact Factor) = kgs waste / kg product
Nature of Specialty & Fine Chemicals manufacturing:
• Complex molecules
• Multi-step synthesis in relatively high volumes
• Chemistry Intensive processes (& inherent nature of chemistries like Nitration, Diazo,..)
• Use of classical stoichiometric reagents (potential of “catalysis” not fully explored)
The above leads to High E - Factor.
Sector E - Factor Product Tonnage
Oil Refining ≤ 0.1 106 - 108
Bulk Chemicals 1 – 5 104 – 106
Fine Chemicals 5 – 50+ 102 – 104
Pharmaceuticals 25 – 100+ 10 - 103
E-Factor in Specialty & Fine Chemicals Industry
Impact of High E-Factor
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 - 1 Medium
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)
Impact of High E-Factor
Impact: huge threat to water bodies & human health
Quantity : approx. 50 - 75 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 than
1% of human pharmaceuticals…Ref: journal “Regulatory
Toxicology Pharmacology, April’2004)”
Degradation : very slow, impact unknown after degradation
Impact on Economics
Direct Cost : loss of solvent, utilities, raw material & finished product,
treatment cost, higher overheads, losing business
Indirect Cost : unreliable suppliers, credibility in market, anxiety, etc.
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
Reality of our processes
Step 1 Step 2 Step 3 Step 4
4 - 5 different
chemicals
4 - 5 different
chemicals
4 - 5 different
chemicals 4 - 5 different
chemicals
No option except
Effluent Treatment Plant or
Incineration
Cocktail of 15 - 25
different chemicals
Impossible
to separate,
recover or
recycle
Manufacturing Site
Reality of our plants
Mfg. Block for
Campaign
Products
Mfg. Block for
Dedicated
Products
Dedicated
Product
Step 1 Step 2 Step 3
Product 1 Product 2 Product 3
Step 1 Step 2 Step 3
Step 1 Step 2 Step 3 Step 4
Step 1 Step 2
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
Current industrial practice
Effluent stream from
dedicated products Effluent 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
Step 1 Step 2 Step 3 Step 4
2 - 3 Raw Materials
Reaction Medium
Extraction Medium
Finished Product
Effluents Step 1
Reaction & Extraction
Medium
Product/Intermediate
Organic Impurities
Inorganic Impurities
Recycle@SourceTM
Recycle@SourceTM
Solution: Concept
Source of Effluent Streams:
REACTION MEDIUM EXTRACTION MEDIUM
After Process
AQUEOUS STREAM SOLVENT STREAM
(acidic, neutral, or alkaline)
Raw Finished Organic Inorganic
Materials Product Impurities Impurities
Recycle@SourceTM
Solution: Concept
AQUEOUS STREAMS SOLVENT STREAMS
(acidic, neutral, alkaline)
Raw Finished Organic Inorganic
Materials 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
Conventional Technology: High pressure catalytic hydrogenation with Raney Ni
Chemistry: Nitro to Amine Reduction
Recycle@SourceTM
Solution: Case Study 1
Feedback from customer: Recycling mother liquor for over 2 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
Solution: Case Study 1
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 over 20,000 TPA)
Known in the industry for it’s high E-Factor (over 50 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
Solution: Case Study 2
Fusion &
Evaporation Isolation
Vessel
CENTRIFUGE
Amine Methanol Caustic
Acidic Mother Liquor
H-Acid
Representative diagram of Conventional Process
Dilute
Sulphuric Acid
Characteristics Colour Deep Red
pH 1.5 - 2.0
COD 150,000
TDS 15 - 20%
Toxicity Not Known
Recycle@SourceTM
Solution: Case Study 2
Fusion &
Evaporation Isolation
Vessel
CENTRIFUGE
Amine Methanol Caustic
Acidic Mother Liquor
Storage
Vessel
Mother Liquor Recycle
H-Acid
More than 25 recycles
E-Factor = 90%
Patented Technology Yield = 10%
RCat
Treatment
Recyle CatTM
Filter
Spent
RCat
Representative diagram to explain the concept of
Recycle@SourceTM solution as applied to H-Acid
Recycle@SourceTM
Solution: Case Study 2
In the face of challenges that chemistry intensive 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 of Recycle@SourceTM Solutions
Organized by :
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 Green Engieering based product, technology or services
Apply for an Award: Apply for an award under various categories
Participate in IGCW’2013 Symposium: Opportunity to meet pioneers and senior scientists from the field of Green Chemistry & Engineering
IGCW2013: Invite you to be a stakeholder
www.industrialgreenchem.com
Thank You
&
Wish all of You a
“Greener Future”
from
Newreka & Green ChemisTree Foundation Team