TM Solution: a platform technology in the Green Chemistry tool box

Transcription

1 TM Solution: a platform technology in the Green Chemistry tool box Nitesh H. Mehta Newreka Green Synth Technologies Pvt. Ltd. Mumbai, India nitesh.mehta@newreka.co.in

2 Flow E-Factor in Specialty & Fine Chemicals Industry Impact of High E-Factor Reality of our processes, plants & effluents Current Industrial practice TM Solutions: Concept Case Studies Benefits of TM Solutions

3 E-Factor in Specialty & Fine Chemicals Industry E-Factor (Environmental Impact Factor) = kgs waste / kg product Sector E - Factor Product Tonnage Oil Refining Bulk Chemicals Fine Chemicals Pharmaceuticals Nature of Specialty & Fine Chemicals manufacturing: Source: R A Sheldon 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.

4 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 % Very High Agro % Very High Pigment % Medium High Dyes % High Total volume of liquid effluents (world) Indian Market Total volume of liquid effluent (India) = around 70 bn lits/year = 7 million trucks/year % of global = bn lits/year = million trucks/year = 4,000 trucks/day Total Organic Mass in effluents (India) = 875,000 TPA (avg. COD = 50K)

5 Impact of High E-Factor Impact: huge threat to water bodies & human health Quantity : approx bn kgs of liquid effluents include solid & gaseous effluents include all wastes from all other sectors (mining, steel, power,..) Practice Issue : End-of-pipe-treatment (converting one kind of effluent in to other) : 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.

6 Reality of our processes Step 1 Step 2 Step 3 Step Raw Materials Reaction Medium Extraction Medium Step 1 Intermediate/Product Effluents Reaction & Extraction Medium Intermediate/Product By-products Organic Impurities Inorganic Impurities

7 Reality of our processes Step 1 Step 2 Step 3 Step different chemicals 4-5 different chemicals 4-5 different chemicals 4-5 different chemicals Cocktail of different chemicals No option except Effluent Treatment Plant or Incineration Impossible to separate, recover or recycle

8 Reality of our plants Manufacturing Site Mfg. Block for Dedicated Products Mfg. Block for Campaign Products Dedicated Product Product 1 Product 2 Product 3 Step 1 Step 2 Step 3 Step 1 Step 2 Step 1 Step 2 Step 3 Step 1 Step 2 Step 3 Step 4

9 Reality of our effluent streams 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

10 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 different chemicals End-of-the-pipe Treatment (primary & secondary treatment, triple effect evaporator, incineration, solid waste disposal sites, land fill, etc.) Our Environment

11 TM Solution: Concept Step 1 Step 2 Step 3 Step Raw Materials Reaction Medium Extraction Medium Step 1 Finished Product Effluents Reaction & Extraction Medium Product/Intermediate Organic Impurities Inorganic Impurities Recycle@Source TM

12 TM Solution: Concept Source of Effluent Streams: REACTION MEDIUM EXTRACTION MEDIUM After Process AQUEOUS STREAM (acidic, neutral, or alkaline) SOLVENT STREAM Raw Finished Organic Inorganic Materials Product Impurities Impurities

13 TM Solution: Concept AQUEOUS STREAMS (acidic, neutral, alkaline) SOLVENT STREAMS Raw Finished Organic Inorganic Materials Product Impurities Impurities Recycled back to process selectively removed RCat TM (customized proprietary catalytic formulation for Source) selectively & effectively removes undesired org. & inorg. impurities such that the streams can be recycled back in the process.

14 TM Solution: Case Study 1 Conventional Technology: High pressure catalytic hydrogenation with Raney Ni Chemistry: Nitro to Amine Reduction

15 TM 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

16 TM Solution: Case Study 2 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

17 TM Solution: Case Study 2 Amine Methanol Caustic Dilute Sulphuric Acid Fusion & Evaporation Isolation Vessel CENTRIFUGE H-Acid Representative diagram of Conventional Process Acidic Mother Liquor Characteristics Colour Deep Red ph COD 150,000 TDS 15-20% Toxicity Not Known

18 TM Solution: Case Study 2 Amine Methanol Caustic Mother Liquor Recycle Storage Vessel Recyle Cat TM Fusion & Evaporation Isolation Vessel RCat Treatment CENTRIFUGE H-Acid Filter Spent RCat More than 25 recycles E-Factor = 90% Patented Technology Yield = 10% Acidic Mother Liquor Representative diagram to explain the concept of Recycle@Source TM solution as applied to H-Acid

19 Benefits of TM Solutions 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 TM 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

20 Organized by :

21 IGCW2013: Invite you to be a stakeholder 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 krishna.dave@newreka.co.in

22 Thank You & Wish all of You a Greener Future from Newreka & Green ChemisTree Foundation Team