Knowledge Paper on. Reengineering Chemistry for better tomorrow

Transcription

1 Knowledge Paper on Reengineering Chemistry for better tomorrow Released at Industrial Green Chemistry World December 2013

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3 Contents Acknowledgements... 3 Foreword... 4 Executive Summary... 5 Overview of Indian Chemical Industry... 8 The need for Green Chemistry Industrial Green Chemistry and Engineering (IGC&E) Practices What is Green Chemistry? What is Green Engineering? Global evolution of Green Chemistry and Engineering Practices The Global Green Chemistry Opportunity Metrics for Green Chemistry and Engineering Material Efficiency Energy Efficiency Reduced Hazards Holistic Design Barriers in implementation of Green Chemistry and Engineering Practices Financing barriers Economic Feasibility barrier Technology Barriers Regulatory Barrier Awareness Barriers Tools for implementing Green Chemistry Life Cycle Analysis isustain TM EcoScale Strategies for implementing Green Chemistry and Engineering Immediate Term Implementation Strategies Sustainable recycling solutions Zero Liquid Discharge (ZLD) COD reduction

4 Short Term Implementation Strategies Solvent recovery practice Alternate Solvents Biocatalysts Alternate Additives Surfactants, chelates and Reagents Medium Term Implementation Strategies Microreactor Technology Microwave Chemistry and Engineering Organic solvent free process Supercritical fluids Long Term Implementation Strategies Bio-based Chemicals Biomimicry Industrial Ecology The Way Ahead Case Studies References The Expert Comments About Tata Strategic Tata Strategic Contacts About IGCW

5 Acknowledgements We deeply acknowledge the contributions from the following green chemistry experts who have shared their experiences with us in the course of preparation of this report. Our sincere thanks to: Dr. Anil Kumar, Principal Scientist, Tata Innovation Centre, Pune Dr. David Constable, Director ACS Green Chemistry Institute, USA Mr. Nitesh Mehta, Founder Director Newreka Dr. R. Rajagopal, CCO, KnowGenix Dr. Rajiv Kumar, Chief Scientist, Tata Innovation Centre, Pune Dr. Rakeshwar Bandichhor, Director API-R&D, Dr. Reddy s Laboratories Ltd. Mr. Satish Khanna, Founder LAZORR Initiative, Ex-Group President, Lupin Dr. Vilas Dahanukar, Vice President, Dr. Reddy s Laboratories Ltd. We express our gratitude to the following industry leaders for sharing their point of view Dr. Joerg Strassburger, Country Representative & Managing Director, Lanxess India Pvt. Ltd. Mr. Nitin Nabar, Executive Director & President (Chemicals), Godrej Industries Limited Mr. R. Mukundan, Managing Director, Tata Chemicals Limited Dr. Rajeev Vaidya, President South Asia & ASEAN, DuPont Mr. Rakesh Bhartia, CEO, Indian Glycols Mr. Vipul Shah, President CEO & Chairman, Dow Chemical International Pvt. Ltd. We are thankful to IGCW for providing the opportunity and support in developing the knowledge paper on Industrial Green Chemistry and Engineering 3

6 Foreword Manish Panchal Practice Head - Chemical & Energy Tata Strategic Management Group manish.panchal@tsmg.com Charu Kapoor Engagement Manager - Chemicals Tata Strategic Management Group charu.kapoor@tsmg.com The world today is facing a number of environmental challenges like global warming, ozone depletion, depletion of non-renewable energy resources, water pollution and reduction in fresh water supplies and increased generation of complex industrial wastes. Often the Chemical Industry is found and perceived to be a significant contributor to the global environmental issues. This not only impacts the image of the Industry but also creates a pressure to shift to green practices. A key question therefore in front of the Industry is What should be done to make the transition to green practices in a profitable manner? In this context, as a significant step towards promoting implementation of green chemistry and engineering practices, Industrial Green Chemistry World (IGCW) approached Tata Strategic Management Group to develop a knowledge paper on Industrial Green Chemistry and Engineering. The report explains the necessity and importance of Green Chemistry and Engineering practices for the current Chemical Industry. The report builds upon the globally recognized green chemistry and engineering principles and identifies the four metrics for green chemistry and engineering practices through which companies can evaluate their current performance and take necessary actions for transition to green practices. The report highlights the key barriers faced by the industry in implementation of green chemistry, and explores the possible solutions to overcome the same. The report also looks at the possible strategies which can aid the companies in implementing the green practices. At the end, the report includes various successful stories of green chemistry implementation by companies which highlight the benefit obtained by the companies by implementing green practices. The report has been developed by combination of primary and secondary research. We hope that this knowledge paper would help in promoting green chemistry and engineering practices in the industry, and provide possible direction to the companies in implementing green chemistry and engineering practices 4

7 Executive Summary This report is developed by Tata Strategic Management Group with support of IGCW (Industrial Green Chemistry World) as the knowledge paper for IGCW 2013 convention. The present chemistry can be classified as DIRTY, DANGEROUS and DEMANDING posing a number of challenges, economic and environmental for the Industry. As a result the industry faces increasing pressure from the customers and the NGOs for shifting to green practices. With strict regulations like REACH in European Union and California Safer Consumer Product Law it has become imperative for the Chemical Industry to make a transition to green chemistry and engineering practices. The green chemistry implementation strategies based on implementation time, resources involved and associated implementation risks can be categorized into four types; immediate term, short term, medium term and long term implementation strategies. On an immediate basis companies can look at building sustainable recycling and zero liquid discharge solutions. On a short term companies can implement solvent recovery solutions and switch to greener bio-degradable alternatives like biocatalysts, green solvents and additives. On a medium term companies can explore opportunities presented by microreactors and microwave chemistry and supercritical fluids. Over long term companies can make transition to bio-based chemicals, develop products based on biomimicry and build symbiotic interdependent relationships with the key stakeholders of the ecosystem. However the industry faces barriers in implementation of green chemistry and engineering. The key barriers are: Financing barriers, Economic Feasibility Barriers, Technology Barriers, Regulatory Barriers and Awareness Barriers. It is to be however understood that the industry cannot overcome the barriers in isolation. It requires support from the academia, government and regulatory bodies for implementing green chemistry and engineering practices. Some of the possible solutions to overcome the barriers are: Investment in Research and Development activities, inclusion of green chemistry concepts in the academic course structure, support and encouragement for academia for research in green chemistry, training and development programs for academia and the industry in the domain of green chemistry, support for green practices from the top management and key decision makers, and financial and regulatory support from the government to the industry. The domain of green chemistry provides huge opportunities for product and process innovations and opens up new market opportunities for the industry. With increasing demand for green products, shifting to green chemistry is not an option but a necessity for the companies. It is to be understood that green chemistry practices are essential for the long term survival and business sustenance of chemical companies. 5

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9 SECTION 1 Overview of Indian Chemical Industry 7

10 Overview of Indian Chemical Industry Chemical industry is a capital as well as knowledge intensive industry. This industry plays a significant role in the global economic and social development. It is also a human resource intensive industry and hence generates significant employment. Globally, the industry employs more than 20 million people. The diversification within the chemical industry is large and constitutes approximately 80,000 products. Global chemical industry is estimated at USD 3.7 trillion in 2012 and is expected to grow at 4-5% per annum over the next decade to reach USD 5.8 trillion by exports. Indian chemical sector is very crucial for the economic development of country. (Refer figure 1). Indian chemical industry comprises both small scale as \well as large scale units. The large scale units are able to set up capital intensive projects with long gestation periods. While the fiscal incentives provided to small scale units earlier led to development of large number of small and medium enterprises (SME). It is also a significant employment generator. Over the last five years Indian chemical industry has started The chemical industry can be classified into four key segments 1. Chemical sector: It includes basic organic chemicals (methanol, acetic acid etc.), basic inorganic chemicals (caustic soda, chlor alkali etc.), specialty chemicals (colorants, water treatment etc.) and agrochemicals (pesticides etc.) 2. Petrochemical sector: Petrochemicals includes polymers, synthetic fibers, surfactants and elastomers 3. Fertilizers: Include all types of N,P& K based fertilizers like Urea, DAP 4. Pharmaceuticals: It includes formulations, APIs and biotechnology Indian Chemical Industry 1 India currently accounts for only 3.3 % of the total chemical market with a market size of ~ USD 110 billion in Indian chemical industry accounted for ~13% of the total India s Figure 1: Indian Chemical Industry 2012 to evolve rapidly. With significant capacity additions coming into place, the focus has also been towards investments in R&D (Research and Development). India s competence in this knowledge intensive industry is increasing however the tapped potential is very limited. The Indian Population today stands at more than 1.2 billion. 63% of the Indian population lies in the year age group which forms the earning population group. Within the year age 8

11 group, 55% of population belongs to the age groups. The increasing urbanization, increasing percapita disposable income and increasing number of double income nuclear families has resulted in a very strong growth outlook for the key end user industries. For instance, growing eating out habits and increase in consumption of packaged food has positively impacted packaging industry. Packaging industry is expected to grow at ~15% p.a. over the next five years, similarly Electronic is expected to grow at ~12% p.a. over the next five years, Construction and Automotive both sectors are expected to grow at ~12% p.a. over the next five years. Hence, going ahead the demand of chemical products is expected to grow at 1.5 times of GDP and with project growth rates, Indian Chemical Industry is expected to grow at 8-9 % p.a. over the next five years. 9

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13 SECTION 2 The need for Green Chemistry 11

14 The need for Green Chemistry The rapid growth in global population, rapid industrialization and urbanization has led to a number of environmental concerns. The world today is grappling with issues like global warming, ozone depletion, rapid depletion of non-renewable energy sources, reduced fresh water supplies and increased generation of complex industrial wastes. The chemical industry touches all facets of human lives and is an important source of world s energy and raw materials requirements. However, it has always been perceived as a contributor in degradation of environment across the globe and has been labeled as Dirty, Dangerous and Demanding. Unfortunately, this has been supported with infamous instances like Cuyahago river fire incident of 1969 or Bhopal Gas tragedy of 1984 and various other instances across the globe. Today, in India the river bodies and ground water in various parts of the country are contaminated with various unwanted products on account of reckless behavior of people and careless disposal of post-production wastes either without appropriate treatment or namesake treatment. These contaminants may or may not be chemicals but often it is the chemical industry which gets the maximum blame. Many of these products are toxic, carcinogenic and harmful to life and to the environment. The chemical industry is material and energy intensive and is facing a number of challenges today due to above mentioned issues and perception in society at large. Moreover, the industry today has a significant dependence on non-renewable petrochemicals as feedstocks. With increasing volatility of petrochemical feedstocks prices, supply constraints due to diminishing natural reserves and political uncertainties in several feedstock rich nations, the industry is finding it difficult to maintain a reliable and predictable feedstock situation. Besides feedstocks, the industry is also facing challenges in controlling its energy and water footprint. At various stages of processes wastes and hazardous substances are generated. Often these wastes are not treated properly or can t be treated easily resulting in increasing waste creation and waste disposal costs. Strict government regulations and new legislations like Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) are creating further pressure for chemical industry to relook at their manufacturing processes and develop products which are less or non-toxic. NGO s and end consumers are now demanding products which are green and cause little or no negative impact to environment (Refer figure 2). In general the present chemistry can be classified as DIRTY (handles non-renewable raw materials and generates hazardous wastes and emissions), DANGEROUS (handles hazardous reagents and solvents) and DEMANDING (multi-step material and energy intensive processes involving reworks and reprocessing), leading to excessive strain on environment, natural resources and human health and the companies will need to think holistically for long term survival. 12

15 Figure 2: Challenges faced by Chemical Industry 2 Within the chemical industry it is the speciality and the fine chemicals segments which are the significant contributor to the hazardous waste generating and environmentally inefficient chemistry. This is due to the complex molecules, multi-step synthesis in high volumes, use of traditional stoichiometric reagents and chemistry intensive processes resulting in high e-factor i.e. amount of waste generated per kilogram of product manufactured. Compared to oil refining (e-factor <0.1) and bulk chemicals (e-factor 1 to 5) speciality and fine chemicals have e-factors ranging from 5 to (Refer Table 1). Almost 80% of the mass in chemical reactions consists of solvents and water, which are discharged post treatment as waste. This leads to raw material usage inefficiency and generates wastes which could have been recycled and reused in chemical reactions. Often the solvents are costly and disposing them as wastes leads to increased manufacturing costs. For example, the pharma sector alone generates wastes Industry E-factor Volume of liquid COD Toxicity sector (kg waste/kg product) effluents (100 (billion liters) thousands) Pharma Very high Agro Very high Pigment Medium high Dyes High Table 1: Waste generation across Industries 4 13

16 almost 50 to 100 times of finished products. According to indicative rough estimates the total volume of liquid effluents generated by the above mentioned four segments annually worldwide is 60 to 80 billion liters. It is estimated that the Indian market alone is responsible for approximately 20% to 30% of global liquid effluents amounting to 15 to 20 billion liters annually. Furthermore, the annual organic mass generated in effluents in India is almost 875,000 metric tons with an average Chemical Oxygen Demand (COD) of 50, efficiency, thereby reducing the generation of hazardous wastes. Companies will also gain by having lower material costs, significantly reduced environmental and health risks thereby creating an improved image for themselves across stakeholders (Refer figure 3). To solve the above mentioned challenges and create sustainable businesses, Green Chemistry and Engineering can play a significant role. Through implementation of green practices companies can improve mass and energy Figure 3: Transition from present chemistry to Green Chemistry 14

17 SECTION 3 Industrial Green Chemistry and Engineering (IGC&E) practices What is Green Chemistry? What is Green Engineering? Global evolution of IGC&E practices The Global Green Chemistry opportunity Metrics for Green Chemistry and Engineering 15

18 Industrial Green Chemistry and Engineering (IGC&E) Practices What is Green Chemistry? Green chemistry is a philosophy of chemical research and engineering that involves the design of products and processes that minimize the use and generation of hazardous chemicals. Unlike the environmental chemistry which focuses on the study of pollutant chemicals and their effect on nature, green chemistry aims to reduce the pollution at the source. The concepts of green chemistry ranges from general principles like prevention and production of less waste to specific recommendations of preferring catalytic reagents over stoichiometric ones. The term green chemistry was first coined by Paul Anastas of United States in Green chemistry involves waste minimization at source, use of catalysts in place of reagents, use of non-toxic reagents, use of renewable resources, improved atom efficiency and use of Solvent Free or Recyclable Environmentally Benign Solvent systems. According to P.T. Anastas and J.C. Warner, Green chemistry can be defined by a set of 12 principles 1. Prevention: It is better to prevent waste than to treat or clean up waste after it has been created. 2. Atom Economy: Synthetic methods should be designed to maximize the incorporation of all materials used in the process into the final product. 3. Less Hazardous Chemical Syntheses: Wherever practicable, synthetic methods should be designed to use and generate substances that possess little or no toxicity to human health and the environment. 4. Designing Safer Chemicals: Chemical products should be designed to effect their desired function while minimizing their toxicity. 5. Safer Solvents and Auxiliaries: The use of auxiliary substances (e.g., solvents, separation agents, etc.) should be made unnecessary wherever possible and innocuous when used. 6. Design for Energy Efficiency: Energy requirements of chemical processes should be recognized for their environmental and economic impacts and should be minimized. If possible, synthetic methods should be conducted at ambient temperature and pressure. 7. Use of Renewable Feedstocks: A raw material or feedstock should be renewable rather than depleting whenever technically and economically practicable. 8. Reduce Derivatives: Unnecessary derivatization (use of blocking groups, protection/ deprotection, temporary modification of physical/chemical processes) should be minimized or avoided if possible, because such steps require additional reagents and can generate waste. 9. Catalysis: Catalytic reagents (as selective as possible) are superior to stoichiometric reagents. 16

19 10. Design for Degradation: Chemical products should be designed so that at the end of their function they break down into innocuous degradation products and do not persist in the environment. 11. Real-time analysis for Pollution Prevention: Analytical methodologies need to be further developed to allow for real-time, in-process monitoring and control prior to the formation of hazardous substances. 12. Inherently Safer Chemistry for Accident Prevention: Substances and the form of a substance used in a chemical process should be chosen to minimize the potential for chemical accidents, including releases, explosions, and fires. 17

20 What is Green Engineering? Green engineering involves development and commercialization of industrial processes and products which are economically feasible and simultaneously ensuring minimization of pollution generation at the source, and mitigating the risk to human health and environment. The focus of green engineering is to minimize the overall environmental impact throughout the entire life cycle of a product starting from the extraction/procurement of raw materials required for manufacturing to the disposal of the waste materials which cannot be reused or recycled. The concept of green engineering is not limited to specific field of engineering or an industry but rather it includes all engineering disciplines and is pertinent to every industry. According to P.T. Anastas and J.B. Zimmerman, Green engineering can be defined by a set of 12 principles: 1. Inherent rather than circumstantial: Designers need to strive to ensure that all materials and energy inputs and outputs are as inherently nonhazardous as possible 2. Prevention instead of treatment: It is better to prevent waste than to treat or clean up waste after it is formed 3. Design for separation: Separation and purification operations should be designed to minimize energy consumption and materials use 4. Maximize efficiency: Products, processes, and systems should be designed to maximize mass, energy, space and time efficiency 5. Output-pulled versus input-pushed: Products, processes and systems should be output-pulled rather than input-pushed through the use of energy and materials 6. Conserve Complexity: Embedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse, or beneficial disposition 7. Durability Rather Than Immortality: Targeted durability, not immortality, should be a design goal 8. Meet Need, Minimize Excess: Design for unnecessary capacity or capability (e.g., "one size fits all") solutions should be considered a design flaw 9. Minimize Material Diversity: Material diversity in multicomponent products should be minimized to promote disassembly and value retention 10. Integrate Material and Energy Flows: Design of products, processes, and systems must include integration and interconnectivity with available energy and materials flows 11. Design for Commercial "Afterlife": Products, processes, and systems should be designed for performance in a commercial "afterlife" 12. Renewable Rather Than Depleting: Material and energy inputs should be renewable rather than depleting 18

21 Global evolution of Green Chemistry and Engineering Practices 1960s and 1970s: The evolution of green chemistry and engineering practices can be traced back to the 1960s when environmental activist Rachel Carson published Silent Spring which brought attention of the public towards environmental impact caused by the use of pesticides. The 1960s saw an increased attention towards environment quality with Citizen s Advisory Committee on Environmental Quality and a cabinet level Environmental Quality council being established in United States in 1969 followed by the Environmental Protection Agency (EPA) in The 1960s and 1970s saw an increase in environmental statutes and regulations resulting in increased restrictions on chemical use, increased testing of chemicals for hazard determination. This resulted in increased awareness and knowledge of the types and degrees of hazards associated with various chemicals. 1980s: The growing awareness and knowledge pertaining to environmental impact resulted in an increase in public demand in 1980s for more information regarding the chemicals. For instance EPCRA (Emergency Planning and Community Right-to-Know Act) was passed which made public relevant data on chemicals being released to air, water and land by the industry. This led to an increase in pressure on the industry to not only reduce the release of toxic chemicals to the environment but also reduce the overall use of hazardous chemicals. The EPA recognized the importance of pollution prevention over end-to-end pipeline treatment control leading to establishment of Office of Pollution Prevention and Toxics in the late 1980s. In 1985, Responsible Care a global voluntary initiative by the Chemical industry was launched with focus on improving performance, communication and accountability. The initiative aims at continuous improvement in health, safety and environmental performance products and processes and helps in development and application of sustainable chemistry. The initiative is managed at the global level by International Council of Chemical Associations (ICCA) and runs in 52 countries accounting for 90% of global chemical production. 1990s: The 1990s saw an increased focus on Green Chemistry. Pollution Prevention Act was passed in 1990 by the US government which emphasized on pollution reduction by improved design involving cost-effective changes in products, processes, use of raw materials, and recycling instead of post-production treatment and disposal. To aid its implementation the EPA shifted from the typical monitoring and controlling approach to actually implementing a green chemistry program. In 1991, the Pollution Prevention and Toxics office of EPA launched a research grant program encouraging redesign of existing chemical products and processes to reduce impacts on human health and the environment. In association with the U.S. National Science Foundation (NSF) EPA provided funds for research in green chemistry in the early 1990s. The annual Presidential Green Chemistry Challenge Awards introduced 19

22 in 1996 brought the academic and industrial green chemistry success stories to the forefront. The Awards program and the technologies it showcases have now become key learnings both for the academia and for the industries. A key highlight for green chemistry in the 1990s was the laying down of the 12 principles of Green Chemistry by Paul Anastas and Jon Warner in These principles provide a framework to the companies for implementing the green chemistry and engineering practices. 2000s: Till the late 1990s a number of chemical companies had limited commitment to sustainability. Very few companies were willing to commit beyond green painting which implied commitment from them was limited to communication and image. However in 2000s, with increasing pressures on chemical industry due to requirement in reduction of greenhouse gases, environmental issues and health of public at large, green chemistry and engineering practices witnessed a growing importance. Advancements in biotechnology have created new processes for the manipulation of organisms (bacteria, yeasts, and algae) to produce industrially useful compounds with maximum efficiency and minimum waste. At the same time, the rising prices of petroleum which is essential both as process energy source and as a raw material for a number of chemical processes has developed interest and investment in finding alternative, renewable feedstocks. Over the years, product traceability has become a key feature in chemical industry where on case to case basis companies are establishing the material and energy consumption, carbon and water footprint and waste generation. In 2006 REACH Legislation was enacted by European Union (EU) and which was put into phased implementation since According to the legislation substances manufactured/imported over 1 ton per year in EU need to be registered with European Chemical Agency (ECHA) by EU manufacturers and importers. These substances would be evaluated by ECHA and their environmental and health impact would be assessed. Based on the impact a list of Substances of Very High Concern (SVHC) would be developed and would not be allowed in the EU unless granted an authorization. The ECHA would also determine substances whose use would be restricted or banned. The legislation has far reaching consequences impacting industries such as chemical industry, textiles, tyres, toys and electronics Onwards: The industry has witnessed an increase in collaborations amongst the various stakeholders of the value chain are for implementation green chemistry and engineering practices. Some of the examples are: 1. The Rhodia-GranBio partnership: Rhodia has partnered with GranBio, a Brazilian biotechnology company for production of bio n-butanol, made from sugar cane straw and bagasse. 2. ACS GCI Industrial Roundtables: American Chemical Society Green Chemistry Institute (ACS GCI) organizes various industrial roundtable conferences to encourage the industrial implementation of green chemistry and engineering practices. The institute 20

23 started pharmaceutical roundtable in 2005 (key members: Eli Lilly, GSK, Merck and Pfizer), formulator s roundtable in 2009 (key members: Amway, Novozymes, Ecolab, Florida Chemical and J&J consumer) and chemical manufacturer s roundtable in 2010 (key members: Arizona Chemical, Dupont, Pennakem, Sigma Aldrich) Axelera: Axelera is cluster which brings together leaders from industry, research and academia from the Rhone-Alpes region. The key focus areas are use of bio-resources, developing clean processes, material recyclability and conservation of natural resources. Started in 2005, the cluster has more than 250 members 6. Some of the key members are Rhodia, Michelin, Arkema, Total and Schneider electric. 4. LAZORR: LAZORR is a collaborative platform between six large Indian pharmaceutical companies, Lupin, Aurobindo, Zydus, Orchid, Ranbaxy and Dr. Reddy s (LAZORR). Established in 2010 the platform brings in together the best practices implemented by the companies resulting in cost reductions and implementation of green practices. Apart from the collaborations a number of publicly available tools like life cycle assessment, isustain, EcoScale and sustainability footprint tools have been developed which aid in implementation of green chemistry and engineering practices. chemicals in consumer goods, create new business opportunities in green chemistry and reduce the burden of consumers in deciding which product to buy or not. 1,200 chemicals have been identified as toxic by Department of Toxic Substances Control. Some of the chemicals are formaldehyde, aluminum, benzene, phthalates and parabens. 200 products will be identified having such chemicals out of which five priority products would be finalized and would be reformulated and replaced by safer alternatives 7. Going forward there will be three major themes driving green chemistry and engineering. They are: 1. Waste minimization in chemical production processes 2. Replacement of hazardous chemicals in finished products with less toxic alternatives 3. Shift towards renewable feedstocks Post 2010, the key landmark in Green Chemistry has been the implementation of California Safer Consumer Product Law. Effective from October , the law aims at reducing the toxic 21

24 The Global Green Chemistry Opportunity According to industry estimates, the global green chemistry industry which stood at USD 2.8 billion in 2011 is expected to grow at a CAGR of 48.5% and reach USD 98.5 billion by The estimated direct and indirect savings would be USD 65.5 billion by The key industries where green chemistry applications are expected in the next decade are pharmaceuticals, fine chemicals, plastics, textiles, paints and coatings, paper and pulp, agrochemicals, adhesives, nanotechnologies and fuel and renewable energy technologies. The key growth regions for green chemicals are Asia Pacific, Western Europe and North America (Refer figure 4 and figure 5). Figure 4: Global Green Chemistry Industry 8 Figure 5: Global Green Chemicals Market by Regions:

25 Metrics for Green Chemistry and Engineering Even though the above mentioned principles define green chemistry and engineering practices, key metrics are required which would help the companies to evaluate their current performance with respect to green practices. The metrics would help the companies to identify the necessary actions required for transition to green practices and the benefits obtained from implementation of green practices. Four key metrics can be identified from the principles of green chemistry and green engineering. The metrics are: Material efficiency, Energy efficiency, Reduced hazards and Holistic design (Refer figure 6). Material Efficiency In order to reduce the increasing dependence on petrochemical resources and to reduce the amount of wastes generated it is imperative for Chemical Industry to seek material efficiency in their processes. Some of the possible ways of achieving material efficiency are: Emphasis on recycling and subsequent utilization of the recycled products as inputs Minimizing material diversity so as to increase the chances of re-use at the end of life cycle Redesigning of chemical processes based on the output requirements Use of bio-based chemicals Avoiding chemical derivatives Atom economy (mass of input reactants incorporated into the desired product) and environmental e factor (amount of waste generated per unit of product) help in measuring the material efficiency of a process. Some of the companies who have successfully implemented green chemistry and engineering practices and achieved improvements in their material Figure 6: Green Chemistry and Engineering metrics 11 23

26 efficiency are Pfizer, Dr. Reddy s, Aurobindo, Solvay, Dupont and Mylan. Mylan Case Study: Improved yield through Green Process 12 Mylan replaced the conventional technology of manufacture of amines by reduction of nitro compounds in presence of Raney Nickel catalyst and high pressure hydrogen gas to a patented recycling solution. It utilized a proprietary reducing agent and catalyst and a patented recycling process to develop green amines. the new process operates at atmospheric pressure and nominal ph and temperature. The commercial application of the new process has resulted in achievement of 95% yield compared to 85% in the conventional process. The e-factor achieved has been as low as Also the sludge obtained from the process is sold to cement industries thus resulting in effective management of waste as well (Refer figure 7 and 8). The new process provides a number of advantages over the conventional process of reduction. The advantages are: 1. Cleaner product: New process produces white to off-white amines while the conventional process produced brown colored amines 2. Material handling efficiency: New process utilizes safe raw materials compared to the conventional process which uses hazardous materials like Raney Nickel. Also it does not use any acid or alkali which can be hazardous. Compared to the conventional process which uses two solvents, the new process uses water as a reaction medium eliminating the need of harmful solvents. While the conventional process generates harmful effluents containing spent solvents the mother liquor in new process can be recycled 800 times. 3. Energy efficiency: The conventional process operates at high pressure while 24

27 Figure 7: Conventional Technology for Reduction Figure 8: The Green Technology for Reduction 25

28 Energy Efficiency Chemical companies can achieve energy efficiencies in their process by modifying the existing processes or technologies. Some of the possible ways to improving the energy efficiency are: Use of energy efficient equipments Use of microreactors over the batch reactors Use of microwave technologies Carrying out reactions at room temperature and pressure Designing energy efficient strategies for separation and purification of materials Developing sustainable solutions like using waste heat as a means of process steam It is not necessary to always make huge investments to achieve energy efficiency. There have been instances where even good housekeeping activities have resulted in a substantial amount of energy and monetary savings. A number of companies like Dow Chemicals; Tata Chemicals; Neville Chemicals; Clorox; Asian Chemicals, Thailand have successfully implemented projects to achieve energy efficiency in their plant operations. GERIAP project. Several energy conservation options were generated out of which six options were implemented (Refer Table 2). The implementation of energy conservation options had significant benefits. The total investment required was ~USD 73,000 with annual savings of USD 20,000. The total payback period was 3.5 years. In terms of greenhouse gas emissions the annual reduction was of 288 tons of CO 2 was achieved. Asian Chemicals Company Ltd, Thailand, Case Study: Energy efficiency by new technologies and good housekeeping 13 Asian Chemicals Company Ltd. located in Bang Pakong, Thailand manufactures chemicals like copper sulfate, copper oxide, copper chloride and etching solutions. In order to improve its energy efficiency the company participated in 26

29 Focus area Clean production Financial benefits Environmental benefits technique Steam system New technology/ Investment: USD 55,000 Fuel Oil Saving: 38,000 l/yr boiler, Equipment Cost Savings: USD 7,600 GHG emission reduction: 114t Replacement of Payback period: 7.2 year CO 2 /yr inefficient and unsafe boiler with a new boiler Steam system New technology/ Investment: USD 17,000 Fuel Oil Saving: 16,500 l/yr Boiler, Installation Equipment Cost Savings: USD 3,317 GHG emission reduction: 50t of insulated Payback period: 5.1 year CO 2 /yr storage tank for Water savings: 2,700 m 3 /yr collecting steam condensate water for reuse as boiler pre-heated feed water Steam system Good Investment: USD 400 Fuel Oil Saving: 32,000 l/yr Distribution, Housekeeping Cost Savings: USD 6,500 GHG emission reduction: 97t Replacement of Payback period: 23 days CO 2 /yr damaged steam traps Steam system Good Investment: USD 30 Fuel Oil Saving: 1,300 l/yr Distribution, Housekeeping Cost Savings: USD 270 GHG emission reduction: 4t Steam leak survey Payback period: 44 days CO 2 /yr and repair of leaking joints and pipes Compressed air Good Investment: USD 150 Electricity savings: System, Replace or Housekeeping Cost Savings: USD ,000 kwh/yr repair pipe and Payback period: 25 days GHG emission reduction: 20t filter connections CO 2 /yr to avoid compressed air leakage Cooling Tower, Production Investment: USD 165 Electricity savings: Install temperature process/ Cost Savings: USD 280 4,000 kwh/yr Table 2: Energy Efficiency at Asian Chemicals 27

30 Reduced Hazards According to green chemistry and engineering, systems are to be designed such that the emphasis is on avoiding the hazards instead of controlling them. This involves changing of technology, processes, and raw materials to reduce the number of hazardous operations carried out in the plant and the amount of hazardous materials generated. Some of the possible strategies for reducing the hazards are: Building sustainable recycling solutions Zero liquid discharge techniques COD reduction techniques Solvent recovery techniques Developing solvent free processes A number of companies like ITC, Pfizer, Merck, Hyosung, Praj Industries and Nowra chemicals, have successfully reduced the amounts of hazardous wastes generated in their plants. Hyosung Ebara Case Study: Reduction of Nitrous Oxide Emissions 14 Nitrous Oxide is a powerful greenhouse gas. Thought the total industrial emissions are low, its impact is very high. The gas has more than 300 times the ability to trap heat in the atmosphere as compared to carbon dioxide. The manufacture of caprolactum, a major raw material for nylon fibers results in nitrous oxide emissions. Hyosung Ebara Engineering Co. Ltd. (HECC), a Korean Chemical company proposed nitrous oxide emissions abatement project to Capra, a South Korean caprolactum manufacturer and is partly owned by the Hyosung group. Pilot Studies: In 2009 HECC started with pilot tests on different nitrous oxide abatement systems to evaluate their performance. A larger pilot test was conducted in 2010 resulted in development of tertiary abatement systems for two caprolactum plants in Ulsan, which was financed by Hyosung. Process: The tertiary abatement systems work by heating the tail gas to the optimum reaction temperature, passing it through CRI Catalyst Company s (CRI) C-NAT catalyst in a lateral flow reactor and releasing the cooled products to atmosphere. The nitrous oxide generated breaks down into nitrogen and oxygen without leaving any undesirable by-products. The process uses a special ceramic material to absorb heat from the cooling process and transfer it to the incoming gas, which helps to minimize energy consumption. The lateral flow reactor is also compact compared with other similar reactors and does not create a large pressure drop resulting in improved energy efficiency. Another advantage is that the C-NAT catalyst does not require reducing agents such as methane which lowers down the operating costs. Commercialization: The process was commercialized in the two plants in Nitrous oxide destruction rates of about 91% for Plant 1 and 92.5% for Plant 2 were reported, higher than the 90% design specification. The emissions reduction were verified through the CDM, which helped Hyosung and Capro to sell certified emission reduction, or carbon credits to companies in Kyoto Protocol countries. Also the validation process was transparent, as the documents were publicly available from the 28

31 (United Nations Framework Convention on Climate Change) UNFCCC website. The annual reductions of carbon dioxide equivalent emissions across the two plants were 660,000 tonnes. In monetary aspects at certified emission reduction credit price of USD 10 per tonne of carbon dioxide equivalent, the company generated additional revenue of about USD 6.6 million a year. Holistic Design The true benefits of implementation of green chemistry and practices cannot be achieved in isolation. While material efficiency, energy efficiency, wastes and hazards reduction can be achieved separately or in combination, the chemical industry to truly implement green chemistry has to change its approach from gateto-gate (company s procurement process to manufacturing to the dispatch of finished product to customer) to cradle to cradle (the process from raw material extraction to manufacturing, consumption and finally recycling the used product). The cradle to cradle design (also called regenerative design) is a paradigm shift in industrial production. It involves design and manufacturing processes shifting from the traditional linear approach towards closed cycles. It involves choosing materials and processes such that the products become nutrients at the end of their life cycle. It is a philosophy which involves a biomimetic approach to design of the systems. The holistic design concept challenges the existing concept of wastes. Each and every object we deal with can be redesigned as nutrients for biological or technical cycles. This opens up a new dimension where products and processes do not need to be regulated by law anymore, in order to reduce environmental impacts. The model is implemented in a number of companies, mostly in European Union, China and United States. It is not easy for companies to develop products and process based on holistic design in a short span of time. However the key thing is to build a culture in the organizations to shift towards cradle to cradle design with emphasis in terms of resources and moral support for research and development activities to develop products on commercial scale based on holistic design. NatureWorks LLC Case Study: Cradle to Cradle approach in polymer manufacture 15 NatureWorks LLC is one of the world s largest manufacturers and suppliers of biopolymers for customers in plastics and fibers market. The company's products are used in the production of rigid and flexible packaging, food service ware, semi-durable products, fibers and nonwovens. The polymer called Ingeo uses renewable biobased material like corn or sugar cane from which lactic acids are produced via a patent-protected fermentation technology. The lactic acids are in turn used to manufacture polymers. Apart from the advantage of nonreliance on fossil fuels as a feedstock, another advantage for NatureWorks is that it can base its production on a variety of different plants. The environmental impact is a significant reduction in the carbon footprint of any plastic product made from Ingeo. For example, the manufacturing of 29

32 Ingeo emits 60 per cent less CO 2 than PET (Polyethylene Terethalate), and the production process consumes 50% less non-renewable energy as compared to PET. The company has set targets of 75% and 55% respectively. As a part of holistic design involving cradle to cradle approach, NatureWorks is also able to turn many products made of Ingeo back into lactic acid from which new polymers can be made, and the company is working on a take-back system for more durable plastic products. For instance at the UNFCCC's COP15 (15 th Conference of the Parties) in Copenhagen, NatureWorks worked with a Belgian carpet producer for carpeting the conference. All carpets were taken back and depolymerized back into lactic acid. In terms of monetary benefits, over the past few years NatureWorks has seen a growth in product demands of annual 25-30%. For its customers the benefits are in the form of price stability, as the polymers are not based on petroleum, and in the form of lower environmental impact and more positive consumer image due to environmental performance. 30

33 SECTION 4 Barriers in implementation of Green chemistry and engineering practices Financing barriers Economic feasibility barriers Technology barriers Regulatory barriers Awareness barriers 31

34 Barriers in implementation of Green Chemistry and Engineering Practices Green chemistry has been in practice in some way or the other in last seventy five years. Over the years because of regulatory pressures by the domestic governments and those of exporting countries, increasing pressure by nongovernment organizations, customers preference of green products and rising fear and instances of bad press have resulted in rise in implementation of green chemistry practices in the industry. Companies like Nike and Unilever have not only made their process green but have also ensured that their suppliers also implement green chemistry practices. However, the industry still faces some key barriers which impede the implementation of green chemistry practices in the industry on a large scale. Financing barriers Access to Capital: One of the key barriers in implementation of green chemistry is the access to capital. While green chemistry initiatives may get seed money / financing to demonstrate the proof of concept, the challenge lies ahead. The first challenge is to switch from the proof of concept (i.e. the laboratory scale) to the pilot scale; and the other is to shift from pilot scale to the commercial scale. Thus the industry faces two pitfalls in making transition from the laboratory scale to commercial level. The technologies and the chemistries involved in transition to green practices are often perceived to be risky as compared to traditional chemistry by the investors leading to their unwillingness to fund such projects. Due to the nature of the projects, many times, there is not enough information or data available to make comparisons, and there is not much past experience available for project financers to do due-diligence and risk assessment. Compared to the small companies big companies with deep pockets are able to afford the risks involved, have better credit worthiness and thus have easier access to capital. Given that more than 90% of companies globally fall under small to medium scale; it is the SME segment which actually requires the funding. Some of the possible ways to overcome the funding barriers (highlighted in figure 9) are: 1. The companies can benefit from Government of India s Credit Guarantee Fund Scheme for MSMEs (Micro and Small and Medium Enterprises). Under the scheme the MSMEs can get loan from the banks up to INR 100 lakhs without any collateral. The government provides the guarantee cover for the loan which ranges from 75% to 80% depending on the loan amount. 2. While it is hard to overcome the perceived risks involved with a new technology, the government can mandate the banks to provide lending to the chemical industry at lower interest rates for green projects. For instance, in the realty space if the developer can display the green certificate for his building, then his customers can get home loan from the bank at lower interest rates. 32

35 3. Chemical companies should also carry out life cycle analysis of the existing process/product with the newer one. The comparison and the potential benefits associated with the green processes/products can be quantified and can therefore help in reducing the risk perceived by the financial institutions and investors to some extent. Economic Feasibility barrier Tied up capital: Chemical enterprises are essentially capital intensive and have large capital investments in existing plant setup thus making it difficult to abandon the existing investments. The cost of shutting down the operations in an existing and comparatively inefficient plant can be very high and it can leave enterprises without any resources available for reinvesting in new technologies and processes. Building up new infrastructure is usually expensive and the high upfront costs pose a significant barrier in implementation of green chemical processes. Often the existing plants meet the environmental norms and generate emissions within the specified limits. Hence there is no incentive for switching to green practices at the expense of existing investments. Exhibit 1 16 explains why inspite of the advantages provided by micro-reactors the industry has not been able to implement them in practice. Figure 9: Financing barriers 4. If possible by involving the investors in the project right from the laboratory scale it can help them better understand the potential long term benefits associated with green chemistry and engineering practices and can help them make informed decisions while deciding whether to fund a project or not. Some of the possible strategies to overcome the reluctance of the companies to relinquish their existing setup are 33

36 Pigovian Tax: Government should impose strict regulations for companies to shift to green practices. The government should impose taxes on the companies following polluting chemistry. Also it should be ensured that these policies are actually practiced and do not remain merely in principle. With strict regulations in countries like USA, Europe and Japan the companies would not be able to export their products if their manufacturing processes do not follow the required green practices. Hence, chemical companies, especially the small sized companies should be educated that even though switching over to green practices may require an initial capital burden, but in the longer run green chemistry is essential to avoid the threat to long term survival. Scale up Issues: Any product or a process should meet two criteria economic performance and environmental performance. Human health and environmental benefits are not sufficient for a company to implement green chemistry and engineering practices. The product or process should result in potential cost savings for the companies. Though technologies are available, the companies are facing challenges in scaling up to the commercial level. Often the cost effectiveness is not there making it difficult to achieve breakeven. It becomes difficult to strike a balance between delivery timelines, cost and green philosophy. The companies which are succeeding are the ones which are bringing to market the high margin speciality chemicals. However the transition in case of commodity chemicals is difficult and they are unable to compete with the products made from the fossil fuels. Often the large companies can afford the risks involved and can manage with initial losses but the small sized industries find it difficult to transition even though the technology is available. Some of the possible ways for overcoming the scale up barrier (highlighted in figure 10) are: Vendor client collaboration: Collaboration with the vendor can help in overcoming the scale up issues. If the vendor owns the pilot plant the client would feel more comfortable, and by watching the performance of the pilot plant would add to confidence of the client in its potential success on the commercial level. The vendor must hand hold the client at the scale up time. Cost and benefits sharing with the vendor would enhance the confidence and trust amongst both the vendor and the client and can help in scaling up of the green chemistry practices. Incorporation of green chemistry and engineering principles right from the design stage An important dimension of economic feasibility is affordability. If affordability becomes the crux of the whole situation, it is possible to implement the green chemistry practices. For instance, DG sets are one the significant pollution contributors. Fuel cells are a greener alternative to DG sets. The technology is available and however due to high capital costs it is not 34

37 people who are developing the technologies of what it takes to succeed in the business. For example, even though new technologies like microreactors or continuous flow reactors are coming up the chemists are not trained to use them. Inspite of the technology availability most of them still rely on batch chemical operations and find it difficult to handle controlling heat and mass transfer inside the reactor. Figure 10: Economic Feasibility barriers affordable in India. On the other hand the fuels cells are extensively used in Japan. Thus we see that science is ready but the industry and the society is not. Even though the technology may be available it is not affordable. Hence it is critical to develop an ecosystem so that science can be converted to affordable technology; otherwise the science will remain where it is. Technology Barriers Transition towards sustainable chemistry: The chemistry we understand and study is inherently unsustainable. Most of the named reactions which are carried out in the industry were developed in 19 th and early 20 th century when the concepts of sustainability were not there and fossil fuels were present in abundance. However over the period of time there has not been any transition in the chemistry which is taught in the schools or colleges. There is a lack of understanding on the Availability of knowledge: Availability of the knowledge is another barrier which the industry faces. The industry is more comfortable with the conventional chemistry involving petrochemical sources. On the other hand, the molecules obtained from the bio-feedstock are highly functionalized. Working with the biological molecule requires working in an opposite direction. Currently we do not have the chemistry and the chemical technology to work with such molecules as a result there are only few raw materials that can be generated from bio-renewable sources. The possible strategies (highlighted in figure 11) to overcome the barriers are: Education and training o Alter the academic curriculum starting from the schools to undergraduate to postgraduate institutions to incorporate green chemistry and engineering practices o Develop green chemistry centers of excellence. For instance GSK supports center of excellence based at University of Nottingham, and is planning to form collaboration with Sao Paulo Research Foundation in 35

38 Brazil. Some of the universities and agencies actively working in the field of green chemistry are University of York, Warner Babcock Institute for Green Chemistry, University of Massachusetts, American Chemical Society and U.S. Environmental Protection Agency. o Provide adequate financial and technical aid for green chemistry o Organize training programs, workshops and symposia for industry and academia o Assess educational and training programs to gauge their effectiveness Emphasis of the academia should be on developing the applied knowledge instead of maintaining the focus on theoretical knowledge. This would help in successful transition of the theoretical knowledge to the actual industry implementation. Develop multidisciplinary teams to bring together the chemists, toxicologists, business and economic experts which help in developing technologies and processes that are non-toxic and sustaining. Investment in R&D activities to build knowledge and technology to develop sustainable raw materials. Public private partnership funding of consortia consisting of industry and academia like the Innovative Medicines Initiative in the European Union can be a possible solution for funding the research and development projects. Industrial round tables: Interaction within and across industry sectors can help at various levels of management can help the companies overcome the technology Figure 11: Technology barriers 36

39 availability barrier. Instead of competing with each other, by building up collaborative platform companies can learn from the best practices prevalent in other companies. Such platforms build trust amongst the companies resulting in sharing of knowledge and expertise which is important for dissemination of green chemistry and engineering practices resulting in development of greener processes and products cost efficiently. Exhibit 2 16,17 describes LAZORR, a collaborative platform amongst 6 leading Indian pharmaceutical companies. To overcome the barrier, universities and the publicly funded agencies should be encouraged to generate the IP by providing funds and should be allowed to own the IP. This would make them an ideal place to generate low cost IP. The IPs generated can be sold or co-owned by the companies leading to benefit sharing at a reasonable cost. Exhibit 3 16 describes the Bayhdole Act implemented in United States which helped in overcoming the intellectual property barrier. Regulatory Barrier Intellectual Property (IP): Another barrier faced in the availability of technology is the intellectual property barrier. Even though the industrial researches have resulted in development of new reactions or greener routes for a chemical, the knowledge is not available readily amongst the chemistry in the industry. The firms which develop it often protect it as an intellectual property to achieve competitive advantage resulting in low transmission of knowledge and technology within the industry. Risk Control vs. Risk Prevention: Most of the environmental, health and safety regulations focus on reducing the risk by reductions in exposure. Thus many enterprises have to spend on regulatory mandated and expensive end-ofpipe technologies instead of investing in R&D in developing safer products and safer processes. The focus on risk control rather than risk prevention is an important barrier resulting in little incentive for companies to invest in green chemistry practices. Sector Specific Regulations: There are barriers that emerge due to sector specific regulations. For example in USA, if a pharmaceutical company wants to change 37

40 certain portion of its manufacturing process, it must undergo a time-consuming and expensive recertification process with the US FDA (Food and Drug administration). If a company develops a safer pesticide produced in less hazardous and environment friendly manner, it has to undergo a process of certification with EPA under TSCA. While the intent of the regulations is to provide protection, however they themselves become an impediment in implementation of green chemistry and engineering practices. The possible strategies (highlighted in figure 12) to overcome the barriers are Regulations aimed at risk prevention should be developed as compared to risk control. The government should also revisit their existing policies, make them favourable for green practices implementation so as to promote alternate green chemical products and processes (Refer figure 13). o Through the PAT (Perform, Achieve and Trade) scheme under the purview of Ministry of Power, companies in Figure 12: Regulatory barriers energy intensive industries can gain from reduction in overall energy expenses and if they are surplus can trade Energy Saving Certificates (ESCerts). Thus, through the PAT scheme the government can reward the achievers while impose penalties to the under achievers. For companies into self-generation, Ministry of New and Renewable Energy has mandated companies to meet certain portion of energy requirement through renewable sources through the e Figure 13: Government policies Key to successful implementation of green practices 16 38

41 Renewable Purchase Obligation (RPO) Mechanism. o Considering green chemistry and engineering implementation as part of corporate social responsibility can encourage companies for developing and implementing green practices. Awareness Barriers In the companies people working in sales, marketing and operations have little or no understanding of green chemistry practices and potential benefits associated with it. Many have no idea that science of green chemistry is available and can have important benefits. There is a notion that all environment friendly changes are expensive and not worthwhile to implement. Another issue faced by the companies is the focus of individual divisions on the impact of green chemistry and engineering practices on their division s bottom line even if the end results benefits the overall organization. strategies (highlighted in figure 14): Ensuring commitment towards green chemistry right at the highest management level. The top down approach, along with provision of adequate resources and moral support is important to ensure that green chemistry and engineering gets top priority. Support from key decision makers for implementation of green chemistry and engineering practices Regular training programs along with understanding of life cycle benefits by implementation of green chemistry and engineering practices can help the companies to increase the significance of green chemistry and engineering practices amongst the non R&D people of the organization. As an organization, companies should These barriers can be overcome by following have a common environmental goal. Figure 14: Awareness barriers 39

42 Changing the traditional accounting process of CAPEX (capital expenditure) and OPEX (operating expense) and activity based accounting. A more holistic view of the costs involved by analysing the life cycle costs should be carried out which is however not incorporated in most of the economic and financial analysis. 40

43 SECTION 5 Tools for implementing Green Chemistry Life Cycle Analysis isustain TM EcoScale 41

44 Tools for implementing Green Chemistry Various tools have been developed by the industry and academia which aid in implementation of green chemistry and engineering practices. These tools help the companies to compare various processes/products and help companies in quantifying the benefits obtained from green chemistry and engineering practices. Some of the important tools are life cycle analysis, isustain TM green chemistry index and EcoScale. Life Cycle Analysis Life cycle analysis (LCA) is a tool to evaluate the environmental impacts associated with all stages of a product s life from cradle-to-grave (i.e. starting from raw material extraction to disposal or recycling), taking into consideration that all the stages are interdependent and one operation leads to another. Thus it helps in estimating the cumulative environmental impact resulting from all stages of the product life cycle. There are different versions of life-cycle analysis like cradle-to-gate, gate-to-gate, cradle-to-grave and cradle-to-cradle. Life cycle analysis consists of four components 1. Goal Definition and Scope: In the first step the company has to define and describe the product, process or activity which is to be evaluated. It involves establishment of system boundaries and impact categories (environmental impacts) which are to be evaluated. It also involves clearly defining the assumptions and limitations associated with the assessment process. 2. Life Cycle Inventory: It involves identifying and quantifying energy, water and materials usage and environmental releases (e.g. air emissions, solid waste disposals, waste water discharges) for each life cycle stage. 3. Impact assessment: It involves applying science based models to assess the potential impact by the environmental releases on human life and the ecosystem. 4. Interpretation: The results of inventory analysis and impact assessment are evaluated to select the desired product, process or technology with clear understanding of the sensitivity of the results to the assumptions which have been made. Green Chemistry and engineering practices aim at achieving environmental improvements at every stage of the life cycle of the product or a process, however the principles are qualitative in nature. Hence it becomes difficult to prioritize when companies are trying to implement one or more of the principles of green chemistry and engineering to a particular product or a process. Life cycle analysis provides the quantitative analysis and helps the company to understand the key focus areas. Life cycle analysis can help a company in understanding a product s carbon and water footprint and the amount of wastes it generates. It helps a company not only in comparing two products but also helps a company in realizing unintended consequences associated with a particular technology or a process. The life cycle 42

45 analysis therefore helps a company understand the potential dangers and opportunities and supports in better informed decision making. By comprehensive understanding of the environmental impacts it also helps the companies to avoid shifting environmental problems from one form to another. For instance, if there are two options it may be possible that option 1 may be generating more solid wastes compared to option 2. Thus option 2 would be preferred in a single-view approach. However by LCA it can be possible that overall emissions and waste generated by option 2 are much more than option 1. Under such instances, therefore option 1 is the better solution. Exhibit 4 18 describes the sustainability footprint tool implemented by Dow Chemicals. Companies can develop their own sustainability footprint tools which can help them in life cycle analysis, identify areas of improvements and evaluate impacts of green practices implementation. Apart from Dow Chemicals the major companies performing LCA are BASF, DuPont, Eastman Chemicals, GE, P&G and Unilevers. Eastman Chemical Company Case Study: Environmental impact assessment through Life Cycle Analysis 19 Eastman Chemical Company performed life cycle analysis to assess the environmental impact of its Tritan copolyester which is used to manufacture sports bottles. A Tritan bottle was compared with 18/8 stainless steel and aluminum in three key areas of energy use, greenhouse gas emissions (CO 2 equivalent) and Smog formation potential (NO x equivalent). The cradle to grave analysis for 500 ml bottles (without caps) was undertaken. For all the three options material production required the greatest amount of energy. Amongst the three Tritan copolyester required the least as the steel and aluminum bottles had decorative exterior coatings while the aluminum bottles had interior coatings as well. Fuel related emissions were responsible for the largest portion of Greenhouse gas emissions and smog potential but were found to be least (40-50%) of that in stainless steel and aluminum bottles. Thus Life cycle analysis clearly indicates sustainable advantages of the Tritan copolyester compared to stainless steel or aluminum (Refer table 3 and figure 15). 43

46 Parameter Tritan copolyester Stainless steel Aluminum Energy use (million Btu/1,000 bottles) GHG emissions 1,400 2,400 2,900 (lb CO 2 basis/1000 bottles) Smog formation (lb NO x basis/1000 bottles) Table 3: Lifecycle analysis of Eastman Tritan copolyester, Stainless Steel and Aluminum Figure 15: Comparison of Eastman Tritan copolyester, Stainless Steel and Aluminum 44

47 isustain TM The isustain TM Green Chemistry Index is a tool consisting of sustainability metrics based twelve principles of green chemistry and some of the factors taken into consideration are waste generation, energy usage, atom economy, health and environmental impact of raw materials and products and safety of processing steps. The tool provides a methodology to generate sustainability based score for chemical products and processes. The quantitative assessment helps the chemical manufacturers and the consumers to track their progress in developing greener products over a period of time and assess the sustainability of their products. The isustain TM tool was developed with two objectives 1. To provide a measure of sustainability of products/processes so as to develop an initial sustainability baseline and provide guidance for process improvements 2. To help scientific community get familiarized with twelve principles of green chemistry and aid the scientists getting an understanding of the factors under their control that can impact the overall sustainability of their process To use the isustain TM tool the user has to generate a scenario. The scenario contains the information about the materials going into a process, the products and waste streams coming out of the process and the conditions or the parameters used in various process steps; providing a gate to gate assessment. The tool helps the user to perform what-if analysis by allowing the user to generate multiple scenarios for same product/process, thereby helping the user to evaluate the impact of various scenarios on the overall sustainability score. The tool is different from life cycle analysis. The tool provides evaluation of a product/process using readily available information, hence taking lesser time than a full life cycle analysis. The isustain TM Green Chemistry Index has been developed through an alliance between Cytec Industries Inc., a speciality chemicals and materials company; Sopheon, a software and service provider for product life cycle management and Beyond Benign, a non-profit organization in the field of green chemistry education and training. The tool is available for the academic community while the industry users have to pay a small subscription fee. Since March 2010 when the tool was made available to the public to the end of 2010 over 750 users including industry, government and academia have used the tool developing over 1,000 scenarios using 440 substances from material database of 5,500 substances 20. EcoScale EcoScale is a semi-quantitative tool which is used to evaluate the effectiveness of an organic reaction based on economic and ecological parameters. It takes into account cost, yield, safety, technical-setup and ease of workup/purification aspects while evaluating a chemical reaction. The evaluation starts by giving a value of 100 to an ideal reaction and then subtracting penalty points to the parameters for non-ideal conditions. According to research paper on the EcoScale, the ideal 45

48 reaction can be defined as Compound A (substrate) undergoes a reaction with (or in presence of) inexpensive compound B to give desired compound C in 100% yield at room temperature with minimal risk for the operator and minimal impact for the environment 21. The analysis can be modified by chemists by assigning different relative penalty points depending on the importance of different parameters. The tool provides a quick evaluation of the greenness of the reactions, help comparing different synthesis routes of the same product and helps in identifying the areas of improvement. 46

49 SECTION 6 Strategies for implementing green chemistry and engineering Immediate term Short term Medium term Long term 47

50 Strategies for implementing Green Chemistry and Engineering Based on the implementation time, resources involved and associated implementation risks green chemistry strategies can be categorized into four types: Immediate term implementation strategies, short term implementation strategies, medium term implementation strategies and long term implementation strategies (Refer table 4). Immediate Term Implementation Strategies On an immediate basis the industry should look for possible ways to optimize their current business practices as shifting to new routes of synthesis by using greener raw materials or by changing the processes not only investment in terms of time and money, but also requires efforts in developing an understanding of the advantages of new means and all possible risks and hazards they involve. Some of the possible implementation strategies which can be undertaken on an immediate basis are: Sustainable recycling solutions comprising of various used chemicals. The final effluent stream obtained from the chemical process is a combination of effluent streams from various steps consisting of a number of chemicals. Such heavy effluent load is nonbiodegradable and consists of organic impurities, acids, alkalis, toxic metals and carcinogenic materials. Because of the complexities involved in treating the effluents generated from the industries many times the treatment is bypassed and the effluents are directly discharged in water bodies. With increasing business activities the quantity of wastes generated also increases, making it difficult for the effluent treatment plants to treat the effluent load. Thus the focus of industries should be to develop recycling solutions which can help the companies to shift from dirty and dangerous chemistry to greener practices. Chemical process occurs in a series of steps, Exhibit 5 describes the advantages of and each process generates an effluent stream Strategy Implementation time Resources required Associated risks Immediate 1 to 6 months Very low Very low Short term 6 months to 2 years Low to medium Low to medium Medium term 2 years to 4 years High High Long term 4 years to 10 years Very high Very high Table 4: Strategies for Green Chemistry Implementation 22 48

51 sustainable recycling solutions. Some of the companies who have successfully implemented sustainable recycling solutions are Dow Chemicals, Solvay, BASF, Kanoria Chemicals, Dr. Reddy s and SMS Pharma. Case studies 1 and 2 in the annexure demonstrate the benefits obtained by companies by implementing sustainable recycling solutions. Zero Liquid Discharge (ZLD) The conventional wastewater treatment processes do not remove salinity in the treated effluent. Discharging the saline waste water pollutes the ground and surface waters, also impacting the nutrient value of the soil. In order to overcome the scarcity of water, impact of saline water discharge and regulatory pressures associated, zero liquid discharge solutions have been developed which mean zero discharge of wastewater from industries. It involves advanced wastewater treatment technologies to recycle recover and re-use the treated wastewater, ensuring bare minimum discharge of wastewater to the environment. Exhibit 6 describes the key advantages and industrial applications of Zero Liquid Discharge. Case study 3 in the annexure explain detailed benefits of employing ZLD technology in a textile dyeing common effluent treatment plant and pulp and paper company respectively. The Business Case for ZLD: The yarn production in India stands at 6.8 million tons. As per industry estimates, almost 30% of the yarn produced is directly exported. The rest 4.76 million tons is processed into fabric. Taking the economic parameters from the Arulpuram case study, following are the assumptions made: 1. Water used for dyeing: 60 liters per kg of fabric 2. Savings of recovered water: Rs 70 per kl 3. Cost of zero liquid discharge: Rs 3 per kg of dyed fabric Although the water recovery in the case study has been as high as 98%, however even by considering water recovery of as low as 90% it can be found that savings of almost 78 paisa per kg of dyed fabric can be obtained. The overall benefits for the industry can be as high as Rs 370 crore. COD reduction Industrial wastewater containing organic and inorganic impurities are toxic and can t undergo direct biological treatment. The industrial wastewater resulting from the spills, leaks, product washings and effluents discharged from the chemical plants differ in characteristics amongst themselves and from the domestic 49

52 wastewater. Some of the key waste generating sectors are pharma, agro and pigment industries. In order to meet the specifications for discharge or for recycling the industrial effluents have to be treated. Exhibit 7 describes the key industrial applications of COD reduction techniques. Various methods have been developed to reduce the COD of the industrial waste water. COD can be reduced by using H 2 O 2, subcritical water oxidation, thermal-liquid phase oxidation, isolated bacteria and using adsorbents like activated carbon, fly ash and neem leaves. 50

53 Short Term Implementation Strategies Solvents along with water typically constitute almost 80% of the process mass and contribute 15-25% of the manufacturing costs. In an API unit the number of solvents ranges from with the number of used solvent stream being more than 100 in number. Compared to other countries the spent solvents are usually discarded or sold-off as a waste and there is almost negligible recycling of the used solvents 23 (Refer table 5). reaction media and for products extraction in the pharmaceutical, specialty chemicals and fragrance industries. Except few cases, the solvents used do not participate in the reaction. At the end of the process, the solvents are usually contaminated and cannot be reused. Hence the practice is to dispose them and use fresh solvents. This makes solvent recovery an important means to implement green and sustainable chemistry and engineering. Exhibit 8 describes the harmful impact of the traditional solvents used. On a short term basis the companies should look for how they can change their chemistry so that they can maximize the efficiency of their consumption of solvents, reagents and surfactants. This helps companies to reduce the amount of wastes generated, improve their material efficiency and reduce the costs involved. Some of the implementation strategies are: Solvent recovery practice The chemical industry, specifically the pharmaceutical industry heavily uses large quantities of organic solvents in a great number of manufacturing steps which include chemical synthesis, fermentation, extraction, formulation and finishing of products. They are used as Some of the companies who have implemented solvent recovery practices are Pfizer, Bristol Myers Squibb, Merck, and GSK. Case study 4 in Annexure explains the benefits of solvent recovery process employed by Bristol Myers Squibb in recovering THF solvent. Solvent disposal strategy Developed economies India Sell-off used solvent Low High Incineration Considerable Low Reprocessing/Recycling Moderate to high Low to moderate Losses Low to moderate High Table 5: Comparison of solvent disposal strategies 23 51

54 The Business Case for Solvent Recovery: The Indian Pharma industry currently stands at USD 32 billion. Considering the API industry as 30% of the total industry and solvent cost as 20% of the total API synthesis cost, the total solvent consumed is USD 1.92 billion. Assuming 50% solvent recovery (similar to Bristol Myers case study) savings by solvent recovery stand approximately around USD 0.96 billion. Assuming disposal cost as 10% of the total solvent cost, the total savings are approximately around USD 1.05 billion. Taking CAGR of 14% for the pharmaceutical industry and considering the solvent recovery to continue at 50%; by FY17 the industry can save almost USD 1.78 billion. Alternate Solvents Over the last few years the solvent market has seen an increase in usage in industries like aerosols, pharmaceuticals, printer inks, cleaners and paints and coatings. Traditionally the solvents used are derived from crude oil and result in high levels of toxic emissions in the atmosphere. The increasing usage of the solvents along with strict environmental regulations to lower the VOC (Volatile Organic Compounds) has resulted in growth of biosolvents (greener alternatives). According to a research the green solvent market is expected to reach USD 6.5 billion by 2018 at a CAGR of almost 8.5% (Refer figure 16) 24. The green solvent market is segmented based on applications such as adhesives, cosmetics, pharmaceuticals, paints and coatings. Depending on product type, green solvents are categorized as soy methyl esters, lactate esters, specific fatty acid esters, D-Limonene, and polyhydroxyalkanoates. The soy methyl esters Figure 16: Global Green Solvent Industry 24 derived from soyabean oil, a biodegradable alternative can replace almost 500 pounds of traditional chlorinated and petroleum solvents. Ethyl lactate, another green solvent has replaced solvents like NMP, toluene, acetone and xylene. Exhibit 9 describes the key advantages of green solvents. Some of the companies who have successfully switched to green solvents are Pennakem, Zeon Corporation, Dow Chemicals, Lyondellbasell Industries, Bioamber, Cargill and Ashland. Case study 5 in the Annexure describes the benefits obtained by Pennakem LLC by switching to green solvent 2-MeTHF over the Chemical THF. 52

55 Biocatalysts Biocatalysis is the use of isolated enzymes or whole cells for synthetic transformation. Enzymes are catalytic proteins that catalyze reactions in the living organisms. Enzymes are highly efficient catalysts resulting in rate enhancement 25 of reaction to about 10 6 to Enzymes have a very good selectivity i.e. ability to work with a single compound resulting in high yield of a specific product. Compared to chemical catalysts biocatalysts require milder reaction conditions (ph range of 5-8 and temperature range of o C) 26. Biocatalysts are more efficient (lower concentration of enzymes are needed), can be easily modified to increase their selectivity, stability and activity. Traditionally biocatalysts have been used in production of alcohol and cheese, however recently they are being increasingly used in the pharmaceutical, agricultural and food industries. The use of biocatalysts can therefore help the chemical companies to improve their yield and reduce the wastes generated. Exhibit 10 highlights the advantages obtained from use of biocatalysts. Some of the companies which have used the biocatalysis route are Buckman International, Pfizer, BASF, Codexis, Elevance, isoy Technologies and Lilly Research Laboratories. Another key application of enzymes has been in carrying out enzymatic bio-transformation. Large percentage of Agrochemicals and Pharmaceutical products, which were earlier being used in Racemic form are increasingly being replaced by their more active and safer single isomers. Currently most of these products are produced through synthesis route and in racemic form and then optically active isomers are separated through chemical resolution process. After this, desirable isomer is taken forward as product but undesirable isomer is a waste product as many of undesirable isomers are not able to get racemized back on account of their thermal stability characteristics. This way, huge load comes to the environment and significant extra costs are incurred additionally for resolution, racemization of undesirable isomer both in capital expenditure for creating extra hardware and operating expenses due to double raw material consumption, extra energy, manpower and for waste disposal. It makes the whole operation extra Dirty, Dangerous and Demanding. Greener technology is being developed for targeted production of desirable isomer by using enzymatic biotransformation. This is more useful when the final product has multiple chiral centres and end product is of very selective set of chiral centres. Huge reduction on environment load, raw material consumptions, energy consumptions and lesser hardware requirement makes the process much cleaner, leaner and hence greener. Companies like Provivi, Codexis, 53

56 Amano are doing pioneering work in this direction Alternate Additives Surfactants, chelates and Reagents Traditional surfactants used in soaps and detergents, personal care products; lubricants, textile processing, and wastewater treatment are derived from petroleum feedstock. The commonly used chelates like EDTA (ethylenediamine tetraacetic acid) and NTA (nitrilotriacetic acid) are derived from aminocarboxylic acids; while STPP (sodium tripolyphosphate) is derived from phosphates and phosphonates and are known to have serious detrimental impact on the environment and human health. Similarly the traditional stoichiometric reagents are also a source of toxic and hazardous wastes (Refer table 6). derived alternatives. For instance the green surfactant market in the Asia-Pacific Region which stood at USD 590 million in 2011 is expected to grow to USD 1,075 million by 2018 at CAGR of 8.9% 27. Personal care companies like Johnson & Johnson and P&G today are rapidly switching to greener alternatives. Other companies which have successfully demonstrated the use of green additives are Lubrizol, Akzonobel, Novartis, Arkema and Colonial Chemicals. Case study 6 describes the successful implementation of greener alternatives at Dr. Reddy s Laboratories. The harmful impact of the traditional surfactants, chelates and reagents is shifting the focus of towards designing greener, biological substrates Additive Potential Impact Surfactants Incomplete biodegradation in soil/water, formation of harmful compounds Increased diffusion of environmental contaminants Chelates Eutrophication Discharge of heavy metal ions Mercury, nickel, cadmium, lead Reagents Poor atom economy (50%) Toxic and hazardous generation Table 6: Potential impact of traditional surfactants, chelates and reagents 54

57 Medium Term Implementation Strategies In the medium term companies should look for bringing a change in engineering aspects. New aspects of chemistry and chemical engineering like micro-reactor technologies, micro-wave engineering (based on flow chemistry) are gaining prominence. While shifting to solvent recovery processes and green solvents can help companies in reducing the costs and wastes generated, companies should eventually shift towards developing solvent free processes. Some of the medium term implementation strategies are Microreactor Technology Microreactors are miniature reactors in which chemical reactions take place. A microreactor consists of thousands of continuous smalldiameter tubes with overall volume of a few liters, compared to conventional vessel which can be as large as 10,000 liters. Usually the microreactors have a channel diameter of microns and channel lengths of 1-10mm 2. Exhibit 11 describes the advantages of microreactor technology. Pharmaceuticals, textiles, energy, automotive, aerospace, electronics, process-technology and material industry are some of the sectors where microreactors are used in manufacturing processes. Case study 7 in the annexure illustrates the potential benefits of microreactors over the conventional batch reactor technology. The Business Case for Microreactor Technology: Assuming the blending level for biodiesel to be 5%, the biodiesel consumption in India stands at 3 million tons. Assuming that 10% of the production would be switched from conventional batch process to the continuous process by microreactor technology, 0.3 million tons biodiesel production would be through microreactor technology. Considering the performance parameters similar to CSIR case study the reductions in manufacturing costs can be approximately Rs 5.5 per kg of biodiesel produced. This can result in total savings of Rs 165 crore. Assuming CAGR of 7% for biodiesel, same as that of diesel, and taking 10% production by microreactor technology the potential savings achieved can be almost Rs 215 crore by FY17. Microwave Chemistry and Engineering Microwave chemistry involves use of microwave radiations to carry out chemical reactions. Microwaves act as high frequency electric fields and heat any material containing mobile electric charges such as polar molecules in a solvent or conducting ions in a solid. This involves agitation of polar molecules or ions that oscillate under 55

58 the effect of an oscillating electric or magnetic field. Under the presence of an oscillating field, the particles try to orient themselves or be in phase with the field. But due to inter-particle interaction and electrical resistance the motion of these particles gets restricted resulting in random motion generating heat. Different materials have different response to microwaves, some are transparent to them (e.g. sulphur), some reflect them (e.g. copper) and some absorb them (e.g. water). Microwave chemistry is used in organic synthesis at elevated pressures or in dry media, synthesis of organometallic and coordination compounds, synthesis of ceramic products and have applications in polymer chemistry. Exhibit 12 describes the advantages from implementation of microwave chemistry and engineering practices. Organic solvent free process While chemical companies can shift to green solvents to implement green chemistry the greenest route is to eliminate the commonly used organic solvents which are toxic and generate hazardous wastes. A number of industrial reactions are carried out in gas phase or without adding any organic solvent. Solidstate synthetic approaches for instance do not involve solvents. In many of the solvent free reactions one of the reagents is a liquid and often acts as a solvent resulting in homogeneous reaction solution. In some solvent free reactions there can be a liquid (like water) formed during the reaction and acts as a solvent by assisting the reaction at the interface between the reagents. Use of ionic liquids can also help in eliminating the organic solvents. However currently the ionic liquids have limited industrial applicability. BASF is one of the major contributors to success story in Ionic Liquids. Exhibit 13 describes the advantages of solvent free process over traditional chemistries. Microwave chemistry finds applications in pharmaceutical industry, food processing, polymer synthesis, chemical synthesis and extraction, nanoparticle synthesis and biochemical and drying activities. Solvent free process finds wide application in paints and polycarbonate production. Some of the companies which have switched to solvent free processes are Eastman Chemicals, GVD 56

59 Corporation, Nextec Applications and Sulzer Chemtech. Supercritical fluids Another green chemistry technique which is increasingly being used is the use of supercritical fluids. Supercritical fluid is a substance at a temperature and pressure above its critical point such that no distinct liquid and gas phase exist. It can effuse through solids like a gas and dissolve materials like a liquid. An advantage with supercritical fluids is that close to the critical point, small changes in pressure and temperature can result in large changes in density as a result of which many properties of supercritical fluids can be altered as per requirements (e.g. dissolving power is pressure dependent). Exhibit 14 describes the advantages of supercritical CO 2, a commonly used supercritical fluid. Some of the industry applications are coffee decaffeination, hops extraction, essential oil pro production, waste extraction/recycling, analytical instrumentations, homogeneous and heterogeneous catalytic reactions and Biocatalysis.. 57

60 Long Term Implementation Strategies In a long term Chemical companies should look for developing new green routes of chemical synthesis. This involves shifting dependence form fossil fuels to renewable resources, and biomass as feedstock to develop biochemicals. Companies should also look for possible opportunities of developing symbiotic relationships with other industrial partners and stakeholders, thereby controlling their environmental footprint and raw material and waste disposal costs incurred. Biomimicry is another means by which companies can develop green products replicating the properties of nature. Bio-based fine chemicals are projected to increase from 20% market penetration in 2010 to nearly 35% by Bio-based speciality chemicals are projected to rise from 20% to 30% by 2025, polymers from 5% to 15% by 2025 while commodity chemicals are projected to move from 2% to 6% of markets by 2025 (Refer figure 18) 28. Bio-based Chemicals The bio-based chemical market estimated at USD 78 billion in 2012 is expected to grow to USD 198 billion by 2017, at a CAGR of 20.5% (Refer figure 17) 28. Figure 17: Global bio-based chemical market Figure 18: Global penetration of bio-based chemicals Among the renewable chemicals ethanol is a well-established commercial product with strong presence in USA and Brazil with growth opportunities in Europe and Asia (especially India and China). The biopolymer market is expected to have a CAGR of 22.7% and the sales are expected to rise from USD 3 billion in 2009 to USD 8 billion in Starch plastics have the highest share of 38% amongst the biopolymers while PHA (Polyhydroxyalkanoates) is expected to have the highest CAGR of over 40%. With developments in bio-transformation technologies, bio-catalysis, genomics and metabolic engineering it is anticipated that biobased chemicals will form almost 50% of the chemicals market by (Refer Table 7 for 58

61 key growth drivers, key challenges and possible solutions to overcome them for bio-based chemicals). The Business Case for Bio-ethanol in India: Petrol demand in India is estimated to be 28,000 million liters. Assuming ethanol blending to Key Growth Drivers Key Challenges Possible Solutions Rising oil prices and associated volatilities Irregularities in crop yield, quality and supply Strategic alliances amongst stakeholders Focus on environment Unproven and complex Feedstock guarantee footprint reduction technologies Technology Growing customer Scale up issues Funding availability demand for green Monitoring of product Access to distribution products quality and process channels and markets Advances in efficiency Government support biotechnology and Cost efficiency R&D investment biomass conversion Funding issues technologies Food vs. fuel conflict Avoid dependence on politically unstable nations for feedstock Table 7: Key growth drivers, challenges and possible solutions for Bio-based chemicals 28 A number of companies are developing green processes to manufacture bio-based chemicals. France based Roquette has the largest biorefinery in the world, Rennovia is producing biobased intermediates for polyamide 6,6 and polyols, Vencorex in France has world s first biosourced isocyanates for polyurethane, Lanxess Elastomers sells world s first bio-based polyamides. The academia has also been quite active in developing bio-based chemicals. Osaka University has developed routes to produce monomers from the plant oil. University of Bologna has developed phenols from natural resources which could replace bisphenol A in epoxy coatings. Institute of Chemical and Engineering Sciences has developed routes to manufacture green polyamides with adipic acid from biomass. Case study 8 in the Annexure illustrates the benefits of bio-chemicals. remain at 5% the demand of ethanol is 1,400 million liters. The manufacturing cost of petrol for oil manufacturers is Rs 45 per liter. The production cost for bio-ethanol manufacturers is Rs 37/liter. The oil manufacturing companies are planning to buy bio-ethanol for Rs 40/liter. This leads to potential saving of Rs 0.25/liter for oil manufacturing companies leading to total savings of Rs 700 crore. The profits for the bioethanol manufacturers is Rs 420 cr. Taking 11% CAGR in petrol demand, oil manufacturing companies can save up to Rs 1050 crore in FY17 while ethanol manufactures can make profits of 640 crore. Biomimicry Biomimicry involves developing sustainable solutions by studying nature s best ideas and then imitating them to develop designs and process to resolve the human problems. It 59

62 involves the creation of new, life-friendly technologies based on the learnings obtained from nature. The nature s chemistry follows a particular set of principles: it is essentially waterbased; uses self-assembly at ambient conditions, subset of elements in the periodic table, renewable feedstock, and freely available natural energy sources. Thus, we can see that nature s chemistry creates conditions conducive to life. A lot of research has been going on in the field of biomimicry. Today the scientists are able to develop self-healing plastics based on the body s ability to heal itself of cuts and wounds. The applications involve making lighter, fuel efficient and safer cars, planes and spacecrafts. Another example is of artificial photosynthesis where in sunlight can be used to split water into hydrogen and oxygen for use as clean fuels for vehicles. Successful implementation can not only reduce the CO 2 in the atmosphere but also provide an efficient, self-charging and less expensive way to create and store energy for home and industrial systems. Exhibit describes the advantages and possible opportunities associated with Biomimicry. Some of the companies who are actively working in the field of Biomimicry are Proctor and Gamble, InterfaceFLOR, PAX Scientific and Qualcomm. artificially setup in which various stakeholders (Industries, Government bodies, educational institutes, NGOs and society) come together and develop a symbiotic system where the entities through the dependence on outputs and byproducts generated by other members of the ecosystem achieve material and energy efficiency and reduction in wastes generated. Apart from depending on other partners for raw materials, companies also have the opportunity to look for possible ways of converting the wastes generated from their processes into useful products which can be used for their own operations. By developing a complete chain of green chemical processes in different sectors, Industrial ecology helps in establishing a viable Industrial Ecology Industrial ecology is a multi-disciplinary approach that combines different aspects of engineering, economics, sociology, toxicology and natural sciences. It is an ecosystem 60

63 and sustainable looping system. Exhibit 16 describes the various advantages chemical companies can achieve from Industrial ecology Case study 9 in the Annexure explains the Kalundborg Industrial Park and the benefits the participating companies got by industrial symbiosis. 61

64 62

65 SECTION 7 The Way Ahead 63

66 The Way Ahead Green Chemistry and engineering helps the companies to design new products and processes with sustainability as the core principle. This helps the companies not only in improving their top and bottom line but also helps them to differentiate themselves and gain competitive advantage. However, the industry cannot implement the green chemistry and engineering practices in isolation. It is imperative to build a collaborative ecosystem in which the academia, industry, government and regulatory bodies come together and create opportunities for the industry, academia and the Entrepreneurs to test, scale-up and commercialize their ideas in the domain of green chemistry practices. Ideas or concepts with potential to solve challenges faced by the industry in the domain of green chemistry should be nurtured and adequate support should be provided for scale-up and commercialization. This would encourage creation of inventions and innovations in the field of green chemistry. Instead of being mandated by the government and the regulatory restrictions, the industry should take initiatives in implementation of green practices. The companies should develop their own footprint tools to perform a 3D (Dirty, Dangerous and Demanding) audit of their existing products. This would help the companies to perform an environmental MIS of their current products and process, evaluate the potential impacts of their products, and based on that develop possible strategies and actions to develop greener products and processes. Figure 19: The Ecosystem for the Green Future 64

67 Going forward, the green chemistry provides market opportunity of USD 98 billion globally for the chemical industry. By implementing green chemistry practices companies stand to gain by first mover advantage leading to increased revenues and profits and long term business opportunities. However the barriers faced by the industry in green chemistry implementation highlight the fact that although the science is ready, the industry is not. This makes the role of academia, government, regulatory bodies, and above all mindset of industry players off-key importance in successful implementation of green chemistry. Refer figure 19 for possible ecosystem for successful implementation of green chemistry and engineering practices. Green Chemistry and engineering combines together company profits, human health and ecological well-being right from the stage of product design and manufacturing. It has the potential to overcome the challenges faced by the chemical industry and can help in long term sustenance of the business. It therefore, is the way ahead for the chemical industry. 65

68 66

69 SECTION 8 Annexure 67

70 Case Studies Case Study 1: Kanoria Chemicals Recycling Solution for water consumption reduction 31 Kanoria Chemicals & Industries Limited (KCI) is a manufacturer of chemical intermediates in India. The company has two plants, one at Ankleshwar, Gujarat, which manufactures alcohol and alcohol based intermediates and the second plant at Vishakapatnam, which manufactures formaldehyde and hexamine. Reduction in water consumption by recycling: The Ankleshwar plant launched a waste to wealth program with the objective of recovery of recyclable water from distillery effluents. KCI went for reverse osmosis technology to achieve maximum recycle and minimum possible disposal. At the point of time when the decision was taken, the technology was never been used for treatment of industrial effluents in India. Pilot plant trials were taken conducted in The reverse osmosis plant for recovery of clean water from the distillery effluent was commercialized and installed in The technology resulted in recycling of 330 m 3 /day of clean water from distillery effluent back to the process, resulting in a saving of identical quantity of fresh water consumption. The success of RO technology treatment of distillery effluent encouraged the company to install another RO plant to recycle effluents generated from the chemical plants. This resulted in an additional savings of 200 m 3 /day of water. Total almost 65-70% of recovered water was recycled back to the manufacturing process. Power generation: During the treatment of distillery effluent bio-gas is generated which, after the removal of H 2 S can be used for power generation. H 2 S is removed with the help of "Thiopaq" scrubber technology supplied by Paques Bio-system of the Netherlands resulting in reduction in sulphur emission into the atmosphere from 900 kg to 9 kg per day. The electricity generated reduced the company s demand of electricity from the state electricity board from 3,000 KVA to 1,000 KVA. Sustainable decomposition: KCI started with a bio-compost manufacturing facility on a trial basis on a 7 acre land. Encouraged by the results, KCI shifted this facility to a 60 acres land, 20 kilometres away from the plant. Thus the use of distillery waste in bio-compost results in recycling of nutrients available in the molasses back to the soil, and reduces the dependence on chemical fertilizers. 68

71 Case Study 2: SMS Pharma 100% Atom efficiency through green synthesis route 32 SMS Pharma is world s largest exporter of ranitidine. Even though the company had reduced its manufacturing process from 11 steps to 4 steps with elimination of hydrogen sulphide emissions the company was facing the issue with methyl mercaptan emissions which get generated in the coupling reaction in which ranitidine base in generated. Changing to a radically alternate synthesis route was not possible due to regulatory complexities and high costs associated with changing the Drug Master File. Hence the company developed an innovative two-step process in which methyl mercaptan was converted to useful dimethyl sulphoxide (DMSO). The first step involved absorption of methyl mercaptan in aqueous sodium hydroxide to form sodium methyl mercaptide which is used in agrochemical industry as a raw material. In the next step methylation was carried out with dimethyl sulphate to from dimethyl sulphide which was then oxidized with hydrogen peroxide to form DMSO. The DMSO formed is used back in the process and the catalyst used is recyclable. The company achieved an atom efficiency of 100% by following the green route of synthesis. 69

72 Case Study 3: Arulpuram CETP (Common Effluent Treatment Plant) ZLD solution for water and salt recycling 33 The Arulpuram common effluent treatment plant in Tirupur, Tamilnadu is a textile dyeing CETP being setup by 15 member units. The CETP has a design capacity of 5,500 m 3 /day and is currently operating successfully under ZLD mode at 70% of design capacity. The technology has been approved by Anna University and has been evaluated by Department of Science and Technology. The broad technology adopted by the effluent treatment plant consists of a pretreatment system followed by water recovery system using reverse osmosis and reject management system using evaporators (Refer figure 20). The key benefits of the ZLD project are recycling of more than 98% of water and reuse of more than 90% of the salt (Refer table 8 and table 9). Figure 20: Arulpuram CETP S.No. Parameter Recovered Glauber salt 1 Purity (%) as sodium sulphate@105 o C 98.5% 2 TH as CaCO 3 (mg/l) Nil Table 8: Performance parameters of Arulpuram CETP 70

73 S.No. Parameter Units Influent Recovered Brine Solution water (MVR concentrate) 1 ph@25 o C TDS mg/l 6, ,972 3 Chloride as Cl - mg/l , Sulphates as SO 4 mg/l 3, ,459 5 BOD@20 o C mg/l 251 BDL NA 6 COD mg/l 1,034 BDL 1,820 7 TH as CaCO 3 mg/l 111 BDL Total alkalinity as mg/l 1, CaCO 3 IGC&E Report Note 1: BDL Below Detection Limit Table 9: Performance parameters of Arulpuram CETP 71

74 Case Study 4: Bristol-Myers Squibb Solvent recovery 34 Bristol-Myers Squibb carries out constant volume distillation in synthesis of an oncology drug. In order to recover THF which is used as a solvent, Bristol-Myers Squibb went for integrating the pervaporation technology with constant volume distillation operation. The earlier CVD process required 13.9 kg of THF/kg API (7.85 kg THF as entrainer/kg API) and generated 9.2 kg waste/kg API. With the integrated CVD-PV approach Bristol Myers achieved 56% reduction in THF (100% reduction in entrainer) and 93% reduction in wastes generated (Refer figure 21). Figure 21: Performance comparison of Current and New process 72

75 Case Study 5: Pennakem LLC Use of Green Solvent 34 Pennakem, a speciality chemical company based in USA initiated and developed the market for ecomethf (2-MeTHF) as a greener alternative to petroleum-derived ethers and volatile chlorinated solvents. Pennakem s proprietary technology produces ecomethf with hydrogen from natural gas and water as the solvent. The manufacturing process involves corn cobs waste as raw material. The corn cobs are cyclized to furfural in aqueous solution. Furfural is further dehydrogenated to make ecomethf. ecomethf can reduce process mass intensity (PMI, i.e. mass used in process with respect to mass of desired product generated) to facilitate greener processes in chemical manufacturing. The advantages achieved by using ecomethf are and easy phase separation (reducing PMI by 50 percent) 5. Elimination of hydrophobic cosolvents (reducing PMI by 30 percent) By using ecomethf almost 30,000 metric tons of THF per year can be eliminated along with 30,000 metric tons of hydrophobic cosolvents from Grignard workups. Usually THF and cosolvent mixtures are incinerated, hence using ecomethf reduces carbon dioxide (CO 2 ) emissions by 90%. Apart from this 2-MeTHF is east to dry and recycle due to its rich azeotrope with water (10.6%) and simple distillation at atmospheric pressure. Almost 70% of energy savings can be achieved with respect to THF. ecomethf is found to be 30 times more environment friendly than chemical THF (Refer figure and table 10). 1. Higher reaction yields (reducing PMI for organometallics by percent) 2. Increased solubility of organometallic reagents (reducing PMI by percent) 3. Higher extraction yields during workup (reducing PMI by percent) 4. One-pot reactions due to cleaner reactions, increased solvent stability, Figure 22: Total cycle emissions comparison 73

76 Solvent Chemical THF ecomethf Total air emissions, kg/kg CO 2 emissions, kg/kg Total water emissions, kg/kg Total soil emissions, kg/kg Total emissions, kg/kg Table 10: Emissions comparison of Chemical THF and ecomethf 74

77 Case Study 6: Dr. Reddy s Laboratories Eco-friendly and cost effective sulfoxidation through green reagents 16 The synthesis of sulfoxides from sulfides has been widely explored and numerous oxidants have been developed to achieve a facile, efficient and selective sulfoxidation. However, most of the reagents require controlled reaction conditions including the quantity of oxidants because of the formation of sulfones as side products. In particular, controlling the oxidation of sulfides to avoid formation of sulfones has been difficult since the first oxidation to the sulfoxides requires relatively high energy. One of the oxidants, m-chloroperbenzoic acid (MCPBA) has been intensively used in the synthesis of prazole derivatives. Under the traditional approach, the sulfide intermediate is oxidized by using MCPBA to manufacture Rabreprazole. The yield of the MCPBA mediated oxidation of sulfide intermediate to manufacture Rabeprazole is not more than 50% and also involves cumbersome isolation. MCPBA mediated oxidation step is most environmentally unfriendly in the synthesis of Rabeprazole. By addition of one oxygen to the sulfide, more than ten times of m- chlorobenzoic acid is generated as a waste. Definitively this transformation is certainly not green and the reagent itself is expensive, hazardous and shock sensitive. sulfide intermediate involves the aqueous media and eco-friendly reagent sodium hypochlorite (NaOCl). The method is efficient, versatile, and produces sulfoxides under mild conditions. These reactions have also been developed with a large variety of substrates like other prazole congers precursor. Sodium hypochlorite is a common and comparatively lesser expensive reagent. It also affords high yields of sulfoxides and the over oxidized product sulfone is minimized in the transformation. The only byproduct generated in sodium chloride. In the new process the yield of the sulfoxidation of sulfide intermediate to manufacture Rabeprazole increases from 45% to 76%. The method produces environmentally acceptable sodium chloride salt. The stage cycle also get reduced to 24 hours from 72 hours. The weight by weight loading of oxidizing agent NaOCl in the reaction is almost five times less than that of MCPBA. The process is both eco-friendly and cost effective. To overcome the harmful impacts of the traditional approach, Dr. Reddy s has developed a new green approach in which oxidation of 75

78 Case Study 7: CSIR Biosciences Microreactor technology for biodiesel production 36 CSIR Biosciences was working on production of biodiesel from different sources of vegetable oil like soya, sunflower, canola, jatropha, palm, and peanut. The reactions involving production of bio-diesel were scaled to the plant level from the laboratory level using the traditional batch technology of stirred tank, jacketed reactors. The agro-processing and chemical technologies group was looking for using the microreactor technology for commercial production of biodiesel. A laboratory scale experiment was successfully conducted followed with construction of pilot unit and commercialization of the process. Biodiesel production parameters Batch plant Microreactor plant Plant output (tons/yr) 20,000 20,000 Comparison of microreactor plant w.r.t. batch plant Reactor volume (m 3 ) x x smaller Plant footprint (m 2 ) % smaller Surface area to volume ratio (m 2 /m 3 ) x x higher Productivity (kg/h/m 3 ) x x higher Energy input (kj per kg) Mass transfer coefficient k l a (s -1 ) Heat transfer coefficient (kj/m 3 ) x lower higher x x higher Mixing efficiency (Re) 7x x10 4 higher Capital cost (R million) The process involved using sunflower and soya as the oil sources in a base catalyzed transesterification reaction with methanol. Different kinds of microreactors were evaluated to measure reaction performance with regards to conversion, selectivity and productivity. The reactor with optimum performance was selected. The process was optimized followed with study of downstream processing. Reaction kinetics as well as key process parameters were also evaluated. The trans-esterification reaction takes almost three hours to complete in a stirred tank batch reactor. On the other hand the time required by using microreactor was less than a second. The reaction rate increased by 10,800 times by using microreactor, implying improved reaction efficiencies by using microreactor (Refer table 11) % saving Manufacturing costs (R/L) % saving Table 11: Batch vs. Microreactor performance for biodiesel production 76

79 Case Study 8: Dupont, Tate & Lyle Bio-based thermoplastic polymer 37 Dupont manufactures Sorona, a renewable sourced thermoplastic polymer which is commercially used in carpet and apparel manufacturing. Sorona consists of 37% renewable plant based ingredients (28% biobased carbon) by weight. The corn feedstock is converted to glucose at the Tate & Lyle corn wet mill. The glucose is converted to form bio 1,3- propanediol (PDO) by using a proprietary fermentation process followed with cleaning and distillation. The Bio-PDO then goes through continuous polymerization operation to produce Sorona polymer. The polymer is extruded into multiple strands, cooled and passed through a pelletizer to manufacture small sized pieces. The production of Bio-PDO consumes up to 40% less energy and reduces greenhouse gas emissions by more than 40% compared to petroleum-based PDO. By using Bio-PDO as a monomer in production of Sorona, Dupont is able to reduce greenhouse gas emissions by 63% compared to petroleum-based nylon-6. Sorona manufacturing also reduces the use of non-renewable energy resources by 30% (Refer table 12). Parameter Sorona Nylon 6,6 Nylon 6 Non-renewable energy consumption (MJ/kg polymer) Greenhouse gas emissions (kg CO 2 equivalents/kg polymer) Table 12: Performance comparison of Sorona, Nylon 6,6 and Nylon 6 77

80 Case Study 9: Kalundborg Industrial Park Symbiotic relationship for reduced external dependence 38,39 Kalundborg is an industrial eco-park in Denmark. The project began in 1972 and by 1995 estimated savings were around USD 10 million a year. The project involved nine core stakeholders of the Kalundborg area 1. Novo Nordisk, pharmaceutical manufacturer 2. Novozymes, enzyme manufacturer 3. Gyproc, plasterboard manufacturer 4. Kalundborg Municipality 5. Dong Energy, Asnaes Power Station 6. RGS 90, soil remediation and recovery company 7. Statoil, oil refinery 8. Kara/Novoren, waste treatment company 9. Industrial Symbiosis Institute The stakeholders exchange materials and energy such that by-products from one business can be used as low-cost inputs by the others. For instance the Asnaes power plant which operates at 40% thermal efficiency generates heat, which is used as process steam by StatOil, Novo Nordisk and Novozymes. The same steam was used in homes in Kalundborg for central heating. In return treated wastewater from the Statoil Refinery is used as cooling water by the Asnaes power station. The power station produces other valuable byproducts. For instance it produces almost 170,000 tons of fly ash per year which is used in cement manufacturing and road building. Gyproc uses the power plant's fly ash to obtain gypsum, a by-product obtained from the chemical desulphurization of flue gases. Gyproc purchases about 80,000 tons of fly ash each year accounting for almost 66% of its annual requirements. Surplus gas from the Statoil refinery which was earlier flared off is now delivered to the power station and to Gyproc as a low-cost energy source. Novo Nordisk's byproducts are used by the farmers as fertilizers. Around 1.5 million m 3 of fertilizers are delivered annually to the farmers free of charge. Apart from this, Novozymes produces bio-mass which is processed to develop a fertilizer branded as NovoGro which is inturn distributed to the local farmers. The waste collection company Kara/Noveren collects used plasterboards and provides them to Gyproc for reuse replacing tons of natural gypsum which would have been imported. RGS 90 treats oil and chemically polluted soil through a bio remediation process that uses Novozymes sludge bi-product as a key nutrient. Post treatment, the clean soil is used as filling material for construction activities in the area. Inbicon a technology company is putting up a bio-ethanol plant. The bio-ethanol plant will operate on straw, a by-product of the agricultural activities in the region, thus creating another symbiotic relationship (Refer table 13 and table 14). 78

81 Collaboration amongst the various stake holders of the eco-system resulting in innovative solutions applicable to the local area, along with emphasis on recycling, degradation and commercial afterlife of the product and biproducts has resulted in development of a symbiotic relationship for the city of Kalundborg. This holistic approach has not only reduced the dependencies on external resources but has also reduced the waste emissions in the environment and improved material and energy efficiencies for all the stakeholders, thereby creating a sustainable solution. Annual resource savings through interchanges Location Resource Savings Statoil Water 1.2 million m 3 Asnaes Coal 30,000 tons Novo Nordisk Oil 19,000 tons - Fertilizer Equivalent to 800 tons Nitrogen and 400 tons phosphorus - Sulphur 2,800 tons - Gypsum 80,000 tons Table 13: Benefits from Kalundborg Industrial Ecopark Wastes avoided through interchanges Location Waste Avoided Asnaes (Landfill) Fly ash and clinker 200,000 tons Asnaes (Landfill) Scrubber sludge 80,000 tons Statoil (Air) Sulphur 2,800 tons Novo Nordisk (Landfill or sea) Water treatment sludge 1 million m 3 - Sulphur dioxide 2,000 tons - Carbon dioxide 1,30,000 tons Table 14: Benefits from Kalundborg Industrial Ecopark 79

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83 SECTION 8 References 81

84 References 1. FICCI India Chem Report Industrial Symbiosis and Green Chemistry, James Clark 3. Fundamentals of Green Chemistry: Efficiency in Reaction Design, Roger A. Sheldon 4. Indicative approximation by Newreka 5. ACS Green Chemistry Institute Round Tables, Dr. Bogdan Comanita 6. Axelera Director Virginie Pevere, Grenoble Isere Report, June California s Green Chemistry law goes into effect, Green Biz website, September Pike Research Report on Green Chemistry: Green Chemicals set to soar to $98.5 billion by Pike Research Report on Green Chemistry: Green Chemicals will save Industry %65.5 billion by The Business Case for Green and Sustainable Chemistry, Ecochem 11. Dow s pillars of sustainable and green economy 12. Environmental Benign Synthesis of Amine Intermediate, Mylan Case Study, Implementation of Newreka s proprietary Recycle@Source TM Solution 13. ACC Company Case Study, Green Industry Platform 14. Carbon Credit Case Study, Sell website 15. Green Business Model Innovation Business Case Study Compendium, Eco-Innovera publications 16. Primary Research by Tata Strategic Management Group 17. Strong Combination Pill, Business Today, January Dow Chemical Sustainability Footprint Tool, Sustainable Brands, November Preliminary Life Cycle Assessment of popular materials for reusable sports bottles Case Study, Eastman Chemicals 20. EPA Green Chemistry Nomination Table 21. Ecoscale, a semi-quantitative tool to select an organic preparation based on economical and ecological parameters by Koen Van Aken, Lucjan Strekowski, Luc Patiny 22. Realities and Opportunities in Industrialization of Green Chemistry, Nitesh Mehta 23. Analysis by Equinox 24. Pigment & Resin Technology, Volume 42, Issue Enzymatic Reaction Mechanisms by Perry A. Frey, Adrian D. Hegeman 26. Biocatalysis by Tyler Johannes, Michael R. Simurdiak, Huimin Zhao 27. Frost & Sullivan Report on Strategic Analysis of APAC Green Surfactants Market 28. Bio-based chemicals: In need of innovative strategies, Chemical Weekly, February 28, Markets and Markets Report on Renewable Chemicals Market 30. Executive Summary on Global Biomimicry Efforts: An Economic Game Changer, San Diego Zoo website 31. Kanoria Chemicals company Website 82

85 32. Regulators urged to frame guidelines to tackle VOC emissions to combat odour issues, Chemical Weekly, September 17, Zero Liquid Discharge Facility in Textile Dyeing Effluents at Tirupur, Sajid Hussain 34. Solvent Recovery Strategies for the Sustainable Design of APIs, Mariano J. Savelski, C.Stewart Slater 35. Low Carbon Footprint Solvents for the fine chemicals industry, Speciality Chemicals Magazine, March Microreactors A marvel of modern manufacturing technology: Biodiesel Case Study, S.R.Buddoo, N.Siyakatshana, B.Pongoma 37. Dupont website 38. Kalundborg Industrial Park Case Study, International Institute for Sustainable Development 39. Kalundborg Industrial Symbiosis Case Study, Robert Suarez, June

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87 SECTION 9 Quotes 85

88 The Expert Comments Green chemistry and engineering has been variously defined and is largely misunderstood as a result. It is, at the very least, a way of thinking about chemistry and engineering through the application of design principles that drive us towards more sustainable actions and outcomes. It is the practice of chemistry and engineering as though the world s future is at stake. DAVID CONSTABLE, Director ACS Green Chemistry Institute, USA "In today s age of rapid industrialization, sustainable development is certainly the need of the hour for businesses and governments at large. The Chemical industry has a major role to play in this scenario, by taking up the challenge of being innovative in order to meet future demands, while maintaining necessary balance in the environment - all in a commercially viable manner. LANXESS cutting-edge technologies and processes aim at reducing energy consumption, safeguarding natural resources and developing commercially viable solutions at the same time. LANXESS Green Chemistry reduces the environmental footprint at every stage of the value chain right from raw materials to the final product. We continue to systematically expand our research and development activities in order to meet these objectives. In doing so, we have set ourselves specific, time-bound, measurable goals. In fact, a number of LANXESS production sites across the globe are already running on a climate-neutral basis using renewable energy sources while LANXESS products are also helping to drive the sustainable energy revolution." Dr. JOERG STRASSBURGER, Country Representative and Managing Director, Lanxess India Private Limited 86

89 We at Godrej are committed to the green and sustainability principles even before CSR and Green became buzzword in the industry. We pioneered the concept of Vegetable oil based soap and as a group we support large mangroves area which demonstrates the commitment towards nature. On product front, GIL- chemicals is increasingly participating in driving the usage of oleo chemicals & surfactants which are eco -friendly & green. On manufacturing front,at Godrej Industries (chemicals division), we are committed to become Carbon Neutral, Water positive, reduce specific energy consumption by 30%, increase renewable energy use to 30% and zero waste to landfill. Green makes perfect business sense. Conserving natural resources has always paid us back and this is important element in driving our business decisions. NITIN NABAR, Executive Director & President (Chemicals), Godrej Industries Limited Within the industry the focus is going to be on four key steps which industry could undertake: Measure and grow in carbon sensitive way, continuously look at water intensity and end use water footprint, improve energy efficiency and focus on waste reduction. Green Chemistry has a central role and acts as a remedial for the four critical components of environmental sustainability R. MUKUNDAN, Managing Director, TATA Chemicals Limited 87

90 In my view, best-in-class standards of safety and sustainability in our manufacturing sector will determine our country s global competitiveness and will emerge as a key differentiator in this decade and the next, much as the pursuit of quality was a couple of decades ago. As a company looks at green manufacturing processes, optimal use of resources and reduction of waste (be it energy or raw materials) are important considerations in addition to increasing efficiencies and profitability. It is important to evaluate technologies and solutions for responsible management of waste and remediation of any hazardous waste or by products. Many industries in India are reaping the benefits of science powered innovations that help reduce wastage and facilitate manufacturing processes and products that are environment friendly. For example, DuPont PrimaGreen EcoScour solution for the textiles knit processing industry helps reduce water consumption by 20 percent and caustic usage by 30 percent in pretreatment process Similarly, DuPont s advanced polymer Sorona PTT, a renewably sourced fiber that uses Bio-PDO as a key ingredient, helps reduce energy consumption by 30 percent and releases 63 percent fewer greenhouse gas emissions compared to the production of nylon 6. Dr. RAJEEV VAIDYA, President South Asia & ASEAN, DuPont The manufacturing sector in India has come of age and is looking beyond profitability. The social and environmental concerns are growing and the resurgent Indian Chemical Industry is gearing up to meet the new global challenges. There is a need to leverage manufacturing competitiveness through innovative and sustainable chemistry which encompasses what we call today the Green Chemistry. Sustainable solutions through green chemistry can be achieved only if we apply them to whole life cycle of the product starting from feedstock, designing, manufacturing and usage pattern. We can no longer trade off the environmental concerns for short term objectives. The manufacturers and users, both have an equal responsibility to make a commitment towards conservation of environment & resources through Green Chemistry. RAKESH BHARTIA, CEO, Indian Glycols 88

91 "Green Chemistry is a subject that deals prevention of waste in any activity around us by design. Outcome of this discipline can be realized if there are skilled in art manpower, impulsive yet well-defined opportunities and rewarding challenges which would essentially make us to sustain and save our environment." Dr. RAKESHWAR BANDICHHOR, Director, API R&D, Dr. Reddy s Laboratories Ltd Ignoring the effort to turn green would cost much more than the cost of turning green SATISH KHANNA, Founder LAZORR Initiative, Ex-Group President, LUPIN Change and Innovation have been historically the key indicators of where the chemical industry has moved. The industry s evolving inner mind has helped address many of our world s problems as well improve quality of life on the planet and will continue to do so. The chemical sciences and engineering have been in constant pursuit of finding innovative ways to ensure that engineering and manufacturing is designed for sustainability. While the industry has brought new products into the market, they have also established a key indicator of sustainable growth responsibly, to proactively address the many issues and concerns about safety and environmental degradation associated with it. To my mind this has been the result of the emergence of green chemistry. Having said this, I strongly believe that the next era for the industry will be that of sustainable chemistry chemistry that looks beyond only one science. It will be a catalyst for change, an innovative problem-solver and a long-term solutionist to global sustainability challenges. VIPUL SHAH, President CEO & Chairman, Dow Chemical International Private Limited 89

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93 SECTION 10 About Tata Strategic About IGCW 91

94 About Tata Strategic Founded in 1991 as a division of Tata Industries Ltd, Tata Strategic Management Group is the largest Indian own management consulting firm. It has a 70 member strong consulting team supported by a panel of domain experts. Tata Strategic has undertaken 500+ engagements, with over 100 clients, across countries and sectors. It has a growing client base outside India with increasing presence outside the Tata Group. A majority of revenues now come from outside the group and more than 20% revenues from clients outside India. Tata Strategic offers a comprehensive range of solutions covering Direction Setting, Driving Strategic Initiatives and Implementation Support Our Offerings 92