Innovating Towards Sustainability in the Global Chemistry Enterprise

Transcription

1 Innovating Towards Sustainability in the Global Chemistry Enterprise IGCW Inspiration 4 December 2015 David J. C. Constable, Ph.D. Director, ACS Green Chemistry Institute

2 ACS Green Chemistry Institute Engaging you to reimagine chemistry and engineering for a sustainable future. We believe sustainable and green chemistry innovation holds the key to solving most environmental and human health issues facing our world today. Advancing Science Advocating for Education Accelerating Industry

3 Why Reimagine Chemistry? The chemistry enterprise as currently operated is completely unsustainable: Feedstocks Chemicals Chemistries Processes Products Chemists and chemical engineers are uniquely equipped to do something about making the world more sustainable

4 NSF Sustainable Chemistry Workshop Conclusions Jan, 2012 Systems-level thinking is required More fundamental research should be use inspired Green is not synonymous with sustainable Efficiency is necessary but not sufficient due to the rebound effect (Jevon s paradox) Sustainability research and education is multidisciplinary and collaborative

5

6

7

8 Innovation is Essential

9 Green Chemistry Should Spur Innovation Environmentally preferred Green Chemistry Societal Need Economically viable

10 The Market for Green Chemistry is Expanding The green chemistry market will grow from $2.8 billion in 2011 to $98.5 billion in 2020.

11 Sustainable Chemistry Opportunities Exploit greater chemical diversity especially what is available from biorenewables Greater understanding and uptake of synthetic biology as a synthesis tool New reactions that are focused on biologically-derived molecules. Low energy, direct conversion of CO 2 to methanol or >C 1 molecules Sustainable source of hydrogen Closing the materials loop waste as raw material

12 Different Building Blocks are Essential Target different framework molecules Leverage new chemistries New targets. New substrates. 95 % of synthetic chemicals are derived from petroleum. 70% of the core of organic transformations are based around the high volume petroleum precursors. Angew. Chem. Int. Ed. 2006, 45,

13

14 Everyone Needs to See The Big Picture Raw material and energy consumption R&D: Process Development Material Selection Hazard & Risk assessment Resource Extraction Raw Material Manufacture Intermediate Products Final Product Ultimate Ecological Fate Sales and Marketing Final Consumer Use Store Distribution Emissions to air, water and land

15 Innovations are Needed Everywhere The laboratory Development laboratories are full of batch equipment. They need to contain: - Plug-and-play continuous equipment - Infrastructure to feed, monitor, control, acquire data from continuous devices - Ubiquitous property and kinetic measurement capability The chemist and the engineer Whole process thinking is needed New skill sets need to emerge with new ways of processing: - Existing batch skill sets are effective but restricted - Early and effective communication between chemist and engineer is essential to identify process options - Increased pressure on quantitative skills newer process equipment designs are less forgiving Business processes Valuing process robustness and quality Valuing EHS benefits in DfM Planning development activities to allow for working faster Taking a portfolio vs. product perspective Innovation implies more technical decisions to be taken earlier Other Resources Money/Investment to change! Equipment, Time and Information availability Software / modelling tools Complexity Development Process Materials Engineering Chemistry New ways of developing and optimising processes are needed

16 NOW ONLINE Research, connect, collaborate, and innovate with the green chemistry community. ASK QUESTIONS about green chemistry FURTHER YOUR RESEARCH by collaborating with innovators EXPLORE AND VISUALIZE the green chemistry community In collaboration with:

17 Green Chemistry Innovation Forum Talk with the green chemistry community! Green Chemistry Innovation Portal Green Chemistry Innovation Forum Discover research and funding opportunities in green chemistry Continue discussions outside of conferences Ask questions about programs or research and get expert answers In collaboration with:

18 Green Chemistry Innovation Forum Talk with the green chemistry community! Check out the forum if you are a: Researcher with new technology Company looking for greener/safer alternatives Educator who wants to incorporate green chemistry Student pursuing green chemistry Green chemistry professional in any sector In collaboration with:

19 Green Chemistry Innovation Map Explore the green chemistry community! Explore how organizations are connected to green chemistry Shows relationships between green chemistry centers and businesses Academic view highlights universities and NSF Centers for Chemical Innovation In collaboration with:

20 Green Chemistry & Engineering Education Roadmap Destination & Path Partnership to generate Consensus Coordination Short-Term Goals Long-Term Goals Multi-year Effort Stakeholder Investment

21 GC Education Road Map Development What do green chemists need to know? Identify major green chemistry thematic areas Develop Learning Objectives around the themes What are the gaps in existing resources? Inventory & evaluation of existing materials, programs, infrastructure Gaps in Materials Capacity building Implementation strategies Define how to fill the gaps What materials are needed? How should these be developed? Who should develop them? How to leverage existing tools & resources for education 21

22 ACS GCI Industrial Roundtables Catalyzing the integration of sustainable and green chemistry and engineering in the global chemistry enterprise. We convene companies from across the world to focus on the science of sustainable and green chemistry and its implementation. Pharmaceutical Formulators Chemical Manufacturers Hydraulic Fracturing

23 Roundtable Member Companies 23

24 Pharmaceutical Roundtable - Tools ACS GCI PRT Reagent Guides

25 Chemical Manufacturers Roundtable Proposal: DOE Grant Accelerating Industrial Application of Less Energy-Intensive Alternative Separations $5MM and 8-10 projects High Performance Computational Modeling 21 st Century Energy Efficient Manufacturing Fast Track: One Year to Complete: Full Proposal Due Nov 15 DOE s New Initiative

26 Biotechnology Leadership Roundtable (BTLR) Proposed Vision and Mission Vision A sustainable chemicals economy Mission The BTLR will promote and advance a sustainable chemicals economy by: Supporting sound science in research Stimulating innovative ideas in business, education, government and civil society Transferring leading practices to promote the bio-based economy Promoting education and awareness

27 BTLR Proposed Strategic Objectives Key Challenges and Opportunities of Sector Supporting sound science in research Sustainability/Environmental performance standards Developing technology to achieve parity Supporting market opportunities Stimulating innovative ideas in business, education, government and civil society Identify market-ready products and technology Consortium to tackle various pre-competitive topics Assisting small to mid-size businesses on precompetitive topics Transferring leading practices to promote the biobased economy Technology transfer across the value chain Business case (increase market demand) Feedstock (Quality, Cost, Environmental) Promoting education and awareness Building trust in biotechnology Increase awareness

28 Success Stories in Sustainable Innovation

29 PGCCA - 20 Year History of Innovations Focus Area 1: Greener Synthetic Pathways Focus Area 2: Greener Reaction Conditions Focus Area 3: The Design of Greener Chemicals Small Business* (for a technology in any of the three focus areas developed by a small business) Academic (for a technology in any of the three focus areas developed by an academic researcher) Specific Environmental Benefit: Climate Change (for a technology in any of the three focus areas that reduces greenhouse gas emissions)

30 PGCCA Awards Using a Renewable Resource A majority of award winners have not used a renewable resource

31 About 15% of award winners have used some kind of bio-technology to achieve their innovation

32 Process innovations are the most common kinds of innovations, followed by introductions of new chemicals

33 Organic chemistry and biochemistry are the two areas of chemistry responsible for the greatest proportion of innovations.

34 For innovations in a new chemical, the greatest proportion of these are inorganic in nature

35 Organic chemistry is the basis for most innovations that are process-based

36 CASE 1: DOW & BASF PGCCA Winners for Greener Synthetic Pathways Hydrogen Peroxide to Propylene Oxide Process

37 Sustainable Polymers and Composites: Optimal Design Among the top 30 largestvolume chemical intermediates produced in the world Annual worldwide demand is estimated to be over 14 billion pounds Key raw material for PU, propylene glycols, glycol ethers, etc. U.S. EPA

38 Impact of HPPO Process This new route to make propylene oxide with hydrogen peroxide (Solvay s advanced anthroquinone autooxidation process) that eliminates most of the waste and greatly reduces water and energy use compared to traditional technologies PCH PO Process Wastewater reduced up to 80% Energy use reduced by 35% Precursors Intermediate Cl 2, H 2 O HOCl, PCH Production facilities are up to 25 % cheaper to build Coproducts/Recycle t/t PO 2 t Chloride salts 40 t H2O SM PO Ethylbenzene EB-hydroperoxide 2.2 t Styrene MTBE PO Isobutane t-butylhydroperoxide 2.4 t t-butanol Cumene PO Cumene Cumene-hydroperoxide 1.5 t Cumyl-alcohol HPPO H 2, O 2 H 2 O t H 2 O DOI: /CET

39 CASE 2: ELEVANCE RENEWABLE SCIENCES, INC. PGCCA Winner in the Small Business Category

40 Proprietary Metathesis Technology Elevance Proprietary Catalyst ethylene B D B C D Catalyst 1-decene A C A methyl oleate 9-decenoic acid methyl ester D D B C methyl oleate B Catalyst 9-octadecene C A 9-octadecenedioic acid methyl ester A methyl oleate

41 Feedstock Options Soy oil Palm oil Canola oil Elevance Advantage: Superior Process Nobel Prize-Winning Technology Co-Reactants Standard Chemical Unit Operations Derivatization Separations Drop In and and Specialty Products Specialty Chemicals Corn oil Jatropha Metathesis Distillation Olefins Algae Tallow Mustard oil Existing Biodiesel Asset Transesterification Alcohol Glycerol Distillation Hydrolysis/ Hydrogenation Oleochemicals ERS proprietary biorefinery process

42 Impact Economic Benefits Elevance s biorefinery results in lower production costs, energy consumption, and capital expenditures than petrochemical refineries Elevance addresses a market of $176 billion in the specialty chemicals industry Platform Market Segment Addressable Market Size Consumer Ingredients & Intermediates Lubricants & Additives Engineered Polymers & Coatings Detergents and cleaners Personal care products Performance waxes Lubricant base oils Lubricant and fuel additives Specialty polyamides, polyesters, and polyols Epoxies and polyurethanes Coatings and cross linking agents for coatings $20 billion $6 billion $5 billion $17 billion $12 billion $25 billion $58 billion $33 billion Consumer Impact Example: Detergents o Elevance s specialty chemicals enable detergents that have more concentrated formulations and improved solvency (better cleaning) while working in cold water (reduced energy costs)

43 CASE 3: MYRIANT Commercializing Bio-Based Chemicals

44 Bio-Succinic Acid Drops-In to Chemical Manufacturing to Replace Petroleum Myriant Bio-Succinic Acid Molecule SAC Replacement $7.5B Succinic Acid Market High Value Proven Chemistry/Scale High Performing Cost Competitive Better Environmental Footprint Extensive IP BDO PBS Serving Immediate Demand in Multiple Application Markets

45 Myriant s Bio-Succinic Acid Value Proposition Bio-succinic Acid Process Has Low Greenhouse Gas Emissions 94% less than petrochemical succinic acid* 93% less than petrochemical adipic acid* Renewable Feedstocks are Cheaper and Less Volatile Than Petroleum Efficient Fermentation and Downstream Processes Optimize Production Costs Feedstock can be sorghum (nonfood) based or corn based Drop-in Replacement Anywhere Succinic Acid is Currently Being Used Replaces petroleum based chemicals in Urethane, Plasticizer, Coatings and Polymer Applications

46 CASE 4: RICHARD WOOL, University of Delaware 2013 PGCCA Winner in Academic Category

47 Sustainable Polymers and Composites: Optimal Design New biobased materials substitutes for toxic substances used to make highperformance materials, like adhesives, composites, and foams Fatty acids Triglycerides Lignin Chicken feathers U.S. EPA

48 Sustainable Polymers and Composites: Optimal Design Twinkling Fractal Theory (TFT) to predict the functional properties of a material based on its molecular properties Evaluates the potential toxicity of the materials using the U.S. EPA s EPI Suite TM software Impact: requires less H2O, energy, & toxic waste vs. traditional technologies Commercialization: Dixie Chemical & Crey Bioresins U.S. EPA

49 Conclusions There s a lot going on in green and sustainable chemistry in the United States (and the rest of the world)! The chemistry and chemical engineering communities are the best suited to make a difference in moving sustainability forward Sustainable and Green chemistry is more than just hazard and pollution reduction Innovation is key to making chemistry greener and more sustainable Early design that incorporates sustainable and green chemistry and engineering principles is imperative to achieve the most cost effective gains There are many examples of success

50

51 Questions? David J. C. Constable What s Your Green Chemistry? TM We want to hear your story. Contact gci@acs.org