© 2013 Equinox. All rights reserved | 1 Sanjiv Bachal & Alok Pandit Equinox Software & Services...

© 2013 Equinox. All rights reserved | 1

Sanjiv Bachal & Alok Pandit Equinox Software & Services Private Limited

Dec 2013

Potential Environmental Impact (PEI) Assessment of

Solvent Recovery System Using

Waste Reduction Algorithm (WAR)


1. Introducing Equinox

2. The importance of solvents

3. Process design of Solvent Recovery system

4. Waste Reduction Algorithm (WAR)

5. Case studies

6. Conclusion

7. Vote of Thanks

Agenda

2


EQUINOX

Improving process and plants performance globallyThrough

IT-catalyzed Chemical Engineering


“…Gain better “process”

understanding to

“process” better

Gains…”

Our Mantra


A New Kind Of Process Company Model Based Process Consulting,

Process IT Solutions & Services

Among the largest # Software platform independent companies in its chosen business areas for CPI/HPI/Pharma

India based company in active business since 2007

Successful Delivery of 100+ projects

50+ customers in 10 countries in 3 continents

Novel Application Solutions deployed thru internal R&D

Profitable growth, based on internal funds

Broad Base of Customers


Member – NASSCOM, FICCI, MCCIA

Incorporated in 2005 Operational in 2007

Clocked a CAGR of 60% over last five years

Consistent repeat business – A sign of customer’s trust.

Delivered 100,000+ Hours of Consulting in last 18 months

Strategic Alliances with world leaders – FRI and OLI

Global customers in UAE, Malaysia, Qatar, Saudi Arabia, Italy, India, USA, Thailand, Netherlands

Now in its 7th year…


Importance of Solvents

Why solvents are needed:– Solubilizing the reactants– Facilitate reaction– Facilitate heat transfer/control– Purification

Solvents constitute typically 80-90 wt% of the process mass

Contribute about 15-25 % to the cost of manufacturing of Active ingredient

Number of solvents used in an API unit could be anywhere in the range of 10-50

Number of used solvent streams could be > 100


Process Design Challenges

Binary solvent mixtures are a rare occurrence – multi-component systems are common

Multi-step separation processes with multiple permutations and combinations of distillation train


Process Design - Engineering Practices

Methodologies followed in Industries for design of solvent recovery system:

Experience/Operation wisdom Consultants Commercial Simulators etc


Process Design - Engineering Practices

MAXSOL – The complete science driven product/Application to maximize solvent recovery

Considers various aspects in process Designing: Thermodynamics Operation Hardware Economics Environment


Design of Solvent Recovery Systems

The Green/Environment Aspect:

The Environment Impact Assessment (EIA) of the Design Alternatives


EIA - Waste Reduction Algorithm

What is Waste Reduction Algorithm (WAR):– Algorithm developed by US EPA to evaluate

environmental impacts of process design

How it works– By evaluating processes in terms of their potential

environment impacts (PEI)

What is PEI– Effect a chemical would have on the environment

if it were simply emitted into the environment


PEI categories considered in the Waste Reduction Algorithm (WAR):– Toxicological

Human Toxicity Potential by Ingestion (HTPI) Human Toxicity Potential by Exposure (HTPE) Aquatic Toxicity Potential (ATP) Terrestrial Toxicity Potential (TTP)

– Global Global Warming Potential (GWP) Ozone Depletion Potential (ODP) Photochemical oxidation or Smog Formation Potential

(PCOP) Acidification or Acid-Rain Potential (AP)




Energy Generation Process

Recovery Process

PEIin PEIin

MASS MASS

MASSMASS

Energy

PEIoutPEIout

WasteEnergy

WasteEnergy

PEI Analysis Envelope



A case study is discussed here to highlight the application of WAR algorithm to understand the PEI of various design alternatives for an actual solvent mixture separation

MDC – THF – Water System


New Design - Option 1

Reuse

Reuse

Waste

Waste


Reuse

Reuse

Waste

Waste

New Design - Option 2


PEI Analysis Using WAR

External Environment Efficiency of the process

Total Rate

0

50

100

150

200

250

300

350

400

Impa

ct (P

EI/h

r)

Output rate of PEI

Option 1

Option 2

• The contribution due to

PCOP is predominant in

both the options

• Option 2 PEI is

marginally better due to

lower contribution of

PCOP category



External Environment Efficiency of the process Rate per kg of product

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

Impa

ct (P

EI/k

g pr

oduc

t)

Output Rate of PEI per kg Product

Option 1

Option 2

• Option 1 shows a better

performance per kg of

product – Option 1 has

higher product yield

compared to Option 2



Internal Environment Efficiency of the process Total rate of PEI generation

-600

-500

-400

-300

-200

-100

0

Impa

ct (P

EI/h

r)

Generation Rate of PEI

Option1

Option 2



Internal Environment Efficiency of the process Generation per kg of product

-1.2

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

Impa

ct (P

EI/k

g pr

oduc

t)

Generation Rate of PEI/kg Product

Option 1

Option 2



PEI Generation - Energy Usage Environmental Energy efficiency of the

process

0.00

1.00

2.00

3.00

4.00

5.00

6.00

Impa

ct (P

EI/h

r)

Output Rate of PEI - Energy Generation

Option 1

Option 2


Key Take-Aways

Simple and technically sound assessment of environmental impact of process design alternatives

Equinox has developed MAXSOL with proven track record to handle new design and revamp of solvent recovery system


Contact Information

Contact: Dr. Sanjiv BachalPhone: +91-20-41020122Email: [email protected] Website: www.equinoxweb.co.in

mailto:[email protected]

http://www.equinoxweb.co.in/

© 2013 Equinox. All rights reserved | 1 Sanjiv Bachal & Alok Pandit Equinox Software & Services...

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