Lecture

Fine Chemical TechnologyCLL786

Lecture 1

Prof. Rajesh Khanna

Department of Chemical Engineering

Indian Institute of Technology Delhi

January 11, 2016

Lecture 1 Fine Chemical Technology

Fine chemicals

Products of high and well defined purity

Manufactured in reasonably small amounts

Sold at relatively high prices Types:

Intermediates Final products

Active ingredients Additives Aids in processing


Fine chemicals industry

Drug industry (50%)

Agriculture industry (25%)

Fragrances/Flavors

Dyes/Pigments

Food additives

Trends in Industry Custom synthesis

Chemical trees


Manufacturing processes

Differences between Commodity chemicals

and fine chemicals

Complex multifunctional molecules labile unstable at high temperature sensitive to environment (pH etc.,)

Hence, inherently safer designs and high levelsof controls



High added value products Expensive raw material Selectivity is crucial Degree of utilization isolation/purification is difficult large stream of pollutants

Use of hazardous chemicals for production safety euent disposal



Batch/stirred tank reactors Large inventory Heat transfer limitation unlike continuous processes

Great variety of products multipurpose plants

Accurate analytical methods (ppm or ppblevels)

Chemistry + Catalysis + Process intensification


How a Chemist works?

Focus on properties (end result) Means are not so important

Raw material Time Waste disposal Exothermic reactions Less inventory Diff. conditions


Course Overview?

Course deals with issues whichchemists neglect to lead to economic

manufacture of fine chemicals.


Course Content

Introduction to fine chemicals Catalysis and selectivity

homogeneous vs. heterogeneous catalysis Bio-catalysis Clays (Zeolites) Phase transfer catalysis


Course Content

Selectivity knowledge about elementarysteps

Process intensification Manipulating equilibrium Large surface area for mass transfer controlledreactions

Solvents (Ionic liquids)


Process Development

Impurities in raw material

Recycled streams

Level of understanding

Numerical methods

Different steps

Accessing hazard/safety

Development personnel


Process Development

Separation methods RO Filtration Chromatography

Plants (Multipurpose) Batch or Continuous Homogeneous or Heterogeneous


Objective

Process development and scale up

Techniques for product isolation

Implementation of new processes


Textbook

Fine Chemicals Manufacture: Technology and Engineering

Andrezi Cybulski

M. M. Sharma

J. A. Moulign

R. A. Sheldon

Elsevier Science and Technology Books (2001)


Evaluation

Minor I 20%

Minor II 20%

Major 40%

Term Paper 10%

Assignments 10%

Open book, Open notes examinationNon graded courses unit: 20 design projects


Classifications of Chemicals

Chemicals are classified based on production volumeand character.

Commodities: large volume and industryspecification (acetone, ethylene oxide phenoletc.)

Pseudo Commodities: large volume but sold onthe basis of performance (polymers,surfactants, paints etc.)

Speciality: low volume but sold on the basis ofperformance (pharmaceuticals, pesticides,flavours, fragrances)

fine: low volume but sold as per customersspecification (intermediates for speciality)


Example

Ampicillin Production

Commodities: Toluene and Glucose

Fine Chemicals: D-Phenylglycine,6-Aminopenicillanic acid, bulk ampicillin

Speciality: Formulated ampicillin


Process Selection

Cost of goods (raw material, energy, labour)supplied (CGS) approach does not work.Process Profile Analysis is much more useful.

Operating cost

Capital investement

Process control

Risk to personnel and plant

External factors

developed in 1980s, less emphasis on environmentalimpact


Volume Value Factor (VVF)

VVF is used to further subdivide the categories

VVF =(kg/yr) $/kg

103

High VVF > 70Medium VVF 10 69Low VVF < 10


Operating Cost Analysis by VVF

Parameter High Medium Lowraw material cost 16 13 10($/kg)yield efficiency 15 13 10(avg. yield)throughput time 10 9 8(time per cycle)throughput volume 9 8 7(reactor space/kg product)Subtotal 50 43 35


Capital Investment Analysis by VVF

Parameter High Medium LowNumber of steps 4 6 8Special equipment/technology 2 7 12Subtotal 6 13 20


Process Control Analysis by VVF

Parameter High Medium LowReproducibility 6 4 3Tolerance to abuse 6 4 3Linearity 2 2 3Subtotal 14 10 9


Process Profile Analysis Scores

Parameter High Medium LowOperating Costs 50 43 35Capital investment 6 13 20Process control 14 10 9Risk to plant and personnel 16 21 24External factors 14 13 12Subtotal 100 100 100


Risk to Plant and Personnel

Environmental abuse potential

Occupational health/safety hazard


External Factors

raw material availability

susceptibility to regulatory changes

patent protection


Example


Lecture

Documents

Transcript of Lecture