MAGIC ProcesTransform Manufacturing

Vivek VChemical Engineering & Pr

National ChemPune Pune

National Chemic

Create Innovations & Knowledge

sses & Plantsg of Specialty Chemicals

V. Ranaderocess Development Division

mical Laboratory 411008 411008

al Laboratory 2011

base to Solve Relevant Problems

Outline

S i lt h i l• Specialty chemicals– Key requirements/ drivers

Challenges/ technology p– Challenges/ technology p

• MAGIC processes and pMAGIC processes and p– Key attributes– Realizing MAGIC in practi

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ea g G C p act

• Summary & path forwar

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ab©

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l

splatformsplatforms

plantsplants

icece

rd

Specialty Chemicals

Characterized by low volu• Characterized by low voluprice, sold on performanc

• Key sub-sectors– Catalysts– Textile chemicals– Textile chemicals– Water treatment chemicals– Adhesives and sealants

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– Leather chemicals– Detergents & surfactants

Paper chemicals

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ab – Paper chemicals– Electronic chemicals– Biomarkers

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– API

umes niche applications highumes, niche applications, high ce specifications

– Paints, pigments and colorants– Flavors and fragrances

Foundry chemicals– Foundry chemicals– Rubber chemicals – Photographic/reprographicPhotographic/reprographic

chemicals– Printing inks

dd f l– Additives for polymers– Construction chemicals– Oil field chemicalsOil field chemicals– Cosmetics

Indian Specialty Chem

C t t 15• Current turnover: ~ 15– Expected to grow at doub

economy like Indiaeconomy like India

• Turnover will cross 75

• Need significant techno

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1 addition turnover of 6

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ab©

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micals Sector

50000 C50000 Croresble the rate of GDP in emerging

50000 Crores by 2022y

logy inputs to create 600000 Crores!

Growth Potential

Gl b li ti f b i• Globalization of busines• Shifting manufacturing• Growing concerns for s

– Catch up with and exceedt i bilitsustainability

• Changing customer expd hi

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1 demographics– Address unmet needs & n

developing nation (capac

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ab developing nation (capac

• Rapid market fluctuatioIndustry consolidation

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atio

nal • Industry consolidation

ss geographiessustainabilityd the global benchmarks on

pectations driven by new

newer demands of rapidly ity/ quality)ity/ quality)

ns/ cycles

Key Drivers for Growt

L t ti /• Low cost operation/ ma

• Develop better process p pquality

• Provide systems solutio• Provide systems solutio

• Develop new application

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• Develop new products ton unmet needs of cust

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on unmet needs of cust

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nal

th

f t ianufacturing

technologies/ product g p

nsns

ns for existing products

to create new market based tomertomer

Indian Specialty Chem

• Business issues• Business issues– Fragmented capacity; low cap– Threat of horizontal transfer o

due to commoditization of pro– Difficulties in identifying new g– Lack of deep pockets to sustaiLack of deep pockets to sustai

supplier/ manufacturing entity

• Technological issues

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1 • Technological issues– Cost of new product introducti– Relative unfamiliarity with cata

conventional engineering prac

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ab conventional engineering prac– Limited in house technology d– Innovation deficit; few process

serious issues of talent retenti

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nal serious issues of talent retenti

– Increasing regulatory (environ

micals: Challenges

ital/ technology intensityof technology/ quicker erosion of margins oductsgrowth platforms in business cycles; branded as low costin business cycles; branded as low cost y; managing supply chain of raw materials

ions/ cost of raw materials & energyalytic processes/ different reactors; ticesticesevelopment strengthses based on proprietary knowledge/ IP; on/ flighton/ flight

nment, health and safety) frameworks

Possible Ways to Ove

• Improve productivity an• Improve productivity anproducts; Adjust with racycles; Reduce time tocycles; Reduce time to – Multiple products from th– Improve functionalities –Improve functionalities – Flexible & multi-purpose – Focus on formulated prod

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p– Products with unique raw– Process intensification &

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– Use continuous processes– Computational modeling

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Science, Technology &

rcome Challenges

nd develop innovativend develop innovative apid market fluctuations/ marketmarket

he same facilitiesnew marketsnew marketsplantsducts

w material advantagescompact plantssfor faster lab to market

& Innovation

Some Key Principles

• Use catalysts not stoich• Use catalysts, not stoich• Use better (& safer) sol

conditionsconditions • Design syntheses so tha

maximum proportion ofmaximum proportion of• Prevent waste, leave no• Design safer (non-toxic)

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1 • Design safer (non toxic)• Maximize energy efficie• Use multi-functional & i

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ab • Use multi functional & iequipment

• Real-time monitoring an

© N

atio

nal Real time monitoring an

hiometric reagentshiometric reagentsvents and reaction

at the final product contains f the starting materialsf the starting materialso waste to treat or clean up) chemicals and products) chemicals and productsncy & effectivenessntensified processntensified process

nd process controlnd process control

Key Technology Platf

Ch i t• Chemistry– Catalysis (replace reagen

Improved solvents (super– Improved solvents (super– Other tools like chiral swi

encapsulation, Suzuki couencapsulation, Suzuki couand so on

• Chemical engineering &

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1 • Chemical engineering &– Batch to continuous, mult– Micro-reactors new react

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Micro reactors, new react– Novel separation platform– Computational modeling,

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nal p g,

CSIR - National Che

forms

t based processes)rcritical media ionic liquids)rcritical media, ionic liquids)tches / single enantiomers, micro-upling, metathesis, click chemistryupling, metathesis, click chemistry

& process intensification& process intensificationtifunctional reactorstors and mixerstors and mixers

mssimulation & visualization

emical Laboratory

CSIR

CSIR’ i i• CSIR’s mission– To provide scientific indu

economic environmentaleconomic, environmentalpeople of India.

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Lab

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Total No. of Laboratories/Institu

strial R&D that maximizes the and societal benefits for the and societal benefits for the

NPL, CRRI, IGIB, NISCAIR, NISTADS

CEERI

CSIOCDRI, CIMAP, IITR, NBRI

NEIST

IMT CBRIIIP

IHBTIIIM

CIMFR

NIO

CSMCRI CGCRI

NCL

AMPRI

NEERI

NML

IMMT

CMERI

IICB

Physical SciencesChemical SciencesBiological Sciences

CCMBIICTNGRI

SERCCLRI

CECRI

NIIST

NAL

CFTRI

o og ca Sc e cesEngineering SciencesInformation Sciences

utes: 37 Outreach Centres: 39

CSIR Today: Played K

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Key Role

CSIR Vision: New CSIR

P i hi h t• Pursue science which sttechnology that enablesand nurture trans discipand nurture trans-discipcatalyzing inclusive econpeople of Indiapeople of India– Establish science & engin– Provide innovative techno

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Provide innovative techno– Harness open innovation – Encourage science based

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g– Realize socio-economic tr

intervention

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R for New India

t i f l b l i ttrives for global impact, s innovation-driven industry plinary leadership therebyplinary leadership thereby nomic development for the

neering leadershipology solutionsology solutionsand crowd sourcing entrepreneurship p pransformation through S&T

N  CSIR f  New CSIR for New India

National Chemical La

NCL’ i i• NCL’s mission– To further knowledge in t

for the benefit of the peofor the benefit of the peo

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Lab

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aboratory

the chemical sciences and apply it opleople.

• Knowledge creation, g ,capability building, PhD researchK h t h l• Knowhow, technology, innovations

• Research servicesResearch services, consulting, technical support

• Establish & nurture resource centers

NCL Eras: Lab to Mar

Basic chemicals; Dye st

Agrochemic

Pharmaceuticals; Fine che

Import subs;

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1 Import subs;

R h i I di Gl

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ab Research services; India – GlPatenting; Global tech trans

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PartnershipInnovatio

ket

tuffs (1950s)

cals; Organic chemicals (1960s)

emicals (1970s)

Catalysis; Tissue culture Catalysis; Tissue culture (1980s)

l b l R&D h b lobal R&D hub; sfer (1990s/early 2000s)

p models; Entrepreneurship; on networks (mid/late 2000s/ 2010s)

National Chemical La

Create innovations and kn• Create innovations and knquality of life via contribu– Create value through innovaCreate value through innova

infringing processes and scicomplex processes

• Capabilities– Strong process chemistry/ p

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1 – Competence in homogeneo– Process intensification, reac

S ti i

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ab – Separation sciences– Strong domain knowledge i

advanced process control st

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Close association with i

aboratory

nowledge base to enhancenowledge base to enhance utions to key industry sectorsations IP development of non-ations, IP, development of nonience based understanding of

process design and engineering skillsous and heterogeneous catalysisctor engineering & scale-up

n process modeling, simulation, trategies and flow modelingg g

industry/ a credible partner

Process Intensificatio

Fi t i i iti ti• First in initiating researcIndia

Established first of its kin– Established first of its kinreactors’ at NCL

– Equipment manufacturesEquipment manufactures

• Complemented consorti

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1 center of excellence (Co– Development of new proc

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ab devices– Convert batch processes

Intensify processes to ach

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nal – Intensify processes to ach

plants

on at NCL

h i t ich on micro-reactors in

d industry consortium on ‘microd industry consortium on ‘micro

to usersto users

ium with CSIR funded oE) on micro reactorscess equipment/ multifunctional

to continuous oneshieve compact & multi purposehieve compact & multi-purpose

MAGIC Plants & Proce

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Lab

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esses

Modular

AGile

IntensifiedIntensified

Continuous

M for Modular

M d l l t• Modular plants– Designed as interchangea

equipment with pre-definequipment with pre defin– Reduce field work/ reduc– Facilitate shorter scheduleFacilitate shorter schedule

testing– Enhance flexibility/ reloca

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• Need to develop& b

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ab – New & better connectors– Intensified & compact rea

New concepts in modular

© N

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nal – New concepts in modular

– Standardization and inter

able modules containing groups of ned interfaces to utilities etcned interfaces to utilities etc.e time from lab to practicees, compact design & rigorouses, compact design & rigorous

ation

actorsrizingrizing roperability policies

AG for Agile

A ilit• Agility– Ability to change process

market needs and to manmarket needs and to man– Demands re-configurable

• Dynamic plant layouty p y

• Need to develop

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1 – New & multifunctional pro– New design paradigms: r

parameters instead of po

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ab parameters instead of poCombinatorial methods todesign variables and proc

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g p– Use of wireless technolog

plants quickly in response to nufacture new productsnufacture new productse process and plant designs

ocess equipmentanges of the values of the design int values as input parameters;int values as input parameters; o scan the domain consisting of cess functionsgies as enabler in plants

I for Intensified

• Enhanced transport rate• Enhanced transport rate– Very large surface area to

interactions– Fast mixing/ heat transfe– Precise control on residen

• Small reaction volumes– Low inventories/ safer op

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1 Low inventories/ safer op– Ability to withstand extre

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ab • Possibility of integratingseparations on single pl

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eseso volume ratio/ interfacial

r/ mass transfernce time distribution

perationsperationsme conditions

g multiple reactions/ latform

C for Continuous

C t & l i t• Compact & low inventor– Safer operations, lower fo

• Consistency in product q– Better control on selectivBetter control on selectiv– Better atom efficiency

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• Optimal use of utilities– More efficient

Che

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• Better process control

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ryoot print

qualityityity

Drivers for MAGIC

• Enhanced quality and sa• Enhanced quality and saenvironmental impact– Modular and agile (ability to co

minimum down time & off spe– Lower E factor, carbon & wate

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Lab

From

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PissAICh

afety at reduced cost andafety at reduced cost and

onduct several product campaigns with ec products)er footprints, hazards (green)

Calabrese and Calabrese and savini (2011) hE J, 57, 828

MAGIC Plant: Scientif

• Early stage reaction en• Early stage reaction en– Selected reaction platfor

• New concepts & design

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1 • New concepts & designequipment/ process con– Delivering materials and

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ab

gplace (manipulate design

• Understand, quantify &

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nal

– Corrosion/ erosion/ cloggswitching products/ reco

fic Challenges

gineering analysis:gineering analysis: ms (chemistry/ reaction kinetics)

ns for intensified processns for intensified process ntrolenergy at right time and at right gy g g

n & process control strategies)

& manage other issues:ging/ maintenance/ cleaning/ onfiguration

Indus Magic©Indus MagicInnovate, Develop & Up Scale Modular, Agile, Intensified & Continuous Processes & Plants

• Magically transform Indindustryy

ProchemPro

chem

Reaction

MAGIC (AGile, In

& ContReaction

MAGIC (AGile, In

& Cont

bora

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1 Reaction kinetics &

engineering

& Contpl

Reaction kinetics &

engineering

& Contpl

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• Likely project partners (

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– ICC, sector specific indus– NCL, IICT, NIIST, CSMCR

New Age Specialties

dian specialty chemicals

ocess mistryocess mistry

Process

(Modular,ntensified tinuous) Process

(Modular,ntensified tinuous) Process

intensification & synthesis

tinuous) ant

Process intensification

& synthesis

tinuous) ant

(industry, CSIR, others)try consortiums

RI, NEIST + CEERI, CMERI

Indus MAGIC E

Conventional wayh b hBatch or semi-batch processes

Stirred reactorsLess flexible plants, clumsy cleaning

Use of stoichiometric reagentsGenerate significant waste per unit product

Large water foot print

Use hazardous solventsReactions limited by transport limitations

Separate unit operations: reactors,

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tory

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Separate unit operations: reactors, separations

Cabled process instrumentation & control

Che

mic

al L

ab©

Nat

iona

l

nhance Productivity & Profitability

Indus MAGIC wayContinuous processes

Compact, intensified reactorsModular, agile and reconfigurable plantsUse of catalysts & catalytic processes

Intensified processes/ operation to maximize atom efficiency

Reduced water foot print via water recycle and reuse

Conduct reactions in water/ benign solventsReactions at intrinsic rates without any

transport limitations Integrated processes with multi-functionalIntegrated processes with multi functional

reactors/ process equipmentWireless process instrumentation & control/

new paradigms for process optimization

Indus MAGIC Approac

• Establish focused research• Establish focused research – Continuous reactors & process

processes by catalytic process– Reduce, reuse & recycle

• Establish industry consortiu– Include industry representative

consortium

bl h ‘ G C l ’ f

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1 • Establish ‘MAGIC Plant’ facito specialty chemicals indus

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ab • Associate large number of f– Formulate final year projects a

© N

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nal

• License technologies, createventures & globally leading

ch

programs on work packagesprograms on work packagesses, separations, replace reagent based es, use benign solvents …

um to involve industrieses in the management board of

l d klity to demonstrate key concepts stry

final year ChE studentsaround Indus MAGIC theme

e new entrepreneurs, start-up specialty chemical industry

Pre-project of Indus M

I iti t d j t f• Initiated pre-project of – Reposition research focus

iCPs©

– Focus on developing inte

Develop Intensified & Continuous Processes for Specialty Chemicals

bora

tory

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1

p gand plants

• Associated industry consor• Associate large number of

Che

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ab • Associate large number of

– Develop multifunctional p• Compact modular reactors

© N

atio

nal p

like helical coils, diodes, m

www.indusmagic.org will b

MAGIC

I d MAGIC t NCLIndus MAGIC at NCLs on MAGIC concepts

nsified & continuous processes p

rtiumf BE project students for pre screeningf BE project students for pre-screening

processess: assembled using a few basic devices g

mixers

be launched soon

Realizing MAGIC Proc

w

ates

al

©

ICC & othconw

ays/

new

arke

ts

mis

ing

s fr

om

othe

r

al c

andi

daen

t/ in

itia

Sch

olar

hola

r© conN

ew w ma

on o

f pr

omes

/ in

puts

CPI/

ICC/

oso

urce

s

f po

tent

iaev

elop

me

via

Indu

s

us S

ch

zed

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tory

201

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Eval

uati

proc

esse

Indu

s C s

fica

tion

of

proc

ess

dcr

eeni

ng v

Indu

ecen

tral

izct

urin

g

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ab

Iden

tif

for

p sc Indu

n ti

me/

dm

anuf

ac

Currently

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nal

Just

in

y

Indus MAGIC w

cesses & Plants

her industry ntacts

Li i /

ntacts

Licensing/ Commercialization/ Spinout companies

iCPs©

p p

©us CPI©

8 members

will be initiated under 12th five year plan

Summary

Realizing next phase of g• Realizing next phase of gspecialty chemicals requ

Innovations in process int– Innovations in process intengineering: iCPs/ Indus

– Proactive participation of p p– Harnessing large number

students: Indus Scholar

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1 • Will be agents of transform

• Significant potential to tr

Che

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al L

ab • Significant potential to trchemical industry by parother CSIR chemical clus

© N

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nal other CSIR chemical clus

growth & leadership ingrowth & leadership in iretensification & reactortensification & reactor MAGIC industry: Indus CPIy

r of young chemical engineers/

mation in the coming years

ransform Indian specialtyransform Indian specialty rtnering with CSIR – NCL and ster laboratoriesster laboratories

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Lab

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Specialty Chemicals M

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From Burgess et al. (2003), Europe

Market

an Management Journal, 20(2), 199–212