Products and Processes for a Sustainable Chemical Industry

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JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006 Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com) J.JENCK , ENKI Innovation (France) M. DROESCHER, DEGUSSA, Düsseldorf (Germany) F. AGTERBERG , DSM and Cefic, Brussels (Belgium) ACHEMA Frankfurt, 18 May 2006 Communicated for educational purpose only Communicated for educational purpose only Communicated for educational purpose only (reference to author (reference to author (reference to author - - - no commercial use) no commercial use) no commercial use) Products and Processes for a Products and Processes for a Sustainable Chemical Industry: Sustainable Chemical Industry: a review of achievements and a review of achievements and prospects prospects

Transcript of Products and Processes for a Sustainable Chemical Industry

Page 1: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

J.JENCK, ENKI Innovation (France)M. DROESCHER, DEGUSSA, Düsseldorf (Germany)

F. AGTERBERG , DSM and Cefic, Brussels (Belgium)

ACHEMA Frankfurt, 18 May 2006

Communicated for educational purpose onlyCommunicated for educational purpose onlyCommunicated for educational purpose only(reference to author (reference to author (reference to author --- no commercial use)no commercial use)no commercial use)

Products and Processes for aProducts and Processes for aSustainable Chemical Industry: Sustainable Chemical Industry:

a review of achievements and a review of achievements and prospectsprospects

Page 2: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Chemistry is everywhere !

www.cefic.org

Page 3: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Chemistry is everywhere....

Page 4: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

www.chemistryandyou.org

Page 5: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

1 500 billion €/yr turnover10 millions employees

(Pr = 150 k€/employee !)

7% of world’s sales9% of international trade

The chemical industry is a heavy weight in the world’s industry:

Page 6: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

The industry doubts,but identifies innovation and

sustainable developmentas a chance.

Page 7: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

The chemical identifies innovation... but does it act ?

R&D intensity drop

Page 8: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

The industry identifies sustainable development…

…but does it learn from its past ??

Courtesy A.Stankiewicz

80 y

ears

Page 9: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

...but has a very serious image challenge(therefore of social and financial attractiveness)

Chemistry is everywhere....

Page 10: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Chemistry is everywhere....

...but has a very serious image challenge(therefore of social and financial attractiveness)

Page 11: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

De Re MetallicaG.Agricola, 1556

but did we progresssince 1556 ?

Courtesy A.Stanjiewicz

Chemistry is everywhere....

Page 12: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

achievements of the industry

?

Page 13: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Planning Group of CEFIC-SusTech in 2002-2003

A ‘white paper’ for preparation of the europeanChemical Technology Platform (now SusChem):

FACTS and FIGURES

• Philip BOYDELL (DU PONT) • John-Edward BUTLER-RANSOHOFF (BAYER)• Dirk CARREZ (Fedichem)• Ian DOBSON (BP)• Marcos GOMEZ (BASF)• Jacques JOOSTEN (DSM)• Hans-Jürgen KLOCKNER (VCI)• Bruno PIPERNO-BEER (POLIMERI)• Matt STEIJNS (DOW)

…But the presentation does not (necessarily) reflecttheir views nor the opinion of CEFIC

Thanks for their contributions !

Page 14: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Green Chem Journal 2004 (6) 544-556

A tutorial review with 158 references…

…but not a comprehensive database.

Products and Processes for aProducts and Processes for aSustainable Chemical Industry:Sustainable Chemical Industry:

a review of achievements and prospectsa review of achievements and prospects

Page 15: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Part 1: SD concepts, the 3 P, the 3 R, the 3E.Issues, role of Green Chemistry/Green Engineering

Part 2: Sustainable chemistry: achievements10 technical fields

Part 3: Sustainable chemistry: challenges10 key disciplines in development

Products and Processes for aProducts and Processes for aSustainable Chemical IndustrySustainable Chemical Industry

As a conclusion: a proposal within SusChem

Page 16: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

People

Planet Profit

Part 1: SD concepts, the 3 P, the 3 R, the 3E.Issues, role of Green Chemistry/Green Engineering

Page 17: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

The triple P of Sustainable Development:People, Planet and Profit

Profit : “economic area”shareholder value, capacity for development

Planet : the “environmental area”ecosystem preservation, renewable resourcespollution abatement and cleaning,

People : the “social area”societal acceptance, human and workers’ rights,poverty gap closing, governance, ethics…

Page 18: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Industrial drivers for sustainability

• profitability, fiscal changes• environmental conscience, legislation and regulations• concerns from shareholders, employees, customers• long term business related to public image

DJ World Sustainability Index : 300 companies from 22 countriesSTOXX Sustainability Index : 178 companies from 13 countries.

Industry : a major contributor to environmental degradation?In the European industry, from 1985 to 2000 :

CO2 decreased 11% and N2O 53%,

acidifying gases 67% (16% of the total)

ground-level ozone-precursors 25% (11% of the total)

high-altitude depleting-gases (CFCs, halons) >90%

Cost of environmental policies in the European Union : 32 billion €

in 1998: 0.4% of the GDP or 2.0% of the industry value-added

Page 19: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Most chemical companies makeenvironmental and societal pledges.

DuPont has set four goals for 2010 “as part of its sustainability mission”- derive 25% of revenues from non-depletable resources (14% in 2002)- reduce global carbon-equivalent greenhouse gas (GHG) emissions by 65%- hold energy use flat using 1990 as a base year- source 10% of the company's global energy use from renewable resources.

BASF, for year 2012 compared to 2002, aims to:- cut 10% of GHG emissions per ton of sales- cut 40% air pollutants, 30% heavy metal emission- have 80% fewer lost-time accidents, 70% fewer transportation accidentsBy 2008, the company will have “all relevant information” on chemicals handled >1t/yr

Page 20: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

World Business Council for Sustainable Development :Reduce, Reuse, Recycle = the 3 R of Eco-efficiency

“ Creating more value with less impact ”

1- reduction of the material intensity of goods and services

2- reduction of the energy intensity of goods and services

3- reduction of toxic dispersion

4- enhancement of material recyclability

5- maximization of the sustainable use of resources

6- extension of material durability

7- increase the service intensity of goods and services

Page 21: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

A general issue:from Green chemistry to Sustainable Engineering

1- mass & energy in- and outputs should be inherently non-hazardous2- prevention of waste is better than to treat or clean up3- minimize energy in separation / purification4- maximize mass, energy, volume and time efficiency in product/process5- output-pulled is preferred to input-pushed6- exergy is a criterion for choice between recycle, reuse or disposal7- durability must be targeted (no eternal life)8- avoid one-size-fits-all, minimize excess9- minimize materiel diversity in multicomponent products10- integration & interconnectivity are a way to industrial ecology11- design for performance in a commercial “after-life”12- favor mass & energy inputs from renewables rather than depleting

12 Principles of Green EngineeringAnastas P, Zimmerman JB, Environ.Sci.Tech, Mar03, 94-101

Page 22: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Part 2 Sustainable chemistry: achievements(industrial practices implemented)

2.1 Renewable resources2.2 Bioprocesses2.3 Energy efficiency 2.4 Reduction of waste2.5 Non-toxic intermediates2.6 Waste re-use2.7 Increased function-mass ratio2.8 Eco-friendly products

2.10 Distributed manufacturing2.9 Inherently safe processes

Page 23: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

• NatureWorks™

Bio-degradable polymer made from corn

Examples:

• Sorona®

Polymer based on dextrosefrom corn

2.1 Renewable ressources

200 gigatons of biomass per year (4% used by humans)

Two major areas of development:• bio-mass for energy uses, directly or after conversion• bio-mass as base source for chemicals, materials and products

Page 24: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Citric acidCitric acid

SorbitolSorbitol

EthersEthersEstersEstersEthanolEthanolAcrylamideAcrylamide

AntibioticsAntibioticsPigmentsPigments

Fatty acidsFatty acids

Lactic acidLactic acid

OilsOils

PolylacticPolylactic acidacid

BiopolymersBiopolymersResiduesResidues

Page 25: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.2 Bioprocesses (biotransformations and microbio processes)

Example: BASF vitamine B12

soybeanoil

soybeanoil Ashbya gossypii Vitamin B2Vitamin B2

glucoseglucose

Ashbya gossypiiWildtype

Ashbya gossypiiWildtype

Mutant M 2/14Mutant M 2/14

95%less waste

40%cost reduct°

O OH

OHOHOH

OH

OOH

OHOHOH

OH

OOH

OHOHOH

OH

O O

OHOH

OHO OH

OHOH

OH

NH

OH

OH

OH OH

NH

OHOH OH

N

OH

N

OHOH OH

OH

NNH

O

ONN

Page 26: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.3 Energy efficiency

Example: Polimeri Europa ethylbenzene and cumene: new zeolite-catalyzed processes> conventional alkylation technologies, based on aluminium chloride or phosphoric acid

Example: Eastman Chemicals reactive distillationa tower reactor integrating esterification and distillation of methyl acetate in one single vessel, with liquid-phase catalyst

Page 27: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.4 Reduction of waste

Ex1 - ‘Smarter’ production

Many industrial processes are scaled-up versions of lab experiments, in single-stage batch mode- fast and reliable ; pressure of time-to-market…- frequently far from technological, economic and ecologic optimum: waste/product up to 100 !

Switch to continuous processes :- easier to monitor and to control than the inherently dynamic batch - quality control of the product and process safety easier to achieve- flow as close to perfect plug flow as possible

Example: Air Products monolith loop reactor MLR

Page 28: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Ex2 - Liquid and process water waste

Chips fabrication plants (Agilent Technologies): up to 15 000 tons of wastewater in a typical day, and large amount of isopropyl or other alcohol is used as drying agent

Example: SC Fluids SCORR process:supercritical CO2 rather than wet chemical treatmentto remove photoresist masks and post-etching residues :

- semiconductor device in CO2 plus 1% propylene carbonate- pressure pulses dislodge the resist- final rinse… and CO2 is recycled.

Page 29: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Ex3 - Solid waste

Example: caprolactam (Nylon 6) classical old route- hydroxylamine sulfate, oleum, toxic and corrosive reactants - co-production of ammonium sulfate, of poor fertilizing properties, economic and environmental concerns

replaced at SUMITOMO Chem + EniChem by two catalytictechnologies:

1- cyclohexanone + NH3 + H2O2 over TS-1, a Ti-MFI type zeolite2- catalytic rearrangement of the intermediate oxime to final caprolactame

(also dramatically reducing gaseous emissions)

Example: production process for Ibuprofen- noncatalytic processes > 30 kg of waste per kg of active ingredient- catalytic way produces less than 1 kg.

Page 30: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

anthropogenic source warming potential

CO2 fossil fuel combustion (96%), waste combustion (<1%), processes (3%)

1 (ref)

CH4 waste (38%), agriculture (26%), gas distribution (35%), coal mining

21

N2O agriculture (74%), energy (17%), nitric and adipic acid production (7%) 310

HFC refrigerants, foam blowing, fire fighting 140 to 9800

PFC electronics, refrigerants, aluminium smelting 4800 to 9200

SF6 high-V switches, magnesium smelting, gas-filled shoes 23 900

Fatal co-product in HNO3 chemistry: 300 kg N2O are co-produced per ton adipic acid

Example: N20 abatement technologies by the major producers- catalytic decomposition of N2O to N2+O2 by DUPONT- incineration : N2O as an oxidant in a burner by BAYER- HT oxidation to NOx (recycled nitric acid) by RHODIA

Ex4 - Reduce GHG-emissions

Page 31: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

December 1997 Kyoto Protocol : reduce CO2 and 5 other greenhouse gases emissions by an average of 5.2% (2010 vs. 1990 levels).It is a very modest target : IPCC has estimated that emissions may have to be reduced by 60-70%.

Many companies have made their own voluntary commitments, often stricter than KP requirements.

Examples:

• Lafarge (world’s largest cement producer) : cut CO2 by 15%

• DuPont : reducing its GHG emissions by 60%

Page 32: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.5 Non-toxic intermediates

Example: hydrogen peroxide-based systems are ‘green’alternatives to chlorine (and water is sole final by-product)- for propylene oxide- for bleaching of paper, textiles, etc…

Wastewater treated by enzymes (catalase) to break down the H2O2 to H2O+O2

Dimethylcarbonate by methanol oxycarbonylation, with O2 as a direct oxidant, avoiding use of phosgene (Polimeri Europa)

DMC = eco-friendly substitute to toxic reactants, such as phosgene and chloroformates, methyl halides or dimethylsulphate

Page 33: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.6 Waste re-use

‘From waste to value’: new material from by-products of another industry

Ruetgers : dyes from cokes use in metallurgical industry (improved isolation process by static crystallisation eliminates the use of solvents and reduces energy use)

Example:Uniqema extraction of squalene fromolive oil waste instead of shark livers (for health and personal care, cosmetics).

Page 34: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.7 Increased function-mass ratio

Example: DOW Chemicals ‘renting’ its chemicals to customers in a closed-loop delivery system, Safe Tainer®

Two double-skinned containers, for delivery of solvents to customers (dry-cleaning) in a safe system and then collecting it for recycling. It is far more than just safe containers considerably reducing emissions, Safe Tainer® is a service provider selling minimum volumes and maximum customer support.

A safer way to deliver chlorinated solvents : excellent

cleaning efficiency

Page 35: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.8 Eco-friendly products

Example: lanthanides replacing toxic heavy metals as dyes: RHODIA Neolor, eco-safe yellow / red pigments based on cerium sulfide instead of toxic cadmium salts

Improved thermal insulation by IR-absorbing materials BASF

IR-absorbing / scattering material

IR radiationIR radiation

low-density polymer matrix

Styropor® Neopor®

Page 36: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.9 Inherently safe processes

Example: “Benign-by-design” processesuse only passive controls, with no human intervention needed.

Inherent safety = remove hazards in the first instance.

- intensification: reduction in the quantity of hazardous materials- substitution: use of safer materials- attenuation: run at safer operating conditions (room T P, liquid phase)- limitation of effects: change design and operation for less-severe effects- simplification: avoid multi-product or multi-unit operations- error tolerance: more robust equipments, upsets bearing processes, etc.

Page 37: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

2.10 Distributed manufacturing

- Reduce the inventories of dangerous reactive intermediatesand produce them at the closest point of their use

- Distributed manufacturing, ‘on-site on-demand’: continuous mode followed by immediate consumption

Example: Interox makes 1 ton per day of peroxysulfuric acid in a 20 cm3 tubular reactor with only 1 second residence time

- Kvaerner : Phosgene COCl2 modular, point-of-use, skid-mounted generator

- DuPont : a small facility delivering HCN just-in-time, 5 tons per year (useful for pharma, for gold metallurgy…)

- chlorine dioxide, ethylene oxide

Page 38: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Part 3 Sustainable chemistry: challengeskey disciplines in development

3.1 ‘White’ biotechnology3.2 Catalysis

3.3 Process Intensification

3.4 Microtechnologies and structured devices

3.5 Integrated Multiscale Design

3.6 Neoteric solvents (‘environmentally benign solvents’)

3.7 New activations

3.8 Product engineeringemerging product-oriented technologies

3.9 New metrics : Thermo-economics

3.10 Perspective: Industrial Ecology

Page 39: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.1 ‘White’ biotechnology, or industrial biotechnology

- and a considerable potential for production of high added-valueproducts (pharmaceutical products and agrochemicals)

Bio-mass for production of materials: 3 domains

- direct use of specific materials from plants and trees, for construction materials, paper, textiles, etc.

- specific products based on specific constituentsof crops (oil, fibers etc.) by chemicalconversion e.g. for specialty chemicals,biodegradable polymers, etc.

- generic conversion of the biomass to basicconstituents: ’building blocks’ such asCO, H2, CH4, ethanol, acetone, etc.through fermentation

Page 40: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Vegetals for chemistry !the concept of biorefinery

3 types of biorefineries :dry residues - cereals - wet feedstock

Page 41: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

– Biological processes for vitamin production

– Bio-based polymers

– Enzymes for the textile industry

www1.oecd.org/publications/e-book/9301061e.pdf

Page 42: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.2 Catalytic processes

~75% of current chemical processes use catalysts:environmental protection (35%), chemicals (23%),oil processing in refineries (22%), polymers (20%)

Catalysis = higher yields, less waste and less energy

Challenges:- engineering of existing catalytic systems- coupling of a catalytic reaction with another reaction or a separation

- new catalysts for customized polymers, stereospecificity, self-repairing abilities, retroconversion of macromolecules to starting materials- activation of C1-feedstock: natural gas follower of oil as primary resource

Page 43: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

“ Doing more with less ”Process Intensification is a strategy to adapt

the process to the chemical reaction

and not anymore the physico-chemical transformation to existing, known, depreciated

but often inadapted equipment

adapting the size of equipment to the reaction replacing large, expensive, inefficient

equipment by smaller, more efficient and less costly

choosing the technology best suiting each stepsometimes combining multiple operations in

fewer apparatuses.

DSM UreaPlus

3.3 Process Intensification

Page 44: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

R.Bakker in « Reengineering the Chemical Processing Plant »,

Marcel Dekker ed. 2003Process Intensification strategy

Principle 1: multifonctionality (design methodology) unit operations have to be ‘compatibilized’

Principle 2: energeticscreate force fields at a mesoscopic level

Principle 3: thermodynamicsincrease potential of reactants, by activity or diffusivity

Principle 4: miniaturization to increase force fields

R.Jachuck + J.Jenck, PD Symposium, Palm Springs, 12 June 06

Page 45: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

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JacketedStirred Tank

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Pulsed Column

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Rotating Packed Bed

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Static Mixer/Plate Exchanger

PlateExchanger

Spinning DiscReactor

STT ?

Page 46: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Examples of intensifiedequipment

Page 47: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.4 Microtechnologies and structured devices

Smaller is better for mass & energy transfer :

- decrease of linear dimensions:higher gradients of physical properties

- higher driving forces for heat transferor mass transport

- increase of surface to volume ratio:increase of the effective exchangesurface (microreactors showsurface-to-volume ratios of up to200 000 m2/m3)

- decrease of volume: smaller material hold-up, improved safety

Page 48: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

UCC, Bhopal 3 Dec 1984:

cloud of 41 tons MIC

An inventory of 10 kgis sufficient

(D.Hendershot, CEP 2000)

Smaller is safer !

1 ppm COCl2

Page 49: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Safety first !

Accidents are due to large inventories !

Page 50: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

ref: Merck

Batch 5m3

-20°C 5hYield 72%

5 MINI-reactors0°C < 1 mn

continuousYield >92%

Continuous mode in a smaller equipment performs better !

Page 51: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Smaller is more flexible

Courtesy A.Green BHRG

Page 52: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Micro mixers Mixing from few ml/h

up to 30 l/h

IMM:

Interdigital micromixer

Heatric:

Cross Flow HeatExchanger

Mikroglas:

Microreactor

Micro heat exchangersMaximum value of 700 W/m2K at an air flow rate of 75 l/min

Micro reactorscombinaison of µHE and µmixers

Microstructured components are available

Page 53: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.5 Integrated Multiscale Design

Advantages of microstructures :- very homogenous temperature and concentration fields

- strongly exothermic reactions kept under control- explosive or even detonating mixtures (inherent safety)

Multiscale Process Unitslarge-scale systems constructed

from micro- / meso- technologies

cf. the IMPULSE Project(designed by T.Bayer, J.Jenck, M.Matlosz in 2002)

Industrial examples:

Page 54: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Microstructured epoxidation reactor

Page 55: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

A fine chemicals plant in a ‘shoe-box’

www.fzk.de 6 July 06, 2005

• Chemical production with FZK microstructured reactor atDSM Fine Chemicals GmbH in Linz, Austria.

• Within 10 weeks more than 300 tons of high-value product.

• Product yield increased compared to conventional processing

• Less raw material use and less waste generation, more process safety

• Micro-reactor dimensions: 65 cm 290 kg heavy; 1700 kg/h liquid throughput; several 100 kW power

Other annoucements:Clariant (2005): 1000 t/a pigment plant.Degussa (2006): several production plants.Batch cryo to continuous process.

FZK

Page 56: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Radical polymerization

10 t/a 3.5m × 0.9m

Plant running at industrial site of Idemitsu Kosan

Dr. Takeshi Iwasaki (MCPT)Proceedings IMRET 8, Atlanta, April 2005.

heating shell

cooling shell )inlet

outletID = 500µm L=60 cm 94 pieces

Page 57: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Nitroglycerin microstructured pilot-plant (Xi‘an, China)investment ~5 M €

• Nitroglycerin production on a pilot plant level (15 kg NG; >100 l/h solution)• Manufactured nitroglycerin used as medicine for acute cardiac infarction• Product quality on highest grade• Plant to operate safely and fully automated• Environment protection by advanced waste water treatment & closed cycle

C&EN cover story

May 30, 2005

Chemie Ingenieur Technik, May 2005

Volume 77 (5)

OHOH OH

OO O

O2N

O2N

NO2HNO3 / H2SO4

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JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

40% of the emission of VOC (~15% of global anthropogenic GHG), originate in organic solvents massively used in the chemical and related industries. Some are also highly flammable or toxic.Tremendous efforts to replace hazardous solvents by alternative media, such as oxygenates, super-critical solvents, ionic liquids, … not forgetting solventless processes

Example SC media: DuPont 275 M$ for a tetrafluoroethylene

SC polymerization production unit. Fluorinated vinyl polymers are non-explosive when mixed

with CO2 and can be continuously polymerized in SC

medium.

Thomas Swan C° world’s first multi-reaction super-critical flow reactor, a commercial-scale continuous facility for running reactions in SC CO2

3.6 Neoteric solvents(environmentally benign solvents)

Page 59: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Ionic liquids (IL)

Organic salts with low melting point (usually <100°C) :- vapor pressure is extremely low, no solvent lost- large range of temperature (200 to 300 Kelvins)-‘melt catalysts’ at the industrial pilot scale

liquid-supported organometallic catalysis

DEOPP is an intermediate for

the photoinitiator Lucirin® TPO

new solvent-free process

increased yield and space-time

PCl

Cl N

N+ 2 EtOH + 2

POEt

OEt

N

NH+

Cl -

DEOPP

BASIL: Biphasic Acid Scavenging utilizing Ionic Liquids

New ? a very fashion-driven

rediscovery of early work in the

1970s on ‘molten organic salts’

Example: BASF

Page 60: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.7 New activations

Energy sources such as UV light, microwaves, ultrasounds used in a controlled way to heavily increase the efficiency of a chemical reaction, thus making it more eco-friendly.

Little is known on commercial applications / design rules.

Page 61: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.8 Product engineeringemerging product-oriented technologies

Intense competition (and secrecy)

General expectations :bioplastics, self-healing polymers, polymer conductors, mass-production of fullerenes, organic ferro-magnetic materials, functional polymers, hybrid materials, etc.

Innovations expected for emerging markets: energy systems, ultra-thin coatings, µ electro- and mechanical systems, construction(low weight, high strength), …

Polymers continuously broadening, in electronic components, where polymeric printed circuits could replace silicon, with a definite advantage of easier recycling.

Page 62: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Product Engineering by Process Intensification

Page 63: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

Mono-disperse silica generated by a segmented flow microreactor

Page 64: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.9 New metrics : Thermo-economics

“In a world rapidly running out of fossil fuel, the second law of thermodynamics may well turn out to be

the central scientific truth of the 21st century”

Exergy, based on entropy, is a suitable concept in the development of a sustainable industry as it clarifies resource depletion, waste emissions, losses in processes.Exergy measures the physical value of inputs and outputs, thus relating to economic value. Non-sustainability could be penalized by its amount of exergy. Due to its flexibility across the breadth of industrial application and its potential as a tool for quantitative assessment, the concept of exergy quantifier is now investigated.

Page 65: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

3.10 A longer term perspective: Industrial Ecology

Traditional Industry = strictly linear production :extracting raw materials and fossil energy, processing the material and energy, dumping the waste back into natural systems

Industrial Ecology :incorporate cyclical patterns of ecosystems into designs for industrial production processes.

Eco-Parks (multi-industry networks) Industrial symbiosis - diversity, for an ecology based on waste to resource

- proximity (transportation cost can quickly offset other advantages)

- cooperation and mutual confidence

Page 66: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

A technological platform for EU R&D on sustainable chemistry, with 3 key sectors :

Materials technology : new materials with better performance including processing and recyclability

Reaction and process design : faster, cheaper and cleaner production processes for existing chemicals.

Industrial biotechnology : biological raw materials (glucose, vegetable oils, enzymes) to develop products such as pharmaceuticals, bio-colorants, solvents, bio-degradable plastics, vitamins, food additives, bio-pesticides and biofuels

A horizontal group: strategic approaches other than just cost reduction and environmental performance:

- economic or financial barriers- regulation- societal acceptance of chemicals

www.susc

hem.org

www.susc

hem.org

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JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

A technological platform for EU R&D on sustainable chemistry

Horizontal group: strategic approaches other than just cost reduction and environmental performance

- economic or financial barriers- regulation- societal acceptance of chemicals

Proposal:

Build a SusChem database:real world examples ofsustainable chemistry

Page 68: Products and Processes for a Sustainable Chemical Industry

JENCK, DROESCHER, AGTERBERG ACHEMA Frankfurt (D) , paper n° 1029 18 May 2006

Jean F JENCK ([email protected], +33 672 950 750) ENKI Innovation (www.enki2.com)

SusChem database: real world examples of sustainable chemistryObjective: collect, organize, communicate FACTS and FIGURES “Sustainable” chemistry is not a buzz-word, “green” chemistry is not a research item, SusChem is not a window-dressing action : it is all about real cases on Eco-friendly PRODUCTS and eco-efficient PROCESSES

- already existing as industrial achievements - in progress [New Technologies, industrial development]- in prospect for a better future [Research & Development] [vertical technology pillars]

Building a large and strong database will increase the credit / advocacy of our industry : we can communicate, with a pro-active and not defensive mode, on non-disputable facts and figures.Methodology:• input of information : collect, carry out direct interviews, web search, verify and homogenize current and new information, organize it in a globally endorsed format• cooperate with similar actions in USA (ACC, Vision 2020, GC Institute) and Japan (JCIA, JCII)

Deliverables:• an electronic database (MS Access or Excel format)

a. easy to integrate into a website such as www.suschem.orgb. able to be updated on a regular basisc. accessible to multiple stake-holders

• a paper version (SusChem position paper ; publication in journals, reviews ; etc.)• a SusChem Science & Technology meeting/symposium (with journalists)

Notes:1. beyond pro-active communication (politicians, decision-makers, opinion leaders, NGOs, journalists, etc.), a Facts and Figures database is a strong element for training, life-long learning and education (grad level), as a source for training modules, position papers, technical dossiers ['at all levels' : executives, R&D personal, young scientists, post-docs, SD directors]2. building such a database is a rather sizeable but doable task