Sanjiv Bachal & Alok Pandit Equinox Software & Services Private Limited Dec 2013
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Transcript of Sanjiv Bachal & Alok Pandit Equinox Software & Services Private Limited Dec 2013
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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)
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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
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EQUINOX
Improving process and plants performance globallyThrough
IT-catalyzed Chemical Engineering
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“…Gain better “process”
understanding to
“process” better
Gains…”
Our Mantra
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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
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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…
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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
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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
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Process Design - Engineering Practices
Methodologies followed in Industries for design of solvent recovery system:
Experience/Operation wisdom Consultants Commercial Simulators etc
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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
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Design of Solvent Recovery Systems
The Green/Environment Aspect:
The Environment Impact Assessment (EIA) of the Design Alternatives
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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
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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)
EIA - Waste Reduction Algorithm
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EIA - Waste Reduction Algorithm
Energy Generation Process
Recovery Process
PEIin PEIin
MASS MASS
MASSMASS
Energy
PEIoutPEIout
WasteEnergy
WasteEnergy
PEI Analysis Envelope
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EIA - Waste Reduction Algorithm
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
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New Design - Option 1
Reuse
Reuse
Waste
Waste
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Reuse
Reuse
Waste
Waste
New Design - Option 2
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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
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PEI Analysis Using WAR
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
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PEI Analysis Using WAR
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
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PEI Analysis Using WAR
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
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PEI Analysis Using WAR
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
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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
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Contact Information
Contact: Dr. Sanjiv BachalPhone: +91-20-41020122Email: [email protected] Website: www.equinoxweb.co.in
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