PowerPoint Presentation · Title: PowerPoint Presentation Author: SATISH KHANNA Created Date:...
Transcript of PowerPoint Presentation · Title: PowerPoint Presentation Author: SATISH KHANNA Created Date:...
LAZORRizationfor
3D Management in
Chemical Manufacturing
6th December 2013, Mumbai
3DJapanese Immigration system
•Dirty
•Dangerous
•Demanding
LAZORRization…
3D in Chemical Industry• Dirty: Long route, Side reactions, conventional synthesis
– High Hydraulic And Organic Liquid Waste– Multiple And Mixed Solvents– Un-incinerable Waste – Nox, Sox, Volatiles, – Undesirable Isomers– Bye Products
• Dangerous: Toxic, explosive, safety issues– Explosive– Corrosive– Volatile Compounds– Run Away/Exothermic Reactions– Low TLV Gases, Toxic
• Demanding: Capex, Opex, Labile– Multiple Steps– Solid-liquid Separations– Solid Handling– Protecting/De-protecting– Manpower Intensive
Product A Dirty Dangerous Demanding
Organic Load, Kg/Kg 8
Hydraulic Load, Kg/Kg 6
Undesirable isomers 0
Incinerable waste, Kg/Kg 3
Landfillable Waste, Kg/Kg 2
NOx, SOx, Volatiles 2
Explosives 8
Corrosives 6
Run-Away reactions 0
Toxic chemicals 7
Multiple steps, Number 8
Solid-Liquid separations, Number 7
Capex oriented, Capex/Sales 9
High Opex Orientation, % of sales 6
Manpower intensive, Number/MT 5
TOTAL 21 21 35 77Worst 150; Best 0010: Worst; 00: Best
3D and Economic Sensitivity
0
1
2
3
4
5
6
7
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9
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0 2 4 6 8 10
Y-High on 3DX- High on Economic Contribution
Bring in Green Chemistry
Enjoy this zone
3D
Rs
Consider fixing or dropping
Cost of staying conventional
• Business affordability: Capex and Opex will make your business inefficient, more so, in me-too range
• Creative Energy: Efforts wasted in managing 3D
• Some one is coming: Will lose to smarter manufacturers
• Stricter Controls: Enforcement will be stricter than ever
• Be Responsible: Enjoy longer and better life
Gods way of handling extremely
complex Chemistry in 7 Bi reactors
1. Lots of electronics, lots of chemistry and lots of mechanics2. Lots of bioconversions3. No organic solvents, Water the key solvent4. All reactions at almost ambient temperatures and pressures5. No corrosives, no run-away or exo/endo-thermic reactions6. No protections and de-protections7. No manual intervention, all automated8. Recycling and closed loops galore9. Capex and Opex friendly10. Effortless, reproducible, credible, world-over 7 Billion
reactorsEXTREMELY LOW ON 3D
Obligation of Being Green….?
• Legal
• Economic
• Moral
• All of above
Have seen so many…..
• FDA Warnings
• Plant Closures
• Professionals going in
• Cricketers, Journalists, Bureaucrats, Industrialists going in
• Politicians too going in
We need to adopt real definition of
Managing
The Arnold-Brustad-Coelho (ABC) Catalyst
9 P. S. Coelho et al., US Provisional Patent Application (2012)
Provivi’s Technology – A Living Chemical Factory
ABC catalyst
Conventional Provivi
Final product: 5 steps from EDA
Final product: 1 step from EDA
Biocatalysis enables process intensification thus reducing reactors, solvents and reagent costs
Low on Capex-Low on Opex
Managing 3D through….
• Bio Transformations
• Green Solvents
• Green Catalysts
• Green Engineering
• Green Processes
• Zero discharge technologies
• Green ……….
• Green ……….
Intensity of 3D to be managed….
• By 2017, World API market, 163 Billion US $• By 2017, Herbicide and Insecticide to be 2 Mi MT• Fungicides, Entire Rest of the Chemical Industry?
Imagine the 3D Load in future
LAZORRization for 3D Management
• To Create Industry Clusters: 5-6 Members
• To identify few common contributors to 3D
• Create teams that concentrate on specific areas
• To undertake 3D scan for each product
• Know, Help, Achieve , Seek, Share: KHAASS
• Involve global experts in these clusters
If they can, why cannot we?
Live-in real 3D world