chemistry, chemical industry & society: transformations conference/day 1... · chemistry,...
TRANSCRIPT
RAVI RAGHAVAN
Editor, Chemical Weekly
Chemistry, Chemical Industry & Society: Transformations
Contents
Relevance of chemistry
The risks from chemicals & society’s response
The quest for Sustainable Development Green Chemistry
New raw materials
Energy conservation
Indian chemical industry
Conclusions
Where do you find chemicals?
The short answer is everywhere
Homes: Teflon in the kitchen; soaps & detergents in the bathroom
In our bodies: DNA, RNA, proteins, enzymes, amino acids
Beneath our feet: the ores & minerals in the earth
Above our heads: gases (e.g. ozone) in atmosphere
In the natural environment: Smell & colour of flowers; the constitution of biomass
4
Chemistry transforms the natural raw materials of the earth, sea and air into products that we use every day
Source: “Strategy for delivering Chemistry-fuelled growth of UK economy” by Chemistry Growth Strategy Group (Oct 2013)
RAWMATERIALS
PRIMARYBUILDINGBLOCKS
PRIMARYCHEMICALBLOCKS
FORMULATEDCHEMICALPRODUCTS
CUSTOMERINDUSTRIES
AIRANIMAL FATS, VEG
OILS, BIOMASS, PLANTSUGAR, STARCH
HYDROCARBONS:GAS, OIL FRACTIONS
ORESMINERALS
GASESPRIMARY
OLEOCHEMICALSBIOCHEMICALS
ORGANICSINORGANICS
PIGMENTS SURFACTANTSRESINS
PLASTICSSYNTHETIC RUBBER
FERTILISERS
SOAPSDETERGENTS
PERSONAL CARE
COSMETICS
PHARMAPAIN
TINKS
FOOD PROCESSIN
G
CHEMICALS
GENERALINDUSTRIA
L
ELECTRONIC
MEDICAL
AGRICULTURAL
FINE ORGANICS
FOODINGREDIE
NTSFRAGRANC
ESFLAVOURS
AGRICULTURAL
CHEMICALS
DYES
SPECIAL INDUSTRIALCHEMICALS,
PROCESSADDITIVES
FIBRES,ADDITIVE
SSEALANTS
CONSTRUCTION
MEDIA
TRANSPORTEQUIPMENT
INDUSTRIAL
FOOD PROCESSIN
G
CONSUMER PRODUCTS
AGRICULTURAL
TEXTILE
HEALTH
WATER
CHEMICALS
GENERALINDUSTRIAL
CONSTRUCTION
TRANSPORT
TEXTILE
GENERALINDUSTRIAL
CONSTRUCTION
HOUSEHOLD
PACKAGING
TRANSPORT& CONSTR-
UCTIONCOMPONEN
TS
CONSUMERELECTRONI
CS
PLASTIC & RUBBER
PRODUCTS
Vital role of chemicals
0% 20% 40% 60% 80% 100%
Paints
Medicines
Cleaning compounds
Cosmetics & toiletries
Tyres
Batteries
Consumer electronics
Chemicals as % of material inputs in manufacture of ….
Source: Kline & Co
Contents
Relevance of chemistry & role of chemists
The risks from chemicals & society’s response
The quest for Sustainable Development Green Chemistry
New raw materials
Energy conservation
Structure of global chemical industry
Indian chemical industry Opportunities for speciality & fine chemicals
Conclusions
What are the Risks from Chemicals?
Risks from chemicals have two components Intrinsic properties (hazards)
In principle: universal, independent of location
Exposure (determined by dose, duration and frequency)
Can be dependent on location/situation/context
Chemical safety: Managing risks vs hazards Principally amongst developed countries
But India is also getting into the act
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Risks vs hazards: Key points
Chemicals cannot be simply divided into hazardous & non-hazardous All substances are hazardous
to some degree
Removal on basis of hazard alone does not guarantee safety
Avoidance of a hazardous material does not promote sustainability per se Efficient use of energy, water
& other resources could be as or more important than marginal reductions in toxicity
Risk cannot be eliminated, but can and must be assessed & managed (even imperfectly) Safe management may involve
strict controls on use ….
…. But bans could have consequences of eliminating beneficial use [e.g. DDT]
Substances have a profile of hazards, rather than just one Focusing on single hazard may
result in substitutions that produce higher risk [e.g. CFCs vis-à-vis HFCs]
Decisions on management & use of substances need to be holistic
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How have governments responded to these risks: e.g., REACH – European chemicals regulation
Largest, most complex & most comprehensive regulatory effort Applies to EU industry & all who chose to do business with it Policy reflects the Precautionary Principle
Objectives Improve & protect human health and environment Enhance competitiveness & innovation in EU chemical industry
Reverses burden of proof for chemical safety & costs onto industry Industry fears extensive testing for toxicological & eco-toxicological profiling Difficulty of sharing of data (& costs) amongst participants
Possible outcomes Permission to manufacture, import and use chemical Partial ban (in one or more uses) or Total ban (for all applications)
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No data, no market!
Contents
Relevance of chemistry & role of chemists
The risks from chemicals & society’s response
The quest for Sustainable Development Green Chemistry
New raw materials
Structure of global chemical industry
Indian chemical industry Opportunities for speciality & fine chemicals
Conclusions
What is Sustainable Development?
Development that meets the needs of present without compromising the ability of future generations to meet their
own needs.
It is the pattern of resource use that aims to meet human needs while preserving the environment so that these
needs can be met not only in the present but also for generations to come.
Why is Sustainability Important?
Increasing demand for all sorts of products
Rising economic prosperity especially in the populous BRICS
Limited resources (oil/ gas/ coal/ water)
Environment/Pollution Awareness
Climate Change, Greenhouse gases, Carbon footprint
How can we make the chemical industry more sustainable?
New Technologies
Green Chemistry, Green Engineering
New Raw materials
Biomass instead of petroleum
Reducing Water footprint
Recycle, reduce
Reduce Energy footprint
Energy conservation; Use of renewables
E-factor (Roger Sheldon): Waste generated (kg) per kg of desired product
The Environmental Impact of the Chemical Industry
IndustryProduction,
TPA
E-factor
Kg/kg product
Role of catalysis
Operation and steps
Petroleum
Refinery106-108 ~0.1 Max Continuous
Bulk Organic 104- 106 < 1 to ~5 AverageConti., few steps
2-4
Intermediate &
Fine102 – 104 5-25 Less >4
Pharmaceuticals 10 – 103 25 To >100 Lesser Batch, several stages >5-10
Green Chemistry: Guiding Principles15
• Prevent waste than clean it laterPrevention
• Maximize materials (atoms) used in the process into the final product
Atom Economy
• Use substances that possess little or no toxicityLess Hazardous Chemical
Syntheses
• To effect their function with minimum toxicityDesign Safer Chemicals
• Make auxiliaries (solvents) unnecessary, or innocuous
Use safer Solvents & Auxiliaries
• Conduct synthetic methods at ambient temp. & pressure
Design for Energy Efficiency
• Rather than depleting, where technically/economically practical
Use Renewable Feedstock
• Protection & deprotection be minimized or avoidedReduce Derivatives
• Catalytic reagents are superior to stoichiometric onesCatalysis
• At end of use, products break down into innocuous ones
Design for Degradation
Why Green Chemistry?
• More precise conversions• Reduces costs• Drives competitive advantage
Economic impacts
• Less energy• Less water• Less waste disposal
Environmental impacts
• Ensures sustainable right-to-operate• Avoids fines• Enhances reputation
Social impacts
Why is glycerol now important?
Usage for commodity chemicals
By-product of biodiesel
1-kg of glycerol/10-kg of biodiesel
Biodiesel output: ~6-mt
Serves low volume markets that cannot handle the expected glut Pharmaceutical, cosmetics,
tobacco etc.
New raw materials: Glycerol
Propylene glycol Used for polyesters etc.
Annual demand: ~2-mt
Epichlorohydrin Use for epoxy resins
Global market: ~1.2-mt
Commercial plants being built
New raw materials: Glycerol
Where do we get it from? What can we do with it?
1st gen: Fermentation of sugars [e.g. molasses] Technology well established Limited volumes Questionable sustainability [Food vs
fuel debate]
2nd gen: From cellulosic biomass [e.g. agri waste] Science well known, technology still
has gaps Intense R&D: cell biology, enzymatic
processes, engineering, etc. Large volume production possible Sustainable – if done rightly
Ethanol is already being used as automotive fuel Brazil: Sugarcane derived India: Molasses based alcohol [5%
mandatory; 10% planned] US: Corn derived alcohol
India has a well developed chemicals industry using ethanol Acetic acid, MEG, vinyl acetate – now
Scale of chemical manufacture can be significantly ramped up with larger volumes of ethanol Brazil: World scale PE plant
New raw materials: Ethanol
Energy & ammonia: The connection
Process improvements
Fertilizers consume 1.2% of world’s energy
Ammonia accounts for 87% of industry’s energy For fuel & feedstock
Natural gas - preferred primary feedstock Cleaner, more efficient
Coal-based unit produces ~2.4 times more CO2 than natural gas-based unit. Coal making a strong comeback in
China
Reducing the energy footprint: Ammonia
Energy consumption per ton 30% less than four decades ago
Best performers approaching the thermodynamic limit of energy use!
Importance of chemical industry for India
With India having 16% of global population, significant headroom for
growth exists for chemicals market in India
Though direct contribution of chemical industry is ~7% to India’s GDP but
indirectly it’s overall contribution is ~60% of India’s GDP
19 Acts
Environment & Forests
Petroleum & Natural Gas
Shipping, Road
Transport, Highways
LabourHealth & Family Welfare
Agriculture
Commerce & Industry
22
Indian Chemical Industry: Government Monitoring
19 Acts & 16 Rules from diverse Ministries now govern chemical industry
Legislations
Hazardous wastes
Pollution control
Adulteration
Manufacture, storage & handling
Imports
Disaster Management
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Indian Chemical Industry: Legislative emphasis
Emphasis is on licences, consent, penalties, inspection and prohibition.
What India must do to prepare for a world with greater regulation?
Priority 1: Prepare Indian chemical inventory – None exists! Listing of industrial chemicals manufactured in country or imported
Minimum content: CAS No; Name; Amount produced / imported; Uses
Improve co-ordination at GOI level amongst ministries
Ministry of Chemicals & Fertilisers (MoCF) best placed to understand full ramifications
Greater co-ordination between key industry associations & MoEF
Regulators need to discriminate between the good, bad and ugly!
Create laboratory infrastructure Toxicological / eco-toxicological data generation – a business opportunity
OECD GLP accreditation opens new opportunities for serving new markets
Augment human resources Experts in product safety and regulatory affairs needed
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The past (and even today?) The future
The transformation of the chemical industry: Key role of chemistry
