Sustainable Industrial Processes Research Articles

An efficient basic catalyst based on a new germanium coordination complex

Abstract The replacement of liquid bases by solid base catalysts is a crucial requirement for sustainable industrial processes. The use of heterogeneous catalysts can improve the overall atom catalytic efficiency of reactions and facilitate the organic separation process. Here, we report the synthesis and characterization of a germanium coordination complex Ge(C3H6ONH2)2(OH)2 (1). Complex 1 is obtained by hydrothermal synthesis and is crystallized in the monoclinic system, space group P21/c with a = 10.250 (2) A, b = 9.810 (2) A, c = 10.360 (2) A, and β = 100.70 (3)°. Single crystal data indicate that the Ge4 + ion has octahedral coordination geometry surrounded by two 2-hydroxypropylammine molecules. Knoevenagel condensation of benzaldehyde and ethyl cyanoacetate is carried out with compound 1 as solid catalytic support in ethanol at 333 K. Experimental results indicate that it is an efficient base catalyst. The reaction gives a 98% yield for the condensation product.

Implementation of sustainability drivers in the design of industrial chemical processes

AbstractA methodology based on key performance indicators was developed and applied to the design of sustainable industrial processes. The methodology provides a procedure for the definition of a dynamic set of quantitative key performance indicators suitable to capture the environmental, economic and societal impacts of process options, thus, tracing the sustainability footprint of alternatives. The preliminary design of a production plant for cyclohexanone is presented as the leading case in the discussion. The influence of design choices on environmental impact profiles, economic efficiency and inherent safety performance was pointed out. The application evidenced that the definition of appropriate indicators may have an important added value in supporting design activities, both for the correct assessment of alternative options and for the proactive identification of design improvements. © 2011 American Institute of Chemical Engineers AIChE J, 2011

Examples of heterogeneous catalytic processes for fine chemistry

Fine chemicals are highly pure substances that are commercially produced by chemical reactions for highly specialized applications. In most cases, however, these reactions involve stoichiometric and highly polluting steps. A possible solution is the development of processes using enzymatic, homogeneous or heterogeneous catalysts. In this review, selected examples of clean heterogeneously-catalyzed reactions applied to the synthesis of fine chemicals are reported for the purpose of highlighting the growing need for more sustainable industrial processes, i.e., processes that produce minimal waste and avoid as much as possible the use of toxic and/or hazardous reagents and solvents. A thorough knowledge of catalyst properties, reaction conditions and interactions with the reacting substrate are essential for optimizing the synthesis, thus making it possible to move on from laboratory to industrial production.

Embedded Phases: A Way to Active and Stable Catalysts

Industrial catalysts are typically made of nanosized metal particles, carried by a solid support. The extremely small size of the particles maximizes the surface area exposed to the reactant, leading to higher reactivity. Moreover, the higher the number of metal atoms in contact with the support, the better the catalyst performance. In addition, peculiar properties have been observed for some metal/metal oxide particles of critical sizes. However, thermal stability of these nanostructures is limited by their size; smaller the particle size, the lower the thermal stability. The ability to fabricate and control the structure of nanoparticles allows to influence the resulting properties and, ultimately, to design stable catalysts with the desired characteristics. Tuning particle sizes provides the possibility to modulate the catalytic activity. Unique and unexpected properties have been observed by confining/embedding metal nanoparticles in inorganic channels or cavities, which indeed offers new opportunities for the design of advanced catalytic systems. Innovation in catalyst design is a powerful tool in realizing the goals of more green, efficient and sustainable industrial processes. The present Review focuses on the catalytic performance of noble metal- and non precious metal-based embedded catalysts with respect to traditional impregnated systems. Emphasis is dedicated to the improved thermal stability of these nanostructures compared to conventional systems.

Water content of a Brazilian refinery oil sludge and its influence on pyrolysis enthalpy by thermal analysis

Residual oil sludges represent an environmental problem in the oil industry and need a proper destination in order to allow sustainable industrial processes when exploring natural resources. In the present paper, the influence of the water content on the oil sludge pyrolysis process was studied by thermal analysis. A method using thermogravimetry on calcined mass basis was developed to estimate the water content of oil sludges. The water present in the sludge vaporizes during the first thermal processing stage, interfering in the initial process of the organic components pyrolysis and increasing the total oil sludge pyrolysis enthalpy. By quantitative differential thermal analysis (DTA) it can be seen that the water content of the sludge may significantly affect the thermal balance of its industrial pyrolysis process.

Computer aided design for sustainable industrial processes: Specific tools and applications

AbstractChemical Process Sustainability can be estimated using different sustainability indicators. The quantitative estimation of those indicators is necessary (i) for evaluating the environmental impact of a chemical process and (ii) for choosing the best design among different available alternatives. To accomplish these goals, the computerized calculation of sustainability indicators requires the use of at least three computer tools: (i) process simulation, (ii) molecular modeling and a (iii) sustainability indicators software code. In this work, a complete software platform, Process Sustainability Prediction Framework, integrated with process simulation programs, which support the CAPE‐OPEN interfaces, is presented and discussed. The article contains also description and application of molecular modeling techniques to estimate different toxicological data, which are used in the calculation of sustainability indicators. A representative example of one chemical process and thermo‐physical properties used in the toxicological data calculation, are reported to demonstrate the applicability of the software to real cases. © 2009 American Institute of Chemical Engineers AIChE J, 2009

The use of plate heat exchangers to improve energy efficiency in phosphoric acid production

This paper originated as a part of a comprehensive research project designed to develop ecologically sustainable, environmentally friendly, resource- and energy-saving industrial process technology for the production of a wide class of phosphorus containing substances. The essential feature of the research was designed for the replacement of tubular heat exchangers with Plate heat exchangers (PHEs) and for the installation of these units in new locations in the processes to optimally improve energy efficiency and to prevent pollution. Despite the severe operating conditions in the production of phosphoric acid PHEs of various designs find the application in these processes. For such a corrosive environment as a phosphoric acid production plant, the Hastelloy G30 alloy is used as the material for the plates and synthetic rubber EPDM is used as the material for inter-plate gaskets. The analysis of the data shows, that using mixed groupings of plates in the unit allows one to obtain optimal solutions. The simulation of barometric mixing condenser recycled water cooling with plate heat exchanger shows the possibility of an application which minimizes the waste water pollution by closing the condenser cooling water circuit. Software was developed for calculations of units working both with liquid and phase changing streams.

Natech risk and management: an assessment of the state of the art

The present state-of-the-art for natech risk and management is discussed. Examples of recent natechs include catastrophic oil spills associated with Hurricane Katrina and hazardous chemical releases in Europe during the heavy floods of 2002. Natechs create difficult challenges for emergency responders due to the geographical extent of the natural disaster, the likelihood of simultaneous releases, emergency personnel being preoccupied with response to the natural disaster, mitigation measures failing due to the effects of the natural disaster, and others. Recovery from natechs may be much more difficult than for “normal” chemical accidents, as the economic and social conditions of the industrial facility and the surrounding community may have been drastically altered by the natural disaster. Potential safeguards against natechs include adoption of stricter design criteria, chemical process safeguards, community land use planning, disaster mitigation and response planning, and sustainable industrial processes, but these safeguards are only sporadically applied. Ultimately, the public must engage in a comprehensive discussion of acceptable risks for natechs.

Application of Biotechnology to Industrial Sustainability

The increasing focus on sustainable industrial processes for the chemical industry has resulted recently in a number of new bio-based initiatives. Environmental pressures and a shift towards the use of agricultural-based raw materials, as well as rapid developments in the science supporting biotechnology, have stimulated this interest. The recent sequencing of the human genome and the associated sequencing of industrial bacterial and yeast genomes have also played their part. In addition, the fields of metabolic engineering, bioinformatics and computer-based modelling and process optimization are opening up opportunities for new products and cost reductions. In the present review, a number of these new industrial bio-based processes are identified. A case study on fuel ethanol, using agricultural residues and based on a genetically-engineered micro-organism (rec Zymomonas mobilis), is presented as such a process provides an opportunity for reducing fuel ethanol production costs as well as facilitating the infrastructure for other higher value bio-based products.

A methodology to evaluate process sustainability

AbstractChemical and engineering research over the past several years has seen a dramatic increase in activity in the area of green chemisty. As these developments continue, it is reasonable that some of these chemistries or technologies have the potential to be implemented on the plant scale. With this in mind, a new green technology will most certainly have a potential impact on the sustainability of a process. It should also be noted that although a “green” technology may appear environmentally friendly, there currently is no all‐inclusive methodology for assessing the actual sustainability of the chemical reaction orprocess. In order to assess a process, a set of sustainability indicators, or metrics, are required.Research within the U.S. Environmental Protection Agency (USEPA) has laid the foundationfor an indicator model, GREENSCOPE (Gauging Reaction Effectivenessfor the ENvironmental Sustainability of Chemistries with a multiObjective Process Evaluator), that evaluates a particular reaction or process for sustainability in the following areas: Environment,Energy, Efficiency, and Economics. These four Es provide a quantitative definition of process sustainability, and allow for a direct comparison between two similar processes with differing reaction chemistries or process technologies. These aspects of sustainable chemical research will also be of importance as bench processes are scaled up to sustainable industrial processes.

An undergraduate teaching initiative to demonstrate the complexity and range of issues typically encountered in modern industrial chemistry

In 1997 the Chemistry Department at the University of Glasgow introduced a new initiative into its undergraduate teaching programme. Two exercises were developed that require the students to operate in small groups and to work through exercises that are representative of issues in contemporary industrial chemistry using a problem-based learning format. These modules, termed interactive teaching units, aim to demonstrate the number of factors, often disparate, that contribute to the implementation of successful and sustainable industrial chemical processes. The units are a vehicle for presenting applied chemistry, and also introduce the economic and environmental issues affecting an overall business area. Although these units do not specifically target the concepts of green chemistry, they do enhance student awareness of the principles that underpin the discipline. This report provides an overview of this initiative and briefly outlines the methodology adopted.