Transcript OPTIMIZE™ 2013 Presentation Template

Sanjiv Bachal & Alok Pandit
Equinox Software & Services Private Limited
Dec 2013
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Agenda
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
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EQUINOX
Improving process and plants performance globally
Through
IT-catalyzed Chemical Engineering
© 2013 Equinox. All rights reserved
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Our Mantra
“…Gain better
“process”
understanding to
“process” better
Gains…”
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A New Kind Of Process Company
 Model Based Process Consulting,
Process IT Solutions & Services
Broad Base of Customers
 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
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Now in its 7th year…
Incorporated in 2005
Operational in 2007
Clocked a CAGR of 60% over last five years
Global customers in UAE, Malaysia, Qatar, Saudi
Arabia, Italy, India, USA, Thailand, Netherlands
Member – NASSCOM, FICCI, MCCIA
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
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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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EIA - Waste Reduction Algorithm
 PEI categories considered in the Waste
Reduction Algorithm (WAR):
– Toxicological



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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)
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EIA - Waste Reduction Algorithm
PEI Analysis Envelope
MASS
Waste
Energy
PEIout
PEIout
Energy
Generation
Process
Energy
MASS
Recovery
Process
MASS
MASS
PEIin
PEIin
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Waste
Energy
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
Waste
Reuse
Waste
Reuse
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New Design - Option 2
Reuse
Waste
Waste
Reuse
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PEI Analysis Using WAR
 External Environment Efficiency of the
process
• The contribution due to
 Total Rate
PCOP is predominant in
both the options
Output rate of PEI
• Option 2 PEI is
400
Impact (PEI/hr)
350
marginally better due to
300
250
lower contribution of
200
150
Option 1
100
Option 2
PCOP category
50
0
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PEI Analysis Using WAR
 External Environment Efficiency of the
process
 Rate per kg of product
• Option 1 shows a better
Output Rate of PEI per kg Product
performance per kg of
Impact (PEI/kg product)
0.80
0.70
product – Option 1 has
0.60
0.50
higher product yield
0.40
0.30
Option 1
0.20
Option 2
compared to Option 2
0.10
0.00
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PEI Analysis Using WAR
 Internal Environment Efficiency of the
process
 Total rate of PEI generation
Generation Rate of PEI
0
Impact (PEI/hr)
-100
-200
-300
Option1
Option 2
-400
-500
-600
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PEI Analysis Using WAR
 Internal Environment Efficiency of the
process
 Generation per kg of product
Generation Rate of PEI/kg Product
Impact (PEI/kg product)
0.0
-0.2
-0.4
Option 1
Option 2
-0.6
-0.8
-1.0
-1.2
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PEI Analysis Using WAR
 PEI Generation - Energy Usage
 Environmental Energy efficiency of the
process
Output Rate of PEI - Energy Generation
6.00
Impact (PEI/hr)
5.00
4.00
3.00
Option 1
2.00
Option 2
1.00
0.00
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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:
Phone:
Email:
Website:
Dr. Sanjiv Bachal
+91-20-41020122
[email protected]
www.equinoxweb.co.in
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