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

8

9

10

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