CSIR National Chemical Laboratory 2017 Overview of Continuous
CSIR - National Chemical Laboratory 2017 Overview of Continuous Flow and Industrial Effluent Treatment Processes at CSIR-NCL Industrial Green Chemistry World Convention, October 6, 2017
NCL at a Glance: Divisions, Themes and competencies Industry Sectors Catalysis CSIR - National Chemical Laboratory 2017 Chemical Engineering & Process Development • • Polymer Science & Engineering Chemicals & Petrochemicals Sustainable Chemical Industry Clean Energy: coal, biomass, solar Affordable Healthcare: API, detection Better crops and Nutrition, Advanced Materials: polymers, biomaterials Clean Environment: water, air, CO 2 Agri – food & water Venture Center Organic Chemistry Biochemical Sciences Physical & Material Sciences
Competencies of CEPD Division CSIR - National Chemical Laboratory 2017 Catalysis & Reaction Engineeri ng Process Engineerin g& Process Developme nt Modeling, simulation, optimizati on & data mining CEPD @ NCL Separatio n Engineeri ng Fluid Dynamics Biochemic al engineerin g
CSIR - National Chemical Laboratory 2017 Resources • Facilities and Resources • Indus. Magic • Continuous processing plants • Intensified flow reactors • High Pressure Lab • Batch Reactors [ < 2 liter, 1 < P < 500 bar] • Fixed Bed Reactors • Supercritical reactor • Process Intensification • Several flow reactors • Multipurpose distillation facility • Solvent evaporation & recovery • Biochemical Engineering • Fermenters, Membrane units, Spray dryer, Protein Chromatography, HPLC • Analytical Facilities • Distributed: GC, GC-MS, HPLC, UV-vis, FT-IR and polarimeter • Central facility: ICP analysis, AAS , Autosorb
Recent Processes & Products Developed & transferred • Acrylamido tertiary-butyl sulfonic acid (ATBS) process • Vinyl Benzoate, Vinyl 2 -ethyl-hexanoate and Vinyl Neo-decanoate • Iso-Butyl Acetophenone • Racemization of l 2 - amino butanol to dl 2 -amino butanol by hydrogenation CSIR - National Chemical Laboratory 2017 • Microreactors • Para-aminophenol • Artificial Intelligence based soft-sensors for Polyethylene plant • Artificial Intelligence based supervisory control for 500 MW thermal power station
CSIR - National Chemical Laboratory 2017 Some of Our Industry Partners
Continuous Flow Synthesis of API, Agrochemicals and Nanomaterials Dr. Amol A. Kulkarni Chemical Engineering & Process Development Division CSIR-National Chemical Laboratory, PUNE, INDIA-411008 CSIR - National Chemical Laboratory 2017 WE NEED CHEMICALS EVERYDAY & CSIR-NCL CAN MAKE A CHEMISTRY FLOW TO MAKE IT SUSTAINABLE! • • Improved mixing Precise temperature control Selectivity Small holdup Reproducible operation Shorter reaction time CSIR-NCL team can design, fabricate and assemble the flow synthesis facilities specific to the chemistry Enhanced reaction rates with very efficient mixing, heat & mass transfer reduces reaction time from few hours to a few tens of seconds in flow
Advantages of Continuous Flow Reactors • Better reaction control - Better mixing , Better control of reaction parameters such as time, temperature and pressure - Increased catalyst turnover and catalyst life - Increased atom efficiency due to high selectivity and hence yield - Reduction in generation of waste per kg of the product - Improved reproducibility • Improved process safety - Better management of heat of reaction - Low reactant inventory reducing the hazard involved - Real time evaluation of reactions • Lower manufacturing cost and shorter development cycle - Higher selectivity leading to higher yield - Reduced the raw material consumption - Reduced size of the plant - Faster scale-up from bench scale to plant scale
Reactions in Continuous Flow Reactors • • • Nitration Reaction Diazotization Reaction Coupling Reaction Reductive amination Reaction Diels-Alder Reaction Suzuki-Cross Coupling Reaction Grignard Reaction Cyclization Reaction Ritter Reaction and …………….
Continuous flow reactors CSIR - National Chemical Laboratory 2017 Glass lined flow reactors Metallic flow reactors 2 All designs patented
CSIR - National Chemical Laboratory 2017 Treatment of Industrial wastewater & sewage water by using AOPs/ microalgae coupled MBR system
Treatment of Sewage Wastewater Using Advanced Oxidation Process (Source: Pune Municipal Corporation STP) o Treatment of actual Sewage wastewater collected from STP Pune was done by AOP process. CSIR - National Chemical Laboratory 2017 o Photo-Fenton shows highest TOC reduction using Photo-Fenton/persulfate & Aeroxide P 25 Ti. O 2 photocatalyst. Treatment Sewage WW using Photo. Fenton process (Fe. SO 4/H 2 O 2= 10/60 g/L, Time= 3 hrs) Parameter Initial Final Desired COD (mg/L) 680 182 200 BOD (mg/L) 75 12 20 5000 l per day pilot plant facility under development at NCL Comparison of AOPS for the treatment of Sewage wastewater 12
Treatment of industrial wastewater using advanced oxidation processes (AOP) v Uses coagulation + Fenton process v Validated for wastewater collected from a textile industry Initial textile wastewater v Successful demonstration at pilot scale: 50, 000 L/batch at client’s site CSIR - National Chemical Laboratory 2017 v Quality of treated water is at par with pollution control board specs. v Presently, they are recycling 60% of treated water for dying and washing operations. During the demonstration v Cost of treatment: 3 -4 Paise/L. v Process can be continuously used for treatment of other industrial wastewater Final appearance of water after treatment
PFD for treatment of sewage water by Microalgae MBR based system CSIR - National Chemical Laboratory 2017 Effective reduction in COD, BOD, nitrates, and phosphates Community residency Sewage water collection tank • • Microalgae MBR based system for treatment of sewage water Validated at 30 l capacity (batch mode) Passes PCB criteria Treated water useful for non-potable usage (toilet flushing, gardening, etc) Biomass can be used as fertilizer, animal/poultry feed
Vortex Diode and Cavitation Process for Industrial Wastewater Treatment Dr. Vinay M. Bhandari- CSIR-NCL Pune - 2017 Pilot plant, Capacity: 1 m 3/h Cavitation increases Gas Yield q Application of Cavitation Technology - CSIR-NCL’s device Vortex Diode (Patent filed) ü For Dye wastewater a very high COD/ color removal ü Effective for Pharmaceutical industry wastewaters ü Can reduce COD and Ammoniacal nitrogen from industrial wastewaters ü Useful in desulfurization transportation Fuels ü ü Cyclic process (10 -15 cycles ) Industrial Trials In Progress Commercially industries being used in of three *Indus Magic & SETCA(CSC 0123 & CSC 0113)
Newer Materials & Methods for Wastewater Treatment Dr. Vinay M. Bhandari- CSIR-NCL Pune - 2017 Newer Biocoagulants Newer Adsorbents ACS Sustainable Chem & Eng. , 2016 * NCL’s adsorbents- better than commercial materials Industrial & Eng Chem Res. , Dec. , 2015 Ranade V. V. , Bhandari V. M. and L. G. Sorokhaibam. 2014. A process for removing pollutants/chemicals from aqueous as well as organic streams using cassia fistula (Golden shower). Patent Filed (0231 -NF-2014 : 2014 -INV-0088) *Indus Magic & SETCA (CSC 0123 & CSC 0113)
Summary Dr. Vinay M. Bhandari- CSIR-NCL Pune - 2017 • CSIR-NCL has developed a portfolio of a number green processes and technologies that include • Continuous flow processes • Industrial effluent treatment • Catalytic processes • Harnessing these technologies and processes offer various benefits such as scale, efficiency, uniform quality, lower operating cost, sustainability, environment friendliness etc. • CSIR-NCL is an ever-willing partner of the industry for designing, developing and deploying green, sustainable, efficient and innovative chemical processes.
Thank you!
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