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LIFE CYCLE RESEARCH AND THE APPROACHES TO SUSTAINABILITY

LIFE CYCLE RESEARCH AND THE APPROACHES TO SUSTAINABILITY. Professor Michael Overcash North Carolina State University overcash@eos.ncsu.edu. ADVANCED ENVIRONMENTAL FRAMEWORKS. SUSTAINABILITY INDUSTRIAL ECOLOGY GREEN CHEMISTRY AND GREEN ENGINEERING PRINCIPLES.

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LIFE CYCLE RESEARCH AND THE APPROACHES TO SUSTAINABILITY

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  1. LIFE CYCLE RESEARCH AND THE APPROACHES TO SUSTAINABILITY Professor Michael Overcash North Carolina State University overcash@eos.ncsu.edu

  2. ADVANCED ENVIRONMENTAL FRAMEWORKS • SUSTAINABILITY • INDUSTRIAL ECOLOGY • GREEN CHEMISTRY AND GREEN ENGINEERING PRINCIPLES

  3. LIFE CYCLE IS THE PRINCIPAL TOOL • OF ADVANCED ENVIRONMENTAL FRAMEWORKS • IT IS THE QUANTIFICATION MECHANISM • IT ENGENDERS IDEAS OF LIFE CYCLE THINKING • IT IS EMERGING

  4. LIFE CYCLE TOOLS LIFE CYCLE STAGE DECISIONS IMPROVEMENT ANALYSIS IMPACT ASSESSMENT • POLICY ISSUES • SUSTAINABILITY • MACRO • IMPROVEMENTS • NEW • TECHNOLOGY • POLLUTION • PREVENTION • PROCESS ALTERNATIVES INVENTORY ANALYSIS

  5. Ethyl Acetate Dichlorobenzene Carbon Disulfide HCl Sodium bicarbonate Benzene Hexane Aluminum Chloride T Toluene Methylene Chloride SMB EtOH S NaOH Water THF Sodium Borohydride Toluene Thionyl Chloride Succinic Anhydride

  6. LIFE CYCLE IS A TOOL • DEVELOPED TO DEAL WITH COMPLEXITY OF ENVIRONMENT AND PRODUCTS • HELPS US QUANTIFY, UNDERSTAND, AND SEEK IMPROVEMENT • IMPROVE ENVIRONMENT • IMPROVE ECONOMICS

  7. IMPROVED LCI CLASSIFICATION SYSTEM • LOW COMPLEXITY PACKAGING, BASIC MATERIALS • MODERATE SEMICONDUCTORS, PHARMA- COMPLEXITY CEUTICAL PRODUCTS, MANY CONSUMER PRODUCTS • HIGH COMPLEXITY AUTOMOBILE, FIGHTER AIRCRAFT

  8. FOUR GENERAL METHODS FOR LIFE CYCLE INVENTORY DATA • DIRECT MEASUREMENT FROM FACILITIES • CONSORTIA OF STAKEHOLDERS • ECONOMIC INPUT/OUTPUT • CHEMICAL ENGINEERING DESIGN METHOD

  9. LIFE CYCLE EFFORTS AT NCSU • RESEARCH TO DEVELOP RAPID LCI TECHNIQUES • DEVELOPMENT OF GENERIC TOOLS FOR LCI • CREATION OF LCI LIBRARY • RESEARCH TO INTEGRATE LCI WITH ENVIRONMENTAL DECISION-MAKING

  10. A LIFE CYCLE INVENTORY (LCI) IS A COMPLETE MASS AND ENERGY BALANCE TO DETERMINE • INPUTS • CHEMICAL EMISSIONS • ENERGY NEEDS SOME BOUNDARY MUST BE SPECIFIED

  11. LIFE CYCLE INVENTORY QUALITY • TRANSPARENCY • ENGINEERING PRINCIPLES OF MASS & ENERGY • MULTIPLE VIEWS • LOGICAL MECHANISM TO CHANGE • EXPECTATIONS OF DECISION-MAKERS • CRITICAL RELATION OF SYSTEM TO SUSTAINABILITY FACTORS

  12. Ammonia Process • CONTENTS OF FACTORY GATE TO FACTORY GATE • LIFE CYCLE INVENTORY SUMMARY (Byproduct allocation not included) • Chemistry • Process Summary • Summary of LCI Information • Process Diagram Interpretation Sheet • Process Diagram or Boundary of LCI • Mass Balance of Chemicals in each Process Stream (Highlighting Chemicals that are Wastes and the Physical State when Lost) • Graph of Cumulative Chemical Losses through Manufacturing Process • Graph of Cumulative Non-Contaminated Water Use/Emission through Manufacturing Process (Not applicable) • Graph of Cumulative Non-Contaminated Water Use/Emission through Manufacturing Process • Energy Input for each Unit Process, Cumulative Energy Requirements, Cooling Requirements (exotherms), and Assumed Heat Recovery from Hot Streams Receiving Cooling • Graph of Cumulative Energy Requirements • Conversion of Chemical Losses and Energy Requirements into Environmental Parameters, Prior to any Treatment or Discharge to the Environment • Waste Management Summary • CHEMISTRY: • N2 + 3H2 2NH3 • Nitrogen Hydrogen Ammonia • CH4 + 2H2O CO2 + 4H2 • Methane Water Carbon dioxide Hydrogen • PROCESS: • Ammonia is produced by the reaction of nitrogen and hydrogen, The source of hydrogen is natural gas, and nitrogen is air. Carbon dioxide is also produced in the ammonia plant. This is regarded as a by-product. Ammonia is purified by refrigeration

  13. Air 1108 kg/hr Water 106kg/hr CO2 46.61 kg/hr NO 3.52kg/hr NO2 5.39 kg/hr N2 560 kg/hr Ar 10 kg/hr O2 27 kg/hr 25oC 1 atm 4 Compressor A 497.8oC 27.2 atm 974oC 31 atm (g) 788oC 47 760oC 27.2 atm 5 8 25oC 1 atm (g) Secondary reformer 3 Water 1200 kg/hr (g) (g) 2 6 (l) (l) (l) 25oC 1 atm (g) 9 788oC 31 atm Pump 1 Primary reformer Natural gas 446.75kg/hr 1-a 360oC 31 atm (g) (g) Heat recovery A 1 25oC 1 atm (g) Burner 7 C C1 20 oC C2 20 oC Used as a fuel 48 (g) 25oC 1 atm Heating fuel Pump A C3 50 oC A Air 688kg/hr C26 20 oC (g) 16 (g) C25 20 oC 40oC 31 atm Shift converter High temp. Shift converter Low temp. 10 12 427oC 31 atm Pump J 266oC 31 atm C7 20 oC Pump C (g) C8 20 oC Gas/liquid Separator A 13 14 (g/l) (g) Cooler A 40oC 31 atm Heat recovery B Heat recovery C 90oC 31 atm C9 50 oC (g) (l) 243oC 31 atm C4 20 oC C6 50 oC C27 50 oC 15 C5 20 oC 11 Water 512.85 kg/hr Pump B

  14. B Pump F C13 20 oC C14 20 oC 76oC 20 atm 82oC (g) Carbon dioxide 1179 kg/hr 17 (g) 41oC 21 20 Cooler C 25 25oC Carbon dioxide absorber Carbon dioxide stripper C15 50 oC C11 20 oC Cooler B Pump D A C12 50 oC C10 20 oC 24 Boiler (l) 78oC (g/l) (g/l) 18 18-a 76oC 19 80 oC S1 207 oC(g) 76oC S2 207 oC(l) Heat exchanger A 22 23 82oC (l) Pump E

  15. Steam-turbine centrifugal compressor B 38oC 177 atm 38oC 177 atm 39 41 S7 316 oC (g) (g) S8 149 oC (l) (g) C16 20 oC Pump G Pump H 40 Pump I Steam-turbine centrifugal compressor A S9 316 oC (g) S8 149 oC (l) Heat recovery D C19 20 oC C22 20 oC C17 (g) (g) C20 C23 29 30 31 32 33 Cooler F (g) (g) (g) (g) 313oC 20 atm 147oC 170 atm 93oC 204 atm 27 28 (g) 25oC 43oC 20 atm 177oC 170 atm Cooler D Cooler E C24 50 oC 121oC 20 atm Methanator C18 50 oC C21 50 oC 35 Refrigerator A (g) (g) 158oC 177 atm 36 Heat exchanger B Ammonia Converter (l/g) S5 207 oC(g) S11 207 oC(g) S12 207 oC(l) Gas/Liquid Separator C 254oC 177 atm 34 38 -23oC 204 atm S6 207 oC(l) (g) -23oC 204 atm (g) Heat recovery E 288oC 20 atm 26 (g) (l) (g) -23oC 177 atm C 37 44 S3 207 oC(g) Heater A 371oC 177 atm 42 43 (l/g) -23oC 177 atm (l) S4 207 oC(l) Gas/Liquid Separator D Refrigerator B -23oC 1 atm Ammonia Storage -23oC 177 atm NH3 990.88 kg/hr Water 9.38 kg/hr B (l) 45 46

  16. SUMMARY OF LCI INFORMATION Product: Ammonia Basis: 1,000 kg/hr ammonia Reference: Slack, V. and James R.G., Ammonia, Marcel Dekker, inc., 1973. Brykowski F.J. Ammonia and synthesis gas, Noyes Data Corporation, 1981. Plant Location: Comments: All mass and energy units per hour are equivalent to per 1,000 kgof ammonia Inputs Product

  17. Process emissions* Water (513 kg), oxygen (27kg) and nitrogen (560 kg) are not included.

  18. Energy Requirements * Oxygen and nitrogen are not included; ** Energy requirement minus potential heat recovery from cooling systems N/A not applicable for this chemical process

  19. Ethyl Acetate Dichlorobenzene Carbon Disulfide HCl Sodium bicarbonate Benzene Hexane Aluminum Chloride T Toluene Methylene Chloride SMB EtOH S NaOH Water THF Sodium Borohydride Toluene Thionyl Chloride Succinic Anhydride

  20. IV C O H 2 Cl Cl “Carbon frame” efficiency IX XI X 3 + Benzene T-S yield=33% SOCl2/ AlCl3 VI VII VIII V Tetralone yield=37% Separation Racemic mixture: cis(+,-) & trans(+,-) Total yield=12.2%

  21. 10% IMPROVEMENT IN CARBON UTILIZATION EFFICIENCY • WITHIN THE COMPANY (kg/kg Sertraline): 97 96 1 (most waste is solvent) • THROUGHOUT THE PHARMACEUTICAL COMPLEX (kg/kg Sertraline) 39,098 35,794 3,304 Over 3,000-fold greater impact

  22. Solvent usage efficiency THF THF TiCl4 CH3NH2 0°C THF Naphtale- nona Naphtalen- amine mixing 46 Cool 1-5°C 47 Addition 48 Reaction, Stirring and Cooling <10°C 49 Stirring 17hr, N2 50 Filtration w/washing 51 Vacuum 52 THF TiO2 “cake” + Reactants + Solvent + Chemical losses + Solvent

  23. 10% IMPROVEMENT IN SOLVENT USAGE WITHIN THE COMPANY (kg.kg Sertraline) 97 89 8 WITHIN THE PHARMACEUTICAL COMPLEX (kg/kg Sertraline) 39,098 38,493 605 LARGER EFFECT WITHIN COMPANY, BUT GREATEST IMPACT IS OUTSIDE COMPANY

  24. DIVERSITY OF DATABASE • LARGE MOLECULES • FERMENTATION PRODUCTS • SEMICONDUCTOR FAMILY • COMMODITY • SOLVENTS • OTHERS

  25. AREAS OF LIFE CYCLE RESEARCH AT NORTH CAROLINA STATE UNIVERSITY • CHEMICAL MANUFACTURING (COMMODITY AND SPECIALTY) • ADVANCED ENERGETIC CHEMICALS • PHARMACEUTICALS • CO2 PROCESSING R & D • ANIMAL WASTE MANAGEMENT SYSTEMS • BENEFICIAL REUSE OF WASTE MATERIALS • CARPET PRODUCTS • SEMICONDUCTORS

  26. CONCLUSIONS THE EMPHASIS ON LCI MEETS A SUBSTANTIVE NEED IN THE EVOLUTION OF LIFE CYCLE TECHNOLOGY NET (OR HIDDEN) BENEFITS ARE OFTEN DIFFERENT FROM DIRECT BENEFITS LIFE CYCLE INVENTORY QUALITY IS IMPORTANT FOR DECISION-MAKING APPLICATION OF LIFE CYCLE TO NEW PRODUCTS AND PROCESSES IS AN IMPORTANT NEW USE

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