Professional Documents
Culture Documents
Module Outline
Introduction (4 h) Green chemistry and sustainable energy developments (8 h) Sustainability through engineering design (10 h) Product life cycle concepts (4 h)
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Content
Methodology for environmentally benign process synthesis; design of unit operations and flow-sheet analysis for reducing environmental footprint; risk assessment in process design; environmental cost accounting; case studies.
Course materials
Text book: Green Engineering: Environmentally Conscious Design of Chemical Processes by David T Allen and David R Shonnard; Prentice Hall PTR, NJ, 2002. ISBN 0-13-061908-6 (Chapters 8-12). Journal papers
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Objectives
To introduce the concepts of sustainability and sustainable development, their engineering and social relevance. To introduce the progress that has taken place in developing scientific methodologies to minimize environmental footprint of chemical processes and products.
Learning outcomes
Understanding of the concepts, principles and methodologies. Apply the understanding in course projects. Communicate the findings through written reports and oral presentation to the entire class. Ability to think at the systems level that involves balancing multiple objectives occurring at different scales a much desired attribute necessary to succeed in the complex real world.
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Sustainability
Examples of sustainability issues in engineering Product, process and system design Guiding principles and decision making A quick review of qualitative methodologies of green chemistry
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Sustainable development: to ensure that it meets the needs of the present without compromising the ability of future generations to meet their own needs.
Report of the 1987 World Commission on Environment and Development (The Brundtland Report)
An important theme in local, national and world politics. A central theme for engineering professions around the world. Engineering graduates must leave their courses with understanding of the concept of sustainable development, and relevant knowledge and skills applied in the engineering profession.
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Jubilee River
River instead of a traditional concrete flood channel Reduced flood risk Added wildlife and public amenity features Collaborative effort of engineers, planners, landscape architects and ecologists
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Catalytic Converter
End-of-the-pipe solution to air pollution from automobile exhaust About 3 g of Pt/Pd/Rh per converter Limited localized reserve at ppm level and formidable energy for purification Economic and social welfare of the miners?
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Several decades to evolve from fossil fuel to renewable system Immediate solution: carbon capture and storage With coordination among all stakeholders and political will it is possible to stabilize global CO2 emission by 2050
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Look beyond own locality and immediate future Innovate and be creative Seek a balanced solution Seek to engage all stakeholders Make sure you know the needs and wants Plan and manage effectively Give sustainability the benefit of any doubt If polluters must pollute, they must also pay Take a holistic cradle to grave approach Decide right, do right Do not sacrifice sustainability for cost cutting Practice what you preach
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Decision-making in Engineering
(Royal Academy of Engineering, UK, 2005; Chapter 4)
Decision-making in Engineering
Process design Product design Design of infrastructure Management of an enterprise
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Design of chemical products and processes to reduce or eliminate the use or generation of hazardous substances
Green solvents
Less hazardous Human health Environmental Global Local
Alternative feedstock
Innocuous Less waste Selective Efficient Renewable
Synthesis pathways
Reaction type Atom efficiency
Safer chemistry
Structure-activity relationship Eliminate toxic functional group Reduce bioavailability Easy degradability
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Feedstock for adipic acid manufacture Traditional: nonrenewable and carcinogenic benzene Alternative: renewable and innocuous glucose Solvents Hazardous: halogenated solvents, CFCs, VOCs, etc Alternatives: supercritical CO2, water, HCFCs, etc. Synthesis pathways Friedel Crafts reaction: ~30% mass efficiency Recover and reuse AlCl3 catalyst or find alternative Safer chemistry Increase alkyl chain length, release functionality in-situ, etc
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Tier 1 tools (limited information) Rough emission estimates Tier 2 tools Tier 3 tools
Evaluation method must be rapid and simple to handle large number of process alternatives Elementary data on raw materials, products and bi-products
Environmental criteria
Persistence (atmospheric half life)* Biodegradation index (aquatic half life) Bioconcentration factor
Economic criteria
Compares raw material cost per unit amount of product
Toxicity criteria
Inhalation exposure Threshold TLVs Permissible PELs Recommended RELs Toxicity weight Impact of inhalation and ingestion
* Reaction with atmospheric hydroxyl radicals (1.5x106 molecules/cc) and 12 hr sun light
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Economic Criteria
( compound i fed or produced per unit mass of desired product ) ( unit cost of the compound i)
Limitations
Different processing cost for different pathways Equipment and energy cost depend on operating conditions Use of market price for unit cost
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Environmental Criteria
Acetone Hydrogen cyanide Methanol Isobutylene Pentane Sulfuric acid Methyl methacrylate
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GCM does not estimate; assumed short due to reaction with ammonia
7 hours
Weeks
2.3
Persistence Rapid Moderate Slow Very slow Bioaccumulation High potential Moderate potential Low potential 8.0>Log Kow>4.3 or BCF>1000 4.3>Log Kow>3.5 or 1000>BCF>250 3.5>Log Kow or 250>BCF Rating index = 3 Rating index = 2 Rating index = 1 >60% degradation over 1 week >30% degradation over 28 days <30% degradation over 28 days <30% degradation over >28 days Rating index = 0 Rating index = 1 Rating index = 2 Rating index = 3
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Toxicity Weight
Toxic response
Toxicity Weights
Dose
US EPA Integrated Risk Assessment Information System Database Toxicity weights for 600 compounds using 3 information Inhalation reference concentration (related to TLV) Oral slope factor, SF (unit: risk per mg/kg-day) Inhalation unit risk factor, UR (unit: risk per mg/m3) Weights related to SF and UR A complete description of methodology and toxicity weighs at http://www.epa.gov/opptintr/rsei/
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Class Discussion
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Release assessment
What constitutes release? Information gathering Process analysis
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Process Flowsheets
Urea manufacture
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Release Assessment
Process analysis
Flow sheets of alternative processes Identify on-site releases Releases missing in a flow sheet Routine Fugitive emissions (leaking
valves, pump seals, flanges, etc)
Information gathering
Purpose: screening level risk assessment vs. detailed risk assessment Process flow diagram Waste and emission streams Best way to quantify each release Data/information available Additional data Release rate and frequency
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Release Quantification
Emission factors
Unit or source specific Several databases
US EPA: Air Pollution Emission Factors (AP 42) Database; Factor Information Retrieval (FIRE) System (http://www.epa.gov/ttn/chief/efpac/index.html) National Atmospheric Emissions Inventory, UK (http://www.naei.org.uk/emissions/index.php) Canadian GHG Inventory Methodologies (http://www.ec.gc.ca/pdb/ghg/guidance/calcu_pro_e.cfm)
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E = mVOC EFav M
mVOC EFav M
Rate of emission, mass/time mass fraction of the VOC in a stream or process unit Average emission factor, kg emitted/kg throughput mass flow rate, mass/time
(kg/103 EFav kg throughput) 1.50 0.10 2.20 0.20 0.02 0.70 0.10
Process Unit Reactor vents Distillation column vents Absorber units Strippers Decanters Dryers Cooling towers
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Pumping Pumping Pouring Pouring Gravity drain Gravity drain Gravity drain
Steel drum Plastic drum Bung-top steel drum Open-top steel drum Slope-bottom steel tank Dish-bottom steel tank Dish-bottom glass lined tank
Surfactant: viscosity = 3 cp, surface tension = 31.4 dynes/cm2 Water: viscosity = 1 cp, surface tension = 77.3 dynes/cm2 Kerosene: viscosity = 5 cp, surface tension = 29.3 dynes/cm2 Motor oil: viscosity = 97 cp, surface tension = 34.5 dynes/cm2 Best engineering judgment for viscosity>200 cp
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Source Classification (oil-fired boilers) Utility boilers No. 6 oil-fired, normal firing No. 6 oil-fired, tangential firing No.5 oil-fired, normal firing No.4 oil-fired, normal firing
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Splash loading
Submerged pipe
Vapor balancing
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G = SMVrP/(3600RT)
G Vapor generation rate in g/s V Container volume in cc r Fill rate in containers/hr R Universal gas constant (82.05 atm-cc/gmol K) P in atm, M in g/gmol and T in K
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Vessels
Fill rate gal/min CC 27.5 2.5 167 333 TC 18.3 1.7 167 333
Volume, V (cc) CC 2.1x105 1.9x104 1.9x107 7.6x107 TC 2.1x105 1.9x104 1.9x107 7.6x107 CC 1.0 1.0 1.0 1.0
Drumming (55 gals) Cans/Bottles (5 gals) Tank Truck (5000 gals) Tank Car (20,000 gals)
30 30 2 1
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2 types of losses
Working loss
Movement of liquid level
Standing loss
Loss calculation
Table C-1 for fixed roof tanks Table C-2 for floating roof tanks TANKS software from US EPA
(http://www.epa.gov/ttnchie1/software/tanks/index.html)
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Class Discussion
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Cost and indicators together provide additional guidance on flow sheet performance
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