Institute of Chemical Technology

Mumbai
Extends cordial welcome to all
participants for

Young Innovators’ Choice Competition’10

Industrial Defined Problems

Young Innovators’ Choice Competition’10

 RUBICON RESEARCH PVT. LTD.

Pharmaceutical invention and research are increasingly focusing on delivery

systems which enhance desirable therapeutic objectives while minimizing side
effects. Multiple particulate drug delivery systems especially suitable for
achieving controlled or delayed release oral formulations with low risk of dose
dumping, flexible and short gastric residence time. A recent trend in drug
delivery market is to compressed controlled/ delayed released pallets into tablets
eg. Nexium tablets, Torol XL etc.

 List down the challenges associated with compression of coated pellets

into a tablet
 Enumerate possible reasons for failure of functionality of coated pallets
 Suggest different strategies/ approaches to overcome the challenges
 Provide an account of granulation of diluents(non-pellets exipients) as a
strategy i. e. Use of cushioning beads
 Which of the strategy according to you should be most successful in
preserving the functionality of pallets?
 ESKAY DYESTUFF PVT. LTD.
H
N
H2N SO3H
O

 Suggest different methods

NOH
SO3H
N
H
NH2
/reagents/catalyst for the
.
AcONa/ CH3OH H2O dehydration step.
HO3S  Compare them on the basis of
N
H
N cost and chose best one.
H
H
N
N
H
SO3H NOH  Suggest alternative commer-
NOH
cially viable routes for the
preparation of final compound A
PROBLEM ???
Removal of H2O
N

N
 Compare all the routes w. r. t.
SO3H
N
cost
SO3H N
N

A N
 JAVDEV CHEMICAL INDUSTRIES

 Metathesis Reactions using Economically cheaper

CATALYST for

e.g.
R-CH=CH2 + CH2=CH-OH R-CH=CH-OH
Alpha-Olefin Allyl Alcohol 2-Alkenol
 PIRAMAL HEALTHCARE

 Suggest the methods to remove starting materials

viz. Vitamin A acetate and methyl palmitate and also
by-products of the reaction like Vitamin A alcohol
from vitamin A palmitate

 Compare economy of the processes

DR. REDDY’S LABORATORY LTD.

H O

Provide cost effective (not more than $20)

and scalable synthetic approach for
2-Ethyl-butyraldehyde,
which is key starting material for many APIs
 HUNTSMAN
Pressure less Emulsification of High Density Polyethylene
Wax (HDPE Wax) to make high concentrated emulsion :
 To make such type of emulsion we need pressure vessel because of high
melting point of HDPE wax so their is need to design emulsification
technique to emulsify at atmospheric pressure and in an open top vessel.

 We need cationic nature of the emulsion, reason being cationic nature

gives better exhaustion in application and good handle on the fabric/yarn.

 To select the emulsifier system in such a way that the final emulsion must
be cationic in nature(having pH <6) and the emulsion should be non
yellowing in nature and hydrophilic so the finished substrate can be readily
dyed.

 Their is need in the market for higher concentrated emulsion (Solid

Content more then 40%),with better storage stability at 40 - 450C, no
gelling or solidification of the emulsion.
 HUNTSMAN

How to best use (recycle) waste sulfuric acid

generated from sulfonation reactions

Sulphonation of organic molecules using sulfuric acid / oleum

generated lots of sulfuric acid waste (concentrated/ dilute/
contaminated/ colored). This leads to tremendous load on
effluent treatment which is environmentally non-friendly with
loss of energy and money. This waste/diluted sulfuric acid need
to be reuse to eliminate / minimize the effluent which is eco-
friendly and cost effective.
 METROPOLITAN EXIMCHEM LTD.

1) Manufacture of Chlorostyrene by decarboxylation

of Chloro Cinnamic acid
 Emphasis should be on Yield, Isolation and purity
 Design a plant to manufacture for the best route

2) Desulfonation of 2,6-dinitro-4-toluene sulfonic acid

 Exact and Feasible and route for desulfonation
 COLOURTEX PVT. LTD.

1 ) Economical routes of Synthesis of 4-(2-Methoxyethyl)

phenol CAS No. 56718-71-9 and Comparison of all routes
 Design a plant to manufacture for the best route
 Manufacturing cost should not exceed US$ 12 /kg
 Special emphasis on following starting raw materials,
(a) Phenylethyl alcohol (b) p-Chlorophenol

2) Manufacture of POLYALLYLAMINE
HYDROCHLORIDE starting from Allylamine

 The RMC expected is US$ 2.5-3.0

 CHEMCRUX CHEMICAL ENTERPRISES

Replacement of Nitric acid based oxidation by air oxidation

A large number of intermediates needed for the manufacturing of the
pharmaceutical, agrochemical and colorant products
e.g. 2-4, dichlorobenzoic acid, p-nitrobenzoic acid, cyclohexanone etc. are
currently made by oxidation of respective substrates using HNO3.
These reactions are usually carried out at high temperature and pressure and
characteristically demand large number of safety precautions which results into
high capital cost.
In addition, NOx gases get formed which are either difficult to recover and
forms of strong contendant for global warming
Alternatively, oxidations can be carried out using air.
You are required to develop complete process description along with equipment
design and details for practical implementation point of view
 GLOBAL ENVIRONMENTAL MANAGEMENT CONSULTANTS

Municipal waste: Converting a liability into an

asset
Each town face the problem of the disposal of solid waste. For
instance Mumbai and Singapore individually produce a solid
waste of about 8000 tons per day. The disposal faces several
acute problems.

However there are at least 5 ways by which these liabilities can

be converted into a profit making assets.

You are required to select the most economical one

 ICT PROBLEM -1

 A company is producing 300T/d of ethyl acetate. It has about

0.5 % moisture and the same amount of acidity.
 The management has reviewed the market for semiconductor
quality solvent ( acidity <0.005%; moisture 0.001%;
<0.001% metal content) where the value of the product can
be increased three times.
 An enquiry from a customer for 500T/month has put the
Technical team on job to find requisite solution.
 Develop a methodology for the purification and evaluate the
strategy for economic return. The solution should be
complete in philosophy, sound on theory, suitable for
implementation, with flowsheet.
 ICT PROBLEM -2

 A Company is producing 1000 TPD of palm oil, leaving a

large amount of biomass .

 Since it is being considered as a resource material, develop

a strategy to utilize it as a future business for the company

 The plan should be complete in giving possible earnings to

the company to sustain itself.
 YICC-YRC TEAM, ICT (PROBLEM -3)

 Design an economical functional food for prevention

 Diabetes and

 Coronary Heart Disease (CHD)

 Product should be from Natural sources which can be from

Microorganism and Plant extract

 Design the process using advanced technology.

 Exergy - ICT (PROBLEM – 4)

 A plant is manufacturing Soda Ash using the Solvay Process.

 An important stage of this process is to recover free ammonia which is used
for subsequent recycle.
 This is achieved by steam stripping of the preheated filtrate solution which
contains almost the entire ammonia, in a packed tower.
 This tower employs two beds each packed to a height of 20 ft and a diameter
of 10ft.
 The plant personnel had initialy packed these two beds with 1.5 inch ceramic
Raschig rings.
 During the initial installation, the packings were lowered from the top of the
column in 55 gal drum and spread evenly over the entire 10 ft diameter
tower.
 The normal operation employed a flow rate of filtrate varying from 350 to
480 gal/min.

Cont…..
 Cont…..
 The tower was running successfully for a few months. But suddenly, the
efficiency of the tower decreased considerably.
 Hence, it was shut down for rectification.
 The process consultant was called and he suggested that there might be some
problem with the type of packing used.
 The tower packing were removed and it was repacked with 1.5 inch ceramic
pall rings by dumping the packing from the column sidewall through a
manhole present above the packing.
 However, when the tower duties were resumed, it was noticed that a greater
amount of steam was required to strip the same amount of ammonia from the
filtrate, thus indicating a loss of efficiency.
 In an effort to determine the cause of this decreased efficiency, plant
personnel ran temperature checks along the circumference of the tower.
 The maximum temperature difference of the liquid at the top of the packed
bed was 50F around the entire circumference (radial variation).
Cont…..
 Cont…..
 However, by the time the liquid reached the bottom of the top packed
section, the maximum temperature difference around the circumference was
300F.
 This was a matter of great concern for the plant personnel. The previous
consultant was dismissed and you have been hired as the new process
consultant.
 Based on this, please answer the required questions:
 Would the previous process consultant be absolutely right in claiming to
rectify the problem by substituting rasching rings with pall rings? According
to you, what caused the decrease in the efficiency of the column? Give
justification.
 During subsequent startup, why didn’t the steam stripping efficiency
improve?
 What will you do to rectify the problem of decreased efficiency of the
column?
 Special Thanks to..…
 RUBICON RESEARCH PVT. LTD.
 ESKAY DYESTUFF PVT. LTD.
 JAVDEV CHEMICAL INDUSTRIES
 PIRAMAL HEALTHCARE
 HUNTSMAN
 METROPOLITAN EXIMCHEM LTD.
 INSTITUTE OF CHEMICAL
TECHNOLOGY, MUMBAI
DR. REDDY’S LABORATORY LTD
COLOURTEX PVT. LTD.
 CHEMCRUX CHEMICAL
ENTERPRISES
 GLOBAL ENVIRONMENTAL
MANAGEMENT CONSULTANTS