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Atom Efficiency in the Manufacture of Chemicals

Atom Efficiency in the Manufacture of Chemicals. Most chemical reactions make more waste than product!. … note the recent statement from the GSK CEO…we need more people willing to challenge the “accepted limits”. Pressures on the Chemical Industry Across the Lifecycle.

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Atom Efficiency in the Manufacture of Chemicals

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  1. Atom Efficiency in the Manufacture of Chemicals Most chemical reactions make more waste than product! … note the recent statement from the GSK CEO…we need more people willing to challenge the “accepted limits”

  2. Pressures on the Chemical Industry Across the Lifecycle

  3. IntroductionWhat is Green Chemistry? • Green chemistry is the design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances • Discovery and application of new chemistry/technology leading to prevention/reduction of environmental, health and safety impacts at source Energy Materials Risk & Non- Reducing Hazard renewables Cost Waste

  4. Green Chemistry is about turning a waste into a product and a cost into a profit

  5. Waste is tomorrows resource We have converted virgin resources to waste and we now need to encourage the greater use of chemically rich waste as a resource

  6. bio-adhesives nanocomposites phenols hydrophobes sugars pectin hydrogels starch Food supply chain residues natural dyes chitosan Liquid fuels chemical monomers solid fuels collagen bio-surfactants lignin waxes PVC replacements hemicellulose cellulose films natural chelants cosmetic waxes bio-solvents

  7. Activity Areas The Centre’s Activities can be groups into 4 areas: • Research • Industry collaboration • Education, including development of teaching and promotional materials • Networking with all chemical stakeholders

  8. Natural Solvents Science Leader Dr Andrew Hunt We are interested in supercritical and liquid carbon dioxide as an extraction, fractionation and reaction medium with projects covering areas such as the extraction of waxes from agricultural and food waste for personal care (and other) applications, and the synthesis of flavour and aroma molecules using in-situ biocatalysis. Funding comes from the University, METRC and industry. We have excellent supercritical fluid extraction facilities and access to scale-up facilities.

  9. Greener Solvents Inorganic Petroleum Biomass Solvents Conventional + Neoteric (e.g. Ionic Liquids) Ethanol Ethyl acetate Ethyl lactate Glycerol 2-MeTHF CO2 + Water ‘Natural’ solvents

  10. Case Study 1Extraction with Super-critical CO2 100 Polyphenols 75 Phospholipids Lipids & Waxes oC Carotenoids 50 Sterol monoglycosides Alkaloids Diterpenes 25 Sterols Lipids Phenolics Terpenoids MPa 10 20 30 40 100

  11. Extractables…….…Eco-waxes Cosmetic Products Semiochemicals Wheat straw Wax products ScCO2 extraction Health Products • Strawboard • Garden Mulch • Pulp & Paper • Bioethanol • Electricity Lignocellulose Renewable resource+CO2 extraction = EU “natural”

  12. Renewable Materials Science Leader Dr Avtar MatharuFor us this means the physical and chemical modification of natural abundant materials and especially polysaccharides. Projects include Starbons (new carbonaceous materials derived from starch), new “bio-boards” made entirely of green and sustainable components, novel switchable adhesives, new intumescent flame retardants, and PVC replacements. Funding comes from industry, EPSRC, DEFRA and TSB. The area is supported by state-of-the-art thermal analysis, infrared spectroscopy and extrusion equipment.

  13. Recyclable Materials…… Switchable adhesives for carpet tiles (InterfaceFlor) Diverting millions of Kg pa from landfill

  14. Clean Synthesis and Platform Molecules Science Leader Dr Simon Breeden Very much our root area with interests covering the use of solid catalysts and alternative solvents to “green” reactions. Recently we have become especially interested in doing clean synthesis starting from molecules and mixtures derived from biomass (eg using fermentation broths). We have funding in this area from industry, EPSRC, METRC, and GSK.

  15. Microwave Chemistry Science Leader Dr Duncan MacQuarrie This brings together our long-standing interest in microwave-assisted chemistry with our more recent interest in the conversion of biomass (eg forestry and agricultural wastes, food waste, etc) to useful products. With substantial funding from ERDF, Carbon Trust, METRC and industry we are starting major new projects on fast pyrolysis for the production of liquid fuels, high calorific value chars and chemical intermediates. A major part of this is the design and build of new continuous microwave processors, with the final semi-scale prototype to be located outside the GCC.

  16. Advantages of MW Heating • Rapid internal heating • Uniform heating • Instant control • Acceleration of reaction rate • Selective interaction with active groups

  17. Microwave Processing of Biomass Extracted oil Biomass Microwave processor Pyrolysis Oil Energy Char Low temperature Flexibility of Microwave Parameters (time, temperature, power) Wide range of feedstock + Wide range of products =

  18. Microwave Processing of BiomassRape Seed Example 30 19 www.greenchemistry.net

  19. Biomass Pretreatment Starbonisation Supercritical CO2 extraction Microwave processing Ammonia fibre explosion Higher value products Fermentation 21

  20. mark.gronnow@york.ac.uk Industry Education Any questions? www.greenchemistry.net Research Networking

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