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© 2013 Equinox. All rights reserved | 1 Sanjiv Bachal & Alok Pandit Equinox Software & Services Private Limited Dec 2013
© 2013 Equinox. All rights reserved | 2 1.Introducing Equinox 2.The importance of solvents 3.Process design of Solvent Recovery system 4.Waste Reduction Algorithm (WAR) 5.Case studies 6.Conclusion 7.Vote of Thanks Agenda 2
© 2013 Equinox. All rights reserved | 3 EQUINOX Improving process and plants performance globally Through IT-catalyzed Chemical Engineering
© 2013 Equinox. All rights reserved | 4 4 “…Gain better “process” understanding to “process” better Gains…” Our Mantra
© 2013 Equinox. All rights reserved | 5 A New Kind Of Process Company Model Based Process Consulting, Process IT Solutions & Services Among the largest # Software platform independent companies in its chosen business areas for CPI/HPI/Pharma India based company in active business since 2007 Successful Delivery of 100+ projects 50+ customers in 10 countries in 3 continents Novel Application Solutions deployed thru internal R&D Profitable growth, based on internal funds Broad Base of Customers
© 2013 Equinox. All rights reserved | 6 Member – NASSCOM, FICCI, MCCIA Incorporated in 2005 Operational in 2007 Clocked a CAGR of 60% over last five years Consistent repeat business – A sign of customer’s trust. Delivered 100,000+ Hours of Consulting in last 18 months Strategic Alliances with world leaders – FRI and OLI Global customers in UAE, Malaysia, Qatar, Saudi Arabia, Italy, India, USA, Thailand, Netherlands Now in its 7 th year…
© 2013 Equinox. All rights reserved | 7 A New Kind Of Process Company Highly qualified and experienced team –25% staff have post-graduate qualification in engineering –50% staff have solid operating experience –50% staff have worked on multiple software platforms Equal distribution of projects in India and abroad
© 2013 Equinox. All rights reserved | 8 Importance of Solvents Why solvents are needed: –Solubilizing the reactants –Facilitate reaction –Facilitate heat transfer/control –Purification Solvents constitute typically wt% of the process mass Contribute about % to the cost of manufacturing of Active ingredient Number of solvents used in an API unit could be anywhere in the range of Number of used solvent streams could be > 100
© 2013 Equinox. All rights reserved | 9 Process Design Challenges Binary solvent mixtures are a rare occurrence – multi-component systems are common Multi-step separation processes with multiple permutations and combinations of distillation train
© 2013 Equinox. All rights reserved | 10 Process Design - Engineering Practices Methodologies followed in Industries for design of solvent recovery system: Experience/Operation wisdom Consultants Commercial Simulators etc
© 2013 Equinox. All rights reserved | 11 Process Design - Engineering Practices MAXSOL – The complete science driven product/Application to maximize solvent recovery Considers various aspects in process Designing: Thermodynamics Operation Hardware Economics Environment
© 2013 Equinox. All rights reserved | 12 Design of Solvent Recovery Systems The Green/Environment Aspect: The Environment Impact Assessment (EIA) of the Design Alternatives
© 2013 Equinox. All rights reserved | 13 EIA - Waste Reduction Algorithm What is Waste Reduction Algorithm (WAR): – Algorithm developed by US EPA to evaluate environmental impacts of process design How it works – By evaluating processes in terms of their potential environment impacts (PEI) What is PEI – Effect a chemical would have on the environment if it were simply emitted into the environment
© 2013 Equinox. All rights reserved | 14 PEI categories considered in the Waste Reduction Algorithm (WAR): –Toxicological Human Toxicity Potential by Ingestion (HTPI) Human Toxicity Potential by Exposure (HTPE) Aquatic Toxicity Potential (ATP) Terrestrial Toxicity Potential (TTP) –Global Global Warming Potential (GWP) Ozone Depletion Potential (ODP) Photochemical oxidation or Smog Formation Potential (PCOP) Acidification or Acid-Rain Potential (AP) EIA - Waste Reduction Algorithm
© 2013 Equinox. All rights reserved | 15 PEI categories considered in the Waste Reduction Algorithm (WAR): Human Toxicity Potential by Ingestion (HTPI) Human Toxicity Potential by Exposure (HTPE) Aquatic Toxicity Potential (ATP) Terrestrial Toxicity Potential (TTP) Global Warming Potential (GWP) Ozone Depletion Potential (ODP) Photochemical oxidation or Smog Formation Potential (PCOP) Acidification or Acid-Rain Potential (AP) EIA - Waste Reduction Algorithm
© 2013 Equinox. All rights reserved | 16 EIA - Waste Reduction Algorithm Energy Generation Process Recovery Process PEI in MASS Energy PEI out Waste Energy Waste Energy PEI Analysis Envelope
© 2013 Equinox. All rights reserved | 17 EIA - Waste Reduction Algorithm A case study is discussed here to highlight the application of WAR algorithm to understand the PEI of various design alternatives for an actual solvent mixture separation MDC – THF – Water System
© 2013 Equinox. All rights reserved | 18 New Design - Option 1 Reuse Waste
© 2013 Equinox. All rights reserved | 19 Reuse Waste New Design - Option 2
© 2013 Equinox. All rights reserved | 20 PEI Analysis Using WAR External Environment Efficiency of the process Total Rate The contribution due to PCOP is predominant in both the options Option 2 PEI is marginally better due to lower contribution of PCOP category
© 2013 Equinox. All rights reserved | 21 PEI Analysis Using WAR External Environment Efficiency of the process Rate per kg of product Option 1 shows a better performance per kg of product – Option 1 has higher product yield compared to Option 2
© 2013 Equinox. All rights reserved | 22 PEI Analysis Using WAR Internal Environment Efficiency of the process Total rate of PEI generation
© 2013 Equinox. All rights reserved | 23 PEI Analysis Using WAR Internal Environment Efficiency of the process Generation per kg of product
© 2013 Equinox. All rights reserved | 24 PEI Analysis Using WAR PEI Generation - Energy Usage Environmental Energy efficiency of the process
© 2013 Equinox. All rights reserved | 25 Key Take-Aways Simple and technically sound assessment of environmental impact of process design alternatives Equinox has developed MAXSOL with proven track record to handle new design and revamp of solvent recovery system
© 2013 Equinox. All rights reserved | 26 Contact Information Contact: Dr. Sanjiv Bachal Phone: Website:
© 2013 Equinox. All rights reserved | 27
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