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🌱 Sustainable Process Design - Complete Guide

Integration of energy efficiency, waste minimization, green chemistry principles, and life-cycle thinking into chemical process development.

15
Knowledge Pages
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Interactive Tools
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Case Studies
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Resources
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Lessons
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Sustainable Process Design - Complete Guide

Designing chemical processes that use less energy, create less waste, avoid harmful chemicals, and consider environmenta...

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Quick Start

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Knowledge Base

15 pages
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Key Concepts

Sustainable
Process DesignSolvent Selection
Matrix (EHS + Renewables)
Energy Integration
via Pinch Analysis
Waste Minimization
via Pathway Optimization
Life Cycle Assessment
(LCA) Framework
Green Metrics:
E-Factor, Atom Economy
Process Mass Intensity
(PMI) & Benchmarking
12 Principles
of Green Chem
Carbon
Footprint
Design for
Degradability

Visual overview of key concepts and their relationships

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Real Projects

5 cases
Pharmaceutical API Synthesis Redesign Novartis Basel | E-Factor ↓78% | Solvent Intensity: 2.1 β†’ 0.4 kg/kg CHALLENGES β€’ E-Factor >100 β€’ Chlorinated solvents β€’ 30% yield loss (crystallization) DESIGN APPROACH β€’ Bio-based EtOAc β€’ Catalytic asymmetric hydrogenation β€’ Continuous crystallization + inline PAT RESULTS E-Factor ↓ 78% Solvent Intensity 2.1 β†’ 0.4 kg/kg API Ξ” E-Factor >100 βœ“ EtOAc ↑ PAT Process Mass Intensity (PMI) driven improvement | Continuous flow + green chemistry

Pharmaceutical API Synthesis Redesign at Novartis Basel

Redesign of multi-step synthesis for antihypertensive drug candidate

Challenge: High E-factor (>100), hazardous chlorinated solvents, 30% yield loss in final cr...
Enzymatic\nTransesterificationMembrane\nSeparationAnaerobic\nDigesterSoybean Oil +\nMethanolMethanol (recycled)\nGlycerol (to digester)Biogas +\nDigestateChallenges: High glycerol waste,\nenergy-intensive methanol recovery,FFA variabilityRenewable Carbon: 94.2%Water Use: 0.8 gal/gal

Biodiesel Production Scaling in Iowa Soybean Refinery

Expansion of transesterification plant from 10 to 50 MMgy capacity

Challenge: High glycerol waste volume, energy-intensive methanol recovery, inconsistent fee...
Electrolyte Manufacturing for EV Batteries β€” BASF Ulsan Plant HF Generation 42% F lost as CaFβ‚‚ sludge Cryogenic purification β†’ high energy Electrochemical Fluorination + Regenerative HF Scrubbing Heat-Integrated Distillation Ceramic Membrane Separation Fluorine Recovery 98.7% Energy Consumption 4.1 kWh/kg (vs. 8.3) Process Integration LiPF₆

Electrolyte Manufacturing for EV Batteries β€” BASF Ulsan Plant

New LiPF₆ synthesis line with closed-loop fluorine management

Challenge: HF generation during synthesis; 42% fluorine lost as CaFβ‚‚ sludge; high energy de...
Sterilization(Steam)Evaporation(Steam)Solar ThermalPreheatingMVR SystemCOβ‚‚StrippingEnzymaticLysisIon-ExchangeResinSteam ↓ 62%Citrate recovery ↑ to 89%Protein yield: 68%High steam demandMycelial waste β†’ landfillCitrate recovery <72%

Food-Grade Citric Acid Fermentation Upgrade β€” Cargill Decatur

Modernization of Aspergillus niger fermentation and downstream processing

Challenge: High steam demand for sterilization and evaporation; mycelial waste sent to land...
Recycled PET Flakes Purification for Food Contact Indorama PET Recycling, Rotterdam PET Flakes Acetaldehyde & organics ↑ EU limits Cl⁻ wash β†’ corrosion & AOX scCOβ‚‚ Extraction 15 MPa, 65Β°C FTIR Inline verification Ceramic Filter βœ“ Food-grade Performance β€’ AOX Elimination: 100% β€’ scCOβ‚‚ Energy: 0.42 kWh/kg

Recycled PET Flakes Purification for Food Contact β€” Indorama PET Recycling, Rotterdam

Validation of supercritical COβ‚‚ cleaning for post-consumer PET flake decontamination

Challenge: Residual acetaldehyde and organic contaminants exceeding EU migration limits; ch...
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Downloads

6 resources
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Learning Path

22 lessons

Master Sustainable Process Design through a structured learning path β€” from fundamentals to advanced applications.

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News & Updates

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