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Safer Design & Green Engineering-Rohm&Haas
Safer Design & Green Engineering-Rohm&Haas
Dennis C. Hendershot
Rohm and Haas Company
Engineering Division
C
Croydon,
d PA
Dhendershot@rohmhaas.com
@
• The message:
Once you get something dirty,
dirty the only way to get it clean is
to make something else dirty.
The best way to keep the world clean is to not get it dirty to
begin with.
with
Inherently
Safer
D i
Design
Green Chemistry
G Ch i t
and Engineering
• Minimize
• M d
Moderate
t
• Substitute
• Simplify
Catalyst (usually
sulfuric acid) feed
or p
pre-chargeg
Batch Reactor
~6000 gallons
Raw
Material
Feeds
Organic substrate
Catalyst
Nit i Acid
Nitric A id
Raw
C l d continuous
Cooled ti
Material
mixer/reactor
Feeds
Organic substrate
Catalyst
Nitric Acid
5000 liter
(~1300 gallons)
batch reactor
Hold Break
Tank Tank
Metering Pump
Loop
Reactor
~ 50 liters Product
Storage
Tank
((~13
13 gallons)
42 SACHE Faculty Workshop - September 2003
Good engineering makes existing
chemistry
y “Greener”
• Chlorination reaction – traditional stirred tank
reactor
• Mixing and mass transfer limited
– Chlorine gas liquid reaction mixture solid
reactant particle rapid reaction
• Loop reactor – similar design to polymerization
reactor in previous slide
– Reduce:
• Chlorine usage from 50% excess to stoichiometric
• Reactor size by 2/3
• Cycle time by ¾
• S di
Sodium hydroxide
h d id scrubber
bb solution
l ti usage by
b 80%
• Dilution
• R fi
Refrigeration
ti
• Less severe processing conditions
• Physical characteristics
• Containment
– Better described as “passive” rather
than “inherent”
20,000
ppm
(B) - Release Scenario:
Centerline Ammonia
n, mole p
2 iinch
h transfer
t f pipe
i failure
f il
centration
10,000 Anhydrous
Ammonia
Conc
28%
Aqueous
Ammonia
0
0 Distance, Miles 1
Monomethylamine Distance to
Storage ERPG-3 (500 ppm)
Temperature Concentration
Concentration,
(°C) km
10 1.9
3 1.1
-6 0.6
• Ammonia manufacture
– 1930s - pressures
press res upp to 600 bar
– 1950s - typically 300-350 bar
– 1980s
1980 - plants
l t operating
ti att pressures
of 100-150 bar were being built
• Result of understanding and
improving the process
• Lower pressure plants are cheaper
cheaper,
more efficient, as well as safer
Acetic Acid
Reactor Methanol
Recovery
Solvent
Recovery
Sulfuric
p
Splitter
Acid
Extractive
Distillaton
Water
Methanol
Reactor
Decanter Column
Extractor Impurity
Removal
Columns Heavies
Color
Column
Flash
Azeo Column
Column
Water
Heavies
Flash
Column
Water
Water
• Fewer vessels
• F
Fewer pumps
• Fewer flanges
• Fewer instruments
• Fewer valves
• Less piping
• ......
A
B
C Condenser
D
E
Distillate
Receiver
Steam
Refrigerated
Brine
Water Return
Water Supply
Condensate
C
Refrigerated
Brine
W t R
Water Return
t
Water Supply
Condenser
E
Distillate
Receiver
Steam
Condensate
- Richard P. Feynman
y
Nobel Prize winning physicist,
discussing approaches to
understandingg a physics
p y problem
p