LIFE CYCLE RESEARCH AND THE APPROACHES TO SUSTAINABILITY

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LIFE CYCLE RESEARCH AND THE APPROACHES TO
SUSTAINABILITY

• Professor Michael Overcash
• North Carolina State University
• overcash_at_eos.ncsu.edu

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ADVANCED ENVIRONMENTAL FRAMEWORKS

• SUSTAINABILITY
• INDUSTRIAL ECOLOGY
• GREEN CHEMISTRY AND GREEN ENGINEERING PRINCIPLES

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• LIFE CYCLE IS THE PRINCIPAL TOOL
• OF ADVANCED ENVIRONMENTAL FRAMEWORKS
• IT IS THE QUANTIFICATION MECHANISM
• IT ENGENDERS IDEAS OF LIFE CYCLE THINKING
• IT IS EMERGING

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LIFE CYCLE TOOLS
LIFE CYCLE STAGE
DECISIONS
IMPROVEMENT ANALYSIS
IMPACT ASSESSMENT

• POLICY ISSUES
• SUSTAINABILITY
• MACRO
• IMPROVEMENTS

• NEW
• TECHNOLOGY
• POLLUTION
• PREVENTION
• PROCESS ALTERNATIVES

INVENTORY ANALYSIS
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LIFE CYCLE IS A TOOL

• DEVELOPED TO DEAL WITH COMPLEXITY OF ENVIRONMENT
  AND PRODUCTS
• HELPS US QUANTIFY, UNDERSTAND, AND SEEK
  IMPROVEMENT
• IMPROVE ENVIRONMENT
• IMPROVE ECONOMICS

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IMPROVED LCI CLASSIFICATION SYSTEM

• LOW COMPLEXITY PACKAGING, BASIC MATERIALS
• MODERATE SEMICONDUCTORS, PHARMA- COMPLEXITY
  CEUTICAL PRODUCTS, MANY
  CONSUMER PRODUCTS
• HIGH COMPLEXITY AUTOMOBILE, FIGHTER AIRCRAFT

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FOUR GENERAL METHODS FOR LIFE CYCLE INVENTORY DATA

1. DIRECT MEASUREMENT FROM FACILITIES
2. CONSORTIA OF STAKEHOLDERS
3. ECONOMIC INPUT/OUTPUT
4. CHEMICAL ENGINEERING DESIGN METHOD

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LIFE CYCLE EFFORTS AT NCSU

• RESEARCH TO DEVELOP RAPID LCI TECHNIQUES
• DEVELOPMENT OF GENERIC TOOLS FOR LCI
• CREATION OF LCI LIBRARY
• RESEARCH TO INTEGRATE LCI WITH ENVIRONMENTAL
  DECISION-MAKING

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A LIFE CYCLE INVENTORY (LCI) IS A COMPLETE MASS
AND ENERGY BALANCE TO DETERMINE

• INPUTS
• CHEMICAL EMISSIONS
• ENERGY NEEDS
• SOME BOUNDARY MUST BE SPECIFIED

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LIFE CYCLE INVENTORY QUALITY

• TRANSPARENCY
• ENGINEERING PRINCIPLES OF MASS ENERGY
• MULTIPLE VIEWS
• LOGICAL MECHANISM TO CHANGE
• EXPECTATIONS OF DECISION-MAKERS
• CRITICAL RELATION OF SYSTEM TO SUSTAINABILITY
  FACTORS

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• Ammonia Process
• CONTENTS OF FACTORY GATE TO FACTORY GATE
• LIFE CYCLE INVENTORY SUMMARY (Byproduct
  allocation not included)
• Chemistry
• Process Summary
• Summary of LCI Information
• Process Diagram Interpretation Sheet
• Process Diagram or Boundary of LCI
• Mass Balance of Chemicals in each Process Stream
  (Highlighting Chemicals that are Wastes and the
  Physical State when Lost)
• Graph of Cumulative Chemical Losses through
  Manufacturing Process
• Graph of Cumulative Non-Contaminated Water
  Use/Emission through Manufacturing Process (Not
  applicable)
• Graph of Cumulative Non-Contaminated Water
  Use/Emission through Manufacturing Process
• Energy Input for each Unit Process, Cumulative
  Energy Requirements, Cooling Requirements
  (exotherms), and Assumed Heat Recovery from
  Hot Streams Receiving Cooling
• Graph of Cumulative Energy Requirements
• Conversion of Chemical Losses and Energy
  Requirements into Environmental Parameters, Prior
  to any Treatment or
  Discharge to the Environment
• Waste Management Summary
• CHEMISTRY
• N2 3H2 ?
  2NH3

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Air 1108 kg/hr
Water 106kg/hr CO2 46.61 kg/hr NO 3.52kg/hr NO2
5.39 kg/hr N2 560 kg/hr Ar 10 kg/hr O2 27 kg/hr
25oC 1 atm
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Compressor A
497.8oC 27.2 atm
974oC 31 atm
(g)
788oC
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760oC 27.2 atm
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8
25oC 1 atm
Secondary reformer
(g)
3
Water 1200 kg/hr
(g)
(g)
6
2
(l)
25oC 1 atm
(l)
(l)
9
(g)
788oC 31 atm
Pump 1
Primary reformer
Natural gas 446.75kg/hr
1-a
360oC 31 atm
Heat recovery A
(g)
(g)
25oC 1 atm
1
7
(g)
Burner
C1 20 oC
C
C2 20 oC
Used as a fuel
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(g)
25oC 1 atm
C3 50 oC
Pump A
Heating fuel
A
Air 688kg/hr
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(g)
C26 20 oC
(g)
C25 20 oC
40oC 31 atm
Shift converter High temp.
Shift converter Low temp.
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Pump C
427oC 31 atm
266oC 31 atm
C7 20 oC
Pump J
(g)
C8 20 oC
Gas/liquid Separator A
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(g/l)
Cooler A
40oC 31 atm
(g)
Heat recovery B
Heat recovery C
90oC 31 atm
C9 50 oC
(g)
(l)
243oC 31 atm
C4 20 oC
C6 50 oC
C27 50 oC
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C5 20 oC
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Water 512.85 kg/hr
Pump B
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B
Pump F
C13 20 oC
C14 20 oC
76oC 20 atm
Carbon dioxide 1179 kg/hr
82oC
(g)
17
(g)
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41oC
20
Cooler C
25
25oC
Carbon dioxide absorber
Carbon dioxide stripper
C15 50 oC
C11 20 oC
Cooler B
Pump D
A
C12 50 oC
C10 20 oC
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Boiler
78oC
(l)
(g/l)
(g/l)
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18-a
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80 oC
76oC
S1 207 oC(g)
S2 207 oC(l)
76oC
Heat exchanger A
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23
82oC
(l)
Pump E
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Steam-turbine centrifugal compressor B
38oC 177 atm
38oC 177 atm
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S7 316 oC (g)
(g)
S8 149 oC (l)
(g)
C16 20 oC
Pump G
Pump H
Pump I
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Steam-turbine centrifugal compressor A
S9 316 oC (g)
S8 149 oC (l)
Heat recovery D
C19 20 oC
C22 20 oC
C17
(g)
(g)
C20
C23
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31
32
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Cooler F
(g)
(g)
(g)
(g)
313oC 20 atm
147oC 170 atm
93oC 204 atm
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(g)
25oC
43oC 20 atm
177oC 170 atm
Cooler D
Cooler E
C24 50 oC
121oC 20 atm
Methanator
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C18 50 oC
C21 50 oC
Refrigerator A
(g)
(g)
158oC 177 atm
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Heat exchanger B
Ammonia Converter
(l/g)
Gas/Liquid Separator C
S5 207 oC(g)
S11 207 oC(g)
S12 207 oC(l)
254oC 177 atm
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-23oC 204 atm
S6 207 oC(l)
(g)
-23oC 204 atm
Heat recovery E
(g)
288oC 20 atm
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(g)
(l)
(g)
-23oC 177 atm
C
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S3 207 oC(g)
Heater A
371oC 177 atm
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(l/g)
-23oC 177 atm
(l)
Gas/Liquid Separator D
S4 207 oC(l)
Refrigerator B
Ammonia Storage
-23oC 1 atm
-23oC 177 atm
NH3 990.88 kg/hr Water 9.38 kg/hr
B
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(l)
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SUMMARY OF LCI INFORMATION Product Ammonia Basis
1,000 kg/hr ammonia Reference Slack, V. and
James R.G., Ammonia, Marcel Dekker, inc.,
1973. Brykowski F.J. Ammonia and synthesis
gas, Noyes Data Corporation, 1981. Plant
Location Comments All mass and energy units
per hour are equivalent to per 1,000 kg of
ammonia Inputs
Chemical Amount Units Comments
Air 1,796.85 kg/hr 688.6 kg of air is used in burning flue gas.
Natural gas 446.75
Water 1,200
Total 3,443.6
Product
Chemical Amount Units Comments
Ammonia 1,000 kg/hr 99 purity (9.4 kg/hr water)
Carbon dioxide 1,179 100 purity
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Process emissions
Chemical Amount Amount Amount Amount Units Comments
Air Liquid Solid Solvent
Ar 13.29 kg/hr
CH4 2.23
CO 2.9
CO2 52.54
H2 3.07
NH3 6.42
NO 3.52
NO2 5.39
Mass balance difference -30.72
Water (513 kg), oxygen (27kg) and nitrogen (560
kg) are not included.
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Energy Requirements
Source Amount Units Comments
Electricity 7.00E02 MJ/hr
Heating Steam 9.00E03 Consider the heat transfer efficiency
Heating fuel 9.86E03 Consider the heat transfer efficiency
Cooling refrigeration
Cooling water -1.71E04
Potential Heat Recovery -9.15E03
Net Energy 1.04E04
Oxygen and nitrogen are not included
Energy requirement minus potential heat recovery
from cooling systems N/A not applicable for this
chemical process
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Carbon frame efficiency
XI
IX
X
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Benzene
T-S yield33
SOCl2/ AlCl3
VI
VII
VIII
V
Tetralone yield37
Separation
Racemic mixture cis(,-) trans(,-)
Total yield12.2
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10 IMPROVEMENT IN CARBON UTILIZATION EFFICIENCY

• WITHIN THE COMPANY (kg/kg Sertraline)
• 97 96 1 (most waste is solvent)
• THROUGHOUT THE PHARMACEUTICAL COMPLEX (kg/kg
  Sertraline)
• 39,098 35,794 3,304
• Over 3,000-fold greater impact

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Solvent usage efficiency
THF
THF
TiCl4
Naphtale- nona
CH3NH2 0C
THF
Naphtalen- amine
mixing 46
Cool 1-5C 47
Stirring 17hr, N2 50
Addition 48
Reaction, Stirring and Cooling lt10C 49
Filtration w/washing 51
Vacuum 52
THF
TiO2 cake
Reactants Solvent
Chemical losses Solvent
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10 IMPROVEMENT IN SOLVENT USAGE

• WITHIN THE COMPANY (kg.kg Sertraline)
• 97 89 8
• WITHIN THE PHARMACEUTICAL COMPLEX (kg/kg
  Sertraline)
• 39,098 38,493 605
• LARGER EFFECT WITHIN COMPANY, BUT GREATEST
  IMPACT IS OUTSIDE COMPANY

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• DIVERSITY OF DATABASE
• LARGE MOLECULES
• FERMENTATION PRODUCTS
• SEMICONDUCTOR FAMILY
• COMMODITY
• SOLVENTS
• OTHERS

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AREAS OF LIFE CYCLE RESEARCH AT NORTH CAROLINA
STATE UNIVERSITY

• CHEMICAL MANUFACTURING (COMMODITY AND SPECIALTY)
• ADVANCED ENERGETIC CHEMICALS
• PHARMACEUTICALS
• CO2 PROCESSING R D
• ANIMAL WASTE MANAGEMENT SYSTEMS
• BENEFICIAL REUSE OF WASTE MATERIALS
• CARPET PRODUCTS
• SEMICONDUCTORS

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CONCLUSIONS

• THE EMPHASIS ON LCI MEETS A SUBSTANTIVE NEED IN
  THE EVOLUTION OF LIFE CYCLE TECHNOLOGY
• NET (OR HIDDEN) BENEFITS ARE OFTEN DIFFERENT
  FROM DIRECT BENEFITS
• LIFE CYCLE INVENTORY QUALITY IS IMPORTANT FOR
  DECISION-MAKING
• APPLICATION OF LIFE CYCLE TO NEW PRODUCTS AND
  PROCESSES IS AN IMPORTANT NEW USE