Industrial Problems YICC2010

8/7/2019 Industrial Problems YICC2010

1/20

Institute of Chemical TechnologyMumbai

Extends cordial welcome to all

participants for

Young Innovators Choice Competition10


2/20

Industrial Defined Problems

Young Innovators Choice Competition10


3/20

Pharmaceutical invention and research are increasingly focusing on delivery

systems which enhance desirable therapeutic objectives while minimizing sideeffects. Multiple particulate drug delivery systems especially suitable for

achieving controlled or delayed release oral formulations with low risk of dose

dumping, flexible and short gastric residence time. A recent trend in drug

delivery market is to compressed controlled/ delayed released pallets into tablets

eg. Nexium tablets, Torol XL etc.

List down the challenges associated with compression of coated pellets

into a tablet

Enumerate possible reasons for failure of functionality of coated pallets

Suggest different strategies/ approaches to overcome the challenges

Provide an account of granulation of diluents(non-pellets exipients) as a

strategy i. e. Use of cushioning beads

Which of the strategy according to you should be most successful in

preserving the functionality of pallets?

RUBICON RESEARCH PVT. LTD.


4/20

Suggest different methods/reagents/catalyst for the

dehydration step.

Compare them on the basis of

cost and chose best one. Suggest alternative commer-

cially viable routes for the

preparation of final compound A

Compare all the routes w. r. t.

cost

A

O

NOH

H2N

HN

SO3H

NH

NH2

HN

NH

SO3H

NOH

AcONa/ CH3OH.H2O

SO3H

N

SO3H

N

SO3H

N

N

N

N

NH

HO3S

HN

NOH

PROBLEM ???Removal of H2O

ESKAY DYESTUFF PVT. LTD.


5/20

Metathesis Reactions using Economically cheaper

CATALYST for

e.g.

R-CH=CH2 + CH2=CH-OH R-CH=CH-OH

Alpha-Olefin Allyl Alcohol 2-Alkenol

JAVDEV CHEMICAL INDUSTRIES


6/20

Suggest the methods to remove starting materials

viz. Vitamin A acetate and methyl palmitate and also

by-products of the reaction like Vitamin A alcohol

from vitamin A palmitate

Compare economy of the processes

PIRAMAL HEALTHCARE


7/20

H O

Provide cost effective (not more than $20)

and scalable synthetic approach for

2-Ethyl-butyraldehyde,

which is key starting material for many APIs

DR. REDDYS LABORATORY LTD.


8/20

Pressure less Emulsification of High Density PolyethyleneWax (HDPE Wax) to make high concentrated emulsion :

To make such type of emulsion we need pressure vessel because of high

melting point of HDPE wax so their is need to design emulsification

technique to emulsify at atmospheric pressure and in an open top vessel.

We need cationic nature of the emulsion, reason being cationic nature

gives better exhaustion in application and good handle on the fabric/yarn.

To select the emulsifier system in such a way that the final emulsion must

be cationic in nature(having pH


9/20

How to best use (recycle) waste sulfuric acid

generated from sulfonation reactions

Sulphonation of organic molecules using sulfuric acid / oleumgenerated lots of sulfuric acid waste (concentrated/ dilute/

contaminated/ colored). This leads to tremendous load on

effluent treatment which is environmentally non-friendly with

loss of energy and money. This waste/diluted sulfuric acid need

to be reuse to eliminate / minimize the effluent which is eco-

friendly and cost effective.

HUNTSMAN


10/20

1) Manufacture of Chlorostyrene by decarboxylationof Chloro Cinnamic acid

Emphasis should be on Yield, Isolation and purity

Design a plant to manufacture for the best route

2) Desulfonation of 2,6-dinitro-4-toluene sulfonic acid

Exact and Feasible and route for desulfonation

METROPOLITAN EXIMCHEM LTD.


11/20

1 ) Economical routes of Synthesis of 4-(2-Methoxyethyl)

phenol CAS No. 56718-71-9 and Comparison of all routes

Design a plant to manufacture for the best route

Manufacturing cost should not exceed US$ 12 /kg

Special emphasis on following starting raw materials,

(a) Phenylethyl alcohol (b) p-Chlorophenol

2) Manufacture of POLYALLYLAMINE

HYDROCHLORIDE starting from Allylamine

The RMC expected is US$ 2.5-3.0

COLOURTEX PVT. LTD.


12/20

Replacement of Nitric acid based oxidation by air oxidationA large number of intermediates needed for the manufacturing of the

pharmaceutical, agrochemical and colorant products

e.g. 2-4, dichlorobenzoic acid, p-nitrobenzoic acid, cyclohexanone etc. are

currently made by oxidation of respective substrates using HNO3.These reactions are usually carried out at high temperature and pressure and

characteristically demand large number of safety precautions which results into

high capital cost.

In addition, NOx gases get formed which are either difficult to recover and

forms of strong contendant for global warming

Alternatively, oxidations can be carried out using air.

You are required to develop complete process description along with equipment

design and details for practical implementation point of view

CHEMCRUX CHEMICAL ENTERPRISES


13/20

Municipal waste: Converting a liability into anasset

Each town face the problem of the disposal of solid waste. For

instance Mumbai and Singapore individually produce a solidwaste of about 8000 tons per day. The disposal faces several

acute problems.

However there are at least 5 ways by which these liabilities canbe converted into a profit making assets.

You are required to select the most economical one

GLOBAL ENVIRONMENTAL MANAGEMENT CONSULTANTS


14/20

A company is producing 300T/d of ethyl acetate. It has about

0.5 % moisture and the same amount of acidity.

The management has reviewed the market for semiconductor

quality solvent ( acidity


15/20

A Company is producing 1000 TPD of palm oil, leaving a

large amount of biomass .

Since it is being considered as a resource material, developa strategy to utilize it as a future business for the company

The plan should be complete in giving possible earnings to

the company to sustain itself.

ICT PROBLEM -2


16/20

Design an economical functional food for prevention

Diabetes and

Coronary Heart Disease (CHD)

Product should be from Natural sources which can be from

Microorganism and Plant extract

Design the process using advanced technology.

YICC-YRC TEAM, ICT (PROBLEM -3)


17/20

A plant is manufacturing Soda Ash using the Solvay Process.

An important stage of this process is to recover free ammonia which is used

for subsequent recycle.

This is achieved by steam stripping of the preheated filtrate solution which

contains almost the entire ammonia, in a packed tower.

This tower employs two beds each packed to a height of 20 ft and a diameterof 10ft.

The plant personnel had initialy packed these two beds with 1.5 inch ceramic

Raschig rings.

During the initial installation, the packings were lowered from the top of the

column in 55 gal drum and spread evenly over the entire 10 ft diametertower.

The normal operation employed a flow rate of filtrate varying from 350 to

480 gal/min.

Exergy - ICT (PROBLEM 4)

Cont..


18/20

The tower was running successfully for a few months. But suddenly, the

efficiency of the tower decreased considerably.

Hence, it was shut down for rectification.

The process consultant was called and he suggested that there might be some

problem with the type of packing used.

The tower packing were removed and it was repacked with 1.5 inch ceramicpall rings by dumping the packing from the column sidewall through a

manhole present above the packing.

However, when the tower duties were resumed, it was noticed that a greater

amount of steam was required to strip the same amount of ammonia from the

filtrate, thus indicating a loss of efficiency. In an effort to determine the cause of this decreased efficiency, plant

personnel ran temperature checks along the circumference of the tower.

The maximum temperature difference of the liquid at the top of the packed

bed was 50F around the entire circumference (radial variation).

Cont..

Cont..


19/20

However, by the time the liquid reached the bottom of the top packed

section, the maximum temperature difference around the circumference was300F.

This was a matter of great concern for the plant personnel. The previous

consultant was dismissed and you have been hired as the new process

consultant.

Based on this, please answer the required questions:

Would the previous process consultant be absolutely right in claiming to

rectify the problem by substituting rasching rings with pall rings? According

to you, what caused the decrease in the efficiency of the column? Give

justification.

During subsequent startup, why didnt the steam stripping efficiency

improve?

What will you do to rectify the problem of decreased efficiency of the

column?

Cont..


20/20

Special Thanks to.. RUBICON RESEARCH PVT. LTD.

ESKAY DYESTUFF PVT. LTD.

JAVDEV CHEMICAL INDUSTRIES

PIRAMAL HEALTHCARE

HUNTSMAN

METROPOLITAN EXIMCHEM LTD.

INSTITUTE OF CHEMICAL

TECHNOLOGY, MUMBAI

DR. REDDYS LABORATORY LTD

COLOURTEX PVT. LTD.

CHEMCRUX CHEMICAL

ENTERPRISES

GLOBAL ENVIRONMENTAL

MANAGEMENT CONSULTANTS

Documents

Industrial Problems YICC2010