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Lecturer-Practitioner (LP):
Sustainable Chemical
Process Industries
Study Material For Education Purpose (30 Slides)
Pamulang University

About Me
/LinkedIn
https://www.linkedin.com/in/muh
ammad-faris-naufal-684a031a9/
Muhammad
Faris Naufal
/Email
consultantfaris@gmail.com
Technical-Process Engineer:
Vinyl Chloride Monomer Plant
Full Time – PT Sulfindo
Adiusaha
ESG & GHG Accounting
Consultant
Freelance – CarbonEthics
2018 2023
2020
2019
Air Pollution and GHG
Emissions Control Manager:
GHG Mitigation & Cost Saving
2022
Lead Process Engineer
& Hazop Leader: Chlor Alkali,
Monomer, Polymer Plant
GHG Accounting &
Reporting Section
Head
Full Time – PT
SMART Tbk
Providing Services
Corporate Sustainability Trainer |
Technical Reviewer for ISO 14064 |
Energy & GHG Reduction Strategies |
Environmental Impact Assessment
Bachelor of Chemical Engineering | Certification: Certified Risk Associate (CRA), HAZOP, Air Pollution
Control Manager, Life Cycle Assessment, Energy Management System | Lecturer-Practitioner (LP) |

The Principle of Green Chemistry &
Green Chemical Engineering

Sustainable Development
Fig 1. Sustainable Development Goals (SDG) via ESG view1)

Green chemistry focuses on the design of chemical products and processes that are environmentally benign. Green
chemistry can be seen as a tool by which sustainable development can be achieved. The application of green chemistry is
relevant to social, environmental, and economic concerns.
Paul Anastas and John Warner in their book published in 1998 introduced the concept of green chemistry as a philosophy
for the design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances.
Fig 2. Design of green chemical process2)

1. Prevent
Waste
Twelve Principles of Green Chemistry
Design the process such that waste is prevented at the outset rather than treating or
cleaning up waste after it has been generated
Fig 3. The costs of waste3) Fig 4. Waste management within a chemical
manufacturing process3)

2. Maximize
atom
economy
Synthesize or design methods that maximize the incorporation of all materials used
in the process into the final product to minimize waste generation. Select an
alternative synthesis route or raw material such that the number of side reactions
generating undesired by-products is minimal
Atom economy =
Molecular weight of desired product
Sum of mol eecular weight of all the products produced
x 100%
Atom economic reaction is considered with a high ratio of
atom utilization. Therefore, features are born with
(1) maximizing the conversion of raw materials (a
measure of how efficiently the raw material is used)
(2) minimizing the waste emission: e.g., the ideal “zero
emission” process.
According to the concept, the higher the atom efﬁciency
is, the less waste is produced; as a result of less pollution
to the environment.

Criteria for Evaluation of Reaction/Process
The concept of atom economy has been expanded usefully by Sheldon [8,9], by the introduction of the term ‘E factor’,
which is the ratio of the kilograms of by-product per kilogram of product.
Conversion =
Transformed quantity of substrate A
Total amount of substrate A
x 100% Yield =
Experimental quantity of the target product
Theoretical quantity of the target product
x 100%
Selectivity =
Quantity of the target product
Total quantity of reactants subtracts the remaining reactants
x 100%
Of course, the atom economy concept should not replace consideration
of yield, ease of product isolation, purity requirements, etc. when
devising a chemical synthesis but it should be thought of as an additional
consideration.
The economics of chemical production are changing, particularly in
the ﬁne, specialty, and pharmaceuticals sectors, where waste generation
and other environmental considerations are becoming an increasingly
signiﬁcant [10] proportion of the overall manufacturing cost.

Raw material yielding maximum atom efficiency is selected. For example, maleic anhydride can be produced using
either benzene or n-butane as raw material and the corresponding reactions are
Case Study: Atom Economy
Atom economy for the n-butane route is 57.6% and 44.4% for the benzene route. Thus, n-butane is preferred over
benzene as a raw material for production of maleic anhydride. Choosing an atom-efficient raw material is the first
step in designing an environment-friendly chemical process.

Case Study: Atom Economy

3. Design less
hazardous
chemical
synthesis
Synthetic methods should be designed to use and generate substances that possess
little or no toxicity to human health and the environment.
4. Design for
Safer
Chemicals
Design chemical products with the least toxic contamination to the human and
environment.
5. Use safer
solvents and
auxiliaries
The use of auxiliary substances (e.g. solvents, separation agents, etc.) should be
made unnecessary wherever possible and innocuous where necessary. If necessary,
use solvents that are benign to the environment.
In this context, supercritical CO2 (scCO) and ionic liquids show remarkable potential
as eco-friendly substitutes for toxic solvents.

6. Design for
Energy
Efﬁciency
Design processes for higher energy efficiency so that net consumption of energy (fuel) is
minimized and the impact of energy usage on the environment is reduced.
The processes that operate at ambient
temperature and pressure consume less
energy and are preferred over high-
temperature and high-pressure
systems. The possibility of reducing
energy and material consumption through
appropriate processes and heat
integration should be explored.
Novel combo systems that integrate
reactors with mass exchangers offer
plenty of opportunities for the design of
energy-efficient chemical processes.

Industrial Practice for Energy Efficiency: ISO 5000 Series (Energy Management System)

Industrial Practice for Energy Efficiency: Case Study in EDC-VCM Production
Energy Mapping in EDC-VCM Production Process

EDC Cracking Furnace Process Philosophy

Energy Consumption 2021 (GJ) – VCM Plant

Production Capacity 2021 (MT) – VCM Plant

Specific Energy Consumption (SEC) 2021 in GJ/MT – VCM Plant

Baseline and Baseload 2021 – VCM Plant
𝑲𝒐𝒏𝒔𝒖𝒎𝒔𝒊 𝒆𝒏𝒆𝒓𝒈𝒊 𝑮𝑱 = 𝟎. 𝟗𝟏𝟏𝟑 × 𝑷𝒓𝒐𝒅𝒖𝒌𝒔𝒊 𝑽𝑪𝑴 (𝑴𝑻) + 𝟏𝟑𝟏𝟗. 𝟔
Indicator Value Recommendations
Coefficient of Determination (R
2
) 0.89 ≥ 0,75
Coefficient of Variation of Root
Mean Square Error (CV RMSE)
0.10 < 0,2
T-statistic (for Produksi) 9.05 > 2
Baseload Value per Month 1,319.62 ≥ 0
Bias Model 0% < 0,0005%

Actual Energy Consumption vs Modelling 2021 – VCM Plant

Industrial Practice for Energy Efficiency: Case Study in EDC Cracking Furnace
Specific Energy Consumption (SEC) – Design Condition

Heat Duty Profile in EDC Cracking Furnace (April – Mei 2022)

EDC Feed Flowrate to EDC Cracking Furnace (April – Mei 2022)

Specific Energy Consumption (SEC) – Actual Condition

Comparison SEC Actual and Design
EDC Cracking Furnace
UDARA
FLUE GAS
TO STACK
EDC
VCM, HCl
Steam
Gen
WATER
(TON/HOUR)
STEAM
(TON/HOUR)
FLUE GAS
TO WHB BFW
PRE-HEAT
BFW
(TON/JAM)
HOT WATER

Cost Saving Opportunity in EDC Cracking Furnace
SEC Alteration
22.8 kkal/kg EDC
Energy Saving Opportunity
8.347.625.690 kcal/year
EDC Feed Flowrate
46280 kg/hour
1 year = 7920 hours
EDC Feed Flowrate
366.527.600 kg/year
Energy Saving Opportunity
33.232,25 MMBTU/year
Cost Saving Opportunity
Rp. 2.417.646.473/year
1 MMBTU = US$ 5

Process Review – O2 Flue Gas Profile (April – Mei 2022)

Recommendations
1) Recheck Gas Composition And Calorizing Value Of Natural Gas Used As
Fuel in EDC Cracking Furnace
2) Re-evaluate Potential Points Of Air Entry that Cause Increasing Air Excess
3) Check the Heat Transfer in the Radiation Zone that Flows into the Coils,
Especially the Potential for Carbon Deposit Hotspot in the Coils

7. Use
renewable
feed stocks
Choose a raw material or a feedstock that is renewable rather than depleting, wherever
possible. The alternate route for the synthesis of chemicals using biomass as feedstock is
an option to be explored.
For example, the biochemical synthesis of adipic acid using d-glucose as a feedstock is
an eco-friendly alternative to the traditional chemical synthesis of adipic acid using
benzene as feedstock.
The two main arguments for reducing our dependency on
fossils and increasing our use of renewable feedstocks
are:
1) To conserve valuable supplies of fossil fuels for
future generations (a core principle of sustainability).
2) To reduce global emissions of greenhouse gases,
especially carbon dioxide (renewable resources being
CO2-neutral overall).
Chemicals manufacture from renewable resources,
therefore, ideally should provide additional benefits
such as reduced hazard, more efficient processes,
reduced cost, reduced pollution, meeting market
needs, etc.
Chemistry does have a vital role to play in reducing the
requirement for fossil fuels, e.g. more efficient
combustion processes, the development of energy-
efficient solar and fuel cells, and the production of
biodiesel.

8. Reduce or
avoid the use
of chemical
derivatives
Unnecessary derivatization (e.g. use of blocking groups, protection/deprotection,
temporary modiﬁcation of physical/chemical processes) should be minimized or avoided if
possible because such steps require additional reagents, energy use, and generate
waste.
9. Use catalysis
in place of
stoichiometric
reagent
Use catalysis in place of stoichiometric reagents: Catalyst-based synthesis of
chemicals results in lower pollution generation compared to synthesis routes that
make use of stoichiometric reagents. Thus, a catalyst plays a crucial role in the
design of environmentally benign chemical processes. A significant improvement in
waste reduction can be achieved through the proper selection and design of solid
catalysts.

10. Design
chemicals to
degrade after
use
Chemical products should be so designed that at the end of their function, they break
down into innocuous products and do not persist in the environment. For example,
biopolymers such as polylactic acid (PLA) and polyhydroxyalkanoates (PHA), used as
substitutes for chemical plastics, exhibit excellent biodegradability, unlike plastics.
11. Real-time
Analysis for
Pollution
Prevention
Develop analytical methods that allow for real-time monitoring and control prior
to the formation of hazardous substances.
12. Inherently
Safer Chemistry
for Accident
Prevention
Substances used in chemical processes should be chosen to minimize the potential
for chemical accidents including releases, explosions, and fire.

Twelve Principles of Green Chemistry: Summary

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