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Transforming Waste into Wealth; A Speciality Chemicals Case Study

Updated: Mar 5

Abstract


In this case study, we delve into the innovative simulation services provided by Parenting Absolute Engineering. Focused on the speciality chemicals sector, the study outlines the objectives, methods, and impactful results achieved through advanced simulation techniques. Our collaborative approach, rigorous methodology, and cutting-edge tools have empowered clients to make informed decisions and drive success. This case study offers a glimpse into the transformative power of simulation in translating waste to wealth in the speciality chemicals sector, showcasing Parenting Absolute Group's commitment to excellence and green, lean, and clean client-centric solutions.


Keywords: Speciality Chemicals, Waste to Wealth, Simulation, Performance Enhancement, Green Technology, Green Chemistry, Case Study


Introduction



Specialty chemicals are unique and high-value chemicals used for specific applications such as industrial, agricultural, and personal care products. These chemicals are tailored to meet specific performance requirements and are often used in small quantities. They can include adhesives, coatings, polymers, and additives, among others. Their diverse applications make them essential for various industries, from healthcare to electronics. Manufacturers and suppliers of speciality chemicals focus on innovation and customization to meet the evolving needs of their customers. This sector plays a crucial role in driving technological advancements and enhancing product performance across numerous industries.


In the ever-evolving landscape of chemical processing and manufacturing, innovation isn't just about creating new products; it's about reimagining processes to align with sustainability and economic efficiency. Our journey into sustainability and green process design was sparked by ABC Co.*, a company specializing in the manufacture of speciality chemicals, with their facilities manufacturing over 45 chemical compounds, some, precursors to other processes, some, laboratory salts, and others, pharmaceutical and biochemical ingredients.


At the heart of their operations, a transformative process design not only minimized environmental impact but also unlocked a stream of revenue previously discarded as waste. This case study delves into the strategic use of simulation and optimization to revolutionize the production process.


Let's delve into the details of how this company harnessed cutting-edge technology to reshape its manufacturing paradigm.


Performance


The consultation was initiated by ABC Co.* after it was observed that a large quantity of a compound, considered waste, was ultimately converted into carbon dioxide. Subsequent to this discovery, Parenting Absolute was consulted by ABC Co.*, at whose behest, our team of seasoned engineers embarked on a journey to design and develop an intricate process. Thus began our voyage towards facilitating a reaction transforming the formerly disposed compound into utilitarian compound possessing the potential of commandeering its own share of the market.


Initiating the project, our engineers analyzed the data from the research performed by ABC Co.* Subsequently, the development and design of the process at hand was set in motion. Working synergistically, the engineers developed the process, which may, as a whole, be summed up in Fig. 1.


Figure 1 Process Flow Diagram

Working wholeheartedly on constructing the process most nearing ideality, a culminating solution was developed on the foundation of three principles.


  1. Minimize the concentrations of pollutants present in the exit stream.

  2. Minimize the overall costs of the process and maximise profits.

  3. Maximise the yield and purity of the products exiting the final processing stage. 


The process depicted in Figure 1 was designed through a cascading approach. To provide an overview of the cascading approach, two known processes are modelled and the degrees of freedom are analyzed. The residual stages of the process are subsequently modelled and placed in their own virtual environment on our simulation software. The performance of the machines in the virtual environment is then fine-tuned to achieve the maximum possible outcome.


With a comprehensive flow sheet and simulated virtual equipment, the design system produced by the engineers at Parenting Absolute observed the overall levels of carbon dioxide produced at the process drop to near zero, while the final yield of the compound at the tail end of the process could be divided into two purities, extra pure (99.9%), and pure(98-99%) [to be further assayed on complete equipment operation].


Results


The simulation performed provided our clients with invaluable strategies and an enhancement in the profitability of their processes. The quantified outcomes obtained have been depicted in Table 1.


Table 1 Quantifiable Results of Simulation

 

  1. The carbon footprint of the organisation was reduced by approximately 40%, while other pollutants released were reduced by a similar factor (25-37%).

  2. The excess chemical compounds from other processes were efficiently integrated into the newly formed process, effectively decreasing waste generation.

  3. The ROI of the project was obtained at an approximate 43%.


 

Services Utilized


Process Plant Simulation

Scale up your existing facilities to increase your products and enhance your processes





 






*Anonymity for purpose of case study

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