Fine Chemical Technology
CLL786
Lecture 1
Prof. Rajesh Khanna
Department of Chemical Engineering
Indian Institute of Technology Delhi
January 11, 2016
Lecture 1
Fine Chemical Technology
Fine chemicals
Products of high and well defined purity
Manufactured in reasonably small amounts
Sold at relatively high prices
Types:
Intermediates
Final products
Active ingredients
Additives
Aids in processing
Lecture 1
Fine Chemical Technology
Fine chemicals industry
Drug industry (50%)
Agriculture industry (25%)
Fragrances/Flavors
Dyes/Pigments
Food additives
Trends in Industry
Custom synthesis
Chemical trees
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Fine Chemical Technology
Manufacturing processes
Differences between Commodity chemicals
and fine chemicals
Complex multifunctional molecules
labile
unstable at high temperature
sensitive to environment (pH etc.,)
Hence, inherently safer designs and high levels
of controls
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Fine Chemical Technology
Manufacturing processes
High added value products
Expensive raw material
Selectivity is crucial
Degree of utilization
isolation/purification is difficult
large stream of pollutants
Use of hazardous chemicals for production
safety
effluent disposal
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Fine Chemical Technology
Manufacturing processes
Batch/stirred tank reactors
Great variety of products
Large inventory
Heat transfer limitation unlike continuous processes
multipurpose plants
Accurate analytical methods (ppm or ppb
levels)
Chemistry + Catalysis + Process intensification
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Fine Chemical Technology
How a Chemist works?
Focus on properties (end result)
Means are not so important
Raw material
Time
Waste disposal
Exothermic reactions
Less inventory
Diff. conditions
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Fine Chemical Technology
Course Overview?
Course deals with issues which
chemists neglect to lead to economic
manufacture of fine chemicals.
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Fine Chemical Technology
Course Content
Introduction to fine chemicals
Catalysis and selectivity
homogeneous vs. heterogeneous catalysis
Bio-catalysis
Clays (Zeolites)
Phase transfer catalysis
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Fine Chemical Technology
Course Content
Selectivity knowledge about elementary
steps
Process intensification
Manipulating equilibrium
Large surface area for mass transfer controlled
reactions
Solvents (Ionic liquids)
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Fine Chemical Technology
Process Development
Impurities in raw material
Recycled streams
Level of understanding
Numerical methods
Different steps
Accessing hazard/safety
Development personnel
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Fine Chemical Technology
Process Development
Separation methods
RO
Filtration
Chromatography
Plants (Multipurpose)
Batch or Continuous
Homogeneous or Heterogeneous
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Fine Chemical Technology
Objective
Process development and scale up
Techniques for product isolation
Implementation of new processes
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Fine Chemical Technology
Textbook
Fine Chemicals Manufacture: Technology and Engineering
Andrezi Cybulski
M. M. Sharma
J. A. Moulign
R. A. Sheldon
Elsevier Science and Technology Books (2001)
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Fine Chemical Technology
Evaluation
Minor I 20%
Minor II 20%
Major 40%
Term Paper 10%
Assignments 10%
Open book, Open notes examination
Non graded courses unit: 20 design projects
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Fine Chemical Technology
Classifications of Chemicals
Chemicals are classified based on production volume
and character.
Commodities: large volume and industry
specification (acetone, ethylene oxide phenol
etc.)
Pseudo Commodities: large volume but sold on
the basis of performance (polymers,
surfactants, paints etc.)
Speciality: low volume but sold on the basis of
performance (pharmaceuticals, pesticides,
flavours, fragrances)
fine: low volume but sold as per customers
specification (intermediates for speciality)
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Fine Chemical Technology
Example
Ampicillin Production
Commodities: Toluene and Glucose
Fine Chemicals: D-Phenylglycine,
6-Aminopenicillanic acid, bulk ampicillin
Speciality: Formulated ampicillin
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Fine Chemical Technology
Process Selection
Cost of goods (raw material, energy, labour)
supplied (CGS) approach does not work.
Process Profile Analysis is much more useful.
Operating cost
Capital investement
Process control
Risk to personnel and plant
External factors
developed in 1980s, less emphasis on environmental
impact
Lecture 1
Fine Chemical Technology
Volume Value Factor (VVF)
VVF is used to further subdivide the categories
VVF =
(kg /yr ) $/kg
103
High VVF > 70
Medium VVF 10 69
Low VVF < 10
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Fine Chemical Technology
Operating Cost Analysis by VVF
Parameter
raw material cost
($/kg)
yield efficiency
(avg. yield)
throughput time
(time per cycle)
throughput volume
(reactor space/kg product)
Subtotal
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High Medium Low
16
13
10
15
13
10
10
50
43
35
Fine Chemical Technology
Capital Investment Analysis by VVF
Parameter
Number of steps
Special equipment/technology
Subtotal
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High
4
2
6
Fine Chemical Technology
Medium
6
7
13
Low
8
12
20
Process Control Analysis by VVF
Parameter
Reproducibility
Tolerance to abuse
Linearity
Subtotal
High
6
6
2
14
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Medium
4
4
2
10
Low
3
3
3
9
Fine Chemical Technology
Process Profile Analysis Scores
Parameter
High
Operating Costs
50
Capital investment
6
Process control
14
Risk to plant and personnel 16 21
External factors
14
Subtotal
100
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Fine Chemical Technology
Medium
43
13
10
24
13
100
Low
35
20
9
12
100
Risk to Plant and Personnel
Environmental abuse potential
Occupational health/safety hazard
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Fine Chemical Technology
External Factors
raw material availability
susceptibility to regulatory changes
patent protection
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Fine Chemical Technology
Example
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Fine Chemical Technology
Example
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Fine Chemical Technology
Example
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Fine Chemical Technology
Example
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Fine Chemical Technology
