Sustainable Value Creation in the Fine and Speciality Chemicals Industry

R. Rajagopal KnowGenix, IndiaForeword by Dr David Constable,Director, ACS Green Chemistry Institute, American Chemical Society

• Foreword xv Preface xviiAcknowledgement xxiAbout the Author xxiii1 Transformations in the Fine and Speciality Chemicals Business 11.1 Fine and Speciality Chemicals Industry Structure 11.1.1 Global Chemical Industry Trends 21.1.1.1 Macro Trends Shaping the Fine and Speciality Chemicals Industry 31.1.1.2 Consolidation Continues 31.1.2 Managing Transitions in the Fine and Speciality Chemicals Industry 51.1.2.1 Manage Commoditization Threats 61.1.2.2 Restructure Portfolios through Mergers and Acquisitions 81.1.2.3 Investing in Innovative R&D Platforms 101.1.2.4 Leveraging Emerging Technologies 111.1.2.5 Tapping the Promise of Renewables 121.1.2.6 Rationalization of Cost Structures 121.1.3 Industry Shifts, Competitiveness and Markets 131.1.3.1 Understanding Fine and Speciality Chemicals 131.1.3.2 Shift of Manufacturing and Markets to Emerging Economies 151.1.3.3 Market Focus on Sustainable Products 161.2 Regulations and Fine and Speciality Chemicals Industry 181.2.1 New Directions in Regulatory Regimes 181.2.1.1 GHG and Water Footprint Mapping 201.2.1.2 Impact of REACH on Fine and Speciality Chemicals Industry 201.3 Fine and Speciality Chemicals Industry and Sustainable Practices 211.3.1 Sustainable Value Creation in the Fine and Speciality Chemicals Industry 211.3.1.1 New Growth Models Driven by Sustainability Forces 221.3.1.2 Customer Drives Industrial Sustainability 23References 242 Sustainable Management: Evolution, Transitions and Tools 292.1 Chemical Industry: Aligning with Sustainable Development Mandates 292.1.1 Developing a Sustainable Strategy 302.1.1.1 Defining Sustainability 312.1.1.2 New Green Chemistry and Technology Strategies 322.1.1.3 Sustainability Moves Beyond Manufacturing 332.1.1.4 Managing Sustainability Initiatives 332.2 Sustainability Performance Assessment 342.2.1 Evolution of Tools and Metrics 352.2.1.1 Sustainable Value Creation Tools 362.2.1.2 Sustainable Reporting 372.2.1.3 Role of Sustainability Exchanges and Indices 392.2.1.4 Sustainability Certifications 402.2.2 Carbon Footprint Analysis 402.2.2.1 Trends in CFA 412.2.2.2 Industrial Initiatives in Lowering Carbon Footprints 412.3 Sustainability Trends in the Chemical Industry 432.3.1 Sustainability Strategies 432.3.1.1 Industry Strategy for Sustainable Management 442.3.2 Innovation and Sustainability 452.3.2.1 Innovations: Commercial Developments 452.3.2.2 Regulation Drives Innovation 462.3.2.3 Drivers and Limiters for Innovation 472.3.3 Sustainable Technologies: Reflections 482.3.3.1 Contemporary Trends 482.3.3.2 Promotional Barriers in Developing Countries 492.3.3.3 Future Directions 50References 513 Research and Technology Directions 573.1 Shifts in Fine and Speciality Chemicals Technologies 573.1.1 Evolution of Green Chemistry and Engineering 583.1.1.1 Emergence of a Novel Technology Pool 613.1.1.2 GCT as a Sustainability Tool: Evolving Perceptions 633.1.1.3 Developing Green Chemistry Tools and Metrics 643.1.2 Strategies for Commercializing GCT Models 673.1.2.1 Trends in Design of Greener Processes 673.1.2.2 Advances in Novel Reaction Media 723.1.2.3 Nonconventional Process 733.1.2.4 New Activations 743.1.2.5 Leveraging Green Engineering Principles 753.1.3 Future Directions in GCT 773.1.3.1 Policy Initiatives 773.1.3.2 Emerging Perspectives and Future Challenges 783.1.3.3 The Road Ahead: What Has Been Learnt? 783.2 Catalytic Technologies 793.2.1 New Catalytic Technologies Shape the Fine Chemicals Industry 793.2.1.1 Homogeneous and Heterogeneous Catalysis 803.2.1.2 Phase Transfer Catalysis 843.2.1.3 Asymmetric Catalysis 863.2.2 Biocatalysis 883.2.2.1 Advances in Biotransformations through Biocatalysis 893.2.2.2 Advances in Biocatalysis for Fine Chemicals Synthesis 913.2.2.3 Biotransformations Driven by Microbial Cells 943.2.2.4 Future Directions in Biocatalysis 953.2.3 Advances in Catalysis 963.2.3.1 Novel Catalysis 963.2.3.2 Future Directions in Catalytic Technologies for Fine Chemicals 983.3 Enabling Technologies 993.3.1 Process Intensification: Concepts and Evolution 993.3.1.1 Process Intensification: PI Equipment and PI Methodology 1003.3.1.2 Enabling New Process Options 1013.3.1.3 Micro Reactor Technologies (MRTs) for Fine Chemical Synthesis 1033.3.2 Tools for Eco-Efficient Process Development 1083.3.2.1 Reaction and Process Design 1083.3.2.2 Computational Tools 1093.3.2.3 Combinatorial Chemistry Tools 1103.3.3 Nanotechnology 1103.3.3.1 Nanotechnology: Emerging Areas 1113.3.3.2 Future Directions 1123.4 Product Engineering: A Key Sustainability Tool 1123.4.1 Product Engineering: A Multidisciplinary Approach 1133.4.1.1 Product Design in Formulated Products 1143.4.1.2 New Directions in Product Engineering 1143.5 Emerging Trends in Chemical Sciences and Engineering Education 1153.5.1 New Directions 1153.5.1.1 Context-Based Model 116References 1174 Resource Optimization Strategies 1354.1 Resource Optimization: A Systems Approach 1354.1.1 Process Integration 1354.1.1.1 Heat and Mass Resource Optimization 1364.1.1.2 Water Networks 1374.1.2 Solvent Optimization Approaches 1374.1.2.1 Solvent Optimization Tools 1384.1.2.2 Advances in Solvent Recovery Systems 1394.1.3 Water Optimization Strategies 1394.1.3.1 Closed Loop Wastewater Recycling 1394.1.3.2 Complexities in Wastewater Minimization 1414.2 Waste Valorization to High Value Chemicals 1414.2.1 Chemical Waste Recovery and Valorization 1424.2.1.1 Waste By-products to High Value Chemicals 1434.2.1.2 Waste Exchanges as a Route to Pollution Prevention 1434.2.2 Valorization of Bio-Based Organic Wastes 1444.2.2.1 Bio Wastes to High Value Specialities: Prospects and Challenges 1444.2.2.2 Biosurfactants from Wastes 1454.2.3 Valorization of Carbon Dioxide and Carbon Monoxide 1454.2.3.1 High Value Chemicals from Carbon Dioxide 1464.2.3.2 Novel Developments Based on Carbon Dioxide 146References 1485 Bio-Based Chemicals, Specialities and Polymers 1535.1 Towards a Bio-Based Economy 1535.1.1 Bio-Based Industry: Evolution and Structure 1555.1.1.1 Bio-Based Industry Attracts Investments 1565.1.1.2 Bio-Based Industry Adopts Diverse Strategies 1575.1.1.3 Bio-Based Markets and Trends 1595.2 Biorefinery and Biofeedstocks 1605.2.1 Biorefining Technologies 1625.2.1.1 Conversion Technologies 1625.2.1.2 Biorefineries go Commercial 1635.2.1.3 Future of Biorefining Technologies 1645.2.2 Biofeedstocks 1645.2.2.1 Emerging Trends in Biofeedstocks 1655.2.3 Platform Chemicals: Technologies at a Nascent Stage 1665.2.3.1 Bio-Based Products Value Chain 1675.2.3.2 Platform Chemicals to High End Specialities 1695.2.3.3 Future Research Directions 1725.3 Bioproducts: Moving from Laboratory to Markets 1735.3.1 Bio-Based Commodities 1735.3.1.1 1,3-Propanediol (1,3-PDO) 1745.3.1.2 Epichlorohydrin 1745.3.1.3 Propylene and Derivatives 1745.3.1.4 Butanol 1745.3.1.5 Glycerine 1755.3.1.6 Cellulosic Ethanol 1755.3.1.7 Methyl Methacrylate 1755.3.1.8 Isoprene 1755.3.2 Bio-Based Fine Chemicals 1765.3.2.1 Biosuccinic Acid 1765.3.2.2 Acrylic Acid 1765.3.2.3 Adipic Acid 1775.3.2.4 Furfural 1775.3.2.5 Sorbitol 1785.3.2.6 Levulinic Acid 1785.3.2.7 Glucaric Acid 1785.3.3 Biospecialities 1785.3.3.1 Biolubricants 1795.3.3.2 Biosolvents 1795.3.3.3 Biosurfactants 1805.3.3.4 Bioadhesives 1805.3.3.5 Miscellaneous Specialities 1805.3.4 Biopolymers 1805.3.4.1 Evolution of Biopolymers 1815.3.4.2 Driving Innovations in Bioplastics 1815.3.4.3 Biopolymers Going to the Market Place 1825.3.4.4 Polymeric Resins from Plant Oils 1835.3.4.5 Algal Bioplastics 1845.3.4.6 Bio-Based Natural Polymers 1845.3.4.7 Bio-Based Polymers: Commercial Challenges 1845.4 Lab to Markets: Challenges of Commercialization 1855.4.1 Strategies for Growth: Diverse Perspectives 1855.4.1.1 Commercialization Barriers 1865.4.1.2 Sustainability Strategies in Bio-Based Chain 1885.4.1.3 Future Directions for a Bio-Based Economy 189References 1916 Sustainable Practices in the Fine and Speciality Chemicals Industry 1996.1 Shifts Towards Sustainable Practices 1996.1.1 Investing in Innovative Models 1996.1.1.1 Moving to the Next Level in Sustainability Management 2006.2 Sustainable Practices in the Pharmaceutical Industry 2016.2.1 Sustainabile Transitions 2026.2.1.1 Sustainable Initiatives 2026.3 Sustainable Practices in the Crop Protection Chemicals Industry 2036.3.1 Evolving Sustainability Trends in Crop Protection Chemicals 2046.3.1.1 Diverse Strategies 2046.3.1.2 Biopesticides 2056.4 Sustainable Practices in the Oleochemicals and Surfactants Industry 2056.4.1 Shifts Towards Sustainable Models 2056.4.1.1 Newer Approaches to Novel and Safer Surfactants 2076.4.1.2 Biosurfactants 2106.4.1.3 New Technologies Redefine Oleochemicals 2116.4.1.4 Sustainability Trends 2126.5 Sustainability Practices in the Personal and Home Care Chemicals Industry 2146.5.1 Sustainability Practices gain Momentum in the Personal and Home Care Sector 2156.5.1.1 Industry Developed Rating Standards and Indices 2156.5.1.2 Greener Product Innovations 2166.5.1.3 Shift to Natural Products 2166.5.1.4 Future Directions 2176.6 Sustainable Practices in the Coatings Industry 2176.6.1 Transitions to Sustainable Models 2176.6.1.1 Innovative and Sustainable Coating Technologies 2196.6.1.2 Sustainable Practices at Industry Level 2206.6.1.3 Developments in Sustainable Coating Additives 2216.6.1.4 Future Directions 2226.7 Sustainable Practices in the Adhesives and Sealants Industry 2236.7.1 Transformations in the Adhesives and Sealants Industry 2236.7.1.1 Development of Sustainable Adhesives and Sealants 2236.7.1.2 Commercial Developments 2246.7.1.3 Future Directions 2256.8 Sustainable Practices in the Lubricant and Greases Industry 2266.8.1 Emergence of New Generation Lubricants 2276.8.1.1 Biolubricants: Market Trends 2276.8.1.2 Biodegradable Lubricants: Trends 2286.8.1.3 Product Certifications 2296.8.1.4 Future Directions 2296.9 Sustainability Practices in the Colourants Industry 2306.9.1 Evolution of the Colourants Industry 2306.9.1.1 Emergence of Hi-Tech Colourants 2316.9.1.2 Industry Initiatives Address EHS Concerns 2326.9.1.3 Transitions to Sustainable Practices 2326.9.1.4 Future Directions 237References 2387 Sustainable Value Creation Strategies 2457.1 Why Sustainable Value Creation? 2457.1.1 Evolving a Strategy for Sustainable Value Creation 2457.1.1.1 Value Creation Initiatives 2467.1.1.2 Approach to Create Sustainable Value 2477.1.1.3 Strategic and Operational Approaches 2487.2 Innovating for Sustainable Value Creation 2497.2.1 Innovation in Practice 2497.2.1.1 Capturing Value Through Innovations 2517.2.1.2 New business models 2537.2.1.3 Collaborative Innovation 2547.2.2 Innovation in Technology, Feedstocks and Materials 2557.2.2.1 Technology 2557.2.2.2 Feedstocks 2557.2.2.3 Materials 2567.2.3 Innovation in Supply Chains 2567.2.3.1 Chemical Management Systems 2567.2.3.2 Chemical Servicing 2577.2.3.3 Chemical Leasing 2577.3 Strategic Cost Management 2577.3.1 Strategic Cost Management: A Key Tool 2587.3.1.1 Green Chemistry and Technology Tools 2597.3.1.2 Cluster Models: A Key to Sustainable Manufacturing 2597.3.1.3 New Operating Models 2607.3.1.4 Product Portfolio Rationalization 2617.4 Prognosis for the Future 2617.4.1 Moving up the Value Chain 2617.4.1.1 Managing Sustainability Goals 2627.4.1.2 Innovation to Markets 2637.4.2 Emerging Perspectives in Sustainable Technologies 2647.4.2.1 Technology Transfer 2647.4.2.2 Technology Strategy 2657.4.2.3 Human Resources Development: Shifting Focus 2667.4.3 Game Changers in the Industry 2667.4.3.1 Game Changing Technologies 2677.4.3.2 Power of the Consumer 268References 270Index 273