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Chemingineering – Sense out of Sensors

Sensors are the eyes and ears of a chemical plant. They are traditionally used for process control and optimisation. But in recent years, sensors have expanded their sphere of influence and they are getting increasingly integrated into new applications like predictive analytics and predictive maintenance. Sensors are helping to improve the efficiency, reliability, safety and security of chemical plants.

Sensors play a crucial role in process control in the chemical industry. Classically the sensors have been limited to detect the five major process parameters – pressure, temperature, flow, level and composition. But increasingly, the scope of sensors has been expanding away from traditional process control to a whole gamut of new areas including predictive analytics, asset monitoring and predictive maintenance, leak detection and corrosion monitoring. Many bigger industries have installed a variety of sensors to improve the efficiency, safety, reliability and security of their operations. The deployment of sensors for these unconventional applications are growing exponentially.

Thermography

Thermography uses an infrared camera to detect the heat emitted from various equipment and is an invaluable diagnostic tool for predictive maintenance. It is a quick, real-time, and non-invasive method of collecting valuable information about the health of plant assets. Thermography is used for the early detection of material wear and tear and thus avoid unscheduled plant outages and loss of productivity. It can detect impending insulation failures and thus reduce energy losses through taking corrective actions in advance. It has been used for troubleshooting performance loss in heat exchangers. Thermography can complement traditional methods to provide valuable insights about the plant equipment and improve their performance, efficiency and reliability.

Steam Traps

The ubiquitous steam traps play an extremely crucial role of conserving energy and water in the chemical industry. Yet they don’t usually get the attention they deserve as they are small and notoriously difficult to access. Steam traps are often prone to malfunction and failure. They can get plugged by solids and corrosion debris in condensate. They are also vulnerable to vibration induced by water hammer. A 2014 survey by US Department of Energy reported that approximately 20% of steam generated in a boiler is lost due to faulty and malfunctioning steam traps in the consumers. A good way of understanding steam trap’s performance is to listen to them. Steam traps open intermittently to discharge condensate in slugs and this creates a characteristic noise in the condensate piping. Tracking the signature of this noise will reveal a good deal of information about the health of the steam trap. Installing an acoustic transmitter in the steam trap discharge piping will help to monitor the health of steam traps and plan their predictive maintenance.

Fugitive Emissions

Chemical industry is plagued by fugitive emissions, which occur due to a plethora of complex reasons that are either accidental or unplanned. Faulty equipment is the most common reason. Evaporation losses from storage tanks are classified under fugitive emissions. Fugitive emissions are difficult to monitor and measure as they are small and scattered over a wide area of the plant facilities. Besides creeping loss of material, they are also a serious threat to health and environment. There is a rising clamour to curb fugitive emissions through design and engineering solutions. But their effectiveness can be understood only if there is a robust method of detecting these emissions in the first place. Also, if the exact sources of these emissions are not identified, it is impossible to fix the problem. Portable leak detection instruments have been used for monitoring fugitive emissions. Flame Ionisation Detectors (FID) are commonly used for this purpose. The sample is ionised in a hydrogen flame and the positively charged ions are attracted to a negatively charged collector to produce a current that is proportional to the concentration of ions. FID is a highly sensitive instrument to detect hydrocarbons. Another commonly used detector is the Photo Ionisation Detector (PID) which uses UV light for ionising the sample. FID can detect VOCs more accurately than PID. PID is more useful to monitor a single compound in low concentrations. Infrared cameras have recently been pressed into service for detecting the thermal signatures of emissions from large industrial sites.

Corrosion Monitoring

Corrosion is a pernicious problem in the chemical industry. It can cause catastrophic failure of equipment and piping if left unattended. Round the clock monitoring of corrosion is desirable to maintain the mechanical integrity of plant assets. Monitoring is essential to establish the efficacy of corrosion management and inhibition programmes and fine tune them. Corrosion monitoring can be offline through weight loss measurements in the laboratory or online by inserting probes into the process streams. Probes may be mechanical, electrical or electrochemical. A simple way of monitoring corrosion is to measure the change in ohmic resistance of a corroding probe inserted into the process stream. Another common method is to insert two electrodes of dissimilar metals and measure the current flowing between them. The current will change when one of the electrodes starts corroding. This technique is particularly useful for monitoring systems where the corrosion is due to dissolved oxygen. Asset failures typically occur due to wall thinning below a critical thickness due to corrosion or erosion. Ultrasonic thickness measurement is the most accurate and reliable method of assessing corrosion. Online ultrasonic probes can be installed in a specific part of the equipment where high degree of corrosion is anticipated to closely monitor the thickness during the asset’s entire service life.

Biosensors

Biosensors use biological molecules like enzyme or DNA to detect the presence of chemicals in trace amounts. They are used to measure pesticide residues and other toxic substances in the environment. Biosensors are made up of bioreceptors, like DNA or enzymes, which interact with the sample that is being tested. The resulting biological response is translated by transducers into optical or electrical signals. Biosensors have a wide range of applications, especially in medicine. In the chemical industry, they are used to control fermentation processes and also to monitor industrial effluents for trace contaminants.

Soft Sensors

A soft sensor uses process data measured by “hard” sensors and a model to predict a target output. Soft sensors thus provide indirect measurement. They are used to predict process parameters that cannot be measured at all or only through sophisticated instrumentation. For example, biomass concentration in a bioreactor. Soft sensors can also be used to detect sensor faults. A hard sensor reading that diverges widely from that predicted by soft sensor can be quickly red-flagged as an outlier and ignored. Soft sensors are expected to come into prominence as more and more mainstream chemical processes are replaced by biotechnological routes. Soft sensors will play a crucial role in the inferential control of biotechnological processes.

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NEW 3-in-1 Spectrophotometer – Quality Control for Chemicals

The new, compact METTLER TOLEDO EasyPlus UV/VIS instruments set a new standard of versatility and ease of use in the lab and at line for the Chemical industry. EasyPlus UV/VIS spectrophotometers combine conventional spectrophotometry, color measurements, and water analyses within one compact instrument. The spectrophotometers are designed to greatly facilitate your routine spectroscopic workflows, saving bench space and reducing your investment in equipment and service.

Conventional spectroscopy
Measure absorbance and/or transmittance at multiple wavelengths, e.g., for raw material analysis.

Color measurement
30 standard-compliant and ready to use color scales(e.g., CIELAB, EBC, Gardener, etc.)shorten the time to result.

Water analytics
Easy water testing including>150 ready-to-use methods validated with the Spectroquant®test kits.

About METTLER TOLEDO
METTLER TOLEDO is a leading global manufacturer of precision instruments. The Company is the world’s largest manufacturer and marketer of weighing instruments for use in laboratory, industrial and food retailing applications. The Company also holds top-three market positions for several related analytical instruments and is a leading provider of automated chemistry systems used in drug and chemical compound discovery and development. In addition, the Company is the world’s largest manufacturer and marketer of metal detection systems used in production and packaging. Additional information about METTLER TOLEDO is available at www.mt.com.

Visit us: www.mt.com/easyplus-uvvis
Email us at – sales.sales@mt.com
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Precious Metals E-waste Recovery: An Ideal Solution for Protecting Environment and Conserving Natural Resources

The global precious metals e-waste recovery market size is predicted to be valued at $18,645.2 million by 2030, surging from $9,434.5 million in 2021, at a noteworthy CAGR of 7.0%.

Global Precious Metals E-waste Recovery Market Analysis

Increasing expansion of the IT and communication sectors, particularly in countries such as India and China, is a significant driver of market growth in the forecast period. This increase is mostly related to an increase in electronic consumption, which is driving the advancement of new electronic devices and influencing the disposal of obsolete electronics. This immediately increases global e-waste creation while also boosting demand for e-waste recycling to address environmental issues such as soil contamination. Such factors are expected to drive market expansion over the analyzed period. Furthermore, major market competitors are always focused on initiatives to raise consumer awareness regarding e-waste recycling.

However, several factors impact precious metal prices, including inflation, currency changes, government reserves, and geopolitical uncertainty. Due to such price fluctuations, demand and supply for certain metals are adversely impacted, affecting industrial production operations. Furthermore, mining for precious minerals is a laborious operation requiring big investments in gear and lengthy working hours, and production unpredictability is expected to stymie expansion. Furthermore, ineffective polishing to maintain the sheen and color of these metals will impede the market.

For recovery precious metal from e-waste materials, vat leaching is commonly used, in which crushed e-waste is combined with a sodium cyanide solution in enormous tanks. As cyanide leaching is so efficient, it enables for the lucrative recovery of valuable metals. Cyanide, on the other hand, is a very poisonous chemical that can have serious environmental and public health consequences. Cyanide spills have contaminated drinking water sources, destroyed agricultural fields, and resulted in fatalities. Although cyanide aqueous solutions breakdown quickly in sunlight, less hazardous compounds such as cyanates and thiocyanates may linger in the soil for several years. Cyanide leaks into groundwater can remain for longer periods of time and affect drinking water aquifers.

Global Precious Metals E-waste Recovery Market Share, Segmentation

The global metals e-waste recovery market share is segmented based on metal type, source, and region.

Metal Type:

The metal type segment is further classified into gold, copper, silver, and others. Among these, the copper sub-segment is anticipated to have a fastest market share and surpass $4,003.7 million by 2030, with an increase from $1,912.8 million in 2021. It is mostly due to urbanization, huge population, and rising disposable income that will provide attractive opportunities for electronic household appliances in the approaching years. Electrical and electromechanical devices are domestic gadgets that aid in homemaking and household duties such as cooking, food preservation, and cleaning.

Source:

The source segment is further classified into home appliances, consumer electronics, IT & telecommunication equipment, and others. Among these, the consumer electronics sub-segment is anticipated to have a dominant market share and surpass $7,827.6 million by 2030, with an increase from $3,814.6 million in 2021. As the amount of consumer electronic has grown over the last decade as a result of revolutionary developments in the electric and electronic industries, burning and recycling of these materials have gained popularity.

Region:

The precious metals e-waste recovery market in the Europe region is projected to show the fastest growth. This region’s market generated a revenue of $2,376.6 million in 2021 and is projected to reach up to $4,948.4 million by 2030. The region’s demand for precious metals e-waste recovery was driven by factors that led to the market growth due to rising demand for consumer electronic items and increasing demand from automotive and electronics companies. European Union legal framework and certification scheme, along with wide financial measures, will promote the investments needed to make recycling essential raw materials more commercially feasible and reduce Europe’s reliance on external supply sources.

Key Players in the Global Precious Metals E-waste Recovery Market

Some of the leading e-waste recovery market players are

  1. Johnson Matthey
  2. Umicore
  3. Materion Corporation
  4. Boliden Group
  5. Sims Lifecycle Services, Inc.
  6. TANAKA Holdings Co., Ltd.
  7. Metallix
  8. TES
  9. Heraeus Holding
  10. Enviroleach Technologies Inc.

Source: https://www.researchdive.com/8365/precious-metal-e-waste-recovery-market

Mechanical separation processes in the chemical industry – Filtration is the key to safe production and efficient processes

Abstract

Filtration and separation are indispensable processes not only in the production of chemicals, but in all areas of the process industry. This is because mechanical separation processes are not only used for the production of pure chemicals. They can also improve process safety and increase material efficiency. The latest developments in separation technology will be showcased again by international exhibitors and lectures at FILTECH in February 2023. As the most important platform for filtration and separation of all types of media, the event invites visitors to Germany for a combination of trade fair and congress.

All over the world, the chemical industry is characterized by the quest for safe processes and high-quality products. The bar is being raised ever higher, because not only limit values, standards, and laws, but also customer requirements are becoming stricter. And finally, measurement methods for detecting undesirable components are also becoming increasingly better.

Expertise in filtration and separation

FILTECH therefore provides both technical know-how and industry-related expertise: The world’s most important platform for the filtration and separation of all types of media will take place again next year. From February 14 to 16, 2023, visitors to the exhibition center in Cologne (Germany) will get answers to all questions about the filtration and separation of all kinds of media.

Due to the dynamic development of the Corona pandemic, the long-standing successful combination of trade show and congress has already expanded its website at the beginning of 2021 to include a detailed information area that presents solutions online to interested parties for their challenges in filtration. In March 2022, however, the organizer, numerous exhibitors, speakers, and 14,750 visitors already demonstrated that it is once again possible to safely hold focused trade shows.

Safe primary processes, efficient secondary processes

At the same time, the range of exhibitors and participants in the conference section proves the cross-sectional nature of the topic: Filter technology is the key to efficiency and safety not only in the primary processes of chemistry and life sciences, pharmaceutical production, and the food and beverage industry, but also in secondary areas. Thus, visitors to FILTECH will also receive information about materials and consumables that are essential for the operation of filtration systems.

Finally, the FILTECH topic of ventilation and air purification technology is also highly relevant, because clean air can be an effective measure for reducing the risk of infection by aerosol-borne viruses in all areas of companies. The event brings together numerous suppliers of ventilation and filtration technology who support plant operators with efficient solutions for production and all other operational areas.

Focus on India in exhibitors and lectures

Visitors from India will also have the opportunity to network with companies from their home country at FILTECH: According to the current status, the organizer reports 16 exhibitors from India. Among them is a2z Filtration Specialities, a company that continues to develop new products for the filtration market as a supplier of special purpose filter manufacturing and testing equipment.These include among others completely automated HEPA mini pleat lines, which come with the option of rotary orblade pleaters and foamed or solid hot melt glue, including converting rolls of Glass fiber and synthetic media into mini pleat packs, automatically cut to the required size or pleat count, then conveyed to an intelligent servo filter framing system.

Other representatives from India include nonwoven manufacturers such as AIM Nonwovens and Interiors, PARK INDUSTRIES, WELSPUN GLOBAL and AUTOTECH Nonwovens. Suppliers of woven filter fabrics will also be exhibiting: for example, Arvind, SHRINATH ADHESIVE PRODUCTS and KHOSLA PROFIL, which also offer needle felts and sewing threads. SACHIN INDUSTRIES, a leading manufacturers of filter plates, filter presses and membrane filter presses, will be present.

HYDRO PRESS INDUSTRIES produces high performance filter presses that can increase production capacity and significantly reduce wax cake moisture. Eco Green Clean tech, KALIMATI CARBON and ECO FRESH CARBON offer activated carbon, which serves for special filtration applications where the purity of the filtrate plays a special role.

From clean drinking water and ultra-filtration to filtering exhaust gases from diesel vehicles and auto rickshaws, several presentations in the FILTECH congress area also provide insights into scientific and technical developments by Indian institutes and companies. Contributions will come from representatives of the Indian Institute of Technology Madras, the PSG College of Technology and companies such as Technorbital Advanced Materials and Varroc Polymers.

Whether air purification or filtration processes in chemical production: The fact that the demand for new products and services remains high is also demonstrated by the large number of exhibitors. As things stand, the organizer is already expecting over 440 companies at FILTECH 2023 – more than ever before.

Personal exchange at the heart of the congress

Especially on the congress area of FILTECH visitors traditionally have the opportunity not only to experience current products and services live but also to find out about trends in research and development in the congress area. The FILTECH Scientific Advisory Board, chaired by Dr. Harald Anlauf (KIT) and Prof. Eberhard Schmidt (Bergische Universität Wuppertal), guarantees the high quality of all presentations: Experts from international universities, research institutions and companies review the submitted contribution proposals and compile a program that guarantees valuable information from all areas of the industry. The organizer expects more than 200 presentations at FILTECH 2023.

The congress at the event is divided into units covering all relevant topics. Seven thematic areas will be in focus:

  • Solid-liquid separation
  • Solid-Gas Separation
  • Filter media
  • Testing, instrumentation, and control
  • Simulation and modeling
  • product related processes
  • Membrane processes

In addition, the congress at FILTECH 2023 will be dedicated to current industry trends such as selective separation, micro process technology, and nanofluidics, mist and droplet separation as well as biological exhaust gas cleaning with biofilters. On February 13, 2023, already one day before the opening of the exhibition area, two focused one-day courses will be held, which will also specifically address engineers, scientists, managers, and other technical personnel who need applied knowledge on topics related to solid-liquid separation and fine particle separation.

Filtration processes for quality and reliability

In production, what counts above all is the quality, safety, and efficiency of the processes. But the safety of employees, the environment, and equipment must also be guaranteed at all times. Filter solutions specifically designed for the harsh environments of processing support operators in all these challenges. They increase the service life of the plant and equipment, ensuring high performance.

At FILTECH, processing companies will find the right products and services for this purpose and can exchange information with experts on current trends. For successful planning of the visit, interested parties can find a list of exhibitors, an overview of focus topics and industries as well as the extensive conference program at filtech.de.

FILTECH 2023 – the facts

  • Venue: Cologne Exhibition Center (Germany), Halls 7 and 8
  • Event date: Tuesday, February14 to Thursday, February 16, 2023
  • Exhibition frequency: every 1.5 years
  • Opening hours:
    February 14: 9 a.m. – 6 p.m.
    February 15: 9 a.m. – 6 p.m.
    February 16: 9 a.m. – 5 p.m.
  • Further information: filtech.de

FILTECH 2023:

Expert knowledge and personal exchange: at FILTECH, visitors can find out about the latest trends in research and development and experience a wide range of products and services.

Source: FILTECH Exhibitions Germany

Domestic natural gas price increased by 40 per cent – A careless, short sighted and counterproductive decision

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Government of India has hiked the domestic natural gas price by 40 percent to $8.57 per mBtu on gross calorific value for the second half of FY23, beginning October 1, compared to the April -September 2022 period. The gas price ceiling for extracting the key commodity from challenging fields – deep water, ultra-deep water and high pressure-high temperature fields – has also been revised upwards by around 25 per cent to $12.46 per million British thermal units (mBtu).

This is the highest price for procuring natural gas in the country, since the Government of India introduced the New Domestic Gas Pricing Guidelines in November 2014. The previous high in gas price was recorded in the first half of the current fiscal year at $6.10 per mBtu. Before this, the highest price was reported for the November 2014-March 2015 period at $5.05 per mBTU.

Similarly, the highest ceiling price for gas from challenging fields was during H1 FY23 at $9.92 per mBtu. Prior to H1 and H2 FY23, the highest price reported was during the April 2019-September 2019 period at $9.32 per mBtu. India meets half its natural gas requirement through domestic production, while the other half is imported as liquified natural gas (LNG).

Price Trends

Price of imported liquefied natural gas are always raised largely in tune with the increase in international price. However, Government of India seems to be increasing the price of domestic natural gas also in tune with the international price trend.  This certainly is not in order. The government’s move to increase the price of domestic gas is unwise, as it will result in cost push inflation and consequently several undesirable developments with regard to the national economy.

To protect the economics of   a few oil exploration companies, the government is upsetting the economics of hundreds of industrial, commercial and service oriented organizations in the country by steeply hiking the domestic natural gas price. Natural gas is an essential feedstock and fuel and around 50 percent of Indian requirement of natural gas is met by domestic production.  With the increase in the price of natural gas, the cost of production of goods and services will increase proportionately, that will lead to increase in the market price of derivative products. In effect, this would amount to transferring the cost burden to the common man.

Consequently, the cost index in the country will go up that will lead to demand for higher salaries and wages both in the organised and unorganised sector.  Inevitably, the expenses of the organisations and that of the government will go up significantly and this will be a vicious cycle. While increasing the price of essential inputs like natural gas should be the last option, it appears to have become the first option for the government.

Alternate Options

Obviously, the government has chosen the easy option of increasing the price of natural gas, without carefully examining the alternate options for holding the price of natural gas at the present level. One is not sure whether the government has carefully carried out cost auditing with regard to the performance of the oil exploration companies in India. If it has done, it should have publicized the results of the auditing in a transparent manner, so that the people will be able to judge the price increase decision of the government.

The feasibility of subsidising the domestic natural gas price to the extent necessary to ensure price stability in the domestic market, ought to have been carefully and judiciously examined.  In the last several months, it is known that many petrochemical companies in India, both in the public and private sector have been turning out good performance and making good profit. The feasibility of raising the tax level on the profit made by petrochemical companies to subsidise the natural gas price, should have been considered as one option.

In any case, price increase of natural gas at periodical intervals seems to have become a habit for the government. When the feasibility of reducing the price of natural gas due to any international development is there, the government just ignores it.

Government Should Make India Pharmacopeia (IP) Certification Mandatory for IPAs Used in Pharma Industry

Indian Pharmacopoeia (IP) certification should be made mandatory for isopropyl alcohols (IPA) used in pharma applications by the Union Government, as usage of imported IPA is fraught with risks. Indian IPA manufacturers allege that cheap imported IPA, fails to meet various critical parameters covered in Pharmacopeia Standards such as UV absorbance test, identification of unsaturated hydrocarbons and rapidly carbonizable material. Use of such sub-standard non-pharma grade IPA adversely affects the quality of the drug exposing millions of Indian consumers to severe health hazards. It also jeopardises the reputation of the country’s pharma industry.

IPA, commonly called isopropanol, is a colourless, flammable liquid with a strong odour. It is used in the manufacture of a wide variety of industrial and household chemicals and finds major applications in the production of bulk drugs and drug formulations which are vital in the pharma manufacturing process. It is also used as a common ingredient in products such as hand sanitizers, antiseptics and disinfectants. Indian pharmaceutical sector consumes roughly 170,000 MT of the overall India IPA demand of around 240,000 MT in FY21. Of the 170,000 MT of IPA consumed by the pharma Industry, only about 12 % is pharma grade, meeting Indian and other Pharmacopeia Standards. The rest is non-pharma grade.

Fear of Contamination

Incidentally, solvents such as IPA, Toluene, Acetone, and others are imported in bulk and stored in a co-mingled fashion in shore tanks located at Kandla, Vizag, and other ports. These solvents get contaminated at the various handling stages starting from loading at the port to getting delivered to end-users. The contamination, industry players claim, either comes from tank cars or dissolutions of lacquers from the inside coating of metal vessels.

As a result, imported IPA stored in co-mingled tanks at Indian ports do not meet the pharmacopoeia standards. If used to produce medicines, they contaminate the drug, change its quality and deteriorates during shelf life. Therefore, imported excipients, especially solvents, must be carefully examined by regulators for traces of contamination. Traceability of source which is one of the important parameters carefully pursued by the pharma industry is completely missing when it comes to co-mingled storage of solvents

Section 16 of the second schedule of The Drugs and Cosmetics Act mandates IP specifications for pharma application. IP standards strengthened by the Indian Pharmacopoeia Commission (IPC) and FDA authorities of states like Goa, Maharashtra and Uttarakhand have directed drug manufacturers to use only pharma grade IPA.Despite these regulatory specifications, the ground reality is different. The Indian pharma industry is using IPA that does not fulfil pharmacopoeia criteria which is dangerous and hazardous to health.

Quality Par Excellence

It may be noted that nations including the US, Europe and China demand that IPA used in the drug manufacturing process meet their individual pharmacopoeia criteria for medications exported to these countries. China Food and Drug Administration (CFDA) too has exhibited concern about the quality of drugs entering Chinese soil by imposing stringent regulations not only on the final products but also on all ingredients including excipients. Indian pharmaceutical companies like Aurobindo Pharma, Alembic Pharma, Cipla and Dr Reddy’s Laboratories planning to tap the large Chinese market will have to get all ingredients, needed for the production of drugs and related ingredients such as APIs, intermediates and excipients, approved by CFDA compulsorily.

Indian government is yet to impose stiff rules to curb the use of imported excipients and solvents including IPA by the pharma industry.The recent embarrassing incident in Gambia due to contaminated cough syrup, originating from a Indian Company, highlights how contaminated raw materials are being used by the pharma industry, severely compromising the quality of drugs and risking the lives of millions not only in India, but globally too.

This incident has also tarnished India’s reputation as a pharmacy to the world. In this particular case, WHO has already issued global alerts against the Indian company. In response, various FDA authorities such as Maharashtra and Karnataka have also issued circulars stating that all pharma manufacturers need to procure solvents complying to pharmacopeial standards directly from manufacturers. While actions are now warranted, a proactive approach would have prevented such an incident. Isopropyl alcohol is a key solvent for multiple drugs that carries a similar risk of contamination and health hazard, hence requiring urgent attention. Keeping in mind the health of Indian consumers as well as the stature of the Indian pharma industry, it is critical to mandate the use of IPA with Indian Pharmacopeia (IP) certification in pharma.

Energy Transition and the Path to Net-Zero

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The U.S. Energy Information Administration projects a nearly 50 percent increase in world energy use by 2050, led by growth in renewables. Similarly, the demand for electricity will increase 75 percent to 100 percent within the same time-period, driven by the shift in mobility to electric vehicles, and industrial electrification. Most of the projected increase in demand will be met by renewable energy. As most renewable power options, such as solar and wind, will be generated away from population centers, larger capacity, and more resilient transmission systems will be key. While distribution systems need to grow and be more dynamic, cybersecurity remains a concern.

The game changer lies with digital technology, which is mission-critical for electrification, as the shift from fossil-based systems to electric will drive change within the existing power infrastructure and beyond, with new microgrids, and self-generation at industrial sites. Digital solutions used in power management will manage the complex power requirements, facilitate cybersecurity, integrate advanced analytics and AI to automate reliability, and flexibly enable distributed, loosely coupled microgrids.

Mitigating GrowingEnergy Demand and Emissions

According to McKinsey, the top three generators of greenhouse gas (CO2 and methane)emissions in 2019 were from power generation (30%); industry (20%); mobility (19%) – mostly from the burning of fossil fuels for energy. This January 2022 report titled “The net-zero transition: what it would cost, what it could bring” focuses on opportunity for power generators and industry to invest preferentially in renewable, low-carbon energy sources, and electrify industrial processes. As such, the electrification of heavy industry to meet the decarbonization imperative is driving 50% more growth in electricity, than from mobility alone.

To mitigate growing global energy demand, energy efficiency is key. Digital technologies will be instrumental in achieving 10% – 20% increase in energy efficiency. In support of net-zero targets, capital-intensive industries are focused on electrifying energy production and process heat, while ensuring that electrical generation aligns with their own sustainability initiatives.

At the same time, carbon trading, and carbon tax emissions-cutting policies are increasingly crucial in providing access to the right levels of capital for decarbonization investment in the most challenged economic zones and industry sectors. Investments in renewables and intelligent grids, go together with carbon trading. Digital solutions supporting distributed generation sources and grids are crucial for tracing carbon emissions from renewable source to industrial end use – and onward, complementary
mass-balance solutions enable calculation and tracking the carbon intensity of finished products produced via renewable energy.

Fossil fuels will continue to be a significant source of global energy through 2050. However, carbon capture, utilization and storage (CCUS) will play an increasingly important role. To move beyond what CCUS can achieve, electrification has a key role in reducing carbon emissions.This is especially so, with new investments, almost exclusively in low-carbon electricity sources, and the retrofitting and replacement of older CO2 emitting utilities and processesin energy-intensive plants, which includes refining units, bulk chemicals, metals, such as aluminium. This shift in investment will drive a new generation of digital solutions to support the growing appetite for electrification.

Turning Challenges into Opportunities

With distributed power resources, grids will need to accommodate rapidly expanding and evolving distributed power production, storage and consumption models. New digital software will need to rapidly keep pace with the innovation of the power generation system.

Power grids will need to expand steadily beyond their current capacity and change their structure to eliminate single points of failure and to accommodate the dynamic nature of distributed renewables. Traditional grids are expensive to upgrade and digital solutions commonly used for transmission and distribution management are insufficient. The underlying solutions must be structured to accommodate increasing adoption of AI-driven solutions to further optimize and protect electrical networks.

With the increasing complexity of distribution systems, reliability and outage prevention becomes more challenging to manage with traditional approaches. Digital technology based on advanced data analytics and AI will become essential to assist operators in responding quickly and effectively to situations across a diverse system. To succeed, digital management systems will need to provide granular and easily visualizable views of the customer distribution network.

It is necessary to monetise distributed power, as advances in digital software provide this visibility, enabling distribution companies to monetise operations, optimization, maintenance and pricing of distributed power and storage. As vehicle batteries increase their capacity and capabilities, the mobility network can be monetized as a storage element of the connected grid.

Cybersecurity needs need to be met. Software providers like OSI have proven track records in meeting standards, reacting rapidly and updating systems for electric utility providers. Microgrids have emerged as a key investment area to fill the regional void, while meeting demand and increasing reliability and security required by large power consumers, communities and localities. The right digital solution enables efficient, optimized development of microgrids, integrated with regional grids and developed in a more cohesive, intelligent way. This approach proactive innovation and adoption in new power generation connected storage,while ensuring reliable supply. In addition to battery storage, innovations, such as commercialisation of hydrogen fuel cell storage, can be integrated easily.

Distributed power generation in industrial facilities is another important electrification opportunity. Cogeneration optimises the usage of waste heat during power generation for supplemental process heat. Using the same adaptive process control and digital twin technologies applied to process equipment, an optimised amount of electricity is produced and predictively available. Digital software technologies are key in this area to make cogeneration practically available to a wider spectrum of industrial entities. These include energy management, electric utilities optimization, and self-maintaining advanced process control.

Between distributed generation, batteries, storge and integration, digital technology is a critical enabler of innovation and proactive planning for navigating the risks posed by increasingly interconnected grids. AI, advanced analytics, and system risk analysis are essential to understanding and planning for complex systems. Modeling and optioneering of new battery chemistry and industrial scale fuel cells with rigorous digital models are playing a crucial role in enabling the ecosystem of startups and innovators.

Energy Management and Beyond

As the process industry transforms to operate in a low-carbon future, electrification is a critical part of this journey. Product mixes are shifting from the use of transportation fuels to new sustainable materials. To support this trend, microgrids will become increasingly valuable for energy management at industrial sites. Industrial power producers need to align the renewables component of electric power consumed and generated onsite, with the associated carbon footprint benefit. Producers need to optimize power generation and satisfy process energy requirements from electricity.

Chemingineering – MOF – Material Of The Future?

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Metal-Organic Frameworks are an exciting class of materials with unparalleled properties that can be customised to suit a variety of applications. The ease with which these properties can be tuned, make them a versatile material in gas separation and storage, energy storage, catalysis, drug delivery and sensing among others.

First synthesised in 1995 by Prof Omar Yaghi, Metal-Organic Frameworks (MOF) have become one of the most widely investigated materials of the 21st Century. MOFs are hybrid inorganic-organic crystalline porous materials with a positively charged metal ion surrounded by organic ligands commonly called “linkers”. Because of their cage-like hollow structure, they have an extraordinarily large internal surface area; MOFs with a whopping surface area of 7800 square meters per gram have been synthesised. A plethora of applications in diverse fields have been developed to exploit the unique structural properties of MOFs.

Unique Properties
With metal centres and organic linkers MOFs form infinite crystalline networks. The crystalline structure is characterised by very high surface to volume ratio and extraordinary flexibility in pore morphology and chemical functionality. Their unique structure endows on MOFs properties that are not available to other conventional porous materials, for example zeolites. The geometry and connectivity of the linker molecules influence the structure of the MOF. The size, shape and properties of the MOF can be tuned to suit a targeted application by modulating the linker geometry and functional groups. The ease with which these tuning can be done make MOFs a very versatile material for diverse applications.Among the numerous applications to which MOFs have been put are gas separation, gas storage, catalysis, drug delivery and sensing.

Gas Separation
Gas separation is one application of MOFs that has attracted considerable interest. These include carbon dioxide separation, oxygen purification, separation of light hydrocarbons and separation of noble gases. A particularly exciting application is CO2 capture. It is possible to tailor the functionality of MOFs to obtain high adsorption selectivity and capacity for CO2 capture. Various types of MOF-based membranes have been developed and studied for CO2 capture. The early MOF-based membrane configurations like thin film and hollow fibre suffered from stability issues. New hybrid configurations developed recently combine high separation performance with robust mechanical strength. MOF Technologies, a spin-off from Queen’s University, Belfast is a case in point. The company claims to have developed a carbon capture system using MOF-based membrane filters at 80% less energy compared to conventional technologies.

Gas Storage
The exceptionally high porosity of MOFs has captured the imagination of scientists and engineers to consider them as low-cost media for high-density storage of gases. Hundreds of MOF materials have been investigated as potential candidates for storing hydrogen. Compared with traditional porous materials like zeolites and activated carbons, the performance of MOFs has been vastly superior with record uptakes of gases like hydrogen and methane. However, they are still short of the ambitious targets set by the US Department of Energy.

Catalysis
MOFs having many open metal sites have been used as highly active catalysts. Open metal sites for catalyst applications are generated by replacing some of the original organic linkers. While the open metal sites in the framework act as active sites for catalytic reactions, the well-developed porous network in MOFs provide an excellent platform for mass transfer. Ziegler-Natta polymerisation, Diels-Alder reaction, and photochemical reactions are some excellent examples where MOF-based catalysts have been successfully used. Molybdenum-based MOFs have been used as catalysts for biodiesel production from oleic acid and palmitic acid via esterification reaction with methanol. Zinc-based MOFs have been developed as catalysts to synthesise high-purity precursors of pharmaceutical and bio-pharmaceutical compounds. MOFs and MOF-derived materials are emerging as excellent catalysts for water splitting both by electrochemical and photoelectrochemical routes, with a number of early studies yielding extremely promising results.

Drug Delivery
The highly ordered structure of MOFs together with the ultra-high surface area and large pore volume make it possible for them to adsorb functional molecules on their external surface as well as trap them inside the framework. MOFs can be functionalised with therapeutic agents for biological applications. Anti-cancer drugs have been incorporated into MOFs for intracellular delivery. MOF nanocarriers have been studied for delivering biomolecules like proteins, nucleic acids, lipids and carbohydrates. MOFs are now regarded as one of the best candidates for drug delivery.

Sensing
The most recent application of MOFs is in sensing. Precise chemical modifications can infuse MOFs with specific functions that make it possible to develop a new generation of sensors. MOF-based sensors have been used to detect solvents, pesticides, explosives and biological markers. MOF-based sensors have been extensively deployed for food safety control, where they have been able to detect pesticide residues, mycotoxins, pathogens, heavy metals, illegal additives and other contaminants. Hydration and dehydration of MOFs can significantly alter their 3D structure and this property has been tapped for detecting different levels of humidity in gaseous environments. MOF sensors have tailor made pockets to absorb a particular molecular species. Occlusion of different molecules or ions into the pores of MOFs lead to changes in their optical and electrical properties which can be exploited for sensitive detection of these species. Considerable amount of work is currently being done to study the optical and electrical response of MOFs to different species and understand the underlying mechanisms.

Energy Storage
MOFs have the potential to meet the needs of the next-generation energy storage technologies. They are already being used in electrodes of batteries and supercapacitors. A unique feature of MOFs is the ability to tweak select functionalities for improving electrochemical properties and thus lead to better performance in energy storage devices.

Synthesis
The size and architecture of MOF, and hence its properties, depend on how it is synthesised. Rather, MOFs are “designed” for a specific application by selecting the appropriate metal centre and the organic linkers. The chemical properties are further modified by chemical functionalisation of the linkers. Typically, the metal precursors and the organic linkers are dissolved in a suitable solvent and placed in a reaction vessel for the formation and self-assembly of the MOF crystals. The crystallisation time can vary from several hours to several days. The synthesis and crystallisation conditions play a very important role in determining the crystal morphology and size. Introduction of additives during crystallisation is an important strategy to control the morphology and size of MOF crystals. Many novel methods like electrochemical, sonochemical, mechanochemical, microwave-assisted, microfluidics etc. have been used in recent years for MOF synthesis. Over 90,000 MOFs have been synthesised so far. At least 500,000 have been predicted. The classification and characterisation of MOFs continues to be a work in progress.

Epilogue
MOFs are an intriguing class of materials with properties that sets them apart from other porous substances. The inherently unprecedented structural and compositional diversity of MOFs make them extremely exciting for a variety of applications. MOF research is still a nascent area and many exciting materials are yet to move from laboratory to industry. But it is a matter of time, before they make their presence felt in many cutting edge technologies

Readers’ responses may be sent to:
k.sahasranaman@gmail.com or
chemindigest@gmail.com

Chemical Industry Digest – September 2022

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Chemingineering – MOF – Material Of The Future?
– K Sahasranaman, Consultant – Process Engineering and Safety
This column reviews Metal-Organic Frameworks. These are infinite crystalline networks with inherently unprecedented structural and compositional diversity, which make them extremely exciting for a variety of applications.

Energy-Materials Linkage in the Emerging Scenario of Renewable Energy (RE): New Dimension in Energy Conservation for Chemical Industry 
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This article presents a new dimension of energy-material duality which opens up an entirely new world that enables manufacture of chemicals using renewable energy, water, hydrogen and carbon dioxide making for sustainable operations.

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Steam Consumption Optimization in Amine Regeneration Unit by using Advanced Process controller
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Book Review: Carbon, Capital, and the Cloud
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