Transfer of the Epoxidation of Soybean Oil from Batch to Flow Chemistry Guided by Cost and Environmental Issues

Abstract

The simple transfer of established chemical production processes from batch to flow chemistry does not automatically result in more sustainable ones. Detailed process understanding and the motivation to scrutinize known process conditions are necessary factors for success. Although the focus is usually "only" on intensifying transport phenomena to operate under intrinsic kinetics, there is also a large intensification potential in chemistry under harsh conditions and in the specific design of flow processes. Such an understanding and proposed processes are required at an early stage of process design because decisions on the best-suited tools and parameters required to convert green engineering concepts into practice-typically with little chance of substantial changes later-are made during this period. Herein, we present a holistic and interdisciplinary process design approach that combines the concept of novel process windows with process modeling, simulation, and simplified cost and lifecycle assessment for the deliberate development of a cost-competitive and environmentally sustainable alternative to an existing production process for epoxidized soybean oil.

Life Cycle Analysis within Pharmaceutical Process Optimization and Intensification: Case Study of Active Pharmaceutical Ingredient Production

“…[50][51][52]. Thus, focus was given on life cycle approaches that covers all life cycle stages of a process or product system, and which were combined with an iterative screening and optimization procedure.…”

Sustainability lessons from practice: how flow intensification can trigger sustainability and modular plant technology in EU projects

“…This was because the environmental performance significantly dropped in case of lower yields due to the high environmental burden of the agricultural production of the feedstock soybean oil. [59] Moreover, as mentioned earlier, the decomposition of the hydrogen peroxide was a significant factor in determining the environmental performance of the process-increasing the amount of hydrogen peroxide in the continuous pilot process (scenario M) would result in an increase in the HTP. Figure 9 shows the effect of various scenarios and parameters on HTP and GWP for this continuous pilot process:…”

A View Through Novel Process Windows

“…Although such process design intensification could provide step-change improvements, the design focus is typically on individual units due the lack of standard modules, the focus on reaction optimization, the fact that components cannot simply be plugged into a plant and the rarity of systems that allow an integrated design. [59] …”

“…[73] Although the used microorganisms are cheap, their performance leaves to be desired; low activity, large amounts of by-products and waste water, high oxygen consumption and the need for a sterile environment. [72] A holistic evaluation on soybean-oil processes was previously done by Kralisch et al [59] For the oxidation of glucose, alternative processes are based on noble metal catalysts or isolated enzymes, which each have their own challenges. Noble metals, while cheap and easily recovered, require the use of 99% pure glucose, are vulnerable to deactivation and have a low selectivity.…”