Rethinking traditional manufacturing processes to identify green opportunities
Some call it magic we call it science, says Geert Schelkens, R & D manager, at Ajinomoto Sustainable Solutions
Developing competitive, more sustainable processes across the fine chemicals industry is critical and must be top of mind for developers and manufacturers alike. The complexities of high-value batch chemistry processes produce a significant amount of waste by way of consumption, work-up and crystallisation. As a result, the carbon footprint and waste-to-product ratio in the fine chemical industry is very high.
To combat this, developers will need to enlist a broad array of renewable, raw material sources, green chemistry strategies and innovative technologies. The key is identifying how best to break bad manufacturing habits, developing strategies for sustainable chemical production, and designing approaches to reach sustainability targets.
Approach sustainable manufacturing strategically
Beyond responsibility to the community and our environment, sustainability is a strategic choice and differentiator in the fine chemicals field. In our work at Ajinomoto Sustainable Solutions, we’ re striving to build a vision for sustainable growth that prioritises and strengthens our core capabilities. Our team developed the‘ Net Zero Strategy’, which emphasises the following targets:
• Manufacturing to ensure carbonneutral production via the
Figure 1- Visualisation of the carbon footprint distribution
electrification of our processes, i. e., replacing fossil fuels used for heating reactors with electric heating
• Purchasing from a green supply chain
• Leveraging a low footprint portfolio during R & D
• Maintaining and managing an overarching green strategy
If we translate this goals into figures, in combination with a portfolio growth, the footprint of our commercial processes should reduce 40 % by 2030. Furthermore, in 2030, new processes ought to have a footprint that is 80 % lower compared to 2019.
As demonstrated in Figure 1, energy represents only 9 % of our footprint. Even by electrifying and making our energy supply green, we are still a long way from our goals.
Building Blocks( 46 %)
• Agree with customers
• Collaboration
Energy( 9 %)
• Scope 1 & 2
• Green electricity
Solvents & Waste( 33 %)
• Green solvents
• Need customer support
Solvent and waste represent 33 % of our footprint, which calls for the use of green solvents, solvent recycling, and the reduction of waste.
The advanced and typically complex chemicals that are used as the basis for our processes are often known as building blocks and purchased from external suppliers. These building blocks account for 46 % of our footprint. To change this, our team will need to reach agreements with our customers, and switch to suppliers with smaller footprints.
Ajinomoto Sustainable Solutions shaped its R & D targets around the 12 principles proposed by Paul Anastas in the book, Green Chemistry: Theory and Practice, published in 1998, most of which are highly important, including atom economy and the reduction of derivatives( Figure 2).
40 SPECIALITY CHEMICALS MAGAZINE ESTABLISHED 1981