The search for "greener chemistry",
described in the previous chapter, can lead to many exciting developments.
New, simpler synthesis pathways could be discovered for complex
chemical products resulting in a process that generates less toxic
byproducts and lowers the overall risk associated with the process.
Toxic intermediates used in the synthesis of commodity chemicals
might be eliminated. Benign solvents might replace more environmentally
hazardous materials. However, these developments will involve new
chemical processes as well as Green Chemistry.
The art and craft of creating chemical processes
is the topic of a number of excellent textbooks (see, for example,
Douglas, 1988). A fundamental theme that arises in each of these
texts is that the design process proceeds through a series of steps
each involving an evaluation of the associated environmental impacts.
At the earliest stages of a design, only the most basic features
of a process are proposed. These include the raw materials and chemical
pathway to be used, as well as the overall material balances for
the major products, by-products and raw materials. Large numbers
of design alternatives are screened at this early design stage,
and the screening tools used to evaluate the alternatives must be
able to handle efficiently large numbers of alternative design concepts.
As design concepts are screened, a select few might merit further
study. Preliminary designs for the major pieces of equipment to
be used in the process need to be specified for the design options
that merit further study. Material flows for both major and minor
by-products are estimated. Rough emission estimates, based on analogous
processes, might be considered. At this development stage, where
fewer design alternatives are considered, more effort can be expended
in evaluating each design alternative, and more information is available
to perform the evaluation. If a design alternative appears attractive
at this stage, a small-scale pilot plant of the process might be
constructed and a detailed process flow sheet for a full-scale process
might be constructed. Very few new design ideas reach this stage,
and the investments made in evaluating design alternatives at this
level are substantial. Therefore, process evaluation and screening
tools can be quite sophisticated.
Traditionally, evaluations of environmental
performance have been restricted to the last stages of this engineering
design process, when most of the critical design decisions have
already been made. A better approach would be to evaluate environmental
performance at each step in the design process. This would require,
however, a hierarchy of tools for evaluating environmental performance.
Tools that can be efficiently applied to large numbers of alternatives,
using limited information, are necessary for evaluating environmental
performance at the earliest design stages. More detailed tools could
be employed at the development stages, where potential emissions
and wastes have been identified. Finally, detailed environmental
impact assessments would be performed as a process nears implementation.
This chapter and Chapter 11 present a hierarchy
of tools for evaluating the environmental performance of chemical
processes. Three tiers of environmental performance tools will be
presented. The first tier of tools, presented in Section 8.2, is
appropriate for situations where only chemical structures and the
input-output structure of a process is known. Section 8.3 describes
a second tier of tools, which is appropriate for evaluating the
environmental performance of preliminary process designs. This tier
includes tools for estimating wastes and emissions. Finally, Section
8.4 introduces methods for the detailed evaluation of flowsheet
alternatives, which will be discussed in Chapter 11.
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