Costs Processing cost, reducing

In 1987, Toray Industries, Inc., announced the development of a new process for making aromatic nitriles which reportedly halved the production cost, reduced waste treatment requirements, and reduced production time by more than two-thirds, compared with the vapor-phase process used by most producers. The process iavolves the reaction of ben2oic acid (or substituted ben2oic acid) with urea at 220—240°C ia the presence of a metallic catalyst (78). 

Solvent extraction removes chlorophyll and other pigments to give a light-colored product but increases processing costs. Furthermore, solvent extraction removes p-carotene and reduces vitamin A activity (89) (see Terpenoids Vitamins). Supercritical CO2 extraction at 30 and 70 MPa (4,350 and 10,150 psi) and 40°C removed 90 and 70% carotene and lutein, respectively, from alfalfa LPC (96). This process avoids organic solvent residues and recovers valuable by-products. 

Enzymatic hydrolysis is also used for the preparation of L-amino acids. Racemic D- and L-amino acids and their acyl-derivatives obtained chemically can be resolved enzymatically to yield their natural L-forms. Aminoacylases such as that from Pispergillus OTj e specifically hydrolyze L-enantiomers of acyl-DL-amino acids. The resulting L-amino acid can be separated readily from the unchanged acyl-D form which is racemized and subjected to further hydrolysis. Several L-amino acids, eg, methionine [63-68-3], phenylalanine [63-91-2], tryptophan [73-22-3], and valine [72-18-4] have been manufactured by this process in Japan and production costs have been reduced by 40% through the appHcation of immobilized cell technology (75). Cyclohexane chloride, which is a by-product in nylon manufacture, is chemically converted to DL-amino-S-caprolactam [105-60-2] (23) which is resolved and/or racemized to (24)... 

Distillation processes typically reduce the IDS concentration to levels weU below the required specifications. Because the product water from the two processes is combined, the RO process can produce water at higher I DS concentrations and stiU meet the potable water specifications. In addition, the power produced from the MSF process can be used in the RO process, cutting energy costs. 

These universal concentrates are preferred if they can be used, because inventorying costs can be reduced it is not necessary to stock different concentrates for different colorants. In some performance polymers this concept is not appHcable because the universal vehicles have a negative effect on weathering, transparency, or processing performance. 

Finally, the main benefit as far as competitive business performance is concerned is the potential for reduction in failure costs. Studies using CA very early in the development process of a number of projects have indicated that the potential failure costs were all reduced through an analysis. This is shown in Figure 2.47, where this potential failure cost reduction is shown as the difference between pre-CA and post-CA application by the teams analysing the product designs. 

Economic evaluations of waste-reduction options should involve a comparison of operating costs to illustrate where cost savings would accrue. For example, a waste-reduction measure that reduces the amount of raw material lost down the drain during the process will reduce raw-material costs. Raw-material substitution or process changes may reduce the amount of solid waste that must be transported offsite, reducing the transport costs for waste disposal. 

SCR units require handling, storage, and continuous injection of the reducing agent. The temperature level is critical because the SCR operates in a narrow temperature range between 550°-750°F (260°-399°C), and thus an exchanger is necessary to cool the exhaust stream. This leads to a complicated and costly process system that must be added to the engine exhaust. 

Strong elongational deformation and use of matrix polymers whose viscosity is higher than that of TLCP phase are better to ensure uniform and fine fibril formation. But application of compatibilizing techniques to in situ composite preparation can be useful to get the most desirable products. These can reduce the high costs of the liquid crystalline polymers and expensive special engineering plastics used for the in situ composite preparation and reduce the processing cost, whereas they can increase the performance of produced in situ composites, hence, their applications, too. 

For instance, in 1996, 3M company announced a breakthrough in the process for making medical adhesive tapes, a process that reduces energy consumption by 77 percent. The new process also cuts solvent use by 2.4 million pounds, lowers manufacturing costs, and cuts mannfacturing cycle time by 25 percent. The proprietary process took researchers nine years from conception through final implementation. 

Costs of downstream processing for bioprocesses are increased by 1) low concentrations of products, 2) numerous impurities at low concentration and 3) intracellular materials (if cell disruption is necessary). However, the high specificity of biocatalysts is a benefit to downstream processing since products closely related to the desired product are less likely to be present Waste products of bioprocesses are likely to be less environmentally damaging, which also reduces downstream processing costs. 

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