Deni Faisal, Fatah Sulaiman, Marta Pramudita

Strategies for Clean Production in Methyl Isocyanate Synthesis for Pesticide Raw Materials

Introduction

Strategies for clean production in methyl isocyanate synthesis for pesticide raw materials. Discover strategies for clean methyl isocyanate synthesis in pesticide production. Optimize sodium sulfate recovery (92.5% efficiency) via vacuum distillation, reducing waste & enabling resource reuse.

Abstract

The increasing demand for pesticides in agriculture has led to a rise in the production of methyl isocyanate, a key intermediate in carbamate pesticide manufacturing. However, this process generates sodium sulfate as a by-product, dissolved in an aromatic solvent, which, if not adequately managed, contributes to environmental pollution and resource inefficiency. Chemical and environmental engineering are crucial in addressing this issue by developing effective separation and recovery methods. One potential solution is the distillation process, which separates sodium sulfate based on boiling point differences with water. However, the effectiveness of this method depends on operational conditions, particularly pressure and sulfuric acid concentration. This research focuses on optimising the recovery of sodium sulfate from methyl isocyanate production waste by investigating different operating pressures (atmospheric, vacuum, and combined) and sulfuric acid concentrations (0 M, 0.07 M, 0.15 M, 0.22 M, and 0.30 M). A recovery efficiency of sodium sulfate as high as 92.5% using vacuum distillation at a 0.22 M sulfuric acid concentration. Additionally, the condensate water contained 98.7% purity, making it suitable as a precursor for struvite fertiliser. Sodium sulfate is used as a raw material in producing insecticidal pesticides, with a purity level of 97.3%. This study demonstrates that an optimised distillation process can enhance the efficiency of pesticide production by minimising waste and maximising resource utilisation, contributing to cost efficiency and environmental in industrial pesticides.

Review

The submitted research addresses a critical environmental and resource efficiency challenge associated with the growing production of methyl isocyanate (MIC), a key intermediate for carbamate pesticides. The authors highlight the significant issue of sodium sulfate (Na2SO4) by-product generation, dissolved in an aromatic solvent, which contributes to pollution if not properly managed. The paper proposes a pertinent solution through the optimization of a distillation process for the recovery of this by-product. By focusing on critical operational parameters such as pressure and sulfuric acid concentration, the study aims to enhance clean production strategies within the pesticide manufacturing sector, demonstrating a clear commitment to sustainable chemical engineering. The methodology systematically investigates the impact of various operating pressures (atmospheric, vacuum, and combined) and sulfuric acid concentrations (ranging from 0 M to 0.30 M) on the recovery efficiency of sodium sulfate. The results are compelling, showcasing a maximum sodium sulfate recovery efficiency of an impressive 92.5% under optimized conditions, specifically using vacuum distillation in conjunction with a 0.22 M sulfuric acid concentration. Furthermore, the study effectively demonstrates the valorization potential of the recovered products. The condensate water achieved a remarkable 98.7% purity, making it a viable precursor for struvite fertilizer, while the recovered sodium sulfate itself exhibited a 97.3% purity, suitable for use as a raw material in insecticidal pesticide production. These quantitative outcomes underscore the practical applicability and effectiveness of the proposed strategy. This study presents a robust and practical approach to mitigating waste and enhancing resource utilization in MIC synthesis, aligning strongly with principles of green chemistry and industrial ecology. The clear demonstration of high recovery efficiencies for both sodium sulfate and purified water, alongside specific applications for each, represents a significant step towards more sustainable pesticide manufacturing. While the abstract strongly highlights the technical efficacy, future work could potentially elaborate on the energy economics of the optimized vacuum distillation process and explore scale-up challenges to further bolster its industrial applicability. Overall, the research makes a valuable contribution by offering a well-defined engineering solution that simultaneously addresses environmental concerns, improves cost efficiency, and advances circular economy principles within a vital agricultural industry.

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