Green Chemistry Applications and Achievements
1.Everlight Chemical’s Green Chemistry Accomplishments
Everlight Chemical has made long-term efforts in promoting green chemistry practices. All our production sites have been diligently implementing the 12 Principles of Green Chemistry and have achieved substantial results. Our efforts have been recognized by various awards, including the Green Chemistry Application and Innovation Award from EPA Taiwan in 2019 and 2021, and the Circular Economy Achievement Award from TCIA in 2021.
Starting from 2020, we have established the Everlight Green Chemistry Research Paper Award, an annual program to encourage academic research in the field of chemistry and chemical engineering, which can benefit the sustainable development of the chemical industry.
2.How We Implement Green Chemistry Practices
The focus of promoting green chemistry at Everlight Chemical
Improve Atom Efficiency
Starting from 2016, we have included atom efficiency as a key performance indicator, setting a target of 61%. In 2022, our atom efficiency reached 70.9%, representing a waste reduction by 6 tons compared to 2021.
Reduce Waste, Pollution and Emissions from Production Processes
We have introduced new wastewater treatment technologies to reduce sludge and chemical oxygen demand (COD) levels and remove ammonia nitrogen and chromaticity. We have also implemented measures to recover and reuse wastewater from our production processes.
Recycle and Reuse Waste
We achieved a waste recycling and reuse rate of 72% in 2022.
3.Our Green Chemistry Success Stories
Case Study 1: Improved Production Process of Reactive Dyes
Adjusting the conditions for related reaction processes has helped improve atom efficiency, reduce ammonia nitrogen in the effluent and also ensure compliance with environmental regulations.
Case Study 2: Reducing Hardness of Wastewater and Sludge Volume
We re-evaluated existing production processes and made science-based adjustments, without compromising quality or efficiency. The changes implemented helped to significantly reduce acid and base inputs, improve atom efficiency and reduce sludge volume by 14%, saving us NT$200,000 in sludge treatment expenses each month.
Case Study 3: Developing Digital Textile Printing Inks that Embody Green Chemistry Principles
Everlight Chemical has developed and launched digital textile printing (DTP) ink products, which help reduce the environmental burden and carbon emissions on customers’ end. So far, these products have created the following benefits for our customers: reduced carbon emissions by 95%, printing paste consumption by 97%, water consumption by 62%, use of consumables by 85%, and energy consumption by 57%.
Case Study 4: Implementing Advanced Ozone Catalytic Oxidation (OZCO) System
To implement the 12 Principles of Green Chemistry, ECIC Plant IV has introduced an advanced OZCO system to treat wastewater with high chromaticity, which has effectively improved the COD unit utilization rate (from 0.3 to 0.8) and energy efficiency.
More Case Studies
Case Study 5: Process Improvement to Improve Atom Efficiency
Green Chemistry
By applying green chemistry principles to maximize atom utilization in raw materials, we improved the production process of three leather dyes, reducing the acid required in the diazotization reaction by one equivalent and also reducing alkaline consumption, and still maintaining desired productivity and quality.
These improvements enabled a reduction of raw material inputs by 69.3 tons in 2022, saving NT$189,000 in raw material costs and reducing carbon emissions by 0.51 tons.
These improvements enabled a reduction of raw material inputs by 69.3 tons in 2022, saving NT$189,000 in raw material costs and reducing carbon emissions by 0.51 tons.
Case Study 6:Recovery and Reuse of Condensate Water from Vacuum Dryers
Circular Economy
Current Situation:
- Condensate water is directly discharged into the drain, emitting smoke and lacking proper 5S practices.
- As condensate water is clean, it is wasted if not recycled
Solution:
- We set up two catch basins on both sides of the vacuum dryers.
- We also installed piping to direct condensate water to the catch basins for recovery and reuse in the hard water system.
Benefits: The solution enabled recovery of 1,044 tons of condensate water each year, equivalent to 87 tons per month.
Case Study 7: Recycling and Reuse of Filter Media for Liquid Products
Green Chemistry
Current Situation:：
- The filtration process for liquid products utilizes 1um/5um filter cartridges that are disposed of after use
- Approximately three 1uｍ/5uｍ filter cartridges are used per batch of product, resulting in waste generation.
Solution: replacing filter cartridges with double-layer filter bags, which can be cleaned and reused to avoid waste of resources.
Benefits:In 2022, the solution enabled a total cost saving of NT$100,000 and 1 ton of waste reduction, also saving NT$20,000 in waste transportation cost.
Case Study 8: Boiler Efficiency Enhancement
Green Chemistry
We disabled a 10.8-ton smoke-tube boiler and replaced it with three 2.5-ton once-through boilers, which raised operating efficiency from 86.6% to 97.5%, enabling reduced natural gas consumption by 11% per year and contributing to a emissions reduction of 252 tCO2e per year.
Case Study 9: Continuous Improvement in Ink Products
Green Chemistry
(1) Developed sodium salt products as substitutes for lithium salt products to reduce the use of LiOH.
(2) Adjusted the mole ratio in related reactions to reduce consumption of ammonia solution and salts.
(3) In 2022, the atom efficiency reached 73.4%, representing a 7.9% improvement compared to 2021 and a reduction of 2,819 tons of raw material input.
(2) Adjusted the mole ratio in related reactions to reduce consumption of ammonia solution and salts.
(3) In 2022, the atom efficiency reached 73.4%, representing a 7.9% improvement compared to 2021 and a reduction of 2,819 tons of raw material input.
Case Study 10: Conversion of Tar Waste from the SV Production Line into Energy Fuel
Circular Economy
(1) The SV production line generates 90 kg of tar waste per batch o f product (approximately 9 tons per year).
(2) By installing mixing equipment (blending tar waste with recovered solvents), we convert the tar waste into 12 tons of fuel per year, which can produce 60 tons of steam annually.
(3) Financial benefits: saving NT$180,000 on steam procurement each year, and saving NT$300,000 on outsourced waste transportation costs per year.
(2) By installing mixing equipment (blending tar waste with recovered solvents), we convert the tar waste into 12 tons of fuel per year, which can produce 60 tons of steam annually.
(3) Financial benefits: saving NT$180,000 on steam procurement each year, and saving NT$300,000 on outsourced waste transportation costs per year.
Case Study 11: Sale of Methanol Recovered from SV Production Line
Circular Economy
(1) The SV production line recovers 13 tons of 95% methanol solution each month, which was previously reused internally.
(2) By commercializing the recovered methanol, excess amounts recovered can be sold externally, generating an annual income of NT$800,000.
(2) By commercializing the recovered methanol, excess amounts recovered can be sold externally, generating an annual income of NT$800,000.
Case 12: Substituting 53-Gallon Steel Drums with Tanker Trucks for Transporting Bulk Raw Materials, Reducing Both Waste and Costs
Circular Economy
(1) We set up bulk raw storage tanks at our sites and began to request suppliers to deliver specific bulk raw materials in ISO tanks (instead of steel drums).
(2) Financial benefits: savings on raw material packaging costs (approximately 3,250 steel drums per year, equivalent to NT$2.9 million in total cost) as well as transportation and disposal fees of used steel drums.
(2) Financial benefits: savings on raw material packaging costs (approximately 3,250 steel drums per year, equivalent to NT$2.9 million in total cost) as well as transportation and disposal fees of used steel drums.
Case Study 13: Repairing and Reusing Wooden Pallets
Circular Economy
In 2022, ECIC Plant III repaired approximately 400 used pallets (saving NT$64,000) and recycled around 2,000 raw material pallets (saving NT$320,000), amounting to a total saving of NT$384,000.
Case 14: Recycling and Reusing Empty Steel Drums
Circular Economy
In 2020, we began coordinating with our customers to recollect empty steel drums used to carry PUR products, buying back the empty drums to be reused for product packing. This practice has enabled us to save around NT$500,000 on steel drum purchasing costs in 2022.
Case Study 15:Optimize Process for Pharmaceutical Intermediates, Reducing Processing Time and Waste
Circular Economy
Before:：The original production process involved eight steps and required conducting column purifications four times, consuming a substantial amount of solvent.
After: The new process is simplified to seven steps (modifying the protection groups) and only requires one purification step (with column purification replaced by crystallization purification), reducing solvent waste to one-tenth of the original process and significantly bringing down processing time.
Benefits: solvent usage reduced by 2,000 kg/batch; processing costs reduced by 50%.
Case Study 16: Conversion of S olvent Waste from API Production Line into Marketable Products
Circular Economy
Before: the production line generated 4,600 kg of solvent waste each month that required external incineration services.
After: set up an additional waste solvent distillation line to distill marketable products (cleaning agent). The residual waste (1,320kg/month) is then outsourced for incineration.
Benefit: Annual savings of NT$1.38 million in solvent waste disposal fees.
Before: Problem Encountered
After
Benefit
Case Study 17: Repurposing Wood Pallets into Solid Fuel, Unlocking Residual Value
Circular Economy
Before: Waste wood pallets were sent to be incinerated in Hsinchu City for
After: We provide the pallets to manufacturers for processing: wood pallets are crushed into fine pieces -> the crushed pieces are compressed to form solid biomass fuel -> the solid fuel can be used for industrial and household purposes.
Benefits: 15,490 kg of waste wood pallets were processed in 2022.
Case Study 18: Improving Operational Methods to Reduce Solvent Consumption
Green Chemistry
Before: during color powder changeovers, the tanks and pipelines needed to be cleaned with solvents.
After: we replaced the solvent cleaning method with dry ice blasting machine.
Benefits: reduced solvent consumption by 7 liters each time, minimizing hazards and also shortening the cleaning process from 24 hours to 19 hours.
Case Study 19: Replacing Stickers with Metal Embossing/Inkjet Printing to Reduce Waste
Green Chemistry
Before: toner products were labeled with stickers to indicate batch numbers.
After: we replaced stickers with embossing or inkjet printing for labeling.
Benefits: reduced paper waste and sticker labeling costs.
Case Study 20: Recycling and Repurposing Byproducts for Sale
Circular Economy
Before: Fine powder (byproducts) generated from the toner production process couldn’t be for sale and required further treatment.
After: We recovered and reprocessed the fine powder into marketable finished products.
Benefits: In 2022, a total of 21,900 kg of byproducts was reprocessed, significantly improving the atom efficiency of this process.
Case Study 21: Reducing the Use of Hazardous Chemicals
Green Chemistry
Before: the raw material inspection process involved the use of highly toxic and explosive chemicals (potassium permanganate, concentrated sulfuric acid).
After: we improved the inspection process and eliminated the use of these chemicals.
Benefits: significantly enhancing operational safety of the inspection process.
Case Study 22: Recycling of Low-Purity Cleaning Solutions from the Photoresist Production Line
Circular Economy
Before: Low-purity PMA cleaning solution waste (80 tons/year) and EL solution waste (6 tons/year) were sent for incineration.
After: Low-purity PMA cleaning solutions are now recycled and reused by solvent vendors.
Benefits: Recycling and reusing the PMA cleaning solution (80 tons/year) generates an annual income of NT2 million, and recycling and reusing EL solution generates an annual income NT$660,000. The share of solvent recycled and reused also significantly increased from 35% to 94%.
No Data Found
Solvent Recycling Rate: 35% -> 94%
Case Study 23: Replacing Disposable Shipping Temperature Recorders with Reusable Ones
Before: temperature recording for delivery to domestic customers was done using disposable temperature recorders.
After: we switched to reusable electronic temperature recorders.
Benefits: reduced waste of 120 disposable temperature recorders annually.
Case Study 24: Recycling and Reusing Used 53-Gallon Steel Drums for Storing Solvents
Before: empty used steel drums for carrying raw materials were collected and disposed of by recycling service vendors.
After: the empty drums are used to store recyclable solvents for transport to solvent vendors for further recycling and reuse.
Benefits: reduces at least 110 discarded drums, equivalent to 2,200 kg/year of waste.
4.Future Outlook
Everlight Chemical strives to put green chemistry concepts into practice to advance both business and sustainable development, and hopes to contribute to the healthy and happy life of our customers.
As noted by the father of green chemistry, John Warner, green chemical products should incorporate zero-toxicity, sustainability, cost competitiveness and outstanding product performance. All of these characteristics are indispensable.
On top of years of efforts in green chemistry, Everlight Chemical further launched two major projects in 2022: Blueprint for Evaluation & Development of Sustainable Products and Carbon Footprint Verification and Reduction Pathway Project. The projects aim to help evaluate where the Company stands and devise practical long-term plans to guide us in implementing measures such as combining the use of innovative chemical technologies and advanced production equipment and to drive further success in the near future.
E verlight Chemical’s aspiration is that green chemistry is not just a goal, but can be implemented in the daily operations of the chemical industry.
As noted by the father of green chemistry, John Warner, green chemical products should incorporate zero-toxicity, sustainability, cost competitiveness and outstanding product performance. All of these characteristics are indispensable.
On top of years of efforts in green chemistry, Everlight Chemical further launched two major projects in 2022: Blueprint for Evaluation & Development of Sustainable Products and Carbon Footprint Verification and Reduction Pathway Project. The projects aim to help evaluate where the Company stands and devise practical long-term plans to guide us in implementing measures such as combining the use of innovative chemical technologies and advanced production equipment and to drive further success in the near future.
E verlight Chemical’s aspiration is that green chemistry is not just a goal, but can be implemented in the daily operations of the chemical industry.