ZLD solution for Pharmaceutical Industry

Size: px

Start display at page:

Download "ZLD solution for Pharmaceutical Industry"

Hugo Marshall
6 years ago
Views:

1 ZLD solution for Pharmaceutical Industry Hemant Wagh Associate Vice President Water & WW solutions Group

2 Major Concerns... Where is the space for process plant??? Can I generate/save energy??? Can I use treated wastewater somewhere??? Can I avoid liquid discharge??? Reduce Foot Print, Recycle Wastewater, ZLD, Energy Recovery

3 Solutions... Selection of Appropriate Technologies Integrated Design Approach Solution under one roof for ZLD

4 Challenges Accurate data TDS Determines Evaporation Duty Determines Salt Handling Capacity Organic Matter Determines Purity Of Salt Determines Process Condensate COD & BOD Determines Organic Cut from Evaporation Compositional Analysis Concentration Pure Salt Vs. Mixed Salt Recovery Process Schematics Operating Parameters MOC compatibility Selection Of Type of Evaporators Selection of Process Schematics Confidential 4

Design Considerations Temperature scaling flow ability issues due to viscosity and salt solubility Corrosion Effluent Composition Selection of Type of Evaporators Energy Consumption Organic Cut

5 Design Considerations Temperature scaling flow ability issues due to viscosity and salt solubility Corrosion Effluent Composition Selection of Type of Evaporators Energy Consumption Organic Cut Auxiliary Evaporators Load Mixed Salt quantity Boiling Point Elevation in Evaporators Crystallization Methodology Utility Requirements Operating Cost Choking Issues and Salt Dryness Confidential 5

6 Typical comparison Offerings Features/Applications Advantage Benefits & Limitations Falling Film Evaporators Effluents with Low TSS, Low hardness & Silica Higher Heat Transfer Coefficient Less Power Consumption, Not suitable for highly viscous liquids Forced Film Evaporators Effluents with High TSS, high hardness & silica Reduction in CIP Frequency, Suitable for High Viscous Effluents Low Scaling Tendency due high Tube Velocity, High operating cost TVR Acts as additional effect Increase in Steam Economy Reduces Operating Cost. Cant recover pure steam condensate MVR Where steam is not available/steam generation cost is high, Operates on Power No steam is required during operation Beneficial where power is surplus. Higher Capex Pusher Centrifuge Concentrate from MEE is treated in PC. End product is salt Crystalline salts can be separated easily Simple in Operation, Lower Capex & Opex. Amorphous salt cant be separated ATFD - EcoDry To convert concentrate from MEE to dry powder. Zero Clearance Hinged Scrapping Blades No chemical CIP required, Higher Heat Transfer Coefficient Moisture content <8 to 10% Very less mechanical break down As end unit operation opex is high 6

Solvent Recovery - Stripping Praj Patented Rh Grid trays are compatible to TSS load up to 2000 ppm without affecting performance Most effective on multiple feed inlet, gives flexibility in

7 Solvent Recovery - Stripping Praj Patented Rh Grid trays are compatible to TSS load up to 2000 ppm without affecting performance Most effective on multiple feed inlet, gives flexibility in operation depending on variation in feed condition In Tray column the pressure drop is comparatively less hence less steam consumption Software design like CHEMCAD helps in getting accurate Process results

8 Chemcad Simulation NH 3 & SOLVENT Stripper Praj Industries Ltd 8

General API Effluent Pharma API effluent ML Stream ( High COD High TDS Stream) FROM PLANT Product Separation First washing of reactors Traces of solvents & Ammonia from Plant Lean Stream ( Low COD

9 General API Effluent Pharma API effluent ML Stream ( High COD High TDS Stream) FROM PLANT Product Separation First washing of reactors Traces of solvents & Ammonia from Plant Lean Stream ( Low COD Stream) FROM PLANT Reactor Washings (2 nd washing onwards) UTILITY WASTE DM Plant Regeneration RO water Reject Cooling Tower blow down Boiler blow down OTHER Floor washing Praj Industries Ltd 9

water Low TSS / TDS and Low Hardness water UF - RO Based systems

10 Typical Recycle & ZLD scheme Cooling towers Blow Down effluent/reactor washings MGF Clarification systems Solvent Stream Cooling Tower Make up water Low TSS / TDS and Low Hardness water UF - RO Based systems Solvent recovery Salt for disposal ATFD Multiple Effect Evaporator Reject RO 10

11 EXPECTED SOLVENTS IN EFFLUENT FROM PHARMA API EFFLUENT Solvent Boiling Point (ºC) Acetic Acid Acetic Acid Anhydride Acetone 56.3 Acetonitrile 81.6 Benzene 80.1 iso-butanol n-butanol tert-butanol 82.5 Carbon Tetrachloride 76.5 Chlorobenzene Chloroform 61.2 Cyclohexane 80.7 Cyclopentane 49.3 Dichloromethane 39.8 Diethyl Ether 34.6 Dimethyl Acetamide Dimethyl Formamide Dimethyl Sulfoxide Dioxane Praj Industries Ltd Solvent Boiling Point (ºC) Ethyl Ether 34.6 Ethylene Dichloride 83.5 Ethylene Glycol Heptane 98.4 n-hexane 68.7 Hydrochloric Acid 84.8 Methanol 64.7 Methylene Chloride 39.8 MTBE 55.2 Pentane 36.1 Petroleum Ether iso-propanol 82.3 n-propanol 97.2 Pyridine Tetrahydrofuran 66.0 Toluene Trifluoroacetic Acid 71.8 Water Xylene

12 Typical API Parameters High COD High TDS Stream Parameters Unit Concentration ph 1-14 TDS ppm COD ppm Ammoniacal Nitrogen ppm Solvents (Methanol. IPA, Toluene, MDC, TBME, Ethyl Acetate, DMSO, DMF, Heptane, Hexane, THF) % 5-12% Lean Stream ( Low COD Stream) Parameters Unit Concentration ph 7-8 TDS ppm COD ppm BOD ppm Ammoniacal Nitrogen ppm Praj Industries Ltd 12

13 Typical Issues - Pharma API Effluent 1. Large Variations in Parameters & Shock Loads Results in under performance of plant & inefficient operations. 2. Variations in Solvent Mix based on the Product mix Inefficient operation of Stripper affecting MEE & contaminated Process Condensate 3. TDS composition Varies & is difficult to predict Inconsistent operations of MEE 4. Wide variation in Hardness & Silica levels - Frequent Scaling & down time for cleaning 5. Ammoniacal Nitrogen - Affects the down stream MEE & Process Condensate quality 6. Design of UF/RO Recycle Plant Inconsistent Operations & frequent fouling Praj Industries Ltd 13

14 Pharma Case Study Praj Industries Ltd

15 Thermo Multiple Vapor Effect Recompression Evaporation Motive Steam STEAM FEED 2 EFFECTS WITH FALLING FILM AND 3 rd EFFECT WITH FORCED CIRCULATION

16 Design Features If both streams are mixed, steam condensate of the MEE can not be reused due to TVR. The condensate might have contaminated with solvents Due to above reason, it was decided to go for separate MEEs for RO Reject & ML Also, as Ammonical Nitrogen effluent may not be component of all streams, it was decided to strip it separately using Ammonia Stripper at high ph

17 Final Scheme RO PERMEATE EXISTING ETP RO RO Reject MEE MEE CONDENSATE RO REJECT 2% solids RO MEE STREAM 40% TDS ML STREAM 13% TDS SOLVENT STRIPPER Ammonia STRIPPER STRIPPER BOTTOM ML MEE ML MEE STREAM 40% TDS ATFD DRY SOLIDS

18 Plant photographs Torrent Pharmaceuticals Ltd, India Calandria Stripper Column MEE Plant Praj Industries Ltd 18

19 Plant photographs ZLD Plant Agitated Thin Film Dryer (ATFD) Praj Industries Ltd 19

20 Plant photographs ATFD Dry Powder Video Dry Powder 20

21 Praj An Overview LEED Platinum Certified Green Building 21

22 Praj - Overview Experience Solutions Presence Certification Standards > 30 years in Distillery, Power, Pharma, Chemicals, Ferrous & Non ferrous, Food & Beverages, Textiles. WTP, ETP, Effluent Recycling systems (ERS) & Zero Liquid Discharge (ZLD) Over 65 countries across the globe, Listed on BSE & NSE ISO 9001:2008 (Certification by Bureau Veritas), U Stamp, U2, ISO 14001:2008 ASME Sec VIII Div. I, IS 2825, TEMA, DIN, API 650 Developing sustainable solutions to transform the world s most difficult waters into valuable resources 22

Unit 2 - high thickness vessels Fabrication capacity -

23 Pune Kandla Wada Manufacturing Capability Domestic Unit Fabrication capacity MT/Year SEZ Units 1&2 SEZ Unit 2 - high thickness vessels Fabrication capacity MT/Year US FDA, UK MHRA and WHO compliant systems 23

24 Key References And Many More Praj Industries Ltd 24

25 Think Forward!

Green Business Options: Zero Liquid Discharge Solutions for Industries. By Manish Kharwade

Green Business Options: Zero Liquid Discharge Solutions for Industries By Manish Kharwade Industries Major Concerns Praj Industries Ltd www.praj.net Major Concerns... Where is the space for process plant???