Implementation of a Multi-product Process Intensified Plant
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1 Implementation of a Multi-product Process Intensified Plant Implementation of Process Intensification Technologies (IPIT) symposium Delft, The Netherlands 15 April 2011 Nigel A Fletcher Manager, Speciality Products Foster Wheeler 2011 FOSTER WHEELER. ALL RIGHTS RESERVED.
2 Introduction The Challenge Finding Solutions The Realisation Conclusions
3 The Challenge Pharmaceutical client Many products Traditional batch production Forward-looking R&D - continuous future One key target product + six other possibles New paradigm One continuous plant Raw materials to product QUICKLY Reduced capex and operational costs
4 Finding Solutions ISOLATED SOLID ADDITION ISOLATED SOLID ADDITION LIQUID REACTANT ADDITION VENT VENT REACT CRYSTALLISE REACT REACT CRYSTALLISE FILTER DRY FILTER DRY RUN/STANDBY GAS CYLINDERS ISOLATED PACK OFF ISOLATED PACK OFF ISOLATED SOLID ADDITION ISOLATED SOLID CHARGING VENT COARSE MILLING SOLVENT EXTRACTION CRYSTALLISE FILTER DRY FINE MILLING EXTRACTING SOLVENT SOLUTION ISOLATED PACK OFF
5 Finding Solutions ISOLATED SOLID ADDITION GASEOUS REAGENTADDITION ADDITION LIQUID REAGENT ADDITION REACT SOLVENT REACT REACT EXCHANGE SOLVENT EXCHANGE LIQUID LIQUID EXTRACTION EFF. TREAT EXCHANGE SOLVENT EXCHANGE SOLVENT SOLN EXTRACTING SOLVENT Raw Material In CONTINUOUS CRYSTALLISATION VENT Twelve stages removed - multiple crystallisation, filtration, drying & pack off Three additional stages - solvent exchange & liquid-liquid extraction (LLE) Final Product Out FILTER DRYER FILTER DRY ISOLATED PACK OFF ISOLATED PACK OFF
6 Finding Solutions Continuous (chemical) plants typically high volume and dedicated. Plant design to meet GMP requirements of small volume multi-purpose unit? Inherent Flexibility Equipment and systems built for flexibility Micro Adaptability Change part or all of an equipment item Meso Adaptability Re arrange skids Macro Adaptability Change large sections of plant / modular buildings
7 The Realisation Skid design Mobile Re-arrangeable configuration Power, instrumentation, services, process in / out, drains, safety vents, other safety systems Interfaces with other skids Interfaces with facility Other constraints t Maintenance Ex environment Equipment selection Remote DCS Input/Output box DCS = Distributed Control System MCC = Motor Control Centre MCC
8 The Realisation
9 The Realisation Process Intensification Scale Basis 1m/s 1 flow velocity of 10% API concentration ¼ (6 mm) Tb Tube ½ (15 mm) Tube 1 (25 mm) Tube 2 (50 mm) Tube Litres / min Tonnes / yr
10 The Realisation The challenge of scale Space constraints process design / equipment interaction p ball valve ½ T-port Actuator
11 The Realisation The challenge of scale Cable connection box ½ HP zone II gearbox and motor Control cable Main process line Armoured cable Gear pump head
12 The Realisation The challenge of control 1. Control strategy depends d on process dynamics of each of the stages 2. Introduction of process analytical technology (PAT) LC LC Buffer Buffer LC = level control
13 Conclusions Process understanding P d di (B (Britest) i ) Each process analysed and common aspects p identified Determine if micro, meso or macro adaptability required C fi Configuration ti strategy t t mobile bil or? Equipment selection may be influenced by factors y process p Novel designs may be required Size and space are serious challenges! Control has to match the chosen adaptability PAT Can it succeed Yes!
14 Thank You. Any Questions? Nigel A Fletcher Manager, Speciality Products Foster Wheeler nigel_fletcher@fwuk.fwc.com
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