OSMOTRON PRO. Professional Process Management for Your Production

Transcription

1 OSMOTRON PRO Professional Process Management for Your Production

2 2 OSMOTRON PRO Professional Process Management for Your Production With the launch of OSMOTRON in 1996 BWT Pharma & Biotech offered the first skid-mounted system for the production of pharmaceutical water. At present more than 700 systems are in use across the world. With OSMOTRON PRO BWT Pharma & Biotech introduces a completely reengineered line of products that was developed to ensure ergonomic, economic and environmental qualities. OSMOTRON PRO offers you a faster and more cost-effective way of reaching your goal. The new design that along with many other advantages makes this system distinctive ensures that OSMOTRON PRO, with its many technical innovations, is the most attractive Purified Water system of all times. Various standards and options make the system operation safer, more energyefficient and easier. OSMOTRON PRO processes involve pretreatment via softening and microfiltration stages followed by a reverse osmosis stage and a final demineralization via the patented SEPTRON EDI module. This process technology meets current USP and European Pharmacopoeia requirements in a safe and reliable way. Each system is pre-qualified before shipment and undergoes a full functional FAT test at our factory. OSMOTRON PRO is available in various versions with outputs of 500 l/h to 10,000 l/h. OSMOTRON PRO Different Types for Every Application OSMOTRON PRO Product Line For production of Compliant with Process stages Sanitization Softener Sanitization RO/EDI EP USP Softener Microfiltration Reverse Osmosis Electrodeionisation Ultrafiltration (integrated in the EDI module) Chemical SANISAL P Hot water Chemical Hot water OSMOTRON PRO PW OSMOTRON PRO PW-S OSMOTRON PRO PW-2S (double S) OSMOTRON PRO HPW OSMOTRON PRO HPW-S OSMOTRON PRO HPW-2S (double S) Purified Water Highly Purified Water

3 BWT For You and Planet Blue. 3 OSMOTRON PRO Many Innovations Giving You a Lot of Advantages OSMOTRON PRO was developed to ensure high ergonomics and optimal energy efficiency. The most important innovations are presented below. Highlights The new ERGOSKID frame offers integrated sewage drains. As a result there is less piping, less welding seams and an optimum separation of pure water and sewage water. Windows-based software developed by BWT Pharma & Biotech can be interfaced with all visualization systems (Siemens, Rockwell/Allen Bradley etc.). Ergonomics and Design All parts and sampling points of OSMOTRON PRO ensure optimum access, which facilitates maintenance and sampling. The appealing, functional, clear and orderly design is based on the state-of-the-art horizontal and vertical raster division and integration of cable ducts and sewage drains in the ERGOSKID frame. OSMOTRON PRO is easy to qualify and validate: full FAT in operating conditions constitutes a part of the IQ/OQ qualification phase. Easy sampling: all quality relevant samplings are integrated on a central panel. Easiest handling via PC panel and user friendly AQU@VIEW-Software. Quality is measured after each stage, it is possible to take samples following each process stage. Easiest sampling of all quality relevant sampling points due to the central panel The sewage drains are integrated into the ERGOSKID frame allowing for clear design and less pipework

4 4 OSMOTRON PRO Professional Process Management for Your Production Energy efficiency Thanks to its efficient rinsing method applied during production and in idle time for EDI and RO stage the recovery of OSMOTRON PRO exceeds 70 % in the basic version. With additional concentrate processing stage total recovery can be increased to 90 %. As a result, due to reduced waste water levels, operational costs are even lower. One of the available options includes performance regulation via tank volume. This allows to operate the system using the optimum performance mode of 70 to 100 % and thus ensures continuous production as far as possible. As a result operational costs are additionally optimized thanks to low waste water level and low energy consumption. ECOSALT option offers softener regeneration which is not released by volume, but by capacity. This can save some 15 to 30 % of salt due to longer operating periods, depending on the hardness of raw water. Moreover, ECOSALT prevents damages to the subsequent membrane stages due to reliable and permanent control of the softener. Modularity and flexibility The modular concept ensures easy adjustment to customer s specifications. Depending on country-specific requirements the construction can follow either DIN or ASME standards. The new MULTIJOINT block valves provide deadleg-free construction and highest microbiological safety

5 BWT For You and Planet Blue. 5 Safety The system adjusts automatically to the variable raw water conditions (e.g. pressure, temperature and conductivity, with the ECOSALT option the system also adjusts to the changing water hardness). OSMOTRON PRO offers intelligent and simplified process management with the shortest possible distance between water input and output, water is continuously flowing through all pipes in contact with water both during normal operation and during recirculation, giving the highest microbiological safety (see diagrams 1 and 2 below). The new MULTIJOINT block valves substitute 8 single valves, which reduces deadlegs, facilitates emptying process, improves flow and lowers documentation and validation load, as there are less welding seams. The benefits of OSMOTRON PRO for you The highest possible operational safety Facilitated handling due to advanced automation and easier solutions The lowest possible operational costs Hundreds of validated BWT systems are successfully in operation worldwide The shortest possible lead times due to standardized, prefabricated ERGOSKID frames Automation Concentrate to drain Loop return Drinking water High-pressure pump Reverse osmosis Tank Softener SEPTRON EDI SEPTOPERM rinsing Pump Diagram 1: Normal operation Filling the storage tank Automation Concentrate to drain Loop return Drinking water High-pressure pump Reverse osmosis Softener SEPTRON EDI Diagram 2: Recirculation Storage tank full SEPTOPERM rinsing Pump All aggregates and components are perfectly accessible for maintenance work

6 6 OSMOTRON PRO Professional Process Management for Your Production Heart of the System The Unique SEPTRON Module SEPTRON is a patented, spiral-wound EDI module, manufactured by BWT Pharma & Biotech exclusively for OSMOTRON PRO systems. SEPTRON is the only EDI module manufactured in Europe and is a product of genuine Swiss quality. Each module is tested in the factory and delivered with a factory and test certificate. Various sizes of the SEPTRON modules ranging from 150 to 4,000 l/h ensure a wide range of applications for the production of Purified and Highly Purified Water. The modular design of BWT systems meets a wide range of requirements and performance. Permeate The concentric electric field which results from the geometry of the spiral-wound module ensures very high regeneration of the ion-exchange resin used in the system. In addition to the excellent water quality, this solution offers further advantages: Significant reduction of CO 2 and SiO 2 levels Excellent TOC reduction = compliance with the USP limits, also with high TOC content in raw water High degree of regeneration thanks to the homogeneous electric field = the highest possible water quality Low voltage (< 100 V) = more safety Concentrate Ultrapure Water Concentrate to Drain

7 BWT For You and Planet Blue. 7 Flexible Sanitization Concepts for Your Quality Demands In the basic version of OSMOTRON PRO all process stages can be sanitized with chemicals. The need of sanitization is significantly reduced thanks to optimum fluid management with high flow rates. A softener system that is controlled microbiologically prevents microbial contamination at subsequent stages of the process. BWT Pharma & Biotech offers various solutions for the sanitization of system components. SANISAL P tabs for the simultaneous sanitization and regeneration of the softener SANISAL P combined safety SANISAL P is the first regeneration agent with 2 in 1 functionality for regeneration and sanitization in one go. It is a perfect and cost-effective alternative to hot water sanitization. Contrary to this method SANISAL P can be applied in existing systems without the necessity to modify them. SANISAL P offers the following advantages: The easiest possible application (like a regular softener salt) Automatic sanitization during each regeneration Integrated protection of the brine tank Perfect alternative to more expensive thermal or chemical sanitization methods Increased operational and production safety Low investment and energy costs Also applicable in existing systems

8 8 OSMOTRON PRO Professional Process Management for Your Production Flexible Sanitization Concepts for Your Quality Demands Hot water sanitization Hot water sanitization of water treatment systems has several advantages compared with chemical disinfection: The process can be simply monitored with the aid of an integrated temperature measurement Hot water reliably prevents the development of biofilms No need to rinse out chemical agents Simple and reliable process validation BWT Pharma & Biotech offers various hot water sanitization options: S-Option comprises hot water sanitization at > 80 C of the demineralization stages of reverse osmosis and electrodeionization (as well as of the UF stage of the OSMOTRON PRO HPW) Double-S-Option also includes a softener stage in hot water sanitization version at > 80 C The process stages are sanitized independently thanks to their different starting positions. With regular sanitization of the softener with SANISAL P or hot water, sanitization of the next process steps becomes a safety measure, due to the superior dynamic operation mode of OSMOTRON PRO.

9 BWT For You and Planet Blue. 9 Efficient Options Offer More Possibilities Output and WCF regulation Output regulation allows to run the OSMOTRON PRO system with full tank at the lowest capacity at approx. 70 % of the nominal output. In order to avoid downtimes the operational mode is adjusted with output regulation. Further, the OSMOTRON PRO system can be operated by means of a variable Water Conversion Factor (WCF) thanks to the availability of the WCF regulation function. It reduces water consumption during recirculation by approx. 50 % and lowers electrical power consumption by approx. 40 %. Moreover, waste water volume is reduced up to 90 % of its nominal value. Finally, level regulation in the storage tank allows for a fully automated adjustment of water production to the liquid level. ECOSALT hardness monitor With ECOSALT the softener regeneration is not released by volume, but by capacity. Additionally it extends the life cycle of the next process stages. ECOSALT is a miniature online measuring system with a continuous measurement cycle every 30 seconds. Contrary to the regular residual hardness measuring devices ECOSALT does not use up indicators and monitors its own measuring functionality, thus ensuring an absolutely reliable monitoring of the softener function. With the LIPROCONTROL software all system states can be easily monitored and registered An optional membrane degassing stage removes high CO 2 concentrations

10 10 OSMOTRON PRO Professional Process Management for Your Production OSMOTRON PRO HPW For Best Water Quality With SEPTRON BIO-SAFE, BWT Pharma & Biotech offers the first electrode ionisation module with an integrated membrane stage in the world. Based on our proven and patented spiral coil technology, it has been completed with a membrane unit for particulate and germ removal. This unit is used in the HPW-build of the new OSMOTRON PRO device. SEPTRON BIO-SAFE can be used together with reverse osmosis integrated upstream to achieve Highly Purified Water quality (HPW) with germ counts of 10 KBE/ 100 ml without adding another ultrafiltration stage. In contrast to traditional HPW treatment systems, cold and hot water SEPTRON BIO-SAFE builds have the advantage of achieving a high pure water quality at low operational and energy costs. SEPTRON BIO-SAFE is particularly suitable for pharmaceutics applications where efficiency and low effort are important. The membrane stage is exchanged by our technicians in the scope of routine maintenance of the high-purity water system to ensure long-term freeness of germs. The unit is replaced without being touched, using a special replacement system; GMP-compliant operation is thus always ensured. The user does not have to perform any work at the system. For customer- and project-specific requirements, OSMOTRON PRO HPW can also be equipped with a downstream ultra filtration stage. SEPTRON BIO-SAFE is used by default in the OSMOTRON PRO HPW for the production of Highly Purified Water.

11 BWT For You and Planet Blue. 11 Excellent, Proven and Documented Quality Uniform and transparent documentation for a successful project Consistent documentation is absolutely necessary for the successful approval of water treatment systems by authorities. With our own automation department and persistent qualification in accordance with cgmp, GAMP, USP and Eur. Ph. requirements, we create the conditions to make sure you experience a successful inspection of your system at first go. BWT Pharma & Biotech also complies with the recommendations of the ISPE Engineering Baseline Guide, Vol. 4 Water and Steam Systems. Our qualification engineers follow each project throughout all stages of the V-model, from URS (User Requirement Specification) to the final FAT/SAT (Factory or Site Acceptance Test) which is carried out before the system is finally handed over to the customer. Our Customer Service Cares for Ongoing Partnership Even after the handover BWT Pharma & Biotech remains at your side as your reliable partner: Our international customer service offers various service and maintenance packages with differing levels of support. If desired, the system can also be equipped with a remote monitoring function AQU@VIEW or it can even be fully maintained and operated by BWT Pharma & Biotech.

12 BWT The Company The Best Water Technology Group was formed in 1990 and is today Europe s leading water technology company. More than 2,700 employees in over 70 subsidiaries and associates together with thousands of service employees, plumbers, planners, architects and hygiene experts constitute the BWT water partner network. Employees in Research & Development work on new processes and materials using state-of-the-art methods to target the development of ecological and at the same time economical products. Thereby the reduction of energy consumption of products and the consequent minimisation of CO 2 emissions is a key issue. When it comes to water, almost everywhere, whether at the entrance of the water pipe into a building the Point of Entry - or at the tapping point the Point of Use, the trend-setting products by BWT are in use and have proved their quality millions of times. For the treatment of drinking water, mineral water and ultrapure water for the pharmaceutical industry as well as in swimming pools, heating and process water, boiler and cooling water as well as for water for air-conditioning. Extensive innovations guarantee our customers maximum security, hygiene and health in the daily use of water, the precious elixir of life. These innovations, among others, include SEPTRON, the worldwide first electrode deionisation module (EDI) with spiral wrap, the MDA (manganese oxide activation) method for effective manganese removal, the bipolar technology AQA total for chemical-free lime protection, SANISAL the worldwide first regeneration salt for softening systems, which at the same time works as a disinfectant as well as the new, revolutionary Mg 2+ - technology for better taste of filtered water, coffee and tea. With unique high efficiency membranes for fuel cells and batteries, BWT is bringing about a cleaner and sustainable energy supply in the 21 st century. BWT For You and Planet Blue is our mission to take eco logical, economical and social responsibility, to provide our customers and partners with the best products, systems, technologies and services in all areas of water treatment and simultaneously contribute valuably to preserve the global resources of our blue planet. BWT Druck: DK Contact: BHF Technologies The Filtration Specialists +61 (03)