Implementation of a Multi-product Process Intensified Plant Exploring Continuous Processing YCF Seminar: AstraZeneca, Macclesfield April 24, 2013 Nigel A Fletcher Manager, Speciality Products Foster Wheeler 2011 FOSTER WHEELER. ALL RIGHTS RESERVED.
Introduction The Challenge Finding Solutions The Realisation Conclusions
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
Finding Solutions ISOLATED SOLID ADDITION REACT CRYSTALLISE FILTER-DRY VENT x ISOLATED SOLID ADDITION RUN/STANDBY GAS CYLINDERS x x LIQUID REACTANT ADDITION VENT REACT REACT CRYSTALLISE FILTER-DRY x x ISOLATED PACK OFF ISOLATED PACK OFF x ISOLATED SOLID ADDITION SOLVENT EXTRACTION EXTRACTING SOLVENT SOLUTION x CRYSTALLISE x VENT FILTER-DRY ISOLATED SOLID CHARGING COARSE MILLING FINE MILLING ISOLATED PACK OFF
Finding Solutions ISOLATED SOLID ADDITION GASEOUS REAGENT ADDITION LIQUID REAGENT ADDITION REACT SOLVENT EXCHANGE REACT REACT 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
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
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 Maintenance Ex environment Equipment selection Remote DCS Input/Output box MCC DCS = Distributed Control System MCC = Motor Control Centre
The Realisation
The Realisation Process Intensification Scale Basis - 1m/s -1 flow velocity of 10% API concentration ¼ (6 mm) Tube ½ (15 mm) Tube 1 (25 mm) Tube 2 (50 mm) Tube Litres / min 0.95 4.9 23 106 Tonnes / yr 38 190 900 4800
The Realisation The challenge of scale Space constraints process design / equipment interaction ½ T-port ball valve Actuator
The Realisation The challenge of scale Cable connection box ½ HP zone II gearbox & motor Control cable Main process line Armoured cable Gear pump head
The Realisation The challenge of control 1. Control strategy depends on process dynamics of each of the stages 2. Introduction of process analytical technology (PAT) LC 1 2 3 LC Buffer Buffer LC = level control
Conclusions Process understanding (Britest) Each process analysed and common aspects identified Determine if micro, meso or macro adaptability required Configuration strategy mobile or? Equipment selection may be influenced by process factors Novel designs may be required Size and space are serious challenges! Control has to match the chosen adaptability PAT Can it succeed Yes!
Thank You Any Questions? Nigel A Fletcher Manager, Speciality Products Foster Wheeler nigel_fletcher@fwuk.fwc.com www.fwc.com