ZLD solution for Pharmaceutical Industry · Design of UF/RO Recycle Plant – Inconsistent...
Transcript of ZLD solution for Pharmaceutical Industry · Design of UF/RO Recycle Plant – Inconsistent...
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ZLD solution for
Pharmaceutical Industry
Hemant Wagh Associate Vice President Water & WW solutions Group
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Where is the
space for
process
plant???
Reduce Foot Print, Recycle Wastewater, ZLD, Energy
Recovery
Major Concerns. . .
Can I use treated
wastewater
somewhere???
Can I avoid liquid
discharge???
Can I
generate/save
energy???
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Integrated Design Approach
Selection of Appropriate Technologies
Solution under one roof for ZLD
Solutions. . .
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www.Praj.net Confidential
• Determines Evaporation Duty
• Determines Salt Handling Capacity TDS
• Determines Purity Of Salt
• Determines Process Condensate COD & BOD
• Determines Organic Cut from Evaporation
Organic Matter
• Pure Salt Vs. Mixed Salt Recovery
• Process Schematics
• Operating Parameters
• MOC compatibility
Compositional Analysis
• Selection Of Type of Evaporators
• Selection of Process Schematics
Characteristic @various
Concentration
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Challenges – Accurate data
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• scaling
• flow ability issues due to viscosity and salt solubility
• Corrosion
Temperature
• Selection of Type of Evaporators
• Energy Consumption
Effluent Composition
• Auxiliary Evaporators Load
• Mixed Salt quantity
• Boiling Point Elevation in Evaporators Organic Cut
• Utility Requirements
• Operating Cost
• Choking Issues and Salt Dryness
Crystallization
Methodology
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Design Considerations
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Typical comparison
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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
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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
Solvent Recovery - Stripping
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Chemcad Simulation
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NH3 & SOLVENT Stripper
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General API Effluent
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Pharma API effluent
Lean Stream ( Low COD
Stream)
ML Stream ( High COD – High
TDS Stream)
FROM PLANT
Reactor Washings (2nd washing
onwards)
UTILITY WASTE
DM Plant Regeneration
RO water Reject
Cooling Tower blow down
Boiler blow down
FROM PLANT
Product Separation
First washing of reactors
Traces of solvents & Ammonia
from Plant
OTHER
Floor washing
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Cooling
towers
Blow Down
effluent/reactor
washings
Low TSS / TDS
and Low
Hardness water
MGF
Clarification
systems
UF - RO Based
systems
Cooling Tower
Make up water
Multiple
Effect
Evaporator
Reject RO Salt for
disposal ATFD
Typical Recycle & ZLD scheme
Solvent
Stream
Solvent
recovery
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Solvent Boiling Point (ºC)
Acetic Acid 118.0
Acetic Acid Anhydride 139.0
Acetone 56.3
Acetonitrile 81.6
Benzene 80.1
iso-Butanol 107.7
n-Butanol 117.7
tert-Butanol 82.5
Carbon Tetrachloride 76.5
Chlorobenzene 131.7
Chloroform 61.2
Cyclohexane 80.7
Cyclopentane 49.3
Dichloromethane 39.8
Diethyl Ether 34.6
Dimethyl Acetamide 166.1
Dimethyl Formamide 153.0
Dimethyl Sulfoxide 189.0
Dioxane 101.0
Solvent Boiling Point (ºC)
Ethyl Ether 34.6
Ethylene Dichloride 83.5
Ethylene Glycol 197.5
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 35.0-60.0
iso-Propanol 82.3
n-Propanol 97.2
Pyridine 115.3
Tetrahydrofuran 66.0
Toluene 110.6
Trifluoroacetic Acid 71.8
Water 100.0
Xylene 140.0
EXPECTED SOLVENTS IN EFFLUENT FROM PHARMA API EFFLUENT
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Typical API Parameters
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Parameters Unit Concentration
pH 7-8
TDS ppm 3000 - 4000
COD ppm 3500 – 5000
BOD ppm 1500 – 2000
Ammoniacal
Nitrogen
ppm 50-100
Lean Stream ( Low COD Stream)
Parameters Unit Concentration
pH 1-14
TDS ppm 5000 - 6000
COD ppm 60000 – 150000
Ammoniacal Nitrogen ppm 500 - 900
Solvents
(Methanol. IPA, Toluene,
MDC, TBME, Ethyl
Acetate, DMSO, DMF,
Heptane, Hexane, THF)
% 5-12%
High COD – High TDS Stream
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Typical Issues - Pharma API Effluent
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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
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Pharma Case Study
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Thermo Vapor Recompression
FEED
STEAM
2 EFFECTS WITH FALLING FILM AND 3rd EFFECT WITH FORCED CIRCULATION
Multiple Effect Evaporation Motive Steam
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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
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Final Scheme
EXISTING ETP
RO
RO Reject MEE
RO PERMEATE
DRY SOLIDS
ML STREAM 13% TDS
SOLVENT STRIPPER
ML MEE
MEE CONDENSATE
STRIPPER BOTTOM
ATFD
RO REJECT 2% solids
ML MEE STREAM 40% TDS
Ammonia STRIPPER
RO MEE STREAM 40% TDS
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Torrent Pharmaceuticals Ltd, India
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Calandria
Stripper Column
Plant photographs
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Plant photographs
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ZLD Plant Agitated Thin Film Dryer (ATFD)
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Plant photographs
Dry Powder
ATFD Dry Powder Video
ATFD Performance.mp4
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Praj – An Overview
LEED Platinum Certified Green Building
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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
Praj - Overview
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Manufacturing Capability Pune
Domestic Unit
Fabrication capacity - 6000 MT/Year
Kandla
SEZ Units 1&2
SEZ Unit 2 - high thickness vessels
Fabrication capacity - 5000 MT/Year
Wada
US FDA,
UK MHRA and WHO compliant systems
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Key References
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And Many More……
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Think Forward!