r pharmaceuticals waste incineration & heat recovery at roche ireland ltd. andrew carden
TRANSCRIPT
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Waste Incineration & Heat Recovery
at Roche Ireland Ltd.
Andrew Carden
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• Roche Ireland Ltd: Bulk Pharmaceutical Manufacturing Site.
• Operates under an Integrated Pollution Control License issued by Environmental Protection Agency.
• Emissions to Atmosphere
• Emissions to Water
• Emissions to Land
Background
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• Legislation
• 1987 Air Pollution Act
• Air Emissions within EPA Limits
Legislation
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• A number of technologies examined to meet legislative requirements
• Criteria for Technology Selection
• Varying Calorific Load
• Varying Volumetric Load
• Organochlorides
• Wide Range Compounds
• Economic Factors
• Emission Limits
• Selected Technology: Direct Fired Thermal Incineration
Technology Selection
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• Air Emissions Reduction Project consisted of two parts:
• Fume Collection system
• Incinerator Package
Project Overview
r
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ticalsFume Collection System
•Volatile Organic Carbon Vapour Collection
•Collect VOC Vapours from Chemical Reactors, Dryers
•Network of piping with safety equipment:-
•Flow, Pressure and Oxygen monitoring
•Deflagration, Detonation, Hydraulic and Dynamic Flame Arrestors to meet German TRbF 100 standard
r
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- 1 0
UEL
FlammableRegion
LEL
50% MOC
MOC
•Vent collection designed to
•Prevent Explosion
•Contain Explosion
High Oxygen
Low OxygenHigh Solvent
Low Solvent
X
X
X
X
X
X
X
X
X
Contain ExplosionPrevent Explosion
Flammability Diagram X = Areas of Operation
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• Kraft, Energie & Umwelttechnik (KEU)
• 10.6 MW
• Steam Generation using waste heat from incinerator
• Incineration of Waste Liquids from Site Production Processes
• Odour Reductions by Incinerating Biological Waste Treatment off gases
Incinerator Package
r
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• Operational Qualification Tests:
• To Test Incinerator to Design Limit
• Contractual Test Burns with KEU
• Test Burns with EPA
• Examples of Tests:
• Destruction Removal Effieiency including HCl removal and Dioxin formation
• High and Low Thermal Capacity
• NOx removal
Commissioning: Test Burns
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• Legal Compliance
• IPC licence.
• EC Directive.
• Heat Recovery
• Capacity of 10,000 kg/hr of steam
• Current generation at approx 5000 kg/hr, meeting large proportion of site demands
• Reduction in offsite waste incineration costs
• Incineration up to 760 kg/hr on site
Benefits
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• January 1999: Change from Heavy fuel oil to Diesel
• June 2000: Air reduction leading to Fuel reduction
• June 2000: Stack gas plume elimination
• December 2000: New state of the art in situ HCl laser analyser
• Future
• July 2003: Change from Diesel to Natural gas
Continuous Improvements