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Waste Incineration & Heat Recovery at Roche Ireland Ltd. Andrew Carden PowerPoint PPT Presentation


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Waste Incineration & Heat Recovery at Roche Ireland Ltd. Andrew Carden. Background. 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

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Waste Incineration & Heat Recovery at Roche Ireland Ltd. Andrew Carden

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Waste Incineration & Heat Recovery at Roche Ireland Ltd.

Andrew Carden


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Background

  • 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


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Legislation

  • Legislation

    • 1987 Air Pollution Act

    • Air Emissions within EPA Limits


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Technology Selection

  • 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


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Project Overview

  • Air Emissions Reduction Project consisted of two parts:

    • Fume Collection system

    • Incinerator Package


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Fume 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


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Fume Collection System

  • Vent collection designed to

    • Prevent Explosion

    • Contain Explosion

Low Oxygen

High Solvent

50% MOC

X

MOC

X

UEL

X

Prevent Explosion

Contain Explosion

X

X

Flammable

Region

X

X

X

LEL

High Oxygen

X

Low Solvent

Flammability Diagram

X

= Areas of Operation


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Incinerator Package

  • 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


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Incinerator Package


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Commissioning: Test Burns

  • 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


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Benefits

  • 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


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Continuous Improvements

  • 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


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