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Simulation Design of the Protease Inhibitor Production Plant and Pollution Control Strategies. By Mr. Kanatip Ratanachoo. Simulation Design of the Plant Process Synthesis and Analysis Environmental Regulation Pollution Control System and Waste Disposal Environment Management Strategies.

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simulation design of the protease inhibitor production plant and pollution control strategies

Simulation Design of the Protease Inhibitor Production Plant and Pollution Control Strategies

By Mr. Kanatip Ratanachoo

presentation outline

Simulation Design of the Plant

  • Process Synthesis and Analysis
  • Environmental Regulation
  • Pollution Control System and Waste Disposal
  • Environment Management Strategies

Presentation Outline

1 simulation design of the plant

1. Simulation Design of the Plant

  • HIV positive in Thailand ~ 755,000 persons (WHO estimated, end of 1999)
  • Dose : protease inhibitor (Ritronavir): 600 mg twice daily = 1.2 g/patient/day
  • Assumption : Market analysis ~ 300,000 persons (40%) need Ritronavir
  • Production Quantity ~ 131,400 kg/yr

Production Quantity

1 simulation design of the plant con t

1. Simulation Design of the Plant (con’t)

  • Batch Mode
  • Operating time = 7,920 h/yr
  • Plant batch time = 24 h
  • Number of batches per year = 330
  • Production Rate = 398 Kg/Batch

Plant Mode of Operation

1 simulation design of the plant con t5

Refer to the United State Patent number 5,846,987 : Retroviral Protease inhibiting compounds.

  • SuperPro Designer Program Version 3.05
  • Limitation and Assumption
  • - lack of thermodynamic data
  • - over-engineering
  • - 90 % conversion of all reaction
  • - no recycle and waste minimization
  • - my stupid knowledge in synthesis chemistry

1. Simulation Design of the Plant (con’t)

Design consideration

2 process synthesis and analysis

Composed of 9 main reactions, and 8 flowsheet

2. Process Synthesis and Analysis

(2S,3S,5S)-5-(N-(N-((N-Methyl-N-(2-isopropyl-4- thiazolyl)methyl)amino)carbonyl)valinyl)amino)-2-(N-((5-thiazolyl)methoxycarbonyl)amino)-1,6- diphenyl-3-hydroxyhexane

reaction 1

Reaction 1

Consists of 4 sub-reactions

N-(((Benzyl)oxy)carbonyl)-L-phenyllalaninal

reaction 2

Reaction 2

(2S,3R,4R,5S)-2,5-Bis-(N-(((Benzyl)oxy)carbonyl)amino)-3,4-dihydroxy-1,6- diphenylhexane

reaction 3

Reaction 3

(2S,3R,4R,5S)-3-Acetoxy-2,5-bis-(N-(((Benzyl)oxy)carbonyl)amino)-3- bromo-1,6- diphenylhexane

reaction 4

Reaction 4

(2S,3R,4R,5S)-2,5-Bis-(N-(((benzyl)oxy)carbonyl)amino)-3,4-epoxy-1,6- diphenylhexane

reaction 5

Reaction 5

(2S,3S,5S)-2,5-Bis-(N-(((benzyl)oxy)carbonyl)-1,6-diphenyl-3- hydroxyhexane

reaction 6

Reaction 6

(2S,3S,5S)-2,5-Diamino)-1,6-diphenyl-3-hydrohexane

reaction 7

Reaction 7

(4S,6S,1’S)-6-(1-Amino-2-phenylethyl)-4-benzyl -2-phenyl-3-aza-2-bora-1-oxacyclohexane

reaction 8

Reaction 8

(2S,3S,5S)-5-Amino-2-(N-((5-thiazolyl)methoxycarbonyl)amino)-1,6-diphenyl -3-hydroxyhexane

reaction 9

Reaction 9

(2S,3S,5S)-5-(N-(N-((N-Methyl-N-(2-isopropyl-4- thiazolyl)methyl)amino)carbonyl)valinyl)amino)-2-(N-((5-thiazolyl)methoxycarbonyl)amino)-1,6- diphenyl-3-hydroxyhexane

3 environmental regulation

3. Environmental Regulation

  • Ministry of Industry
  • Ministry of Science, Technology and Environment
  • Ministry of Interior

3 Ministry involved in Pollution Control

facility and operation

Environmental Regulation(con’t)

Air

Wastewater

Facility and

operation

Hazardous/solid Waste

industry facility and operation

Industry(facility and operation)

  • Factory Act, B.E.2535
  • Pharmaceutical Industry :
  • - Classified in category 46
  • - Group 3 industry : must be granted a permit prior to the engagement
air quality

Factory Act, B.E.2535

  • Enhancement and conservation of National Environmental Quality Act, B.E.2535
  • Notification of Ministry of Industry, no.2, B.E.2536 and no.9, 2538
  • Notification of Ministry of Interior, Chemical concentration in working condition, B.E.2520
  • Ambient Air Standard, Environmental Board B.E. 2538

AIR quality

wastewater

Factory Act, B.E.2535

  • Enhancement and conservation of National Environmental Quality Act, B.E.2535
  • Notification of Ministry of Industry, no.2, B.E. 2539
  • Notification of Ministry of Science, Technology and Environment, no.3, B.E. 2539

Wastewater

hazardous solid waste

Factory Act, B.E.2535

  • Enhancement and conservation of National Environmental Quality Act, B.E.2535
  • Notification of Ministry of Industry, no.6, B.E. 2540
  • Notification of Ministry of Industry, no.1, B.E.2541

Hazardous/solid waste

4 pollution control system and waste disposal

4. Pollution Control System andWaste Disposal

  • Waste generated from reaction 1 (7 points)
  • Liquid Waste : 6 points
  • Air emission : 1 point

Total waste produced : 46 points (all reactions)

liquid waste

Total flow : 13,701 m3/yr

  • Characteristics:
  • - COD = 1,168,504 kg/yr
  • - BOD = 124,690 kg/yr
  • - TKN = 12,360 kg/yr
  • - TS = 143,637 kg/yr
  • - TDS = 143,637 kg/yr
  • - pH = acidic condition
  • Treatment Method :
  • - design of a wastewater treatment plant

Liquid Waste

air emission

Total flow : 60,889 kg/yr

  • Characteristics:
  • - Citric acid = 13,846 kg/yr
  • - Dimethylsulfide = 41,762 kg/yr
  • - DMSO = 1,297 kg/yr
  • - HCl = 3,982 kg/yr (1.45E06 mg/m3, std. not more than 200 mg/m3)
  • Treatment Method :
  • - Design of a incinerator.

Air Emission

slide29

Air Emission (con’t)

  • Design of a Incinerator Unit
  • Exhaust air to stack :
  • - CO2 = 104,300 mg/m3
  • - HCl = 100 mg/m3 (std. 200 mg/m3)
  • - O2 = 37,900 mg/m3
  • - SO2 = 1,400 mg/m3 (std. = 3,278 mg/m3)
  • - water = 84,500 mg/m3
hazardous solid waste30

Reaction 1 : no

  • if produced;
  • Disposal Method
  • - non-hazardous waste : local municipal authority.
  • - hazardous waste : GENCO company.

Hazardous/solid waste

5 environmental management strategies

5. Environmental Management Strategies

  • Plant management structure and environmental unit
  • Environmental monitoring and regulatory report
  • Environmental management system (EMS)
plant management structure and environmental unit

Environmental Division

Administrative Division

Engineering Division

Operation Division

Maintenance Division

Purchasing Division

Plant Manager

Plant management structure and Environmental unit

Pollution control system

supervisor(no.13, 2525)

Pollution control system operators

(no.13, 2525)

environmental monitoring and regulatory compliance

Environmental Monitoring and regulatory compliance

  • Stack monitoring : every 3 months
  • Ambient monitoring : once a month
  • Working environmental : twice a year.

AIR quality monitoring

environmental monitoring and regulatory compliance con t

Environmental Monitoring and regulatory compliance (con’t)

  • Inlet-outlet (treatment system) : twice a month
  • Plant outlet : twice a month

Effluent quality monitoring

  • Hazardous waste monitoring
  • Recording the type, quantity and disposal method at the time of waste generated and dispose.
regulatory reporting and recording

Department of Industrial works : every 3 months (stack monitoring, inlet-outlet treatment system, and plant outlet)

  • Department of Industrial works : once a year (hazardous waste data)
  • Ministry of Interior : twice a year (chemical concentration in working environment)
  • Keep environmental records for random and periodical audit at the plant

Regulatory Reporting and Recording

conclusion

Simulation Modeling (SuperPro Designer)

  • - required it before setting-up a plant
  • - scale-up of plant
  • - reaction synthesis and analysis
  • - reactor volume
  • - functionality
  • - environmental impact evaluation
  • - waste treatment system
  • - economic analysis

Conclusion

Plant Design

plant design con t

Conclusion (con’t)

  • Limitations
  • - thermodynamic data of some reagents, reactions and associated products
  • - patent and synthesis pathway
  • - synthesis chemist
  • - competent in SuperPro Designer
  • - waste recycle and minimization
  • - cost-effectiveness analysis

Plant Design (con’t)

plant design con t39

Conclusion (con’t)

  • Achievement
  • - establish a bulk scale infrastructure of protease inhibitor production plant
  • - establish a process synthesis and analysis of reaction 1 and waste treatment system
  • - exploited of computer simulation modeling
  • - logical scheme for real world situation

Plant Design (con’t)

pollution control strategies

Conclusion (con’t)

  • Environmental regulations are the important issues which the plant have to deal with and follow
  • Plant should be designed at the best standard, and more stringent to protect the environment
  • Pollution control system must be designed, constructed and installed
  • Environmental management have to set-up for ensuring the environmental performance and continual improvement

Pollution Control strategies

acknowledgement

Prof. John, Prof. Ram and Dr.Ganesh

  • Dr. Maria and Dr. Suvit
  • Asso. Prof. Dr. Somsak R.
  • Dr. Poolsak S. (laboratory of Medical chemistry, CRI.)
  • Dr. Army
  • CRI staffs
  • “My beloved girlfriend”

Acknowledgement

punishment

Punishment ??

“ Usually interrupt my work by taking me to have some delicious meals”