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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. 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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Presentation Transcript
slide2

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
slide3

Legislation

  • Legislation
    • 1987 Air Pollution Act
    • Air Emissions within EPA Limits
slide4

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
slide5

Project Overview

  • Air Emissions Reduction Project consisted of two parts:
    • Fume Collection system
    • Incinerator Package
slide6

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
slide7

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

slide8

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
slide10

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
slide11

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
slide12

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