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

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

  2. 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

  3. Legislation • Legislation • 1987 Air Pollution Act • Air Emissions within EPA Limits

  4. 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

  5. Project Overview • Air Emissions Reduction Project consisted of two parts: • Fume Collection system • Incinerator Package

  6. 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

  7. 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

  8. 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

  9. Incinerator Package

  10. 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

  11. 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

  12. 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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