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Site visit COVEX

CONSEJERIA DE MEDIO AMBIENTE, VIVIENDA Y ORDENACIÓN DEL TERRITORIO. Comunidad de Madrid. Site visit COVEX. Site visit Visit to COVEX, S.A. Site visit Vist to COVEX, S.A. COVEX, S.A. General Data Location: Industrial facility “South”, Colmenar Viejo

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Site visit COVEX

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  1. CONSEJERIA DE MEDIO AMBIENTE, VIVIENDA Y ORDENACIÓN DEL TERRITORIO Comunidad de Madrid Site visit COVEX Site visit Visit to COVEX, S.A

  2. Site visit Vist to COVEX, S.A COVEX, S.A. General Data • Location: Industrial facility “South”, Colmenar Viejo • Historical land use: Crops and meadows. Agricultural use. • Beginning of activity (year): 1979 • Main activity: Manufacturing of pharmaceuticals • Employees: 50 • Work shifts: 3 shifts/day, 8 hours • IPPC Directive item: 4.5. “Installations using a chemical or biological process for the production of basic pharmaceutical products.” Slide 1

  3. Site visit Vist to COVEX, S.A COVEX, S.A. Industrial process • Raw materials: Vegetal raw materials • Solvents (ethyl acetate, heptanes, methanol, ethanol, chloroform, …) • Reactants (formic acid, ammonia hydroxide, sulphuric acid, acetic acid, HCl, …) • Process: Purification, synthesis and etherification. • Final products: Vincamine, Vinpocetin, Vinburnine y vegetal extracts. Slide 2

  4. Site visit Vist to COVEX, S.A COVEX, S.A. Installation’s general features • Area: 6.000 m2 • Water source: Public network • Fuel: C Gas-oil • Combustion plants: 3 vapor generators • Emission sources into the air: 13 • Emission sources into sewer system: 1 • IOWWTP: Physic-chemical • Hazardous Waste generation: 435 t/year • Non-hazardous Waste: 15 t/year Slide 3

  5. Site visit Vist to COVEX, S.A COVEX, S.A. IPPC Permit • Issuing date: 6 March 2008 (Amended on 29 September 2009) • Permit monitoring: • Every 3 months: Waste water sampling • Every year Air emissions measurement • Waste generation declaration • Solvent Management Plan • Reporting on resource and raw material use • When revising IPPC permit: Soil situation report Slide 4

  6. Site visit Vist to COVEX, S.A COVEX, S.A. Implemented BAT • Environmental, safety and health aspects to be integrated within the process: • Replace substances by less-dangerous ones. • Process safety and prevention of non-controlled reactions: • Assess safety under normal operating conditions and take into account those deviations due to chemical variation and operation conditions. • Apply procedures and measures to limit the risk associated to hazardous substances use and handling. • Provide staff with appropriate training to handle hazardous substances. Slide 5

  7. Site visit Vist to COVEX, S.A COVEX, S.A. • Plant design: • Install laminar flow pumps in reactors starting point • Closure of PQIII reactor building. • Condensation equipment in all production units. • Soil and groundwater protection: • Design, build and maintain installation (sealed, stable and resilient against mechanical thermal and chemical)in order to minimize spills • Implement in situ leak detectors. • Install leak and spill retention containers for further treatment and disposal. Slide 6

  8. Site visit Vist to COVEX, S.A COVEX, S.A. Implemented BAT • VOC reduction: • Contain and seal any source to minimize diffuse and non-controlled emissions. • Dry by using close-circuits and include condensation equipments to recover solvents. • Maintain closed any equipment when proceeding with the cleaning of solvent containers. • Recirculation of process vapors when concentration requirements allow. Slide 7

  9. Site visit Vist to COVEX, S.A COVEX, S.A. Implemented BAT • Reduce waste gas flows: • Ensure that equipments are hermetic, specially reactors. • Minimize waste gas flows in distillation, optimizing condensation design. • Apply liquid feeding at the bottom of the reactor, unless a chemical reaction advices against, to reduce COT values in waste gas. • Minimize peak loads by optimizing production patterns and ad hoc filters. Slide 8

  10. Site visit Vist to COVEX, S.A COVEX, S.A. Implemented BAT • Minimize volumes and waste water pollution charge: • Avoid discharges of main solution with high salt content or applied separation techniques: process membranes, reactants extraction, solvent-based processes. • Mass balance and waste water sampling: • Establish mass balances for VOC, TOC, COD, AOX and metals to better understand processes and implement improvements. • Undertake a detailed analysis of the waste water stream in order to identify origins and prepare basic data to handle and treat waste gas emissions, waste water and solid wastes. Slide 9

  11. Site visit Vist to COVEX, S.A COVEX, S.A. Implemented BAT • Solvent recovery: • Recover solvents when used in high quantities. • Waste gas treatment: • Condensation equipments for reactors. • Waste water treatment: • Recover solvents from waste water by distilling. • Treat high-COT effluents by appropriate biological treatment Slide 10

  12. CONSEJERIA DE MEDIO AMBIENTE, VIVIENDA Y ORDENACIÓN DEL TERRITORIO Comunidad de Madrid

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