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

r Pharmaceuticals 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 Background

r Pharmaceuticals Legislation 1987 Air Pollution Act Air Emissions within EPA Limits Legislation

r Pharmaceuticals 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 Technology Selection

r Pharmaceuticals Air Emissions Reduction Project consisted of two parts: Fume Collection system Incinerator Package Project Overview

r Pharmaceuticals 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

r Pharmaceuticals Fume Collection System UEL Flammable Region LEL 50% MOC MOC Vent collection designed to Prevent Explosion Contain Explosion High Oxygen Low Oxygen High Solvent Low Solvent X X X X X X X X X Contain Explosion Prevent Explosion Flammability Diagram X= Areas of Operation

r Pharmaceuticals 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 Incinerator Package

r Pharmaceuticals Incinerator Package

r Pharmaceuticals 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 Commissioning: Test Burns

r Pharmaceuticals 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 Benefits

r Pharmaceuticals 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 Continuous Improvements