1. Festo in BiotechPharma and Cosmetics
Inertisation Save cost with proportional valve technology for inert gases
Example in chemical API production
Thomas Schulz
Head of ISM and KAM BiotechPharma and Cosmetics
Phone: /
Mail:

2. Automation of vessels – inert gas control

3. Automation of reactors/fermenters/vessels – inert gas control
Flow and Pressure control of the gas phase on top of the reactor
Inertisation Complete exchange of gas volume before new filling of the next batch
Pressure superimposition Pressure control e.g. with mbar at the tank in operation or at rest (maintain overpressure of sanitized reactor until next filling)
Flow regulation of the pressure less reactor Flow control, the gas volume on top of the media in the reactor in operation is exchanged/vented within a certain time, avoid accumulation of gas which might have negative effect on the product/process and for Ex-protection
Material transfer from tank to tank Pressure control e.g. at 1 bar transfer pressure
Slide-ring seal pressurization by gas Pressure control, keeping a constant differential pressure in the seals at the reactor
Liquid
Gas

4. Traditional automation with control valve
Ethernet
Control valve
Fieldbus
Flowmeter
Pressure regulator
In einigen Anlagen gibt es Behälter, die mit einem bestimmten Druck beaufschlagt werden müssen, z.B. zum
Transport in einen anderen Behälter.
Dies erfolgt über Druckregelventile, z.B. dieser Bauart.
Diese Druckregelfunktion kann auf eine Ventilinsel integriert werden N2

5. Integration of functions – Control valve and flow meter
Ethernet
VPPM
Fieldbus
in der Pneumatik sprechen wir hier von Proportionalventilen – diese Anwendung natürlich
immer in Verbindung mit einem Sterilfilter, weil die Pneumatikkomponenten in der Regel nicht
FDA-konform sind.
Bei solchen VI-Konstellation wird normalerweise die Luft für das Druckregelventil nochmal separat eingespeist N2
SFAB
SFAB
N2 or inert gas / process air

6. Installation example – New production facility for chemical API
Primary project goals
Higher flexibility in production
Fast changeover between batches
Faster production
Higher grade of automation

7. Existing installation - air/gas and mechanical installation (1)
Ethernet
4-6 bar
Air
7 bar
Positioner
2,5 bar Ar
2,5 bar
Positioner
Einbau „Schaltschrank Inertstation“ abgespeckt in Folie
2,5 bar N2
60 mbar
9 bar
2 - 8 bar

8. Slide ring seal agitator
New Inert gas station – function integration of control valve and flow meter
Fieldbus
4AI
8DO
4AI-P
0..2 bar
0..6 bar
0..10 bar
24 V
Air
N2 9 bar
9 bar
Ar 2,5 bar
24 V 4 2 1 3 5 4 2 1 3 5
0,01 µm
0,01 µm
l/h
l/h
4..20 mA
Reactor
Slide ring seal agitator

9. Function I - V – Fully integrated control cabinet for 2 reactors
Profinet node
8x Proportional pressure control valve
2x N2 for reactor
1x N2 for agitator seal
1x for Argon
Pressure gauge
4x Flow meter
6x Switching valves
The pressure superimpositoin usually followed the three inertization cycles. For example, the reactor is filled with product, then superimposed with pressure and so provided for later applications.
When the pressure build-up must be done completely, we suggest to use an intermediate step with higher outlet pressure or controlled flow.
It is assumed that the required over pressure in the tank has already been reached and must be maintained.
Note: system should be tight, flow rates low and pressure sensors for monitoring are required (to detect pressure losses).
Proportional valve : 0..2 bar
Process:
close exhaust
open fast-switching valve and setpoint ca mbar for the proportional valve
4x Filter 0,01 µm

10. Chemical API production, plant layout – installation example
Personel access floor
Door
Door
Door
Reactor room
Cleanroom Class D
Ex Zone 1
Reactor room
Cleanroom Class D
Ex Zone 1
Reactor room
Cleanroom Class D
Ex Zone 1
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Door
Door
Door
Technical floor
Media and utilities distribution
Piping, Valves, Sensors, control cabinets, inert gas station Festo

11. Project targets – Benefits for the customer
Main customer advantages during purchasing and installation
Reduced purchasing cost for components and for the whole system
Reduced and easier installation due to less piping towards the reactor (flexible tubes up to DN 15)
Less installation space required
Reduced number of suppliers
Easier and cheaper automation, less cabling needed by using modern valve terminal technology

12. Project targets – Benefits for the customer
Main customer advantages during operation and maintenance
Higher flexibility for the multipurpose plant, system fully automated
Flow and pressure control can be done with the same installation
More diagnostic options, integrated pressure and flow sensor for all functions
Increased plant safety
Significantly reduced N2 consumption
system installed in non-explosion-hazard zone (outside Zone 2)  lower cost and higher safety

13. Saving ~ 3.250,- €/per reactor  Project saving ~ 32.500,- €
Comparision of costs Proportional valve technology – Standard control valve
Gas control reactor 1:
Gas control of nitrogen and argon, 2 control valves, 1 flow sensor, higher installation cost … ~7.500,-- €
Gas control reactor 2:
Gas control of nitrogen and argon, 2 control valves, 1 flow sensor, higher installation cost … ~7.500,-- €
total ~15.000,-- €
Inertgasstation for 2 reactors:
Gas control of nitrogen and argon, 6x Prop. Valves, 2x flow sensor, installed in complete control cabinet, lower installation cost …
total ~ 7.500,-- €
- 50%
Saving ~ 3.250,- €/per reactor  Project saving ~ ,- €

14. Thank you for your attention

15. Contact data Thomas Schulz Head of Industry Segment Management and
Key Account Management
Biotech/Pharma/Cosmetics
+49 (0) 