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    This document contains diagrams and descriptions of various systems within a pharmaceutical plant. It includes sections on fermentation, penicillin extraction, the boiler plant, steam distribution, and proposals to improve efficiency. The diagrams show process flows and equipment for fermenting, filtering, extracting, and distributing steam throughout the plant. The proposals suggest ways to reduce water and heat losses, improve boiler efficiency, and increase fermentor availability to boost production and profits.

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    This document contains diagrams and descriptions of various systems within a pharmaceutical plant. It includes sections on fermentation, penicillin extraction, the boiler plant, steam distribution, and proposals to improve efficiency. The diagrams show process flows and equipment for fermenting, filtering, extracting, and distributing steam throughout the plant. The proposals suggest ways to reduce water and heat losses, improve boiler efficiency, and increase fermentor availability to boost production and profits.

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    © All Rights Reserved
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    5 views8 pages

    3 Pharma

    Uploaded by

    alokbdas
    This document contains diagrams and descriptions of various systems within a pharmaceutical plant. It includes sections on fermentation, penicillin extraction, the boiler plant, steam distribution, and proposals to improve efficiency. The diagrams show process flows and equipment for fermenting, filtering, extracting, and distributing steam throughout the plant. The proposals suggest ways to reduce water and heat losses, improve boiler efficiency, and increase fermentor availability to boost production and profits.

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    of 8

    About

    JKPL

    FERMENTATION
    Steam, Air, Cooling water
    Chilled water

    Steam, Air, Cooling water


    Chilled water
    Steam, Air, Cooling water
    Chilled water

    Chilled Brine

    Compressed Air, Treated


    Water, Raw Water

    GERMINATOR
    PREFERMENTOR
    FERMENTOR

    Seed Inoculation
    Raw Material

    Raw Material

    Raw Material

    NON FILTERED
    BROTH TANK
    FILTER PRESS

    To Extraction

    Mycelium
    to ETP

    PENICILLIN-G EXTRACTION
    18 m3/hr
    Filtered
    Broth
    Tank

    8oC
    WESTFALIA SEPARATOR

    To Solvent Recovery

    Butyl Acetate

    Plate Heat Exchanger


    Nitrogen Blanketing

    Filter Press
    Separator
    22oC
    Collection
    Tank

    Carbon for
    declorisation

    Filter Press
    Sparkler Filter

    Re-suspension
    Tanks

    Centrifuge

    Drier

    Guard Filter

    65oC

    Brine
    Condenser

    Membrane Filter
    Packing
    Crystaliser

    To Butanol Tanks

    BOILER PLANT
    5 Bar, Comp. air/steam for
    atomisation

    Steam

    HP Dosing
    (Phosphate)

    3 Bar
    180o C

    Fur.Oil
    Tank
    4.5 KL

    Heater/3.5 kw
    Filter units

    Water tube Boiler


    30 TPH
    12 Bar

    Bio Gas from ETP

    FD
    Fan

    12 Bar/190o C

    Air

    160o C
    66m

    170o C

    75 KW
    35640m3
    540mm WC

    Chimney
    LP dosing
    (Oxytreat)

    Condensate return

    125o C

    Deareator
    10m3

    Condensate
    tank 25m3

    8.95 KW
    36 m3/hr
    1.5m
    DM water tank
    250 m3
    2.8 KW
    48.1 m3/hr
    21.5m

    Economiser

    Blowdown
    tank
    4.5 KW
    48.1 m3/hr
    21.5m
    Drain

    STEAM DISTRIBUTION
    (During peak Demand)
    24 TPH
    Boiler
    Steam

    PRDV
    12 Bar

    Distribution
    Header

    8 bar
    7 TPH VAPOR ABSORPTION
    REFRIGERATION
    4 TPH

    DG Set
    WHR
    Steam

    2 TPH

    CONTINUOUS
    STERILISER

    8 Bar
    PRDV
    3 Bar
    0.5TPH

    11 TPH

    DEAERATOR
    FERMENTATION
    PILOT PLANT
    MICRO BIOLOGY
    LAB

    Bleed

    3
    TPH

    4 TPH
    Media
    Sterilisation

    Germinator 4 TPH
    Sterile vessels
    Pre fermentor
    0.5 TPH

    EXTRACTION
    SOLVENT
    RECOVERY

    2.5 TPH

    FUEL OIL TANK


    FARM

    0.5 TPH

    Avoid Deaerator Overflow


    Overflow of DM water at 40 % level
    setting
    30 tons/day loss of DM water
    Heat Losses

    Change setting to 20 %
    Nil overflow

    Savings - Rs7.62 lakhs/year

    Improve Boiler Efficiency


    CO2 in flue gas increased from 8.5 to 12
    %
    Flue gas losses reduced from 9 to 6 %
    Efficiency increased from 79 to 82 %

    Savings - Rs. 14.7 lacs/year

    INCREASE FERMENTOR
    AVAILABILITY
    Clean and inspect once in every two batches
    instead of every batch
    31 batches more per year
    Turnover up by Rs.3.25 crores

    Use continuous steriliser for media and sterile


    water
    Turnover up by Rs.4.86 crores

    Clean and inspect once in three batches ?


    Turnover up by Rs.6.24 crores

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