WATER TREATMENT PLANT (WTP)

INTRODUCTION :

A water treatment plant is a destination where wastewater (water which is no longer fit for its current
purpose) moves to once it leaves homes and businesses through sewage pipesA wide variety of products
are made in the chemical and pharmaceutical manufacturing industries, typically requiring large volumes
of chemicals, materials, and substances that are used throughout process operations.

In industrial manufacturing sectors, water is a critical ingredient in pharmaceutical and chemical

manufacturing operations; consistent and high-quality supplies are needed for a range of purposes
including production, material processing, and cooling. As disruptions in raw water supply represent a
significant concern, more companies are turning to water efficiency initiatives to help mitigate water
scarcity-related risks.

Sources of Water

Ground water (well)

Surface water. Lake. River. Stream (creek) Shallow well.
Rainwater.
Seawater.

Types of Pharmaceutical Water

Non-potable.
Potable (drinkable) water.
purified water.
water for injection (WFI)
sterile water for injection.
sterile water for inhalation.
bacteriostatic water for injection.
sterile water for irrigation.

Method of Water Treatment

Reverse osmosis is a water purification process that uses a semi-permeable membrane (synthetic lining)
to filter out unwanted molecules and large particles such as contaminants and sediments like chlorine,
salt, and dirt from drinking water. In addition to removing contaminants and sediments, reverse osmosis
can also remove microorganisms. It gets water clean down to a molecular level, leaving only pure
H2O behind.

How Does Reverse Osmosis Work

Osmosis is the process by which water passes through a semi-permeable membrane from a less
concentrated solution into a more concentrated one. In other words, the pure water passes through the
filter to the contaminated water in order to equalize the concentrations – which is not what we want our
drinking water to do. This movement generates osmotic pressure.

In reverse osmosis, an applied pressure is used to overcome the osmotic pressure and push the water from
high concentration of contaminants to low concentration of contaminants. This means it’s being forced in
reverse and the contaminated water is trying to move into the pure water, but because it must pass through
a filter first, the contaminants get trapped and only the pure water passes through; resulting in the cleanest
possible drinking water – which is exactly what we want.

Reverse osmosis typically involves four stages of filtration: a sediment filter, pre-carbon block, reverse
osmosis membrane, and post-carbon filter. The sediment filter removes the largest particles, like dirt,
sand, and rust to prevent clogging of the subsequent filters. The pre-carbon filter uses activated carbon to
prevent anything larger than a spec of flour from passing through as well as attracting and bonding with
positively charged ions to prevent chemical compounds, like chlorine and chloramines, from passing
through to the third filter. The reverse osmosis membrane then removes molecules heavier than water,
such as sodium, high levels of lead, dissolved minerals, and fluoride. Finally, the post-carbon filter
polishes the water.

Advantages of Reverse Osmosis

It is the best method for water softening.
The semipermeable membrane will block all ion particles.
Maintenance of the system is very simple.
It gives us clean and pure water by blocking all contaminants.
The available RO systems are very compact, and it requires little space

Disadvantages of Reverse Osmosis

Although ultra clean water seems like a fantastic idea, it has its detractors. Some believe that removing all
of the impurities through the reverse osmosis process also reduces the number of beneficial minerals.
Water carries calcium and magnesium in healthy quantities for growing children and healthy adults. The
drawback of RO water is that it can significantly reduce these good minerals that can aid in overall heart
and muscle health. Those who use reverse osmosis as their main source of water can suffer from side
effects, such as tiredness, muscle cramps, general weakness and, in severe cases, cardiovascular disorders.
Some critics have also suggested that drinking reverse osmosis water dilutes the body of electrolytes.

Demineralization
Demineralization is also called as Ion exchange or de-ionization process .This softening process is carried
out with help of organic substances called as ion-exchange resins . Principle : Ion-exchange resins are
insoluble , crosslinked organic polymers with a microporous structure and the functional groups attached
to chains are responsible for exchanging ions .Ion exchange resins are of two types : a) Cation exchange
resins (RH+) : Resins which contain acidic functional groups (-COOH ,-SO3H ,etc ) are capable of
exchanging their H+ ions with other cations .These are mainly styrenedivinyl benzene copolymers which
on sulphonation/carboxylation become capable of exchanging their H+ ions with other cations in water .
Eg .Amberlite IR-120 ,Dowex-50 . 2RH+ + Ca2+ → R2Ca2+ + 2H+ b) Anion exchanger resin (ROH-
):Those resins containing basic functional group (-NH2 ,= NH as hydrochloride ) are capable of
exchanging their anions with other anions in contact .The styrene-divinyl benzene or amine formaldehyde
copolymers ,which contain amino/quaternary ammonium/quaternary sulphonium groups ,on treatment
with dilNaOH becomes capcble of exchanging their OH- ions with any other anion . Eg .Amberlite400
,Dowex-3 . ROH- + Cl- → R+Cl- + OH.
Flow chart of water treatment plant:
Water reservoir (2000 liter ,filled with raw water)

Multimedia filter

Activated carbon filter

Water softner

5 Micron pp filter (2 pieces)

RO membrane (1)

RO membrane (2)

Charge vat (450 litre)

5 micron pp filter

RO membrane (3)

UV light

Charge vat

Process of WTP
WAREHOUSE
Warehouse
Warehouse or Stores are the department in pharmaceuticals where Raw material (Active & Excipients)
and Packing materials which are used in the manufacturing of batches shall be received and stored at
required storage condition.
After final packing products are stored in Finished Goods stores of warehouse and after Quality control
and Quality Assurance released products are dispatched to market.

Procedure for Receiving materials into warehouse

When starting materials first arrive at the facility, they fall under the control of the warehouse. Different
types of materials can be treated in a number of different ways. For example, materials consumed in
production need to be registered and checked for approved supplier and grade (pharmaceutical or
medical), but may or may not need a unique identifying number. Ensure that you know your Standard
Operating Procedures.

In the case of starting chemicals used in product formulation, they will always need to be checked to see
that they;

Arrived from an approved supplier

Are not damaged
Are correctly labeled and identified with the supplier’s lot number for traceability
purposes
Are given a unique in-house lot number
Registered in inventory, and
Quarantined, then sampled for release testing

Some of these chemicals may also deteriorate when exposed to heat, so they may have to be stored under
controlled temperatures, or even frozen.

Pharmaceutical products need to be stored under strict conditions; requirements such as hygiene,
temperature, traceability are paramount in this sector. Specifically, the following challenges have to be
taken into consideration when designing warehouses of pharmaceutical industry:

1. Ideal temperature to maintain efficacy of drugs: Different drugs have different temperatures at
which they become deactivated/denatured. Hence, they should be stored in appropriately maintained
temperature and humidity zones. Warehousing solutions provide different temperature zones (Ambient
(15–25ºC), Cold Room (2–8ºC), Freezers (minus 25–minus 15ºC) and Ultra-low Temperature Freezer
Rooms (<minus 25ºC)) that can be individually controlled and maintained with the help of sensors and
alarms.

2. Total traceability for fail-safe monitoring of expiry dates: Minimal hand-touch and mechanised
tracking of inventory is essential to keep track of usable, expired, recalled or returned stock as well as
stock for temporary as well as bulk storage. The pharmaceutical warehouse design needs to account
for a designated area for such stock segregation.
3. Clean and protected environment: Storage facilities for pharmaceutical warehouses need to be free
from accumulated waste or vermin. They also need to be able to allow pest-control programs that do
not contaminate the chemicals or drugs.

4. Sterile environment: Certain products require a total absence of microbial contamination, with
minimal human intervention.

5. Space for a wide range varied SKUs: Depending upon seasonality, different drugs might be stored
in warehouses at different times of the year. The pharmaceutical warehouse layout design should be
such that space should be adequate and the configuration should be flexible enough to accommodate
such changes.

6. High Safety Standards: Pharmaceutical warehouses need to ensure that their storage facilities are
compliant with USFDA and OHSAS standards.

7. Technology: From RFID (Radio Frequency Identification) labeling and contamination protection
devices to full-fledged pharmaceutical Warehouse Management Systems, technology and intelligent
tools can significantly raise the efficiency, output and profitability.

Fig. Warehouse store room

EFFULENT TREATMENT PLANT (ETP)
Effluent Treatment Plant
Nowadays, thewaste water which is generated from the pharmaceutical industries of Bangladesh has
become a big concern for the environment. There is a great deal of the pollutants that is being dumped
constantly from various pharmaceutical industries which causessevere damages to the environment and
public health because of its containing highorganics as well as inorganic loadings and thus
demandsproper treatment before final disposal to the environment.

Effluent Treatment Plant or ETP is one type of waste water treatment method which is particularly
designed to purify industrial waste water for its reuse and it’s aim is to release safe water to environment
from the harmful effect caused by the effluent.
Industrial effluents contain various materials.Some effluents contain oils and grease, and some contain
toxic materials.. Since pharmaceuticals waste water contains a diversity of impurities and therefore
specific treatment technology called ETP is required.
The ETP Plant works at various levels and involves various physical, chemical, biological and membrane
processes to treat waste water from pharmaceutical.

Function of Effluent Treatment Plant

Effluent Traetment Plants are used by all leading industries to treat their wastewater. All the leading
pharmaceutical, chemical, textile, and other industry that generate the wastewater used ETP’s to purify
water and remove any non toxic or toxic materials or chemical from it. All the companies used these plant
to follow the government guideline, and for environment protection.
The ETP functionality can be understand by the image given below-
Flow Chart of Effluent Treatment Plant

Water reservoir (filled with waste water)

Equalization tank

Flocculator (dosing PAC & polymer)

Lamella clarifier tank

Aeration tank (sampling for BOD)

UF tank

Multigrade sand filter

5 micron pp. filter

Ultra filter

Effluent Treatment Plant