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Pharmaceutical Wastewater Experience
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Ultrasound Destruction of Active
Pharmaceutical Ingredient (API) - Brazil
Itapevi, Brazil
Scope:
- Design
- HAZOP
- Bid Package
- Contractor Procurement
- Fabrication Oversight
- Installation Oversight
- Startup
- Performance Verification
Advanced GeoServices in conjunction with a pharmaceutical client designed a
near-source wastewater treatment system targeting API destruction for a key
product at their manufacturing facility located in Brazil. The project is
unique because it transitions technology developed from academic research to
a “real world” application. Advanced GeoServices was also engaged to manage
the procurement and fabrication of system components. The system will be
fabricated, skid-mounted, and tested in the United States and then shipped
to Brazil for final installation. The primary treatment system components
include: influent equalization, inline cooling heat exchange system,
filtration, chemical injection systems, ultrasound treatment reactors, an
effluent holding tank, and a fully automated PLC system. Advanced
GeoServices completed the detailed design, specifications and procurement
activities for this project within 120 days of project kickoff. The project
is in the final stages of fabrication and Factory Acceptance Testing (FAT).
The target for installation, startup, and performance testing will be 40
days after receipt of equipment in Brazil. |
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Pharmaceutical Steam Stripper - Solids &
Chemical Fouling
New York
Scope:
- Root Cause Investigation;
- Remedial Alternatives Evaluation
- Feasibility Analysis
A pharmaceutical
plant was experiencing significant maintenance issues with a steam stripper
designed and installed by others to remove VOCs. Severe fouling within the
stripper did not allow the plant to meet permit discharge levels without
processing the wastewater several times through the steam stripper. In
addition, the steam stripper needed cleaning several times a month to remove
the solids that were building up in the steam stripper. Advanced
GeoServices conducted a comprehensive field investigation and sampling event
to help determine the source of the fouling. A forensic analysis of the
wastewater and sludge samples indicated that calcium phosphate was the
primary precipitate. Specialized laboratory measures including Computer
Controlled Scanning Electron Microscopy (CCSEM) were utilized for the
project. In addition, it was discovered during the study that particulate
matter was also contributing to the problem.Recommendations to change the
operating pH of the system resulted in a reduction of calcium phosphate
precipitation. In addition a feasibility study was conducted to determine
effective technology to remove or sequester the calcium phosphate. Advanced
GeoServices’ worked closely with plant and corporate personnel in selecting
an appropriate remedy.
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Active Pharmaceutical Ingredient
(API)
Removal Using MBRs & Ozone - Ireland
Newbridge, Ireland
Scope:
- Work Plan
- Sampling and Analysis
- Data Evaluation
- Water Reuse Evaluation
- Cooling Tower Evaluation
A pharmaceutical company asked Advanced GeoServices to assess
and evaluate the performance of the first wastewater treatment plant in the
world specifically designed to remove APIs from wastewater. The treatment
system consists of drum screening, equalization, Membrane BioReactors, and
Ozone prior to discharge to the local Publicly Owned Treatment Works (POTW).
Advanced GeoServices assisted in development of the Work Plan; coordinated
the sampling and analysis with the laboratories; sampled the plant while
incorporating appropriate residence times; evaluated the sample results;
conducted mass balance for the APIs; and evaluated the wastewater effluent
reuse in the cooling tower. |
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Conceptual Wastewater Treatment Plant
Upgrade Design for Pharmaceutical Research Facility - Biological Phosphorus
Removal
New York
Scope:
- Wastewater Characterization
- Investigation
- Source Reduction
- Historical Information Evaluation
- SBR Performance Evaluation
- Process Modification Evaluation
- Jar Testing
- Process Optimization
A laboratory facility operates a biological and chemical
treatment system to meet state permit discharge limits. Recent regulations
required the facility to meet more stringent effluent criteria, specifically
for phosphorus. Two Sequencing Batch Reactors (SBRs) followed by chemical
precipitation, sand filter, and ozone treatment were being used to treat the
wastewater. The system was not effective in reducing the phosphorus
concentrations to the new limits. Advanced GeoServices was hired to
evaluate the treatment plant and determine if operational changes or process
modifications could be made to improve phosphorus removal. Advanced
GeoServices worked closely with plant personnel in selecting the appropriate
remedy. Advanced GeoServices worked closely with plant personnel
during the project and after evaluating plant data and sampling determined
that the SBRs were underloaded with COD and process flow through the plant
was highly variable; phosphorus removal with the current precipitation
system was not effective; and nitrification was not occurring within the SBR
due to low COD, thereby inhibiting the possibility of Enhanced Biological
Phosphorus Removal. The following recommendations were made to address
these issues equalize the flow to the SBR; operate (1) and use second SBR as
EQ to maximize equalization capacity; install and operate a chemical
precipitation system within the SBR tank to maximize mixing and settling
capacity; test the Blue Pro® Phosphorus Removal Process at the bench-scale
level for phosphorus removal; and evaluate converting the SBR to MBR to
increase plant capacity and meet TSS, coliform, and settleable solids
limits. |
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Plant Expansion Evaluation - Singapore
Infant Nutritionals Production Wastewater
Tuas, Singapore
Scope:
- Model Selection
- Model Setup and Calibration
- Site Assessment
- Data Review
- Engineering Evaluation
- Model Simulations
A pharmaceutical company
with a nutritionals division produces infant formula asked Advanced
GeoServices to evaluate the need for a Wastewater Treatment Plant (WWTP)
facility upgrades if the manufacturing plant is expanded to 150% of its
current manufacturing capacity. The 0.3 Millions of Gallons per Day (MGD)
wastewater treatment process consists of equalization, two Sequencing Batch
Reactors (SBRs), sand filtration, and ozone. A portion of the effluent
wastewater is used as cooling tower makeup. The remainder of the wastewater
is discharged to the Publicly Owned Treatment Works (POTW). Advanced
GeoServices evaluated the applicable biological models; selected the
biological model (GPS-X); conducted a site assessment; evaluated the data;
setup and calibrated the model; performed model simulations under various
hydraulic and contaminant load conditions; and
presented the results. |
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