Pharmaceutical Water System Operating Cost
Optimization
Presented by: Jeff Okun
There are many ways to design a water
system…
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History of USP Purified Water Design
„Equipment cost was primary consideration
„Utility costs were not seriously considered
„Bacteria control was primary factor in the design
„Continuous water recirculation was utilized
„Not many changes over the last 15 years
„ Hot water RO/CEDI was last significant change
„ (Better membranes, CEDI modules,
instrumentation and controls).
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Water and Sewer Rates
„Water and Sewer
„
„
„
„
Cambridge, MA…………………$15.00 per 1000 gal.
Puerto Rico………………..…….$41.00 per 1000 gal.
Canton, MA………………………$10.50 per 1000 gal.
Swiftwater, PA…………………..$31.00 per 1000 gal.
„
Seattle, Wa………………………$10.00 per 1000 gal
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Electricity Rates
„New England
„Mid Atlantic
„South East
„Southern California
$0.09 to 0.14 /KWH
$0.06 to 0.09 /KWH
$0.05 to 0.09 / KWH
$0.04 to 0.15 / KWH
„Seattle
$0.05 to 0.06 / KWH
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Cost of Steam
„The current price for natural gas is $12.80 per 1,000 cubic
feet. It was as high as $14.50.
„A 1,000 cubic feet of natural gas can generate 1,011,569
BTU.
„A gallon of heating oil generates 138,890 BTU. A barrel of
oil contains 42 gallons. The price of a barrel of oil today is
$59.75. It was as high as $70.25.
„It takes 7.2 gallon of oil to generate a million BTU.
„The minimal cost of a 1,000 pounds of steam is
$14 (using either oil or natural gas).
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Pharmaceutical Water System Optimization
„ Reduce water and power consumption
„ Reduce or eliminate backwashing
„ Reduce rinse water
„ Increase RO water recovery
„ Eliminate unnecessary recirculation and waste water
„ Eliminate unnecessary unit processes
„ Ultraviolet light
„ Submicron filters
„ Reduce installation costs
„ Reduce validation costs
„ Reduce space requirements
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Process flow diagram
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What design changes are necessary?
„ Modify Pretreatment operation
„ Increase RO recoveries
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Pretreatment - Multimedia
„Conserve water
„ Multimedia
„
Options
„
„
„
„
Replace with disposable filter cartridges
Backwash on differential pressure or extended
time (3 months est.)
Eliminate process – over used on many feed
waters
Can reduce equipment cost
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Multimedia Depth Filtration
Anthracite
Sand
Fine Garnet
Coarse Garnet
Medium Gravel
Coarse Gravel
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Feed
Particles
Trapped
in Sand
Multimedia Filter
in Operation
Gravel Bed
Filtrate
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Case study
„ 36” diameter unit
„ Weekly backwash and rinse
„ $15/1000 gallons + 10% annual increase
„ $26,538 savings for 10 years (quarterly
backwash)
„
„
Additional long-term saving in maintenance cost
Operating costs over 10 years are more than the
cost of equipment
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Activated Carbon
„ Hot water sanitizable
„ Cleaner non- backwashable type design
„ No waste water
„ Waste water equivalent to sulfite injection
„ Utilize offsite preconditioned carbon
„ Similar water savings as with the multimedia filters
„ 10 year operating utility savings will exceed the
equipment price
„ Softener water savings can be similar
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Reverse osmosis unit
„High recovery built into unit for recoveries up to
90%
„
Cost savings example
„
„
„
„
„
„
Start/stop operation
10 gpm RO at 75% recovery versus 90%
12 hour per day operation – 5 days per week
415,500 gallon per year savings
$6,225 first year savings
$99,227 over 10 years
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Staging
75 gpm
product
33 gpm
product
100 gpm
feed
22.5 gpm
product
67 gpm
reject / feed
19.5 gpm
product
44.5 gpm
reject / feed
Three Stage
3x2x1-3
25 gpm
reject
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Reverse Osmosis / CEDI
„Start/Stop/Sanitize
„Operation
„
„
„
No continuous recirculation
Rapid hot water sanitization prior to start
Capability for extended hot water sanitization if
desired
„ Robust CEDI design is required for pulsed heat
Capability to recirculate the CEDI waste back to the
feed of the system without a break tank
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Process flow description
„The Activated Carbon, RO and CEDI are
heated up quickly prior to filling USP
Storage tank
„ Heating
„
„
„
sources
In-line heat exchanger
Hot Purified Water storage
Stored hot water
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Advantages of frequent pulse
sanitizations
„
Never have time to develop a biofilm on
surfaces
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Advantages of frequent pulse
sanitizations
„
„
„
„
System is sanitized prior to filling storage
tank
Low bacteria every time you feed the
RO/CEDI
Better control over activated carbon filters
No polish necessary downstream
„
„
Ultraviolet lights
Submicron (0.2µ) filters
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Hot water sanitization data
„Microbial type (cfu/mL)
„ Fungi 500,000
„ Yeast 3,800,000
„ Cocci 2,400,000
„ Pseudomonas 2,600,000
„ Entero bacteria 2,600,000
„Results (cfu/mL)
„ 0 after 15 minutes at 65OC
„ 0 after 15 minutes at 60OC
„ 0 after 15 minutes at 60OC
„ 0 after 15 minutes at 55OC
„ 0 after 15 minutes at 60OC
„
All these bacteria levels are 4
to 5 log higher than most
water systems
„ 1- 2 hours at 80 C is a
conservative approach to
sanitize systems
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Process flow diagram - previous
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Process description
„Simplified system design
„
Break tank is not required to recovery RO or CEDI water
during recirculation
„ Ultraviolet units are eliminated because system is sanitized
prior to each start
„ Eliminate post CEDI submicron final filter for bacteria
control
„
Rationale – WFI loops (intermittent hot) never have submicron
filters
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Process diagram – New Optimization
Revolutionary Design : Reverse
Osmosis / Continuous Deionization
(RO/CEDI)
Multi-media
Filter
Dual Softeners
Heat
Exchanger
A
Hot Water
Sanitizable
Activated Carbon
Unit
to storage and
distribution
A
5 Micron
Prefilter
Hot Water
CDI LX Unit
Sanitizable
Reverse Osmosis
Unit
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Case Study 1 – small system
„
„
„
„
„
„
Typical single train of continuous recirculation,
hot water sanitizable RO/CEDI system
Water and waste water cost - $15/1000 gallons
Electricity
- $0.12 per KWH
Steam
- $33/1000 lbs.
RO/CEDI 10 gpm product
Operation (make up to storage tank)
„
„
„
12 hours per day
5 days per week
250 days per year
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Operating cost reduction
„ Water
savings per year (start/stop versus
recirculation)
„ 1,219,940 gal/year
„ Subtract Pulse heat
(54,750 gallons per
year)
„ Net savings: 1,1653,390 gal/year
„ $18,299 per year savings
„ $821 cost per year for up to 4 times per day
pulse heat
„ Total $17,474 per year
„ $283,709 over 10 years
„
Assumes costs increase 10%/year
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Operating cost reduction
„ Steam savings
„ $8,353 for feed water per year
„
Assumes temper water to 77 °F
„ $825 for pulse heating
„ $7,528 per year
„ $121,953 for 10 years
per year
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Operating savings continued:
„ Power
savings
„ 5,640
hours operation per year (8,760 hours
in a year)
„ 10.5 KWH per hour
„ $7,106 per year
„ $115,117 per 10 years
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Operating savings continued:
„ Consumables
„ Prefilters - $0.60 per 1000 gal. of waste
water
„ 1,110,440 gal./year water savings
„ $666 per year
„ $10,789 over 10 years
„ Salt $0.88 per 1000 gal.
„ $977 per year
„ $15,830 per 10 years
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Summary Case 1
„Yearly Savings
„
„
„
„
Water and waste water
Steam
Electricity
Consumables
$17,474
$ 7,528
$ 7,106
$ 1,643
„
TOTAL (Yearly)……………… $33,751
„
10 year TOTAL………….$546,766
„
Typical system price $300,000
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Case Study 2 – large system
„ Dual 80 gpm RO/CEDI trains with continuous
recirculation
„ 100% redundant system for Pharmaceutical
manufacturing plant
„ 12 hours per day operation
„ 7 days per week operation
„ 350 days per year
„ Same utility cost as Case Study 1
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Case 2
„ Water
savings per year (start/stop versus
recirculation)
„ 23,711,040 gal/year
„ $355,665 per year savings
„ Subtract Pulse heat (876,000
gallons per
year)
„ $13,140 per year for up to 4 times per day
pulse heat
„ Total $345,525 per year
„ $5,548,905 per 10 years
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Case 2
„ Steam savings
„ $ 513,555 for feed water per year (20° F
delta T)
„ $ 33,712 for pulse heating per year
„ $ 479,843 per year
„ $ 7,773,457 for 10 years
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Case 2
„ Power savings
„
„
„
13,320 hours operation per year 112 KWH per hour
$ 179,020 per year
$2,900,136 per 10 years
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Case 2
„ Consumables
„ Prefilters - $0.60 per 1000 gal. of waste
water
„ 22,835,040 gal./year water savings
„ $13,700 per year
„ $221,940over 10 years
„ Salt $0.88 per 1000 gal.
„ $ 20,095 per year
„ $ 325,536 per 10 years
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Case 2
„Yearly Savings
„
„
„
„
Water and waste water
Steam
Electricity
Consumables
„
TOTAL (Yearly)……….$1,037,583
$ 345,525
$ 479,843
$ 179,020
$ 33,195
„
10 year TOTAL…….$16,808,845
„
Typical system price $1,500,000
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Summary
„ Every project should evaluate operating costs
„ Operating costs may far exceed capital costs
„ New system design can reduce both operating and
capital costs
„ Water and energy are not unlimited resources and
conservation is a common goal
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Questions???....Thank You
JEFFREY M. OKUN
DIRECTOR
SALES AND MARKETING
BioPharm
WATER & WASTEWATER GROUP
10 TECHNOLOGY DRIVE
LOWELL, MA 01851
TELEPHONE: 978-470-1179
CELL PHONE: 978-764-7635
FACSIMILE: 978-453-5821
EMAIL: okunj@usfilter.com
www.usfilter.com
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