The original aim of this project based at

a bulk active pharmaceutical ingredient

manufacturing site, was to investigate
the reuse of a waste stream in the
cooling system.

CGPP2004/13
Investigation into the reuse of
Methanol/MTBE waste in the low
temperature cooling system

Daily Methanol Requirement

1400

Reactor jackets utilise various services

to heat and cool the reactors. One such
service is low temperature cooling
using a methanol water solution. This
project
proposed
using
waste
methanol/MTBE instead of fresh
methanol
to
maintain
system
concentration.
After a detailed study, the project
found there would be no detrimental
effects to production or the safe
operation of the plant by reusing the
methanol/MTBE waste in the low
temperature cooling system. In
addition payback would be less than
three years. However, it was found that
the MTBE would not sufficiently digest
in the waste water treatment plant.
The focus of the project moved to
identify why there is also a continual
need for top up of the low temperature
cooling medium. It was found that
jacket services of the process reactors
should be investigated to reduce the
occurrence of dilution in the low
temperature cooling system.
Measures have been put in place to
reduce the methanol requirement such
as density meters. There is the potential
to reduce the requirement for the
addition of 245,350 litres of food
grade methanol each year to the
system.

Extracts were taken from the utilities log

detailing the volumes of pure methanol required
to maintain the concentration of the low
temperature cooling system fluid at the required
level.

Litres

1200
1000
800
600
400
200
0
Jan '04

Apr '04

Jul '04

Oct '04

Feb '05

Date

Pfizer Ireland Pharmaceutical,

Little Island, Co. Cork
Pfizer Ireland Pharmaceuticals, Little Island is a
bulk
active
pharmaceutical
ingredient
manufacturing (API) facility. The site opened in
1978, employs 200 staff and manufactures a
range of products for the global market.

Figure 2 Historical Methanol Requirement daily additions

to the low temperature cooling system

The concentration of methanol prior to addition

was also tracked. This was used to ascertain the
current variation in concentration that is
acceptable for the production process.
Concentration Variation

Aim of this Project

The aim of the project was to investigate the
feasibility of reusing a waste stream containing
methanol and MTBE (methyl-tert butyl ether), a
by-product from the manufacture of active
pharmaceutical ingredients (APIs). This stream
would be reused in the low temperature cooling
system that provides cooling for the jackets of
reactors used in various processes within the
production buildings.

37
36

% methanol

At a Glance

35
34
33
32
31
30
Dec '03

Apr '04

Jul '04

Oct '04

Feb '05

Date
Figure 3 Low Temperature Cooling System Variation in
Methanol Concentration

Project Description
Each reactor jacket is served by a common
manifold which facilitates the use of various
services within the jacket. A simplified schematic
of a typical arrangement employed on the
reactor jackets in the production building is
shown in figure 1.

The properties of the proposed cooling medium,

the waste methanol/MTBE, were determined.
Heat transfer calculations were performed and a
and
complete
system
safety
review
environmental review were carried out.
Equipment modifications required for the new
transfer system of the waste were determined
and costed.
A recovery unit to recover the waste was
investigated but payback was not viable.

Achievements

Figure 1 Jacket Services Manifold Arrangement

In terms of reusing the methanol/MTBE waste in

the low temperature cooling system it was found
there would be no detrimental effects to
production or the safe operation of the plant
and payback would be less than three years.
However, the study found MTBE would not
subsequently be sufficiently digested in the
waste water treatment plant. Hence this aspect
of the project was not implemented.

The study identified that the jacket services of

the process reactors should be investigated to
reduce the occurrence of dilution in the low
temperature cooling system. This will reduce,
or possibly eliminate, the requirement for the
addition of 245,350 litres of food grade
methanol each year to the system to maintain
the concentration requirement.

Cleaner Greener Production Programme

One of the outcomes of the study was to install

a methanol water return density meter
connected to the site distributed control system
(DCS) to track dilution trends within the
system, in order to aid the identification of the
source of dilution in the plant and facilitate
remedial action.

Cleaner Greener Production is the application

of integrated preventive environmental
strategies to processes, products and services
to increase overall efficiency and reduce risks
to humans and the environment.

Observations
Contributory factors identified in the dilution
of the low temperature cooling system were
found to include older reactor jacket design
that resulted in incomplete drainage and not
running the nitrogen blow to the jacket for
a sufficient period of time.

Lessons
Previous to this study it was a belief on site that
losses to the low temperature cooling system
were a normal operating cost associated with
operating a system of this type. This belief has
been challenged and further study is required
on the jacket services to ascertain when and
how the dilution of the methanol water system
is occurring. When this occurs and the
methanol dilution is significantly reduced, it will
negate the requirement to look for alternatives
to the methanol for the low temperature
cooling system.

More Information
For more information on this project please
contact:
Martin OConnor,
Pfizer Ireland Pharmaceuticals
Little Island, Co. Cork
email. martin.oconnor@pfizer.com
tel.
00 353 (0) 21 452 3673

The Cleaner Greener Production Programme

(CGPP) of the EPA was funded under the
National Development Plan 2000 2006. The
CGPP was launched in 2001 as a grant
scheme to Irish organisations to implement
cleaner greener practices while achieving
significant cost savings.

Production processes: conserving raw

materials and energy, eliminating toxic raw
materials, and reducing the quantity and
toxicity of all emissions and wastes
Products: reducing negative impacts along
the life cycle of a product, from raw
materials extraction to its ultimate disposal.
Services: incorporating environmental
concerns into designing and delivering
services.
The programme aims are focussed on avoiding
and preventing adverse environmental impact
rather than treating or cleaning up afterwards.
This approach brings better economic and
environmental efficiency.
Under Phase 2 of CGPP, 22 organisations were
funded from a variety of sectors (e.g.
chemicals, food, metals, electronics, service).
The total achievements from the projects for
the participating organisations included
annual reductions of 250,000 tonnes in
input/output streams (water/waste water),
660 MWh energy reduction and 1.6m cost
savings.
The programme will continue to be funded by
the EPA in the NDP 2007-2013.
This case study report is one of the reports
available from the companies that
participated in the second phase of the
Cleaner Greener Production Programme.
A summary of all the projects and CD
containing all the reports are also
available.
More information on the programme is
available from the EPA:
Ms. Lisa Sheils or Dr Brian Donlon,
Environmental Protection Agency,
Richview, Clonskeagh Rd., Dublin 14, Ireland.
www.epa.ie/researchandeducation/research/

Programme Managers...
The Clean Technology Centre (CTC) at Cork
Institute of Technology was appointed to
manage the programme. Established in 1991,
the CTC is now nationally and internationally
regarded as a centre of excellence in cleaner
production, environmental management and
eco-innovation across a range of industrial
sectors.