1. r Pharmaceuticals Waste Incineration & Heat Recovery at Roche Ireland Ltd. Andrew Carden

2. r Pharmaceuticals Roche Ireland Ltd: Bulk Pharmaceutical Manufacturing Site. Operates under an Integrated Pollution Control License issued by Environmental Protection Agency. Emissions to Atmosphere Emissions to Water Emissions to Land Background

3. r Pharmaceuticals Legislation 1987 Air Pollution Act Air Emissions within EPA Limits Legislation

4. r Pharmaceuticals A number of technologies examined to meet legislative requirements Criteria for Technology Selection Varying Calorific Load Varying Volumetric Load Organochlorides Wide Range Compounds Economic Factors Emission Limits Selected Technology: Direct Fired Thermal Incineration Technology Selection

5. r Pharmaceuticals Air Emissions Reduction Project consisted of two parts: Fume Collection system Incinerator Package Project Overview

6. r Pharmaceuticals Fume Collection System Volatile Organic Carbon Vapour Collection Collect VOC Vapours from Chemical Reactors, Dryers Network of piping with safety equipment:- Flow, Pressure and Oxygen monitoring Deflagration, Detonation, Hydraulic and Dynamic Flame Arrestors to meet German TRbF 100 standard

7. r Pharmaceuticals Fume Collection System UEL Flammable Region LEL 50% MOC MOC Vent collection designed to Prevent Explosion Contain Explosion High Oxygen Low Oxygen High Solvent Low Solvent X X X X X X X X X Contain Explosion Prevent Explosion Flammability Diagram X= Areas of Operation

8. r Pharmaceuticals Kraft, Energie & Umwelttechnik (KEU) 10.6 MW Steam Generation using waste heat from incinerator Incineration of Waste Liquids from Site Production Processes Odour Reductions by Incinerating Biological Waste Treatment off gases Incinerator Package

9. r Pharmaceuticals Incinerator Package

10. r Pharmaceuticals Operational Qualification Tests: To Test Incinerator to Design Limit Contractual Test Burns with KEU Test Burns with EPA Examples of Tests: Destruction Removal Effieiency including HCl removal and Dioxin formation High and Low Thermal Capacity NOx removal Commissioning: Test Burns

11. r Pharmaceuticals Legal Compliance IPC licence. EC Directive. Heat Recovery Capacity of 10,000 kg/hr of steam Current generation at approx 5000 kg/hr, meeting large proportion of site demands Reduction in offsite waste incineration costs Incineration up to 760 kg/hr on site Benefits

12. r Pharmaceuticals January 1999: Change from Heavy fuel oil to Diesel June 2000: Air reduction leading to Fuel reduction June 2000: Stack gas plume elimination December 2000: New state of the art in situ HCl laser analyser Future July 2003: Change from Diesel to Natural gas Continuous Improvements