OptiTherm Increases Reactor Efficiency, Saves Vitamin Manufacturer $430,000/Yr

By Ralph Exton, BetzDearborn, Inc.

Background

A leading pharmaceutical company and producer of Vitamin C uses several glass-lined steel reactors in the production process, but common fouling of the jacket space caused the reactors to lose efficiency.

The production process has very stringent heating and cooling requirements. Because of the fouling typically found in the reactor jackets, heating and cooling requirements were not met, batch cycle time increased, and product quality suffered. The fouled jacket space ultimately resulted in lower yields.

Plant personnel were reluctant to conduct acid cleaning of the vessel because of potential hydrogen penetration and spalling of the glass (figure 1). They were also very concerned with additional damage and base metal attack of the reactor wall. In addition, replacing or reglassing the reactor would be very costly.

In the past, this plant attempted a caustic-based cleaning. While it was safe with respect to protecting glass from the spalling phenomenon, the cleaning was ineffective at removing the scale buildup within the jacket space. As a solution, several glass-lined reactor experts, including the manufacturer of this plant's reactors, recommended BetzDearborn's Ferroquest technology and the OptiTherm service.

The vitamin manufacturer utilized the OptiTherm service to restore their reactor heat transfer efficiency. BetzDearborn and Glasteel Parts and Services (GPS), a unit of Pfaudler, utilized their alliance to jointly provide OptiTherm—a complete service for cleaning glass-lined reactor jackets.

The OptiTherm service features BetzDearborn's patented Ferroquest technology—a proprietary blend of surfactants, reducing agents, organic complexing agents, and corrosion inhibitors—with the expertise of Pfaudler/GPS, the glass steel experts. As the only safe and effective, manufacturer-recommended method to clean glass-lined steel reactors, Ferroquest and the OptiTherm service maximize glass-lined reactor efficiency without risk of glass damage.

Before conducting the on-site service, the OptiTherm team conducted a deposit analysis to determine the reason for fouling and to match the foulant with the appropriate cleaning chemicals and technique. When deployed, the OptiTherm service team immediately began with ultrasonic thickness (UT) measurements of the vessel wall and the jacket itself to determine the extent of damage. Vessel entry was performed to inspect the interior vessel for any existing glass damage, wear patterns, spalling, or etching. Glass thickness and spark testing is also included in the OptiTherm service.

The OptiTherm team then hooked up a customized recirculation rig and thoroughly cleaned the jacket using Ferroquest. This treatment removes iron oxide deposits at a neutral pH, does not generate hydrogen, and therefore poses no risk of glass damage.

As part of the overall OptiTherm service, mechanical and chemical evaluations and recommendations are provided to enhance the ongoing operation of the vessels. A detailed evaluation of the water-side conditions of the jacket revealed low and/or fluctuating inhibitor levels, which had been causing damage to the jackets and associated piping. A mechanical evaluation of the jacket piping, impingement plates and agitating nozzles, their direction and use, was also provided.

Results

The OptiTherm service increased operating efficiency of this particular reactor by over 30% and saved the manufacturer more than $430,000 per year. The cool-down times of each batch decreased 45%, and the heat-up times decreased 27%. Similarly, Ferroquest effectively removed corrosion deposits, leaving a clean, passivated surface for optimal efficiency and equipment longevity.

The main benefits of the cleaning were:

• Increased Production Over 5% by reducing batch times and increasing the number of batches produced per month
  
• Improved Product Quality through better temperature control
  
• Increased Equipment Life by effective removal of corrosion sites and deposits

The OptiTherm service team also improved the cooling water treatment program, which will now protect all of the reactors and reduce the frequency of cleaning. The results on this particular reactor were so impressive that there is now a schedule in place to clean all of the remaining reactors on a regular schedule.

ROI Example

16% Improvement on One Reactor Yields $270,000 Annually

One batch of product takes 52 hours to complete before the OptiTherm service, and takes only 45 hours after. This is roughly a 16% improvement in productivity. Assume that each batch is worth about $10,000 in revenue, and that the OptiTherm service cost is $12,000.

Before: 1 Batch / 52 Hours = 168 Batches / yr = $1.68 MM Revenue / Year

After: 1 Batch / 45 Hours = 195 Batches / yr = $1.95 MM Revenue / Year

Productivity: [(1.95-1.68) / 1.68] x 100 = 16% Improvement

Additional Revenue / Year = $270,000

Total Investment:

• OptiTherm Service: $12,000
  
• Downtime: $20,000 (3 Days, or about 2 batches)
  
• Total Investment: $32,000

ROI (%) = [(270,000-32,000) / 32,000] x 100 = 744 %

Length of Payback = [32,000 / 270,000] x 365 = 43 Days

By using the example above, an impressive and easily justifiable Return on Investment can be calculated for just about every project. The OptiTherm team works closely with the customer in order to gather the appropriate information and calculate a return.

For more information: Ralph Exton, Pharmaceutical Industry Marketing Manager, BetzDearborn Water Management Group, 200 Witmer Rd., Horsham, PA 19044. Tel: 215-773-6262. Fax: 215-674-5067. Email: ralph.e.exton@
betzdearborn.com.