The VOCs waste gas in the pharmaceutical raw material storage tank area mainly comes from the large breathing generated by the raw material storage tank receiving and receiving operation, as well as the small breathing exhaust caused by the change of ambient temperature around the day and night, covering a variety of high-value pharmaceutical organic solvents such as ethyl acetate, dichloromethane, acetone, tetrahydrofuran, methanol, isopropanol, etc. A large amount of high-concentration organic steam will be discharged instantly during the receiving and receiving operation of the storage tank, which is a pulsed large breathing discharge. The small breathing exhaust gas caused by the temperature difference between day and night is small, but the concentration will continue to fluctuate with the rise and fall of the ambient temperature. Under the condition of parallel operation of multiple raw material storage tanks, the exhaust gas as a whole presents the characteristics of intermittent emission and large concentration span. Exhaust gas flow will entrain solvent droplets and saturated water vapor, halogenated solvent in water vapor hydrolysis to generate acidic corrosive medium, easy to cause tank area gas gathering pipe network, buffer unit and equipment internal heat exchange components corrosion damage. The pharmaceutical raw material storage tank area belongs to Class A explosion-proof control area. The pipeline layout of the tank area is dense and the site space is limited. Strict technical requirements are put forward for the pressure fluctuation adaptation capacity, instantaneous peak processing capacity, fog droplet impurity pretreatment level, corrosion resistance performance, explosion-proof safety interlocking system and intermittent start-up and stop operation stability of the resource recovery unit.
The traditional waste gas treatment process is applied to the breathing waste gas condition in the storage tank area of pharmaceutical raw materials, and there are many practical shortcomings. The incineration process can oxidize and decompose the organic waste gas, but the high-value organic solvent volatilized from the storage tank will be directly incinerated, and the material loss is large. When the exhaust gas contains halogenated components such as dichloromethane, high-temperature incineration is easy to generate corrosive toxic by-products such as hydrogen chloride, which requires the construction of complex post-processing systems such as quenching and tail gas absorption, resulting in high equipment investment, fuel consumption and daily operation and maintenance costs.activated charcoalAdsorption is a pollutant transfer treatment method, which cannot realize solvent resource recovery. In the face of intermittent exhaust gas with alternating high and low concentrations in the storage tank area, superimposed with solvent mist droplets impurities entrained in the intake air, the adsorption filler is easy to bond and bond, and quickly reaches adsorption saturation. Under high-concentration impact conditions, there is also a potential safety hazard of adsorption and heat release. Frequent shutdown and replacement of adsorption consumables are required. The output of hazardous waste is large, and the storage and transportation pressure in the storage pressure in the tank area is heavy. The simple condensation process relies on low-temperature liquefaction solvent, and the recovery effect is better only in the high-concentration exhaust stage of the tank receiving and sending materials. Under the low-concentration condition of small breathing, the partial pressure of organic vapor is insufficient, the recovery efficiency of solvent liquefaction is greatly attenuated, and a large number of organic components are emptied with the exhaust gas, which cannot realize all-weather stable resource treatment. A large number of project practices show that a single process mode is difficult to adapt to the real working conditions of intermittent pulses in the storage tank area, the processing capacity of the large breathing peak impact time group is insufficient, the emission index of the small breathing low concentration interval is easy to exceed the standard, and it is difficult to meet the multiple demands of safe production, environmental protection compliance and solvent recovery and cost reduction in the tank area at the same time.
The compression condensation film is coupled with a complete set of full physical treatment process, which runs without combustion and chemical reaction in the whole process, and is highly suitable for the VOCs waste gas resource recovery unit in the pharmaceutical raw material storage tank area. The exhaust of the breathing valve of each raw material storage tank is collected through a closed gas collecting pipe network, and the exhaust gas buffer unit is configured to stabilize the violent fluctuation of the pressure and flow in the tank area. The waste gas first enters the pretreatment unit of the unit, and relies on the multi-stage filtration and defoaming structure to remove the solvent droplets and free moisture carried by the airflow, so as to avoid impurities from entering the back-end compressor, heat exchanger and membrane components, causing blockage, glue and irreversible pollution of membrane components. In view of the working conditions of intermittent emission of respiratory exhaust gas and obvious entrainment of mist droplets in storage tanks, the pretreatment unit adopts a hierarchical interception structure to complete purification protection step by step according to the particle size of impurities, effectively protecting the precision core components at the back end and prolonging the service life of the whole unit. After pretreatment and purification, the waste gas enters the compression unit to increase the partial pressure of organic steam, change the gas-liquid phase equilibrium condition, and create favorable conditions for solvent liquefaction. The gas is sent to the multi-stage gradient condensation module, and gradient cooling is carried out based on the boiling point difference of various solvents. Most organic solvents are liquefied and precipitated, and the preliminary solvent recovery is completed.
After condensation treatment, the tail gas still retains some unliquefied organic components, enters the organic membrane separation unit, and completes the enrichment and concentration of organic components by means of the difference between the permeation rate of organic solvent molecules and air molecules by means of polymer membrane materials. The high-concentration organic gas flow obtained from the membrane side enrichment is returned to the compressor inlet to form a closed-loop cycle of the system, further improving the overall recovery rate of a variety of mixed solvents. After precipitation, water separation filtration and index detection, the recovered liquid mixed organic solvent can be sent back to the corresponding raw material storage tank for recycling and reuse after its quality meets the feeding process requirements of the raw material storage tank, so as to recover the solvent resources originally volatilized with the size of the storage tank, reduce the amount of hazardous waste generated from the source, and reduce the solvent procurement cost and hazardous waste disposal expenses of enterprises. The whole unit adopts a skid-mounted integrated structure. The factory completes the assembly, explosion-proof calibration and pressure test of the whole unit. The on-site installation work is small, which can directly connect with the original breathing valve gas gathering pipe network in the tank farm, thus minimizing the hot work in the tank farm and reducing the interference to the storage operation of the raw material storage tank.
The entire unit has been designed in strict compliance with pharmaceutical and chemical explosion-proof standards. All pipelines, valves, and heat-exchange components that come into contact with the waste gas are made of corrosion-resistant materials to withstand the acidic corrosion caused by hydrolysis of halogenated media, thereby ensuring long-term continuous operation of the unit. The unit is equipped with comprehensive overpressure, overtemperature, and combustible gas detection systems, as well as automatic interlock protection mechanisms, to address the instantaneous concentration surges caused by large breathing during tank loading and unloading operations and to mitigate various safety risks associated with flammable and explosive media. The intelligent variable-frequency control system automatically starts, stops, and adjusts the unit’s operating load in response to changes in pipeline pressure, exhaust gas flow rate, and concentration. It is designed to accommodate the irregular, intermittent emission patterns associated with tank breathing, preventing overloading or idle operation and optimizing overall energy consumption. Based on the measured parameters of storage tanks at the site, the composition and concentration fluctuation ranges of waste gases, the layout of the piping network, and the available site conditions in the tank farm, we conduct customized design without relying on standardized, off-the-shelf models. We provide end-to-end services covering tank-farm condition surveys, process‑solution design, equipment manufacturing and production, on‑site installation and commissioning, operator training, and subsequent operation and maintenance.Standardized production and manufacturing, standardized on-site construction, and routine inspection and maintenance ensure the long-term reliable operation of the complete VOCs waste gas resource recovery system, achieving the dual objectives of compliant treatment of waste gases from pharmaceutical raw material storage tank areas and cost reduction and efficiency improvement through the resource recovery of organic solvents.
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