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eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

EXECUTIVE SUMMARY FOR ENERGY AUDIT OF

SUBMERGED FERMENTATION PLANT -STEAM CONSUMPTION AT BIOCON BOMMASANDRA PLANT


BY

eQube
Conducted in January 2007

Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

SUBMERGED FERMENTATION PLANT


1. Cost of steam generation for Biocon plant > Rs.1100 per tonne. 2. Present consumption of steam in SFP 1900 tonnes per month. 3. Present methodology first heats the vessel and media by conduction and convection method. Then introduces steam in direct contact with media. The condensate gets drained to recovery tank. 4. Media takes over 2 to 2and Half hour to reach 100oC and then another half an hour to reach 121oC and then held for an hour for sterilization. 5. Suggested to inject 15.25% steam at 3.5 Bar, directly to 84.75% of desired quantity of media and then start the hold process for sterilization. 6. Some precautionary measures to be taken at the steam injection stage, may be some modification in the steam nozzle, to prevent thermal knock/ hammering of the steam in the line. 7. Pilot project to be taken up with 2KL of media and then based on the results, and fine tuning of the method/ process, the process can be stabilized and standardized. 8. Anticipated saving of over 800Tonnes of steam in a month. 9. Savings of almost Rs. 108 lakhs per year. 10. Less than Rs. 5,00,000/- investment. Almost NIL as compared to savings.

Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

ENERGY AUDIT REPORT FOR

SUBMERGED FERMENTATION PLANT -STEAM CONSUMPTION AT BIOCON BOMMASANDRA PLANT


BY

eQube
Conducted in January 2007

Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

SFP OPERATION
VESSEL STERILISATION The empty vessel is first washed with caustic solution. The caustic solution temperature is maintained to around 90oC and circulated for upto 45minutes. Then the vessel is washed with potable water. The empty vessel is then subjected to direct steam injection for empty sterilization where the temperature is raised to 125-`26oC and held for 30 minutes. Subsequently the cooling tower water is circulated in the jacket and the temperature brought down to room/ ambient and then the lid is opened. And condensate in the vessel is drained. ALL TANKS ARE SUBJECTED TO SIMILAR PROCEDURE (give or take a few steps) before any production process is taken up. MEDIA CHARGING Water along with media is charged into the 10KL tank. Both are subjected to agitation to bring the media to a homogenous solution (almost). In TWO products, it is required to heat the water upto 60-90oC to make the media soluble. After the homogenous solution is prepared, the same is pumped to the main 30KL vessel. In case the production batch is less than 8KL, then in one shot this process is completed, else for upto 15-16KL two 10KL tanks are used and then both are pumped simultaneously. However, when the batch is over 16KL, then the process has to be repeated as only two 10KL tanks can be taken into service at a time for one product. (other tanks may be being used for other products) This process of transferring the prepared media to main vessel may take over 30-35 minutes. MEDIA STERILISATION The media is subjected to pH balancing at 30oC and then steam at 3.5 bar is injected into the vessel jacket and the drain is kept open for condensate to be released and collected in recovery tank. This is done till the media temperature in the vessel reaches upto 100oC. Subsequently the steam is directly injected into the vessel to raise the temperature to 121oC. Then the steam flow is modulated in the jacket to hold the media temperature at this temperature upto ONE hour. This completes the sterilization process and the temperature is brought down to 30oC by Cooling tower water and chilled water as required.
Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

At 30oC the tissue or culture as it is termed is mixed to the media and then the media temperature is to be maintained at 27oC + 3oC by use of cooling or chilled water circulation in the jacket, till the fermentation process is complete. OBSERVATIONS: Since the steam is used in the jacket of the vessel and the vessel being of stainless steel with very poor heat conduction properties, heat transfer rate is slow. The problem is aggravated because of the huge quantity of the media at low temperature provides a very huge thermal inertia to the media mass. Hence the time required for the steam to raise the temperature of the whole media is very high as the amount of steam that can be released into the vessel is limited. Thus the steam also gets condensed very fast and the same has to be drained to allow the new saturated steam to enter into the jacket of the vessel. This process which goes on for over 2 hours results in drainage of close to 26Tonnes of steam for each batch of 24KL of media sterilization. This matches with the monthly consumption of 1200Tonnes for sterilization purposes only, balance 600-700 tonnes of steam is required for holding, cleaning and sterilizing the vessels etc. The steam neither adds to the pH nor reduces the same. At the same time whatever steam is added to the vessel directly after the temperature in the vessel reaches 100oC, a bit of same gets leaked out of the top vent. This further adds to the heat or energy loss. RECOMMENDATION/ SUGGESTIONS 1. Since the steam neither increases nor decreases the pH, it is not detrimental to direct addition to the media in whatever quantity. 2. Since the steam is directly added to the vessel (for empty sterilization) thereby it is proven that it does not have any detrimental effect on the vessel or its construction strength. 3. If the steam is directly released into the cold media, due to the presence of condensate of the steam and existing media solution in the pipe line, the steam coming in at approximately 40m/s gets suddenly stopped by this. This results in severe knocking or hammering sound, which may result in cracks in the steam/ air line inside the vessel. 4. The solution will be to introduce the steam into the vessel above the liquid level. However this will not result in fast mixing of the steam into the media and
Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

thereby delaying the process. Hence to have a fast mixing and quick absorbing of steam and heat into the media, it is proposed to create a fine spray/ mist of media on the top and then release the steam into it. Having large surface area because of smaller size of the water droplets because of the spray, the heat can be quickly picked up & steam can get mixed up in the media almost instantaneously. This will solve the issue of knocking as well as the time required to heat up the media. 5. 84.75% of the desired final quantity of the media shall be charged and pH balancing shall be done. Once stabilized, the steam at 3.5 Bar shall be introduced directly into the vessel, instead of introducing into the vessel jacket. Till the temperature of the media reaches 121oC and then the media can be held at the same temperature as per the existing procedure. Amount of steam added will be balance 15.25%. (see annexure steam calculations). 6. To create a mist or a fine spray of media at the top of the vessel, it is proposed to have a line coming out of the vessel, near the bottom, connected to the SS pump and the SS line taking the media to the top of the vessel and connected to a ring with sprinkler nozzles. Since the whole process requires approximately 20M3 of media to be circulated, the pump shall be of 20M3/Hr capacity with a static head of 25m. 7. Modification in vessel by introducing a ring with nozzles in the top needs to be undertaken, which will be connected to by a SS pump with a SS line. The line size shall be of 3 line. Pump shall be of 2.2KW rating. We can consider 15 nozzles in the ring inside the vessel. INVESTMENT: For each vessel Pipe line Rs 10,000/Nozzles with cost of installation 25,000/Inline Pump with valves and installation 1,25,000/Hence for 4 such vessels: Net cost shall be Rs. 1,60,000/- x 4 = Rs. 6,40,000/SAVINGS: An anticipated saving of close to 800tonnes of steam per month. This by present cost of steam of Rs. 1100/- per tonne will work out to Rs. 9 lakhs per month. PAYBACK PERIOD: TWO weeks. Actually, not applicable, as the savings are with almost nil investment.
Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

eQube

#48,1st Floor, (bh. Misra Furnitures)


2A Main, New Thippasandra, Bangalore 560 075 Phone: 080- 6566 3540 Email- sahay@eqube.co,in

ANNEXURE
STEAM CALCULATIONS: 3.5bar steam properties: Enthalpy hf - 584.34Kj/Kg hfg- 2148.1 Kj/Kg hg 2732.44 Kj/Kg liquid Vapour Density 927.16 Kg/m3 1.907 Kg/M3 0.524m3/Kg Velocity

40m/s

Specific Volume

CASE - 1 We require 24KL of sterilized media for culture. Approximate weight of the media 24000 Kg. Approximate temperature of the media at start of sterilization 25oC Specific heat of media 1 cal/g or 4.182Kj/KgoK Desired End temperature 121oC Hence approximate total heat required: 10x106 KJ Amount of steam required at 3.5bar 3660Kg ~ 15.25% of total media. CASE 2 We require 8KL of sterilized media for culture. Approximate heat required: 3.35x 106 KJ Steam required at 3.5 bar 1225Kg ~ 15.3% of total media.

Regd. Office : # 29, 6th G Cross, Khaggadaspura, post CV RamanNagar, Bangalore 560 093

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