What are the applications of deodorization towers in the pharmaceutical industry
Information summary：Deodorization tower (whose core function is to remove odorous substances and harmful components from exhaust gas through physical adsorption, chemical absorption, biodegradation and other processes, and achieve standard emissions) is a key environmental protection equipment in the pharmaceutical industry for controlling volatile organic compounds (VOCs), odorous gases and harmful exhaust gas pollu
Deodorization tower (whose core function is to remove odorous substances and harmful components from exhaust gas through physical adsorption, chemical absorption, biodegradation and other processes, and achieve standard emissions) is a key environmental protection equipment in the pharmaceutical industry for controlling volatile organic compounds (VOCs), odorous gases and harmful exhaust gas pollution. It is widely used in the entire process of pharmaceutical production to produce odorous and harmful gases. The specific application scenarios and core functions are as follows:
1、 Core application scenario 1: Production process of chemical synthetic drugs (treatment of high VOCs and odorous waste gases)
The production of chemical synthetic drugs requires steps such as "raw material synthesis → intermediate reaction → finished product refining". During the process, a large amount of organic solvents (such as methanol, ethanol, ethyl acetate) and acid-base reagents (such as hydrochloric acid, ammonia water) are used, which will produce exhaust gas containing "unpleasant odor+toxic components". The core function of the deodorization tower is to "remove solvent odor+degrade harmful components". Specific scenarios:
1. Waste gas treatment in the synthesis reaction section
Source of exhaust gas: During raw material synthesis, substitution/addition reactions, kettle reactors will evaporate a large amount of organic solvent vapors (such as dichloromethane and DMF used in the synthesis of antibiotics), as well as reaction by-products (such as sulfur-containing and nitrogen-containing compounds, with a putrid and fishy odor);
Deodorization tower function: adopting a combination process of "chemical absorption+activated carbon adsorption" - first absorbing acidic waste gas (such as salt acid mist and organic acids) through alkaline absorption solution (such as NaOH solution), and then adsorbing organic solvent vapor and odorous substances (such as sulfides) through activated carbon filling layer. The odor removal rate of the waste gas is over 90%, and the VOCs emission concentration meets the "Emission Standards for Air Pollutants in Pharmaceutical Industry" (GB 37823-2019);
Typical case: In the cephalosporin antibiotic synthesis workshop, a deodorization tower is used to treat the reactor exhaust to prevent the unpleasant odor of dichloromethane from spreading to the factory area and surrounding areas, while also preventing toxic solvents from endangering the health of operators.
2. Waste gas treatment in the refining and purification section
Source of exhaust gas: During the refining process of finished products (such as crystallization, centrifugation, and drying), organic solvents (such as ethanol and acetone) will evaporate with the drying airflow, producing high concentration solvent odors; Some products (such as nitrogen-containing heterocyclic drugs) release trace amounts of nitrogen-containing odorous gases when dried;
Function of deodorization tower: Adopting the "condensation recovery+adsorption" process - first, most of the organic solvents are recovered through the condenser (such as ethanol recovery rate of over 85%, achieving resource recycling), and the remaining low concentration waste gas enters the deodorization tower. The residual solvents and odors are adsorbed by molecular sieves or activated carbon to ensure that the exhaust has no obvious odor and the solvent emission is reduced to below the environmental protection limit;
Advantages: It not only reduces exhaust gas pollution, but also recovers valuable organic solvents, reducing production costs.
2、 Core application scenario 2: Biopharmaceutical production process (biological odor and odor control)
Biopharmaceuticals, such as vaccines, antibody drugs, and enzyme preparations, are centered around microbial fermentation and cell culture. During the production process, a "biological odor" (such as fermentation exhaust gas and bacterial residue treatment exhaust gas) is generated. The core function of a deodorization tower is to "remove biological odors+kill harmful microorganisms". Specific scenarios include:
1. Tail gas treatment in the fermentation section
Source of exhaust gas: During the aeration and cultivation process of the fermentation tank, the exhaust gas carries a large amount of microbial aerosols (such as bacteria and fungal spores) and metabolic by-products (such as organic acids and amines), with a "sour and moldy smell". If directly discharged, it will cause odor disturbance in the factory area and surrounding areas, and there is a risk of microbial diffusion;
Function of deodorization tower: The combination process of "biological filter+ultraviolet disinfection" is adopted - the exhaust gas enters the biological deodorization tower filled with microbial carriers (such as volcanic rock, organic fillers), and microorganisms metabolize and degrade odorous substances such as organic acids and amines; After further disinfection with ultraviolet disinfection equipment, residual microorganisms were eliminated, and the exhaust had no biological odor. The microbial concentration met the requirements of "no obvious odor" and "microbial compliance" in the "Discharge Standards for Water Pollutants in Medical Institutions" (GB 18466-2005);
Typical case: In the insulin fermentation workshop, a deodorization tower is used to treat fermentation exhaust gas, avoiding the spread of moldy odors to surrounding residential areas and preventing the leakage of fermentation bacteria (such as Escherichia coli engineering bacteria).
2. Waste gas treatment in the bacterial/residue treatment section
Source of exhaust gas: After fermentation, the bacterial separation and centrifugation residue (containing proteins and nucleic acids) will spoil and deteriorate during storage and transportation, releasing "putrid" gases (such as hydrogen sulfide, ammonia, volatile fatty acids);
Deodorization tower function: adopting the "acidic/alkaline absorption+activated carbon adsorption" process - first using acidic absorption solution (such as sulfuric acid solution) to absorb alkaline ammonia, and then using alkaline absorption solution to absorb acidic hydrogen sulfide. Residual volatile fatty acids are adsorbed by activated carbon, and the odor removal rate is over 95%, avoiding the impact of spoilage odor on the workshop environment and the health of operators.
3、 Core application scenario 3: Production process of traditional Chinese medicine pharmaceuticals (volatile components and processing odor treatment)
The "extraction, processing and drying" process of traditional Chinese medicine (such as Chinese medicine decoction pieces and traditional Chinese patent medicines and simple preparations) will produce "the unique volatile smell of traditional Chinese medicine" (such as menthol and volatile oil) and the burnt paste smell in the processing process. The core role of the deodorizer is to "recover the useful volatile components+remove the unpleasant odor". The specific scenario is as follows:
1. Waste gas treatment in the traditional Chinese medicine extraction section
Source of exhaust gas: During the process of traditional Chinese medicine decoction and alcohol extraction, volatile oils (such as peppermint oil and cinnamon oil) in the herbs evaporate with steam, producing a strong aroma of traditional Chinese medicine; If directly discharged, although the odor is non-toxic, it can easily cause discomfort to surrounding residents (such as those who are sensitive to the smell of traditional Chinese medicine);
Function of deodorization tower: Adopting the "condensation recovery+adsorption" process - first, volatile oil is recovered through the condenser (such as peppermint oil with a recovery rate of over 70%, which can be used for subsequent product production or sold separately), and the remaining low concentration odorous gas enters the activated carbon deodorization tower to adsorb residual volatile components, significantly reducing exhaust odor and avoiding disturbance to the public;
Typical case: Menthol extraction workshop, deodorization tower not only recovers peppermint oil resources, but also reduces the unpleasant odor of peppermint around the factory area.
2. Waste gas treatment in the traditional Chinese medicine processing section
Source of exhaust gas: The "stir frying, calcining, and roasting" processes used in the processing of traditional Chinese medicine (such as stir frying Atractylodes macrocephala, calcining gypsum, and wine roasting Angelica sinensis) can produce a burnt and alcohol volatile taste (during wine roasting), and some processing processes may also produce trace amounts of dust and unpleasant gases (such as sulfur dioxide during calcination);
Deodorization tower function: Adopting a combination process of "cyclone dust removal+chemical absorption+biological filter" - first removing dust through a cyclone dust collector, and then treating harmful components with absorption solution (such as water absorbing alcohol, alkaline solution absorbing sulfur dioxide), degrading burnt organic matter through a biological filter, ensuring that the exhaust has no obvious processing odor and meets environmental protection requirements.
4、 Core application scenario 4: Pharmaceutical auxiliary processes (solvent recovery, wastewater treatment, waste gas)
The auxiliary processes in the pharmaceutical industry, such as solvent recovery and wastewater treatment, also generate exhaust gases. Deodorization towers need to be treated specifically to avoid "secondary pollution". Specific scenarios:
1. Waste gas treatment in solvent recovery section
Source of exhaust gas: When the solvent recovery device in the pharmaceutical workshop (such as the distillation tower) recovers organic solvents, the top of the tower will emit "low concentration solvent exhaust gas that has not been fully recovered" (such as methanol, ethyl acetate). Although the concentration is low, the odor is obvious and belongs to the VOCs category, which needs to be discharged in compliance with standards;
Deodorization tower function: Adopting the "adsorption desorption+catalytic combustion" process (suitable for medium and low concentration VOCs) - first, the solvent in the exhaust gas is adsorbed by activated carbon, and after adsorption saturation, it is desorbed with hot air. The desorbed high concentration solvent gas enters the catalytic combustion device and is decomposed into CO ? and H ? O under the action of the catalyst, achieving "zero odor+VOCs standard" and no secondary pollution;
Advantages: Compared to simple adsorption, catalytic combustion can degrade solvents and avoid the problem of "hazardous waste treatment" caused by activated carbon saturation.
2. Pharmaceutical wastewater treatment plant waste gas treatment
Source of exhaust gas: Pharmaceutical wastewater (such as synthetic drug wastewater and biopharmaceutical wastewater) will volatilize a large amount of "odorous gases" (such as hydrogen sulfide, ammonia, volatile phenols) during the treatment process in regulating tanks, aeration tanks, and sludge concentration tanks, with strong odors. If not treated, it will seriously affect the surrounding environment of the wastewater treatment station;
Function of Deodorization Tower: Adopting the "Cover Collection+Biological Deodorization Tower" process - first seal the wastewater tank, collect the exhaust gas through pipelines, and then send it to the deodorization tower filled with biological fillers (such as bio ceramic particles). Microorganisms degrade odorous substances (such as sulfurizing bacteria degrading hydrogen sulfide and nitrifying bacteria degrading ammonia), with an odor removal rate of over 98%, ensuring that there is no obvious odor around the wastewater station.
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