Takeda (Ireland) Ltd

Integrated Thermal Oxidation and Gas Scrubbing for Pharmaceutical Manufacturing in Dublin

Project Overview

ERG Air Pollution Control supplied an integrated thermal oxidation and gas scrubbing package for Takeda (Ireland) Ltd at its pharmaceutical manufacturing facility in Dublin, Ireland.

Delivered in 2023, the project involved the treatment of process vent gases containing chlorinated volatile organic compounds (VOCs), sulphur dioxide (SO₂) and nitrogen oxides (NOx).

The system was designed to treat a process gas flow of 300 Nm³/hr of nitrogen (N₂) carrying the identified contaminants.

The equipment package combined a thermal oxidiser, thermal oil heat recovery, quench and packed tower scrubbing, selective catalytic reduction (SCR) for NOx abatement, and associated utilities, instrumentation and controls.

The original case study identifies the installation as compliant with the Industrial Emissions Directive (IED).

This project demonstrates ERG’s experience in engineering integrated emissions treatment systems for pharmaceutical manufacturing, where multiple contaminants require different treatment technologies within a coordinated process.

The Challenge – Treating Complex Pharmaceutical Process Vent Gases

Pharmaceutical manufacturing can generate process vent gases containing a combination of organic solvents and inorganic pollutants.

These gas streams may require more than one treatment technology to address the different chemical properties of the contaminants.

For Takeda’s Dublin facility, the documented process gas stream contained chlorinated VOCs, sulphur dioxide and nitrogen oxides.

Chlorinated organic compounds require careful consideration during thermal oxidation because their destruction can produce acidic combustion products, including hydrogen chloride (HCl).

Sulphur-containing compounds can contribute to sulphur dioxide emissions, while nitrogen oxides may require additional treatment to achieve the specified emission requirements.

The project therefore required an integrated approach combining thermal destruction, heat recovery, acid gas treatment and NOx abatement.

ERG’s Solution – Integrated Thermal Oxidation and Scrubbing

ERG supplied a multi-stage process gas treatment package incorporating several complementary technologies.

The thermal oxidiser provides high-temperature treatment of suitable organic contaminants, while downstream equipment addresses heat recovery, gas cooling and the removal of additional pollutants.

The documented system included a thermal oil heat recovery package, quench and packed tower scrubber for HCl and SO₂ treatment, and an SCR system for NOx abatement.

The combination of these technologies provides an engineered approach to treating a complex pharmaceutical process gas stream.

Thermal Oxidation of Chlorinated VOCs

Thermal oxidation is an established technology for treating volatile organic compounds in industrial process gases.

Within a thermal oxidiser, organic compounds are exposed to elevated temperatures in the presence of sufficient oxygen and appropriate residence time to promote oxidation.

For chlorinated VOCs, the treatment process must also consider the formation of acidic combustion products.

The Takeda installation incorporated downstream quench and wet scrubbing equipment for HCl and SO₂ treatment.

The original project case sheet does not specify the operating temperature, residence time, VOC destruction efficiency or outlet concentrations.

Thermal Oil Heat Recovery

The system incorporated a thermal oil heat recovery package.

Thermal oil systems can transfer recovered heat from high-temperature process equipment to suitable downstream applications.

Integrating heat recovery into a thermal oxidation package can improve the overall utilisation of energy generated during the treatment process.

For the Takeda installation, thermal oil heat recovery formed part of the documented equipment scope.

The original case study does not identify the recovered thermal duty or the final use of the recovered heat.

Quench and Packed Tower Scrubbing

Following high-temperature treatment, the process gas treatment arrangement included quench and packed tower scrubbing equipment.

A quench system provides rapid gas cooling, preparing the gas for subsequent treatment stages.

Packed tower scrubbers use circulating liquid and specially designed packing media to provide contact between the gas and scrubbing solution.

For the Takeda project, the documented scrubber duty included treatment of hydrogen chloride and sulphur dioxide.

The selection of scrubbing chemistry and operating conditions depends on the characteristics of the gas stream and the required treatment performance.

Selective Catalytic Reduction for NOx Abatement

The equipment package also included selective catalytic reduction (SCR) for nitrogen oxide abatement.

SCR is an established technology for reducing NOx emissions from suitable industrial gas streams.

The process uses a reducing agent and catalyst to convert nitrogen oxides into nitrogen and water under controlled operating conditions.

The inclusion of SCR demonstrates the need to address NOx alongside VOCs and acid gases within the overall emissions treatment system.

The original case study does not specify the reducing agent, catalyst configuration or achieved NOx removal efficiency.

Supporting Equipment and System Integration

The project involved more than the primary treatment vessels.

ERG’s documented scope also included inlet and discharge fans, ductwork, access and support steelwork, utility chemical handling, a chiller package, an MCC/ICA panel and a stack continuous emissions monitoring system (CEMS) package.

These supporting systems are important for integrating the individual treatment technologies into a complete industrial emissions control installation.

The project photographs show the external process plant, structural steelwork, ductwork and associated treatment equipment at the Dublin facility.

Project Specifications

Integrated Emissions Treatment for Pharmaceutical Manufacturing

Pharmaceutical manufacturing facilities can require specialist air pollution control systems capable of treating multiple contaminants within a single process gas stream.

Thermal oxidation provides treatment of suitable organic compounds, while wet scrubbing can be used to remove acid gases generated during oxidation or present in the original process stream.

Where nitrogen oxides also require treatment, SCR can be incorporated into the overall emissions control arrangement.

Heat recovery and continuous emissions monitoring may provide additional operational and environmental benefits.

The Takeda project illustrates the integration of these technologies within a pharmaceutical manufacturing application.

ERG’s Experience in Pharmaceutical Air Pollution Control

ERG Air Pollution Control designs and supplies engineered emissions treatment systems for pharmaceutical, chemical and other industrial manufacturing applications.

Its technology portfolio includes thermal oxidation, wet scrubbing, heat recovery and specialist gas treatment equipment.

The Takeda (Ireland) Ltd project demonstrates ERG’s experience in delivering integrated treatment packages incorporating multiple technologies to address complex process emissions.

Delivered in 2023, the installation provides a reference for thermal oxidation, HCl and SO₂ scrubbing, SCR NOx abatement and associated emissions monitoring within an IED-compliant pharmaceutical manufacturing application.

**For further information about pharmaceutical emissions treatment, thermal oxidation, packed tower scrubbers or integrated industrial air pollution control systems, contact ERG Air Pollution Control