How can modern pharmaceutical clean workshop achieve the purpose of energy saving?
Energy conservation is an important energy policy in China's sustainable development strategy. However, for a long time, the main contradiction in the clean room design of pharmaceutical plants has been particle, and energy saving has not been paid much attention.
With the rapid development and expansion of clean room construction scale of GMP standard pharmaceutical plants in China, it is urgent to take effective measures to reduce energy consumption and save energy from the design of clean room of pharmaceutical plants, and to effectively reduce energy consumption and drug production cost by adopting advanced energy-saving technologies and measures from the layout of buildings and technological conditions.
1. Design appropriate workshop type
It is the best way to build a large square workshop with single story and large frame. It has the advantages of minimum external wall area, low energy consumption, saving the investment of building, cooling and heating load and equipment operation cost. In addition, the window wall ratio can be controlled and reduced, and the air tightness of the door and window structure can be strengthened. In addition, the clean room with high temperature difference shall be provided with heat insulation layer, the enclosure structure shall be made of materials and structures with good heat insulation performance and air tightness, the inner side of the external wall of the building shall be made of heat insulation or sandwich heat insulation composite wallboard, and the humidity control room shall be provided with a sealed room with good moisture-proof performance: these measures can achieve the purpose of energy saving.
2. Reduce the volume of clean space
The reduction of clean space means that the air volume ratio, air change times and air supply power consumption are all reduced. The energy consumption per square meter of clean room is 10-30 times that of ordinary air-conditioned office building. If the clean volume is reduced by 30%, 25% energy can be saved. And since the power consumption in the clean area of grade 10000 is 2.5 times of that of grade 100000, the enterprises should arrange them separately according to the requirements of different air cleanliness levels, try their best to reduce the area of the clean room, especially the high-level clean room, and at the same time, make the clean room with high cleanliness requirements close to the air conditioning room as much as possible, so as to reduce the length of pipelines and energy consumption.
One of the practical technologies to reduce the volume of clean space is to establish a clean tunnel or tunnel type clean room, which can meet the double requirements of production for high cleanliness environment and energy saving, so as to minimize the space of clean process area and greatly reduce the air volume. In addition, clean tunnel laminar flow hood can also be used to resist the interference and pollution of low cleanliness operation area to high cleanliness process area. Under the same total air volume, the clean sectional area before the hood can be expanded by 5-6 times. At the same time, local air flow protection can also be implemented in the form of clean room, clean work table, self-cleaning device, micro environment, etc., such as weighing work table with laminar flow device and filling and sealing machine with laminar flow device, so as to maintain the requirements of high cleanliness level in the area and reduce the volume of clean space.
3. Reduce the pollution value of clean room
Reducing the pollution value of clean room is also beneficial to the energy saving of clean room in pharmaceutical factory. The main pollution source of clean room air is not people, but new building decoration materials, cleaners, adhesives, modern office supplies, etc. Therefore, the use of green environmental protection materials with low pollution value can make the clean room of pharmaceutical factory in a low pollution state, which is also a good way to reduce the fresh air load and energy consumption.
4. Reasonable design of air cleanliness level
In the clean room design of pharmaceutical factory, the air cleanliness level standard should be determined on the premise of ensuring the production quality, and the factors such as process production capacity, equipment size, operation mode, connection mode of front and rear production processes, number of operators, equipment automation degree, equipment maintenance space, equipment cleaning mode should be comprehensively considered, so as to reduce investment and operation cost and achieve energy conservation Requirement. The first is to determine the purification level according to the production requirements. For example, the diluted injection can be set as 10000 level, while the concentrated injection can be set as 100000 level if the environmental requirements are not high. Second, local purification measures are used in places with high cleanliness requirements and relatively fixed operation posts. For example, the filling and sealing of large infusion can be operated in the local 100 level production environment under the background of 10000 level. Third, it is allowed to adjust the production environment cleaning requirements with the change of production conditions. If the injection is diluted to 10000 levels, the production environment can be 100000 levels when the closed system is used.
5. Adjust temperature and humidity according to different seasons
On the premise of meeting the production process, from the perspective of energy saving, it is necessary to determine the appropriate cleanliness level, temperature, relative humidity and other parameters. According to GMP, the production conditions of clean room in pharmaceutical factory are: temperature 18 ℃ ~ 26 ℃, relative humidity 45% ~ 65%. Considering that the indoor relative humidity is too high and easy to grow mold, which is not conducive to the maintenance of clean environment, and too low is prone to generate static electricity, making the human body feel uncomfortable. According to the actual production of the preparation, only part of it
The process has certain requirements for temperature or relative humidity, others are focused on the comfort of operators. Therefore, from the point of view of people's habits and physique, it is more appropriate to raise the temperature in summer from 24 ℃ to 26 ℃ and the relative humidity from 45% to 65%. In winter, the temperature should be above 20 ℃, while the relative humidity should be reduced from 45% to the natural state (such as 20%) so as to save energy.
6. Reduce the number of air changes in the clean room
On the premise of ensuring the clean effect, reducing the number of air changes and air supply is one of the important means of energy saving. The number of air changes is closely related to the production process, the advanced level and layout of equipment, the size and shape of the clean room, and the density of personnel. For example, a room equipped with an ordinary ampoule filling and sealing machine needs a higher air change rate, while a water needle production room equipped with an air purification device and a washing and filling coupling machine only needs a lower air change rate to maintain the same cleanliness.
7. Properly reduce the lighting intensity
The lighting of clean room in pharmaceutical factory should meet the physiological and psychological requirements of workers. Local lighting can be used for high illuminance operation points, but it is not suitable to improve the minimum illuminance standard of the whole workshop. At the same time, the lighting of non production room should be lower than that of production room, but the lighting should be no less than 100 lumens. According to the illumination level of Japanese industrial standard, the medium precision operation is set as 200 lumens, while the operation of pharmaceutical plants will not exceed the medium precision operation, so it is appropriate to reduce the minimum illumination from ≥ 300 lumens to 150 lumens, which can significantly save energy.
8. Comprehensive utilization of clean air flow
Comprehensive utilization of clean air flow and heat recovery of process and air conditioning system are energy-saving measures that can directly benefit. For the clean room of the pharmaceutical factory without the influence of dust particles, the clean air flow is connected in series, and the clean room is connected in series according to the cleanliness. The initial air supply is sent to the low-level room through the high-level room and then returned to the air conditioning unit, which can save a number of high-efficiency filters. For rooms that mainly eliminate waste heat and do not have high purification requirements, clean air flow can be used and the flow direction of down supply and up return can be used. Down supply can reduce the air supply speed, improve the air supply temperature and reduce the temperature difference, while the up return can increase the return air temperature.
9. Energy saving of process equipment
The design and selection of clean room process equipment in pharmaceutical factory must realize energy saving while meeting the requirements of mechanization, automation, program control and intelligence. For example, for the production of water injection, we can design a new type of injection filling equipment into the wall, so that the machine is connected with the wall of the sterile room, and the maintenance is carried out in the non sterile area next door, without affecting the sterile environment. Due to the small floor area of the machine, the space required for 100 level parallel flow in the clean workshop is reduced, as well as the impact of project investment cost and personnel on environmental cleanliness, which greatly saves energy. At the same time, necessary technical measures should be taken to reduce the heat and air volume of production equipment. For example, water-cooled equipment should be used as far as possible, and the heat insulation measures for production equipment and pipes in clean rooms should be strengthened to reduce heat emission and energy consumption. (from clean room)
Shandong ed purification Engineering Co., Ltd. focuses on laboratory system engineering, medical purification engineering and clean workshop system engineering. It has relevant business qualifications in the industry, from engineering consulting design, construction management, equipment and consumables supply, technical services, to laboratory certification, maintenance management, etc., to provide a comprehensive and complete solution for the medical purification engineering, laboratory system engineering, clean workshop system engineering industry. For more knowledge of medical purification industry, please pay attention to WeChat public address: Aide-188 (Ed purify oxygen supply).