MeOH + THF Spent Distillation Costing Details
If Spent directly sale to external customers:
THF : 76% MeOH : 23% & MC : 20%.
%
Present Spent sale cost per Kg in Rs/-
Total Spent Quantity in Kgs
Total Spent Cost in Rs /- ------------------------------------- (A)
Input Material Balance:
Total Spent MeOH + THF + H2O Quantity in Kgs
► Moisture Content
► After removal of Water THF + MeOH quantity in Kgs
► MeOH Content in mixture
► THF Content in mixture
► MeOH Content in spent in Kgs
► THF Content in spent in Kgs
Total Spent taken for distillation:
► Input Quantity in Kgs
► THF recovered output quantity in Kgs (5% water) THF : 98 to 99% MC : 5 to 6%
► THF recovered output quantity in Kgs (anhydrous basis)
► % of THF recovery spent to recovered
► % of THF recovery on 100% basis
► % of THF recovery on 100% basis (Anhydrous basis)
Product Cost Details:
THF recovered selling price in Rs/-
Total material cost after distillation in Rs /- ------------------------------------- (B)
Process Costing Details:
Process Cost in (Power, Steam & Utility) in Rs/-
Total process cost in Rs /-
Consumed water quantity for extractive distillation in Ltrs
Portable Water Cost in Rs/- per Kg
Portable Water Cost in Rs/-
High COD & TDS effluent generation quantity in Ltrs
High COD & TDS effluent disposal cost in Rs/-
Total High COD & TDS effluent disposal cost in Rs/-
Cost savings in Rs/- month
I Part : Take this mixture in column kettle and heat to Reflux & stabilize the column. Add water from top continuous
top. MeOH gets supressed & remains in the kettle. Collected THF Analysis will be THF: >99.0%, MC: 4.0 - 6.0%.
II Part : Take this THF Recovered in Reactor & dehydrate using Caustic soda Flakes till required moisture under nitr
layer. Adjust the pH to neutral using Sulphuric acid. Again seperate the salts.
III Part : Take this dehydrated THF in column kettle, add BHT(Butylated Hydroxy Toluene) to prevent peroxide f
column. Remove initial fraction from top, check MC, if MC is <0.1% then collect/flash the THF using DOWN COM
THF: >99.5%, MC: <0.1%.
ng Details
Input Details
Analysis
Methanol
MC%
: 17.65
: 46000 Output Details
: 811900 1 Lot
st
2nd Lot
: 46000 3rd Lot
: 20.00%
: 36800 Total Output : 2024+2400+3678 = 8102 L
: 23.16% High MC/ RMS : 900 L
: 76.42%
: 8523 Note:Feed the water 300L/hr, collection 150-
: 28123 175 L/hr & 4 days running the column.
Quantity : 20000 kg, Water Content : 20.0%
Purity : MeOH - 23.17%, THF - 76.42% & Impurity : 0
: 46000
: 20650 Calculation :
: 19411
: 44.89% 20000 - 20% (Water Removed) =
: 73.43% 16000 × 76.42% (as 100%) =
: 69.02% 12227.20 × 65.0% (expected THF Recovery) =
7947.70 × 130/- (Fresh Cost) =
20000 × 10/- =
1033201 - 20000 =
833201/20000 =
: 120
: 2478000 Per kg MeOH + THF (Process Recovered) Cost is Rs. 41.6
: 5
: 103250
: 75000
: 0.35
: 26250
: 206000
: 0.25
: 51500
:
ater from top continuously during Reflux & collect the THF from
9.0%, MC: 4.0 - 6.0%.
uired moisture under nitrogen blanket. Seperate the bottom acquous
ne) to prevent peroxide formation and heat to Reflux & stabilize the
THF using DOWN COMER. Collected THF Analysis will be
Input Details
76.416 (THF Purity)
23.166
20
Output Details
2024 L (Purity: 99.53%)
4625 L (Purity: 97.58%) take to
Re-distilled & Output 3678 L
(Purity: 99.16%)
2400 L (Purity: 98.80%)
Total Output : 2024+2400+3678 = 8102 L
High MC/ RMS : 900 L
Note:Feed the water 300L/hr, collection 150-
75 L/hr & 4 days running the column.
Quantity : 20000 kg, Water Content : 20.0%
urity : MeOH - 23.17%, THF - 76.42% & Impurity : 0.41%
Calculation :
20000 - 20% (Water Removed) = 16000.00 kg
16000 × 76.42% (as 100%) = 12227.20 kg
12227.20 × 65.0% (expected THF Recovery) = 7947.70 kg
7947.70 × 130/- (Fresh Cost) = 1033201.00 /-
20000 × 10/- = 200000/-
1033201 - 20000 = 833201/-
833201/20000 = 41.66/-
er kg MeOH + THF (Process Recovered) Cost is Rs. 41.66/-
IPA + MeOH Spent Distillation Costing Details
If Spent directly sale to external customers:
IPA : 92% MeOH : 7% & MC : 14%.
Present Spent sale cost per Kg in Rs/-
Total Spent Quantity in Kgs
Total Spent Cost in Rs /- ------------------------------------- (A)
Input Material Balance:
Total Spent IPA + MeOH + H2O Quantity in Kgs
► Moisture Content
► After removal of Water IPA + MeOH quantity in Kgs
► MeOH Content in mixture
► IPA Content in mixture
► MeOH Content in spent in Kgs
► IPA Content in spent in Kgs
Total Spent taken for distillation:
► Input Quantity in Kgs
► IPA recovered output quantity in Kgs (10% water)
► IPA recovered output quantity in Kgs (anhydrous basis)
► % of IPA recovery spent to recovered
► % of IPA recovery on 100% basis
Product Cost Details:
THF recovered selling price in Rs/-
Total material cost after distillation in Rs /- ------------------------------------- (B)
Process Costing Details:
Process Cost in (Power, Steam & Utility) in Rs/-
Total process cost in Rs /- ------------------------------------- (C)
Cost Saving in Rs/- : (B - C - A)
Cost saving per Kg Spent generation in Rs /-
High COD & TDS effluent generation quantity in Ltrs
High COD & TDS effluent disposal cost in Rs /-
Total high COD & TDS effluent disposal cost in Rs /-
Total process cost in Rs /- ------------------------------------- (C)
Transportation Cost in per Kg Rs/-
Total Transportation Cost in Rs/- ------------------------------------- (D)
Cost Saving in Rs/- : (B - D - C - A)
Cost saving per Kg Spent generation in Rs /-
Note: For any Spent Compostion costing, Red colour font to be change only
ing Details
: 23
: 17850
: 410550
: 17850
: 14.30%
: 15297
: 7.70%
: 92.30%
: 1178
: 14120
: 17850
: 13785
: 11304
: 77.23%
: 80.06%
: 60
: 689250
: 6
: 82710
: 195990
: 10.98
: 75000
: 0.25
: 18750
: 148250
: 2
: 92000
: 1425850
: 31.00
Cooling Tower - 101
(CTU - 101)
SL No. SL No.
1 MAKE SOUTHERN COOLLING TOWER 1
2 MODEL 5984-6 2
3 TYPE FCI-11-116 3
4 LOCATION Terrace 4
5 DATE OF INSTALLATION Oct/11 5
6 CAPACITY 300TR 6
7 USED FOR RECOVERY BLOCK 7
PUMP (PUU - 101)
SL No. SL No.
1 MAKE JOHNSON PUMP 1
2 TYPE CN 80-200 G1S2L3 2
3 SR. No. R212036024 3
4 M3/HR 250 4
5 HEAD 40 5
6 K.W. 33 6
7 RPM 2900 7
8 EFFICIENCY 68% 8
9 LOCATION Terrace 9
MOTOR (MOU - 101)
SL No.
1 MAKE CROMPTON GREAVES (N.F.L.P.)
2 MACHINE No. NADM12A
3 FRAME ND200L
4 K.W.(HP) 30(40HP)
5 RPM 2950
6 EFFICIENCY 91.50%
7 VOLTAGE 415±10%
8 AMPS 52A
9 BRG 6312-2RS/6212-2RS
10 REF No. KGEM0458
11 LOCATION Terrace (CTU-101 PUMP)
12 CONNECTED PUU-101
PUMP (PUU - 102)
SL No.
1 MAKE JOHNSON PUMP
2 TYPE CN 80-200 G1S2L3
3 SR. No. R212036024
4 M3/HR 250
5 HEAD 40
6 K.W. 33
7 RPM 2900
8 EFFICIENCY 68%
9 LOCATION Terrace
MOTOR (MOU - 102)
SL No.
1 MAKE CROMPTON GREAVES (N.F.L.P.)
2 MACHINE No. NADM12A
3 FRAME ND200L
4 K.W.(HP) 30(40HP)
5 RPM 2950
6 EFFICIENCY 91.50%
7 VOLTAGE 415±10%
8 AMPS 52A
9 BRG 6312-2RS/6212-2RS
10 REF No. KGEM0458
11 LOCATION Terrace (CTU-101 PUMP)
12 CONNECTED PUU-102
FAN MOTOR (MOU - 103)
SL No.
1 MAKE CROMPTON GREAVES (N.F.L.P.)
2 TYPE AMW 160M4
3 VOLTAGE 415 (at 450c)
4 AMPS 20.6
5 EFFICIENCY 88.40%
6 K.W.(HP) 11(15HP)
7 RPM 1460%
Cooling Tower - 102 /
(CTU - 102)
MAKE SOUTHERN COOLLING TOWER
MODEL 5982-6
TYPE FCI-11-138
LOCATION Terrace
DATE OF INSTALLATION Nov/11
CAPACITY 250TR
USED FOR RECOVERY BLOCK
PUMP (PUU - 103)
MAKE JOHNSON PUMP
TYPE CN 50-125 G1S2L3
SR. No. X212052227
M3/HR 35
HEAD 20
K.W. 5
RPM 2900
EFFICIENCY NA
LOCATION Terrace
Product Name : Meropenem Sterile
Solvent : Acetone
Input / Batch : 4008.5 kg
Loss at plant Block : 66.7 kg
Loss at SRS : 611.5 kg
Recovered Qty : 3330.3 kg Solvent Recovery : 83.08%
Stage wise Solvent usage & losses details:
Plant Qty. in Ltrs
Stage Quantity MC % GC % As 100% Losses
Batch Operation 4200.0 2.00 99.57 4098.3
Cake Washings in ANFD 1000.0 2.00 99.57 975.8
Total Acetone Input 5200.0 5074.1
Water Washing 1520.0
Spent Generated 6720.0 25.00 99.00 4989.6
Total Spent Output 6720.0 4989.6 84.5
Column Qty. in Ltrs
Stage Quantity MC % GC % As 100% Losses
Acetone Spent 6720.0 25.00 99.90 5035.0
Distillation Output 4300.8 0.50 99.57 4260.9 774.1
Product Output : 132 kg
Solvent Consumption : 5.1430 kg/kg
Specific Gravity : 0.79
Observations Action Plan EDC
Consider 64% Recovery as such
3382.86809448
4282.111512
8
4368
21.84
4346.16
4327.471512
707.488488000001
558.915905520001
Product Name : Imipenem Sterile
Solvent : Acetone
Input / Batch : 3458.0 kg
Loss at plant Block : 10.9 kg
Loss at SRS : 484.0 kg
Recovered Qty : 2963.1 kg Solvent Recovery : 85.69%
Stage wise Solvent usage & losses details:
Plant Qty. in Ltrs
Stage Quantity MC % GC % As 100% Losses
Batch Operation 4200.0 2.00 99.57 4098.3
Cake Washings in ANFD 300.0 2.00 99.57 292.7
Total Input 4500.0 4391.0
Water Washing 1500.0
Spent Generated 6000.0 26.31 99.00 4377.2
Total Spent Output 6000.0 4377.2 13.9
Column Qty. in Ltrs
Stage Quantity MC % GC % As 100% Losses
Acetone Spent 6000.0 26.31 99.90 4417.0
Distillation Output 3840.0 0.50 99.57 3804.4 612.6
Product Output : 32 kg
Solvent Consumption : 12.8857 kg/kg
Specific Gravity : 0.79
Observations Action Plan EDC
Consider 64% Recovery as such
DCB Column Efficiency present Boil-up
SRS/DC001 (800 mm) SRS
Solvent MDC
1 Vapor Rate (M) 4655 Kg/hr 1
2 Vapor Velocity (V) 0.80 m/s 2
3 Solvent Molecular Weight 85 moles 3
4 Solvent Boiling Point 40 0
c 4
5 Vapor Density (ծ) 324248.4 5
3.24 Kg/m 3
6 Vapor Flowrate (Q) 1435.63 m3/hr 6
7 Cross Sectional Area (A) 0.50 m2 7
8 Diameter of Column (D) 0.80 mts 8
798.69 mm
present Boil-up
SRS/DC001 (600 mm)
Solvent Methanol
Vapor Rate (M) 950 Kg/hr
Vapor Velocity (V) 0.80 m/s
Solvent Molecular Weight 32 moles
Solvent Boiling Point 64.7 0
c
Vapor Density (ծ) 131703.0
1.32 Kg/m3
Vapor Flowrate (Q) 721.32 m3/hr
Cross Sectional Area (A) 0.25 m2
Diameter of Column (D) 0.56 mts
564.76 mm
Silicon Life Sciences
SRS Physical Stock Statem
Storage Capacity
S. No. Equipment ID Item Code Material Name Each cm in Ltrs
(KL)
1 STA101 20.0 56.5
2 STA102 20.0 56.5
3 STA103 10.0 34
4 STA104 10.0 34
5 STA105 10.0 34
6 STA106 10.0 34
7 STR101 25.0 58.4
8 STR102 25.0 58.4
9 STR103 20.0 56.4
10 STR104 20.0 56.4
11 STR105 20.0 56.4
12 STR106 25.0 58.4
13 STR107 25.0 58.4
14 STR108 20.0 56.4
15 STR109 20.0 56.4
16 STR110 20.0 56.4
17 STR111 20.0 56
18 STR112 20.0 56
19 STR113 20.0 57
20 STR114 20.0 57
21 RTR101 3.0 17.6
22 RTR102 3.0 18
23 RTR103 3.0 18
24 RTR104 3.0 18.2
25 RTR105 5.0 26
26 RTR106 5.0 25.6
27 RTR107 3.0 17.2
28 RTR108 3.0 17.2
29 RTR109 5.0 25.4
30 RTR110 5.0 25.6
31 RTR111 10.0 42
32 RTR112 10.0 41
33 RCC108 20.0
34 RCC109 20.0
Silicon Life Sciences
SRS Physical Stock Statement
Stock
Tank BDV in Present Level Present Stock As 100% Stock Specific
% Of Recovery Qty in
Ltrs in cm Qty in Ltrs Qty in Ltrs Gravity
Kgs
800
800
340
340
340
340
478
478
413
413
413
478
478
413
413
413
1355
784
240
603
490
557
522
519
910
797
556
499
953
799
1510
1520
Total Stock in
Kgs
Sl No. Column ID Column Dia. Product Stage Solvent Name Batch Input in Block
MDC - 9700*7 (67900 L)
1 SR-1 800 mm MDC + HMDO
HMDO - 1260*7 (8820 L)
2 SR-2 600 mm MeOH 2*7000 (14000)
3 SR-3 500 mm Toulene 7*1500 (10500)
76720
Column Ca
MLs Output
Column As 100% in
Generation Analysis Reflux Collection
Input (L) (L) Qty (L)
(L) (LPH) (LPH)
MDC - 62% HMDO MDC - 19313
31150 31150 17380 2000 1500
- 21% IMP - 17% HMDO - 6542
MC - 8% GC - 90%
14200 14200 12780 8500 1500 800
IMP - 10%
9100 9100 MC - 2% GC - 97% 8827 7500 1000 800
16500
19313 10185
6541.5
1233
18000
100 17730
Column Capacity & Efficiency
ut Fraction-I
As 100% Fraction -I
Time Analysis Analysis
in (L) Output (L) Reflux Collection Time
(hrs) (LPH) (LPH) (hrs)
MDC - 98.5% MDC - 60% HMDO
12 17119 1600 2600 400 5
IMP - 1.5% - 25% IMP - 15%
GC - 99.5% GC - 67% IMP -
11 8458 4100 1800 300 19
MC - 0.3% 10% MC - 1%
GC - 99.8% TOXIC - 67% IMP -
10 7485 1400 1500 150 10
MC - 0.3% 33%
17119.3
11698.215 8.54346813027495
8800
8756
Fraction-II
As 100% in Fraction -II As 100% Residue
Analysis
(L) Output (L) Reflux Collection Time in (L) Qty (L)
(LPH) (LPH) (hrs)
MDC - 960 HMDO - 60%
9950 500 2000 6 5970 400
HMDO - 400 IMP - 40%
2747 - - - - - - 1100
- - - - - - - 100
5970
1600
Total Time Loss Qty
Loss % Remarks
Cycle (hrs) (L)
MDC - 1650 MDC - 2.4%
28 -
HMDO - 172 HMDO - 2%
32 500 3.5 -
24 210 2.3 -
3.521126761
