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· McIlvaine will Speak at Pharmaceutical Water Treatment June 12, 2013
· Chemistry in Power Plants 2012 focused on European Power Plants
· The Electricity Chemistry Workshop will be in Champaign, IL on June 11-13, 2013
· China has Cleanroom Shows and Substantial Media Coverage
· INTERPHEX Included a Number of Cleanroom Displays
· Medtec U.K. was Devoted to Medical Device Manufacture and Use
· World Cleanroom Space will Increase by 6 Million Square Feet This Year
· Asian Ultrapure Water Sales to Exceed $3 Billion in 2015
McIlvaine will speak at Pharmaceutical Water Treatment June 12, 2013
Here is the program for the ultrapure water conference which will be held next month in Chicago. Bob McIlvaine will speak about the industry trends on the second day.
Pharmaceutical Water Treatment
June 11-12, 2013
Embassy Suites -- Lombard (Chicago)
ULTRAPURE WATER--Pharma 2013 is a two-day conference on Pharmaceutical Pure Water. This conference offers an Executive Forum consisting of state-of-the-art technical papers.
Click here to register online.
Download Registration Form (PDF file).
Preliminary Program:
Co-moderators: Anthony Bevilacqua, Ph.D., METTLER-TOLEDO Thornton;
and William V. Collentro, Water Consulting Specialists
Tuesday, June 11 Session 1:
■ Microbial Control in Purified Water
Systems
8:45 AM-Session Introduction
9:00 AM-Biofilm Control in Manufacturing/Water Systems
Mark more, Ph.D., Baxter
9:45 AM-Engineering Controls for Microbial Control in Pharmaceutical Water
Systems
Mukesh Yadav, Genentech
10:30 AM-Coffee Break
10:45 AM-Procedural Application of Root Cause Analysis for Microbial Excursions
Roderick Freeman, Beckman Coulter
11:30 AM-Ozone versus Heat Sanitization of Pure Water Distribution
Nik Krpan, Cheme' Engineering, Inc.
12:15 PM-Lunch Break
1:30 PM-Mitigating Biofilm with Ozone for Best Results
Erika Hanley-Onken, MKS Instruments
2:15 PM-Case Study: Lessons Learned from an In-Depth FDA Inspection
Roderick Freeman, Beckman Coulter
3:30 PM-Coffee Break
3:45 PM-Updates on Compendial Sterile and Bulk Water Standards
Antonio Hernandez-Cardoso, United States Pharmacopeial Convention Inc.
4:30 PM—Roundtable Discussion
5:45 PM--Reception
Wednesday, June 12: Session 2:
■ Control of Pharmaceutical Water Systems
8:45 AM-Trends and Developments in Pharmaceutical Water Markets
Robert McIlvaine, The McIlvaine Co.
9:30 AM-A Treatment System Based on Electrical Hardness Precipitation and UV
Destruction
Shlomo Sackstein, Biopharmax Group
10:00 AM-Monitoring/Continued Verification of Pharmaceutical Water Systems
Walter Henkel, Concordia ValSource
10:30 AM-Coffee Break
10:45 AM-Enhanced TOC Reduction in Pharmaceutical Water Systems using Highly
Reflective UV Disinfection
Randy Cooper, Neotech Aqua Solutions
11:15 AM-New Calibration Methods for Conductivity Systems
John Groetsch, METTLER-TOLEDO Process Analytics
11:45 AM-Development of an Improved Pharmaceutical Cosmetic Plant Water System
Chris Gallagher, Mar Cor
12:15 PM-Lunch Break
1:30 PM-The Efficacy of Ozone and Chemical Sanitization for Microbial Control
Nissan Cohen, Rohrback Cosasco Systems, Inc.
2:00 PM-Verifying Pharma UPW Excursions with an Automated TOC Sample Capture and
Validation Method
Terry Stange, Ph.D., and Chris Crone, Hach ULTRA; and Slava Libman, Ph.D.,
Balazs Air Liquide
2:30 PM-TOC Measurement Improvements for Pharmaceutical Water Treatment
Applications
Roger Schmid and Randy Turner, SWAN Analytical
3:00 PM-Improving WFI and CIP Process Control Using Dual Input Instrumentation
Chris Crone, ULTRA
Chemistry in Power Plants 2012 focused on European Power Plants
The power industry is an important market for chemicals suppliers. Nalco and some other suppliers participated in Chemistry in Power Plants 2012.
Event Start Date: 2012.10.24 Event Start Time: 9:00 a.m. Event End Date: 2012.10.25
This VGB annual Conference took place at the CCH-CONGRESS CENTER HAMBURG,
Germany.
The conference is a forum for operators of energy utilities and industrial power
plants.
The following major items were presented at the conference:
· Conditioning of water steam cycles and cooling water cycles
· Methods of water preparation and waste water treatment
· Chemical aspects of co-firing secondary fuels
· Chemical aspects of flue gas cleaning methods and CO2 separation
· Analytic and quality assurance
· Chemistry in nuclear power plants
The conference was accompanied by a Foyer Exhibition, the exhibitors were:
AGIR Dreherei & Filter, Plochingen, Germany
Aquis Wassertechnik GmbH i.G., Butzbach, Germany
Ashland Water Technologies, Krefeld, Germany
Berkefeld/VWS Deutschland GmbH, Celle, Germany
BK Giulini GmbH BKG Water Solutions, Düsseldorf, Germany
Centec GmbH, Maintal, Germany
Chemische Fabrik Wocklum Gebr. Hertin GmbH & Co. KG, Balve, Germany
Chemische Fabrik Wibarco GmbH, Ibbenbüren, Germany
CWB Wasserbehandlung GmbH, Berlin, Germany
Deutsche METROHM GmbH & Co. KG, Filderstadt, Germany
Dow Deutschland Anlagengesellschaft mbH, Schwalbach, Germany
ElringKlinger Kunststofftechnik GmbH, Bietigheim-Bissingen, Germany
Endress + Hauser Messtechnik GmbH & Co. KG, Weil am Rhein, Germany
EPSCO Ltd., Perth, Scotland
FINEX OY, Kotka, Finland
GBT Bücolit GmbH GmbH, Marl, Germany
Georg Fischer GmbH, Albershausen, Germany
Ing. Büro Gronowski, Berlin, Germany
Grünbeck Wasseraufbereitung GmbH, Höchstadt, Germany
HACH LANGE GmbH, Düsseldorf, Germany
Hager + Elsässer GmbH, Stuttgart, Germany
Hamm Chemie GmbH, Oberhausen, Germany
HAW LININGS GmbH, Bockenem, Germany
Gebr. Heyl Vertriebsgesellschaft für innovative Wasseraufbereitung mbH,
Hildesheim, Germany
Infracor GmbH, Marl, Germany
JNW CleaningSolutions GmbH, Bochum, Germany
Knick Elektronische Messgeräte GmbH & Co. KG, Berlin, Germany
Kurita Europe GmbH, Viersen, Germany
LANXESS Deutschland GmbH, Leverkusen, Germany
LECO Instrumente GmbH, Möchengladbach, Germany
Dr. Leye GmbH, Geringswalde, Germany
Mettler-Toledo GmbH Prozessanalytik, Gießen, Germany
MionTec GmbH, Leverkusen, Germany
Nalco Deutschland GmbH, Marl, Germany
ORBEN Wasseraufbereitung GmbH & Co. KG, Wiesbaden, Germany
OSMO Membrane Systems GmbH, Korntal-Münchingen, Germany
Pall Industrial, Saint Germain-en-Laye, Frankreich
PANalytical GmbH, Kassel, Germany
ProMinent Dosiertechnik GmbH, Heidelberg, Germany
Purolite (Deutschland) GmbH, Ratingen, Germany
r-concept - Dr. Bernhard Ruchti, Laupheim, Germany
ROKA GmbH, Butzbach, Germany
Swan Systems AG, Hinwill, Switzerland
Thermo Fisher Scientific, Idstein, Germany
DR. THIEDIG + CO, Berlin, Germany
Voigt GmbH, Wernau, Germany
WALTRON B.V., Panningen, The Netherlands
WAT-Membratec GmbH & Co. KG, Erkrath, Germany
H. Wösthoff Meßtechnik GmbH, Bochum, Germany
WP-ARO GmbH, Alzenau, Germany
The Electricity Chemistry Workshop will be in Champaign, IL on June 11-13, 2013
The Electricity Chemistry Workshop is now in its 33rd year. This comprehensive program features state-of-the-art information on controlling corrosion, improving operation efficiency, and meeting environmental challenges in fossil- and nuclear-fueled power plants. This year’s program is geared toward improved training and continuing education of personnel responsible for electric utility cycle and environmental chemistry.
More than 3,000 chemists, consultants, and power plant administrators have attended the workshop since its inception in 1981. The 2013 program has been developed by a committee of representatives from Midwestern Electric Utilities, the Illinois State Water Survey, the University of Illinois at Urbana Champaign and consultants serving the power industry.
Exhibitors include the following:
Advanced Sensors
Aquatech International Corporation
AVANTech, Inc.
Baker Hughes PMG
CHEMetrics, Inc.
Chemtrac, Inc.
Conco Systems Inc.
Day & Zimmermann
GE Power & Water
Graver Technologies
Hach
Illinois Water Technologies
Industrial Analytics Corp
LANXESS Sybron Chemicals Inc.
Layne Christensen
Martek Instruments, Inc.
Mettler-Toledo Thornton
Nalco Company
Ovivo Water
Plastocor, Inc.
Plymouth Tube Co.
Process Solutions, Carmel IN
Process Solutions, Inc., Campbell, CA
Sentry Equipment
Siemens Industry, Inc.
Solutions Inc
Swan Analytical USA
Thermo Fisher Scientific Water Analysis Instruments
Veolia Water Solutions & Technologies
Waltron L.L.C.
Waters Equipment
Wolcott Water Systems, Inc
There will be some valuable presentations on treatment chemicals. Here are some of the abstracts:
Troubleshooting an Ion
Exchange Unit Mixed Bed
Don Downey, Purolite
In the water treatment plant the Ion exchange mixed units can be your best
friend or worst enemy. Mixed bed can provide very high quality water, for days,
weeks or even months without regeneration. This means less hand on by operations
allowing more time for other task. Compared to normal demin trains that could
regenerate up to twice/day, operators do not retain the day to day routine of
regenerating a mixed bed can become unfamiliar with how to trouble shoot
problem. When a mixed bed unit does not work properly – it could take months or
even years to get it back into proper operation. This paper will discuss some of
the author’s +35 years of experience with trouble shoot and repairing various
mixed bed system in North America. It will cover cases involving resin problems,
mechanical failure inside the vessels and changes in feed water quality
Evaluating the Use
of Condensate Polishers: Economic and Operational Considerations
Colleen M. Layman, HDR Engineering Inc
Today’s power plant steam-water cycles are subjected to more strenuous chemistry
challenges than ever. Guidelines developed by EPRI, ASME, VGB and other
organizations recommend stricter control of condensate, feedwater, and boiler/HRSG
operating chemistry limits to prevent corrosion and deposition in the
steam/water cycle. The power delivery market requires many units, including some
that were not initially designed for such, to operate on a cycling basis and
often also necessitate quick startup times. Water management practices have
driven operators to cool the turbine exhaust steam with recycled water sources
or increase cycles of concentration in fresh water towers. Factors such as these
can make condensate polishers valuable tools in power generating facilities
today. However, condensate polishers can be costly to install. They incur
significant operating and maintenance costs, generate a wastewater stream which
must be treated and disposed of, and require trained staff to maintain. The
question of “to polish or not to polish” can be a complicated and difficult one.
This paper will provide an overview of condensate polishing technologies and
configurations, including the pros and cons associated with each technology and
configuration. It will also provide a risk-based cost-benefit analysis to assist
owners/operators in determining whether they should consider implementing
condensate polishing at a new or existing facility. The paper will address
situations in which each of the various types of polishers are best suited for
application and discuss basic criteria for proper polisher technology selection
and implementation at a power generating facility.
Manganese-Induced
Pitting of Stainless Steel Piping and Heat Exchanger Tubing
George J. Licina, Structural Integrity Associates
Many power plant heat exchangers and piping systems have experienced severe
degradation due to pitting beneath manganese-rich deposits. Such failures
occurred in heat exchangers tubed with copper based alloys and especially with
stainless steels. Such failures continue today. Plants that have been plagued
with this problem have generally been confounded by it. Often, the problem is
incorrectly diagnosed as microbiologically influenced corrosion (MIC), based
upon the morphology of the pits, however, the same tunneling pit morphology that
is often associated with MIC of stainless steel can be produced when manganese
rich deposits contact chlorinated water, whether bacteria are present or not.
As such, chlorination or increased chlorination to address a supposed MIC
problem will simply exacerbate situations where manganese-induced pitting by
producing an even more aggressive underdeposit environment. This paper will
provide an overview of manganese-induced pitting, discuss the operative
mechanisms, and provide recommendations for diagnosis and control.
Photosynthesis-Inhibiting Biocide Solves Algae Fouling Problems in Recirculating
Water Systems
Jeffrey Kramer, BWA Water Additives
Cooling tower systems offer the ideal conditions for microbiological fouling:
warm heat transfer surfaces, exposed to the open air, complete with sunlight.
Algae growth can accumulate on wet cooling system surfaces, particularly during
the prime cooling season, thereby impeding heat transfer, leading to increased
energy consumption. Algae growth can also cause cooling tower surfaces to be
slippery, creating a work safety hazard. Even in closed loop systems where
treated sanitary wastewaters and recirculating cooling water ponds are utilized
to remove and dissipate unwanted heat from heat exchangers and other plant
processes, it can be challenging to control algae. Many common industrial
biocides applied do not offer adequate protection against algae, which is
difficult to remove, particularly if low flow conditions exist in parts of the
distribution system. One specialty algaecide, terbuthylazine (TBZ), has been
particularly successful at resolving algae issues in power plant cooling towers
and holding ponds due to its ability to inhibit photosynthesis. This paper will
examine a field application of TBZ and the resulting impact on cooling system
operations.
Novel Biocide
Program Maintains Condenser Cleanliness for Power Plant
Chris Baron, Ashland Water Technologies
A zero liquid discharge power plant in New England had historically been
challenged with maintaining condenser cleanliness and maximum power production
as an apparent result of high iron and manganese in the cooling tower make-up.
Additionally, the cooling tower operated at 40 cycles of concentration,
exceeding saturation indices. Under these operating conditions, the plant had
been shutting down 2 to 3 times per year to clean the condenser with significant
lost efficiency in between and during cleaning cycles. Past treatment focused on
inorganic oversaturation of silica, iron, and calcium. Ashland sought to
understand the fouling mechanism through the use of the OnGuard™ 2-plus
analyzer, a proprietary monitoring and control system. This technology
accurately simulates the steady state conditions in plant heat exchangers while
revealing differentiation among various causes of fouling (e.g., sedimentation,
scaling, microbiological, etc.). This diagnostic tool was essential in
validating the response to the treatment program changes before they could
impact plant efficiency. As a result, it was discovered that fouling rates were
dependent on Oxidation-Reduction-Potential (ORP) and not mineral saturation.
Although traditional bio-assay slides suggested good bacterial control, the
OnGuard 2-plus analyzer results indicated that the fouling mechanism was
biological in nature. Based on this information, Ashland recommended a new
biocide, Biosperse™ XD3899 Microbiocide. The active, Bromide-Activated
Chloramine (BAC), performs at much lower ORP relative to traditional strong
oxidizers and not only stabilized, but effectively reversed the established
condenser fouling. This paper will present data correlating the optimization of
the BAC treatment program with a reduction in fouling. The plant is now setting
power generating records and shows no indications of condenser fouling after six
months.
Optimization and
Successful Chemical Cleaning of a Supercritical Boiler
Christopher Hegger, Ameren Missouri
Since changing boiler chemistries to oxygenated treatment in the mid-90's, the
once through supercritical boilers at Ameren's Sioux Energy Center have
struggled with obtaining adequate boiler chemical cleans. This paper describes
the procedural and equipment modifications made to the boiler chemical cleaning
process, which lead to a successful clean in 2012.
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Cooling Water Microbial Control Impacts Overall Plant Performance
INTERPHEX included a number of cleanroom displays INTERPHEX 2013, the large trade event and conference program dedicated to the pharmaceutical manufacturing industry, was held April 23 - 25, 2013 at the Javits Center in New York City. With over 12,000 industry professionals present, show attendees numbered at over 8,100, a 20 percent increase over last year’s show. Exhibitors included: AES Clean Bahnson, Christ Aqua Cleansesl Door Dycem Gemu Valve Hach HEPA Howorth Air Isolaton Systems Laminar Flow Lighthouse Lymtech Mettler Toledo Meissner Filtraton Nilfisk Palbam Class Particle Measuring Systems Steris Telstar TSI Uniclean Vaisala Walker Barrier
There were a number of papers of importance to the cleanroom industry. Here are abstracts of the two of them: Effective Cleaning Procedure for Medical Devices Using Laboratory Studies #400 Speaker: Elizabeth Rivera
Description:
· Review critical factors affecting the cleaning of medical devices
Design Aspects for a Bio Fill and Finish Facility #403 Speaker: Josef Trapl
Description:
Medtec U.K. was devoted to medical device manufacture and use The conference and exhibition held May 1 – 2, 2013 at the Olympia in London covered medical devices. Exhibitors of cleanroom products included: · Connect 2 Cleanrooms · Guardtech
World Cleanroom Space will Increase by 6 Million Square Feet This Year By 2014 there will be 131 million ft2 of cleanroom space in use across the world. This will be an increase of five percent over 2013. This is the latest forecast in Cleanrooms World Markets published by the McIlvaine Company. Cleanroom Space in Use (Million ft2)
This is net space in operation and reflects the retirements of older plants. The semiconductor industry generally builds new plants rather than renovating existing ones. This is due to contamination concerns. Asia has surpassed the other regions due to its dominance in flat panel displays, hard disk drives, storage, and photovoltaics. China, Taiwan and South Korea are leading investors in semiconductor chip plants. The semiconductor industry is the largest user of cleanrooms worldwide. The amount of cleanroom space is now at near record highs. Semiconductor sales for 2012 reached $291.6 billion, the industry’s third-highest yearly total ever, but a decrease of 2.7 percent from the record total of $299.5 billion set in 2011. Some segments are in decline but are offset by growth in others; facing competition from tablets, smart phones, solid state drives (SSD), and global hard disk drives (HDD). Market revenue in 2013 will decline more than 10 percent this year. Revenue is set to drop to $32 billion in 2013. The pharmaceutical industry continues to show steady growth. Much of the new growth is taking place outside the U.S. and Europe. The pharmaceutical industry in Russia has been witnessing a double-digit growth rate recently. According to the new regulations that will be enforced in Russia from 2014, it will be imperative for the pharmaceutical companies to pursue GMP-compliant production procedures. Over the last decade the solar industry has had the highest percentage growth. Photovoltaic Module shipments in 2013 are forecast to exceed 34,000 MW, up 10 percent over 2012. For more information on World Cleanroom Markets, click on: http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=73
Asian Ultrapure Water Sales to Exceed $3 Billion in 2015 In the rapidly growing Asian market, sales of ultrapure water systems and consumables will exceed $3 billion for the first time ever in 2015. This is the conclusion reached in the McIlvaine online report Ultrapure Water World Markets. Industry Totals ($ Thousands)
Asia is building more new coal-fired power plants than the rest of the world combined. The majority of these power plants are of the ultrasupercritical design. These power plants need the highest purity boiler feedwater. Contrary to public perception, the Chinese fleet is operating more efficiently than the U.S. counterpart. The reason being that most of the Chinese plants have been built since 2000. By contrast, the average coal-fired power plant in the U.S. is more than forty years old. Asia has been quick to embrace newer technologies such as electrodeionization (EDI) as a substitute for ion exchange. Asia is proceeding with come nuclear power plants. These power plants require the highest quality water. Combined cycle gas turbine plants also require high quality water but their needs per megawatt are less than half of that of a coal-fired power plant. Over 50 percent of the market is attributable to the electronics and flat panel segment. Asia has more electronics facilities using ultrapure water than the other continents combined. One of the bigger growth segments in China has been photovoltaic cells for the solar industry. These plants do require ultrapure water although not as pure as required for semiconductor manufacture. The one application where Asia does not dominate is pharmaceuticals. Water for injection (WFI) needs to be ultrapure because it is mixed with substances which are then injected into humans. The bulk of the manufacturing of pharmaceuticals is still in the U.S. and Europe.
Special instrumentation which can measure dissolved oxygen and other
constituents in parts per billion are required in ultrapure water systems.
There are a series of filtration steps ending in treatment by reverse
osmosis. Even after the water is ultrapure there is a concern about
re-contamination in pumps and piping. Consequently, in a semiconductor
plant, the water leaving the RO system passes through piping and then into
an end point membrane cartridge filter before being used to wash the wafer.
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Bob McIlvaine
President
847 784 0012 ext 112
rmcilvaine@mcilvainecompany.com
191 Waukegan Road Suite 208 | Northfield | IL 60093
Ph: 847-784-0012 | Fax; 847-784-0061
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