1

GLOCHEM INDUSTRIES PRIVATE LIMITED

A MINOR PROJECT

Submitted in partial fulfilment of the

Requirements for the award of the Degree of

BACHELOR OF TECHNOLOGY

In

CHEMICAL ENGINEERING

By

PEROLLA SAI SHRUTHI (20011A0833) PODILA PAVAN KUMAR (20011A0834)

KUNTALA SANJANA (20011A0823) INJETI SUMAHITHA (20011A0815)

under the esteemed guidance of

EXTERNAL GUIDE INTERNAL GUIDE

Mr. KRISHNA ELASAGARAM Dr. T. BALA NARSAIAH Ph.D. (O.U)

VICE PRESIENT-OPERATIONS PROFESSOR HEAD OF THE DEPARTMENT

GLOCHEM INDUSTRIES PRIVATE DEPARTMENT OF CHEMICAL ENGINEERING

LIMITED, IDA BOLLARAM JNTUHUCESTH

DEPARTMENT OF CHEMICAL ENGINEERING

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

UNIVERSITY COLLEGE OF ENGINEERING SCIENCE AND TECHNOLOGY

(AUTONOMOUS) HYDERABAD, TELANGANA 500085
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A REPORT ON

AWARENESS ON PHARMA INDUSTRIES

By

PEROLLA SAI SHRUTH (20011A0833) PODILA PAVAN KUMAR (20011A0834)

KUNTALA SANJANA (20011A0823) INJETI SUMAHITHA (20011A0815)

At

GLOCHEM INDUSTRIES PRIVATE LIMITED

IDA BOLLARAM

EXTERNAL GUIDE INTERNAL GUIDE

Mr. KRISHNA ELASAGARAM Dr. T. BALA NARSAIAH Ph.D. (O.U)

VICE PRESIENT- OPERATIONS PROFESSOR, HEAD OF THE DEPARTMENT

GLOCHEM INDUSTRIES PRIVATE DEPARTMENT OF CHEMICAL ENGINEERING
LIMITED, IDA BOLLARAM JNTUHUCESTH

DEPARTMENT OF CHEMICAL ENGINEERING

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

UNIVERSITY COLLEGE OF ENGINEERING SCIENCE AND TECHNOLOGY

(AUTONOMOUS) HYDERABAD, TELANGANA 500085
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ACKNOWLEDGEMENT

We express our sincere gratitude to the prestigious institution JNTUHUCESTH

for providing the required facilities to carry out the present work.

We express our gratitude to GLOCHEM INDUSTRIES PRIVATE LIMITED

IDA BOLLARAM for giving us the opportunity to complete Minor Project

Training. We are deeply thankful to all those who, with their good grace, given

us their valuable time and energy to express the rightful experience about the

instrumental terms, conditions and procedures.

Particularly we want to acknowledge the helpful, supportive, and creative

contribution of Mr. KRISHNA ELASAGARAM Sir GLOCHEM
INDUSTRIES PRIVATE LIMITED.

We owe a special thanks to our training co-ordinator Mr. HEMANTH

MSRDA Sir for providing great ambiance.

We are grateful to Dr. T. Bala Narsaiah Sir (Professor and Head of the
Department) for his unparalleled guidance. We are sincerely thankful to his for
his suggestions.

PEROLLA SAI SHRUTHI

PODILA PAVAN KUMAR

KUNTALA SANJANA

INJETI SUMAHITHA
Mr. HEMANTH MSRDA
26/05/2023
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DECLARATION

I hereby declare that the mini project report entitled “AWARENESS ON

PHARMA INDUSTRIES-GPIL” is carried out by us during the year 2023-

2024 in partial fulfilment of the requirements for the Degree of BACHELOR

OF TECHNOLOGY with specialization in CHEMICAL ENGINEERING

from Jawaharlal Nehru Technological University Hyderabad, University

College of Engineering Science and Technology, under the guidance of Dr. T.

Bala Narsaiah, Professor and Head of the Department, Department of Chemical

Engineering, JNTUHUCEH. We have not submitted the same to any other

University / Institute for the award of any degree or diploma.

Mr. HEMANTH MSRDA

26/05/2023
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ABSRACT:

The project starts by discussing the concepts of various

departments in the industry (that is unit operations, plant process flow, utilities,
solvent recovery systems, effluent treatment plant), basic concepts of reactors,
filtration, distillation, extraction, dryers, size reduction etc.
• The concepts of effluent treatment plant (zero liquid discharge plant) and
solvent recovery system gives us an awareness of chemical engineer in
pharma industries.
• Basically, a Pharma Industry consists of two units 1) Active Pharmaceutical
unit (API) and 2) Contract Research Organization (CRO).
• Glochem Industries Private Limited is of Active Pharmaceutical unit (API).
• In API unit For Product Manufacturing initially charging of Raw Material
takes place in a Reactor then Adjustment of pH is done which is followed
by Separation of Immiscible liquids, Distillation, Bi-Product Filtration,
Centrifuge, Drying, Shifting, Milling, Product Complete Analysis, packing
Material.

KEY WORDS:

Reactor, Condenser, Re-Boiler, Filtration, Utilities, Dryers,

Distillation Column, Multiple Effect Evaporator, Stripper, Agitated Thin
Film Dryer, Reverse Osmosis, Ultra Filtration……etc
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CONTENTS PAGE NO.

1) INTRODUCTION 07
2) PLANT PROCESS FLOW 07-08
3) REACTOR 09
3.1) STAINLESS STEEL REACTOR 10
3.2) GLASS LINED REACTOR 11
4) FILTRATION 12
4.1) CENTRIFUGE 12
4.2) LEAF FILTER 13
4.3) SPARKLER FILTER 13
4.4) NUTSCHE FILTER 13-14
5) DRYER 14
5.1) TRAY DRYER 14-15
5.2) ROTA CONE VACCUM DRYER 15-16
6) SIZE REDUCTION 16
6.1) MICRONIZER 16-17
6.2) SIFTER/SIEVING 17
6.3) MULTI MILLER 17-18
7) CRYSTALIZATION 18
8) DISTILLATION COLUMN 18-20
9) EXTRACTION 21
10) UTILITIES 21-22
10.1) BOILER 22
10.2) COOLING TOWER 22-23
10.3) CHILLER/RERIGERATION 23-24
11) ZERO LIQUID DISCHARGE 24-27
11.1) PRIMARY TREATMENT
11.2) STRIPPING
11.3) MUTIPLE EFFECT EVAPORATORS (MEE)
11.4) AGITATED TIN FILIM DRYER (ATFD)
11.5) BIOLOGICAL TREATMENT
11.6) ULTRA FILTRATION
11.7) REVERSE OSMOSIS
12) CONCLUSION 28
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INTRODUCTION:

This document contains brief theory about the various unit Operations or
processes and equipment’s being used in the API development. Process
engineer shall go through this document during the product development in the
lab. It also provides the selection criteria of various unit operations/processes
like, reaction, filtration, drying, size reduction etc. during the API development.

PLANT PROCES FLOW:

Ware House:
• Receiving Raw Materials and Packing Materials from Approved Vendor.
• Dispensing of Raw Material.
• Receiving of Finished Goods and Dispatching to Customer.
• Sending Raw Materials, Packing Materials, and Finished Goods to
Quality Control for Analysis.
• Storage of Raw Materials, Packing Materials, and Finished Goods for
Quarantine (Approved/Rejected).
• Issuance of Raw Materials and Packing Materials for Production on
Requirement.
Production:
• Receiving of Raw Materials and Packing Materials as per Requirement
from Ware House.
• Batch Manufacturing Process.
• Recording of Batch Manufacturing Data/Record.
• Cleaning of Equipment’s.
• Recovery of Solvents.
• Sending inprocess and Intermediate Sample for Analysis to Quality
Control.
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Quality Control:
• Sampling of Raw Materials, Packing Materials, Finished Goods and
Solvents (Fresh/Recovery).
• Analysis of Raw Materials, Packing Materials, Finished Goods and
Solvents. (Fresh/Recovery)
• Analysis of inprocess or Intermediate.
• Analytical Data Record.
Quality Assurance:
• Control of Documents from All the Departments.
• Issuance and Retrieval of Documents.
• Archiving the Documents.
• Assurance of Document and Quality.
Research and Development:
• Design of Lab Scale Experiment (new molecules).
• Yield and Analytical Data Providing for new Molecules Developed.
Engineering and Projects:
• Maintenance and Preventive Maintenance of Equipment’s and Utilities.
• Qualifications for Equipment’s and Utility System.
Environment, Health, and Safety (EHS):
• Ensuring the Safety of Personnel Environment and Product.
• Maintaining the Safe Working Environment.
• Effluent Treatment Process (ZLD).
• Performing Fire Drills, Mock Drills, and EHS Trainings.
Human Resource and Administration:
• Recruiting of candidates Based on Requirement.
• Maintaining of Food and Transport for Employee and any other
Administrative Related Activities.
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REACTOR:
• A typical batch reactor consists of a Motor Followed by Gear Box,
Shaft, Shell, Agitator, Jacket, and integral heating/cooling system. These
vessels may vary in size from less than 1 litre to more than 15,000 litres.
• Motor Capacity, Gear Box Ratio, Type of Agitator, Design Temperature
and Pressure need to be Fixed.
• They are usually fabricated in steel, stainless steel, steel with glass lined
hast alloy.
• Reactor design involves all the basic principles of chemical engineering
with the addition of chemical kinetics.
• Mass transfer, heat transfer and fluid flow are all concerned and
complications arise when, as so often is the case, interaction occurs
between these transfer processes and the reaction itself.

• Reactors are of two types used in Pharma Industry Based on the Type of
Reactions:

They are 1) Stainless Steel Reactor 2) Glass Lined Reactor

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Stainless Steel Reactor:

• A typical batch reactor consists of a tank with an agitator and integral

heating/cooling system. These vessels may vary in size from less than 1
litre to more than 15,000 litres.
• They are usually fabricated in stainless steel (SS-316, SS-304, SS-316L)
• It is used for basic medium reactions. The main advantage of stainless-
steel reactor is that it has a low instrumental cost and a very flexible use
as it can be stopped fast and easily.
• Overall Heat Transfer Coefficient is more for Stainless Steel Reactor.

• Anchor Agitator is used for radial mixing of solvent and solute. It is coated
with a jacket for no heat loss.
• Baffles and placed inside the reactor to avoid vortex. For safety measures
reactors are fitted with safety relieve valve and rupture disc.
• Propeller Agitator is used for Axial Mixing of Solvent and solute.
• Turbine Agitator is used for both Axial and Radial Mixing .
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Glass-Lined Reactor:
• Glass-lined steel process equipment is used in virtually all the
world’s pharmaceutical manufacturing facilities and is also widely
employed by the chemical, petrochemical, pesticide,
metallurgical and food industries.
• There are several advantages in the unique characteristics of glass lining
that make this material of construction a top selection of design
engineers.
• It is used for acidic medium reactions. It is corrosion resistance, easy to
clean and has many more advantages.
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FILTRATION:

• Filtration is any type of various mechanical, physical or biological

operations that separate solids from fluids (liquids or gases) by adding a
medium through which only the fluid can pass.
• The fluid that passes through is called the filtrate.

Following are the filters commonly used for filtration of pharmaceutical

intermediates and finished APIs.
1) Centrifuge 2) Leaf Filter
3) Sparkler Filter 4) Nutsche Filter

Centrifuge:
• A centrifuge is a device that uses centrifugal force to subject a specimen
to a specified constant force, for example to separate various components
of a fluid.
• This is achieved by spinning the fluid at high speed within a container,
thereby separating fluids of different densities or liquids from solids.
• It uses a perforated basket rotating on a vertical axis to produce a
centrifugal force on the slurry that is fed to the basket through the feed
pipe.
• The perforated basket is lined with a filter bag of desired pore size. This
filter bag retains the solid particles as wet cake, while the filtrate passes
through the filter medium.
• The filtrate flows out of the basket through the perforations and gets
collected outside through the outlet valve.
• Cake washes can then be performed through similar steps by feeding the
wash solvent to the basket.
• If the Solvent Medium or the Product is in acidic nature ,Centrifuges with
halar lining are to be used.
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Leaf Filter:
• Leaf filters work by feeding a liquid (dirty influent) into a pressure vessel
under pressure.
• The liquid passes through filter leaves leaving behind the solids in the
form of a cake.
• The filtered liquid (filtrate, or clean effluent) exits the filter through the
manifold connecting all the filter leaves.
• Leaf Filter is a Horizontal type filter which discharges the cake as dried
solid.
• The Main Principle Involved in Leaf Filter is Surface Filtration.
Sparkler Filter:
• A sparkler type filter is a type of filter that uses a filtering medium such
as activated carbon to remove impurities from a liquid or gas.
• The filter is constructed of a cylindrical vessel that contains a series of
horizontal filter plates with vertical frames called sparklers.
• The filter medium is placed on the plates, and the liquid or gas to be
filtered is passed through the medium, removing any impurities present in
the fluid.
• The principle of sparkler filter operation is based on the principle of
gravity filtration.
• The liquid to be filtered is fed into the filter, and it flows through the
filtering medium under gravity.
• The impurities present in the fluid are trapped by the medium, and the
filtered liquid is collected in a container below the filter.
Nutsche Filter:
• Nutsche filters can effectively perform the separation of solid matter from
a liquid under pressure or vacuum, in a closed system.
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• The ability to isolate the product not only reduces product handling but
also minimizes operator exposure and serves as environmental protection
against solvent vaporization.
• The entire vessel can be kept at desired temperature by using a limpet
jacket, jacketed bottom dish & stirrer (blade & shaft) through which heat
transfer media can flow.
• The vessel can be made completely leak proof for vacuum or pressure
service.

DRYER:
Drying is a mass transfer process consisting of the removal of water or

another solvent by evaporation from a solid, semi-solid or liquid. This process is

often used as a final production step before selling or packaging products.

Common dryers used in pharmaceutical industry are:

1) Tray dryers 2) Rotary cone vacuum dryers (RCVD)

Tray dryers:

• A tray dryer in the pharmaceutical industry is used to dry powders,

granules, and other types of materials.

• It consists of a heated chamber with trays to place materials. The

trays are usually stacked one on top of each other, and the drying
process is usually done under controlled temperature and humidity
conditions.

• The principle of a tray dryer is based on the process of convection

drying.
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• Convection drying involves the use of hot air to remove moisture

from the material being dried.

• The hot air is circulated throughout the drying chamber, and as it

passes over the trays, it removes moisture from the materials on the
trays.

• The temperature and humidity inside the chamber are controlled to

ensure that the materials are dried at the appropriate rate.

Rotary cone vacuum dryers (RCVD):

• RCVD consists of a rotating vessel in the shape of a double-cone

supported by two stationary trunnions.
• The vessel is surrounded by a heated jacket and a small vacuum line is
installed within one of the trunnions and extends into the vessel (angled
in the upward direction).
• The dryer can also be equipped with a depluming bar that extends into the
vessel from one of the trunnions.
• The double-cone drying chamber rotates about the axis of the trunnions,
causing the material to cascade inside.
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• Through gentle tumbling and folding, the material is contacted with the
heated wall to facilitate drying without a significant amount of shear
being imparted to the material.

SIZE REDUCTION:

Within pharmaceutical manufacturing, size reduction is one of the most

extensively used and vital unit operations. Size reduction is a process of

reducing large solid unit masses into small unit masses, coarse particles, or fine

particles. Size reduction process is also termed as Comminution or Diminution.

Types of size reduction equipment’s are:

1) Micronizer 2) Sifter/Sieving 3) Multi Miller

Micronizer:

It is a Disintegrator, in which feed particles are entrained in a pressure jet (steam

or air) and whirled through a cylindrical chamber with sufficient force to break

them.
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Sifter/Sieving:
• Sifter or screener is an essential part of every pharmaceutical production
process, particularly as product quality and integrity are so important.
• The use of a sieve gets rid of oversized contamination to ensure that
ingredients and finished products are quality assured during production
and before use or despatch.

Multi Miller:

• Multi Mill is designed to utilize the principle of variable force swing

beaters having both knife and impact edges rotating within a selected
screen to control the particle reduction.
• Material fed in to the processing chamber moves to the periphery and
passes through the screen radially and tangentially.
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• The principle involves variable force, rotating blades having both

knife and sharp edges with validated screen size to reduce particles
in a controlled manner.

CRYSTALIZATION:

• Crystallization operation is performed to isolate the product as solid.

• It can be used for different objectives as purify by leaving impurities in
the liquid phase (re-crystallization) and create particles of correct form
(polymorphs creation) and desired physical properties.
• The driving force for crystallization is the Supersaturation of the solution.
• Supersaturation is the fundamental driving force for crystallization. There
are four main methods to generate supersaturation, and hence four types
of crystallization associated accordingly:

1. By Temperature change - Cooling crystallization

2. By Evaporation of solvent - Evaporative crystallization
3. By Chemical reaction - Reactive crystallization
4. By changing the solvent composition - Anti solvent crystallization

DISTILLATION COLUMN:

• Distillation is a chemical process where a mixture made of two or

more liquids (called "components") with different boiling points can be
separated from each other.
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• The Mass Transfer Operation involved in Distillation Process is

Separation.
• The mixture is heated until one of the components boils (turns to
a vapour). The vapour is then fed into a condenser, which cools the
vapour and changes it back into a liquid that is called distillate.
• What remains in the original container is called the "residue".
A fractionating column (that is a distillation column with more than two
outlets) can be used to improve the separation.

Types of Distillation:
1)Atmospheric Distillation 2) Vacuum/ High Vacuum Distillation

3) Fractional Distillation

Atmospheric distillation:
• Check the solvent boiling point and thermal stability of product Ensure
distillation equipment should contain thermometer to check the
temperature of reaction mass and vapour.

• Use the silicon oil for distillation temperature above 150.0°C.

• The volume of reaction mass or solvent to be distilled should not be more

than 50.0% of the capacity of equipment.

• Heat the reaction mass slowly by controlling the distillation rate and to
avoid reaction mass/ solvent blow-out.

Vacuum distillation:
• Establish the optimum vacuum range for distillation to get maximum
recovery.

• Ensure the receiver should have 50.0% free space on vacuum distillation.
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• Avoid the vapour loss providing vacuum trap between receiver and
vacuum pump.

• Ensure the vacuum trap chilled properly.

• Apply the vacuum before heating the reaction mass.

• Heat the reaction mass slowly by controlling the distillation rate and to
avoid reaction mass/ solvent blow-out.

• Break the vacuum slowly by applying nitrogen only

Fractional distillation:
• Check the solvent boiling point and thermal stability of product.
• Select the column size based on difference in solvent boiling point and to
attain the desired quality.
• Ensure the receiver should have 25.0% free space and chilled properly by
keeping in ice bath.
• Heat the reaction mass slowly by controlling the distillation rate and to
avoid reaction mass/ solvent blow-out.
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Solvent Recovery System:

A solvent recovery system is a process system that takes effluent and extracts
useful raw materials back out of the process waste stream. They can reduce the
demand for raw materials, by recovering chemicals that can be reused in
production, or used to flush the system between runs. The solvent input is 70%-
75%. It consists of

• Kettle Reboiler
• Distillation Column
• Condenser
• Decanter
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EXTRACTION:
• The objective of extraction is to bring the product from aqueous phase to
organic phase for further reactions.
• It can be used to remove organic impurities or remove inorganic salts or
to quench the reaction mass generally referred as Washing.
• In principle washing and extraction is same, where one substance moves
from one phase to another phase.
• Generally, the reaction mixture is organic and the added liquid is water or
an aqueous salt solution but the reverse is also possible.

Definition:
Liquid extraction is a mass transfer operation in which a liquid solution (the

feed-F) is contacted with an immiscible or nearly immiscible liquid (solvent-S)

that exhibits preferential affinity or selectivity towards one or more of the

components in the feed.

UTILITIES:

Basically, Pharma Industry uses three types of Utilities They are:

1)Boiler for the Generation of steam Utility.

2)Cooling Tower for the Generation of Room Temperature Water (RTC)Utility.

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3)Chiller for the Generation of brine Utility.

Boiler:

• A boiler is defined as a closed vessel which is used to heat liquid usually

water or to generate vapour or steam or any of such combination under
pressure for external use by combustion of fossil fuels.
• Hot gases are produced by burning fuel in the furnace. These hot gases
are made to come in contact with the water vessel where the heat transfer
takes place between the water and the steam.
• Therefore, the basic principle of the boiler is to convert water into steam
by using heat energy.

Cooling Tower:

• A cooling tower is a heat rejection device that rejects waste heat to

the atmosphere through the cooling of a water stream to a lower
temperature.
• Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of closed circuit dry cooling towers, rely
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solely on air to cool the working fluid to near the dry-bulb air
temperature.
• Common applications include cooling the circulating water used in oil
refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings.
• The classification is based on the type of air induction into the tower: the
main types of cooling towers are natural draft, Forced Draft and induced
draft cooling towers.

Chiller:

• A chiller is a machine that removes heat from a liquid via a vapor-

compression or absorption refrigeration cycle.

• This liquid can then be circulated through a heat exchanger to cool

equipment, or another process stream (such as air or process water).
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• As a necessary by product, refrigeration creates waste heat that must be

exhausted to ambience, or for greater efficiency, recovered for heating
purposes.

• Chilled water is used to cool and dehumidify air in mid- to large-size

commercial, industrial, and institutional facilities.

• Water chillers can be water-cooled, air-cooled, or evaporatively cooled.

• Water-cooled systems can provide efficiency and environmental

impact advantages over air-cooled systems.

ZERO LIQUID DISCHARGE:

• Zero liquid discharge (ZLD) is an engineering approach to Effluent

treatment where all water is recovered and contaminants are reduced to
solid waste.
• While many Effluent treatment processes attempt to maximize the
recovery of freshwater and minimize waste, ZLD is the most demanding
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target because the cost and challenges of recovery increase as the

wastewater gets more concentrated.
• Salinity, scaling compounds, and organics all increase in concentration,
which add costs associated with managing these increases. ZLD is
achieved by stringing together Effluent treatment technology that can
treat wastewater as the contaminants are concentrated.
• Basically, ZLD has 5 Steps: 1) Primary Treatment 2) Stripper
3) MEE 4) ATFD 5) Biological Treatment 6) Ultra Filtration
7) Reverse Osmosis
• Initially in Primary Treatment Coagulation and Flocculation takes place
then it is sent to Clarifier for the HTDS Water and LTDS Water.

• The HTDS is Sent to the Stripper in which Separation of Solvents and

HTDS takes place then through the Condensate the Solvent get
Separated. The Main Principle Involved in Stripper is Absorption.

• The HTDS from the Stripper is sent into the MEE Vapour Separator-1to
which Heat inlet is given for the Vapour Separator-1 then From Vapour
Separator-1 then it is Transferred to Vapour Separator-2, Followed by
Vapour Separator-3 then finally Sludge is Removed From the last
Separator.

• The main Principle involved in MEE is Evaporation.

• In ATFD the Dry Solids from the Concentrations Liquids are Removed.

• The main operation involved in ATFD is Heat Transfer Operation.

• Then ATFD condensate and MEE Condensate is send to the Blending

Tank.

• From Blending Tank, the LTDS water is Sent to the Biological Treatment
then Followed by Ultra Filtration and then by Reverse Osmosis.
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Conclusion:

We conclude as a Part of our Minor Project an Awareness on Various Chemical

Engineering Equipment’s Used in Pharmaceutical industries has led to Improve
our Skills and Knowledge.
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