Case stories

Air purification on demand

Emission Reduction System, ERS, is the name of a couple of towering units which eliminate organic solvents, resulting in the emission of purified air from the production.

The two units work in shifts so that one of them is in operation while the other regenerates. The solvents are absorbed by a granulate somewhat similar to cat litter, and when the granulate has been saturated, it is cleaned by means of vapour. Previously, shifting between the units was determined on a time-basis.

“But by using a concentration gauge, we have found out that the concentration of solvents
varies, and now, it is the concentration gauge that decides when the shift between the units is made,” says Martin Petersen, Automatics Technician.

“The shift between units is made automatically and sometimes they can run for longer than the six hours that was previously the operation time. In some situations, they run for almost 12 hours, before a shift is required. This results in less cleaning and we save oil for the steam. At the same time, the amount of process waste is reduced,” says Kenneth Dalum, Head of Section.

Certification without tears

‘Was that really all?’ was a typical reaction when a sigh of relief was heard after the audit inspection. Many sectors at Valby have now completed the much awaited certification of the Lundbeck HS&E system, and the prevalent opinion is that it was not as tough as expected.

“Many people felt nervous beforehand – it is a kind of exam. But our colleagues also saw being asked about procedures and instructions as a challenge,” says HS&E representative Peter Ellegaard of Chemical & Pharmaceutical Research.

Research is one of the sectors where many people have had reservations about the new rules implemented by the HS&E system.

“Researchers are naturally sceptical of rules and the typical attitude was that ‘this is out of place in research’. They have subsequently realised that there was nothing to be afraid of, and some of the most inveterate sceptics have actually turned out to be some of the greatest enthusiasts about the HS&E system. But great efforts have also been made to explain why we need the system and the certification and what is in it for Lundbeck,” says Divisional Director Ejner K. Moltzen, Medicinal Chemistry.

The benefits that Lundbeck reaps from implementing the HS&E system are first and foremost joint, coordinated HS&E initiatives.

“Moreover, we obtain a ‘discount’ from the authorities as we are exempted from a number of inspections. The certificate may also have a positive impact on Lundbeck’s image as a responsible company that is conscious about the environment and working environment,” says Section Leader Anja Asgaard, Corp. HS&E, who has assisted in preparing managers and employees for the meeting with the external auditors from Bureau Veritas Certification.

Dorthe Belling, who was recently elected HS&E representative of Medicinal Chemistry, only had six months to prepare for the certification. “It was turbo learning. I began with the safety instruction, which I knew had to be updated, and then I went on with the other parts of the system. It was a great way to get accustomed to everything, and it was good to see that everything was under control,” says Dorthe.

In 2008, the rest of Valby will become certified and then we move on to Lundbeck Research in the USA.

Successful Seveso audit

Following the 1976 toxic gas disaster in the Italian municipality of Seveso, in 1982 the EU
Commission issued a directive on the risks of accidents involved in chemical manufacturing, commonly known as the ‘Seveso Directive’.

In Italy, the law is enforced by the Regional Environmental Protection Agency, which performed an audit of Lundbeck Padova in early 2007. The audit included safety studies about a production step (HAZOP, thermodynamic studies, top events assessment, etc.); the shut-off procedure for main equipment during an emergency situation; an emergency drill involving the filter drier and general site evacuation; main equipment design and validation, periodical and compulsory tests, periodical maintenance, etc.

“I took part in the emergency drill involving the filter drier,” explains Fabrizio Borin, Production Manager. The filter drier is based on an innovative concept which aims to reduce the handling of materials and reduce the operator’s exposure to the product. In fact the filter drier combines the substance separation, normally made by centrifuges, and the subsequent drying activities performed by means of driers. This kind of equipment has a high level of automation implemented to ensure a high level of quality and safe and environmentally friendly handling.

“When we decided to start the drill with this equipment, we knew that it would be a difficult task considering the complexity of the plant, but we wanted to demonstrate to the authorities that we are a technologically advanced company.”

Impressed
At first the authorities were a little bit disoriented.

“Not many companies are so technologically advanced as Lundbeck is. So we started off illustrating how the equipment worked. The auditors asked a lot of questions, not only related to the audit, but also simply out of curiosity. That broke the air of formality, and we talked as one technician to the other.”

As the emergency drill started, everything went exactly as explained: The operator in the control room started the shutdown, the engines stopped, the valves and steam closed, and the cooling started immediately.

“Our in-house emergency teams started the simulation of fire prevention with a water wall, and once again the authorities were impressed with the efficiency and the way we manage complex situations.”

“The auditors had no remarks and even suggested that they bring their inspectors to
Lundbeck for training. The inspection evolved into an event which recognised the job we do, and it gave us a lot of incentive to continue our efforts.”

Filter hoist reduces back strain

During one of the processes a filter absorbs water from the THF solvent that is later reused. When the filters cannot absorb any more water they must be changed.

“We change the filters approximately five times a week. The filter works through small balls of clay (molecular sieve) which absorb the water and are held in socks. To change the filters you need to replace the filter sock, which can be rather heavy. The filter tank is quite high, and you have to lift out the socks and displace them into a container,” Shift Production Team Leader Kenneth Humphries explains.

The employees who work in that part of the plant were asked to come up with ideas for improving the process. One was selected, and, although quite simple, it seems to be a success.

“We put a lifting beam directly above the filter tanks with a pulley hoist and a double hook
on the end which hooks inside the sock neck. To operate it you just wind it up with a simplified winding mechanism. We have two hoists that lift out four individual socks, and it may take a little longer, but it has reduced a lot of back strain and is more ergonomic.”

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