What is the importance of solar steams in the pharma industry?
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Abhishek Bhatewara
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The pharma industry produces multiple products in the form of tablets, capsules, ointments, liquids and powder. The manufacturing processes are energy intensive and the requirement of thermal and electrical energy varies depending on the product. The thermal energy requirement typically consists of low pressure steam (~ 5 bar, 150°C) and hot water (60 – 80°C). Some of the industries also require hot air at 60 – 80°C in large quantities. These temperature ranges are suitable for the integration of solar thermal systems in the process. Two typical processes in pharma industry that require heat in some form are sterilisation and granulation. Concentrated solar thermal (CST) technologies are the most relevant and most efficient renewable energy technologies for these as the solar energy is used to convert water into steam and hot air directly.
Sterilisation: All the equipment used for pharma processing as well as active pharmaceutical ingredients (APIs) need to be sterilised. Different types of sterilisers e.g. steam steriliser, dry heat steriliser, sterilising tunnel, Cleaning in Place (CIP) System , Sterilisation in Place System (SIP) use heat in different ways. Sterilisers can use either hot air or steam for sterilisation of the products (medicines). The hot air is used generally at 160°C at least for two hours. The sterilisers that use steam have pressure range up to two bar-121°C.
Granulation: Granulation is a size enlargement process which converts small particles into physically stronger and larger agglomerates. There are several types of granulation processes e.g. wet granulation, fluid bed granulation, spray drying granulation etc. The granulation process typically requires hot air at 60-70°C at very high flow rate up to 250 m³/hr.
Globally, what percentage of solar steam is used in the pharma industry?
CST industry is not very new in the country and globally. Hence, only a few research initiatives have been undertaken so far. As of now, there are no credible figures on the penetration of CST technologies in the pharma sector in India or worldwide. Yes, there is a study on the potentiality of the sector. A study conducted jointly by Ministry of New and Renewable Energy, GIZ and Federal Ministry for the Environment, Nature Conservation and Nuclear Safety, Germany identifies the pharma sector as one of the top 10 sectors in India in terms of potential of application of CST technologies.
Most of the thermal energy applications in pharma units require low-range temperatures which are easily achievable by solar energy applications. It has been observed that approximately 20 per cent of the total energy consumption in the units within the sector is due to heat load. Based on certain empirical analysis it was determined that five per cent of the heat load could be suitably replaced by solar energy applications. The potential is unquestionable.
Are there any laws in place for solar steam usage in the developed markets?
World over there are different regulations regarding the usage of renewable energy technology. The same exists in India as well. However, these regulations exist on using any form of renewable energy. In our view there is no clear mandate to use any particular technology.
What services do you offer to the Indian pharma companies and how cost effective are they?
We are in the domain of CST. This means that we heat water, convert water into steam/hot air by using solar energy directly. We are proud to have India’s only patented technology in the CST domain – ARUN. It is the only CST technology that has proven that temperatures upto 300° C /upto 20 bar pressure is reachable and yet remain commercially viable for an organisation.
It has been developed after research of almost a decade keeping the specific requirements of Indian industries in view. As compared to any other technology, ARUN scores high on all aspects of technology, efficiency, ease of implementation and integration, maintenance and payback.
What are the key features of Arun?
Footprint area: The ARUN solar thermal concentrator has a small footprint area of (3m x 3m per dish). This enables it to be mounted at locations which have space limitations. It can also be erected on rooftops of existing buildings.
Performance guarantee: Clique Solar guarantees the performance characteristics of ARUN concentrated solar thermal system, also known as a solar boiler dish.
High temperature and pressure delivery: ARUN can operate up to 300°C (oil) and 20 bar (steam).
Government subsidy: Ministry of New and Renewable Energy (MNRE) provides support by way of capital subsidy or soft loans for every ARUN solar boilers. Clique solar is the channel partner with MNRE.
Non-solar hours operations: ARUN solar thermal concentrator dish can be augmented with a heat energy storage facility for operation in non-solar hours.
IBR approval: ARUN concentrated solar thermal system is the first IBR approved solar boiler in India.
High wind bearing capacity: ARUN dish is designed to operate in wind speeds of up to 10 m/s and it can survive in wind speeds of up to 47 m/s.
High net energy gain: The net energy gain (i.e. energy gained from energy source – energy expended in harvesting the energy source) of ARUN solar thermal concentrator dish is amongst the highest in solar for industrial process heat (IPH) manufacturing industry.
Clique Solar is specialised in areas of sterilisation and granulation through solar hot air. Could you explain the importance of having a presence in these niche areas?
We provide steam to industrial processes. The segment where heat is required to complement processes of production is called IPH. Our niche is in providing IPH though solar energy, thus saving cost for companies in the short term and insulating them to the impact of rising fuel costs in the long run, as well as helping them strengthen their green initiatives. Thus, in any industry where processes require heat, ARUN technology finds potential application. Hence, the specialisation is not in sterilisation or granulation, but in providing heat required in industry processes through solar energy. Processes in pharma industry like granulation and sterilisation use hot water / hot air / steam which can easily be provided by using solar energy. The importance of being present in this segment can be understood well if we consider the energy usage in IPH processes that is generated using expensive fuels. IPH applications below 250°C contribute to about 15 to 20 per cent of India’s total oil consumption (almost 80 to 90 per cent of which is imported). If we convert this amount into foreign exchange spent in buying this fuel, it comes to $8 billion. Hence, the industry has a lot of potential for the performing technologies.
Cooling and air conditioning is another energy intensive process amongst the various energy consuming applications where CST has an application. We already have two projects installed and working in this segment.
How cost effective and environment-friendly are these solutions?
We can talk about ARUN technology as we can take ownership of the claims made for it. The proposition becomes quite attractive for a company if liquid or gaseous fuels are being used. This is because payback period for such installation range between two and half years to five years (depending on the location, usage, kind of fuel used. Once the payback is achieved, a company receives almost-free fuel (minimal maintenance charges applicable) for the rest of the dish life. Contrast this with the rising fuel costs and you have your answer. As far as reduction in CO2 emission is concerned, ARUN 160 saves 60-70 tonnes annually.
Who are your main clients in India?
Our clients include NETRA (NTPC facility) – Greater Noida, Swaminarayan Akshardham –Delhi, Mahindra – Pune, RKM Students Home – Chennai, Chitale Dairy – Delhi, TEL – Chennai, ITC Maurya Hotel – Delhi, Mahananda Dairy – Latur, and CMC Vellore.
What regulatory approvals do you have for the pharma products?
Since, we are the channel partners with MNRE, it means that not only we are authorised as commercially proven, we can also take off the burden of subsidy from our clients’ books. We can claim the government subsidy directly once the ARUN system is installed and performing. The only other regulatory approval we need is on the boiler part of ARUN system.
What marketing strategies have you planned to encourage Indian pharma companies to opt for solar sterilisation and granulation system?
The biggest hurdle in the adoption of solar thermal technologies is awareness and confidence amongst adopters (clients and technical consultants to the industry). This is compounded by financing challenges as banks across the country are still evaluating the risks to fund projects in this area. We have a two-pronged approach in reaching out to potential clients. We are building a network of experts / consultants across cities who engage with the pharma companies and working with the MNRE to spread word through conferences, workshops and other awareness generating exercises. We are also using social media in a great way. Our website is regularly updated and we receive a lot of queries through it.
In the past we have used Google Hangout to conduct online conferences. With support from the MNRE and the United Nations Development Programme (UNDP) we organised the first ever online CST conference on World Environment Day last year (2013).
The Government has also undertaken the MNRE – UNDP programme to spread awareness about the industry by asking for proposals for demonstration and replication projects. The Government will provide additional subsidy for these projects and make these reference projects for the industry. Solar energy policies of the Indian states are also helping immensely in raising awareness and promoting adoption of solar energy technologies that are commercially viable.
How are you stepping into pharma sector?
We are yet to get a pharma client. Talks are on and we expect to convert a few very soon. Factors that have worked for us tremendously until now with other segments are – performance guarantee, efficiency and space benefit. Also, the type of fuel being used directly affects the motivation to adopt solar energy technology, if cost is a consideration. If the fuel being used to generate heat is LPG, furnace oil, diesel or PNG, it makes for a highly favourable case for the adoption of a solar thermal technology. On top of that, companies get MNRE subsidy and tax benefit provision in wake of 80 per cent accelerated depreciation.
Will the pharma industry adopt renewable energy in near future?
If seen in the right context – ‘not installing a concentrated solar thermal system’ only proves to be costlier. It has two parts to it.
Firstly, the alternate fuel we use is furnace oil, which was our main fuel or only fuel prior to installing solar thermal systems. Spending on furnace oil is also costly, which is increasing at a good rate. Full or a part of this cost can definitely be reduced if a renewable technology is used. The more you delay it the more you are paying for furnace oil or LPG. Remember cost of LPG is not recoverable. While cost incurred in renewable energy technologies is recoverable.
Secondly, the CST technology is an idea whose time has come. So, the more a company delays it, cost of not-installing the CST system is also increasing.
All the extra money spent on diesel or LPG is the cost that a company could have saved had it installed the CST system earlier. And, whenever you install a CST system, it is more or less going to cost you the same.