PhEn-602

Pharmaceutical Facility Design

J. Manfredi Notes #11

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J. Manfredi

Location
Outside air Return air Mixed air

Airflow ( cfm ) 800 3000 3800 3800 3800 3800 500

Temp Moisture ( F ) ( gr/lb ) 91 70 66 86 86 60 70 147 11 20 4 4 4 11

10% rh Room Typical Schematic

Supply air Exhaust air

A B C D E F G

Notes: 1. In this example, no heat gain across the supply fan 2. Pre-cooling coil between A and C provides for sensible cooling prior to dehumidification 3. Post-cooling coil reduces temperature prior to entry into room. Removes the sensible heat added during the dehumidification

process.

D F
F

E
C F

C C

Bypass only at low load

G
P P

T H

Differential pressure control

Hood

300 cfm leaves the room through cracks and doors

Notes: 1. In this example, no heat gain across the supply fan 2. Pre-cooling coil between A and C provides for sensible cooling prior to dehumidification 3. Post-cooling coil reduces temperature prior to entry into room. Removes the sensible heat added during the dehumidification process.

DHH andbook 7

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10% rh Rooms - Other Considerations

Temperature control is often as critical as humidity. Sensible heat load and uniformity requirements may determine system air flow volume. Reactivation energy can exceed installed cost within three years. To reduce energy cost, consider:

Reactivation energy modulation Waste heat for pre-heat Air-to-air heat exchanger

The lower the humidity, the more critical the load calculations. Be sure to specify air leak rates in construction specs. When exhausting from low humidity room, air balance is absolutely
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System 1- Dehumidify Only The Make-up Air

Sensible Heating & Cooling Desiccant Unit Cooling Coil

Make-up Air

Return Air

Pre-cool the make-up air, then dry with desiccant When make-up air percent is high, this is usually the most economical system For example:

Semiconductor clean rooms Pharmaceutical clean rooms above 25% rh Hotels & motels
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Change Reactivation Temperature

250F 190F Reactivation Air Temperature 70F Process Air

Basic Parameters:
Process Air
70F 56 gr/lb 500 fpm

Reactivation Air
190 and 250F
0 10 20 30 40 50 60

56
2 4 6 8 10 12 14 16

13 gr/lb 18 gr/lb

500 FPM Process Air Velocity

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Process Air Temperature Rise

In principle, the heat in the air leaving the dehumidifier equals the sum of:

Latent to sensible heat conversion Plus heat carried over from reactivation to process

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Rough Estimating Method For Process Outlet Temperature

Approximate by assuming a constant enthalpy, plus...........some heat carried over from reactivation:

1. Air entering at 55F and 65 gr/lb

2. Air leaves the unit at 10 gr/lb

Temperature

3. Follow Wet Bulb And Read Dry Bulb @ 10 gr/lb.......91F 4. Add 15% for reactivation heat carryover: 91F x 1.15 = 105 Leaving Process

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Types Of Dehumidification Systems

Passive storage Active storage Product drying systems Industrial building HVAC systems Commercial and institutional HVAC systems

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Active Storage - Refrigerated Warehouse

The purposes of the project include preventing moisture adsorption by cartons and preventing ice build-up around doors and on floors Control levels depend on the purpose:

Ice cream room = -10F dew point, 3.2 gr/lb Candy room = 50% rh, which at 50F = 27 gr/lb Loading dock = 33F dew point, 27 gr/lb
Permeation Products People W et Sur faces Exterior W alls Cracks Door Activity Wall Openings Fresh Air
500 1000 1500 2000 2500

Moisture load profile at the dock, held at 60F, 27 gr/lb

Grains of water vapor per hour ( 000 )

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Re-Calculated Load
Load from first calculation totals 365 lbs/hrvery large! Adjusting assumptions makes the project affordable:

Door openings - change 15 trucks/hr x 3 min to 15 x 1 min Total load drops from 365 to 90 lbs/hr

New moisture load profile at the dock is:

Permeation Products People Wet Surfaces Exterior W alls Cracks Door Activity Wall Openings Fresh Air
500 1000 1500 2000 2500

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Optimizing Mixed Systems

Many, many ways to design for a given project Decisions may include:

Minimize first cost? ... or operating cost? Accept higher first cost for zero-cost future expansion? Minimize costs ... but recognize capacity limitations?

Ultimately, design decisions are governed by the project purpose ... hence the need for clear understanding before the project begins The best system design depends on which factors are most important to the user ... and these can change over the life of the system.
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Industrial HVAC System Pharmaceutical Tableting Room

Purpose: To prevent powders regaining moisture, which clogs presses, slows production and makes poor tablets Powders absorb based on rh, but to design a system, the engineer must define the humidity ratio:

10% rh is maximum based on input from R&D Comfort tolerance allows temp. to swing between 70 & 73F Engineer selects lowest temperature: 70F, 10% = 11 gr/lb At 70F, 11 gr/lb, the load profile looks like this:
Permeation Products People Wet Surfaces Exterior Walls Cracks Door Activity Wall Openings Fresh Air
100 200 300 400 500

Grains of water vapor per hour (000)

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Five-step System Design Process

1. Establish the purpose for the project 2. Establish control levels and tolerances 3. Calculate heat and moisture loads 4. Select and position components 5. Select and locate controls

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Project Criteria
Project Purpose Prevent clogging of packaging machinery for hard candy during peak summer production 70 F 3 35 F Dewpoint (30 gr/lb) +0 gr , -10 gr 100,000 Btu/h 181,800 gr/hr 400 scfm @ 95 F , 140 gr/lb (44.9 Btu/lb enthalpy) 55 F Chilled water @ 45 F 10 F approach of the air to the coolant temperature

Control levels

Internal sensible heat load Internal moisture load Make-up air Minimum delivered air temperature Cooling available

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System 2 Pre-cool Make-upBlendThen DH

Sensible Heating & Cooling Desiccant Unit Cooling Coil

Make-up Air

Return Air

Pre-cool the make-up air, blend that with the return air, then dry with desiccant. When make-up percent is high, but not high enough to remove all internal load if dry, this system is a good choice. For Example:

Supermarkets General industrial building HVAC systems

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System 3 Blend Make-up And Return Air Before Dehumidification Cooling

Sensible Heatin g & C oolin g Desiccant Unit Cooling Coil

Make-up Air

Return Air

Blend the make-up air with return air before cooling When makeup air percent is very low and moisture control level low as well, this system is a good choice Pre-cooling in front of DH allows slight performance improvementuseful at low control levels For example: Product processing below 10% rh
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System 4 Blend Before DH - No Pre-cool

Sensible Heating & Cooling Desiccant Unit

Make-up Air

ReturnAir

Blend make-up and return air before DH with no pre-cooling. When make-up air is very low and control level is mid-range, this system may be best. For example: Candy packaging Electronics assembly Pharmaceutical packaging
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Comparing Systems For This Project

System 1 System 2 System 3 System 4
25 20 15 10 5

17.2

21.8 16.9

Cooling system size ( tons )

Desiccant dehumidifier size ( sq.ft.)

10 8 6 4 2

HC-4500 HC-2250

HC-4500

Desiccant reactivation (000 Btu/h )

125,000 100,000 75,000 50,000 25,000

84

109

127

Reserve moisture removal capacity ( % of room load )

250 200 150 100 50

161 101 13

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Choosing A System Configuration

Can cooling alone provide year-round dehumidification? Yes No Can dehumidification of the make-up air alone provide adequate dehumidification No Yes Check if: Power expensive-thermal inexpensive Dry system desirable SHR below 0.8 Latent and sensible heat peaks differ Yes No

Use cooling and re-heat for control DH

DH

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When do you use desiccant-based dehumidification over coolingbased dehumidification?

?
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When do you use desiccant-based dehumidification over cooling-based dehumidification?

200

Cooling Based Dessicant Based

99% RH

10% RH

Temperature
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Moisture (gr/lb) (Humidity Ratio)

0
21

When do you use desiccant-based dehumidification over cooling-based dehumidification?

The answer can be obtained from the psychrometric chartdepends on temperature of the cooling medium, and the desired conditions in the space. A cooling coil (cooling based dehumidifier) using chilled water at 43 deg F can provide down to 45 degree dewpoint. 45 deg supply air temperature may or may not meet your desired room conditions. If you use a DX coil (refrigerant) can typically go as low as 40 F dewpoint.

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Examples:
Example # 1: Chilled water cooling coil using 45 deg chilled water. Desired room condition: 68 deg F, 45% RH. We can meet these conditions, depending on load in space. Example #2: Chilled water cooling coil using 45 deg chilled water. Desired room condition: 63 deg F, 40% RH. Required dewpoint is about 41 F. Cant do it must go to refrigeration on cooling coil or desiccant.
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Examples:
Example #3: DX (refrigerant direct expansion) cooling coil using providing 40 deg dew point. Desired room condition: 64 deg F, 45% RH. Can meet these conditions, depending on load in space. Dewpoint needed is about 41 F slightly above the achievable 40 F. Example #4: DX (refrigerant direct expansion) cooling coil using providing 40 deg dew point. Desired room condition: 62 deg F, 40% RH. Cannot meet these conditions. Need to go to desiccant-based dehumidification. Why? 62/40 corresponds to a 36 deg dew point lower than the 40 deg dew point achievable with refrigerant.

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Designing for Temperature and RH Control

For cleanroom operations, generally target 68 F as the design temperature, with a tolerance of typically +/- 2 F. Relative Humidity generally maintained between 30 % and 60%. Some designers use 30% - 50%. If the product has specific temperature and humidity requirements, those take precedence. Typically, we maintain temperature by installing reheat coils in the ductwork. Reheat coils typically fed by hot-water Alternatives:

Can also be fed by steam Electric

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Designing for Temperature and RH Control

For aseptic filling rooms and other areas where operators are heavily gowned, often design for lower temperatures and RH levels. No specific levels are accepted by industry, but some design for 62 - 64 F and 30 50 % RH.

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