Sviluppo di tecnologie avanzate per il recupero dell'etanolo dai reflui derivanti dai processi di produzione del plasma umano

The fractionation of human plasma relies extensively on cold ethanol precipitation, generating large volumes of hydroalcoholic waste streams that contain significant amounts of recoverable ethanol. Efficient ethanol recovery is therefore a key factor for both the economic and environmental sustainability of plasma fractionation processes. However, the reuse of recovered ethanol is often limited by the presence of volatile and semivolatile contaminants, as well as by the high energy demand associated with conventional distillation systems. This work investigates the recovery of ethanol from hydroalcoholic effluents generated during plasma fractionation, with a specific focus on the industrial process operated at the Takeda Manufacturing Italia plant in Cittaducale (Italy). The work adopts an integrated approach combining experimental analysis, process simulation, and techno-economic and environmental evaluation. Attention is devoted to the chemical quality of the recovered ethanol, addressing the formation of contaminants such as acetaldehyde and related compounds, which are subject to strict regulatory limits for reuse in pharmaceutical applications. A detailed characterization of the waste streams was performed to assess their compositional variability and to identify potential precursors of volatile contaminants. Laboratory-scale experiments were conducted to investigate the influence of operating conditions, such as temperature, residence time, and redox environment, on contaminant formation, enabling the identification of key kinetic trends and critical process parameters. These insights were used to support strategies aimed at mitigating contaminant generation at the source and reducing fouling phenomena in distillation equipment. In parallel, the existing ethanol recovery system was analysed and optimized through process simulation. Innovative distillation configurations assisted by heat pump technologies were evaluated as alternatives to conventional steam-based systems, demonstrating significant potential for reducing energy consumption and operating costs while maintaining the required solvent quality. Economic and energy performance indicators were used to compare different scenarios and to identify optimal configurations aligned with industrial feasibility and sustainability goals. Finally, the thesis explores a complementary valorisation strategy for pharmaceutical wastewater, proposing the integration of hydrodynamic cavitation into the existing wastewater treatment plant to enhance effluent quality and enable water reuse for irrigation in compliance with stringent European regulations. Overall, this work provides a comprehensive, case-specific framework for ethanol recovery from complex pharmaceutical effluents, combining chemical insight with process and energy optimization. The results contribute practical guidelines for improving solvent quality, reducing environmental impact, and supporting circular economy strategies in plasma fractionation and related industrial contexts.