The Dunkettle site has excellent support functions including a new warehouse, administration buildings, engineering offices and utilities facilities. The utility infrastructure is well designed and has been well maintained. Some highlights of the site support and infrastructure include:

Warehouse

The warehouse was built in 2003 and has an area of approximately 1,580m2. APIs, intermediates and raw materials are stored here. The following floor plan illustrates the storage areas of the building.
The warehouse has over 1,400 pallet spaces and includes:

• 2 x ‘Cold Stores’ (137 pallet spaces) to store temperature sensitive materials at -8 to +8°C;
• Segregated storage area (200 pallet spaces) for containment;
• 2 sample / sub-division rooms with airlocks;
• Mezzanine floor (office area, plant room, label facility, toilet & shower facilities, cloakroom facilities);
• High capacity pallet storage area;
• Manual handling Aids: New Drum Lifter, New Automatic Pallet Wrapper;
• Two loading / unloading Bays (One with dock leveller & one ordinary; and
• A fully validated, stand alone Business Management System.

The other key storage areas are located around the site and have a combined area of just under 1,990m2. These areas consist of bundled drum pads for storage of flammable and toxic solvents, acids and bases. There is also a solvent storage area for small volume flammables and water reactive materials.

Infrastructure

The infrastructure and utility systems are extensive and well maintained. The major systems consist of:

• Steam Generation & Distribution – two medium pressure boilers delivering 10 tons of steam and five low pressure gas boilers;
• Water Systems (Potable and USP) – a 1m3 per hour, low endotoxin purified water system serving Ops 6 and a new state of the art system designed for Ops 4/5 that can generate 3m3 per hour.
• Refrigeration Systems – six chiller units rated for +5 to -250C with storage capacity of up to 130 tons. The cooling system is closed loop and all systems are backed up.
• Electrical Supply – two separate medium voltage 10kV electrical feeds to the Facility, each one capable of supporting the entire Facility. All the voltage equipment is rated for 20kV and can be upgraded at minimal cost.
• Waste Water Treatment – fully automated sludge two stage settlement hydraulic system with an installed capacity of 484,000 L per day. The storm water system is fully automated and based on total organic content / fire alarm activation that reverts to a waste retention pool. The Facility has a storage capacity of 3,440,000 L and currently processes an average of 450,000 L/day. This is about 50% utilization. The Facility could operate several days before the loss of the Waste Water Treatment Plant (WWTP) would start to curtail production.
• Air Compressors & Distribution – two Ingersol Rand oil–free, screw compressors. The water cooled compressor was installed in 1998 and has a capacity of 13.6m3/min. The air cooled compressor also has a capacity of 13.6m3/min and was installed in 2001.
• Nitrogen Distribution – there are two 45,000 L liquid nitrogen tanks and the evaporation rate of the skids for the X,000 L liquid nitrogen tank are 750nm3/hour.
• Waste Systems
  • Storm Water System
  • Storm water is collected in a designated network of drains and touted to the site outfall. The outfall is continuously monitored by TOC to detect any contamination from processing streams. Detection of contamination will automatically divert the storm water to a 2,000 m3 fire water retention pond
  • Weak Chemical Waste
  • All process areas drain to the chemical waste system. This is a designated network of drains which follow to the site waster treatment facility. The drains are chemically resistant are double contained and are routinely pressure test in conformance with the site environmental license.
  • Strong chemical waste
  • Al process streams for waste disposal are pumped to designated central storage tanks for offsite incineration. All process streams for solvent recovery are collected in designated storage tanks for on-site distillation recovery. There are two 3,000 L batch stills and one continuous recovery still.
    
• Fire Systems – the entire plant is fully protected with sprinkler systems. There is a combination of wet, dry and foam systems, in a zoned network. The system is supplied by a 275 m3 tank, with two pumps delivering 180 m3/hr at 8 bars.

Tank Farm

There are two above ground tank farms, one on the north side and one on the south side of the site. The north tank farm services Ops 6 and is dedicated to raw materials storage with room for expansion. The capacity of the six tanks ranges from 30,000 L to 33,000 L.

Op 4 and Op 5 have a dedicated solvent storage and recovery facility. Here solvents are received, stored, isolated for recovery, and separated as new or spent. The storage capacity is 665,000 L. The south tank farm has 33 tanks dedicated to raw material storage with capacities ranging from 2,000 L to 50,000 L and has two waste tanks with volumes of 30,000 L. Both waste tanks service all production units. All tanks have fire protection systems.