ESG-ORIENTED ALTERNATIVE FUELS RESEARCH FACILITY (AFRF) METHODOLOGY FOR SUSTAINABLE WASTE MANAGEMENT IN PHARMACEUTICAL MANUFACTURING

Abstract: Pharmaceutical manufacturing generates complex hazardous waste streams, including expired drugs, effluent treatment plant (ETP) sludge, spent solvents, used oils, and off-specification products, posing significant environmental, social, and governance (ESG) challenges. Conventional disposal methods such as incineration and landfilling result in emissions, leachate generation, and resource loss. This study proposes an Alternative Fuels Research Facility (AFRF) methodology that integrates waste segregation, pre-treatment, thermal conversion (pyrolysis, gasification, distillation, and controlled incineration), and digital traceability using IoT and blockchain. HAZOP and FMEA were conducted for process safety. Results demonstrate 72% overall energy recovery efficiency, 90% waste volume reduction, 78% solvent recovery, 61% reduction in greenhouse gas emissions, and 88% reduction in landfill dependency. ESG performance improved across all pillars (Environmental +86%, Social +61%, Governance +87%). The AFRF offers a scalable, economically viable pathway (3.5-year payback) toward circular economy practices in the pharmaceutical industry.

Keywords: Alternative Fuels Research Facility, pharmaceutical waste, circular economy, ESG, thermal conversion, digital traceability

Highlights:

• Proposes holistic AFRF methodology for multi-stream pharmaceutical waste valorization.