ispe the energy saving in the pharmaceutical industry
TRANSCRIPT
The energy saving in the pharmaceutical industry: a case study at
Sanofi Midy Research Center
International Congress ISPE/PDA
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International Congress ISPE/PDA Pharmintech 2010, Bologna
Marcello Pasquazzo Local project manager new Research Center
Luca Arrighi , Head of HVAC dept., Foster Wheeler Italiana, Pharmaceutical division
Workers’ safety
Safety for people around the plants
Safety for the environment
Workers’ safety
Short response timing for a continuous containment by an integrated system
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Safety for people around the plants
Every in air emissions are filtered
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Only dry cooler to prevent Legionella
Safety for the environment
Corporate 2005 – 2008 objectives
Reduce CO 2 direct emissions by 12%
Maintain constant CO 2 indirect emissions
Reduce CO 2 emissions from
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Reduce CO 2 emissions from Med. Reps cars by 7.5%
Reduce VOC emissions by 15%
Increase solvent recycling from 57% to 63%
Each site has a biodiversity objective
The new Research Center: the task
About 10000 m 2
Full capacity 120 people
10 total floors
Relocation from the old MIDY “via Piranesi” site buil t on ’40 years of the last century to a modern Research Center
designed according to the SA guide lines
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10 total floors
Two Technical floors
~2 MW redundant electrical power supply
~250.000 m3/h supply airflow rate
Once Through HVAC systems
In the labs 20 supply air changes per hours
The new research Center: Today
Moving people in March 2008
Underground floor for parking
ground floor for common services
The Research site is dedicated to SA Drug Discovery :Exploratory Unit
68 total Headcount ( Jan 2009)
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ground floor for common services
1 floor for Administration and Direction
2 and 3 floors Pharmacology units
4 and 5 floors Chemistry units
6 and 7 floors technical floors
The Energy study: The Process
Observe: To understand the research operations needs , to assess the technical infrastructure
Evaluate: To study the solutionsPlan: To plan the facility upgrade
The process adopted is composed by three phases :
Who is involved:
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Who is involved:
Building servicesengineer
Maintenance engineer
The management
BMS supervisor
Equipment and plants suppliers
The user
• Collect the technical documents describing the faci lity• During the review of the documentation it is possib le to identify
the facility weak points
The Energy study: The Data Collection
Collection of the documentation of the installation
Collection of the facility operating trend
• Collect the energy
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• Collect the energy bills and the year trend
• Clarify the utilities provider and the contract principle
Flat profile
• Set the BMS to store the data for a representative long time
The BMS was configured to provide the supply airflow rate
The research center “population”
The Energy study: The Data Collection (cont.)
• Set the BMS to provide trends representative the se veral operating conditions setted (day-night-vacation-week end-shut down)
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provide the supply airflow rate room by room (safety for the
operator was the first goal of this facility).
It was organised the upgrade of the output in order to have the trends of the total air treated air
more suitable for this study
The research center “population” was growing up then was
necessary to identify the most representative month in terms of
labs use
2009 201020082007
The Energy study: The Data Collection (cont.)
The Site Survey• To verify the consistency
of the documentation• To identify the major
problems• To identify areas more
easily upgradeable
• The pump room was hot• Several humidification steam
generators were in maintenance
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The Operating procedure• To share with the user of the
laboratory the usual and the special operations done.
• To facilitate a share of information between the user and the maintenance staff
• The refrigerators installed inside one area requires a control of the max room air temperature. The HVAC is not allowed to stop at night
• The “Night Lab.” is in use 24h/day
The Energy study: The Data Collection (cont.)
The Maintenance procedure• To understand on which basis the maintenance is org anised • To collect important data on the plant failures and performances
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The filters replacement was organised on time basis
The heating coils of many air handling units was sized without consideration of the free pre-heating provided by the heat recovery system
At the 4 th and 5 th floor the night and week end
The Energy study: The Data Collection (cont.)
Other initiatives• To integrate he study with the other projects in pr ogress• To address the energy saving study in the respect o f the future
arrangement of the facility
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the night and week end needs (quantity of hoods in use, heat release by equipment, façade heat transfer) were studied and was defined that a complete shut down of the HVAC was acceptable
The HVAC system was not the only
user primary fluids/energy
The HVAC supply airflow rate was
available as room by room
The Energy study: The study of the solutions
The interpretation of the data
The research centerpopulation was still
growing
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The HVAC system consumption during the year was verified
by a simulation of the typical weather year with a software
The total supply airflow rate was
defined not only by a sum but also
comparing the AHU running parameters
The HVAC running conditions to use in
the study was corrected according
to the long term population forecast
• The energy savings solutions shall not compromise t he leading tasks of the facility
The Energy study: The study of the solutions
Comparison of the energy savings against the other “tasks” constrains of the facility
• The integration of the implementations shall not ad versely affect the facility operations
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The reduction of the supply airflow rates shall never go
below the minimum flow required by the containment of the hoods, an approach
room by room
The humidification section shall have high hygienic
standards
K.O. factors
The Energy study: The study of the solutions
Comparison of the energy savings against the other “tasks” constrains of the facility
• To try to give a value to the pro and cons
Identification of the solutions - Comparison of the energy
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The energy saving solution provided that is prepared by a careful assessment of the operating
conditions can be adopted without risksThe methodology is suggested on ISPE magazine Vol. 27 2007 “Energy savings in Pharma facility” by D. Goswami and ;M. Butler
Identification of the solutions - Comparison of the energy savings against the other “tasks”constrains of the facility (cont.)
• The ROI evaluation is required for the correct asse ssment of the solutions but is not enough….
• In many cases the budget for the most expensive mod ifications can be assigned only as part of a long term investm ent plan. A “site budget friendly approach” is the possible way to follow
Short, medium, long term implementation
The Energy study: The solutions & the planning
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Optimisation of the running parameters
Modification of the “localised” tips
Upgrade of big item
year 1 year 2 year 3
The Energy study: The solutions & the planning
Optimisation of the control logic of the heat recovery
system
Short term implementation: optimisation of the running parameters
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Organise the filters
change on ∆p bases
Re set of the consumption for air humidificationwhen the facility Std. conditions
The Energy study: The solutions & the planning
Short term implementation: optimisation of the runn ing parameters
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when the facility is not in use from
50% r.h. to
40% r.h.
- 7 % humidification consumption (year)
With night / we reset
The Energy study: The solutions & the planning
Medium term implementation: Modification of the “lo calised” tips
• Modification of the heat recovery circuit from flue gas to use the economizer only when the relevant boiler is in operation
• Modification of the heat recovery circuit from chillers to use the
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• Thermal insulation on the hot water circulation pumps and valves.
circuit from chillers to use the economizer only when the relevant chiller is ON
The Energy study: The solutions & the planning
Long term implementation: New centralised generatio n of steam for humidification
• - 38% on CO2 generation
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• - 48% energy cost
• ROI < 5years
The Energy study: The solutions & the planning
Long term implementation: Reduction of the operating temperatures and modification of the hot water gene ration system
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• - 10% on CO2 generation
• - 10% energy cost
• ROI < 4 years
The Energy study: The results
Expected CO2 reduction (%)
(without considering the additional positive results of the
%
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• Energy saving in pharmaceutical facilities is possi ble• The facility budget will better handle the impact o f the future
Carbon Tax
results of the optimisation of the supply airflow-rate studies)
Thanks for your attention !
Aknowledgements
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Antonio Cefalà - Direttore del Centro Ricerche
Ermanno Riva - Responsabile Servizi Tecnici
Marco Landi - Responsabile Servizi Generali
Contacts
Marcello Pasquazzo: [email protected]
Luca Arrighi: [email protected]