Optimizing the energy efficiency of a large pharmaceutical plant

Abstract

This dissertation assesses the energy consumption and carbon emissions of a large pharmaceutical plant and proposes several energy conservation opportunities and renewable energy applications to achieve higher energy efficiency. Energy conservation opportunities were identified for each energy use including air conditioning, power, compressed air, lighting, process heating and hot water. The overall investment to implement the opportunities proposed was found to be €1.3 million. Results showed that with these proposed measures and the inclusion of solar thermal and photovoltaic systems, the facility’s total electrical energy consumption would be reduced by 11%, while the facility’s total thermal energy consumption produced from gasoil would be reduced by 25%. Thus, by introducing all the energy conservations and renewables, the pharmaceutical site under study, would ultimately reduce its overall carbon emissions by 14%. The three conservation opportunities proposed for implementation with the most advantageous payback periods were found to be: the decommissioning of the B16A boilers while replacing three dehumidifiers with ones with higher efficiency; the conversion of all manufacturing, packaging and laboratory area light fittings to LEDs; and the replacement of a fixed speed compressor with variable speed for the manufacturing compressed air system. In effect, the payback periods were found to be 3, 4 and 2 years respectively. With the implementation of these three proposals, this pharmaceutical facility would reduce its total overall energy consumption by 6.8%, while reducing its overall carbon emissions by 6%.