Assessment Overview- improvements. The team electricity and 26.9% in natural gas, examined all large energy-consuming resulting in a 17.4% overall utility cost Pharmaceuticals equipment &systems for potential reduction. Manufacturer savings. They compiled a waste Company Background inventory & investigated the potential AstraZeneca’s plant in Newark, DE, is for waste reduction or improved A team of students & faculty from the a 612,200 ft2 facility that produces disposal/recycling methods. The IAC at the University of Delaware large volumes of pharmaceutical team also examined manufacturing performed an industrial assessment products each year. At the time of processes for potential at AstraZeneca Pharmaceuticals’ the assessment, the plant consumed improvements, & emerging Newark, DE Supply Site. The about 35,762,484 kWh and 187,861 technologies were assessed for assessment was sponsored by the MMBTU of natural gas per year. potential contributions to efficiency Department of Energy and was led by Existing plant Best Energy Practices improvements. Center Director Dr. Keith Goossen, a included updated lighting, VFDs faculty member in the Department of installation for most motors, Summary Electrical and Computer Engineering. insulated structures and input from a Through the Department of Energy’s On March 26th, 2010 the IAC team sustainability team. Industrial Assessment Center (IAC) employed a comprehensive located at University of Delaware, a assessment methodology that pharmaceutical manufacturer was considered energy, waste, & able to realize a 12.8% reduction in Recommendations Implemented Not Implemented Points of Interest It was recommended to adjust the Relaxing HVAC set points during the The table below summarizes specific speed of the desiccant wheel (that weekends, and implementing lighting recommendations that were made dehumidifies the plant) to minimize controls, saved the company ~ $0.5 during the assessment and were steam consumption, and in principle MM/year. Furthermore, this plant implemented or will be implemented save 14,300 MMBTU/year natural also saw significant gains in in the near future. projections of gas, but the wheel speed as not able optimizing boiler efficiency and savings & capital costs identified to be varied. operation. Installing O2 trim, during the assessment have been eliminating low-load operation, and established through engineering returning condensate saved the plant analyses and research. As a result, 32,572 MMBtu and $328,000 per eleven recommendations were year. implemented by the company and are listed below. Implemented Recommendations
Assessment Overview- Pharmaceuticals Manufacturer A team of students & faculty from the IAC at the University of Delaware performed an industrial assessment at AstraZeneca Pharmaceuticals’ Newark, DE Supply Site. The assessment was sponsored by the Department of Energy and was led by Center Director Dr. Keith Goossen, a faculty member in the Department of Electrical and Computer Engineering. On March 26th, 2010 the IAC team employed a comprehensive assessment methodology that considered energy, waste, & improvements. The team examined all large energy-consuming equipment &systems for potential savings. They compiled a waste inventory & investigated the potential for waste reduction or improved disposal/recycling methods. The team also examined manufacturing processes for potential improvements, & emerging technologies were assessed for potential contributions to efficiency improvements. Summary Through the Department of Energy’s Industrial Assessment Center (IAC) located at University of Delaware, a pharmaceutical manufacturer was able to realize a 12.8% reduction in electricity and 26.9% in natural gas, resulting in a 17.4% overall utility cost reduction. Company Background AstraZeneca’s plant in Newark, DE, is a 612,200 ft2 facility that produces large volumes of pharmaceutical products each year. At the time of the assessment, the plant consumed about 35,762,484 kWh and 187,861 MMBTU of natural gas per year. Existing plant Best Energy Practices included updated lighting, VFDs installation for most motors, insulated structures and input from a sustainability team. Recommendations Implemented The table below summarizes specific recommendations that were made during the assessment and were implemented or will be implemented in the near future. projections of savings & capital costs identified during the assessment have been established through engineering analyses and research. As a result, eleven recommendations were implemented by the company and are listed below. Not Implemented It was recommended to adjust the speed of the desiccant wheel (that dehumidifies the plant) to minimize steam consumption, and in principle save 14,300 MMBTU/year natural gas, but the wheel speed as not able to be varied. Points of Interest Relaxing HVAC set points during the weekends, and implementing lighting controls, saved the company ~ $0.5 MM/year. Furthermore, this plant also saw significant gains in optimizing boiler efficiency and operation. Installing O2 trim, eliminating low-load operation, and returning condensate saved the plant 32,572 MMBtu and $328,000 per year. Implemented Recommendations
DL0053-Astra-Zeneca-Case-Study.docx