Assessment Overview-Pharmaceuticals ManufacturerA team of students & faculty from theIAC at the University of Delaware performed an industrial assessment at AstraZeneca Pharmaceuticals’ Newark, DE Supply Site. The assess-ment was sponsored by the Depart-ment of Energy and was led by Center Director Dr. Keith Goossen, a faculty member in the Department of Electri-cal and Computer Engineering. On March 26th, 2010 the IAC team em-ployed a comprehensive assessment methodology that considered energy, waste, & process-related improve-ments. The team examined all large energy-consuming equipment &sys-tems for potential savings. They compiled a waste inventory & investi-gated the potential for waste reduc-tion or improved disposal/recycling methods. The team also examined manufacturing processes for potential improvements, & emerging technolo-gies were assessed for potential contributions to efficiency improve-ments.

SummaryThrough 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

Applications

The assessment personnel of the program identified and evaluated opportunities to conserve energy, minimize waste and improve productiv-ity. In this case important opportunities for energy sav-ings were found in HVAC sys-tems, lighting controls, and motor and boiler efficiency.

Assessment at a Glance

-Implemented 11/15 of recommendations to save an estimated $989,500 per year

-Implemented recommen-dations to improve lighting controls, optimize boiler operation, improve motor efficiency, and reduce unnecessary HVAC con-sumption

-Payback periods of imple-mented recommendations range from .1 to 15 months, averaging 2.6 months

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 in-stallation for most motors, insulated

structures and input from a sustain-

ability team.

Recommendations Implemented

The table below summarizes specificrecommendations that were madeduring the assessment and wereimplemented or will be implementedin the near future. These projections of savings & capital costs identified during the assessment have been established through engineering analyses and research. As a result, eleven recommendations were imple-mented by the company and are listed below.

Not ImplementedIt 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 InterestRelaxing 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

Astra Zeneca Pharmaceuticals is one of the world’s largest pharmaceutical compa-nies. They produce a wide variety of prescription medications and have sales and manufacturing operations in numerous countries worldwide.

Assessment Annual Total Implementation Simple Recommendations Resource Annual Costs Payback

(AR) Savings Savings

1,920,000 kWh $202,000 17,100 MMBtu $170,000

Adjust Thermostats OfHeaters In Boilers Room

4,586,822 kWh

50,546 MMBtu

Relax HVAC Set Points During Weekend $4,000 .1 month

Institute Dynamic Control Of Lighting $123,000 $29,200 2.9 months1,167,300 kWh

4.6 months

Institute Compressed AirLeak Check Schedule $74,000 $700 .1 month

Install Oxygen Trim Control To Regulate Air/Fuel Ratio $80,000 $30,000

702,000 kWh

8,036 MMBtu

Turn Off The Boiler Operating At Very Low Load $61,000 $20 .1 month

Replace Drive Belts On Motors With Energy Efficient Pulleys and

Cog Belts$40,900 $10,240 3 months389,522 kWh

6,136 MMBtu

15.1 months

TOTAL 2.6 months$989,500 $214,310

$25,000 $31,440 Install Variable Frequency Drive (VFD) On Dedicated Weekend

Compressor

$6,000 $10 .1 monthTurn Off Heating Unit InBottling Staging Area

$2,600 $100 .5 months260 MMBtu

614 MMBtu

$18,000 $8,600 5.8 months

$187,000 $100,000 6.4 months

Institute A Chiller Log

Return Condensate ToBoilers

236,000 kWh

18,400 MMBtu

172,000 kWh