Switching to an alternative fuel source case study on installation of a biomass boiler
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Switching to an alternative fuel source - Case study on installation of a Biomass Boiler. Jim Kelly, Maintenance Manager, Centocor Biologics (Ireland). Centocor Biologics (Ireland) - History. Part of Johnson and Johnson since 1999. Cork site chosen as Green field Biotech site.

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Switching to an alternative fuel source - Case study on installation of a Biomass Boiler

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Switching to an alternative fuel source case study on installation of a biomass boiler

Switching to an alternative fuel source - Case study on installation of a Biomass Boiler

Jim Kelly, Maintenance Manager, Centocor Biologics (Ireland)


Centocor biologics ireland history

Centocor Biologics (Ireland) - History

  • Part of Johnson and Johnson since 1999.

  • Cork site chosen as Green field Biotech site.

  • Capable of manufacturing medicines for rheumatoid arthritis, Crohns disease and psoriasis.

  • 2004. Engineering design

  • 2005. Construction

  • 2006. Commissioning

  • 2007. Equipment Validation

  • 2008. Engineering runs, Consistency lots

  • 2009. Process Validation and IMB licence

  • 2010. FDA approval.


Site layout

Site layout

  • 5 buildings covering 25,000 sqm.

    • Manufacturing

    • Warehouse

    • Labs and Admin

    • Central Utilities Plant (CUP)

    • Waste water treatment plant

  • CUP

    • Utility generation

      • Plant Steam

      • Chilled water

      • Compressed air

      • WFI

      • Clean Steam


Steam usage

Steam usage

  • Two 12 tonne, 8.5 bar gas fired boilers.

  • Burning approximately 17 GWhrs of gas per year.

  • Steam demand varying from 2 to 5 tonnes/hr.

  • Annual CO2 emissions of 3100 tonnes.

  • Main steam users

    • WFI generation

    • Clean steam generation

    • Heating hot water for space heating


Existing gas boilers

Existing Gas boilers


Reasons for choosing biomass

Reasons for choosing Biomass

  • Main driver for project – carbon neutral.

  • Carbon emitted from boiler cancelled out by carbon absorbed by trees that are used for woodchip.

  • Second driver was fuel cost, wood is cheaper than gas – up to 15% savings have been achieved.


Project summary

Project Summary

  • Project budget - €2.5M

  • Project duration - 5 months

  • Project Managers – Sisk

  • Payback – 10 years


Boilerhouse

Boilerhouse


Boiler details

Boiler details

  • Manufactured by Binder, AG, Austria.

  • Have 3000 boilers worldwide.

  • 2.1MW, 2.5 tonne/hr, 8.5 bar output.

  • Efficiency 87-90%.

  • Fuel must be <= 50% moisture will go out.

  • S02 150 mg/m3.

  • NOx 250 mg/m3 .

  • CO 150 mg/m3.

  • Total Particulate matter 50 mg/m3.

  • TOC < 5 mg/m3.

  • Ash 1% of fuel volume. 0.8 m3 / day.


Boiler design

Boiler design

  • Moving floor design, similar to old fashioned chain grate coal boilers.

  • Ash removed by cyclone on boiler exhaust, also removed by auger at the end of the moving floor.

  • Hot gas recirc used to clean boiler.

  • Glosfume filtration unit downstream of boiler for removing particulates.


Boiler front

Boiler front


Boiler rear

Boiler rear


Woodchip supply contract

Woodchip Supply Contract

  • Supply contract with Natural Power Systems (NPS), Waterford.

  • Supply woodchip to G100 standard at < 50% moisture.

  • Range has been 36% to 50%.

  • 24/7 supply maintained.

  • Cost of woodchip based on Steam consumption of boiler.

  • Fixed price for kWhr output of boiler.

  • Ash removal once per week, two 200 litre drums per week.


Woodchip containers

Woodchip containers

  • Four specially adapted 40 foot containers.

  • Moving floor, hydraulically driven.

  • Feed into auger supply system that feeds boiler.

  • Each container carries up to 18 tonnes of woodchip.

  • Delivery every 1.5 days, from Fermoy 25 miles away.

  • Wood from Munster.

  • Best results when wood is left to dry for 4 months, moisture will drop from 60% to 36%.


Container delivery

Container delivery


Container docked in position

Container docked in position


Container hydraulic ram

Container hydraulic ram


Glosfume exhaust gas filter unit

Glosfume exhaust gas filter unit

  • Exhaust gas particulates filtered by a Glosfume filter.

  • Particulates filtered down to 0.1um.

  • Particulates removed by banks of ceramic filters elements.


Glosfume exhaust gas filter unit1

Glosfume exhaust gas filter unit


Questions

Questions?


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