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The WW 90°C Project

The WW 90°C Project. of Biochemie Kundl, Tirol, Austria. Biochemie Kundl. R&D, fermentation plants, synthesis plants, pharmaceutical formulation plant One of world’s leading producers of antibiotics Manufacturing of one third of world’s oral penicillin

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The WW 90°C Project

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  1. The WW 90°C Project of Biochemie Kundl, Tirol, Austria

  2. Biochemie Kundl • R&D, fermentation plants, synthesis plants, pharmaceutical formulation plant • One of world’s leading producers of antibiotics • Manufacturing of one third of world’s oral penicillin • >14.000 t/y of antibiotics, proteins and enzymes by fermentation • Size of fermenters: 3000 - 250.000 liters • >3.000 t/y of active substances by synthesis • About 2000 employees

  3. Energy / CO2 • Kundl is largest energy user / CO2 emitter of Novartis • 2,7 Mio GJ/y (~18% of Novartis) • 70.000 t CO2 /y (~15.5% of Novartis) • Major energy use for • Air supply for fermenters (compressors) • Stirring of fermenters • Drying of mycelia, and sludge of waste water plant • Pumps • Solvent recovery • Sterilisation and heating of fermenters

  4. Source of Waste Heat • Hot water from cooling of 10 air compressors • Used for producing 1.5 bar steam • Steam from dryers of mycelia and sludge • Comfort heating and warm water for community of Kundl • Opportunities (before project): • Much warm water below 110°C still not used • Conditions for feasibility for use: • High consumption to justify investment • Consumption throughout whole year

  5. Project Warm water 90°C 6.3% of site’s emission 1% of Novartis’ emissions • Optimization of evaporators in new project to allow low heating temperature (i.e. higher vacuum) • Same optimization in some existing evaporators and other new ones • Investment of ~ 600.000 € • Estimated energy saving 2002: 43.000 GJ, expected after ~ 2 years: 72.000 - 100.000 GJ/y • Savings based on 72.000 GJ/y: • ~360.000 €/y • ~4500 t CO2 /y =

  6. Overview of System

  7. Principle of System Steam Condensate102°C Heat Exchanger(back up) 127°C Secondary back upcooling 90°C 1.5 bar Steam 1.5 bar Steam 90°C Heat Exchanger Generationof 1.5 barSteam 160°C 135°C Users Water CompressorCooling 75°C 65°C Pre-heating of Waterin Boilers Heat Exchanger 160°C 110°C 52°C Water 60°C

  8. Potential Barriers for Project • “Everything feasible already done on site” • Departments don’t know what others do • Quantity not enough to justify investment • Processes “cannot” be changed • Scope is within site border only

  9. Preconditions for Success • Modern energy measurement and information system • Sound knowledge of energy flow on site • Sound knowledge of energy plants and users • Good cooperation between process engineer, energy generator and energy user (knowledge of “other side”) • asking the “right” questions • Step-wise implementation of mid term energy concepts • e.g design new equipment for later change to other energy source

  10. Preconditions for Success (cont.) • Energy saving awareness and management support: • Early energy challenge in projects • Open re-assessment of existing installations. • Openness for new solutions • additional efforts and work load • acceptance of project changes and (possible) delays • acceptance of higher investments

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