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LGM Ireland Ltd. – Energy Services Ltd. Baxter Healthcare - Energy Survey Report CONTENTS PAGE 1.0 INTRODUCTION ................................................................................................................. 5 1.1 BACKGROUND............................................................................................................... 5 1.2 OPERATION AND BUSINESS PROFILE....................................................................... 5 2.0 ELECTRICAL SYSTEMS & METERING ............................................................................ 6 2.1 MAXIMUM DEMAND (MD) ................................................................................................... 6 2.2 MAXIMUM IMPORT CAPACITY (MIC) .................................................................................... 6 2.3 NIGHT CONSUMPTION ........................................................................................................ 7 2.4 POWER FACTOR ................................................................................................................ 7 2.5 STANDBY GENERATION ...................................................................................................... 8 3.0 THERMAL ........................................................................................................................... 8 3.1 CHILLERS & COOLING TOWERS ........................................................................................ 10 5.0 ENERGY MANAGEMENT AND REPORTING SYSTEMS .............................................. 13 5.1 POLICY ........................................................................................................................... 13 5.2 RESPONSIBILITIES FOR ENERGY MANAGEMENT ................................................................. 13 5.3 MONITORING AND TARGETING .......................................................................................... 13 5.4 STAFF INVOLVEMENT/TRAINING (ENERGY EFFICIENCY AWARENESS).................................. 14 6.0 WATER.............................................................................................................................. 14 7.0 POTENTIAL ENERGY SAVING TECHNOLOGIES ......................................................... 15 7.1 ENERGY SAVING TECHNOLOGY CHECKLIST ......................................................... 15 7.2 ENERGY SAVING TECHNOLOGY DETAILS .............................................................. 16 7.2.1 Good Energy Housekeeping Training .............................................................................. 16 7.2.2 Lighting ............................................................................................................................ 16 7.2.3 Space and Process Heating ............................................................................................ 16 7.2.4 VSD's and Soft Starters ................................................................................................... 16 7.2.5 Monitoring and Targeting (M&T) ...................................................................................... 17 7.2.6 Winter Peak Demand Reduction Shceme – WPDRS ................................................. 17 7.2.7 Utility Tariff Optimisation – Electrical ............................................................................... 17 7.2.8 Compressed Air ............................................................................................................... 17 7.2.9 Combined Heat and Power (CHP) ................................................................................... 18 7.2.10 Pinch Analysis ............................................................................................................... 19 7.2.11 Pipe Heat Losses........................................................................................................... 20 7.2.12 Performance Indices ...................................................................................................... 20 APPENDICES ......................................................................................................................... 21 APPENDIX A .......................................................................................................................... 21 Fig. A1. Historical Maximum Demand Vs Maximum Import Capacity ............................ 21 Report Completed: September 2004 1 For inspection purposes only. Consent of copyright owner required for any other use. EPA Export 25-07-2013:19:17:05
Transcript

LGM Ireland Ltd. – Energy Services Ltd. Baxter Healthcare - Energy Survey Report

CONTENTS PAGE

1.0 INTRODUCTION ................................................................................................................. 5

1.1 BACKGROUND............................................................................................................... 5 1.2 OPERATION AND BUSINESS PROFILE....................................................................... 5

2.0 ELECTRICAL SYSTEMS & METERING............................................................................ 6

2.1 MAXIMUM DEMAND (MD) ................................................................................................... 6 2.2 MAXIMUM IMPORT CAPACITY (MIC) .................................................................................... 6 2.3 NIGHT CONSUMPTION........................................................................................................ 7 2.4 POWER FACTOR................................................................................................................ 7 2.5 STANDBY GENERATION...................................................................................................... 8

3.0 THERMAL ........................................................................................................................... 8

3.1 CHILLERS & COOLING TOWERS........................................................................................ 10

5.0 ENERGY MANAGEMENT AND REPORTING SYSTEMS .............................................. 13

5.1 POLICY ........................................................................................................................... 13 5.2 RESPONSIBILITIES FOR ENERGY MANAGEMENT................................................................. 13 5.3 MONITORING AND TARGETING .......................................................................................... 13 5.4 STAFF INVOLVEMENT/TRAINING (ENERGY EFFICIENCY AWARENESS).................................. 14

6.0 WATER.............................................................................................................................. 14

7.0 POTENTIAL ENERGY SAVING TECHNOLOGIES ......................................................... 15

7.1 ENERGY SAVING TECHNOLOGY CHECKLIST......................................................... 15 7.2 ENERGY SAVING TECHNOLOGY DETAILS .............................................................. 16

7.2.1 Good Energy Housekeeping Training..............................................................................16 7.2.2 Lighting ............................................................................................................................16 7.2.3 Space and Process Heating ............................................................................................16 7.2.4 VSD's and Soft Starters ...................................................................................................16 7.2.5 Monitoring and Targeting (M&T) ......................................................................................17 7.2.6 Winter Peak Demand Reduction Shceme – WPDRS.................................................17 7.2.7 Utility Tariff Optimisation – Electrical ...............................................................................17 7.2.8 Compressed Air ...............................................................................................................17 7.2.9 Combined Heat and Power (CHP)...................................................................................18 7.2.10 Pinch Analysis ...............................................................................................................19 7.2.11 Pipe Heat Losses...........................................................................................................20 7.2.12 Performance Indices......................................................................................................20

APPENDICES ......................................................................................................................... 21

APPENDIX A .......................................................................................................................... 21 Fig. A1. Historical Maximum Demand Vs Maximum Import Capacity ............................ 21

Report Completed: September 2004 1

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Fig. A2. Historical Electricity Consumption ..................................................................... 21 Fig. A3. Historical Heavy Fuel Oil Consumption............................................................. 21 Fig. A4. Historical Water Consumption........................................................................... 21

APPENDIX B .......................................................................................................................... 21 Fig. B1.Electricity Demand for Compressor No.4........................................................... 21 Fig. B2. Electricity Demand for Compressor No. 6 (VSD Controlled) ............................ 21 Fig. B3. Electricity Demand for Chillier No.2................................................................... 21

APPENDIX C .......................................................................................................................... 21 Fig. C.1. Energy Efficiency Utilisation............................................................................. 21

APPENDIX D .......................................................................................................................... 21 Compressed Air Audit Synopsis ..................................................................................... 21

Report Completed: September 2004 2

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LGM Ireland Ltd. – Energy Services Ltd. Baxter Healthcare - Energy Survey Report

SUMMARY OF ENERGY SAVING MEASURES

Energy Survey Summary Customer Reference: Baxter Healthcare Our Reference: ES/LGM/Baxter/ScopingSurvey Survey Date: 9th & 10th September 2004

Personnel Brian Scannell and Paul Ryan (Energy Services Ltd.) carried out the scoping survey on behalf

of LGM Ireland Ltd. Ger Murnane and Ciaran Geraghty attended on behalf of Baxter. Customer Details Address: Baxter Healthcare SA, Moneen Road, Castlebar,

Co.Mayo.

Telephone: 094-22244

Fax: 094-22956

E-Mail: [email protected]

Contact: Ciaran Geraghty

Total CO2 Emissions: 39,341 tonnes per annum

Main Electrical Consumption Details Existing Tariff: Energia Medium Voltage

Annual Consumption: 25,926,634 kWh

Average Unit Price: 6.78c/kWh

Night Usage: 36%

Maximum Demand: 4452 kW (4686kVA)

Load Factor: 66.6%

Current Annual Spend: Euro € 1,757,288

Maximum Import Capacity: 4500 kVA

Electrical CO2 Emissions: 20,113 tonnes per annum

Main Thermal Consumption Details Supply Heavy Fuel Oil

Annual Consumption 6,152,985 litres (70,267,088 kWh)

Current Annual Spend: Euro € 1,283,663

Average Unit Cost 1.83 cent/kWh

Average Thermal Demand: 8,021 kW

Estimated MD at 0.8 LF: 10,026 kW

Electrical : Thermal Consumption Ratio 1:2.7

Report Completed: September 2004 3

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Thermal CO2 Emissions: 19,227 tonnes per annum

Report Completed: September 2004 4

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1.0 INTRODUCTION Energy Services Ltd. (on behalf of LGM Ireland) conducted an energy survey

of the Baxter plant in Castlebar, to broadly quantify energy usage, and provide

direction as to in which areas the major opportunities for energy savings might

exist. The survey was driven primarily by Baxters requirements for their IPC

licence outlined by the EPA.

1.1 BACKGROUND

Baxter Healthcare is a subsidiary of Baxter Inc. which is the leading

healthcare company in the world. Baxter Inc. employs 35,000 people

worldwide, has sales in excess of US$6b and its shares are quoted on the

New York stock exchange. Baxter is a leader in medical products and has

developed leading technologies including intravenous solutions, artificial

kidneys, continuous ambulatory peritoneal dialysis and blood substitutes.

1.2 OPERATION AND BUSINESS PROFILE

Baxter established its Ireland Manufacturing Operation in 1972 and now

employs approx. 1000 people at the state of the art manufacturing plant in

Castlebar, Co. Mayo. The Castlebar plant produces a range of medical

solutions for Continuous Ambulatory Peritoneal Dialysis (CAPD) and for drug

administration purposes. The products are exported to global markets

including Europe, US and Japan.

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2.0 ELECTRICAL SYSTEMS & METERING The plant is metered at 10kV medium voltage and is currently supplied by

Energia. Annual electricity consumption at the site is in the region of 25.9GWh

which equates to an annual spend of some € 1,757,288. The Maximum

Demand (MD) recorded in July 2004 last was 4,452kW (4,686kVA). Night

consumption represents 36% of the total load. The monthly electricity

consumption profile can be seen in Fig.2 Appendix A. A noticeable increase

occurs during the summer months which is most likely the result of increased

cooling requirements.

2.1 Maximum Demand (MD) Fig.1 in Appendix A shows the monthly electricity demand in kVA over the

past 12 months. The highest demand recorded during this period was

4,452kW (4,686kVA) which occurred at 11.00hrs on 7th July. The MD should

not exceed the Maximum Import Capacity level or penalties will be incurred.

2.2 Maximum Import Capacity (MIC) Demand customers who are charged on Tariff Schedule DTS-D (i.e. Baxter)

have a contracted MIC value established in their connection agreement. An

MIC value is important because it generally represents the extent to which the

transmission network has been designed to serve the customers and places

an upper limit on the total demand that a customer can place on the network.

It therefore should be high enough to meet the customers needs.

Since Transmission Use of System (TUoS) charges and Distribution Use of

System (DUoS) are based on each customers MIC value, an MIC value in

excess of a customers needs will result in that customer incurring higher

capacity charges than necessary. Conversely if the MIC is set too low and a

customer exceeds the agreed MIC then unauthorized usage charges will be

applied in order to reflect that the network has not been designed to meet

these levels and to discourage use above the MIC.

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The current MIC level of 4,500kVA has been marginally exceeded in recent

months (See Fig.1 Appendix A) and as such unnecessary penalty charges

have been incurred. In order to avoid these penalties Baxter could apply to

increase the current MIC level. However a more energy efficient and cost

effective method would be to monitor and control the electricity demand more

closely and ensure that the MIC level is not breached in the future. A Demand

Manager can be easily installed to control random or sequenced non-

essential loads. The unit can be preset to automatically shed non-essential

loads during the periods of peak demand, thereby ensuring that no penalties

are incurred.

2.3 Night Consumption Night Consumption costs on the current Energia tariff (and the previous ESB

PES tariff) are substantially less than day unit costs. A totally flat consumption

profile would obtain 37.5 % night consumption (normally one would expect the

night load to be less than this). The quantity of night units consumed on the

Castlebar site over the past 12 months was around 36%.

However there could be scope for switching off some electrical equipment

which is not in use during the night-time period (11pm-8am). Further

investigation is required to determine what loads (if any) remain on

unnecessarily during the night. 2.4 Power Factor Low Power Factor (PF) surcharges, sometimes referred to as reactive or

wattless charges are applied to kilo-Volt-Amperes-Reactive-hours (kVARh) in

excess of one third of kilo-Watt-hours (kWh) in the billing period. Baxter has

installed power factor correction equipment at various locations throughout

the site to compensate for the reactive power produced in the plant. Baxter

are not incurring any power factor penalties at present.

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2.5 Standby Generation There is one 500kVA electricity generator on site which is used in the event of

a failure in mains electricity supply to the plant. The unit ensures a continuous

supply of electricity to the EPOMAX production facility in the event of an

outage to ensure product in the EPOMAX area does not become

contaminated. The generator is synchronised with the grid but is currently not

used for any peak shaving / lopping or winter demand reduction schemes.

Peak shaving, and other demand reduction measures such as ‘Powersave’ or

the Winter Peak Demand Reduction Scheme (WPDRS) could be quite

lucrative and the potential merits further investigation.

3.0 THERMAL Heavy Fuel Oil is currently used as the fuel for the steam boilers. Annual

consumption of almost 6,152,985 litres (equates to 70,267,088 kWh) costs

Baxter in the region of € 1.28 million per annum. There is currently no natural

gas supply to the site; however this may change in the near future. By

converting from heavy fuel oil to natural gas Baxter could reduce the plants

CO2 emissions by over 5,000 tonnes annually.

Average thermal demand at the plant amounts to 8,021kW. Taking a load

factor of 80%, this equates to a max thermal demand of 10,026kW. As the

electrical maximum demand is 4,452kW, it appears from initial observations

that the Baxter plant would be an ideal candidate for Combined Heat and

Power (CHP).

The boiler room was noticeably quite warm during the survey as a number of

valves and flanges are uninsulated. It is worth noting that an uninsulated valve

is the equivalent of 1m of unlagged pipework. The details of each of the four

boilers can be seen in the tables below:

Report Completed: September 2004 8

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Boiler No.2

Make B & E Boilers Ltd.

HYD Pressure 247 PSI

Working Pressure 150 PSI

Serial No. 2748

Model European

Burner Hamworthy

Boiler No.3

Make Babcock Robey Ltd

Design Pressure 160 PSI

Working Pressure 150 PSI

Serial No. 32026

Model Lincoln

Burner Hamworthy

Boiler No.4

Make Sernior Thermal Ltd

Design Pressure 160 PSI

Working Pressure 150 PSI

Serial No. C 60003

Model Steampacket

Burner Hamworthy

Boiler No.6

Make Wellman-Robey

Design Pressure 9 BAR

Heat Output 12540 kW

Burner Hamworthy

Boiler No.4 is the lead boiler and satisfies the 70% of the thermal demand of

the site. However maintaining the plant heat requirements is critical to

production. As such the three smaller boilers are maintained on hot standby

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so that in the event of a problem occurring with the lead boiler, the smaller

units can continue to supply the plant with adequate heat to ensure that

production is not affected.

Figure 3 in Appendix A indicates the monthly oil consumption over the past

eighteen months. Some seasonal variations can be seen with a slight

reduction in consumption over the months June to August.

Flue gas temperature on the day was measured in excess of 200°C.

It is estimated that up to 50,000 litres of hot water (~85°C) goes to drain on a

daily basis. Significant savings can be made by recovering these high grade

heat source. Further investigation is required here but it should be possible to

recover much of this heat.

3.1 Chillers & Cooling Towers A number of chillers and cooling towers are used around the plant to provide

cooling and to remove heat from the plant. During the survey Energy Services

installed a portable power monitor on Chiller No.2 located in Transformer

Room No.5 (It is worth noting at this point that the room was noticed to be

very warm on the day as room ventilation appears to be inadequate). The

electrical demand profile of the chiller can be seen in Fig.3 Appendix B.

Controls and set-points for each of the cooling towers and chillers should be

checked to ensure that unnecessary cooling/chilling does not occur. Potential

for VSD’s on the cooling tower fans and pumps should also be investigated.

Report Completed: September 2004 10

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4.0 COMPRESSD AIR There are four Atlas CopCo, oil free, water cooled air compressors on site,

details of each are listed below:

Manufacturer Model kW FAD (l/s)

No.1 Atlas CopCo ZR37 37kW 91

No.3 Atlas CopCo Data Unavailable on the Day

No.4 Atlas CopCo ZR 160 160 485

No.6 Atlas CopCo ZR 160 VSD 160 434

On the day of the survey compressor No.4 was operating as the lead

compressor. Energy Services installed portable power monitoring equipment

on the unit over a 24 hr period (Appendix B, Fig.1). As can be seen from the

graph this unit remained on full load throughout the recording period.

Compressor No.3 was also operating on full load during the survey.

Compressor No.6 with the Variable Speed Drive (VSD) ramped up and down

depending on the demand for air. The electrical demand of this unit was also

monitored by Energy Services (See Fig.2 Appendix B).

The installed Primary air receiver capacity at the Baxter plant is currently

7760litres which is inadequate based on the free air delivery (FAD) of the

compressors which could be causing unnecessarily frequent cycling of the air

compressors. Minimum primary air receiver capacity should be in the region

of 10,000 litres.

A large quantity of heat is being generated within the compressor room by the

compressors themselves. At present this heat is drawn outside by means of

extract fans in the roof. Further investigation is required to establish the

potential for heat recovery within the room. In addition the dryers are air

cooled which further adds to the rooms temperature. For every 4°C drop in

ambient air temperature the efficiency of the compressors can be improved by

1%.

Report Completed: September 2004 11

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Air pressure is being generated at approx 7.9bar. However it is believed that

max pressure required in the building is in fact below this level. The higher

generating pressure could be due to the misconception that large quantities of

air are required in the building and by generating at a higher pressure more

air is stored in the receiver and associated pipework in the event of a high

sudden demand.

While this may assist during periods of high air demand, a more energy

efficient solution would be to conduct a pipe adequacy analysis or

alternatively increase the receiver capacity. Over 7% improvement in

efficiency can be obtained by reducing generating pressure by just 1 bar

which equates to annual savings in the region of € 20,000.

Baxter recently undertook a compressed air audit which identified a number of

areas where potential exist for energy cost savings. The table below outlines

the findings of the audit:

Measure Potential

Annual Savings

Anticipated

Capital Costs

Simple

Payback

Air Dryers € 6.5 k € 40 k 6 yrs

Sequence Controller € 18k € 27k 1.5 yr

Air Receiver Capacity € 10k € 13k 1.2 yrs

A synopsis of the audit can be seen in Appendix D.

Report Completed: September 2004 12

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5.0 ENERGY MANAGEMENT AND REPORTING SYSTEMS

5.1 Policy There is a good awareness of energy production and energy costs on site at

management level. Specific energy programs have been in place for several

years.

5.2 Responsibilities for Energy Management Energy Management responsibilities are well defined on site. The Energy

Manager is responsible for the overall data collection, handling and collation

of the data, and for managing and controlling energy as a resource. The

Energy Manager is also responsible for the investigation, sourcing and

monitoring of energy related projects.

5.3 Monitoring and Targeting The existing M & T system at Baxter is used in conjunction with a Trend

Building Management System (BMS). There are several areas throughout the

site that would benefit from inclusion within the monitoring system. The

system in place is capable of extension to cater for additional electricity loads

and other energy streams including oil, steam and water.

An extension of the system, to include other energy streams will give Baxter a

much improved insight into the total site energy usage. Normalised

Performance Indexes could be established to correlate energy usage per unit

of product and flag exceptions to predicted trends for investigation. In turn,

this should identify, through appropriate reports and benchmarks,

opportunities to make energy cost and resource reductions.

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LGM Ireland Ltd. – Energy Services Ltd. Baxter Healthcare - Energy Survey Report

5.4 Staff Involvement/Training (Energy Efficiency Awareness) There is awareness at Baxter that a number of small low cost energy savings

can quickly amount to significant total savings. Further staff training would

enhance efforts to reduce on-site energy consumption.

Baxter should initiate an in house “good energy house keeping“ policy for all

staff. The idea behind such a policy would be to raise the consciousness of

the staff. A small contribution from staff towards energy awareness can

contribute greatly to the overall efficiency in general. The details of the policy

can be agreed depending on Baxters requirements but should involve all the

staff in the campaign.

This low cost measure will result in reduced energy costs and therefore better

overall efficiency. This policy will also refer to any future works or

refurbishment’s carried out. The policy would specify that any works

undertaken would use energy efficient technologies as much as possible.

6.0 WATER Baxter currently draws water from the county councils main supply. Over the

past twelve months the plant has used some 142 million gallons at an annual

cost of € 284,703.

Baxter should investigate the potential for sourcing water locally by means of

an on site well. Further investigation is requirted to determine the quality and

quantity of water available in order to justify same.

Report Completed: September 2004 14

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7.0 POTENTIAL ENERGY SAVING TECHNOLOGIES

7.1 ENERGY SAVING TECHNOLOGY CHECKLIST Technology Applicable Not

Applicable Air compression – heat recovery

Air compression – precooling Modular Compressor Sequencing

CHP

Condensing boilers Heat recovery – regenerators

Heat recovery – recuperators

Monitoring & Targeting

Variable Speed Drives

Building management systems

Efficient luminaries

Low energy computers

UPS for computer systems Modular boilers Passive solar design – daylighting solution

PIR/lux sensors for Lighting (occupancy and daylight sensing)

Bureau & Reporting Thermal Storage, Ice Bank Technology. Cooling / chilling / absorption chilling.

Standby generator sets. Synchronised generator sets MIC control

Demand Management

Insulation

Load shedding/management

CEM - Contract Energy Management

Energy Training / Housekeeping

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LGM Ireland Ltd. – Energy Services Ltd. Baxter Healthcare - Energy Survey Report

7.2 ENERGY SAVING TECHNOLOGY DETAILS

7.2.1 Good Energy Housekeeping Training General staff at the Baxter plant may benefit from further energy awareness

and efficiency training particularly regarding the benefits to be achieved with

switching off lights, machinery (which have a short start-up time) when not in

use. There are a number of electrically charged forklift trucks on site.

Timeclocks should be installed on the chargers to ensure that charging takes

place outside the day-time tariff period (8am-11pm) where possible, or indeed

outside the WPDRS period if the scheme is implemented on site.

7.2.2 Lighting It was noticed during the scoping survey that many areas were fully

illuminated during the day, despite the noticeable lack of occupants. A

detailed lighting survey should be undertaken to establish the lighting level

requirements throughout the plant and identify areas that would be suitable

for automated lighting controls, using a combination of time-clock control,

occupancy linking, and daylight sensing controls. Some of these technologies

have already been successfully installed in certain areas of the plant. The

survey would also identify areas where energy efficient fittings could be used.

7.2.3 Space and Process Heating

Heat recovery from the flue gas, air compressors and the 85°C waste hot

water should be given serious consideration as large quantities of potentially

useful heat is currently being lost. Due to the proximity of the boilers to the

location of the hot water (going to drain) there may be scope to preheat either

the boiler feedwater or combustion air.

7.2.4 VSD's and Soft Starters A number of VSD’s have been installed on the larger motors in the Baxter

plant, however there is scope for the installation of more units, perhaps on the

vacuum pumps or cooling tower pumps..

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7.2.5 Monitoring and Targeting (M&T) The correct use of a dedicated Monitoring and Targeting system results in

significantly improved cost control and energy management. The system at

Baxter does not appear to be used to its full potential however. The location

of the PC is a contributing factor to this issue. The ideal location for the PC

would be in the office of a person with the responsibility of evaluating the

information gathered by the system.

7.2.6 Winter Peak Demand Reduction Scheme – WPDRS The Winter Peak Demand Reduction Scheme has been developed by

ESBNG and approved by the CER. It is designed to encourage Customers to

reduce their electricity consumption, or increase exports between 17:00 and

19:00 on Business Days between 1st November 2004 and 25th March 2005.

This can be achieved by switching plant off at this time or in Baxters case,

through the use of on-site generation or demand management controller.

By running the 500kVA generator (which is synchronised with the electricity

grid) during the time periods identified above annual savings in the region of

€20,000 could be achieved. Obviously there would be fuel and maintenance

costs associated with running the unit, however the scheme would still prove

to be quite lucrative. Baxter should investigate this immediately as the closing

date for applications for the scheme is the 6th October next.

7.2.7 Utility Tariff Optimisation – Electrical As already mentioned the MIC level has been exceeded by the maximum

demand in recent billing periods unnecessary penalty capacity charges are

being incurred. These penalties could be avoided by implementing demand

management options including peak lopping / shaving.

7.2.8 Compressed Air Air receiver capacities should be investigated as undersized capacity can

contribute to energy losses in that compressors are mar be forced to cycle

repeatedly between on and off-load. In compressed air units 90% of the

electrical energy is converted to heat. Heat recovery is already in place from

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the air compressors to pre-heat steam boiler feedwater, however the

pipework is uninsulated and as such losses are being incurred.

Specific Compressed Air Related Actions

1. Carry out leak tests on air piping system with air-consuming equipment

turned off, using Free Air Delivery (FAD) volumes of sets.

2. Pipe adequacy sizing investigation – 3” pipe is recommended for flow

rates up to 500 scfm. Also investigate moisture/scaling in pipe internals.

Incorrectly-sized distribution piping, and internal pipe build-ups increases

friction losses and energy wastage, whilst decreasing deliverable air

pressures and volumes.

3. Investigate receiver sizes (min. of 900 litres per 100 l/s FAD is

recommended).

4. Investigate additional receivers at points of high demand. This will reduce

the operational burden at centralised air compression plant.

5. Investigate using alternatives for the main compressed air loads. Baxter

presently pay an average of 68cents per generated kWh of compressed

air (10 times the AUP of electricity, compressors are 10% efficient as an

energy conversion plant). If we factor in a further 30 % air-leak losses and

distribution inefficiency losses we can see that the cost of compressed air

energy delivered to the process is almost than 90 cent per kWh. This is an

expensive form of energy by any standards. 6. Investigate the use of ring main distribution piping with solenoid valve

isolation of areas not in use. 7. Is there really a need for compression to 7.9 bar as some equipment may

use compressed air at lower pressures? 7.2.9 Combined Heat and Power (CHP) The Baxter operation and electrical/thermal consumption ratio (1:2.7)

presents good opportunity for the employment of Combined Heat and Power

(CHP) as an efficient means of generating electricity and steam on site.

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CHP is now deemed ‘renewable’ and therefore would assist in the reduction

of greenhouse gas emissions on site. In addition the use of CHP would result

in Baxter possibly being in a position to sell on emissions permits as a

tradeable commodity under the terms of the EU Emissions Trading Directive.

Other benefits include:

Generation of high efficiency, low cost electrical & thermal energy on site

Reduction of performance Indexes per kg product

Reliable on site power not subject to grid variations/outages.

7.2.10 Pinch Analysis This method of analysing thermal energy flows in a process provides a simple

technique for setting energy targets. It allows the engineer to identify the most

beneficial matches between heat exchangers and process streams and to

assess, at minimal cost, the economic effect of changing process operating

conditions.

By representing the heat available in hot process streams as a hot composite

curve and the heat required by the cold process streams as a cold composite

curve, Baxter can make use of a convenient tool for seeing at what

temperature heat is required and how much energy is necessary overall.

Specifying an allowable temperature difference between the hot and cold

streams fixes the separation between the curves. The pinch divides the

process into two regions:

• A high temperature region, or heat sink which requires the input of energy

• A low temperature region or heat source which requires cooling to remove

an excess of energy.

Once the basic concept of pinch analysis has been understood it is possible

to address all aspects of the process design, determine the optimum process

conditions and select the most suitable utility supply systems.

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7.2.11 Pipe Heat Losses Insulation on valves etc. should be checked and improved where necessary.

Pipe systems with uninsulated flanges could have twice the heat losses of a

fully insulated system. A comprehensive steam leak test should be

undertaken on all distribution pipework.

7.2.12 Performance Indices Simple performance indices are for initial energy assessments. Baxter have

historically been monitoring the plants total energy consumption and

comparing it to the quantity of product produced. Fig.1 in Appendix C

indicates the yearly improvement which have been achieved on site over the

past 14 years. Baxter continuously monitor the energy performance indices

and continue to strive to reduce the amount of energy consumed compared to

product manufactured.

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Report Completed: September 2004 21

APPENDICES Appendix A Fig. A1. Historical Maximum Demand Vs Maximum Import Capacity Fig. A2. Historical Electricity Consumption Fig. A3. Historical Heavy Fuel Oil Consumption Fig. A4. Historical Water Consumption Appendix B Fig. B1.Electricity Demand for Compressor No.4 Fig. B2. Electricity Demand for Compressor No. 6 (VSD Controlled) Fig. B3. Electricity Demand for Chillier No.2

Appendix C Fig. C.1. Energy Efficiency Utilisation

Appendix D Compressed Air Audit Synopsis

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