Janssen Pharmaceutical

Power Need

Janssen is a world leading pharmaceutical company. Their site in Cork produces Active Pharmaceutical Ingredients  (API) which are shipped to other sites for incorporation in end products. The company required a Combined Heat and Power (CHP) plant to generate on site power, steam and Low Temperature Hot Water (LTHW) for various site processes. With ever increasing energy bills, the aim was to reduce on-site energy costs.

Solutions

Following  a proposal resulting from careful analysis of the site and sizing requirements, a containerised Caterpillar G3512E gas generator, with an electrical output of 1.0MWe was specified. The solution  includes an exhaust gas boiler producing up to 625kg/hr of steam and a LTHW recovery system generating up to 569kWt.  The CHP solution uses two ways of generating heat for the site. Exhaust gases are used to evaporate condensate return water to generate steam, whilst heat exchangers harvest heat from the engine water jacket circuit to produce LTHW.  The steam and LTHW is then used within various production processes within the plant.  The inclusion of a step-up transformer allows the production of continuous power at 10 kV and integration of the CHP system with the existing site High Voltage (HV) ring infrastructure. The scope of works included a purpose designed building to house the exhaust gas boiler, hot well and blowdown vessel.

Results

Finning was selected as the sole CHP supplier based on previous experience and local coverage.  Finning will provide ongoing maintenance for the plant including preventative maintenance, servicing, genuine spare parts and remote monitoring of the site. Says Finning's Gas Projects Sales Manager Keith Stocker: "This project demonstrates our ability to work with a customer from system design through to implementation and ongoing maintenance. It conveys our knowledge and expertise of CHP applications in the pharmaceutical sector."