Presentation On Sustainability April 2009 Final

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  • 1. Practical Applications of Sustainability in Biopharmaceutical Plant Design Picture: Centocor: Project BioCork, Ireland ISPE Facility of the Year 2009: Category Winner: Sustainability
  • 2. PM Group The largest life sciences focused A&E Design & Project Management firms in Europe 1,700 people – Gross Revenue €200M Specialising in Bio Pharma Project Delivery Permitting & Architectural & Full Service Company Environmental Project Management Engineering Design o Architecture & Engineering Consultancy o Permitting & Environmental Consulting o Procurement & Contract Administration o Project & Construction Management o Commissioning & Qualification Privately Owned Procurement & Contract Commissioning & Qualification Established 1973 Administration Construction Management
  • 3. Contents Introduction Sustainability Defined Sustainability Assessment Schemes Application of Sustainable Design Sustainable design of biopharmaceutical facilities Andy Rayner Group Technology Director PM Group andy.rayner@pmg.ie
  • 4. What is Sustainability Environmental Sustainability – is defined as the ability of the environment to continue to function properly indefinitely. The goal of environmental sustainability is to minimize environmental degradation without using the resources faster than they can be replenished 1987 Brundtland Report
  • 5. Sustainability Assessment Schemes LEED (Leadership in Energy and Environmental Design) 26 Sustainable Sites US Green Buildings Council (USGBC) 10 Water Efficiency – Green Building Rating System LEED 2009 for New Construction and Major Renovations 35 Energy & Atmosphere Otherwise known as LEED version 3.0 Ratings: 14 Materials & Resources Certified (40-49) Silver (50-59) 15 Indoor Environmental Quali Gold (60-79) Platinum (80 points and above) 100 TOTAL 6 Innovation & Design Proces 4 Regional Priority 110 TOTAL
  • 6. Sustainability Assessment Schemes BREEAM (Building Research Establishment Environmental Assessment Method) BRE (Building Research Establishment – introduced scheme in the UK) BREEAM: INDUSTRIAL, BREEAM: BESPOKE, BREEAM: INTERNATIONAL BREEAM assessments can be undertaken for both new build and existing building refurbishment Ratings: Pass (30-45) Good (45-55) Very Good (55-70) Excellent (70-85) Outstanding (>85)
  • 7. Other Sustainability Assessment Schemes NOTE: ABOVE USES LEED V2.2 SCORES
  • 8. Carbon Footprinting & Zero/Low/Neutral Carbon Facilities Carbon Footprinting standards: ISO 14064-1: Specification with guidance at the organization level for quantification and reporting of greenhouse gas emissions and removals The Greehouse Gas Protocol Initiative Corporate Standard Project Protocol Zero Carbon, Low Carbon & Carbon Neutral: A zero carbon development is one that achieves zero net carbon emissions from energy use on site, on an annual basis Industrial production facilities achieving zero carbon unlikely in the near future, some residential and commercial buildings are achieving zero carbon today “Low Carbon” & “Carbon Neutral” is feasible today
  • 9. Some Focus Areas for Sustainable Design Innovation Sustainable Energy & Water Materials & Indoor Sites Atmosphere Efficiency Resources Environmental Quality
  • 10. Typical Greenfield Cell Culture Site Utility Usage POWER WATER GAS 4.2 MVA 720 M3/DAY 1,010 NM3/HR 2 x 15,000L bioreactors Incl. USP + DSP 1 x 1,000L Pilot Plant Labs, Admin, CUB Site Infrastructure WASTE WATER SOLID WASTE 631 M3/DAY <200 TONNE/YR Innovation
  • 11. Typical Greenfield Cell Culture Site Utility Usage POWER WATER GAS 4.2 MVA 720 M3/DAY 1,010 NM3/HR 2 x 15,000L bioreactors Incl. USP + DSP 1 x 1,000L Pilot Plant Labs, Admin, CUB Site Infrastructure WASTE WATER SOLID WASTE 631 M3/DAY <200 TONNE/YR Innovation
  • 12. Possible Disposables Implementation Available – Good Application Available. but must confirm process suitability Available. but must confirm process suitability Unavailable at larger scales Innovation
  • 13. Typical Greenfield Cell Culture Site Utility Usage POWER WATER GAS POWER WATER GAS 4.2 MVA 720 M3/DAY 1,010 NM3/HR 1.9 MVA 64 M3/DAY 160 NM3/HR 2 x 15,000L bioreactors 12 x 2,000L disposable bioreactors Incl. USP + DSP Incl. USP + DSP 1 x 1,000L Pilot Plant 1 x 1,000L Pilot Plant Labs, Admin, CUB Labs, Admin, CUB Site Infrastructure Site Infrastructure WASTE WATER SOLID WASTE WASTE WATER SOLID WASTE 631 M3/DAY <200 TONNE/YR 54 M3/DAY <200 TONNE/YR Innovation
  • 14. Sustainable Sites Site Selection Development Density Brownfield Redevelopment Alternative Transportation Site Development Stormwater Design Heat Island Effect Light Pollution Reduction Sustainable Sites
  • 15. Energy & Atmosphere Commissioning of Building Energy Systems Optimized Energy Performance Refrigerant Management On-site Renewable Energy Measurement & Verification Green Power Energy & Atmosphere
  • 16. Some Renewable Energy Options On Site Wind Power Typical >18 year payback on Wind Turbines Turbine Size typically 0.2kW to 10kW Typical Offices/Laboratories Energy Usage 200,000 kWhr/yr Example above needs 20 off 10kW Wind Turbines Concerns over noise and takes up valuable real estate space Height requirements can mean visual impact concern for planning applications Ducted wind turbines may overcome the visual concerns in future by putting turbines inside buildings Off Site Wind Power Options – Green Energy Purchase power from a renewable energy provider Good option where available – consider during site selection Energy & Atmosphere
  • 17. Some Renewable Energy Options Solar Power Passive Solar Architecture Consider the Building Orientation on the site Significant solar gain issues can be minimised Solar Photovoltaic Power Panels Example : Google Headquarters – 9,000 solar panels gave 1.6MW which was 30% of peak power demand Example : Payback was 7 years, but included a grant Solar Collector Water Heating Consider this approach for some of the hot water duties Payback against electric and gas hot water generation is good Energy & Atmosphere
  • 18. Some Renewable Energy Options Biomass & Biofuels If a carbon source is combusted to release carbon dioxide, then the re-growth of that carbon source will reabsorb the carbon dioxide – net carbon emissions effectively zero Biomass – solid fuels capable of combustion Examples: wood, agricultural waste, living cell materials Biofuels – Liquid versions of biomass Examples: ethanol, methanol, methane, hydrogen Example of Biomass in a Biopharmaceutical Facility Biomass boiler to handle base load heating (2MW) Supplemental to a traditional gas boiler run on demand for peak demand or if biomass (wood chips) supply issues Supplier has stock close to site & delivers to onsite silo Payback CO2 emissions reduced by 88%, but 1 extra boiler Energy & Atmosphere
  • 19. Hot and Chilled Water Sources, Storage and Distribution Geothermal Heating Systems Where geothermal conditions permit hot water can be obtained through geothermal closed loop systems Concrete Thermal Slabs Use of concrete slab thermal capacity for heating and cooling Can use relatively high water temperatures for cooling, and low water temperatures for heating Chilled Beams Active chilled beams reduce the traditional air conditioning requirements for offices Energy & Atmosphere
  • 20. HVAC & Building Services Energy Usage HVAC/Building Services Primary energy users are - Fan Power, Heating, Cooling and Dehumidification Fan Power is the biggest energy user, limit the motive power per m3 of air during the design to save energy and use direct drive fans with VSD (most energy efficient) Reduce air change rates, example: ISO 7 – use 30 ac/hr instead of 40 ach/hr ISO 8 - use 15 ac/hr instead of 20 ac/hr Consider primary air handler (to dehumidify by cooling) & a secondary air handler (to trim temperature) of fresh (20%) and recirculating (80%) air – saves energy overall Widen acceptable humidity bands to reduce humidification loads Energy & Atmosphere
  • 21. Centocor Example - Sustainable Energy Engineering Do NOT deploy Renewable Energy Technology to a ‘Gas Guzzling’ Facility – THIS IS NOT SUSTAINABLE! Begin with Energy Efficiency – Minimise the facility and process Energy Demand Then deploy Renewable Energy In their totality, Energy Efficiency measures reduce Capital investment
  • 22. Centocor - Energy Efficient Design (EED) Application of extensive J&J Corporate Guidelines Centocor Focus Areas During Design Cleanroom HVAC Offices Air Conditioning HVAC Heat Recovery Lighting Management Clean Utilities Waste Water Treatment Black Utilities
  • 23. Centocor - Illustration of EED Approach – Cleanroom HVAC AHU Options Annual Cost 500,000 Centocor 450,000 Base Case Primary /Secondary Air handling Reduce Air 400,000 Change Rates 350,000 Reduce Specific 300,000 Fan PowerWiden Humidity Control Bands Cost €/year Fan 250,000 Cooling Energy Boiler 200,000 150,000 100,000 50,000 0 Option 1 Option 2 Option 3 Option 4 Option 5
  • 24. Lighting Lighting Lighting is a large energy consumer in the manufacturing space Occupancy –vs- Lighting Strategy Assess the various plant areas to determine frequency of occupancy Warehouse, plant room areas, and even some manufacturing areas can have low occupancy In low occupancy areas consider occupancy sensors to switch light down to a minimum level when unoccupied Light Pipes Consider Light Pipes (rather than artificial lights) to bring natural light into warehouse and plant rooms that wouldn’t be directly adjacent to outside locations Energy & Atmosphere
  • 25. Laboratories Fume Hoods & Laboratory Airflow Combination Fume Hood Sashes Variable Air Volume (VAV) Systems Night time Setbacks Ductless Fume Hoods Laboratory Waste Treatment Systems Chemical vs Autoclave treatment Laboratory Furniture Low / no VOC finishes Mobile casework increase flexibility & reduce furniture Energy & Atmosphere
  • 26. Utility Energy Usage Water For Injection (WFI) One of the biggest utility energy users, multi-effect vs Vapor Compression Stills Focus on distribution temperatures – don’t run loops too hot – run at close to 80ºC, not 95ºC BioKill (by Heat) Another energy intensive operation, consider minimum temperatures – avoid excessive safety margin Utility Redundancy Photos coutesy Steritech Many people operate 2 off 75% utility systems, not always efficient at the normal base load Consider alternative strategy of 2 off 66% + 1 off 53% This is usually a more efficient mode of operation Energy & Atmosphere
  • 27. Water Efficiency Water Efficient Landscaping Rainwater Harvesting Stormwater Management Innovative Wastewater Technologies Membrane Bioreactor (MBR) Waste Water Treatment System Smaller footprint and cleaner waste Water Use Reduction Highest Efficiency (90%) Reverse Osmosis (RO) Membranes to reduce waste water Water Efficiency
  • 28. Materials & Resources Storage & Collection of Recyclables Materials Reuse Recycled Content Construction Waste Management Building Reuse Regional Materials Rapidly Renewable Materials (eg Bamboo) Certified Wood Materials & Resources
  • 29. Indoor Environmental Quality Outdoor Air Delivery Monitoring Increased Ventilation Construction Indoor Air Quality Management Plan Low-emitting materials Indoor chemical & Pollutant Source Control Controllability of Lighting & Thermal Comfort Daylight & Views Indoor Environmental Quality
  • 30. What can be achieved? – Example 1 Centocor BioCork Centocor BioCork Project achieved performance metrics against benchmark sites as follows: 40% more energy efficient 97% smaller carbon footprint Significantly smaller waste streams