Presentation On Sustainability April 2009 Final

Practical Applications of Sustainability in Biopharmaceutical Plant Design

Picture: Centocor: Project BioCork, IrelandISPE Facility of the Year 2009:Category Winner: Sustainability

The largest life sciences focused A&E Design & Project Management firms in Europe1,700 people – Gross Revenue €200MSpecialising in Bio Pharma Project Delivery

Full Service Companyo Architecture & Engineeringo Permitting & Environmental Consultingo Procurement & Contract Administrationo Project & Construction Managemento Commissioning & Qualification

Privately OwnedEstablished 1973

PM Group

Architectural & Engineering

Design

Commissioning & Qualification

Procurement & Contract

Administration

Project Management

Construction Management

Permitting & Environmental Consultancy

IntroductionSustainability DefinedSustainability Assessment Schemes

Application of Sustainable DesignSustainable design of biopharmaceutical facilities

Contents

Andy RaynerGroup Technology DirectorPM [email protected]

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

LEED (Leadership in Energy and Environmental Design)

US Green Buildings Council (USGBC) – Green Building Rating System

LEED 2009 for New Construction and Major RenovationsOtherwise known as LEED version 3.0

Ratings: Certified (40-49)Silver (50-59)Gold (60-79)Platinum (80 points and above)

Sustainability Assessment Schemes

4 Regional Priority

100 TOTAL

Water Efficiency

Sustainable Sites26

10

110 TOTAL

35

14

15

6 Innovation & Design Proces

Indoor Environmental Quali

Materials & Resources

Energy & Atmosphere

BREEAM (Building Research Establishment Environmental Assessment Method)

BRE (Building Research Establishment – introduced scheme in the UK)

BREEAM: INDUSTRIAL, BREEAM: BESPOKE, BREEAM: INTERNATIONALBREEAM 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)

Sustainability Assessment Schemes

Other Sustainability Assessment Schemes

NOTE: ABOVE USES LEED V2.2 SCORES

Carbon Footprinting standards:ISO 14064-1: Specification with guidance at the organization level for quantification and reporting of greenhouse gas emissions and removalsThe Greehouse Gas Protocol Initiative

Corporate StandardProject 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 basisIndustrial 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

Carbon Footprinting & Zero/Low/Neutral Carbon Facilities

Some Focus Areas for Sustainable Design

Innovation SustainableSites

WaterEfficiency

Energy &Atmosphere

Materials &Resources

IndoorEnvironmental

Quality

Typical Greenfield Cell Culture Site Utility Usage

2 x 15,000L bioreactorsIncl. USP + DSP

1 x 1,000L Pilot PlantLabs, Admin, CUBSite Infrastructure

POWER4.2 MVA

WATER720 M3/DAY

GAS1,010 NM3/HR

WASTE WATER631 M3/DAY

SOLID WASTE<200 TONNE/YR

InnovationInnovation




POWER4.2 MVA

WATER720 M3/DAY

GAS1,010 NM3/HR




Available Available –– Good ApplicationGood ApplicationAvailable. but must confirm process suitabilityAvailable. but must confirm process suitability

Available. but must confirm process suitabilityAvailable. but must confirm process suitabilityUnavailable at larger scalesUnavailable at larger scales

Possible Disposables Implementation





POWER4.2 MVA

WATER720 M3/DAY

GAS1,010 NM3/HR



12 x 2,000L disposable bioreactorsIncl. USP + DSP


POWER1.9 MVA

WATER64 M3/DAY

GAS160 NM3/HR




Sustainable Sites

SustainableSites

SustainableSites

Site SelectionDevelopment DensityBrownfield RedevelopmentAlternative TransportationSite DevelopmentStormwater DesignHeat Island EffectLight Pollution Reduction

Energy & Atmosphere

Commissioning of Building Energy SystemsOptimized Energy PerformanceRefrigerant ManagementOn-site Renewable EnergyMeasurement & VerificationGreen Power

Energy &Atmosphere

Energy &Atmosphere

Some Renewable Energy Options

On Site Wind PowerTypical >18 year payback on Wind TurbinesTurbine Size typically 0.2kW to 10kWTypical Offices/Laboratories Energy Usage 200,000 kWhr/yr

Example above needs 20 off 10kW Wind TurbinesConcerns over noise and takes up valuable real estate spaceHeight requirements can mean visual impact concern for planning applicationsDucted wind turbines may overcome the visual concerns in future by putting turbines inside buildings

Off Site Wind Power Options – Green EnergyPurchase power from a renewable energy providerGood option where available – consider during site selection

Energy &Atmosphere

Energy &Atmosphere


Solar PowerPassive Solar Architecture

Consider the Building Orientation on the siteSignificant solar gain issues can be minimised

Solar Photovoltaic Power PanelsExample : 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 HeatingConsider this approach for some of the hot water dutiesPayback against electric and gas hot water generation is good

Energy &Atmosphere

Energy &Atmosphere


Biomass & BiofuelsIf 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 zeroBiomass – solid fuels capable of combustion

Examples: wood, agricultural waste, living cell materialsBiofuels – Liquid versions of biomass

Examples: ethanol, methanol, methane, hydrogen

Example of Biomass in a Biopharmaceutical FacilityBiomass 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 siloPayback CO2 emissions reduced by 88%, but 1 extra boiler

Energy &Atmosphere

Energy &Atmosphere

Hot and Chilled Water Sources, Storage and Distribution

Geothermal Heating SystemsWhere geothermal conditions permit hot water can be obtained through geothermal closed loop systems

Concrete Thermal SlabsUse of concrete slab thermal capacity for heating and coolingCan use relatively high water temperatures for cooling, and low water temperatures for heating

Chilled BeamsActive chilled beams reduce the traditional air conditioning requirements for offices

Energy &Atmosphere

Energy &Atmosphere

HVAC & Building Services Energy Usage

HVAC/Building ServicesPrimary energy users are - Fan Power, Heating, Cooling and DehumidificationFan 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/hrISO 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 overallWiden acceptable humidity bands to reduce humidification loads

Energy &Atmosphere

Energy &Atmosphere

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

Centocor - Energy Efficient Design (EED)

Application of extensive J&J Corporate Guidelines

Centocor Focus Areas During DesignCleanroom HVACOffices Air ConditioningHVAC Heat RecoveryLighting ManagementClean UtilitiesWaste Water TreatmentBlack Utilities

Centocor - Illustration of EED Approach – Cleanroom HVAC

AHU Options Annual Cost

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

Option 1 Option 2 Option 3 Option 4 Option 5

Cos

t €/y

ear

Fan Cooling EnergyBoiler

Centocor Base CasePrimary /Secondary

Air handlingReduce Air Change RatesReduce Specific

Fan PowerWiden Humidity Control Bands

Lighting

LightingLighting is a large energy consumer in the manufacturing space

Occupancy –vs- Lighting StrategyAssess the various plant areas to determine frequency of occupancy

Warehouse, plant room areas, and even some manufacturing areas can have low occupancyIn low occupancy areas consider occupancy sensors to switch light down to a minimum level when unoccupied

Light PipesConsider 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

Energy &Atmosphere

Laboratories

Fume Hoods & Laboratory AirflowCombination Fume Hood SashesVariable Air Volume (VAV) SystemsNight time SetbacksDuctless Fume Hoods

Laboratory Waste Treatment SystemsChemical vs Autoclave treatment

Laboratory FurnitureLow / no VOC finishesMobile casework increase flexibility & reduce furniture

Energy &Atmosphere

Energy &Atmosphere

Utility Energy Usage

Water For Injection (WFI)One of the biggest utility energy users, multi-effect vs VaporCompression StillsFocus 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 RedundancyMany people operate 2 off 75% utility systems, not always efficient at the normal base loadConsider alternative strategy of 2 off 66% + 1 off 53%This is usually a more efficient mode of operation

Energy &Atmosphere

Energy &Atmosphere

Photos coutesy Steritech

Water Efficiency

Water Efficient LandscapingRainwater HarvestingStormwater Management

Innovative Wastewater TechnologiesMembrane Bioreactor (MBR) Waste Water Treatment SystemSmaller footprint and cleaner waste

Water Use ReductionHighest Efficiency (90%) Reverse Osmosis (RO) Membranes to reduce waste water

WaterEfficiency

WaterEfficiency

Materials & Resources

Storage & Collection of RecyclablesMaterials ReuseRecycled ContentConstruction Waste Management

Building Reuse

Regional MaterialsRapidly Renewable Materials (eg Bamboo)Certified Wood

Materials &ResourcesMaterials &Resources

Indoor Environmental Quality

Outdoor Air Delivery MonitoringIncreased VentilationConstruction Indoor Air Quality Management PlanLow-emitting materialsIndoor chemical & Pollutant Source ControlControllability of Lighting & Thermal ComfortDaylight & Views

IndoorEnvironmental

Quality

IndoorEnvironmental

Quality

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

Documents

Presentation On Sustainability April 2009 Final