Installing a CHP unit has resulted in an annual saving in excess of €1 million for Bausch + Lomb.
Bausch + Lomb is a global manufacturer of medical devices and pharmaceutical products. Bausch + Lomb Waterford, located in the IDA Industrial Estate, Waterford, is a medical device manufacturer producing contact lenses for the global market.
The facility now produces over one million contact lenses per day and employs 1,250 people at its 44 acre site.
A state-of-the-art Combined Heat and Power (CHP) plant has recently been installed and commissioned at this facility.
"Bausch + Lomb are extremely satisfied with the performance of the CHP unit to date and have exceeded the initial project paback and uptime periods. This has resulted in greater than expected financial and environmnental savings for the site."
CHP, also known as " Co-Generation", is the simultaneous production of electricity and heat, usually in the form of hot water or steam from a primary fuel such as natural gas (see figure 1) . Electricity is generated on site by using natural gas to drive an alternator connected to the engine.
The heat from exhaust fumes generated by the engine is harvested to provide heating and hot water to the hotel and leisure centre, while some of the energy within the hot water can also be used to provide cooling and air conditioning by using absorption.
Having previous experience with CHP the team at the Kilkenny Ormonde hotel invested in a new unit which was specifically tailored to their requirements across the hotel and leisure centre. This upgraded unit would ensure longer up times and better financial savings based on data they had accumulated over 16 years. The unit was supplied within a containerised package and placed on the roof to reduce noise. The CHP unit satisfies 65% of the total heat demands and 40% of the total electrical demands.
Due to potential inefficiencies in electricity generation and the resulting cost of electricity from energy suppliers, significant savings can be made by generating electricity to meet requirements on your own site. The financial benefits of onsite electricity generation (using natural gas to power the electricity generator) are evident by comparing daytime electricity prices in Ireland of circa 12.34/kWh with market natural gas prices of 4.08 cent/kWh (SEAI, April 2016 including VAT and relevant taxes).
The system is powered by a 45 tonne, 4170hp V12 engine running at 1,000 revolutions per minute. THe engine uses approximately 760m3 of natural gas per hour and consists of liquid cooled, twin turbocharged, heavy-duty four-stroke Otoo gas-cycle technology. The engine is controlled centrally via a control system, to ensure optimal efficiencies and low consumption levels.
The installation operates 24 hours a day, 7 days a week generating electricity, steam and hot water all year round.
The custom built CHP buildin incldes some innovative design solutions including; auxiliary equipment located on the roof of the building, additional pipe bridge for the medium voltage (MV) cables and gas pipe, LED lighting, maintenance platforms, additional acoustic properties including a cavity wall and finally, a dedicated viewing platform from which the engine can be viewd without entering the engine room.
The CHP system comes with two separate controller systems: the Inteli Modular Gen-set Controller used to control, monitor and protect the CHP and the Total Electronic Management (TEM) system providing full graphical operating software for manual control and visualisation of TEM control units specifically for gas engines. Both of these control systems offer the latest technology for controlling, monitoring, trending, remote interfacing, archiving, logging and user interface between the CHP and the end user.
The natural gas connection was upgraded by Gas Networks Ireland to deliver the additional capacity required to supply this new CHP.
Edina is a leading suppllier, installer and maintenance provider for gas to power solutions and is the sole distributor in Ireland and the UK for market leading MWM manufactured gas engines.
MWM gas engines are world renowned for achieving market leading electrical and thermal efficiency, low operating and servicing costs and high relability and availability.
Unit 4, Swords Business Park
T:+353 (0) 1882 4800
Bausch + Lomb, a Valeant Pharmaceuticals, Inc. company, is a leading global eye health organization that is olely focused on protecting, enhancing and restoring people's eyesight.
Core businesses include over-thecounter supplements, eye care products, opthalmic pharmaceuticals, contact lenses, lens care products, contact lenses, lens care products, opthalmic surgical devices and instruments. We develop, manufacture and market one of the most comprehensive product portfolios the industry, which is available in more than 100 countries.