The output from the chemical and pharmaceutical industries covers a wide range of products, including base chemicals, specialty chemicals, consumer chemicals and pharmaceuticals. In this sector, production processes are energy intensive. Globally, these industries account for roughly 20% of total worldwide energy demand and 14% of global industrial greenhouse gas (GHG) emissions.
Large energy-saving opportunities exist in the chemical and pharmaceutical sectors. For example, some 90% of chemical processes involve the use of substances known as catalysts, added to increase the rate of chemical reactions. Catalysts enhance production efficiency and reduce energy use. Using improved catalyst technology can offer an important way to achieve greater energy efficiency and further curtail greenhouse gas emissions.
Maximpact has strong expertise in the identification of energy-saving opportunities in the chemical and pharmaceutical sectors using state-of-the-art techniques such as data mining and artificial intelligence to uncover potential energy savings. Our work on energy research projects keeps us current in all aspects of energy-saving technology, and we have developed a database of the newest technologies unrivalled in this sector.
Click here to view one of our energy efficiency projects for a pharmaceutical facility.
Energy Efficiency Indicators in the Chemical Sector
The energy efficiency and potential savings in the chemical and petrochemical sector, by using best practice technologies, are shown in the table below. For example, it appears that in India there is a potential to save 18.6% of energy usage and cost compared to 21% potential savings in China.
By studying your various manufacturing processes and the utility systems, such as compressed air, process heating systems, and water pumping, a Maximpact team can help you save between 10% to 40% on your energy use and costs.
In our experience, 10% of the energy savings can be achieved with small investments that will pay back within 1 year. Another 10% savings can be achieved with medium levels of investments with payback periods of less than 2 years. Higher cost investment can achieve a further 10%-20% energy savings with typical paybacks in less than 4 years.
Please find below our energy efficiency services for the chemical and pharmaceutical industry sector. Contact us for more information.
Comprehensive energy audits
This energy audit will cover all thermal and electrical process plant and utility systems. Our comprehensive energy audit specification will provide you with a detailed specification of our services and saving potential which is typically between 20% and 40% of your existing energy bills.
Data mining and process optimisation opportunities audit
Data mining can uncover a wealth of energy and process saving opportunities in your industry. Maximpact’s ability to uncover patterns in inefficient use of energy or poor process performance and predict the energy-saving potential of utility and process improvements will provide you with a competitive edge that you will want to keep a secret from your competitors.
We can provide a first step study that offers a gap analysis and recommendations as to the measures you need to take now to avail yourself of this new technology and the type of artificial intelligence systems and approaches that would be best applied to your process and utility systems.
New equipment energy efficiency specification
Are you considering purchasing new process or utility equipment, such as a new steam boiler or low-temperature cooling system, a new pumping system or a new cooling tower or air compressor?
If so, we can help you ensure that your vendors provide you with efficient equipment that will help you save on running cost over its lifetime. We can help you include energy efficiency specifications in your tender documents that will ensure a level playing field for all bidders on your jobs.
Perform an energy management system gap analysis
We will study your existing energy management practices and determine what steps are required in order for you to implement a modern energy management system such as that provided by the international energy standard ISO 50001. This is typically called a gap analysis study.
Training in Energy Awareness
Maximpact provides employee training in energy awareness associated with good plant operational practices.
ISO 50001 Full Implementation Support
We provide support for full implementation of the energy management systems ISO 50001 in your factory.
Plant resilience audit and recommendations action plan
How prepared are your manufacturing processes and utility systems to cope with weather extremes caused by global warming?
Are your manufacturing and utility systems capable of coping with climate extremes such as the icy polar vortex extending over northern parts of the United States in December 2022 – a phenomenon that arrived with temperatures as low as -50⁰C?
The purpose of our resilience study is to determine how exposed your manufacturing and utility systems are to the extremes in weather variations that will be more frequently experienced throughout the world due to climate change.
These extremes are occurring right now. It was common practice in the past to design processes for specific minimum low, ambient low, and high temperatures based on weather statistics averaged over 50 to 100 years. Global warming has changed these statistics, but some design engineers are still catching up.
We have formulated an approach to assess your process and utility systems and their resilience to climate change. Don’t wait until your vulnerabilities are uncovered by extreme weather events that may result in enormous costs in lost production and product output. Act now and be prepared.
Renewable Energy in the Chemical and Pharmaceutical Sector
- Potential for use of heat pumps for low-temperature process heat recovery systems
- The use of waste heat and adsorption chillers to make cold water at 3.4⁰C to displace electric chillers used for process or environmental cooling
- Organic Rankine cycle for converting process waste heat into electricity
- On-site wind power generation to displace grid power
- The installation of gas engines or a gas turbine to produce electricity and waste heat for process use. Such systems can reduce the bills for electricity from the grid plus gas and oil by as much as 45%.
- Solar water heating: Solar air heating systems use the building of conventional steel siding that is painted black to absorb solar radiation. Fresh air entering the bottom of the panels is heated by the sun as it passes over the warm absorber. Small air distribution fans are used to move the hot air around the building’s interior. Energy improvements can have a payback period of less than 3 years