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Optimised CHP package delivers savings for pharmaceutical giant

Client: Leading European chemical manufacturer

Location: Middlesbrough, UK

Sectors: Pharmaceuticals

The Challenge

Rapid replacement of aging gas generator

A leading European contract manufacturer of high-quality fine chemicals required a replacement gas generator after its previous model broke down.

The setup in place comprised a 20-year-old combined heat and power (CHP) system, with a major heat recovery boiler and four 1 MW reciprocating gas generators.

When one of the generators broke down, the company looked at its options and decided against rebuilding the aging unit and opted for a new generator.

A rapid solution was required to avoid losses incurred via interrupted production – which is where we got involved.


Project fact file

Energy saved by improved CHP 24MW
Size of gas generators 1.1 MW
Total number of generators 4 x

The Solution

Higher output, smaller footprint with new gas generator

Fundamental to operations was how our solution would work with the current CHP system. Our experts decided that our 1.1 MW gas generator would be ideal to supplement the plant’s power demands.

Our generator was far more compact than the previous generator, so installation was quick and easy, with only minor pipework changes and an adaptation to the exhaust into the heat exchange system needed.

This, coupled with higher output and a smaller footprint, resulted in the company deciding to replace the remaining older generators and replacing them with three further 1.1 MW generators.


The Impact

Improved CHP processes produce savings for customer

Our experts installed the new system rapidly into the CHP system via a one-in-one-out fitting.

Each generator delivers a recoverable heat output of approximately 600 kW, which means a total of 24,000 kW can be used instead of wasted, across the site.

The bottom line? Reduced energy bills, improved site efficiency and lowered emissions.