AB | Case History
AB for PFIZER A SIGNIFICANT TECHNOLOGICAL AND APPLICATIVE CASE IN THE FIELD OF COGENERATION TO SERVE THE PHARMACEUTICAL INDUSTRY
AB for PZIFER
AB IS A PARTNER OF PFIZER, TO WHICH IT SUPPLIES ELECTRICITY FOR ITS INTERNAL MANUFACTURING AND LINES AND UTILITIES.
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strategic
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COGENERAtION:
strategic FOR THE PHARMACEUTICAL INDUSTRY A PROCESS WHERE IT IS ESSENTIAL TO STREAMLINE ENERGY COSTS WHILE MAINTAINING PEAK PERFORMANCE IN FULL RESPECT OF THE ENVIRONMENT. leading
in particular, which is considered the
worldwide
ideal solution for the optimisation
in the field of research applied to
of performance, at the same time
the pharmaceutical industry. For
consolidating a commitment to the
some years now, Pfizer has been
environment from all viewpoints.
extremely
the
The awareness of the advantages of
themes of eco-sustainability and the
cogeneration has, in fact, led Pfizer
quality of the natural and working
engineering to request development
environments. This philosophy has
of a cogeneration plant able to meet
been applied by long-term choices
the growing needs of their production
also involving a growing attention for
lines, and those of the service
energy production and cogeneration
infrastructures.
Pfizer
is
one
international
of
Groups
attentive
the
towards
≤
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THE PFIZER GROUP: RESEARCH, AUTHORITY AND ATTENTION TO QUALITY IN ALL ASPECTS. Founded in the United States of America in 1849,
in recent years.
Pfizer is today the pharmaceutical company that
The research group is involved in various clinical
invests most in research and development, with
experiments aimed at producing data useful to the
more than 8 billion dollars invested in 2007. They
registration of pharmaceutical products the world
have research centres in various different countries,
over. Specifically, many of the clinical studies carried
and particularly in the United States of America
out in Italy today, are multicentre international
and England. Today, they can rely on around 85
studies with phase II, II, III or IIIb.
thousand employees worldwide, with products
In 2007, Pfizer Italy’s total expenditure for research
exported to more than 150 different countries. The
amounted to 8.3 million euros, exceeding the efforts
product portfolio includes 7 different pharmaceutical
made in 2006,when approximately 6 million euros
products, number one in their respective therapeutic
were invested. With 938 centres and 70 researchers
areas, and a turnover that in 2007 exceeded 48 billion
involved (43 employees and 27 on a specific contract),
dollars. Over the last ten years, investment in basic
Pfizer Italy research mainly concentrates on oncology
research has tripled production and allowed for
and other areas of significant interest: infection
the discovery of new pharmaceutical products. The
diseases, central nervous system, endocrinology,
Pfizer research laboratories are responsible for the
cardiovascular diseases, diabetes, urogynecology,
discovery of some of the most innovative medicines
pain and inflammatory diseases.
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The Ascoli Piceno plant was set up in 1972 to produce
year, with three production shifts. Apart from a fully-
for Italy, the United States of America and Japan. It
automated warehouse with 13,000 automatic pallet
is the only plant in the whole world to produce a new
places, it also boasts technology that allows for the
pharmacological product to treat gastrointestinal
highest levels of automation and maximum control of
tumours. Although the production plant dates back to
movement of the active ingredients, which therefore
1972, it is one of the most advanced around, from both
never once come into contact with the production
a technological and industrial architecture viewpoint.
workers. The conditioning system provides ample
Over the years, the plants have been significantly
assurance against cross contamination: the area is
modernised, with the introduction of new technology
never recycled and is treated with absolute filters,
and the extension of services. The plant occupies
both in and out. The main pharmaceutical forms
a total surface area of 164,000 square metres, of
supplied are: granules, simple and coated tablets,
which 24,000 m² covered by plants, warehouses and
rigid capsules, for a total of 1300 presentations
other structures, and 140,000 m² land: the sheer size
distributed on more than 100 markets. More than
of this surface area not only leaves plenty of room
60% of production goes to foreign markets, meaning
for the existing structures, but also allows for the
that the procedures and processes are aligned to the
planning of future extensions according to company
strictest standards imposed by international laws,
strategies and objectives. The large areas taken
and specifically to the United States FDA.
up by production departments and services allow
The Ascoli Piceno plant is currently the only one
for complete compliance with good manufacturing
worldwide to produce a pharmaceutical product,
standards and the movement of raw materials and
Sutent (sunitinb malate) for the treatment of
finished products in accordance with maximum
gastrointestinal tumours and metastatic renal
rationality criteria. The plant has an estimated
carcinoma.
production capacity of around 90 million packages a
The Pfizer Group has been a presence in Italy since 1955, with two administrative offices in Rome and Milan, and production plants in Ascoli Piceno (Marche) and Pisticci, province of Matera (Basilicata).
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A COLLABORATION AND A PLANT TO BE PROUD OF.
AB and
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The system designed and built by AB for the Pfizer Ascoli Piceno plant is a significant technological and applicative case history in the field of cogeneration to serve the pharmaceutical industry. The reasons for the interest in this plant go well beyond the simple fact that working for Pfizer, one of the most important international groups worldwide in the field of applied research into pharmaceuticals, is, without doubt, in itself greatly satisfying. Meticulous as always, in all development initiatives, Pfizer carefully monitored the cogeneration market, identifying AB as their ideal partner for the intended solution, but also in terms of overall business reliability that ranges from the capacity for preliminary consultancy to service and assistance guarantees. After a call for bids, the order was formalised in September 2007. The perfect integration into the general pre-existing plant complex and compliance with the strict, demanding supply timing, stand out in particular. This is also why the Pfizer case
PFIZER history is important, well beyond the technology applied within the plant.
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THE E
P
Pfizer, has specifically requested a plant with the following characteristics: Electrical power: 2,0 MW Thermal vectors: Steam 1,040 kW AT 9 barg / Hot water Maintenance service: 10 years
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Ecomax
®
PLANT ≤
THE ASCOLI PICENO PFIZER PLANT AND THE REQUEST FOR A NEW COGENERATION PLANT. An awareness of the advantages of cogeneration
proposals presented, Pfizer chose AB as their
led Pfizer engineering to evaluate the possibility
ideal partner for the design, realisation and
of a new plant for Ascoli Piceno, technology for
maintenance of the plant, on the basis of the
energy production that would be able to meet
plant’s
the growing needs of their production lines
hypothesised
and service infrastructures. The order was
guarantee. Specifically, AB carried out a detailed
formalised in a call for bids held in September
study on the needs and feasibility, advising Pfizer
2007, specifically setting out the following basic
engineering to opt for the container solution
characteristics: an electrical power of 2.0 MW,
ECOMAX® 18 NGS with electrical power of 1,824
thermal vectors for hot water and steam at 1,040
KW rather than the 2000 initially hypothesised
KW (9 barg), functioning 24 hours a day. Maximum
by the company. The excellent prerogatives of
attention also to the elimination of polluting
the AB plant, the result of unique experience in
substances and emissions into the atmosphere
the sector and tested references in the field of
in accordance with the commitment to eco-
chemical-pharmaceuticals and, in particular, on
sustainability pursued by Pfizer as a company
plants of this range of power, showed, in fact,
value that is an integral part of their market
that optimal performance could be obtained
image, towards public opinion (local and general)
with the ECOMAX® 18 NGS plant, appropriately
and the masters of the company themselves.
implemented for this specific application.
After a strict and meticulous evaluation of the
technical-functional performance
characteristics, and
assistance
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Perhaps one of the determining prerogatives in
from every point of view: technical-functional
Pfizer engineering’s decision to prefer the proposal
characteristics, performance, reliability. In the
drawn up by AB was the certainty of having a point
case of the Ascoli Piceno Pfizer plant, this skill
of reference at top design levels available. The AB
was seen particularly in the implementation of
design department enjoys professional resources
technological solutions able to interface with the
and know-how that are able to develop solutions
pressure values of the plants that were already
able to integrate perfectly with the plant scenario
operative, and with the application of devices built
and specific needs of each customer, providing
to guarantee the best possible heat recovery, with
ad hoc solutions precisely suited to even the most
the production of steam and hot water in excess
articulated and complex demand. The design
of the nominal values, and fume temperatures
department starts with a careful study of the
less than 120°C.
specific needs and feasibility, following through to the implementation of the ideal system,
≤ Ecomax® 18 NGS Fuel consumption
Nm3/h
445
Power introduced
kW
4,318 1,824
Electrical power (cos.phi=1,0)
kW
Electrical yield
%
42.2
Steam
kg/h kW barg
1,200 782 9
Hot water
kW °C
1,007 88
Thermal yield
%
41.4
Total yield
%
83.6
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ELECTRICAL ENERGY 1,824 kW
NATURAL GAS 455 Nm3/h 4,318 kW
STEAM 1,200 kg/H - 782 kW GREENENERGY PFIZER HOT WATER 1,007 kW- 88 °C
Ecomax 18 NGS ®
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The drastic elimination of harmful substances released into the environment. Upon specific request by Pfizer, an industrial company that has always been extremely attentive to eco-environmental problems and the quality of life in the territories where its plants are located, the new cogeneration plant had to comply with strict parameters in terms of release of harmful substances into the environment. The choice for cogeneration in itself was a long-term, significant decision in this direction, further optimised by the characteristics of the plant ECOMAXŽ 18 NGS designed and built by AB. The technological choices have, in fact, allowed for high performance in all operative parameters, at the same time reducing release of CO2 into the environment. The results have been so great that the plant management decided to present the positive scenario in detail during the plant opening ceremony, also attended by the local authorities, and involve the whole team in this eco-environmental threshold. A threshold that falls well in line with the commitment by Pfizer, marked by their own trademark: Greenenergy. In the environments given over to the staff canteen, a display has been put up showing the main data relating to the function of the cogeneration plant designed and built by AB in real time, highlighting the benefits for the environment, work and the eco-system overall. e l’ecosistema nel suo complesso.
In the elements making up the order, one important factor was identifying the timescale and methods by which the supply was to be implemented. In practice, Pfizer wanted to have the plant up and running by the end of September 2008, with terms for the executive development and start-up of just three months. As such, AB developed a meticulously detailed work diagram, able to rely on a carefully planned
ELECTRICAL POWER
ELECTRIC POWER
THERMAL ENERGY
THERMAL POWER
and tested organisation of our departments. The strict delivery times were thus not only respected, but start-up was even brought forward. The site within the Ascoli Piceno Pfizer plant lasted just two months: as the module arrived in
CO2 NOT EMITTED
early August, the engine was started up in late September.
*values refer to the date of plant opening
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The meticulous respect of the strict, demanding supply timing. TIMELINE WORK 2008 Month January February March April May June July August September Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Planning Prefabrication in workshop Realization works buildings Assemblys Realization connections Starters Continuous operation
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PLANT PERFORMANCE IN THE WORDS OF THOSE USING IT. Interview with the engineer Gianluca Fioravanti (Maintenance Manager) ≤
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What led you to decide on a new cogeneration plant for your Ascoli Piceno plant? Essentially, it was the need to optimise our energy potential by using technology that could guarantee high performance, and which at the same time was in line with the Pfizer philosophy of paying great attention to the environment. These principles are an integral part of the approach to eco-sustainable energy that marks our group on an international level. In the particular case of the Ascoli plant, the development of production lines was accompanied by the need to integrate the new cogeneration plant in an overall evolution of the industrial energy plan. We wanted to obtain more, reducing costs. A real challenge that was well met by cogeneration. How was the decision to entrust AB with plant development, reached? We evaluated the market of reference very carefully, and saw that AB was simply the most valid option from all viewpoints. We were positively struck by the fact that today, on the Italian market, only AB is able to monitor the design, construction, installation and maintenance of this type of plant, directly and fully. Pfizer considers, in fact, collaborations and all types of entrepreneurial dialogue, well beyond that of the traditional relationship between customer and supplier, however competent and well-prepared they may be. We look for a real partner, rather than a supplier. First and foremost, this means consultancy, advice, instructions, and making the most of know-how at top levels, together with a willingness to open up to useful dialogue. The case of the cogeneration plant developed by AB is an example of just how important the AB – case history really is: our original supply plans requested a plant with 2000 kW electrical power. By dialoguing with the AB specialists, we were able to understand that even better performance levels could be obtained with a 1800 kW plant built with certain characteristics advised to us by the Brescia-based company staff. There is then the ‘timing’ aspect: we had to remain within strictly defined timescales, avoiding any lengthy suspension of production during the integration of the plant into our energy system. AB was well able to meet both these requirements, supplying us with a perfectly functional plant in record time, and limiting the stop of operation to the time at which the cogeneration plant was linked in synergy to our system. And on this, we should also remember that the AB technicians were able to deliver us a plant that had been practically made-to-measure, integrating optimally with the existing plant. Now that you are using it, are you happy with the plant performance and yields you manage to obtain? Our judgement is all positive. The plant has been working non-stop and at full capacity for some months now, and has shown the validity of the design choices and the quality of what has been installed. We are entirely satisfied with its reliability too, which allows us to relax, and not have to set aside particular resources for checks, maintenance and controls. Again from this point of view, we can also relax in terms of the assistance service entrusted to AB Service, a company belonging to the AB Group, which we consider the logical and beneficial continuation of what engineering has managed to achieve.
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AB SETS THE COGENERATION STANDARDS GLOBALLY been operating for over 30 years in the sector of cogeneration and promotion of energy from renewable sources.
AB is currently made up of 24 companies and over 500 employees and is a single entity able to manage the entire manufacturing cycle of a cogeneration plant: consultancy, design, production, installation and start-up with a comprehensive service. This has enabled AB to acquire unparalleled know-how, to become acquainted with every product detail and to provide a top-quality and highly-effective aftersales service. The success of AB which has already designed and built more than 900 plants - stems from ongoing investments in cutting-edge technologies, from the constant training and professional specialisation of all operators and from the development of an absolutely unique engineering
ita ly SALES
Foreign Branches
AB HOLDING SPA
AB industrial Group has
department: a team of over 110 engineers engaged in developing the industry towards the production of increasingly more reliable and higher performance plants. AB cogeneration plants are distinguished by modularity, compactness and ease of transport and cater to the energy requirements of a number of different companies. Outright leader in Italy, AB is also expanding globally: in Spain (2007), in Romania (2009), in Poland (2010), and again with the opening of subsidiaries in Croatia and Serbia (2011). From 2012 AB is in Czech Republic, from 2013 also in the Netherlands, Austria, Brazil, Francia and Canada. From 2014 AB in UK, Germany, USA and Israel and from 2015 in Russia and Turkey too.
AB Energy SpA
AB Energy International GmbH
AB Energy EspaĂąa S.L.
AB Energy Romania Srl
KWE Technika Energetyczna Sp. z.o.o.
AB Energy Hrvatska d.o.o.
AB Energy Srbija d.o.o.
AB Energy CeskĂĄ s.r.o.
AB Energy do Brasil Ltda
Green House Power Netherlands BV
EPS AB Energy Canada Ltd.
AB Energy (UK) Ltd.
AB Energy Deutschland GmbH
AB Energy Russia
AB Energy Israel Ltd.
AB Energy USA Lcc
AB Energy France
AB Energy Turkey
PRODUCTION
AB Impianti Srl
AB Power Srl
SERVICE
AB Service Srl
FINANCING
AB Fin-solution SpA
RENEWABLE ENERGY
AB Ambiente Srl
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Cogeneration has proven to be a winning choice, also in other industrial and non-industrial fields, such as food chemical, pharmaceutical, textile, plastic, paper, brick, etc. 700 customers, some of them are: Amadori, Benetton, BNL, Buitoni, Cartiere Saci, Coca - Cola, Cotonificio Albini, Eridania, Esselunga, Fatro, Ferrero, Felli Color, Galbani, Garda Plast, Granarolo, Gruppo Cremonini, Gruppo Mapei, kraft, Lafarge, Lilly, Martini & Rossi, Nestlè, Orogel, Pastificio Garofalo, Pastificio Rummo, Peroni, Pfizer, Polynt, Spumador, Wienerberger, etc.
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AB Energy SpA Via Caduti del Lavoro, 13 25034 Orzinuovi BS - Italy T. +39 030 94 00 100 www.gruppoab.com
DIAGRAM OF ECOMAX速 18 PLANT ASSEMBLY
FUNCTIONAL DIAGRAM OF ECOMAX速 18 PLANT
MONITORING SYSTEM