In 2022, a leading life sciences company in the South of Ireland announced a €150 million investment in a new filtration manufacturing facility. This new state-of-the-art plant is a testament to the company’s commitment to environmental sustainability. Designed as a net-zero factory, it aims to balance its carbon footprint by reducing greenhouse gas emissions through cutting-edge energy efficiency measures, the integration of renewable energy, and carbon offsetting initiatives.
To meet these ambitious sustainability goals, the company appointed Tandem Project Management to design and project manage the electrical and mechanical fit out of the new facility. After a competitive tender process involving rigorous engineering analysis, Tandem Project Management partnered with O’Neill Industrial to implement a highly efficient, sustainable compressed air system. This case study explores how this partnership played a critical role in enabling the facility to achieve its net-zero carbon goals.
The company’s global environmental sustainability goals are rooted in the belief that more efficient and innovative processes can dramatically reduce the environmental impact of manufacturing. The new facility embodies this vision by leveraging advanced technologies to minimize the use of energy, water, and raw materials, thereby reducing waste and emissions. The facility is a model of nearly Zero Energy Building (nZEB) standards, aligning with EU directives on energy performance.
Tandem Project Management, experts in sustainable design worked closely with O’Neill Industrial from the design phase through to equipment commissioning to ensure the installed system was of the very highest standard from a reliability, quality and environmental point of view. Their work was conducted in accordance with the EU Energy Performance of Buildings Directive and the Energy Efficiency Directives, ensuring that the installation met the highest standards for energy conservation.
O’Neill Industrial, a trusted distributor of Ingersoll Rand equipment in Ireland for over 50 years, supplied a comprehensive compressed air package comprising two Ingersoll Rand E Series Air Cooled Air Compressors with Integrated Heat Recovery to ensure maximum energy efficiency.
The installation also features advanced air treatment equipment including a Twin Tower Desiccant Heat Regenerative Air Dryer, a filtration system, and air receivers to ensure the highest air quality standards in line with ISO 8573.1 2010 Class 1.2.1. A Master Control System with Helix remote visualization ensures that the health of the system can be continually monitored by the O’Neill Industrial Service team. The Helix™ Connected Platform delivers continuous real-time monitoring to enable maximum operational uptime. These components were selected and configured to meet the demanding criteria necessary for the customers net-zero aspirations.
Energy Recovery System Overview:
A key feature of the compressed air system is the integrated Energy Recovery System, which plays a vital role in reducing the factory’s carbon footprint. The system captures the waste heat generated by the air compressors and repurposes it for domestic hot water use. The Ingersoll Rand E Series Air Compressor range is unique in that it is the only Oil-Free Air-Cooled Air Compressor in the market with Heat recovery as an option. Here’s how it works:
- Air Compressor Heat Recovery: Waste heat generated during the air compression process is transferred to a closed-circuit cooling water loop integral to the Air Compressor. A VSD water pump inside the E Series Compressor pumps the heated water through an integral plate heat exchanger, transferring heat to incoming water.
- Hot Water Storage: The heated water is stored in an insulated hot water tank located in the compressor room.
- Circulation: Standalone Circulation pumps external to the compressor package ensure a continuous flow of water through the heat exchanger and back to the tank, maintaining an efficient heat recovery cycle.
- Temperature Control: Digital thermostats and control valves precisely maintain the desired water temperature.
- Monitoring: The system is equipped with sensors and energy meters that track performance, providing data for continuous optimization.
The advanced compressed air system supplied by O’Neill Industrial, with the design expertise of Tandem, is a critical component of the Life Sciences net-zero strategy at their facility. By integrating heat recovery and real-time monitoring, the system not only meets their immediate operational needs but also significantly reduces energy consumption and greenhouse gas emissions.
Austin O’Neill, O’Neill Industrial, noted: “We are proud to have played a part in this global leader’s journey towards sustainability. The technology we’ve provided is at the forefront of energy efficiency in compressed air systems, and the successful installation is a testament to our expertise and commitment to helping our clients achieve their sustainability objectives.”
Suggested quote from Tandem Project Management Representative: “Designing systems that not only meet regulatory requirements but also push the boundaries of what’s possible in terms of energy efficiency is our passion. Working with O’Neill Industrial on this project has been a rewarding experience, and we are excited to see the long-term benefits it will bring.”
Companies investing in cutting-edge technologies, like the compressed air system provided by O’Neill Industrial in this case study, are leading the way in sustainable industrial practices and setting a new standard for industry. This is the future of manufacturing.
