In 2022, a leading life sciences company in the Republic of Ireland announced a €150m investment in a new filtration manufacturing facility.
Designed as a net zero factory, the company set out 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.
Tandem Project Management was appointed to design and project manage the electrical and mechanical fit out and they partnered with O’Neill Industrial to implement a highly efficient, sustainable compressed air system.
The new facility leverages advanced technologies to minimise 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 worked closely with O’Neill Industrial from the design phase through to equipment commissioning. 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.
Comprehensive compressed air package
O’Neill Industrial, a trusted distributor of Ingersoll Rand equipment in Ireland for more than 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 visualisation 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.
Integrated Energy Recovery System
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 optimisation.
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.