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Sanofi Pasteur

Boiler Plant Burner Replacement & System Upgrades

In pharmaceutical manufacturing, where exactitude and adherence to regulations are  prerequisites, the infrastructure  integrity is paramount. For this project, Genesis was engaged to address  five high-pressure steam firetube boilers. These boilers, with a capacity of 800, faced multifaceted challenges, including the task of meeting rigorous NOx emission standards mandated by both the Pennsylvania Department of Environmental Protection (PA DEP) and the Environmental Protection Agency (EPA). Genesis’ task was to address the confluence of capacity and emissions requirements.

The existing burners, despite their performance with natural gas firing, exhibited inconsistencies that hindered meeting the prescribed standards. Genesis replaced the burners, ensuring output efficiency while adhering to stringent environmental mandates.

Beyond the immediate burner predicament, we also evaluated how to increase the overall efficiency within their boiler plant and its interconnected systems.  To address this, we implemented Boiler Flue Gas Economizers so the boiler plant could effectively recover and utilize heat. This  heightened efficiency and reducted  operational costs, while underscoring Sanofi’s commitment to sustainable practices and resource efficiency.

Another pivotal enhancement was the integration of Variable Frequency Drives (VFDs) on Boiler Feedwater Pumps to adjust their speed and power based on real-time demand. The outcome was twofold: enhanced energy efficiency and a reduction in wear and tear on the pumps, thereby extending their operational lifespan.

The collaboration between Genesis AEC and Sanofi Pasteur o exemplifies the rigorous approach demanded by intricate pharmaceutical manufacturing settings. From addressing high-pressure steam firetube boiler challenges to implementing efficiency-enhancing measures, the project serves as a case study in precision, compliance, and strategic foresight within the realm of pharmaceutical infrastructure development.

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  1. High-pressure Steam Firetube Boilers: A type of boiler design where hot gases from a fire pass through tubes which run through a sealed container of water.
  2. NOx Emissions: Refers to nitrogen oxides emissions, which are pollutants resulting from combustion processes and have environmental and health impacts.
  3. Boiler Flue Gas Economizers: Devices that capture waste heat from boiler flue gases to improve efficiency by preheating a heat sink (like water going into the boiler).
  4. VFD’s (Variable Frequency Drives): Electronic controllers that vary the frequency and voltage supplied to electric motors, allowing them to operate at different speeds and torques. This offers energy savings and better process control.
  5. Boiler Feedwater Pumps: Pumps that deliver fresh water to a boiler for conversion into steam.

In summary, this project with Sanofi Pasteur was not merely about addressing a single issue but optimizing an entire system. Genesis AEC showcased their adeptness in enhancing both the performance and efficiency of critical infrastructure, ensuring that Sanofi Pasteur’s operations remain both robust and compliant.