Reckitt Benckiser plc is a global force in household, health and personal care markets with operations in over 60 countries worldwide employing over 18,500 people worldwide. 230 of these work at the company’s household manufacturing plant in Derby. This site produces more than 160 million aerosols and other liquid products every year. In the past four years it has been transformed from a low automation plant to one of the most modern and efficient factories of its kind in Europe.
Reckitt Benckiser approached Clarke Energy in 2006 as part of the company’s drive to reduce CO2 emissions under a new Environmental Policy. Clarke Energy’s analyses lead to a recommendation for a number of sites to employ natural gas fuelled CHP engines, of which two of these factories were in the UK, at Hull and Derby. Clarke Energy have subsequently designed and installed CHP schemes at both of these locations.
The Derby CHP scheme is based around a GE Jenbacher JMC420GS-NL 1.4MWe spark ignition natural gas engine. This is a containerised unit allowing for a simple integration with existing site energy infrastructure.
The generator connects and synchronises to the site electricity supply at low voltage and the power generated is used to displace imported electricity from the ‘grid’. Heat recovery systems were supplied and installed by Clarke Energy. Energy from the exhaust is recovered in the form of steam providing 480kW output. This is used in the factory processes and displaces natural gas usage in existing site boilers. A further 805kW is recovered from the engine jacket water, turbocharger intercooler and lube oil systems in the form of hot water at 90˚C and is used to heat the aerosol testing ‘baths’; a more efficient system than the prior use of steam for this requirement. This CHP system will deliver a CO2 emission reduction of over 1800tonnes per annum, a reduction of more than 21% on the factory’s existing emissions.
As part of the package Clarke Energy also provide a long-term operation and maintenance agreement for the engine.
