{"id":63160,"date":"2026-04-29T04:01:31","date_gmt":"2026-04-29T03:01:31","guid":{"rendered":"https:\/\/www.icicaldaie.com\/case-study\/%settori%\/new-thermal-plant-pharmaceutical-company\/"},"modified":"2026-04-29T04:01:31","modified_gmt":"2026-04-29T03:01:31","slug":"merck-serono-spa","status":"publish","type":"case-study","link":"https:\/\/www.icicaldaie.com\/en\/case-study\/chemical-and-pharmaceutical\/merck-serono-spa\/","title":{"rendered":"Merck Serono SPA"},"content":{"rendered":"<p> <strong>Industry<\/strong><br \/>\nInside pharmaceutical factories, environments must have a controlled temperature and humidity, not only in the production departments but also inside research and development laboratories.<br \/>\nThe steam used must also have a high degree of pureness both for the sterilization and the product packaging processes.<br \/>\nThese needs make the industry highly energy-intensive and therefore in search of continuous improvements on overall plant efficiency.<\/p>\n<p><strong>Customer<\/strong><br \/>\nInvest in a new thermal plant to reduce the costs of thermal energy generation, simultaneously reduce polluting emissions into the atmosphere, and without interrupting the production cycle.<\/p>\n<p><strong>The new thermal system<\/strong><br \/>\n<strong>Phase 1<\/strong>: As the first phase of work, we designed and subsequently replaced the old waste heat exchanger with our latest WHB boiler for the recovery of hot fumes resulting from electricity production.<br \/>\n<strong>Phase 2<\/strong>: Once the WHB installation was complete, we moved on to the thermal plant.<br \/>\nAt this point, in order not to interrupt production during the revamping phase, we have designed, together with our partners, a temporary thermal power plant.<br \/>\nThe temporary steam boilers, installed outdoors, temporarily replaced the existing boilers, covering the steam needs of the entire plant, and remaining operational for the 3 months necessary to complete the work inside the thermal power plant.<br \/>\n<strong>Phase 3<\/strong>: We now focused on the new thermal plant and on how to meet Merck&#39;s demands for efficiency and emission reduction.<br \/>\nFor the new plant, we chose to install 2 GX-2000 steam boilers with 3.400 kg\/h of steam capacity, equipped with the GSS-72 safety system for continuous 72-hour unsupervised operation, and a vertical economizer for feedwater pre-heating.<br \/>\nCombined with the steam boilers we opted for 2 progressive Low NOx two-stage modulating burners, thermophysical degasser, waste collection tank, manifolds for steam distribution at various pressures, and PLC electronic system for data transmission and cascade management.<\/p>\n<p><strong>Results<\/strong><br \/>\nThanks to the increase in efficiency provided by the new thermal plant, we have found a reduction in CNG consumption of 158.000 Sm3 \/ year (about 132 TOE), equivalent to an annual saving of about &euro; 46.000.<br \/>\nThe increase in global efficiency has also led to lower CO2 emissions into the atmosphere of about 320 tons per year, reducing the environmental impact of the entire production plant.<\/p>\n<p>&nbsp; <\/p>\n","protected":false},"featured_media":78064,"menu_order":1,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0},"country":[1185],"settori":[1182],"tipo_di_fluido":[1216,1221],"class_list":["post-63160","case-study","type-case-study","status-publish","format-standard","has-post-thumbnail","hentry","country-italy","settori-chemical-and-pharmaceutical","tipo_di_fluido-industrial-boilers","tipo_di_fluido-steam-boilers"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Merck Serono SPA - ICI<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.icicaldaie.com\/en\/case-study\/chemical-and-pharmaceutical\/merck-serono-spa\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Merck Serono SPA - ICI\" \/>\n<meta property=\"og:description\" content=\"Industry Inside pharmaceutical factories, environments must have a controlled temperature and humidity, not only in the production departments but also inside research and development laboratories. 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