Evaluating The Feasibility of Electrified Process Heating for Drug Substance Manufacturing

Abstract

The pharmaceutical industry relies on high-temperature fluids such as pure steam to support critical operations including equipment cleaning and sterilization and on hot Water-For-Injection (WFI) as a key ingredient for drug substance manufacturing. These high-temperature process-driven heat demands are fulfilled through fossil fuel-based heating which contributes significantly to Scope 1 carbon emissions. Recognizing the link between environmental stressors and human health, Amgen has committed to achieving carbon neutrality by 2027. This thesis explores the feasibility and implications of transitioning from fossil fuel-based process heating to a fully electric system at one of Amgen’s drug substance manufacturing sites. Amgen’s existing fossil fuel-based steam system was analyzed through site visits, engineering reviews, and stakeholder engagements to quantify capital and operating costs, energy usage, and carbon emissions. A fully electric alternative was designed by researching commercial technologies and collaborating with suppliers as well as internal stakeholders. The analysis found that while the capital investment required for electrification is comparable to that of traditional steam systems, the operating costs for an electric system are significantly higher, driven by the higher price of electricity relative to natural gas. From a sustainability perspective, electrification eliminates on-site Scope 1 carbon emissions but shifts emissions to Scope 2, making the environmental benefit dependent on the carbon intensity of the local electricity grid. As grids transition to renewable energy sources, the potential for long-term emissions reductions strengthens. Future work should focus on evaluating the costs of necessary electrical infrastructure upgrades and identifying regions with lower-carbon, lower-cost electricity grids where electrified systems could be more readily implemented.