WANHUA Global Research Center (WGRC) is located in Shandong Province, China, and serves as the global R&D center for WANHUA Chemical in China, with a total land area of 82.36 hectares. The park has 20 laboratory buildings and 7 office buildings, with a total construction area of 333,000 square meters. This project is for the construction of the global R&D center and headquarters (Phase 1) of the WANHUA Chemical Group, with a total construction area of 105,000 square meters, including 7 laboratory buildings.
By implementing exhaust systems and prefabricated measures, a total of 30,183.7 tons of carbon emissions were reduced, and 11,247 tons of CO2 emissions were reduced.
The exhaust system uses a combination of VAV ventilation technology, fan-coil+new air system, and three-dimensional heat recovery technology.
The laboratory uses a VAV ventilation system, with exhaust settings of 6-8 air changes per hour during working hours (12 air changes per hour for special laboratories), and 2-3 air changes per hour during non-working hours. The automatic control system uses wind speed frequency curves to automatically calculate the wind frequency of the fan, and output the wind speed-time curve. For example, the total wind speed-time curve of all fans in Building C1-1 is 11 hours (7:30-18:30, non-working hours are excluded). The theoretical total wind volume is 222 million m3/h, and the actual measured wind volume is 125 million m3/h using the VAV system, a 43% reduction in wind volume compared to traditional ventilation systems, reducing carbon emissions by 1,447 tons, equivalent to 5,306 tons of CO2 emissions.
VAV systems provide heating and cooling sources to compensate for the heat and cold loads carried away by exhaust systems. The temperature control of the laboratory is maintained by the fan-coil, and after the exhaust system stops running, the fan-coil is used to adjust the indoor temperature. According to statistics, the annual simultaneous usage rate of the laboratory is approximately 80%, and the remaining 20% of the laboratory has no experimental tasks, only turning on the fan-coil to maintain the comfort of the laboratory. Each year, this can reduce carbon emissions by 57.5 tons, equivalent to 211 tons of CO2 emissions.
The three-dimensional heat exchanger heat recovery device consists of the following parts: heat exchanger, exhaust fan, air filter, fan-coil, humidifier, etc. The heat exchanger itself does not require power and is a static heat recovery device. The cross-contamination and leakage rate of new air and exhaust air in WGRC is less than 1%. WGRC has been in use for 2 years, and through monitoring of the central control system of the laboratory, the actual efficiency of the heat recovery system in winter and summer is 52% and 38%, respectively. The heat recovery system reduces carbon emissions by 1,509 tons per year, equivalent to 5,533 tons of CO2 emissions.
A fully prefabricated approach was adopted, with 85% of the work being completed in the factory (see Pic 5). This reduced labor quantity, waste disposal, and on-site change orders, reducing carbon emissions by 5.37 tons and reducing CO2 emissions by 197 tons. The prefabricated implementation method took a controlled collection approach for the gas and dust generated during production in the factory, and used purification devices, with a collection efficiency of 80% and a purification efficiency of 90%, reducing actual emissions by 72% compared to traditional construction methods.
By adopting prefabricated factory production and centralized recycling, the laboratory was able to recover a total of 1.7 tons of recyclable waste, with an overall recycling rate of 92.40%.
The prefabricated electrical implementation mode used robot welding, robot riveting, automatic cutting of raw materials, automatic welding technology, automatic drilling technology, fully automatic painting technology, central transportation, robot transportation, automatic lifting, and lightweight tool installation (see Fig 3), saving a total of 9,499 labor days.
WGRC collects rainwater within the area, processes it, and primarily uses it for landscape irrigation and road cleaning. The rainwater storage pool uses a PP modular combined water pool (storage capacity of 300 cubic meters), with all construction units located below the landscaped surface.
Excess storage capacity rainwater is discharged into the landscape watercourse of the park, reducing the need for water from the river. The large landscape watercourse and artificial lake in the park act as natural air conditioning, lowering the temperature of the park while also providing landscape irrigation and firefighting water. The WGRC water resource utilization rate is 35%, and water consumption is reduced by 20%.
Energy Consumption Analysis Table:
Two types of gas treatment devices are installed: one is for acidic and alkaline gas, organic gas, and cement gas, which are collected by a hood and piped to a dry chemical filter at the end of the system (removal efficiency of at least 90%), and after adsorption purification, they are discharged through a chimney with a height of 26 meters; the other is for dust generated in the preparation of catalysts and the experimental process in certain areas, with a dust removal bag filter installed under the experimental table (removal efficiency of at least 90%), after which the air is piped to a dry filter at the end of the system and discharged through a chimney with a height of 3 meters from the roof. The experimental gas is collected, filtered, and purified after passing through the dust removal, adsorption, and purification processes (see Table 6).
All wastewater systems in the park's laboratories are independently set up, with wastewater collected and transported to the park's wastewater pool, and then transported to Wanhua's self-built wastewater treatment station for treatment.
Pre-Fab MEP construction uses factory-made prefabrication, with 100% high-noise and high-dust welding, cutting, and other work completed by robots in the factory, which is harmless to human health.
Traditional MEP installation work accounts for about 70% of the entire construction task at a height of 2 meters or more, with a wide range of potential hazards. The prefabricated MEP construction method, with all prefabricated work completed on the ground, reduces 90% of high-altitude work and significantly reduces the risk factor.
The construction site only has prefabricated assembly, so due to the production-generated dust, noise, and other pollution, indoor prefabricated PM2.5 levels are reduced to a maximum of 30.4, a decrease of 3.2% compared to traditional construction. The noise level is the highest at 60 decibels, and the overall construction environment is good.
The park is designed with clear pedestrian and logistics zones, ensuring that people and goods do not intersect. Each experimental building is divided into floors based on departments and laboratories, making it both convenient to use and ensuring safety. The office area and laboratory area are clearly separated within each zone, and the areas do not intersect. The laboratories are set on the north side, with the data processing area and rest/discussion area set on the south side. The logistics channel is combined with the experimental operation channel, increasing the usable area by approximately 22%. The office and laboratory areas are connected by invisible corridors (Ghost corridors), and the office area does not have exhaust fans, utilizing the negative pressure exhaust of the laboratory area.
The office area is designed to be only 6 meters deep, allowing natural light to penetrate the office area directly into the laboratory area.
A central management station is set up to monitor the status of all equipment and laboratory temperature, humidity, and pressure, reducing the labor costs associated with personnel patrols. The central management is integrated into the laboratory intelligent management system, with intelligent laboratory systems capable of sensing (monitoring all environmental and equipment status), thinking (collecting fragmented data to form big data and making predictions about the future development trends of the laboratory based on big data), and decision-making (issuing optimal instructions based on the current status of the laboratory).
The project achieved resource sharing: a large-scale shared instrument center is set up on the A3 floor for the entire park area, with shared hydrogen stations, oxygen stations, air compressor stations, pure water stations, hazardous materials storage rooms, waste storage rooms, and reagent storage rooms. The R&D laboratories are both relatively independent and share resources. The management system can automatically record the users of instruments, start times, shutdown times, usage time, and energy consumption situations (electricity, water, gas) and automatically calculate the usage efficiency, usage costs, and fee situations of the instruments, providing accurate data support for use.
By monitoring the cold and heat of the ventilation and air conditioning system, detailed records of the daily cold and heat consumption can be kept, and plans for more reasonable operating plans can be formulated based on the analysis of cold and heat consumption data, ultimately achieving energy-saving goals.
The cold and heat monitoring of the ventilation system is specific to each air handling unit, and the cold and heat monitoring of the air conditioning system is specific to each floor or each area.
Laboratory water supply and wastewater treatment also require costs, which are part of energy consumption. The laboratory's water consumption monitoring is specific to each building, each floor, or each room.
By monitoring wastewater, laboratory sewage costs can be calculated. Depending on the need, laboratory sewage monitoring is specific to each building, each floor, or each room.
Facility managers can check energy consumption at any time through their phoness, including energy data and change trends.
By adopting modular construction methods, the layout is fully set up according to standard modular layouts, and the scaffolding can be adjusted in any direction up, down, left, or right. The labs can be quickly expanded on existing scaffolding structures by adding various systems or even finishing the ceiling, and the rapid transformation of the laboratory dry area.
By using BIM design, electrical wiring is comprehensively laid out and disassembled into modules that can be quickly assembled. Modular electrical systems are flexible and easily assembled, and any device can be fixed and connected. This provides space for sustainable development in future construction.
To ensure the flexibility of general laboratories, sufficient space is reserved for each system during the design process. In each experimental building, two types of reserved gas pipelines are set up, and the laboratory manager has reserved 25% of the gas supply for future gas supply point additions.
In terms of power supply: each laboratory's total power distribution box and end power distribution box have reserved sufficient circuit and power distribution box space, allowing devices to be added or changed at any time.
For the drainage system: a wet column solution is adopted, with reserved drainage pipelines in the wet column for adding drainage points within the floor at any time.
By adopting modular experimental units, the layout of laboratories in each area can be adjusted according to the direction of experiments at any time. The facilities within the laboratory are also modular in form, ensuring that each experimental area can be arbitrarily divided, combined, and transformed. This layout style increases the flexibility of the laboratory space and prolongs the life of the laboratory.
The supply air uses a micro-perforated diffuser format, combining micro-perforated supply air and lighting to save ceiling space while ensuring uniform supply air and promoting the sustainable development of the laboratory.
From companies that manufacture high-quality products and can provide timely high-quality services, with a strong sense of social responsibility and quality and cost improvement awareness, purchasing legal, reliable, and internationally competitively priced products and services. And based on standards such as quality, labor, health and safety, environment, business ethics, and sustainable purchasing, establish a quality, labor, health and safety, environment, business ethics, and sustainable purchasing assurance system for suppliers to comply with local laws and regulations.
WGRC's laboratories all adopt a modular assembly pattern, with the overall electrical layer composed of standard 3.3*3.3 meter modules as the basic unit, constructed through BIM comprehensive construction, and all air, water, electricity, and gas are standard modules. Independent modules can be disassembled and reused. The modules themselves are easily disassembled and reusable.
The overall module is composed of traditional materials, with a wide range of purchasing channels, providing a physical basis for purchasing sustainable, reliable, and internationally competitively priced products and services.
WANHUA Global Research Center (WGRC) is located in Shandong Province, China, and serves as the global R&D center for WANHUA Chemical in China, with a total land area of 82.36 hectares. The park has 20 laboratory buildings and 7 office buildings, with a total construction area of 333,000 square meters. This project is for the construction of the global R&D center and headquarters (Phase 1) of the WANHUA Chemical Group, with a total construction area of 105,000 square meters, including 7 laboratory buildings.
By implementing exhaust systems and prefabricated measures, a total of 30,183.7 tons of carbon emissions were reduced, and 11,247 tons of CO2 emissions were reduced.
The exhaust system uses a combination of VAV ventilation technology, fan-coil+new air system, and three-dimensional heat recovery technology.
The laboratory uses a VAV ventilation system, with exhaust settings of 6-8 air changes per hour during working hours (12 air changes per hour for special laboratories), and 2-3 air changes per hour during non-working hours. The automatic control system uses wind speed frequency curves to automatically calculate the wind frequency of the fan, and output the wind speed-time curve. For example, the total wind speed-time curve of all fans in Building C1-1 is 11 hours (7:30-18:30, non-working hours are excluded). The theoretical total wind volume is 222 million m3/h, and the actual measured wind volume is 125 million m3/h using the VAV system, a 43% reduction in wind volume compared to traditional ventilation systems, reducing carbon emissions by 1,447 tons, equivalent to 5,306 tons of CO2 emissions.
VAV systems provide heating and cooling sources to compensate for the heat and cold loads carried away by exhaust systems. The temperature control of the laboratory is maintained by the fan-coil, and after the exhaust system stops running, the fan-coil is used to adjust the indoor temperature. According to statistics, the annual simultaneous usage rate of the laboratory is approximately 80%, and the remaining 20% of the laboratory has no experimental tasks, only turning on the fan-coil to maintain the comfort of the laboratory. Each year, this can reduce carbon emissions by 57.5 tons, equivalent to 211 tons of CO2 emissions.
The three-dimensional heat exchanger heat recovery device consists of the following parts: heat exchanger, exhaust fan, air filter, fan-coil, humidifier, etc. The heat exchanger itself does not require power and is a static heat recovery device. The cross-contamination and leakage rate of new air and exhaust air in WGRC is less than 1%. WGRC has been in use for 2 years, and through monitoring of the central control system of the laboratory, the actual efficiency of the heat recovery system in winter and summer is 52% and 38%, respectively. The heat recovery system reduces carbon emissions by 1,509 tons per year, equivalent to 5,533 tons of CO2 emissions.
A fully prefabricated approach was adopted, with 85% of the work being completed in the factory (see Pic 5). This reduced labor quantity, waste disposal, and on-site change orders, reducing carbon emissions by 5.37 tons and reducing CO2 emissions by 197 tons. The prefabricated implementation method took a controlled collection approach for the gas and dust generated during production in the factory, and used purification devices, with a collection efficiency of 80% and a purification efficiency of 90%, reducing actual emissions by 72% compared to traditional construction methods.
By adopting prefabricated factory production and centralized recycling, the laboratory was able to recover a total of 1.7 tons of recyclable waste, with an overall recycling rate of 92.40%.
The prefabricated electrical implementation mode used robot welding, robot riveting, automatic cutting of raw materials, automatic welding technology, automatic drilling technology, fully automatic painting technology, central transportation, robot transportation, automatic lifting, and lightweight tool installation (see Fig 3), saving a total of 9,499 labor days.
WGRC collects rainwater within the area, processes it, and primarily uses it for landscape irrigation and road cleaning. The rainwater storage pool uses a PP modular combined water pool (storage capacity of 300 cubic meters), with all construction units located below the landscaped surface.
Excess storage capacity rainwater is discharged into the landscape watercourse of the park, reducing the need for water from the river. The large landscape watercourse and artificial lake in the park act as natural air conditioning, lowering the temperature of the park while also providing landscape irrigation and firefighting water. The WGRC water resource utilization rate is 35%, and water consumption is reduced by 20%.
Energy Consumption Analysis Table:
Two types of gas treatment devices are installed: one is for acidic and alkaline gas, organic gas, and cement gas, which are collected by a hood and piped to a dry chemical filter at the end of the system (removal efficiency of at least 90%), and after adsorption purification, they are discharged through a chimney with a height of 26 meters; the other is for dust generated in the preparation of catalysts and the experimental process in certain areas, with a dust removal bag filter installed under the experimental table (removal efficiency of at least 90%), after which the air is piped to a dry filter at the end of the system and discharged through a chimney with a height of 3 meters from the roof. The experimental gas is collected, filtered, and purified after passing through the dust removal, adsorption, and purification processes (see Table 6).
All wastewater systems in the park's laboratories are independently set up, with wastewater collected and transported to the park's wastewater pool, and then transported to Wanhua's self-built wastewater treatment station for treatment.
Pre-Fab MEP construction uses factory-made prefabrication, with 100% high-noise and high-dust welding, cutting, and other work completed by robots in the factory, which is harmless to human health.
Traditional MEP installation work accounts for about 70% of the entire construction task at a height of 2 meters or more, with a wide range of potential hazards. The prefabricated MEP construction method, with all prefabricated work completed on the ground, reduces 90% of high-altitude work and significantly reduces the risk factor.
The construction site only has prefabricated assembly, so due to the production-generated dust, noise, and other pollution, indoor prefabricated PM2.5 levels are reduced to a maximum of 30.4, a decrease of 3.2% compared to traditional construction. The noise level is the highest at 60 decibels, and the overall construction environment is good.
The park is designed with clear pedestrian and logistics zones, ensuring that people and goods do not intersect. Each experimental building is divided into floors based on departments and laboratories, making it both convenient to use and ensuring safety. The office area and laboratory area are clearly separated within each zone, and the areas do not intersect. The laboratories are set on the north side, with the data processing area and rest/discussion area set on the south side. The logistics channel is combined with the experimental operation channel, increasing the usable area by approximately 22%. The office and laboratory areas are connected by invisible corridors (Ghost corridors), and the office area does not have exhaust fans, utilizing the negative pressure exhaust of the laboratory area.
The office area is designed to be only 6 meters deep, allowing natural light to penetrate the office area directly into the laboratory area.
A central management station is set up to monitor the status of all equipment and laboratory temperature, humidity, and pressure, reducing the labor costs associated with personnel patrols. The central management is integrated into the laboratory intelligent management system, with intelligent laboratory systems capable of sensing (monitoring all environmental and equipment status), thinking (collecting fragmented data to form big data and making predictions about the future development trends of the laboratory based on big data), and decision-making (issuing optimal instructions based on the current status of the laboratory).
The project achieved resource sharing: a large-scale shared instrument center is set up on the A3 floor for the entire park area, with shared hydrogen stations, oxygen stations, air compressor stations, pure water stations, hazardous materials storage rooms, waste storage rooms, and reagent storage rooms. The R&D laboratories are both relatively independent and share resources. The management system can automatically record the users of instruments, start times, shutdown times, usage time, and energy consumption situations (electricity, water, gas) and automatically calculate the usage efficiency, usage costs, and fee situations of the instruments, providing accurate data support for use.
By monitoring the cold and heat of the ventilation and air conditioning system, detailed records of the daily cold and heat consumption can be kept, and plans for more reasonable operating plans can be formulated based on the analysis of cold and heat consumption data, ultimately achieving energy-saving goals.
The cold and heat monitoring of the ventilation system is specific to each air handling unit, and the cold and heat monitoring of the air conditioning system is specific to each floor or each area.
Laboratory water supply and wastewater treatment also require costs, which are part of energy consumption. The laboratory's water consumption monitoring is specific to each building, each floor, or each room.
By monitoring wastewater, laboratory sewage costs can be calculated. Depending on the need, laboratory sewage monitoring is specific to each building, each floor, or each room.
Facility managers can check energy consumption at any time through their phoness, including energy data and change trends.
By adopting modular construction methods, the layout is fully set up according to standard modular layouts, and the scaffolding can be adjusted in any direction up, down, left, or right. The labs can be quickly expanded on existing scaffolding structures by adding various systems or even finishing the ceiling, and the rapid transformation of the laboratory dry area.
By using BIM design, electrical wiring is comprehensively laid out and disassembled into modules that can be quickly assembled. Modular electrical systems are flexible and easily assembled, and any device can be fixed and connected. This provides space for sustainable development in future construction.
To ensure the flexibility of general laboratories, sufficient space is reserved for each system during the design process. In each experimental building, two types of reserved gas pipelines are set up, and the laboratory manager has reserved 25% of the gas supply for future gas supply point additions.
In terms of power supply: each laboratory's total power distribution box and end power distribution box have reserved sufficient circuit and power distribution box space, allowing devices to be added or changed at any time.
For the drainage system: a wet column solution is adopted, with reserved drainage pipelines in the wet column for adding drainage points within the floor at any time.
By adopting modular experimental units, the layout of laboratories in each area can be adjusted according to the direction of experiments at any time. The facilities within the laboratory are also modular in form, ensuring that each experimental area can be arbitrarily divided, combined, and transformed. This layout style increases the flexibility of the laboratory space and prolongs the life of the laboratory.
The supply air uses a micro-perforated diffuser format, combining micro-perforated supply air and lighting to save ceiling space while ensuring uniform supply air and promoting the sustainable development of the laboratory.
From companies that manufacture high-quality products and can provide timely high-quality services, with a strong sense of social responsibility and quality and cost improvement awareness, purchasing legal, reliable, and internationally competitively priced products and services. And based on standards such as quality, labor, health and safety, environment, business ethics, and sustainable purchasing, establish a quality, labor, health and safety, environment, business ethics, and sustainable purchasing assurance system for suppliers to comply with local laws and regulations.
WGRC's laboratories all adopt a modular assembly pattern, with the overall electrical layer composed of standard 3.3*3.3 meter modules as the basic unit, constructed through BIM comprehensive construction, and all air, water, electricity, and gas are standard modules. Independent modules can be disassembled and reused. The modules themselves are easily disassembled and reusable.
The overall module is composed of traditional materials, with a wide range of purchasing channels, providing a physical basis for purchasing sustainable, reliable, and internationally competitively priced products and services.
