Realization and Results

Power Efficiency Guide

Ultimate Guide to Power Efficiency

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The Bayer Climate Check follows the systematic approach described in the first parts of this chapter (Chapter 4).

It incorporates two essential elements, that is, quantification of the climate relevance of the manufactured product by means of the Climate Footprint and identification of savings potential through an 'Energy Efficiency Check'. The value of Bayer Climate Check derives from combining sustainability goals with the corporate-wide motivation to increase its efficiency, reduce costs, and implement innovative solutions.

During the Energy Efficiency Check many potential measures to reduce energy consumption as well as CO2 emissions are identified in a structured and holistic approach. This involves optimization of utilities' consumption such as electricity, steam, cooling water, chilled water, fuels and compressed air as well as usage of raw materials and auxiliary materials. The energy efficiency of plant facilities, energy generation units and buildings are analyzed in detail.

The project was initiated at the end of 2007 with a pilot phase. In this phase the energy efficiency of four plants in the Bayer subgroups MaterialScience, HealthCare and CropScience was evaluated. By the end of 2009 Bayer Technology Services has checked the energy efficiency of more than 100 plants in the Bayer sites worldwide. The climate checks performed indicated an energy saving potential through increased energy efficiency of more than 10% (A and B measures).

Two examples illustrate the effectiveness of the Bayer Climate Check as an instrument for the identification of energy and CO2 reduction potentials. We describe how the approach was applied and which measures have already been implemented in the plants.

Example 1 is a production plant for polymer intermediates on a German Bayer site. We began with a detailed analysis of the actual energy consumption. Then we moderated brainstorming sessions with the plant staff and unit operation and equipment experts from Bayer Technology Services. In these sessions the team elaborated an extensive list of saving ideas. The saving potential of likely profitable and feasible measures identified during the Climate Check was 12% of the total energy costs. The proposed measures were divided between those without investment (so -called quick wins) and those where an investment is necessary. The following measures, which were implemented in the short term, resulted in significant savings shortly after implementation:

• The process control strategies of different big columns, for instance the reflux ratios in partial load operation, were optimized by process simulations and plant experiments. Thereby the energy consumption was reduced significantly.

• The energy consuming drive of a big pump was optimized by implementation of a frequency control. Some permanently running redundant pumps were switched off.

• In a filtration apparatus the temperature of a scrubbing solution was reduced. Because the scrubbing liquid had to be heated with external energy, the necessary energy for heating could be reduced.

• The optimization of heated pipes and heat traces resulted in a reduction of energy losses and therefore in a decreased steam consumption.

• The implementation of an innovative monitoring tool for the actual value of the energy consumption resulted in a higher energy consciousness of the operators and a behavioral change in the plant. This change was a main reason for a sustainable reduction of the energy consumption in the plant. Because of the success of the monitoring tool we plan the transfer of the monitoring tool to other plants.

In 2005 the plant consumed for its yearly production 40 647 MWh of electric energy and 320 134 MWh of thermal energy. After realization of the Bayer Climate Check the plant consumed 36 576 MWh of electric and 281185 MWh of thermal energy in 2007, and that at a comparable production capacity. The year 2006 is not useful for comparison, because the production capacity differed considerably. Taking into account the respective production volumes the savings from 2005 to 2007 sum up to 10% of electric and to 12% of thermal energy. These savings relate to cost savings of 900 000€. Supported by the company-wide energy efficiency management program other measures elaborated during the Climate Check are being implemented. Additional savings of 200 000€ are expected. The energy supply comes from a coal-fired cogeneration power plant.

Example 2 is a production plant for basic materials for the plastic industry, also located in Germany. The saving potential identified during the Bayer Climate Check was 26% of the energy consumption. We found, for instance, saving potentials in the steam distribution net. Large amounts of excess steam, generated from waste heat streams, could thereby be exported into the steam net of the energy provider. As another example the analysis showed the saving potential of a predictive maintenance: if for instance defect steam of cooling water valves as well as steam traps are detected and changed betimes then the waste of energy will be minimized. In 2007 the plant exported 24 979 MWh of thermal energy in the form of steam into the steam net of the provider. After quick implementation of the proposed measures this amount reached 39 991 MWh in 2008. This means an increase of 60%. The customer invested 50000€ for the implementation of the measures. Cost savings in the first year after implementation were 290 000 € per year. The customer plans to implement further measures supported by the company-wide energy efficiency management program. The plant is provided with energy by a gas and steam power station.

In the framework of the Bayer Climate Program the Bayer Climate Check was established as an important tool for the identification of potentials for energy saving and CO2 emission reduction. The application of the Bayer Climate Check revealed significant saving potentials which have already been partly implemented. The examples show that quick win measures can result in significant savings at low investment costs. The implementation of further measures is planned and will be supported by a company-wide energy efficiency management program. The Bayer Climate Check is therefore an important element for the achievement of the ambitious climate related targets of Bayer.

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