Reporting and Target Setting

A common definition and a common measurement of the energy consumption in a company open up the opportunity of consolidating the gathered energy information within the company from the plant level up to company level. That can be used in two directions:

Firstly for reporting: we recommend energy consumption reporting for all operational units of the company. This means that all hierarchy levels are provided with given consumption information for their units. The plant manager will get

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the numbers for his plant, the site manager for the whole site, the business unit head for his business unit and the CEO finally receives a consumption report for the operations unit of the company. This reporting is available on a daily, weekly and monthly basis. It is possible to provide absolute and specific energy consumption data.

Secondly, for the purpose of target setting: the reporting tool provides unbiased data about the energy consumption in all units of the company, gathered by a common and agreed method. Therefore it can serve as the basis to formulate yearly energy consumption targets for every specific unit and to control the achievement of the targets. Plant managers, site managers or business unit heads are enabled to discuss energy consumption data with their supervisors or to control the effect of efficiency measures with the help of the reporting tool. The result is a transparent target discussion in the company on the basis of neutral numbers.

It is a disadvantage of the reporting tool described above that the energy consumption of different productions is not comparable. Obviously a bulk chemical production normally needs less energy per kilogram of product than chlorine electrolysis. The reporting tool can be used to set targets for the plant managers of the bulk chemicals and the chlorine plant, but it cannot decide which of the two plants is more energy efficient. In order to compare different production facilities we expanded the concept of energy reporting by defining a comparative scale. This concept will be presented in Section 4.6.4.

Energy Loss Cascade

The idea of the energy loss cascade is to compare the actual energy consumption of a production plant with a Plant Energy Optimum defined for that specific plant. The Plant Energy Optimum reflects the minimal energy consumption in kWh primary energy per ton of product which is achievable for that plant at an optimal configuration. Figure 4.17 shows the principle of the cascade. It was developed for Bayer Material Science under the name STRUCTese.

The difference between the minimum and the actual consumption is divided in different loss categories (in our standard approach we consider 10 loss categories). These categories reflect static losses and time dependent, dynamic losses.

Static losses are dependent on the asset configuration and cannot be influenced in the daily business. Examples for potential savings in this category are the implementation of heat integration (for instance preheater) or the replacement of not optimal equipment types.

Dynamic losses include different effects like partial load or a specific product mix which may lead to higher specific energy consumption. All other non-specific losses are summarized under the category 'suboptimal operation'. Examples for potential savings in this category are alternative cleaning operations or increased product concentrations, which both can lead to significantly reduced steam consumption.

Energy saving targets will now be presented to different groups of employees. The static losses can be influenced by investment projects initiated and approved by the upper or middle management. Marketing and Sales department is respon-

Dynamic losses -

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Static loss -

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Dynamic losses

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Sub-optimal equipment

Partial load

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Actual consumption

Loss categories

Figure 4.17 Energy loss cascade (STRUCTese).

sible for the reduction of partial load losses. The plant manager will have the target to reduce operational losses. All these groups are committed to saving targets in different loss categories.

Furthermore the energy loss cascade makes it possible to compare the energy efficiency of production plants for different products. The absolute or relative difference between the actual consumption and Plant Energy Optimum is a measure of the absolute energy efficiency of a plant. Plants with high energy awareness will produce near their optimum while plants, which did not focus on energy efficiency in the past, will show a larger difference between the actual and the optimum consumption.

Company-wide definitions are necessary to determine the Plant Energy Optimum and the different loss categories. It is crucial for the acceptance of the program that the values and categories are defined in a uniform way for every plant and the whole company. In a handbook all these definitions and calculation methods were documented in order to achieve a consistent and comprehensive approach.

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