Systematic Procedure for Energy and CO2 Reduction Projects 123

Hans-Joachim Leimk├╝hler

4.1 Overview 123

4.2 Definition of Scope and Task 124

4.3 Analysis 126

4.3.1 Carbon Footprint 126

4.3.2 Energy Distribution per Utility 127

4.3.3 Main Energy Consumers 130

4.3.4 Operational Parameters 132

4.3.5 Process Model 132

4.3.6 Energy Baseline and Milestone 1 132

4.4 Idea Generation 133

4.4.1 Fields of Energy Savings 133

4.4.2 Brainstorming Sessions 133

4.4.3 Equipment Check 135

4.4.4 Operational Improvements and Process Control 136

4.4.5 Process Improvements 137

4.4.6 Heat Integration and Heat Recovery 138

4.4.7 Raw Materials 138

4.4.8 Buildings and Facilities 139

4.4.9 Energy and Utility Systems 140

4.4.10 Milestone 2 141

4.5 Idea Evaluation 142

4.5.1 Technical Feasibility 142

4.5.2 Profitability 143

4.5.3 Savings Portfolio 144

4.6 Sustainable Implementation 147

4.6.1 Implementation Plan 147

4.6.2 Monitoring and Controlling 149

4.6.3 Reporting and Target Setting 150

4.6.4 Energy Loss Cascade 152

4.6.5 Energy Management System and Benchmarking 153

4.6.6 Energy Awareness in Plants 154

4.6.7 Repeated Checks 155

4.7 Case Study: The Bayer Climate Check 155

4.7.1 Situation before the Bayer Climate Check 155

4.7.2 Goal and Concept of the Bayer Climate Program 156

4.7.3 Realization and Results 156 References 158

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