The Energy Efficiency Directive and The Way Forward for Manufacturers

Transcription

1 The Energy Efficiency Directive and The Way Forward for Manufacturers Brigitta Huckestein, BASF SE Energy Efficiency Management in Manufacturing Plants IFMR, Stockholm 27./

2 Agenda BASF Energy Efficiency Strategy and Goals Measures Organisational Processes The EU Energy Efficiency Directive Saving potentials of sectors The energy cap The global context 2

3 BASF The Chemical Company We create chemistry for a sustainable future Our chemicals are used in almost all industries We combine economic success, social responsibility and environmental protection. Sales 2011: 73,497 million EBIT 2011: 8,586 million Employees (as of December 31, 2011): 111,141 In 2011, BASF filed for around 1,050 new patents worldwide 6 Verbund sites and around 370 production sites Platzhalter für Bild 3

4 Structure of BASF s segments Chemicals Plastics Performance Products Functional Solutions Agricultural Solutions Oil & Gas Inorganics Petrochemicals Intermediates Performance Polymers Polyurethanes Dispersions & Pigments Care Chemicals Nutrition & Health Catalysts Construction Chemicals Coatings Crop Protection Exploration & Production Natural Gas Trading Paper Chemicals Performance Chemicals 4

5 Sustainability - firmly established at the Board level Board of Executive Directors of BASF SE Sustainability Council Climate Protection Officer Chairwoman: Margret Suckale Sustainability Center Central units Functional units Operating units Regions 5

6 Energy Supply of the BASF Group Achatz, Globales Energiemanagement

7 Global greenhouse gas reduction and energy efficiency goals (2012) Platzhalter für Bild 7

8 Highly efficient processes: Examples for energy efficiency measures Continuous improvement in energy efficiency and use of modern energy production processes Saving of thermal energy: Heat integration Use of waste heat for drying processes Optimized operation of distillation columns Saving of electrical energy: Use of frequency controlled pumps Energy efficient motors Energy efficient lighting Automation measures Reduction of water consumption and avoidance of wastewater. 8

9 Energy generation at BASF BASF-owned combined heat and power plants (CHP) with combined cycle gas turbines (fuel efficiency of almost 90%) Supply of more than 70% of BASF s own energy requirements for the production of chemicals by CHP plants possible. Annual avoidance* BASF-Group 2011: Primary energy: 1,0 Mio. toe CO 2 emissions: 2,4 Mio. t CO 2 * Comparison: Conventional power and steam generation in separate plants based on natural gas. 9

10 BASF Sites Using Co-Generation Bradford Emlichheim Schwarzheide Freeport Antwerpen Ludwigshafen Geismar Monthey Altamira Boussens Nanjing Port Arthur Tarragona Kuantan - Worldwide 27 gasturbines (GT) at 14 sites - Generation of 70% of the electrical power demand (of total 16.2 TWh/yr) Verbund site major chemical production site 10 Achatz, Globales Energiemanagement

11 Energy (and Raw Materials) Flow in a Chemical Plant Platzhalter für Bild 11

12 Energy Verbund at a Verbund site Example: Steam Cycle at a Verbund Site Steam export Steam consumption Power plant Sulfuric acid plant Annual avoidance * BASF Group 2011: Primary energy: 1,6 Mio. toe Adipic acid plant Urea/carbamide plant CO 2 emissions: 3,7 Mio. t CO 2 Acrylic acid plant Office building *Comparison: Conventional power and steam generation in separate plants based on natural gas. 12

13 Heat Integration in a plant: Optimal concepts of heat exchanger networks Heat integration analysis provides the minimum heating and cooling energy demand by using economic temperature differences Platzhalter für Bild 13

14 Process automation: Effective reduction of process fluctuations by optimizing control Platzhalter für Bild 14

15 Small measures count, too Leakage detection by soapy water Leakage detection by ultrasound 15

16 Energy efficient buildings Buildings accout for 3-5 % of our energy consumption Buildings are long-term infrastructural measures BASF has a buildings policy BASF signed the WBCSD buildings manifesto Platzhalter für Bild BASF Fire station with new wall and roof insulation, new windows and doors 16

17 Limits of Energy Efficiency Innovation needed Specific Energy Consumption Plant today Energy Management Existing plant, ideally operated Energy Management Existing plant, ideally operated + technical improvements New plant Strategic Investment Innovation + Investment New process + new plant 17

18 Energy Efficiency at BASF by new investements in new plant New chemical processes and process technologies L-Menthol (BASF Ludwigshafen, 2012) Bio propylene glycol (Oleon, Belgium, 2012) Toluene diisocyanate and precursors (BASF Ludwigshafen, 2014) Platzhalter für Bild Several investments after conceptual changes for drying of products, separation of mixtures etc. 18

19 Energy Efficiency at BASF Organizational Processes Strategy & goals defined at Board Level People: Organisation, information, involvement Detailed know-how from inhouse experts -> Engagement of all empolyees Data: Monitoring/documentation -> Analysis -> Steering Implementation of ISO 50001: Energy management systems add formalism, but no new ideas

20 Energy Efficiency at BASF Involvement of experts and employees 20

21 Project savings pay for energy managment system costs Initial Costs Engineering Procurement Quality assurance Equipment Construction Commissioning Downtime Operating Cost Raw material Energy Environmental Insurance Staff Maintenance Repairs End-of-life costs Decomissioning Disposal Life cycle view for investments Costs for Energy Management - but savings from more than 100 projects in

22 EU Energy and Climate Goals 2020 Source: EU Commission 22

23 EU Energy Efficiency Directive Ambition Source: EU Commission 23

24 Voluntary actions and existing legislation already taps most of the potential in industry Economic energy efficiency potential per sector in % 70 % 33 % 48 % Source: EED Impact Assessment Transformation, transmission Distribution 24

25 Climate Protection and BASF: Chances for new products and applications The chemical industry is a major driver of innovative technologies in the energy and energy efficiency sector, e.g. innovative insulation insulating windows concrete admixtures lighting products cool paints fuel additives products for wind power or solar industry products for batteries, energy storage 25

26 Climate protection at BASF: BASF Corporate Carbon Footprint 2011 Avoidance of emissions: 330 Mio. t CO 2 e/a Emissions along the entire value chain [Mio. t CO 2 e/a]: Raw materials 65 We help our customers to shrink the carbon footprint. BASF Production Use of BASF end products Disposal Transport 4 Further Sources 3 CO 2 e emissions at customers [Mio. t CO 2 e/a]: Without the use of BASF products: 1768 With the use of BASF products: 1438 CO 2 e emissions BASF Production (GHG Protocol Scope 1&2) CO 2 e emissions along the value chain (GHG Protocol Scope 3) 26

27 Energy Efficiency Directive 2012 General targets and obligations 1474 Mtoe energy consumption Member States to set an national target End-use energy savings of 1.5% per year between 2014 and 2020 Energy efficiency obligation schemes or alternative measures Exemptions up to 25 % Exemption of transport sector (optional) Further measures to be proposed in

28 Energy Efficiency Directive 2012 Industry obligations Energy audits for large companies are now obligatory Cost-benefit-analysis for heat use from installations > 20 MW may be required. Priority access given to renewable energy - may hamper feed in of electricity from combined heat and power (CHP) installations 28

29 Energy Efficiency Directive 2012 Buildings Obligations MS shall establish a long-term strategy for renovation From 2014 until 2020, 3% of the total floor area of central government buildings to be renovated each year 29

30 EU Energy Efficiency Directive 2012: An energy cap may limit growth 30 ZOA/DE

31 CO2 emissions in USA, China, EU CO 2 -emissions per region/country 1990/2000/2011 (unit: billion tonnes of CO 2 ) 10,00 9,70 8,00 6,00 4,00 2,00 0,00 5,87 5,42 4,99 4,32 4,06 3,56 3,79 2,51 USA China EU27 Emissions/capita 2011: 17,3 7,2 7, Source: JRC/EU Commission 31

32 Towards a harmonized EU Energy and Climate policy CO2 is the leading parameter Energy efficiency target as aspirational goal We need more not less industrial solutions Level playing field to ensure energy efficient production in Europe Allow for growth and innovation: No energy cap covering industry Promotion of energy efficiency improvements welcome but cost-efficiency must be given Tap the potential of the building and transport sector 32