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Energy Management – ISO 50001
26 May 2015
Allnex Norway
Roger Søråsdekkan, Allnex Site leader, Lillestrøm
1
2
OUR BUSINESS
• $ 1.5 billion company with main focus on coating resins
• A global leader in the $35 billion coating resins industry
• Our 4 product lines:
- Liquid Resins & Additives
- Radiation Curable Resins
- Powder Coating Resins
- Crosslinkers (Lillestrøm)
• Multiple end-user segments:
- Automotive
- Industrial
- Packaging Coating and Inks
- Protective
- Consumer Electronics & Industrial Plastics
- Specialty Architectural Global Sales 2014
Crosslinkers 23 %
Liquid Resins & Additives
29 %
Powder coating resins
22 %
Radiation Curable Resins
26 %
• 17 manufacturing facilities certified with ISO 14001, ISO 9001 & OHSAS 18001, 2 sites with ISO 50001.
• 11 research & technology centers
• 3 joint ventures (China, Korea & Japan)
OUR GLOBAL BUSINESS
3
More than 2000 MULTI-CULTURE EMPLOYEES WORLDWIDE
N. America Sales 23%
L. America Sales 4%
EU, Middle East & Africa Sales 48% Asia Pacific
Sales 24%
4
OUR TECHNOLOGIES
Broad Products Portfolio for the Coating Industry
Allnex
Key
tec
hn
olo
gies
Radiation Curable Resins
Inks & Overprint Varnishes
Industrial Wood Electronics Plastic
Oligomers Urethane Acrylates,
Epoxy Acrylates, Polyester Acrylates, Amino Acrylates
Monomers UVEKOL® Glass
Lamination VANCRYL® Acrylics
Powder Coating Resins
Architectural Extrusions Domestic Appliances General Metal
Polyester Resins Hybrid, Standard Durable
Super Durable UV Powder Resins
Additives & Master batches
End
use
r ap
plic
atio
ns
Liquid Resins & Additives
Automotive Protective & General
Metal Architectural Plastic
Waterborne PUD, Alkyds, Epoxies,
Acrylics CED Resins Solventborne
Alkyds, Epoxies, Acrylics Coating Additives
Urethane Specialties
Crosslinkers
Industrial Wood Metal Packaging Automotive Tires & Rubber Products
Amino Crosslinkers Formaldehyde-Free
Crosslinkers Phenolic Coating Resins
Technical Phenolics
Key
segm
ents
LOCATION
26 May 2015 5
LIILESTRØM LOCATION OVERVIEW
26 May 2015 6 Capacity: 36.000 MT amino resins.6
DYNEA AS - Wood Adhesives
- Panel Board Resins
- Site Support
-160 employees
Allnex Norge 56 employees
Invitrogen 37 employees
Microbeads 4 employees
M-I Prod. Chem.
9 employees
LILLESTRØM REACTOR TRAINS
26 May 2015 7
Butylated
1 35m3
2 15m3
3 15m3
4 45m3
5 45m3
6 45m3
Methylated
2
15m3
CHEMISTRY
• Multistep reaction - Two main reactions • Methylolation : Formaldehyde + NH2 containing compound
• Alkylation : Reaction between intermediate and an alcohol
26 May 2015 8
Melamine
+ HCHO
Monomethylol melamine
+ 3 HCHO
+ 6 HCHO
Trimethylol melamine
Hexamethylol melamine(HMM)
Melamine
+ HCHO
Monomethylol melamine
+ 3 HCHO
+ 6 HCHO
Trimethylol melamine
Hexamethylol melamine(HMM)
Hexamethylol melamine Hexa-alkyl methylol melamine
RAW MATERIAL RECOVERY
26 May 2015 9
LILLESTRØM MANUFACTURING – INPUT AND OUTPUT
26 May 2015 10
CYMELS CYREZ CYCAT
Raw Materials Number of: 30+ Quantity: 60,000 MT
Steam, 135,000 MT (=75 500 MWh)
Electricity, 7,600 MWh
Products Number of: 70 Quantity: 30,000 MT
Solid Waste Waste Water 30,000 MT 120 MT COD
Air Emission
www.allnex.com www.allnex.com www.allnex.com
ISO 50001
Energy Management Standard
Hvordan gjorde vi det?
www.allnex.com www.allnex.com www.allnex.com
Oppstartsmøte med mai 2013
Kartlegging med juli 2013
GAP analyse med august 2013
Oppfølging og lukking av GAP Q4 2013 og Q1 2014.
Sertifisering av i juni 2014
13
17%
LILLESTRØM ENERGY POLICY: VISION & MISSION
Vision Be recognized as the leading plant at Allnex to have energy management as a continuous and sustainable improvement area.
Mission • Allnex Norway will reduce and economically optimize our consumption
of energy. • Lillestrøm is a LEAN plant, and will use appropriate tools and innovation
to maintain sustained reduced energy consumption. Results • No unnecessary energy consumption • Reduce green house gas emissions • Become more competitive operation
26 May 2015 14
OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
New steam meters installed
26 May 2015 15
ENERGY CONSUMPTION FOR SOME TYPICAL PRODUCTS (2014)
Energi forbruk pr produkt og pr produklinje med hjelp fra :
26 May 2015 16
Goals and effectiveness of energy use and indicators
“We will use the developed energy model to monitor performance and take actions”
Energy models based on standards, climate and level of production predict energy usage. Analysing devaitions from model reveals waste of energy. See next two slides
300350400450500550600650700750
MW
H
Month
Electricity: Modeled and Actual Usages
modeled
actual
2 000
3 000
4 000
5 000
6 000
7 000
8 000
MW
H
Month
Steam: Modeled and Actual Usages
modeled
actual
Month To Date Year To Date
Plant
Modeled energy (MWH)
Actual energy (MWH)
usage variance (MWH)
Total Savings (k$)
Monthly Goal k$
Modeled energy (MWH)
Actual energy (MWH)
usage variance (MWH)
Total
Savings
(k$)
YTD Goal k$
Drogenbos 9665 7783 1882 $104 $25 105320 90610 14710 $803 300 Fengxian 3621 3325 296 $12 $3 43408 40079 3330 $160 41 Hamburg 3228 2769 459 $25 $5 34877 32451 2426 $155 58
Kalamazoo 9256 8555 701 $22 $6 110266 107041 3225 $131 77 Langley 1670 1721 -51 $0 $2 20612 20164 447 $30 25
Lillestrom 6441 5587 854 $87 $17 69822 63324 6497 $661 203 North Augusta 6248 6386 -138 -$5 $7 86400 84917 1482 $34 89
Rayong 1265 1258 7 -$1 $2 15880 15621 260 $12 20 Romano 4892 5523 -631 -$28 $8 50539 50947 -408 $24 91
Schoonaarde 1690 1656 34 $3 $4 23457 24198 -742 -$43 45 Seremban 1851 1464 387 $12 $3 24415 22833 1582 $54 32
Shimonoseki 3824 3812 12 $2 $12 41186 39846 1340 $194 149 Urethanes 2862 3157 -295 -$1 $5 56365 56885 -520 $26 58
Wallingford 11906 12099 -193 -$6 $16 147309 144435 2873 $119 188 Werndorf 3732 3623 109 $4 $6 40141 39178 963 $11 68
Wiesbaden 2405 2683 -278 -$3 $5 28281 30826 -2545 $83 57
Performance 2013
We measure our energy effectiveness in $ savings, for 2013 the figures for Lillestrøm where 6497 MWh or k$ 661.
TARGETS AND PROGRESS
• Activity bridge
Tracks unit energy consumption and total energy consumption of the different activities implemented.
26 May 2015 19
ENERGY MANAGEMENT
• Achieved ISO 50001 certification in 2014 - Supported by Enova and Norsk Industri
• Plan to reduce energy concumtion by 10% by 2017 with 2012 baseline
- Achieved 2/3 of this target by end of 2014
26 May 2015 20
1,500
1,700
1,900
2,100
2,300
2,500
2,700
2,900
3,100
3,300
3,500
2009 2010 2011 2012 2013 2014 2015 2016 Target2017
Total Energy Intensity (MWh/ton)
2009
2010
2011
2012
2013
2014
2015
2016
Target 2017
OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
• Other activities & ideas to reduce energy consumption (not quantified)
- Reduce free form charge. (i.e water/methanol stripp)
- Split D80 pipe from LUWA
- Insulation where needed (pipes)
- Implement action from compressed air leakages audit (Firma)
- Implement action from heat leakages audit (Norisol)
- Control water cooling
“We will use the improvement tracker to manage and monitor actions for energy reduction. Yearly goals will be defined in our business plan.”
26 May 2015 21
OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
Suggestions brought up during management review
• Morten/Ronald: Demontere topp A1 og vurdere performance før sommertopp • Kjell Even: Legge inn audit av «energy program» i audit program • Trond: Øke bevissthet: Hva får vi ut av PI? Info på plant TV? • Geir: PI oppfølging på kolonner • Roger: Beregne energi effekten av ny mix (etter footprint) inn i bridge • Jan Erik: Process review for C1161 og C303, C1123 • Ingvar/Kjell Even: Autostopp på trucker? • Ingvar/Kjell Even: Vurdere el trucker? • Alle: Ledelsen oppmuntre til å entre flere energiavvik • Ronald: Beregne på energiforbruk i SSA • Roger: Beste energi: Vi gir gavekort fra XXL til Runar, ok 25.2.2015. • Trond: Avtalt gjennomgang av REA med Jo minken (3 sessjoner i
2015)
26 May 2015 22
TARGETS AND PROGRESS
• Co2 beregninger....
26 May 2015 23
CO2 reduction
reellt (Kg)
CO2 reduction
(Nordic mix)
CO2 reduksjon
EU mix
CO2 reduksjon
Global mix
Target Amount Saving/unit NOK KWh 0,19 Kg CO2/Kwh 0,345 Kg CO2/Kwh 0,535 Kg CO2/Kwh
D80 distillate (m3) 3 700 300 999 000 2 053 500 159 968 390 165 708 458 1 098 623
MVR unit (h) 200 630 126 000 200 300 38 057 38 057 69 104 107 161
batches on "hot formalin" 500 429 214 500 360 750 28 102 68 543 124 459 193 001
Bottom B1 to WWTP (MT of steam) 300 0 0 0 0 0
Process improvements (less steam) 500 300 150 000 277 500 21 617 52 725 95 738 148 463
New column B2 (less steam) 750 300 287 100 482 850 48 285 91 742 166 583 258 325
Supplier: Schutz: 200 IBC's trough return system 10 000 10 000 10 000 10 000
N2 blåsing for å redusere fri form
Greif transport
Supplier: Solvang: transportation of pallets 3 600 3 600 3 600
D80 distillate (m3) R4 & R5 1 000
1 776 600 3 374 900 296 029 654 831 1 177 941 1 819 172
Achieved savings in 2014 1 303 500 2 342 100
Adittional 2015 savings 473 100 1 032 800
Energy activity goals and estimated savings (yearly)
Goal for 2015 should be implementation of a NOK 500 000 savings.
RESULTS OF INTERNAL/EXTERNAL AUDITS
26 May 2015 24
TRAINING AWARENESS & COMPETENCE
• Senior Engineer responsible for training other employees about energy awareness
• Energy saving activities discussed weekly with shift members
• Monthly energy performance meeting with all sites, sharing BESP
• Morning market twice weekly follow up on key energy indicators
• Allnex Academy (online Allnex training platform) used for operator training and awareness
• Energy projects (CAPEX) followed in monthly CAPEX meetings
• 3 training sessions planned in WWTP (Renseanlegg) treatment plants in 2015
26 May 2015 25
“We will promote a high level of energy awareness among all employees.”
OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
• Changes in operations affecting energy consumption 2013-2014
• 2013: Nitrogen generation plant (=> + 400 MWH)
• 2014: Globalization of free form spesifications (=> + 330 MWh)
• 2014: Summer shut down: New main steam meeter installed
• Smaller changes (not included in energy bridge)
• New workshop with use of exess energy from nitrogen generation
• Reduce number of diesel forklifts from 4 to 3
• Others?
26 May 2015 26
COMMUNICATION WITH EXTERNAL STAKEHOLDERS
26 May 2015 27
Enova • Final report submited in August and compensation of KNOK 1 000 for
implementing ISO 50001 program given in September. • Support investments and worked hours (1 832) on energy management • Total cost of project KNOK 3 260
0
10
20
30
40
50
60
70
80
90
January February March April May June July August September October November December
Allnex Employee Hours
?
26 May 2015 28
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26 May 2015
Thank you
ADDITIONAL INFORMATION AND RESOURCES
• Allnex energy management in articles at Norsk Energi og Standard Norge:
•http://www.standard.no/standardisering/suksesshistorier/suksesshistorie-allnex-norway/
•http://www.energi.no/allnex-norway-ks-har-best%c3%a5tt-eksamen-i-energiledelse
26 May 2015 30
disclaimer
Notice: Trademarks indicated with the ®, ™ or * are registered, unregistered or pending trademarks of Allnex IP Sàrl or its directly or indirectly affiliated Allnex Group companies. Disclaimer: Allnex Group companies (“Allnex”) decline any liability with respect to the use made by anyone of the information contained herein. The information contained herein represents Allnex's best knowledge thereon without constituting any express or implied guarantee or warranty of any kind (including, but not limited to, regarding the accuracy, the completeness or relevance of the data set out herein). Nothing contained herein shall be construed as conferring any license or right under any patent or other intellectual property rights of Allnex or of any third party. The information relating to the products is given for information purposes only. No guarantee or warranty is provided that the product and/or information is adapted for any specific use, performance or result and that product and/or information do not infringe any Allnex and/or third party intellectual property rights. The user should perform its own tests to determine the suitability for a particular purpose. The final choice of use of a product and/or information as well as the investigation of any possible violation of intellectual property rights of Allnex and/or third parties remains the sole responsibility of the user. © 2015 Allnex Belgium SA. All Rights Reserved
disclaimer disclaimer
26 May 2015 31
