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180° Seminar, Green engineering

IGCW-2013 Convention

Bayer Climate Check

2013.12.08 / Jagdish Solanki / BTS India

An integrated tool to mitigate energy consumption and CO2 emissions

Bayer Climate Check, Jagdish Solanki, 2013.12.08

Agenda Introduction of Bayer and BTS-India

Introduction of the Bayer Climate Program and the Bayer Climate Check

Climate Footprint

Energy Efficiency Check

Workflow of the Climate Check

Data required from Client and results delivered by BTS

Page 2

Bayer AG – Facts, Figures, Objectives

Bayer – Facts and Figures 2012

• 110,500 employees worldwide

• Sales: 39.8 Euro Billion

• EBIT: 3.9 Euro Billion

• Net income: 2.5 Euro Billion

• R&D expenses: 3.0 Euro Billion

• Capital expenditures: 4.6 Euro Billion

Bayer – Objectives

• To become a leader in research and technology

• To achieve continuous growth of expertise in the manufacture of high-quality and environmentally compatible products

Bayer Climate Check, Jagdish Solanki, 2013.12.08Page 3

Bayer Technology Services – a Bayer

Group Company


Corporate Center

Bayer AG

Service AreasBusiness Areas

Group Management Board

Holding Company

Bayer BusinessServices

Bayer Technology Services

Currenta

Bayer

HealthCare

Bayer

CropScience

Bayer

MaterialScience

Offers services on

external market

Turnover worldwide(*) 451.0 EUR mil

Employees worldwide(*) 2,371(*)2012

Client industries

• Health Care

• Crop Science

• Material Science/Polymers

• Chemicals

Page 4

BTS India is an integral part of BTS


Location: Mumbai, Thane

Established: 03/2009

Current Staff: 35 + external support

North AmericaBaytown, TX, USA

BeneluxAntwerp, Belgium

IndiaMumbai,

India

AsiaShanghai, China

Latin AmericaMexico City, Mexico

SwitzerlandWitterswil, Switzerland

HQ Leverkusen, GermanySites Berlin, Bergkamen,

Dormagen, Krefeld, Wuppertal

BrazilRio de Janeiro, Brazil

North AmericaBerkeley, CA, USA

AsiaSingapore

AsiaBeijing,

China

RussiaMoscow, Russia

North AmericaPittsburg, USA

Page 5


BTS India – Our focus

BTS India for Indian market:

1. Micro Reaction Systems

2. BayQik

3. Process optimization

4. Environmental Protection Technologies

5. Project Management (Owner’s Engineering)

BTS India for internal (Bayer) market:

1. Execute projects of Bayer in India

2. Sourcing of equipment from India for Bayer globally

3. Ensure Plant and Process Safety standards of Bayer production facilities in India.

Page 6

The Bayer Climate Program was

announced on November 19th 2007


• Program: Bayer launched the Group-wide “Bayer Climate Program” at the

end of 2007, which includes a series of

measures to be implemented in the next

several years

• Goal: Further reduce CO2 emissions in its production facilities and develop new

solutions for increasing climate

protection and dealing with climate

change

• Investment: EUR 1 billion for climate protection in 2008 - 2010

Lighthouse Projects:

• “EcoCommercial Building:” A global concept for zero-emission office and

industrial buildings

• Make plants more resistant to climatic conditions such as drought and heat

• Contribute to the efficient use of plants as energy source

• “Bayer Climate Check” identifies potential for CO2 reduction in production

Page 7


Bayer Climate Check

Page 8

Bayer Climate Check – Main

Characteristics


The Bayer Climate Check…

consists of two elements:

Climate Footprint


is a systematic screening of all relevant production units

worldwide for all Bayer subgroups to identify measures for

energy & CO2e emission reduction.

supports achievement of targeted climate goals of Bayer

subgroups.

Clim

ate

Fo

otp

rint

Energ

y-E

ffic

iency-

Check

Bayer Climate Check

Clim

ate

Fo

otp

rint

Energ

y-E

ffic

iency-

Check

Bayer Climate Check

Page 9


Climate Footprint

part of

Bayer Climate Check

Page 10

The Climate Footprint is the KPI to

assess the total Climate Impact


A new indicator to assess climate impact of Bayer production processes

Based on the Life Cycle Analysis method

Takes into account the influence of energy consumption, raw materials,

logistics and direct emissions

Data acquisition by a detailed questionnaire

Resulting in:kg CO2e / kg product

Electricity

Steam

Factory gate

By-product

Footprint

Product B

Footprint

own raw

material

Footprint

raw material

from

suppliers

Transport

Production

Plant A

Production Plant B

Footprint Product A

Factory gate

Page 11

Carbon, CO2, Climate, …, Footprints:

Semantics and definitions.


Carbon Footprint or CO2 footprint are frequently used phrases with ambiguous meanings.

In simple word, Carbon Footprint can be defined as :

A carbon footprint is a ‘measure of the impact of human activities leave onthe environment, directly and indirectly or is accumulated over the lifestages of a product, in terms of the amount of green house gasesproduced, measured in units of carbon dioxide’.

Definition is usually taken from Life Cycle Analysis (LCA) standards (e.g. ISO14040). Coverage is all gases based on their green house gas potentialmeasured in t CO2e.

LCA covers many more sustainability aspects beyond the carbon footprint.

Application of the phrase carbon footprint is very wide, e.g. products, companies,production units (plants, sites, …), buildings, services, …

Product Carbon Footprints (PCF) are already partly used for product labeling

The Bayer Climate Footprint® is based on the standards for LCA and it is thecertified method within the Bayer Climate Check. Commercial tools anddatabanks are used.

Climate Footprint ® is a registered trade mark for BTS.

Page 12

CO2 emission reporting according to

GHG Protocol distinguishes 3 scopes


Electrical Power

Heat (e.g. steam)

CO

2 Scope 2:

indirect emissions form

energy supply

Scope 3(optional):

material up and downstream

processing, application, transport,

recycling, …C

O2, N

2O

,

SF

6,

CH

4,

Scope 1:

direct emissions

t CO2 e

Page 13

Role of CO2 emission scopes (Carbon

Footprint standards do not distinguish

scopes).


Scope 1: direct emissions from a plant or product

• Direct GHG emissions occur from sources that are owned or controlled by the company, for example,emissions from combustion in owned or controlled boilers, furnaces, vehicles, etc.; emissions fromchemical production in owned or controlled process equipment.

• Most established and published

• Is clearly regulated for large scale GHG emitters (power plants, steel plants, refineries, …)

Scope 2: indirect emissions from energy consumption

• Emissions due to purchased electricity or utilities

• Recently voluntarily reported by companies and organisations.

• No legal regulations exist today for reporting, not part of the certification or trading system, Bayerreporting according to GRI

Scope 3: other indirect emissions from raw materials, product usage, …

• Scope 3 is an optional reporting category that allows for the treatment of all other indirect emissions.Scope 3 emissions are a consequence of the activities of the company, but occur from sources notowned or controlled by the company. Some examples of scope 3 activities are extraction andproduction of purchased materials; transportation of purchased fuels; and use of sold products andservices.

• Not standardized reported by companies though still used

Page 14

The Climate Footprint® is designed to cover

the relevant CO2 contributions for production

units.


Raw

Material

Upstream

Processing

Chemical

ProcessingBayer

Climate

Footprint

Cradle to gate Cradle to grave

Distribution Product

Application

Disposal Total

Carbon

Footprint

Downstream:

Manifold product &

lifecycle routes

Assumptions and

vague approximations

ambiguous footprint

Upstream:

Unique allocation of

production

route

unique CO2 allocation

distinct footprint

The Climate Footprint®

covers the impact of our

products up to the gate (no

downstream contributions)

according to LCA rules

Carbon Footprints can have any scope between cradle to gate and cradle to grave.

Page 15

The Climate Footprint® shows the individual

contributions and the reduction potential.


0

5

10

15

20

25

30

35

40

4541

Iopromid

base

2

Antracol

WP 70

base

3

BPA UER

base

27

Adalat

Gits base

Packaging

Transport

Energy Carrier

Power

Steam

Raw Materials

t CO2e / t

Examples for Climate Footprints Annual reduction potential from

Energy Efficiency measures

0

2000

4000

6000

8000

10000

12000

14000

16000

Power838

Iopromid

1905

FU 1

15271

BPA UER

1950

FSB

Steam

t CO2e / a

Page 16

The Climate Footprint® takes a pragmatic

approach to assess climate impact with

limited effort.


There is no absolutely correct value of a Climate Footprint®. Correctness

is a matter of making appropriate assumptions and applying an accepted

(certified) methodology. Accuracy is a matter of data gathering and

detailing the production chain.

The Climate Footprint® is designed to deliver meaningful results with

limited cost and amount of work.

• Use established databank values where available.

• Application of Proxies for complex raw materials.

• For multi-purpose plants:

• select major products

• Lump products and create typical footprints rather than many individual

• Typically scope to budget for 5 – 8 days is possible (data gathering atplant/site not included)

Page 17

Carbon Footprint, other approaches &

public expectations


• Retailers push the Product Carbon Footprint to differentiate fromcompetitors.

• NGOs push the Carbon Footprint as an industry independent tool toavoid green washing

• Politics is looking for cross-industry applicable methods.

• Non-energy intensive industries (e.g. IT, communications) introducecarbon footprints. This creates pressure on the energy intensiveindustry.

• Winners of a „low carbon society“ push the carbon footprint.

• PCF are used where it promises opportunistic advantages. Nosystematic and comparability of current approaches.

• Most companies communicate the value of their products.

• BTS offers the calculation of Carbon Footprints according to LCAstandards as a service.

Page 18

Product Carbon Footprint: Example

Tesco (UK)


The Climate Footprint is certified by

TÜV Süd


How to get data for the Climate

Footprint


Data Acquisition by a questionnaire concerning:

Energies

Utilities

Raw Materials, Products and byproducts

Auxiliaries

Transportation

Waste and waste treatment

And all further possible sources of emissions

(e.g. refrigeration, direct emissions)

results in:

as-is-state (basis scenario) of the plant

Documentation of the technical processes

Page 21



part of

Bayer Climate Check

Page 22

The Energy Efficiency Check is a

holistic approach


The Energy Efficiency Check…

identifies measures for energy & CO2e emission reduction.

applies of a wide range of state-of-the-art methods and tools in a

systematic approach.

brings together the experience of plant engineers & operators

and BTS experts from several competencies.

BTS has successfully executed more than 130 projects.

Customers are e.g.:

BMS, BCS, BHC, Currenta, Lanxess, Saltigo, H.C. Starck,

Ineos, Clariant

Indswift Lab. Ltd and Indorama through DEG

Page 23

Energy Efficiency Check – Workflow


An Energy Efficiency Check comprises three steps:

Analysis

Idea Generation

Evaluation

Result:

List of feasible improvement suggestions with:

Savings potential

Costs (rough estimate, if possible)

Profitability (rough estimate, if possible)

Analysis

Idea

Generation

Evaluation

Page 24



Analysis

Idea

Generation

Evaluation

Analysis

Goal: - identification of main levers for energy reduction

- acquisition of data

Determine and quantify energy consumers / producers

Determine relevant data of energy consumers /producers,

e.g. power, temperature, flows, technical equipment data

If reasonable: build / update process model

Result: consistent data base – reference case

Sankey DiagramEnergy Distribution

Page 25

Comprehensive Energy Audit –

Workflow


Idea Generation

Goal: determination of measures for energy reduction

Application of a wide range of state-of-the-art methods

Improvement measures range from simple operational

adjustments to complex adjustments

Equipment Check

Operational Improvements

Process Control / Automation

Heat Integration / Heat Recovery

Process Improvements

Energy / Utility Systems

Facility Check:

Insulation / Illumination

Different levels of energy optimization

Analysis

Idea

Generation

Evaluation

Page 26



Idea Generation

Equipment check

• Evaluation of performance of larger energy consumers

• Checklists: check for best practice / benchmarking

• Examples:

• large pumps: operating point, control strategy, frequency drive

• heat exchanger: control strategy, cleaning program in case of fouling

• unit operation such as dryer, high-viscous-equipment etc.

Motors

PumpsCompressors

Analysis

Idea

Generation

Evaluation

Page 27



Idea Generation

Heat Integration / Heat Recovery

• Pinch Analysis (if reasonable):

heat integration possibilities, heat exchanger network

• Total Site Analysis (if reasonable):

heat integration across plants e.g. via utility systems

• Heat recovery and reuse of waste heat:

check application of technical solutions such as absorption

chiller, heat pumps, vapor recompression

Analysis

Idea

Generation

Evaluation

ENTHALPY

TE

MP

ER

AT

UR

E

min cooling demand

min heating

demand Pinch Analysis

pinch

point

heat integration

possible

131.2

69.0

68.4

61.4

26.0

19.0

3.5

0.0

-26.5

-30.0

-66.5

-70.0

-95.0

-100.0

DTMIN: 7.0

(Duty based)

Case: Poly_1

61.5

61.5

19.0

13.0

15.1

13.0

61.5

61.4

64.9

60.0

79.2

70.4

64.9

60.0

41.1

-95.0

41.1

-95.0

59.1

26.0

65.8

61.0

67.7

67.7

60.0

26.0

66.6

32.0

25.6

-90.0

-94.9

-95.0

40.0

30.1

25.6

-90.0

67.7

26.0

122.1

21.0

44.3

26.0

69.0

69.0

69.0

30.0

26.0

-18.0

48.2

26.0

68.0

68.0

68.0

68.0

26.0

-18.0

56.7

26.0

67.0

66.9

5.5

0.0

47.0

47.0

40.4

26.0

43.1

43.1

-94.9

-95.0

235.7

235.7

186.1

186.1

131.2

131.2

23.0

19.0

0.0

0.0

-30.0

-30.0

-70.0

-70.0

-100.0

-100.0

-114.

-114.0

T1REB

Q:616.0

T10REB

Q:254.2

E235

Q:32.5

T2REB

Q:4774.7

T4BREB

Q:1205.2

T4AREB

Q:2311.2

T6REB

Q:346.5

T5REB

Q:678.2

T7REB

Q:453.5

T2CON

Q:4903.0

T1CON

Q:74.7

E98B

Q:1994.9

E98A

Q:3002.8

E22B

Q:156.7

E22A

Q:235.0

E26ABC

Q:2090.1

E27ABCD

Q:1376.7

T10CON

Q:24.7

T6CON

Q:430.3

E205

Q:4.0

T4BCON

Q:2955.7

T5CON

Q:2005.8

E5

Q:40.2

E29

Q:316.2

E28

Q:109.5

E23DE

Q:553.0

E23ABC

Q:829.5

221A

Q:64.2

E12

Q:1.8

E212

Q:1.6

T7CON

Q:508.7

E221B

Q:40.4

E101DE

Q:247.6

E101ABC

Q:371.4

E24DE

Q:371.1

E24ABC

Q:556.7

E21AB

Q:69.5

REACOS

E21C

Q:48.7

REACNS

T4ACON

Q:4253.2

Heat Exchanger Network

Page 28



Idea Generation

Operational / Process Improvements

• Improved process operation and process control: optimize operating

parameters and set points,

example:

• distillation: operating conditions, control strategy

• scenario studies with process models: analyze effect of altering operating

parameters

• analysis of operating data

• Improved / alternative process design

example: replacement of trays by packing in distillation

Analysis

Idea

Generation

Evaluation

Analysis of Operating Data

HE ATE R

iC5

Process Model

Page 29



Analysis

Idea

Generation

Evaluation

Idea Generation

Energy / Utilities

• Auditing of energy and utility systems (dependent on scope):

e.g. steam and electricity generation, cooling towers, pressurized air,

refrigeration, HVAC

• assess utility generation by benchmarks and expert evaluation

• assess utility distribution grids (e.g. leakage elimination, steam-

trap maintenance, return / reuse of condensate)

• Energy contracting:

analyze energy contracts and check for suggestions for cost savings

Utility Systems

Page 30



Analysis

Idea

Generation

Evaluation

Idea Generation

On-site

• Brainstorming and interviews:

Goal: incorporate improvement ideas from plant management

and operating employees

• Perform moderated sessions of open brainstorming

and interviews with:

• Plant management / plant engineers

• Operating employees

• Experts from customer

• BTS experts

• Facility Check:

plant inspection tours by energy experts,

e.g. inspect insulation, assess illumination

Examples

Page 31



Rough evaluation of measures

for energy reduction with regard to:

• Feasibility

• Savings potential

• Costs (rough estimate, if possible)

• Profitability (rough estimate, if possible)

Categories of feasibility :

Result: list of feasible improvement suggestions

with savings potential, costs and profitability

Analysis

Idea

Generation

EvaluationA B C(C1/C2/C3)

Feasible

e.g. proven technology,

no obvious concerns

Needs further

Evaluation

Not Feasible

Examples

Page 32



Analysis

Idea

Generation

Evaluation

Portfolio Categories

A = feasible and profitable

B = likely feasible and profitable, needs further evaluation

C1 = technically (currently) not feasible but profitable

C2 = technically feasible but not profitable

C3 = technically (currently) not feasible & not profitable

C1

C3 C2

A

B

Profitability

Technical

Feasibility

3 years ROI

difficult easy

not

profitable

profitable

Page 33


Thanks for your [email protected]

www.bayertechnology.com

Page 34

http://www.bayertechnology.com/


Questions???

Page 35

Backup


Backup slides

Page 36

Idea Generation- examples


Project Evaluation- example


Short description current situation

Short project idea

Project title

Potential calculation

Investment calculation

Any constrain from customer point

of view

Project evaluation/economics

Page 38

Project Evaluation- example


Thank you!

2011.10.18 / Jagdish Solanki / BTS India

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