1. No category

26 May 2015
Allnex Norway
Energy Management – ISO 50001
Roger Søråsdekkan, Allnex Site leader, Lillestrøm
www.allnex.com
1
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)
Radiation
Curable Resins
26 %
Crosslinkers
23 %
Powder
coating resins
22 %
Liquid Resins
& Additives
29 %
• Multiple end-user segments:
-
Automotive
Industrial
Packaging Coating and Inks
Protective
Consumer Electronics & Industrial Plastics
Specialty Architectural
Global Sales 2014
2
OUR GLOBAL BUSINESS
• 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)
N. America
Sales 23%
EU, Middle East &
Africa Sales 48%
Asia Pacific
Sales 24%
L. America
Sales 4%
More than 2000 MULTI-CULTURE EMPLOYEES WORLDWIDE
3
OUR TECHNOLOGIES
End user applications
Key segments
Key technologies
Allnex
Liquid Resins & Additives
Radiation Curable Resins
Waterborne
PUD, Alkyds, Epoxies,
Acrylics CED Resins
Solventborne
Alkyds, Epoxies, Acrylics
Coating Additives
Urethane Specialties
Oligomers
Urethane Acrylates,
Epoxy Acrylates, Polyester
Acrylates, Amino Acrylates
Monomers
UVEKOL® Glass
Lamination
VANCRYL® Acrylics
 Automotive
 Protective & General
Metal
 Architectural
 Plastic
 Inks & Overprint
Varnishes
 Industrial Wood
 Electronics
 Plastic
Powder Coating Resins
Crosslinkers
Polyester Resins
Hybrid, Standard Durable
Super Durable
UV Powder Resins
Additives &
Master batches
Amino Crosslinkers
Formaldehyde-Free
Crosslinkers
Phenolic Coating Resins
Technical Phenolics
 Architectural Extrusions
 Domestic Appliances
 General Metal
 Industrial Wood
 Metal Packaging
 Automotive
 Tires & Rubber Products
Broad Products Portfolio for the Coating Industry
4
LOCATION
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5
LIILESTRØM LOCATION OVERVIEW
Allnex Norge
DYNEA AS
56 employees
- Wood Adhesives
- Panel Board Resins
- Site Support
-160 employees
M-I Prod. Chem.
9 employees
Microbeads
4 employees
Invitrogen
37 employees
Capacity: 36.000 MT amino resins.6
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LILLESTRØM REACTOR TRAINS
1
22
3
4
5
6
35m3
15m3
15m3
15m3
45m3
45m3
45m3
Butylated
Methylated
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CHEMISTRY
• Multistep reaction - Two main reactions
•
•
Methylolation : Formaldehyde + NH2 containing compound
Alkylation : Reaction between intermediate and an alcohol
+ HCHO
Monomethylol melamine
Melamine
+ 3 HCHO
Trimethylol melamine
+ 6 HCHO
Hexamethylol melamine
(HMM)
Hexamethylol melamine
Hexa-alkyl methylol melamine
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RAW MATERIAL RECOVERY
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LILLESTRØM MANUFACTURING – INPUT AND OUTPUT
Air Emission
Raw Materials
Number of: 30+
Quantity: 60,000 MT
CYMELS
CYREZ
CYCAT
Steam, 135,000 MT
(=75 500 MWh)
Products
Number of: 70
Quantity: 30,000 MT
Electricity, 7,600 MWh
Solid Waste
Waste Water
30,000 MT
120 MT COD
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Energy Management Standard
ISO 50001
Hvordan gjorde vi det?
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
www.allnex.com
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
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14
OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
New steam meters installed
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ENERGY CONSUMPTION FOR SOME TYPICAL PRODUCTS (2014)
Energi forbruk pr produkt og pr produklinje med hjelp fra :
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Goals and effectiveness of energy use and indicators
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
Electricity: Modeled and Actual
Usages
Steam: Modeled and Actual Usages
8 000
actual
7 000
6 000
MWH
MWH
modeled
750
700
650
600
550
500
450
400
350
300
modeled
actual
5 000
4 000
3 000
2 000
Month
“We will use the developed energy model to
monitor performance and take actions”
Month
Performance 2013
Month To Date
Modele
usage
d
Actual varianc Total
energy energy e
Savings
Plant
(MWH) (MWH) (MWH) (k$)
Drogenbos 9665 7783 1882
$104
Fengxian
3621 3325
296
$12
Hamburg
3228 2769
459
$25
Kalamazoo 9256 8555
701
$22
Langley
1670 1721
-51
$0
Lillestrom
6441 5587
854
$87
North Augusta 6248 6386 -138
-$5
Rayong
1265 1258
7
-$1
Romano
4892 5523 -631
-$28
Schoonaarde 1690 1656
34
$3
Seremban
1851 1464
387
$12
Shimonoseki 3824 3812
12
$2
Urethanes 2862 3157 -295
-$1
Wallingford 11906 12099 -193
-$6
Werndorf
3732 3623
109
$4
Wiesbaden 2405 2683 -278
-$3
Year To Date
Modele
usage
Monthl d
Actual varianc Total
y Goal energy energy e
Savings YTD Goal
k$
(MWH) (MWH) (MWH) (k$)
k$
$25 105320 90610 14710 $803
300
$3
43408 40079 3330
$160
41
$5
34877 32451 2426
$155
58
$6 110266 107041 3225
$131
77
$2
20612 20164 447
$30
25
$17 69822 63324 6497
$661
203
$7
86400 84917 1482
$34
89
$2
15880 15621 260
$12
20
$8
50539 50947 -408
$24
91
$4
23457 24198 -742
-$43
45
$3
24415 22833 1582
$54
32
$12 41186 39846 1340
$194
149
$5
56365 56885 -520
$26
58
$16 147309 144435 2873
$119
188
$6
40141 39178 963
$11
68
$5
28281 30826 -2545
$83
57
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.
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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
Total Energy Intensity (MWh/ton)
3,500
3,300
3,100
2,900
2,700
2,500
2,300
2,100
1,900
1,700
1,500
2009
2010
2011
2012
2013
2014
2015
2016
2009
2010
2011
2012
2013
2014
2015
2016
Target
2017
Target 2017
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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.”
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OVERALL ENERGY ANALYSIS AND OPERATION CONTROL
Suggestions brought up during management review
•
•
•
•
•
•
•
•
•
•
•
•
Morten/Ronald:
Kjell Even:
Trond:
Geir:
Roger:
Jan Erik:
Ingvar/Kjell Even:
Ingvar/Kjell Even:
Alle:
Ronald:
Roger:
Trond:
2015)
Demontere topp A1 og vurdere performance før sommertopp
Legge inn audit av «energy program» i audit program
Øke bevissthet: Hva får vi ut av PI? Info på plant TV?
PI oppfølging på kolonner
Beregne energi effekten av ny mix (etter footprint) inn i bridge
Process review for C1161 og C303, C1123
Autostopp på trucker?
Vurdere el trucker?
Ledelsen oppmuntre til å entre flere energiavvik
Beregne på energiforbruk i SSA
Beste energi: Vi gir gavekort fra XXL til Runar, ok 25.2.2015.
Avtalt gjennomgang av REA med Jo minken (3 sessjoner i
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TARGETS AND PROGRESS
• Co2 beregninger....
CO2 reduction CO2 reduction
reellt (Kg)
(Nordic mix)
Energy activity goals and estimated savings (yearly)
D80 distillate (m3)
MVR unit (h)
batches on "hot formalin"
Bottom B1 to WWTP (MT of steam)
Process improvements (less steam)
New column B2 (less steam)
Supplier: Schutz: 200 IBC's trough return system
N2 blåsing for å redusere fri form
Greif transport
Supplier: Solvang: transportation of pallets
D80 distillate (m3) R4 & R5
Achieved savings in 2014
Adittional 2015 savings
Target Amount Saving/unit NOK
KWh
3 700
300 999 000 2 053 500
200
630 126 000 200 300
500
429 214 500 360 750
300
0
0
500
300 150 000 277 500
750
300 287 100 482 850
159 968
38 057
28 102
21 617
48 285
10 000
CO2 reduksjon
EU mix
CO2 reduksjon
Global mix
0,19 Kg CO2/Kwh 0,345 Kg CO2/Kwh 0,535 Kg CO2/Kwh
390 165
708 458
1 098 623
38 057
69 104
107 161
68 543
124 459
193 001
0
0
0
52 725
95 738
148 463
91 742
166 583
258 325
10 000
10 000
10 000
3 600
3 600
3 600
654 831
1 177 941
1 819 172
1 000
1 776 600 3 374 900
1 303 500 2 342 100
473 100 1 032 800
296 029
Goal for 2015 should be implementation of a NOK 500 000 savings.
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RESULTS OF INTERNAL/EXTERNAL AUDITS
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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
“We will promote a high level of energy awareness among all
employees.”
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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?
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COMMUNICATION WITH EXTERNAL STAKEHOLDERS
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
Allnex Employee Hours
90
80
70
60
50
40
30
20
10
0
January
February
March
April
May
June
July
August September October November December
26 May 2015
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?
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26 May 2015
Thank you
www.allnex.com
ADDITIONAL INFORMATION AND RESOURCES
• Allnex energy management in articles at Norsk Energi og Standard
Norge:
• http://www.standard.no/standardisering/suksesshistorier/sukse
sshistorie-allnex-norway/
• http://www.energi.no/allnex-norway-ks-har-best%c3%a5tteksamen-i-energiledelse
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disclaimer
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Group companies.
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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
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