Energy efficiency demonstration in manufacturing industry

Energy efficiency demonstration in manufacturing industry

Bayer Technology Services GmbH (BAY)

Manchester, 3 August 2012

Energy–2011-8-1

EFENIS 296003

Company Profile for EFENISBayer Technology Services

2012-08-03

• BTS Company Profile - EFENIS • 03. Aug 2012

Bayer Technology Services – a Bayer Subsidiary

Business areas Service areas

Holding company

Corporate CenterBayer AG

Group Management Board

Currenta

Bayer Business ServicesBayer HealthCare

Bayer MaterialScience

Bayer CropScience Bayer Technology Services


Bayer Technology Services – A Leading Technology CompanyTechnology solutions, services, know-how – our core competencies for your success.

Competent service partner for value-generating, holistic solutions along the entire life cycle of chemical/pharmaceutical products, processes and plants – we initiate, implement and support technological innovations over the long term from development through engineering and construction to process optimization. Complete technology packages go beyond our spectrum of services.

Technology Development

Project Management & Engineering

Operation Support & Safety


Bayer Technology Services –Full Year 2011

Employees 2,700*

Full Year Sales EUR 460 millionGlobal network 20 offices in 10 countriesHeadquarter Leverkusen, Germany

* as permanent or fixed-term contracts, in FTE


Bayer Technology Services – Organization

Bayer Technology Services

Technology Development (TD)

Project Mgt. & Engineering

(PME)

Customer & Product Mgt.

(CPM)

BTS Americas(BTSA)

Operation Support & Safety

(OSS)

BTS Asia(Asia)

Business Planning & Support

(BPS)

Human Resources(HR)

Enabling Technologies

Process Design & Opt.

Upstream Processes

Downstream Processes

Operations

Technology & Innovation

Mktg of Services & Portfoliomgt.

Invite

Ehrfeld Mikrotechnik BTS

GmbH

Key Experts

BTS Benelux

……

…

……

…

Division Technology Development Staff 330 (ca. 220 scientific) 7 units 2 subsidiaries 1 country organization

Unit Process Design & Optimization Staff:

35 scientific staff mostly ChemEng

4 groups (Customer oriented)


Technology Development –Portfolio

Conceptual and technological product design and development from a

strongly interdisciplinary perspective.

Product-by-Technology

Screening concepts and systems in Life Science R&D and process control.

Automated, miniaturized assay, fluorescence imaging.

Integrated protein analytics.

Customized Analyt ical Solut ions

Support of R&D processes in life science companies by modeling & simulation.

Computat ional Biology

Optimization & development of production processes and future innovative manufacturing concepts.

Chemical & Polymer Processes

Development, scale-up, transfer, optimization and implementation of Biotechnological Processes.

Biotechnological Processes

Centre of expertise for technology evaluation, strategic consulting and

acquisition of public research subsidies.

Technology Consult ing & Public Funding


Process Design & Optimization for chemicals, polymers and active ingredient production

• We develop new process technology & entire processes for Bayer Subgroups and selected external partners by…• integrating broad BTS expertise e.g. by our structured

conceptual design brainstorming approach • fast and realistic evaluation of process variants (CDKOS)• management of cross-functional process initiatives.

• We utilize and maintain a unique network with process & unit operations experts across TD ensuring a holistic process engineering approach

• We optimize existing plants and processes in close cooperation with Bayer Subgroups and selected external partners comprising…• Increase / adapt product quality• Increase plant availability & capacity (de-bottle-necking)• Energy Efficiency Management Systems

• We are the center of expertise for advanced & in-depth process modeling at Bayer and ensure transfer latest modeling developments

Process Design & Optimization

Process Analysis Chemicals & Polymers

Conceptual Design Chemicals & Polymers

Crop Protection & Specialties

Healthcare & Biotechnology


Sustainable energy efficiency is a key topic for BTS: Bayer Climate Check & STRUCTese

● Bayer Climate Check involves two elements:● Climate Footprint® (carbon footprint) to assess

the climate impact of products

● Energy Efficiency Check to identify measures for energy & greenhouse gas emission reduction

● Results based on finalized 160 plants & buildings: energy savings potential 5…30 %

● Several Bayer-external customers

Electricity

Steam

By-product

FootprintProduct BProduction

Plant AProduction

Plant B

Footprint Product A

Factory Gate Transportation

ProductionPlant A

ProductionPlant B

Footprint Product A

Footprint Raw Materialfrom Suppliers

Footprint own Raw Material

Factory Gate

Resulting in:t CO2e per t product

Electricity

Steam

By-product

FootprintProduct BProduction

Plant AProduction

Plant B

Footprint Product A

Factory Gate Transportation

ProductionPlant A

ProductionPlant B

Footprint Product A

Footprint Raw Materialfrom Suppliers

Footprint own Raw Material

Factory Gate

Resulting in:t CO2e per t product

● The Energy Efficiency Management program STRUCTese® enables continuous and sustainable improvement throughout the organization

● Central element is the novel energy loss cascade to measure & visualize energy efficiency

Results:● Implementation finalized at > 45 plants at BMS

● Significant reductions realized● Key contribution to Bayer’s specific CO2

emissions reduction target by 35% (20052020)

Equipment Check

Operational Improvements

Heat Integration & Recovery

Process Improvements

Buildings & Facility

Energy & Utility Supply

Raw Materials

Equipment Check

Operational Improvements

Heat Integration & Recovery

Process Improvements

Buildings & Facility

Energy & Utility Supply

Raw Materials


Bayer Technology Services‘ Interest in EFENISStatus Quo within Bayer Global energy efficiency improvement programs completed (2007…2012) Industry leading energy efficiency management system (STRUCTese®)

developed and implemented globally for Bayer MaterialScience So far with main focus on efficiency improvements at plant/train level

Next steps (supported by EFENIS) Test advanced total site methodology for a real integrated production site Evaluate „future“ State-of-the-Art total-site optimization methodology

Conceptual guidelines for site utility systems design and operation master planning of new integrated production sites.

Technology extension for heat recovery for total site integration Site energy optimization with uncertainty data


Bayer Technology Services‘ Role in EFENIS

BTS will contribute by…

Demonstration & Evaluation of the advanced total site analysis methodology for a pilot site

Development of an IP protection, results exploitation & dissemination concept

Providing feedback on the methodology development from a chemical industry perspective


WP10ProjectManagement

WP9Technology transfer

WP1Total site integration and optimisation

WP5: Chemicals

Decision-supporting Methodology

Enabling Technologies

Demonstration

WP6: Oil Refinery

WP7: Coal-to-Chemicals

WP8: CHP and Distr. Heating

WP2Total Site carbon management

WP3Total Site waste heat recovery with intensified heat transfer

WP4Integration with CHP and distr.heating

Work Packages with BAY coordination/participation


WP Num

WP Title Type ofactivity

Objectives Startmonth

Endmonth

WP 5 Demonstration - Putting into practice total site energy management for the chemical industry (BAYER)

DEMO Task 5.1: Analysis of the as-is state of the site (BAY, support by UNIMAN, UPB and UNIPAN) Year 1

Task 5.2: Perform “fundamentally-improved” Total Site Analysis (BAY supported by UNIMAN, UPB and UNIPAN)

Task 5.3: Detailed planning and implementation of identified improvement measures (BAY, UNIMAN, UNIPAN, UPB)

Task 5.4.: Check transferability to other sites (BAY, UNIMAN, UNIPAN, UPB)

1 36

WP9 Technology Transfer (BAYER)

OTHER Task 9.1 – Protection of project resultsTask 9.2 – Development of exploitation strategyTask 9.3 – Knowledge DisseminationTask 9.4 – Training ActivitiesTask 9.5. Energy Service Centre activities

6 36

Work Packages with BAY coordination/participation

Thank you!



Global Network & Local Offices

Leverkusen (global headquarters)Bergkamen, Berlin, Dormagen,

Krefeld, Wuppertal, WendelsheimMexico-City

Berkeley

Baytown

Pittsburgh

New Martinsville

Belford Roxo

Antwerp

Dubai

Mumbai

Singapore

ShanghaiBeijing

Moscow

Energy efficiency demonstration in manufacturing industry

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