Energy efficiency

According to the International Energy Agency (IEA), improved energy efficiency of buildings, traffic and industry has the potential to lower global energy consumption by 17 to 33 percent until 2050. A study by the German Industry Initiative for Energy Efficiency (DENEFF) documented that the efficiency measures taken until 2020 have the potential to reduce annual power consumption by more than 68 billion kilowatt hours. This is approximately the capacity equivalent of ten nuclear power plants.

Many ALTANA sites have taken numerous large and small measures for improved efficiency. For instance, ELANTAS Beck reduced the natural gas consumption of a thermal afterburner that included a steam generator. Its maximum thermal capacity is 2.1 megawatt (afterburner) or 3.5 megawatt (steam generator). However, the efficiency of the afterburner is comparatively low due to the time and quantity fluctuations in the heat demand of the production. To use the exhaust heat more consistently, a heat exchanger was installed into the afterburner, which is connected to the steam generator. The automatically closing flaps in the outlet air pipes of the exhaust system also prevent unnecessary combustion air input when production is idle over the weekend. This step reduced the natural gas consumption of the steam generator by an average of 45 percent and by an average of 25 percent in the afterburner. The cost for the restructuring was € 15,000, but annual savings will be approximately € 80,000 a year.

ELANTAS Zhuhai also installed a heat exchanger into the heating system for heat transfer oil, which cools exhaust gases from 330 to some 120 ° C. At the same time, the exhaust heat is used for hot water heating in the bathrooms, which had previously been based on electrically operated systems. A heating boiler at the site was upgraded for operation with natural gas. It is currently still fueled with oil, but there are plans to build a gas pipeline to the plant, which will reduce CO2 emissions by approximately 20 percent. The automatic control of the cooling tower fan, which switches off automatically when it is not needed depending on the temperature of the cooling water, also contributes to energy savings. At BYK USA, more than € 90,000 were invested in upgraded lighting until the end of 2009 (this sum included some € 30,000 of subsidies). The resulting energy cost savings are € 24,000 per year. In terms of gross value added, power consumption dropped by 17 percent, although a new finished product warehouse became operational. BYK USA as well as ELANTAS PDG in St. Louis replaced old heating boilers for steam generation and thermal oil heating with more efficient boilers. ELANTAS also installed a heat exchanger and increased its energy efficiency to approximately 95 percent with the € 285,000 investment. The resulting energy savings amount to 600,000 kWh of natural gas a year. The measure was supported by the local natural gas provider with a reimbursement of approximately € 10,000.

Small and large steps taken by the energy manager

At the ECKART plant in Güntersthal, in-house energy manager Siegfried Kreuzer implemented a number of optimization measures in 2010. The exhaust heat of three compressors is now used for heating, the pressure level of compressed air systems was partly reduced, two major compressed air leaks were fixed, and a heat exchanger was optimized for the feedback of distillation heat. All of these measures save the equivalent of € 85,000 or 450 metric tons of CO2 a year.

In a separate effort, the company is developing concepts for larger projects, evaluating their feasibility and profitability, and has assessed their CO2 reduction potential. However, these options have to be coordinated appropriately and combined into an overall concept. They include heating the building with wood chips or pellets, a higher milling temperature with low-temperature heating (e.g. floor heating systems) based on cooling water, as well as utilization of cooling water in heat pumps and community heating networks. Furthermore, the company is currently evaluating the feasibility and profitability of using renewable energy sources such as photovoltaics and particularly wind-generated power.

Mr. Kreuzer, the energy manager, has also performed five-day energy audits at other sites of ECKART. These led to the identification of several reduction potentials, including steam system optimization, reducing energy losses, use of energy-efficient compressors and exhaust heat utilization, air-air and wastewater heat exchangers, exhaust heat use of atomizers and calcining furnaces for reducing heating needs, and the building insulation or heating with compressor exhaust heat. Overall, this resulted in a savings potential of approx. 1,500 metric tons of CO2 emissions.

Renewable energies under review

Another renewable energy project became operational at ELANTAS Deatech in Ascoli. Since 2009, a photovoltaic system covers a roof area of 6,500 square meters at the site, consisting of 5,000 solar panels with a peak output of 785 kilowatt (kWp). The system is engineered to generate at least a million kilowatt hours per year and will cover a fifth of the current power needs of the plant. The purpose of the € 4.7 million system was not only to reduce power costs, but also to help fulfill the environmental protection goals of the ALTANA Group. 2010 was the first full year in which the system was operational. It produced 948,000 kWh of power (five percent less than anticipated) and consequently saved some 377 metric tons of CO2 emissions with reference to the Italian power mix.

Energy-efficient new construction

The construction of a new research laboratory began at the Wesel site in early 2010. From the end of 2011, the three-story building with a utility area of 5,600 m2 will house the areas plastics, biotechnology, industrial applications, research and development, and analysis, with workplaces for up to 130 people. The € 18 million investment will offer the latest laboratory technology and an energy-optimized building concept with an excellent eco-balance. The entire energy consumption will be approximately 30 to 40 percent lower than in a conventional laboratory. For example, some 60 percent of the heating and cooling systems are supplied through heat pumps and groundwater. The new structure meets all requirements for a LEED certificate. LEED (Leadership in Energy and Environmental Design) of the American Green Building Council defines a number for standards for sustainable construction.