Energy Management at BASF Corporation

Energy Management at
BASF Corporation
By:
Ty Geiger
Manager – Plant Optimization, Energy
Management and Advanced Automation
Engineering
BASF Corporation – Freeport, TX
Overview of Today’s Discussion
 Brief introduction to BASF
 BASF Corporate Energy Management
 Management Support
 Goals
 Continuous Improvement
 Best Practices
 Recognition
Summary
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145 years of excellence in chemistry
In 1865 Badische Anilin & Soda
Fabrik (BASF) began manufacturing
textile dyes and other chemicals in a
modest plant in Ludwigshafen, then
part of the kingdom of Bavaria.
Today, Based in Ludwigshafen,
Germany, BASF SE is the world’s
leading chemical company, doing
business on six continents and
serving a wide and varied range
of industries throughout the world.
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BASF – The Chemical Company
2010 snapshot
 The world’s leading chemical company
 Serves all major industries
 Production facilities on six continents
 World-class, innovative, high-value products
 Intelligent, sustainable system solutions
 2010 Sales: $90 billion
 Employees: 109,140
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BASF Worldwide
North
America
FREEPORT
ANTWERP
FLORHAM
PARK
GEISMAR
LUDWIGSHAFEN
NANJING
HONG KONG
KUANTAN
Global Headquarters
Regional Headquarters
SÃO
PAULO
SINGAPORE
Asia
Pacific
Verbund Site
P Selected Production Sites
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BASF’s Business Segments
Products as diverse and varied as chemistry itself
Chemicals:
Inorganics, petrochemicals, intermediates
Agricultural Products & Nutrition:
Crop protection, biotechnology
Functional Solutions:
Catalysts, construction chemicals, coatings
Performance Products:
Dispersion, pigments, care chemicals,
paper chemicals, performance chemicals
Plastics:
Performance polymers, polyurethanes
Oil & Gas:
Exploration and production
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BASF in North America
Sales 2010:
Employees:
Prod. Sites:
R&D Sites:
$13.3 billion
16,000+
100+
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Key Customer Industries
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

Agriculture
Automotive
Chemicals
Coatings
Construction
Health and Beauty
Packaging
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BASF North America
BASF Corp. (USA), BASF Canada, BASF Mexicana
FLORHAM
PARK
FREEPORT
GEISMAR
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BASF in Texas
Employees: 1,300+
Contractors: 700+
Prod. Sites: 10
(5)
Key Customer Industries
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Agriculture
Chemicals
Construction
Health and Beauty
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BASF Corporate Energy Management
Focus on Continuous Improvement
Management
Commitment
Re-Assess
Assess Performance
& Set Goals
Create Action
Plan
Recognize
Achievements
Implement
Action Plan
Evaluate
Progress
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Management Commitment
BASF Corporate Energy Management Department
• CHARTER
To assure reliable and economically competitive energy supplies to satisfy
BASF Corporation’s present and future needs and to promote the most
efficient and economical use of energy throughout North America.
• Promote/Facilitate development of energy optimization projects
• Stakeholder/Owner of energy and utility capital projects
• Energy technology consulting to manufacturing
e.g. Boilers, turbines, waste combustion, compressed air, wastewater treatment,
demineralized water
• Review BASF Corporation’s capital and expense projects which
consume or generate energy
• Regional platform for global energy expert group
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Global Environmental Footprint Goals
BASF Group Targets
Long-term Vision
Reduce emissions from chemical operations
 Greenhouse gases (per metric ton of sales product)
Cost /Risk Reduction
Goal 2020
Status 2010
- 25 %
- 28.9 %
+ 25%
+ 23.7%
Energy Efficiency
 Improve specific energy efficiency of production processes
 Baseline 2002
Near Term Performance
 Annual targets set by individual chemical production plants
 Performance tracking and verification
 Management focus
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BASF Corporate Energy Management
Best Practice and Technology sharing
•
•
•
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Site Energy Teams for implementation
Energy Workshops to identify new projects and review performance
Implementation of Advanced Process Control technologies
Frequent virtual meetings to share Best Practices and successes
between locations
• Maintenance and Operations, e.g. steam systems, insulation,
cooling towers, etc.
• Waste heat recovery
• Combined Heat and Power Concepts
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Effective Energy Management
DYNAMIC
ENERGY CONSUMER
MANAGEMENT STRATEGIES
TECHNICAL ISSUES
THERMAL
Boilers
Steam Distribution
Leaks, Insulation,
Traps
Heaters
Dryers
Ovens/Kilns
Waste Heat Recov.
Pinch Technology
ELECTRICAL
Motors
Air Compressors
Refrigeration/HVAC
Process Equipment
Fans/Blowers
Lighting
Load Management
Generation/Supply
VFD’s
OTHER
Nitrogen
Fuels
Natural Gas
Fuel Oil, Wastes
WWTP
Water
Potable
Demineralized
Process Energy
STRUCTURE
Commitment to continual improvement
Conduct regular management reviews
Identify conversion cost factors
Defined requirements/Facility goals
Documentation
Project planning
Monitoring/measuring
Training
Stable maintenance/Proper purchasing
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Team Work leads to Success
Energy and Process Optimization Workshops
Accepted
Measures
Operations &
Service Know-how
“Good Questions“
Expert
Knowledge
Open-minded
Approach
Knowledge
Tools &
Best Practices
Joint Teams
Creativity
Communication
Discussion
Opportunity
Areas
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BASF Freeport Energy Projects
Combined Heat and Power Concept
CHP Example
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Recognition: American Chemistry Council
Energy Efficiency Awards (Texas specific highlighted)
1996
1997
1998
1999
1999
2000
2001
2002
2003
2004
2004
2005
2006
2007
2008
2008
2009
2009
2009
2010
2010
2010
2010
Energy Survey Program - Division and Site
Energy Cost Reduction Program - HQ/Research
Utilities Expansion Project - Cogen, Waste Fuels
Corporate Energy Management Program
Corporate Motor Management Guideline
Geismar Cogeneration – AOG Fuel Utilization
Freeport Cogeneration Project
Portsmouth Site Energy Team
Freeport ISBL Energy Audits
Energy management Group (Exceptional Merit)
Geismar Flare Best Practice
Site Energy Audits
Multi-Site Energy Reduction Through Teamwork
Energy Efficiency Improvements for Acquisitions
Energy Efficiency Improvement Goal (EM)
Port Arthur: Improved Hydrogen Utilization
Freeport Steam Optimization (Exceptional Merit)
Compressed Air Optimization (EM)
Energy Efficiency Program (EM)
Corporate Energy Efficiency Improvement Goal
Geismar Ethylene Oxide Plant Multivariable Predictive Control Improvements
Geismar Polyol Plant Steam Reduction
Greenville Energy Optimization Initiative
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Summary
• Strategy for success:
• Management support and commitment
• Corporate and global organization
• Clear goals and objectives
• Focus on Continuous Improvement
• Communication of best practices and technologies
• Recognition
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QUESTIONS?
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Back-up Slides
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Verbund
From integrated manufacturing sites to our research
network to our approach to Sustainable Development
Verbund /vər  boont/ n. an
interconnected system of relationships
generating greater value than the sum of
its parts.  adj. characterized by the
effective application of such relationships.
 from German as coined by BASF, late
20th cent.
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