Energy efficiency in in chemical companies and plants
The chemical industry is a high-energy industry: 20 to 40 percent of the manufacturing costs of goods sold (cost of goods sold, COGS) are linked to energy. Due to this particular economic importance and the significant contribution to sustainability, larger companies in the industry are already working intensively on energy efficiency strategies and measures. Many of these correspond to the classic steps for improving the production process, such as identifying bottlenecks or avoiding unnecessary process steps.
Another starting point is to take a structured look at topics such as energy generation, distribution, and consumption. Against the backdrop of rising energy costs, new opportunities and attractive payback are emerging here. There are good examples in the field of thermodynamics: heat pumps, for example, can harness energy from 60-degree wastewater for the production process. It is also worth reviewing the use of energies such as compressed air and high-pressure steam and possibly using new technologies with better efficiency.
Holistic improvement of energy efficiency
Holistic optimization of energy efficiency begins with sufficiently granular measurement. In the past - due to the cost structure - the focus was often on process parameters rather than measuring energy consumption. Refining this and incorporating energy KPIs into performance management are important first steps. In addition to energy management, technical measures play a central role, which can be determined by professional energy scans. The situation often arises where these measures "compete" for both CAPEX and engineering resources. Do "classic" growth projects or energy issues take priority? In the best case scenario, it is possible to combine the two or reserve resources for energy topics so that they can be implemented in parallel.
Further services for the chemical industry
CLIENTS
CASE STUDIES
Lean Digital Manager
Shaping the factory of the future with Lean 4.0. How can lean principles be combined with the technologies and possibilities of networked digitization in value creation networks? By further qualifying employees to become decision-makers. The ROI-EFESO certification program for "Lean Digital Manager" shows how digitalization of lean production works. To do this, it combines strategies with Industry 4.0 technologies.
Smart Factory Planning: Smart Planning for smart Factories
What does the ideal factory of the future look like? Do products there control their production completely independently? A pharmaceuticals and life sciences company plans the main directions for the smart factory transformation of four plants in just one month. Together with ROI-EFESO, the project team creates a "big picture" as a basis for planning and tests three prioritized technologies in pilot projects.
Business Operations Strategy: Re-start for production networks
A market leader strengthens its Global Footprint structures. With a turnover of around EUR 10 billion, the company is one of the market leaders in the life science and chemicals sector. After a long period of successful global growth, developments such as tougher competition and shifts in demand between regions are jeopardizing the achievement of the ROCE (return on capital employed) targets.
Manufacturing Excellence: Optimizing instead of improvising
The global demand for thermosets is increasing, as is the case in the energy industry. A manufacturer of thermosetting resins has positioned itself as a leader in the chemical industry by providing these customers with a variety of innovative technologies, solutions and specialty products. In order to be able to react even more efficiently to market changes and customer requirements in the future, the company is realigning its production network.
OPEX: Redesign of the organization
The demand for high-performance plastics is increasing worldwide. A company in the chemical industry wants to increase the total capacity of its polymer production by more than 50% with a new plant complex. Together with ROI-EFESO, it is aligning its organizational structure to growth and profitability and is realizing an annually recurring benefit of more than EUR 1.5 million through process improvements.
Chemical company on the way to climate neutrality
In order to achieve the self-imposed goal of being climate-neutral by 2050, a manufacturer of basic chemicals has to put its entire business model to the test. ROI-EFESO supported the client with robust scenario planning to develop a sustainability roadmap that enables sustainable growth in a challenging industry environment.
Sustainable Chem: New start for the organization
In order to achieve the self-imposed goal of being climate-neutral by 2050, a manufacturer of basic chemicals has to put its entire business model to the test. ROI-EFESO supported the client with robust scenario planning to develop a sustainability roadmap that enables sustainable growth in a challenging industry environment.