Kemira’s primary tool for improving its energy efficiency is the E3 (Energy Efficiency Enhancement) program. By the end of 2012, sites representing 92% of Kemira’s energy consumption have been audited and 317 improvements implemented. In 2013, Kemira aims to further develop indicators for energy efficiency reporting.
Kemira’s overall target is to improve manufacturing energy efficiency. Furthermore, energy efficiency is one of the aspects in Kemira’s New Product Development process as part of its aim to provide customers with an even more sustainable offering.
Direct energy consumption: E3 Energy Efficiency program
In 2010, Kemira adopted the E3 energy efficiency program (Energy Efficiency Enhancement) to improve energy efficiency in its production plants. Through the program, Kemira’s approach to saving energy is now even more systematic and goal-oriented than before.
The results of the E3 program developed in a positive direction during 2012. There were over 135 improvements implemented, and a total of 1.1 million euros was spent on investments improving energy efficiency during 2012. The savings achieved through the E3 program sum up to 47,000 MWh, calculated as savings of over 2.1 million euros in total at an annual level.
The cumulative savings after the E3 program was taken into use in 2010 are over 5.8 million euros in total calculated at an annual level.
The E3 energy efficiency program helps Kemira meet the requirements of the EU energy efficiency directive, which sets out to establish a common framework to meet the EU’s 20% energy efficiency reduction by 2020.
Audits an important part of the E3 program
Audits provide the opportunity to benchmark new opportunities to save energy, which can potentially be implemented at other sites. During 2012, seven new sites were audited and over 50 follow-up audits were conducted at 26 sites. Since 2010, a total of 26 sites, representing 92% of Kemira’s total energy consumption, have been audited. As part of the process, over 150 potential improvement cases were identified during 2012. The total number of identified potential improvement cases since April 2010 is over 820.
Cost-efficient actions giving significant improvements
Changes that require little or no investments are often the fastest to implement. Considerable improvements to energy efficiency and costs can be made easily by adjusting operating methods and improving process efficiency. Improvements in energy efficiency can also result in improved material efficiency and a reduction of waste.
Another important way to improve energy efficiency is to update process manuals in order to guide employee behavior – a theme that has been in focus in the energy efficiency work during 2012.
Focus on energy efficiency in 2013
In 2012, Kemira took yet another step in its work to improve manufacturing energy efficiency, as this was defined as one of the company’s sustainability targets. In 2013, Kemira aims to introduce an Energy Efficiency Index, which will measure the Group’s performance regarding manufacturing energy efficiency, more accurately reflecting the actual improvements Kemira has achieved through systematic focus on energy efficiency.
Indirect energy consumption
Kemira’s purchase of energy is driven by the EU Emission Trading System, which aims at reducing CO2 emission in the EU area. Kemira for example owns shares in a hydroelectric power plant. Furthermore, byproducts from production, such as hydrogen, as well as process heat and steam condensate are used for energy. For Kemira, nuclear power is the most important CO2 free energy source.
During 2012, the share of primary energy use in Kemira was 84% electricity and 16% steam and heat. The carbon free share of electricity use was 68% and respectively 43% for steam and heat. Of the total energy use 64% was carbon free. As an example, 18% from all steam and heat was produced by hydrogen. In sites where hydrogen is available as byproduct it is major fuel for steam & heat generation. Hydrogen and waste heat recovery will continue.
Kemira has taken measures to reduce its indirect energy consumption. Kemira favors virtual communication tools and has a travel policy in place to minimize traveling as well as a purchasing policy in place for energy-efficient Maintenance, Repair and Operations (MRO).