cray valley iberica - cefic 2011/rcawards20… · european responsible care awards 2011 •• cray...
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European Responsible Care Awards 2011
••CRAY VALLEY IBERICA
ENERGY EFFICIENCY IMPROVEMENT
CRAY VALLEY IBERICA
ENERGY EFFICIENCY IMPROVEMENT
Cray Valley Ibérica 2
MIRANDA, 40.000 Tm
SANT CELONI, 40.000 Tm
MOLLET, 33.000 Tm
CASTILLA Y LEONCATALUNYA
Cray Valley Cray Valley Ibérica in 2010Ibérica in 2010
2010 SALES: 135 M EUR
2010 SALES VOLUME: 82.000 TM
Local sales : 50 %
Export sales : 50 %
Employees: 256
Capacity:
Cray Valley Ibérica 3
Miranda de Ebro, 65 emp
Sant Celoni, 119 empMollet del Vallés, 70 emp
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Products and applicationsProducts and applications
Unsaturated polyesterGel Coat
Reinforced plasticsSanitaryware, construction. Water sports, automotive.Concrete, synthetic marble.Transport, leisure.(Miranda de Ebro)
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Alkyd resinsOF PolyesterAcrylic resinsEmulsions
Decorative paints and wood stainsIndustrial & anticorrosion coatings Printing & adhesives
Products and applicationsProducts and applications
(Mollet del Vallès, Sant Celoni)
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Powder paintsSolid saturated polyester
Products and applicationsProducts and applications
(Sant Celoni)
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Innovation
Competitivity
SustainableDevelopment
Cray Valley Cray Valley IbéricaIbéricaStrategic plan
Why we started the project
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The reorganization of the activities & the economic crisis have reduced the volumes. As a consequence the energy efficiency has decreased ...CVIbCVIb hashas includedincluded the energy efficiency improvementthe energy efficiency improvement inin the Strategicthe Strategic Plan as a Plan as a mean mean project project in in the Sustainable Development principles and Responsiblethe Sustainable Development principles and Responsible Care.Care.Sant Celoni Plant has been chosen as a pilot plant.
Volume
-60%
UnitaryConsumption
Mwh/Tm
+40%
10
20
30
40
50
60
70
0601
0603
0605
0607
0609
0611
0701
0703
0705
0707
0709
0711
0801
0803
0805
0807
0809
0811
0901
0903
1,0
1,2
1,4
1,6
1,8
2,0
2,2
10
20
30
40
50
60
70
0601
0603
0605
0607
0609
0611
0701
0703
0705
0707
0709
0711
0801
0803
0805
0807
0809
0811
0901
0903
1,0
1,2
1,4
1,6
1,8
2,0
2,2
Why we started the project
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We decided to improve the energy efficiency of the plantto reduce the environmental impact & to be more competitive ...
Energetic audit
Action identification
Analysis & execution plan
Implement actions
We get some subventionsfrom the administration
Investments
What we have done
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The energetic audit has identified some actions to improve the energy efficiency of the plant ...
EQUIPMENT IMPROVEMENT saving/year (kWh n.g.)
saving/year (€)
Investment (€)
Pay-back (years)
Energy saving (%)
CO2 emissions reduction (T/year)
Steam boilers Purges heat recovery 621.985 13.901 18.000 1,3 0,6 98,27
Steam boilers Purges continuos process automatization 64.489 1.441 2.850 2 0,1 10,19
Steam distribution network
Thermal compressor for condensed recuperation 4.050.084 90.519 170.000 1,9 4 639,91
Boilers Heat recovery of combustion gases 5.401.077 120.714 201.000 1,7 5,4 853,37
Boilers Burners parameters improvements 1.107.365 24.750 2.200 0,1 1,1 174,96
Generation and steam distribution Insulation improvements 3.975.848 88.847 34.980 0,4 3,9 628,18
What we have done
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The actions with the higher impact andlow pay back time have been implemented ...
action saving/year cost pay-back
GAS powders process improvements 30 K€ 0 -
better management & control of heaters 72 K€ 5 K€ 1 month
thermal insulations 35 K€ 25 K€ 8 months
heat recovery from heaters emissions 31 K€ 55 K€ 1,8 years
ELECT pressure reduction of compressed air 6K€ 0 -
improvements in refrigeration water control 18 K€ 12 K€ 8 months
low consumption lighting 4 K€ 6 K€ 1,5 years
new high effic iency air compressor 21 K€ 40 K€ 1,9 years
What we have done
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20
30
40
50
60
70
80
0601
0604
0607
0610
0701
0704
0707
0710
0801
0804
0807
0810
0901
0904
0907
0910
1001
1004
1007
1,0
1,2
1,4
1,6
1,8
2,0
2,2
Volume
UnitaryConsumption
Mwh/Tm
+18 % efficiency
With excelent results ...and the project is not finished !
This means a reduction of 1.500 Tm of CO2 per year !!
What are the outcomes
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Next step...
To continue with the implementation in Sant Celoni Plant.
Start the process in Mollet del Vallés and Miranda de Ebro plants.