Energy efficiency
demonstration in
manufacturing industry
Energy–2011-8-1
Bayer Technology Services GmbH
(BAY)
Manchester, 3 August 2012
Bayer Technology Services
Company Profile for EFENIS
2012-08-03
Bayer Technology Services –
a Bayer Subsidiary
Holding company
Group Management Board
Bayer AG
Corporate Center
Business areas
Service areas
Bayer HealthCare
Bayer Business Services
Bayer CropScience
Bayer Technology Services
Bayer MaterialScience
Currenta
Page 3 • BTS Company Profile - EFENIS • 03. Aug 2012
Bayer Technology Services –
A Leading Technology Company
Technology solutions, services, know-how –
our core competencies for your success.
Competent service partner for value-generating, holistic solutions along the entire life cycle
of chemical/pharmaceutical products, processes and plants – we initiate, implement and
support technological innovations over the long term from development through
engineering and construction to process optimization. Complete technology packages go
beyond our spectrum of services.
Technology Development
Project Management &
Engineering
Operation Support & Safety
Page 4 • BTS Company Profile - EFENIS • 03. Aug 2012
Bayer Technology Services –
Full Year 2011
Employees
Full Year Sales
Global network
Headquarter
2,700*
EUR 460 million
20 offices in 10 countries
Leverkusen, Germany
*
Page 5 • BTS Company Profile - EFENIS • 03. Aug 2012
as permanent or fixed-term contracts, in FTE
Bayer Technology Services –
Organization
Bayer Technology Services
Project Mgt. &
Engineering
(PME)
Technology
Development (TD)
Enabling
Technologies
…
Operation Support
& Safety
(OSS)
…
Process Design
& Opt.
BTS Americas
(BTSA)
…
BTS Asia
(Asia)
Upstream
Processes
…
Customer &
Product Mgt.
(CPM)
…
Business Planning
& Support
(BPS)
…
Downstream
Processes
Operations
Technology &
Innovation
Mktg of Services
& Portfoliomgt.
Key Experts
BTS Benelux
Division Technology Development




Unit Process Design & Optimization

Ehrfeld
Mikrotechnik BTS
GmbH
Invite
Page 6
Staff 330 (ca. 220 scientific)
7 units
2 subsidiaries
1 country organization

Staff:
 35 scientific staff
 mostly ChemEng
4 groups (Customer oriented)
• BTS Company Profile - EFENIS • 03. Aug 2012
Human Resources
(HR)
Technology Development –
Portfolio
Chemical & Polymer Processes
Product-by-Technology
Customized Analytical
Solutions
Optimization & development
of production processes and future
innovative manufacturing concepts.
Conceptual and technological product
design and development from a strongly
interdisciplinary perspective.
Screening concepts and systems in
Life Science R&D and process control.
Automated, miniaturized assay,
fluorescence imaging.
Integrated protein analytics.
Biotechnolog ical Processes
Computational Biology
Technology Consulting &
Public Funding
Development, scale-up, transfer,
optimization and implementation
of Biotechnological Processes.
Support of R&D processes in life
science companies by
modeling & simulation.
Centre of expertise for technology
evaluation, strategic consulting and
acquisition of public research subsidies.
Page 7 • BTS Company Profile - EFENIS • 03. Aug 2012
Process Design & Optimization for chemicals,
polymers and active ingredient production
• We develop new process technology & entire processes for
Process Design
& Optimization
Process Analysis
Chemicals & Polymers
Conceptual Design
Chemicals & Polymers
Crop Protection &
Specialties
Healthcare &
Biotechnology
Bayer Subgroups and selected external partners by…
• integrating broad BTS expertise e.g. by our structured
conceptual design brainstorming approach
• fast and realistic evaluation of process variants (CDKOS)
• management of cross-functional process initiatives.
• We utilize and maintain a unique network with process & unit
operations experts across TD ensuring a holistic process
engineering approach
• We optimize existing plants and processes in close
cooperation with Bayer Subgroups and selected external
partners comprising…
• Increase / adapt product quality
• Increase plant availability & capacity (de-bottle-necking)
• Energy Efficiency Management Systems
• We are the center of expertise for advanced & in-depth
process modeling at Bayer and ensure transfer latest
modeling developments
Page 8 • BTS Company Profile - EFENIS • 03. Aug 2012
Sustainable energy efficiency is a key topic for BTS:
Bayer Climate Check & STRUCTese
● Bayer Climate Check involves two elements:
● Climate
(carbon footprint) to assess
the climate impact of products
Footprint®
Factory Gate
Factory Gate
Electricity
Transportation
Footprint
Raw Material
from Suppliers
Footprint
own Raw
Material
By-product
Production
Plant
Plant A
A
Footprint Product A
● The Energy Efficiency Management program
STRUCTese® enables continuous and sustainable
improvement throughout the organization
● Central element is the novel energy loss cascade to
measure & visualize energy efficiency
Footprint
Product B
Production
Plant B
B
Plant
Resulting in:
t CO2e per t product
Steam
● Energy Efficiency Check to identify measures
for energy & greenhouse gas emission
reduction
Energy & Utility Supply
Raw Materials
Heat Integration & Recovery
Equipment Check
Operational Improvements
Process Improvements
Buildings & Facility
● Results based on finalized 160 plants &
buildings: energy savings potential 5…30 %
● Several Bayer-external customers
• BTS Company Profile - EFENIS • 03. Aug 2012
Results:
● Implementation finalized at > 45 plants at BMS
● Significant reductions realized
● Key contribution to Bayer’s specific CO2
emissions reduction target by 35% (20052020)
Bayer Technology Services‘ Interest in
EFENIS
Status Quo within Bayer
 Global energy efficiency improvement programs completed (2007…2012)
 Industry leading energy efficiency management system (STRUCTese®)
developed and implemented globally for Bayer MaterialScience
 So far with main focus on efficiency improvements at plant/train level
Next steps (supported by EFENIS)
 Test advanced total site methodology for a real integrated production site
 Evaluate „future“ State-of-the-Art total-site optimization methodology
 Conceptual guidelines for site utility systems design and operation
 master planning of new integrated production sites.
 Technology extension for heat recovery for total site integration
 Site energy optimization with uncertainty data
Page 10 • BTS Company Profile - EFENIS • 03. Aug 2012
Bayer Technology Services‘ Role in
EFENIS
BTS will contribute by…
 Demonstration & Evaluation of the advanced total site analysis
methodology for a pilot site
 Development of an IP protection, results exploitation & dissemination
concept
 Providing feedback on the methodology development from a chemical
industry perspective
Page 11 • BTS Company Profile - EFENIS • 03. Aug 2012
Work Packages with BAY
coordination/participation
Demonstration
Decision-supporting Methodology
WP1
Total site integration
and optimisation
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals
WP2
Total Site
carbon
management
WP4
Integration with
CHP and
distr.heating
WP3
Total Site waste heat recovery
with intensified heat transfer
Enabling Technologies
WP9
Technology
transfer
Page 12 • BTS Company Profile - EFENIS • 03. Aug 2012
WP10
Project
Management
WP8: CHP and
Distr. Heating
Work Packages with BAY
coordination/participation
WP
WP Title
Num
WP 5 Demonstration Putting into
practice total site
energy
management for
the chemical
industry (BAYER)
WP9
Technology
Transfer (BAYER)
Type of
Objectives
activity
DEMO Task 5.1: Analysis of the as-is state of the site (BAY, support by
UNIMAN, UPB and UNIPAN) Year 1
Task 5.2: Perform “fundamentally-improved” Total Site Analysis (BAY
supported by UNIMAN, UPB and UNIPAN)
Task 5.3: Detailed planning and implementation of identified
improvement measures (BAY, UNIMAN, UNIPAN, UPB)
Task 5.4.: Check transferability to other sites (BAY, UNIMAN, UNIPAN,
UPB)
OTHER Task 9.1 – Protection of project results
Task 9.2 – Development of exploitation strategy
Task 9.3 – Knowledge Dissemination
Task 9.4 – Training Activities
Task 9.5. Energy Service Centre activities
Page 13 • BTS Company Profile - EFENIS • 03. Aug 2012
Start
End
month month
1
36
6
36
Thank you!
Page 14 • BTS Company Profile - EFENIS • 03. Aug 2012
Global Network &
Local Offices
Mexico-City
Leverkusen (global headquarters)
Bergkamen, Berlin, Dormagen,
Krefeld, Wuppertal, Wendelsheim
Moscow
Beijing
Shanghai
Pittsburgh
Berkeley
Antwerp
Baytown
Mumbai
New Martinsville
Belford Roxo
Dubai
Page 15 • BTS Company Profile - EFENIS • 03. Aug 2012
Singapore