Multi-Site Energy Reduction Through Teamwork

Abstract

Energy Teams have been established at seven BASF locations to facilitate implementation of the findings from the 2003 and 2004 Energy Audits conducted at these Sites. These Teams were charged with implementation, progress tracking, and management reporting. The Teams are comprised of engineers, technicians, and operators with various backgrounds and responsibilities. The diversity of the Teams was a factor in their success through the willingness to challenge various conditions. The Teams addressed hundreds of Energy Conservation Opportunities (ECOs) to set priorities and create implementation schedules. Many of the ECOs were implemented with little or no cost to BASF. The final Energy Audit of 2004 was conducted in July and the Energy Team for that Site was still able to implement a 7% energy reduction as compared to 2003.

The combined results from these seven Energy Teams represent a 5.8% reduction in energy consumption, for these facilities, within BASF in 2004, as compared to 2003, a total savings of slightly more than $4,900k. The “top ten” items implemented were:

1. Cogeneration load following 2. Creation of a 60 psig steam header between blocks to utilize waste steam 3. Elimination of WWTP steam 4. Incinerator process control 5. Flare switched to stand-by 6. Acid water specification 7. Nitrogen consumption reduction 8. Compressed air optimization 9. Boiler minimum fire set-point reduction 10. Leak reduction