The Biggest Loser - Industrial Energy Efficiency Case Studies

July 21st 2015

Gavin PuckleEngineering ManagerJohnson Matthey – South Africa

Confidential 2

Johnson Matthey

• A speciality chemicals company and a world leader in advanced materials technology

• Origins date back to 1817, floated 1942, FTSE 100 company since June 2002

• £5.9 billion revenue• Operations in over 34 countries with 10,000 employees• 5 Different divisions – Emissions Control Technology• 14 ECT Manufacturing sites around the globe

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Energy ManagementWhat do we do?

Nitrous Oxide

Carbon Monoxide

Hydro Carbons

Water

Nitrogen

Carbon Dioxide

ENERGY

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Energy ManagementImplementation/challenges

TIME LINE

2011

Poor

reco

rds

Can’

t qua

lify

and

quan

tify

savi

ngs

ISO

500

01 Im

plem

enta

tion

Mea

sure

men

t ch

alle

nge

Beha

viou

r ch

alle

nge

Team

Com

positi

on c

halle

nge

ISO

500

01 a

lmos

t

im

plem

ente

dR7

.7M

il Sa

ving

s

ISO

500

01 C

ertifi

catio

n

ISO

500

01 S

urve

illan

ce a

udit

Sav

ings

to d

ate

> R

15 M

il

New

pro

ject

s Su

stai

n pe

rform

ance

2012

20132014

2015

201?

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Energy Management

• Cost of electricity supply in SA

• Produce more product with less energy• JM Global sustainability initiative (MJ / LCP)

What is driving the energy initiative at JMSA

0

2 000 000

4 000 000

6 000 000

8 000 000

10 000 000

12 000 000

14 000 000

16 000 000

18 000 000

20 000 000

0

10000000

20000000

30000000

40000000

50000000

60000000

70000000

2011-12 2012-13 2013-14 2014-15

Prod

uctio

n Vo

lum

es in

LCP

Cost

s in

Rand

& e

nerg

y in

kW

h

Electrical Energy Cost / kWh

cost (Rand) energy (kWh) Production Vol. LCP

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Energy Management

Power x hours ÷ Litres of catalyst produced (LCP)

Awareness and understanding your KPI

Reduce installed

capacity / Optimizati

on

Reduce time

equipment runs

Increase the speed that we run at

Get one right, you make progress. Get two right, you are good!

Get three right and we will fly!!

ENERGY EFFICIENT USE THEREOF

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Energy ManagementKnow your Significant Energy Users

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Energy ManagementMeasuring and monitoring – What you measure is important

0

200

400

600

800

1000

1200

Apr2

013-

Mar

2014

Apr2

014-

Mar

2015

YTD(

Apr2

015-

Mar

2016

)

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

GENERAL USERS POWER OUTPUTS CHARTPower (KW) Power Target

0

50

100

150

200

250

300

350

Apr2

013-

Mar

2014

Apr2

014-

Mar

2015

YTD(

Apr2

015-

Mar

2016

)

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

TOWER MCC POWER OUTPUTS CHARTPower (KW) Power Target

020406080

100120140160

Apr2

013-

Mar

2014

Apr2

014-

Mar

2015

YTD(

Apr2

015-

Mar

2016

)

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

ADMIN BUILDING POWER OUTPUTS CHARTPower (KW) Power Target

0

100

200

300

400

500

600

700

Apr2

013-

Mar

2014

Apr2

014-

Mar

2015

YTD(

Apr2

015-

Mar

2016

)

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

UTILITIES POWER OUTPUTS CHARTPower (KW) Power Target

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Energy ManagementStart the cycle again - PDCA

Plan

Do

Check

Act

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Energy ManagementLessons learned

• Systematic approach is important

• Focus on functional requirements of equipment (Gap)

• Team Composition

• Awareness for the “User”

• All hands on deck

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Energy Management

• Attitude is king

• Awareness and knowledge is the key

• If you don’t know about potential saving opportunities – you wont look for them

• If you don’t look for savings, you won’t find them

• If you don’t care – the savings will not happen.

Conclusion

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Energy Management

Questions