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
Confidential 3
Energy ManagementWhat do we do?
Nitrous Oxide
Carbon Monoxide
Hydro Carbons
Water
Nitrogen
Carbon Dioxide
ENERGY
Confidential 4
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?
Confidential 5
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
Confidential 6
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
Confidential 7
Energy ManagementKnow your Significant Energy Users
Confidential 8
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
Confidential 9
Energy ManagementStart the cycle again - PDCA
Plan
Do
Check
Act
Confidential 10
Energy ManagementLessons learned
• Systematic approach is important
• Focus on functional requirements of equipment (Gap)
• Team Composition
• Awareness for the “User”
• All hands on deck
Confidential 11
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
Confidential 12
Energy Management
Questions