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Celanese - Energy Cockpit
28 Jan 2016

celanese Frankfurt

Aerial view of Celanese’s Industrial Park Höchst (Frankfurt) site.

The case study below is one the entries submitted as part of the European Responsible Care Awards under the “Energy efficiency/SPiCE3” category and represents an example of the high quality of the proposals received from the 68 European companies participating in the Awards scheme organised by Cefic.

The company

Celanese Corporation is a global technology leader in the production of differentiated chemistry solutions and specialty materials. Based in Dallas, but with sales almost equally divided between North America, Europe and Asia, Celanese employs approximately 7,400 people worldwide and had net sales of €6,272 million in 2014.

Europe is a strategically important region for Celanese, accounting for nearly 40% of the company’s sales with a 2,600-strong employee base in 7 different countries. In the Industrial Park Höchst (IPH) Celanese produces Acetyl Intermediates, Emulsions Products, Food Ingredients and the High Perfomance Polymer Hostaform (Polyoxymethylen). IPH is also home for some of Celanese’s global R&D activities.

The solution

Even though Celanese’s Frankfurt site received an ISO 50001 certification in 2013, because of the high degree of complexity site personnel still found it difficult to track energy performance and spot improvement opportunities. To address this and hit the parent company goal of reducing energy intensity by a further 20% by 2015 from 2010’s baseline, the Frankfurt Energy Team and Celanese’s Global Energy Team devised a solution.

The centrepiece has been a combination of thorough data analysis (based on Six Sigma methods) and a comprehensive online monitoring tool (the Energy Cockpit) that displays four energy speedometers and compares actual consumption to targets that include uncontrollable factors. Such factors include market demand and weather conditions that determine throughput and product mix (controllable factors are not included in the mix). The four speedometer levels show: overall plant energy consumption; the efficiency of “subordinated” units; specific consumption for individual energy using units. And the fourth level allows operators to see what causes a deviation in energy efficiency.

The Energy Cockpit is used in Frankfurt on a daily basis. Operators use it for online plant performance energy intensity monitoring. Shift supervisors report on energy intensity performance at daily morning meetings that works as an early alert to deviations from optimal performance. Since its roll out energy savings of up to 20% have been achieved. And since 2013, the POM plant (producing the high performance polymer Hostaform) reduced energy intensity by over 10%, equivalent to an energy saving of 150,000 GJ or 40,000 MWh.

Below a timeline of the project:

Dec 2013 – Mar 2014: SixSigma data analysis modelling

Models were developed for each individual energy consumer by using statistical methods. These models identified the Key Performance Indicators (KPIs) of energy consumption and demonstrated how they correlate with energy intensity.

Mar 2014 – Jul 2014: Programming of the Energy Cockpit

The Energy Cockpit displays energy speedometers in 4 levels:

  • Level 1: shows the overall plant energy consumption
  • Level 2: indicates the efficiency of the subordinated units
  • Level 3: shows the specific consumption for each individual energy consumer
  • Level 4: enables to see what causes a deviation in energy efficiency

Jul 2014 – Sep 2014: Evaluation of the limits and test phase

The dynamic limits derived from statistical analysis of historical data and used in the Energy Cockpit were defined in 3 operating ranges as follows:

  • Yellow: mean of previous year energy usage
  • Green: higher energy efficiency
  • Red: lower energy efficiency

Based on this method and depending on the outcome of the correlation function whilst also considering the boundaries of the process parameters it was then possible to define the limits for the influencing parameters, and therefore develop KPIs.

Oct 2014: Training of the operators

Particular focus was put on training supervisors and operators. The training material includes details of the data analysis, the models used and the parameters utilised in the models. Regular, daily operator engagement is the essential to sustainability, but requires understanding of the rationale behind.

Nov 2014: Final roll-out of the Energy Cockpit and implementation of new procedures

After completion of a test and training phase, the Energy Cockpit was rolled out to be used on a daily basis. This came along with a real cultural change towards Responsible Care excellence in all levels of the organisation.

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