Renewable energy sources, such as

solar and wind, are becoming

cheaper than energy from fossil

sources coal, gas and oil. This will

speed up the energy transition. We

have to work towards a more

flexible system, balancing fossil

fuels and renewable resources, with

larger and local stations for

balancing generation and demand.

Storage is essential for handling

peaks.

Driven by CO2 commitments, many

companies want a climate-neutral

production facility. These companies

have multiple options, that include

reducing energy consumption, using

renewable energy, capturing CO2

and reusing it to grow algae for

biofuel. The ideal situation is a smart

grid, to switch to the most efficient

energy source at any moment.

We create roadmaps to a business

case for the future, including

technical solutions, finance and

local sources, such as biotech and

shared utilities.

Energy Energy from waste: greenhouses profit from industrial CO2

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WE CARE ABOUTENERGY EFFICIENCY

In 2015, OCAP (Organic Carbon dioxide for Assimilation of Plants) celebrated ten yearsof reusing CO2 from heavy industry to grow fruit, flowers and vegetables in theNetherlands. Today, some 600 greenhouse growers no longer need to fire upexpensive gas-fuelled heating systems in summer just to produce CO2.

Growers who reuse CO2 from industry reduce their energy consumption and savemoney. Furthermore, they achieve a cut-back in annual gas consumption by 115 million m3 and reduces CO2 emissions by 205 tons. Last but not least, it meets their end-consumers’ increasing demand for sustainable products.

Sell waste productOCAP connects oil and bio-fuel companies with greenhouse gardeners, enabling themto feed their plant with what industry counts as a waste product. Reusing CO2 hasgreat environmental and economic advantages. ‘The gains for the environment lie atthe greenhouses,’ says Tebodin Lead Process Engineer Mr. Koen van ’t Sant: ‘The CO2

bought up by OCAP still counts as emissions for the industry, but now they can sell thatwaste product.’ The enterprise started in 2001, when Syens Energy developed the idea to deliver CO2

to greenhouses. Together with VolkerWessels and Linde Gas they created OCAP.Recyclers by nature, OCAP’s founders used an abandoned oil pipeline to connect Shellin the Rotterdam area to greenhouse farms in the hinterland.

Optimizing capture and supplyA decade later, OCAP continues to spread its concept to new areas whereconcentrations of greenhouses are close enough to good industrial sources of CO2.With the installation of a so-called peak shaver, liquid CO2 can be stored to covershortages. Furthermore, OCAP’s first supplier Shell has improved its process tomaximize CO2 capture and OCAP has found a second supplier in bio-ethanol producerAbengoa. Still looking to expand the supply side, OCAP has an eye out for bio-LNGplants, which emit large quantities of CO2.

OCAP involved Tebodin in the initiative to perform quantitative risk assessments toensure compliance with Dutch legislation. Especially for the more densely populatedareas where the pipeline is situated, an in-depth study calculated the safe distance incase of CO2 release during calamities.

Energy efficiency as part of a long-term view on sustainability

As a manufacturer of fertilizers and petrochemicals, theGPIC joint venture uses Bahrain’s readily available naturalgas as a feedstock for the production of ammonia, urea andmethanol. It produces a total of 1.5 million tons each year,which it exports around the globe. The joint venture isequally owned by the Government of the Kingdom ofBahrain, Saudi Basic Industries Corporation (SABIC) andKuwait’s Petrochemical Industries Company (PIC).

People, planet, prosperity‘Sustainability is strongly embedded in our company’smission’, says Dr. Jawahery. ‘From the very beginning, wehave been aware that the cutting-edge and competitiveadvantage can only result from weaving social andenvironmental considerations into business strategies. Overthe years, we have learned to take the long-term view andrecognize our responsibility towards stakeholders. We havedeveloped vital programs to support our CSR strategy, whichfocuses on areas such as environmental awareness,education and research, and employee wellbeing.’

SINCE THE COMMISSIONING OF ITS FIRST PLANTS IN BAHRAIN IN 1985, GPIC (GULF PETROCHEMICAL INDUSTRIES

COMPANY) HAS STEADFASTLY IMPROVED ITS ENERGY EFFICIENCY. ‘NO COMPANY CAN IGNORE THE IMPACT IT HAS ON

THE ENVIRONMENT,’ SAYS GPIC’S PRESIDENT DR. ABDULRAHMAN JAWAHERY.

Dr. Jawahery believes that the manner in which anorganization manages environmental issues is a crucialmeasure of its standard of corporate social responsibility,competitiveness and vision. ‘Our Responsible Care andSocial Responsibility ethic is seamlessly integratedthroughout GPIC’s cultural fabric, and is an importantcontributor to our leadership position. In developing oursustainability strategy, we ensure a close-knit integrationbetween the stakeholders’ interest, the environmentalaspects and the core business.’

Efficiency achievementsThe manufacturing of fertilizers is a relatively clean, buthighly energy-intensive process. Since the commissioning ofits first ammonia and methanol plants in 1985, GPIC hasaimed to reduce the process’ greatest environmental impact,the emission of greenhouse gases from the processes itselfand the emissions from fossil fuel-fired boilers and gasturbines.

Dr. Jawahery: ‘Since those early years, we have reduced thetotal energy from 11 gigacalories per metric ton of product to7.34 gigacalories. This has been achieved through reliableoperations and several energy-saving projects, such as theimplementation of the urea plant in 1998 and commissioningof our carbon dioxide recovery unit in 2009. Since itscommissioning this unit has so far extracted over 700,000tons of carbon dioxide.’

‘Further energy-saving projects have included the recentrevamp of the ammonia converter, several equipmentupgrades and energy-saving programs that have beenimplemented across our facilities. These improvements inenergy efficiency have the added benefit of a reduction inCO2 emissions. At present, we have a very ambitious projectin place to replace all conventional lights with LEDs and toprovide solar energy to all buildings outside of the processareas.’

Taking care of the planetGPIC will continue its holistic approach of taking care of theplanet, our people and our prosperity. According to Dr.Jawahery: ‘We strive to make a positive contribution toBahrain’s Economic Vision 2030 and take inspiration fromleading initiatives such as the UN Global Compact. We havecommitted to some of the most stringent standards and havebeen accredited to Environmental Management System ISO14001:2004, Responsible Care management system RC14001:2013 and ISO 50001:2011 Energy Management System.’

'Sustainability isstrongly embedded in

our company’s mission'

GPIC’s President Dr. Abdulrahman Jawahery

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WE CARE ABOUTENERGY EFFICIENCY

Following closely on the design of a new tire factory forMitas in Otrokovice, Czech Republic, Tebodin performedenergy audits of the company’s other factories in Prague andZlin.

Mitas is one of Europe’s leading producers of agriculturaltyres. Mitas also manufactures and distributes a wide rangeof industrial and motorcycle tires. Established in Prague inthe 1930s, Mitas now has three locations in the CzechRepublic, one in Serbia and one in Iowa, USA.

Savings in over 50 buildingsThe aim of the energy audits in Mitas’ original Prague andZlin factories, in addition to complying with energylegislation, was to find opportunities to reduce energyconsumption and save operating costs. ‘Mitas’ facilities in Prague consist of some 50 separatebuildings’, says Mr. Martin Papez, Project Manager forTebodin on the audits, ‘which gives you an idea of thecomplexity of the audit. On top of that, no documentation onthe original design had been preserved – as there wouldhave been on more recent projects.’

The audit teams, however, diligently went to work onevaluating the factories’ systems and found interestingopportunities for improvement. Some of the most frequentlysuggested changes related to the use of steam and hotwater, such as replacements of transformers, re-usingprocess steam for heating water, installing hot-air curtains,and so on.

Unexpected extrasMr. Papez: ‘The outcome of the audits has made it clear thatthere is always room for improvement, and sometimes inunexpected ways. For instance, some of our suggestionsinvolved improvements in lighting installations, which notonly saved energy, but also improved the quality of theworking environment.’

Tebodin’s services in energy improvements don’t stop at thepresentation of audit reports, says Mr. Papez. ‘Our engineersand consultants can help to make the improvements happen,through design, permitting, detailed documentation andtechnical supervision of the implementation. With Mitas, forinstance, we have already discussed collaborating on theenergy performance certification of the many individualobjects in their facilities.’

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Saving heat and shedding light on Czech tire factories

WE CARE ABOUTENERGY EFFICIENCY