European Responsible Care Awards 2011

••CRAY VALLEY IBERICA

ENERGY EFFICIENCY IMPROVEMENT

CRAY VALLEY IBERICA

ENERGY EFFICIENCY IMPROVEMENT

Cray Valley Ibérica 2

MIRANDA, 40.000 Tm

SANT CELONI, 40.000 Tm

MOLLET, 33.000 Tm

CASTILLA Y LEONCATALUNYA

Cray Valley Cray Valley Ibérica in 2010Ibérica in 2010

2010 SALES: 135 M EUR

2010 SALES VOLUME: 82.000 TM

Local sales : 50 %

Export sales : 50 %

Employees: 256

Capacity:

Cray Valley Ibérica 3

Miranda de Ebro, 65 emp

Sant Celoni, 119 empMollet del Vallés, 70 emp

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Products and applicationsProducts and applications

Unsaturated polyesterGel Coat

Reinforced plasticsSanitaryware, construction. Water sports, automotive.Concrete, synthetic marble.Transport, leisure.(Miranda de Ebro)

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Alkyd resinsOF PolyesterAcrylic resinsEmulsions

Decorative paints and wood stainsIndustrial & anticorrosion coatings Printing & adhesives

Products and applicationsProducts and applications

(Mollet del Vallès, Sant Celoni)

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Powder paintsSolid saturated polyester

Products and applicationsProducts and applications

(Sant Celoni)

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Innovation

Competitivity

SustainableDevelopment

Cray Valley Cray Valley IbéricaIbéricaStrategic plan

Why we started the project

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The reorganization of the activities & the economic crisis have reduced the volumes. As a consequence the energy efficiency has decreased ...CVIbCVIb hashas includedincluded the energy efficiency improvementthe energy efficiency improvement inin the Strategicthe Strategic Plan as a Plan as a mean mean project project in in the Sustainable Development principles and Responsiblethe Sustainable Development principles and Responsible Care.Care.Sant Celoni Plant has been chosen as a pilot plant.

Volume

-60%

UnitaryConsumption

Mwh/Tm

+40%

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Why we started the project

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We decided to improve the energy efficiency of the plantto reduce the environmental impact & to be more competitive ...

Energetic audit

Action identification

Analysis & execution plan

Implement actions

We get some subventionsfrom the administration

Investments

What we have done

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The energetic audit has identified some actions to improve the energy efficiency of the plant ...

EQUIPMENT IMPROVEMENT saving/year (kWh n.g.)

saving/year (€)

Investment (€)

Pay-back (years)

Energy saving (%)

CO2 emissions reduction (T/year)

Steam boilers Purges heat recovery 621.985 13.901 18.000 1,3 0,6 98,27

Steam boilers Purges continuos process automatization 64.489 1.441 2.850 2 0,1 10,19

Steam distribution network

Thermal compressor for condensed recuperation 4.050.084 90.519 170.000 1,9 4 639,91

Boilers Heat recovery of combustion gases 5.401.077 120.714 201.000 1,7 5,4 853,37

Boilers Burners parameters improvements 1.107.365 24.750 2.200 0,1 1,1 174,96

Generation and steam distribution Insulation improvements 3.975.848 88.847 34.980 0,4 3,9 628,18

What we have done

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The actions with the higher impact andlow pay back time have been implemented ...

action saving/year cost pay-back

GAS powders process improvements 30 K€ 0 -

better management & control of heaters 72 K€ 5 K€ 1 month

thermal insulations 35 K€ 25 K€ 8 months

heat recovery from heaters emissions 31 K€ 55 K€ 1,8 years

ELECT pressure reduction of compressed air 6K€ 0 -

improvements in refrigeration water control 18 K€ 12 K€ 8 months

low consumption lighting 4 K€ 6 K€ 1,5 years

new high effic iency air compressor 21 K€ 40 K€ 1,9 years

What we have done

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Volume

UnitaryConsumption

Mwh/Tm

+18 % efficiency

With excelent results ...and the project is not finished !

This means a reduction of 1.500 Tm of CO2 per year !!

What are the outcomes

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Next step...

To continue with the implementation in Sant Celoni Plant.

Start the process in Mollet del Vallés and Miranda de Ebro plants.