CARE+ Improve your Energy Efficiency

24 

Loading....

Loading....

Loading....

Loading....

Loading....

Full text

(1)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

CARE+ – Improve your Energy Efficiency

TRAINING SMALL- and MEDIUM-SIZED CHEMICALS

IN RESPONSIBLE USE OF ENERGY

(2)

Table of Contents

1. EXECUTIVE SUMMARY ... 3 1.1. SHORT BACKGROUND ... 3 1.2. ACTIVITIES ... 3 1.3. RESULTS ... 4 1.4. CONCLUSIONS ... 5 2. INTRODUCTION ... 6

2.1. ENERGY EFFICIENCY MAKES BUSINESS SENSE ... 7

2.2. POLITICAL DRIVERS ... 8

2.3. EXISTING SUCCESS STORIES ... 8

2.3.1. THE UK EXPERIENCE ... 9

2.3.2. THE NETHERLANDS EXPERIENCE ... 9

2.4. SMES SHOW UNTAPPED POTENTIAL ... 10

3. THE CARE+ CONSORTIUM ... 12

4. THE SITUATION IN PARTNER COUNTRIES: ... 12

4.1. BULGARIA ... 12

4.2. ITALY ... 13

4.3. POLAND ... 13

5. THE PROJECT CONCEPT ... 13

6. RESPONSIBLE CARE ... 14

7. THE ENERGY EFFICIENCY GUIDANCE DOCUMENTS ... 15

7.1. SELF AUDIT GUIDE AND EXCEL SHEETS ... 15

7.2. BEST PRACTICE WORKBOOK ... 17

8. THE PROJECT STRUCTURE ... 18

8.1. THE OVERALL MANAGEMENT ... 18

8.2. PHASE 1: DEVELOPING THE TOOLS ... 18

8.3. PHASE 2: THE ROLL -OUT CAMPAIGN ... 18

8.4. PHASE 3: INTERNATIONALISATION ... 19

8.5. COMMUNICATION AND DISSEMINATION: ... 19

9. RESULTS ... 19 9.1. BULGARIA ... 20 9.1.1. INTRODUCTION ... 20 9.1.2. RESULTS ... 20 9.2. ITALY ... 21 9.2.1. INTRODUCTION ... 21 9.2.2. RESULTS ... 22 9.3. POLAND ... 22 9.3.1. INTRODUCTION ... 22 9.3.2. RESULTS ... 23 9.4. EUROPEAN LEVEL ... 24 10. NEXT STEPS ... 24

(3)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

1.

Executive summary

1.1.

Short Background

The Care+ project was setup by the European chemical industry (Cefic) to facilitate energy efficiency improvements in SMEs by identifying energy saving opportunities for small and medium-sized companies (SMEs) that lack experience with energy audits.

Bulgaria, Italy and Poland were the first target countries. Along with the three target countries, the project promotes energy best practice throughout Europe and beyond.

Figure A: CARE+ partner countries (in green)

Care+ was funded and supported by the European Commission under the framework of “Intelligent Energy Europe”. The project officially started on 1 October 2008 and lasted until 30 March 2011.

1.2.

Activities

Gap analysis: The three partner countries conducted surveys on energy management

performance and provided a “gap” analysis to help to determine the current situation and needs of chemical SMEs.

Tools development: Based on the survey results and existing expertise, the project evaluated best practices and appropriate delivery mechanisms for improving energy efficiency.

(4)

National test phase and roll-out: The draft tools were tested with two chemical SMEs in each partner country. The “field test” enabled further improvements to match companies’ needs and expectations. The finalised tools were then promoted through a roll-out campaign in the partner countries.

Dissemination in Europe and beyond: based on the experience from the pilot countries, the project aims to expand to a broader European and international audience. Future international dissemination will build on the project’s close links with Responsible Care, the global chemical industry’s voluntary initiative to continuously improve its health, safety and environmental performance.

1.3.

Results

Designed to lower energy costs by as much as 10 to 20 per cent, CARE + has proven to be a useful tool for most of the participating SMEs.

CARE+ has significantly stimulated interest in energy efficiency in SMEs and raised awareness of best practices in the three partner countries but also on a broader European scale.

Flexible tools were created together with SMEs in our partner countries which can be adapted to the individual company needs and combined with already existing measures, e.g. under national funding schemes.

To help reduce each company’s energy bill, a Self Audit Guide (SAG) was developed as a tool to analyse of a company’s energy performance. Accompanying the guide was a spread sheet to help determine each firm’s strengths and weaknesses. From the audit guide and spreadsheet, companies identified energy efficiency measures and possible energy savings and gained valuable information on the costs for short-, medium- and long-term investments and the expected long-term payoff.

In addition, an Energy Management Best Practice manual was provided that focuses on the key areas of energy efficiency in chemical SMEs, e.g. Energy management programmes and steam generation performance, and describes “best in class” energy efficiency applications in different areas.

(5)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

1.4.

Conclusions

Our experiences with CARE+ show that further encouragement of SMEs with practical energy efficiency information works. Member States should encourage the development of appropriate market-based incentives, as the initial investment rate with respect to energy efficiency

measures is high and the pay-back period in most cases takes longer than two years. Cefic will continue to disseminate the CARE+ tools. By strengthening the network within the chemicals industry, Cefic believes in the long run that an exchange of best practices and the development of tools that SMEs use to benchmark their energy use against comparable companies can be achieved. Cefic welcomes the support of the European Commission to this bottom-up approach, and will be happy to continue sharing experiences and work further with the European and local authorities.

The CARE+ tools are flexible and are available today at no cost on the Cefic website in English, Bulgarian, Polish and Italian. More countries such as Finland, Belgium or the Netherlands have agreed to integrate CARE+ in their national approaches. Negotiations with additional countries have recently started.

In parallel, ideas are being developed to disseminate the tools by creating up to three regional “mini” pilot projects in collaboration with the European Chemical Regional Network (ECRN). This process will be an important next step to further collect ideas on how CARE+ can be best

(6)

2.

Introduction:

In the context of rising energy prices, global competition and environmental concerns, energy efficiency is a key competitiveness factor for European chemical companies. Over the past years, the chemical industry has taken many voluntary measures to improve its energy efficiency. Large companies in the sector have been successful in increasing their output while keeping their energy input stable.

But what can be done to help small businesses, who represent more than 90 per cent of the chemicals sector? Even though energy costs can represent up to one quarter of their total production costs, many SMEs do not view energy efficiency as a priority or are not equipped to set up effective energy management programmes. The reason is SMEs often lack financial and human resources to introduce energy efficiency measures. In addition, they are highly diverse and geographically dispersed, making coordinated initiatives challenging to implement. Smaller firms require specific assistance and guidance in order to become aware of the issue and develop the know-how to implement measures leading to a lower energy bill.

Nonetheless, improving energy efficiency makes economic sense for small companies. For example, chemical industry initiatives in the United Kingdom and the Netherlands have shown that energy savings of 15 per cent or more are possible when measures are carried out through strong collaboration of industry associations and local authorities. These results are confirmed in the CARE+ project.

Cefic initiated CARE+, a European project aimed at supporting chemical SMEs in improving their energy efficiency, to help companies tap into this potential. The project is funded and supported by the European Commission under the framework of Intelligent Energy Europe and and is part of Responsible Care – the chemical industry’s commitment to sustainability.

A range of tools were developed from 2008 to 2010 to help small businesses to evaluate their potential energy savings and the expected return on investment, including the Self-Audit Guide with a spreadsheet audit tool and a Manual on Best Practices. Guidance documents were then tested by SMEs and refined accordingly. Following the successful completion of a rigorous development process, the tools were used in roll-out campaigns, including site-visits and further assistance in the three pilot countries - Italy, Bulgaria and Poland. This process was effectively put in place through country-specific teams consisting of two pilot companies, the national association and energy experts. Cefic functioned as project coordinator at European level, and was also responsible for internationalising the initiative.

(7)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

2.1.

Energy efficiency makes business sense

As the European Commission rightly states “Energy is what makes Europe tick.” The chemical industry is energy-intensive.1 This means in fact that the sector is more energy- intensive than most others. The industry, which has more than 29,000 companies in Europe, is particularly affected by EU energy policy decisions. As an “industry of industry”, chemicals is an upstream sector that is dependent on affordable and secure energy supply in Europe. So energy efficiency is an important competitiveness factor for us as a competitiveness issue in a rapidly globalised chemicals market.

Cefic has supported initiatives towards energy efficiency improvements. The sector has taken many voluntary measures to considerably improve its energy efficiency. One example is by installing and using Combined Heat and Power (CHP). As illustrated in Figure A below, the EU chemical industry has over the last decade increased its output while keeping energy input constant. The industry’s energy intensity has decreased by four per cent per year on average and 41 per cent since 2003.

Figure A: Energy intensity* in the EU chemicals industry

These figures do indeed show the chemical industry has realised the significance of energy efficiency improvements. For these reasons, the topic remains continuously high on the political agenda. However, the recent successes described above could potentially be obtained by larger companies as well, not only SMEs. Unlike large companies, SMEs most often neither have the personnel nor the extra money available for implementing advanced energy efficiency measures such as installing the DIN EN 16001 energy management system.

1

(8)

2.2.

Political drivers

Energy has always been the centre of attention of EU and national policymakers. Increased cooperation has been emerging, particularly over the past few years, for instance when the 2007 Spring European Council of Heads of State adopted the EU Energy Action Plan for the period 2007-2009. The plan outlines several priority actions concerning energy efficiency, use of renewable energies, completion of the EU’s internal market for gas and electricity, and targets for renewable energy, energy efficiency and climate (20-20-20 targets). In addition, when in December 2009 the Treaty of Lisbon entered into force, the EU’s commitment to sustainable development received a new legal basis for the first time, allowing the European Union to establish measures relating to energy policy.

Energy was placed at the heart of the EU’s Europe 2020 Strategy for smart, sustainable and inclusive growth and of the transition to a resource efficient economy. Energy also plays a big part in DG Climate Action’s communication on a low-carbon economy, where energy efficiency has been identified as one of the main tools to master the transition towards a low-carbon economy.

The European Commission’s Energy 2020 energy efficiency strategy received confirmation once again in November 2010 as a key priority – namely the 20 per cent emissions reduction target until 2020. As a result, the Commission has developed its new Energy Efficiency Plan which acknowledges that for SMEs the obstacles to investment in energy efficient technologies are the most acute. The Commission therefore supports an exchange of best practices, and the

development of tools that SMEs can use to benchmark their energy use against comparable companies. It also wants to provide help for projects which build capacity on energy

management. All these measures are to be carried out in strong cooperation with industry associations. CARE+ aims to meet all these objectives.

Cefic already agreed years ago that more can to be done, especially to help SMEs. This approach was taken up in the EU’s High Level Group on Competitiveness, Energy & the Environment negotiations. Finally, it was recommended to further stimulate energy efficiency in SMEs in a bottom-up approach: CARE+ was a consequence of this advice.

2.3.

Existing success stories

The CARE+ project mainly builds on experiences of voluntary agreements, concluded between industry and local authorities in the Netherlands and the UK. For instance, a project in the UK has shown an average reduction potential of 15 per cent, mainly to be reached through good housekeeping targets concentrating on how to use and operate the existing facilities as efficiently as possible. Thus, one of the main conclusions is that there is a large potential for

(9)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

energy efficiency particularly in small- and medium- sized chemical companies - as those often have not yet identified the reduction of energy consumption as a priority.

2.3.1.

The UK experience

In the 1990s, the UK’s Chemical Industries Association (CIA) developed a voluntary agreement with the UK government under which they signed up to energy efficiency targets in return for data verification, free energy consultancy for SMEs and the development of guidance. This agreement was replaced by a Climate Change Agreement, which committed the sector to further energy efficiency targets in exchange for a reduction in the newly introduced Climate Change Levy, a tax on business use of energy. Under the combination of these two agreements, the sector improved its energy efficiency by 35 per cent during the period 1990 to2006.

Conclusions on the UK experience

The initiatives in the United Kingdom show the attractiveness of the chemicals sector for energy efficiency measures. In addition, the sector agreements with the chemicals sector in the United Kingdom have shown significant success and demonstrable energy savings over the last 20 years. The figure below shows a 35 per cent improvement from 1990 until 2006, thanks to the voluntary agreement and the Climate Change Agreement.

Figure B: UK chemicals sector energy efficiency

Source CIA

2.3.2.

The Netherlands experience

The Netherlands have two important policy instruments targeting energy efficiency

improvements in industry and more specifically, in the chemical industry, a sector considered one of the largest energy consumers in the Netherlands. Long-term agreements, or so-called “multiyear agreements” have been in place since the beginning of the 1990s, and a

benchmarking covenant was agreed for energy- intensive industries in 1999. Both policy 60 70 80 90 100 1990 1992 1994 1996 1998 2000 2002 2004 2006 Voluntary Agreement, 18% since 1990 CCA, 20% since 1998 35% Improvement since 1990 Index

(10)

instruments are based on voluntary commitments of industry at national, sectoral (including the chemical industry) and company level.

Results of the long- term agreements and the covenant

The energy efficiency progress in the manufacturing industry was nearly 21 per cent between 1990 and 2006. From 1990 on, the starting year for long- term agreements on energy savings, the improvement was more than 1.5 per cent per year for all participants. The chemicals sector, which accounts for half of industry energy consumption in the Netherlands, has improved energy efficiency by 25 per cent since 1990. Steel industry energy efficiency remained relatively unchanged between 1993 and 2001, but started to improve after 2001. Energy efficiency in the paper industry decreased until 1997. The overall increase of energy efficiency has been nine per cent since 1990.

Figure C: Energy efficiency improvements in Dutch industry

Source ODYSSEE database 2008

2.4.

SMEs show untapped potential

Contrary to public perception, small- and medium-sized enterprises (SMEs) represent a significant share of the EU chemicals industry. As shown in the figure below, 96 per cent of all chemical companies have fewer than 250 employees and these are responsible for 28 per cent of all sales and 35 per cent of total employment.

SMEs make a major contribution to upstream innovation transfer in the chemicals value chain to downstream manufacturing industry. As producers of specialty chemicals, SMEs are often customers of larger firms in the sector, rather than suppliers.

(11)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

But, according to the 2007 Observatory of EU SMEs, comprehensive systems for energy

efficiency are much less evident in SMEs (four per cent) than in large enterprises (19 per cent).2 The same applies for simple energy saving measures, which are used by 30 per cent of SMEs and 46 per cent of large companies. The survey also confirms that 89 per cent of SMEs are more dependent on the regional labour market than large enterprises (77 per cent).

Figure D: EU chemical industry: number of enterprises by size-class

Data source: Eurostat SBS (2001)

In addition, beyond the limitations of the demand side, the most important individual business constraint reported by SMEs is compliance with administrative regulations. That is where CARE+ tools can help as they provide a simpler approach than standardised energy management systems such as DIN EN 16001. Nevertheless, the CARE+ tools are seen as a significant first step towards introducing these standards.

2

European Commission, DG Entreprise and Industry: http://ec.europa.eu/enterprise/policies/sme/facts-figures-analysis/sme-observatory/index_en.htm#h2-1 Between (500 and 999), 1.1% Medium (50-249), 10.4% Between( 250 and 499), 2.1% 1 000 or more, 0.7% Small (10-49), 23.1% Micro (1-9), 62.6%

(12)

3.

The CARE+ Consortium

Project Coordination:

European Chemical Industry Council (Cefic)

Project Management Assistance:

Challoch Energy

Partner countries: Bulgaria, Italy, Poland

National Association Technical expert SMEs

SC SVILUPPO CHIMICA S.P.A., a subsidiary of

FEDERCHIMICA

Certiquality srl Ilsa SA

Evonik Goldschmidt Italia Srl

Bulgarian Chamber of the Chemical Industry (BBCI)

Energy Efficient Systems Ltd (EES)

Kaumet JSC Agria SA Polish Chamber of Chemical

Industry (PCCI)

Polish National Energy Conservation Agency (KAPE)

Silikony Polskie Fosfan Spolka Akcyjna

4.

The situation in partner countries:

4.1.

Bulgaria

Turnover in the Bulgarian chemicals sector amounted to about €1.1billion, accounting for approximately 9.9 per cent of Bulgaria’s gross domestic product (GDP)and about 30 per cent of industrial GDP in 2007. The Bulgarian chemical industry production covers all product groups and sectors, with a particular focus on fertilizers, paints, rubber products and essential oils.

In 2007, there were a total of 750 chemicals-producing companies, of which about 90 per cent were SMEs. Thus, SMEs play an important role in the Bulgarian chemical industry.

With an annual energy consumption of 70 peta joules (energy and feedstock) in 2006, the chemical industry accounts for 28 per cent of the Bulgarian industry’s total energy consumption - the highest share of any industry.

(13)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

4.2.

Italy

The Italian chemical industry, which had an estimated turnover of €80 billion in 2007, employs around 194,000 people and comprises almost 3,500 enterprises. SMEs play an important role in the Italian chemical industry, accounting for 97 per cent of companies and 60 per cent of sector employment.

Total energy consumption (energy and feedstock) in the Italian chemical industry was estimated at 590 peta joules in 2006.

4.3.

Poland

Polish sales of chemical products amount to about € billion 15, which accounts for two per cent of the EU-27 chemical industry’s sales in 2007. There are roughly 2,700 chemical SMEs in Poland. Basic chemicals account for more than 50 per cent of total chemical production in Poland; cosmetics and household products, as well as pharmaceuticals ,account for 17 per cent each while 14 per cent are covered by other chemicals.

Total energy consumption (energy and feedstock) in the Polish chemical industry amounted to 300 peta joules in 2006.

5.

The project concept

CARE+ was established to develop and test tools to help SMEs to help themselves to improve their energy efficiency.

The tools have been offered to SMEs in the three pilot countries (Italy, Bulgaria and Poland) in a roll-out campaign after having been developed in a bottom-up approach with two SMEs in each of the partner countries. This process has been accompanied by energy experts and the

respective national chemical associations.

CARE+ is to be further promoted through Responsible Care (see chapter below). Here energy efficiency has always been an important element and is planned to become even more visible in future.

(14)

The tools are aimed at SMEs, but should be also available for other industrial sectors and even the large chemical companies, particularly those which have a decentralised structure.

6.

Responsible Care

Responsible Care (RC) is the global chemical industry’s unique initiative to improve health, environmental performance, enhance safety and security, and to communicate with stakeholders about products and processes.

RC commits companies, national chemical industry associations and their partners to: Continuously improve the environmental, health, safety and security knowledge and performance of our technologies, processes and products over their life cycles so as to avoid harm to people and the environment.

Use resources efficiently and minimise waste.

Report openly on performance, achievements and shortcomings.

Listen, engage and work with people to understand and address their concerns and expectations.

Cooperate with governments and organisations in the development and

implementation of effective regulations and standards, and to meet or go beyond them. Provide help and advice to foster the responsible management of chemicals by all those who manage and use them along the product chain.

CARE+ naturally fits these objectives, and from the very beginning, extensive discussions have occurred with Responsible Care management and selected country coordinators on how best to further disseminate the project. As a result, CARE+ in recent years has become an accepted part of the Responsible Care agenda. Regular updates take place during various Responsible Care events such as its annual conference and in meetings of the group’s various bodies.

CARE+ is also being supported at the global level of Responsible Care, by the International Council of Chemical Associations (ICCA), of which Cefic is a member. ICCA promotes CARE+, for instance, by developing a fact sheet which has been circulated to all ICCA members, who are already aware of CARE+ through various updates from the Cefic RC manager.

CARE+ will be further integrated into the Responsible Care toolbox for SMEs which is currently still under development and should be available on the Cefic website in early July 2011.

(15)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

7.

The energy efficiency guidance documents

The tools developed by the CARE+ project help small businesses evaluate their potential energy savings and the expected return on investment. The tools, including a Self Audit Guide with spreadsheets and a Best Practice Workbook, are available for free in four languages: English, Bulgarian, Italian and Polish.

7.1.

Self audit guide and excel sheets

The Self Audit Guide leads SMEs through the analysis of the company’s energy performance and helps to determine strengths and weak points while managing energy sources. Ultimately, it aims at improving Energy Efficiency, supporting the identification of measures, their expected energy savings, costs and return on investment calculation (suggested evaluation model provided through developed spreadsheet tables).

Figure E: CARE+ Self Audit Guide

Source: CARE+ Self Audit Guide

In combination with the Best Practice Manual, the Self Audit Guide will help to determine the measures which could be implemented, what would be the expected savings, and cost and return on investment.

The self audit guide assists companies in undertaking energy audits and in assessing their energy performance in a simple step-by-step approach.

(16)

Figure F: EXPLANATORY SCHEME FOR THE SELF AUDIT GUIDE AND THE SPREADSHEET TABLES

Source: CARE+ Self Audit Guide

Step 1 – determines the scope and the objectives of the audit: The first thing is to do a rough calculation on how much a company’s energy costs account for in its total cost, as this allows it to establish the importance of energy efficiency for its business.

Step 2 –dedicated to information gathering needed for the audit: It includes qualitative

information for the broader picture and quantitative information. It provides a general overview on the target installation of the energy audit, focusing on space and capacity data, principal products, state of repair and age of the production equipment on site and the energy transformation equipment.

Step 3 – addresses the analysis and evaluation: The qualitative and quantitative information gathered allows for a first analysis of energy performance and improvement potential. This includes two main steps: 1.) an analysis to determine different improvement options and the respective implementation cost needs to be conducted; 2.) there follows a financial comparison of the cost impact and return on investment of the different energy efficiency improvement possibilities.

Step 4 is to prepare a report of the audit results: This report lists recommended energy saving measures for the set- up of an action plan and describes the energy audit procedure.

(17)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

7.2.

Best practice workbook

The Best Practice Guide indicates how to proceed with energy management, irrespective of whether SMEs are right at the start of the process or already more advanced and have implemented all the essential tools to control their energy consumption.

It focuses on eight areas, considered to offer most energy saving opportunities for chemical SMEs. They provide a benchmark for energy management and show the different improvement potentials, differentiating by good housekeeping measures, low or no cost, and issues where investment might be pay off well.

The following areas are covered:

1. Set- up of an energy management programme 2. Accounting & analysis of energy use

3. Set -up of an energy information system

4. Improvement of steam generation performance 5. Reduction of energy use in compressed air systems 6. Reduction of energy use in buildings

7. Improving energy efficiency of motors and drive systems 8. Improving energy efficiency in the process plant

Due to the varied nature of the chemical industry, the focus of these best practices is on more generic energy efficiency measures rather than the very specific process improvement

measures. This focus is important as significant energy savings are achievable through energy efficiency measures such as steam and compressed air zoning, monitoring and targeting, improved insulation and industrial building measures such as lighting and air movement controls.

The first three best practices focus on energy management and measuring of energy consumption, as these two steps are the backbone of any energy efficiency activities. Best practices areas four to eight (see list above) cover specific issues, which are most promising for energy savings. The modular structure also allows for adding additional chapters on issues that are of interest.

(18)

8.

The project structure

Figure G: Flow chart of the work programme

Source: CARE+ Grant Agreement

8.1.

The overall management

Work Package 1 (WP 1) dealt with the overall management and co-ordination of the project: It included:

Project meetings – one took place in each of the target countries Planning, reporting and budget control

Communication management between partners, the EACI and the Steering Committee

8.2.

Phase 1: Developing the tools

Work Package 2 (WP2)to Work Package (WP5) was the preparatory phase of the project: In these four Work Packages the requirements of SMEs were assessed, the experience of national and international programmes analysed, and the materials developed, tested and revised for the roll-out campaign. These four WPs formed the essential first steps for the successful delivery of the project.

8.3.

Phase 2: The roll-out campaign

Work Package (WP6) was the roll-out campaign: In each of the three target countries the CARE+ initiative was launched and 25 SMEs per country were assisted in improving their energy efficiency. For the three national chemical federations, this part of the project was the first phase of a long-term campaign in their countries which will continue long after the IEE project has been completed.

(19)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

8.4.

Phase 3: Internationalisation

Work Package 7 (WP 7) ran in parallel with WP 6: Cefic and the national chemical federations started an initiative to apply the mechanisms and materials developed in CARE+ to other EU Member States and, also internationally through ICCA – the global RC. Naturally, this is a long-running process, which will continue well beyond the completion of the IEE project.

8.5.

Communication and dissemination

Work Package 8 (WP8) and Work Package 9 (WP9) addressed the overall dissemination of CARE+: From the start of the project, objectives and benefits to SMEs and the chemical industry as a whole in each of the target countries were – and are – communicated to the Cefic

membership (through the Cefic network). The transfer of know-how from Cefic, major chemical companies and successful national programmes is an ongoing process, and here are a few examples:

The Cefic website –the main tool to inform the broader public for instance by publishing articles on CARE+ events such as the “European Sustainable Energy Week” or even about a case of successful implementation of CARE+ in Poland.

Cefic presented CARE+ at the IEE Info Day 2011, upon request from the European Commission.

9.

Results

The following CARE+ project objectives have already been achieved:

increasing the energy performance of SMEs, thereby improving their reliability, competitiveness and reputation;

raising awareness among industrial decision-makers of the specific needs and problems of SMEs with regard to energy efficiency;

promoting energy services, energy management schemes, procurement guidelines and training for industry; and

developing well-targeted tools and information for SMEs to reduce their energy use. CARE+ is a well developed and proven energy efficiency route for chemicals SMEs. The best results in the pilot phase occurred when SMEs were individually assisted by energy experts (e.g. through site visits). Experience of deploying CARE+ has indicated there is a scope to develop the documentation further to fit local requirements. The need for energy analysis is a key issue for all SMEs. An energy saving potential of about 15-20 per cent may be reasonably achieved in the majority of audited SMEs, through technical and management actions.

(20)

9.1.

Bulgaria

9.1.1.

Introduction

Thirty-five SMEs participated in the roll-out in Bulgaria, which started with a marketing campaign followed by the actual selection process.

In the various stages of the self-audit process, SMEs were continuously supported by a technical expert (EES), and the Bulgarian chemicals federation (BCCI) functioned as a focal point. Thanks to this set-up, energy efficiency improvement opportunities could be conducted, best practice approaches developed and next steps and concrete actions determined. Due to trainings and site visits, 31 SMEs successfully finalised the self-energy audits by using the provided energy management tools. The locations of the audited companies are shown in the following map.

Figure H: locations of chemical SMEs participating in the Roll- out Campaign

Source: BCCI

9.1.2.

Results

CARE+ in Bulgaria was considered by Cefic, PCCI and participating companies to be a success. Nevertheless, due to the economic crisis, it was a particular challenge to encourage SMEs to improve their energy performance. The most important success factor turned out to be early involvement of top management at each company, who needed to become aware of the energy savings opportunities and how they contribute to overall plant performance. Once they gave their “green light”, the process started to run properly. Furthermore, the participating SMEs needed more assistance than expected for implementing the self audit guide. For this reason, BCCI and EES decided to focus intensively on training and supporting the respective energy managers. As a result, comprehensive site visits were organised, including, for instance, additional individual trainings, energy walks and data checking.

(21)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

One of the success factors in Bulgaria was the close collaboration between BCCI and the

Bulgarian Energy Efficiency Agency, which helped to encourage SMEs to participate and “stay on board”. In addition, local authorities from the very beginning were informed about the project, which led to a continuous exchange of views between industry and the Bulgarian government. CARE+ was also rolled out – as in Poland and Italy – to other industry sectors and large

companies with decentralised production structures, which proves that the tools can be also used on a broader scale.

The average volume of the identified energy savings was about 10.3 per cent in participating companies, with an expected pay-back period of 3.5 years. A five to six per cent average

volume of identified first priority energy savings during the same 3.5-year pay-back

period as above. The technical measures and interventions with the highest energy

efficiency potential for chemical SMEs were, for instance, energy management

programmes, effective electric drives, heat utilization and efficient lighting.

9.2.

Italy

9.2.1.

Introduction

The roll-out campaign in Italy started in April 2010 and lasted almost until the end of the CARE+ project in March 2011. Twenty-three companies participated fully in the CARE+ project and implemented the self audit guide.

Figure I: Locations of chemical SMEs participating during the roll-out campaign

(22)

9.2.2.

Results

The general economic situation in Italy has been dramatic due to the global economic crisis. Many SMEs experienced a strong reduction of sales and production, and decided to focus on the core activities, which led to increasing difficulties in motivating the SMEs and obtaining their collaboration in order to gain the energy information. In addition, a few managers insisted that energy had a limited impact on their profit and loss statement and could not, therefore, be convinced to participate in the project. Normally, the technical manager of the site controls all plant activities, including the energy assets and costs. However, a further obstacle was that those at top management level often lacked awareness regarding the cost benefits of realising energy efficiency improvement measures, making the process generally more difficult.

Despite the difficulties described above, on the basis of all SMEs’ plant condition, an

energy saving potential of about 15-20 per cent may be achieved for the majority of

audited SMEs.

For all SMEs who took part, a comprehensive energy analysis has always proved to be a

key issue as most SMEs have little control of their energy consumption costs. Therefore,

a correctly set-up energy management system significantly helps SMEs in reaching their

energy saving goals. Most notably, companies in Italy find the assistance of an energy

expert crucial to help SMEs to successfully implement the CARE+ self audit.

The main driver for SMEs to participate in CARE+ was the immediate need to reduce

energy costs. The weight of energy cost of SMEs accounts for around one to 11 per cent

of total turnover, with a total monetary value from €100.000 to about €17 million.

9.3.

Poland

9.3.1.

INTRODUCTION

The roll -out campaign in Poland started in summer 2010 when the final English-language version of the Self Audit Guide (SAG) and the Best Practice Manual (BPM) documents had been completed and translated into Polish.

After the first exchange of views it turned out at that time that the overall economic situation for Polish SMEs was quite dramatic. Mainly due to the global economic crisis, many SMEs experienced a strong reduction of sales and production, anddecided to focus on the core activities (increasing difficulties in motivating the SMEs and obtaining their collaboration in order to gain the energy information). Moreover, a few managers insisted that energy use had a limited impact on their profit and loss statement. In general, the technical manager of each plant/site controls all energy use activities, and therefore also the energy assets and costs.

(23)

_______________________________________________________________________________________________________ For any further questions please contact Martina Beitke (mbe@cefic.be).

Furthermore, it became obvious that top-level, management in most cases was not aware of the issue.

Overall, 25 visits to chemical SMEs were organised from July 2010 until February 2011 which represented a wide range of production profiles: fertilizers, plastics, explosives,

pharmaceuticals, chemicals, windscreen washers, sodium glass, petroleum chemistry, , distribution of chemicals, silicones, and paints.

Figure H: locations of chemical SMEs participating in the Roll- out Campaign

Source: PCCI

9.3.2.

Results

Each visit to chemical sites started with an introductory meeting in which the plant management and the chief engineers took part. KAPE organised a walk through main plant installations whereby energy flows were identified and the points of generation, distribution and final consumption of energy analysed.

The site visits showed that each Polish SME differs significantly in terms of energy efficiency awareness. The visits also illustrated that, in general, no overall concrete energy strategy exists. This phenomenon is linked to a lack of energy monitoring systems or only weakly developed ones being in place. In most cases, staff is not used to paying attention to energy savings, but instead keeps most of their focus on production. Finally, plant managers tend to have only basic knowledge on percentage of total share of energy costs as well as operational costs and final product energy intensity indices.

Overall energy savings potential, however, hovers around 10-15 per cent and may be reasonably achieved in the majority of audited SMEs with technical and management actions.

(24)

9.4.

European level

The internationalisation phase of CARE+ officially started with a kick-off event during the European Sustainable Energy Week in spring 2010. Here, we invited representatives of the European Commission, the International Energy Agency (IEA) and the European Association of Craft, Small and Medium-Sized Enterprises (UAPME) to discuss with us different approaches to encourage SMEs to tackle energy efficiency and to present the CARE+ project.

In parallel, we began building upon the chemical industry’s Responsible Care initiative. The strong European and global network in place through Responsible Care was an important channel to spread the idea of CARE+ within the chemicals sector throughout the globe.

The development of the Cefic website and the publication of articles, for instance, about a case of successful implementation of CARE+ in Poland , significantly helped increase awareness of CARE+ and how it helps SMEs and larger companies to tap into their energy efficiency potential. Furthermore, the presentation of the project in events such as Green Week 2011 reached out to an even broader, non-chemicals sector-specific audience.

The successful kick-off was followed by several presentations at events at national and European level. Presentations were given, for example, at the Responsible Care Annual Conferences in 2009 and 2010, IEE Info Day 2011, Green Week 2011, and the ECRN General Assembly 2011. In addition, Cefic had organised in early 2011 an Energy Efficiency Workshop at which, as one of the highlights of the event, the first results of CARE+ were presented. In parallel, bilateral meetings with the respective national associations and in some cases local authorities started, which turned out to be essential part of the process to win new partners. The lesson learned is that both in-person meeting and web-based communications are effective and necessary ways to reach out to members and stakeholders to continue and deepen the dialogue.

10.

Next steps

CARE+ is proven as a route to improve energy efficiency for chemicals SMEs. The tools are now available on the Cefic website for free in English, Bulgarian, Polish and Italian.

More countries, such as Finland, Belgium and the United Kingdom have agreed to integrate CARE+ into their national approaches whereas intense evaluations have started with others, namely the Netherlands, Germany and the Czech Republic. In parallel with current activities under way, ideas are being developed to disseminate the tools by setting up as many as three regional “mini” pilot projects, in collaboration the European Chemical Regional Network (ECRN). Ideas are being developed during the ongoing dissemination process on how CARE+ can be best continued, with the plan to apply for phase II in the next IEE call in 2012.

Figure

Updating...

Related subjects :