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Marten Jansen van Rensburg

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Marten Jansen van Rensburg

  1. 1. 15 September 2017  Regional Risk services and Energy Manager  Merten Jansen van Rensburg  Sappi Southern Africa The Sappi sustainability journey delivering on strategy 2017 Vision 2020 intentional evolution next phase growth 1
  2. 2. Through the power of One Sappi — committed to collaborating and partnering with stakeholders — we aim to be a trusted and sustainable organisation with an exciting future in woodfibre. Our mission 2 Through the power of One Sappi — committed to collaborating and partnering with stakeholders — we aim to be a trusted and sustainable organisation with an exciting future in woodfibre.
  3. 3. Our 2020Vision 3 2020Vision Sappi will be a diversified woodfibre group targeting a substantial increase in EBITDA through an expanded product portfolio with increased margins, providing enhanced rewards to all its stakeholders 25% Graphic papers of EBITDA Packaging and specialities of EBITDA 25% of EBITDA Specialised cellulose 40% of EBITDA New business opportunities 10% Substantially increased group EBITDA
  4. 4. Our 2020Vision 4 Sappi will be a diversified woodfibre group targeting a substantial increase in EBITDA through an expanded product portfolio with increased margins, providing enhanced rewards to all its stakeholders.
  5. 5. Sappi’s 3 P’s 5 Markets Innovation Cost Safety and Health Education and skills Communities Raw materials Water Energy Environment Prosperity People Planet
  6. 6. Move to sustainability Prosperity  Move from “the word for fine paper” to “inspired by life” People  Looking after ourselves  Looking after our own  Looking after others Planet  Environment  Resources 6
  7. 7. A Business about timber 7 Water Cellulose Lignin Roots Branches Leaves Sawdust Bark
  8. 8. Energy Pillars – Security of supply Strategy 8 Based on 3 pillars: • Energy generation • Maximise energy generation from our turbines • Maximise exports into Eskom grid • Minimise imports from Eskom grid • Time of use(TOU) • Effective utilization of energy/power during peak, standard and off peak periods • Energy efficiency • Use the concept of “getting more from less” • Maximise renewable energy sources
  9. 9. 9
  10. 10. Energy policy 10
  11. 11. Energy Plan 11 • Developed in line with the energy pillars per section • Regularly reviewed and updated in line with continual improvement • Subscribe to the group energy policy and Sustainability Charter • Subscribe to ISO 50 001 standards and recommended good practice • Target to achieve ISO 50 001 accreditation in FY2017 • Initially stage 1 certification followed by stage 2 • Supports the mill and regional business strategy and PIP’s • Objectives and targets using FY2014 as baseline as follows as per Sustainability Charter: • Reduce SPFE by 10% by end FY2020 • Reduce STE by 5% by end FY2020
  12. 12. Energy Management Progress Progress • Energy Forum – Established an active, involved and cross functional team. • Energy baseline model established. • Energy projects – Implemented projects, new projects have been identified and quantified. Included in 5 year capex plan. • EnMS Spreadsheet – Populated monthly and reviewed for opportunities. • Energy data analyzed since 2014 for electricity and 2015 for steam. • Policy and energy awareness communication. • Use of Executive Summary to monitor energy. • Started using SAP Deviation for energy deviations. • Energy Awareness added to Induction Site Rules. 12
  13. 13. ISO 50001 – 3 Hurdles  Must use less energy than expected  Must be due to an intervention  Must not be at the cost of business 13
  14. 14. General Manager Energy Manager Process Engineering Mech. & Elec. Engineering Accounts Instrument & Systems Engineering Project Management HR (Communication and Training) Commercial (Co- opted) SHEQ Manager Energy Management Section Management • Energy use metered and allocated per process • Monitored and reported on daily • Financial review posted monthly • Monthly meeting to review performance and identify opportunities or remedial actions • Usage compared to budgeted BOMs and historical performance Energy Forum • Identify opportunities for improvement • Analyze energy trends • Focus on long term objectives • Develop strategies to reduce energy and/or energy cost • Develop project plans and initiatives to reduce usage or improve efficiency • Energy awareness • ISO 50001 - implementation • Identify training and awareness needs 14
  15. 15. Sustainability Targets 15 • Reduce SPFE by 10% by 2020 using 2014 as base • Reduce STE by 5% by 2020 using 2014 as base
  16. 16. Key Drivers – Energy by Source 16
  17. 17. 17
  18. 18. Key Drivers – Coal vs Renewable 18
  19. 19. Significant Energy Users 34% 16% 20% 7% 3% 20% 0% 5% 10% 15% 20% 25% 30% 35% 40% Paper Machine Tissue Machine Pulp Mill Essential Service (compressors, HVAC) Boilers Other - Non SEU % GJ of Overall Usage – Electricity - 2014 32% 20% 11% 25% 0% 5% 10% 15% 20% 25% 30% 35% Paper Machine Tissue Machine Pulp Mill Copeland and Evaporator % GJ of Overall Usage – Steam - 2015 19
  20. 20. Energy consumption driver Millwide Steam Energy Consumption vs. Driver - 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000 - 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 SteamEnergy(GJ) Production-Paper+Tissue+Pulp(tons) Production (Paper + Tissue + Pulp) Steam Energy Decommissioned coater machine 20
  21. 21. Energy models - Tugela 21
  22. 22. Energy models - Ngodwana 22
  23. 23. Energy models - Saiccor 23
  24. 24. Energy Performance Indicators 24 0.40 0.60 0.80 1.00 1.20 1.40 1.60 Oct-15 Dec-15 Feb-16 Apr-16 Jun-16 Aug-16 Oct-16 Dec-16 Feb-17 Apr-17 Jun-17 EnPC(EII) y = 6.1849x + 42601 R² = 0.8498 - 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 - 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 Steam Energy dependence on mill production - FY 2015 Steam Energy (GJ) Linear (Steam Energy (GJ)) -80,000 -60,000 -40,000 -20,000 0 20,000 40,000 60,000 80,000 100,000 Oct-15 Dec-15 Feb-16 Apr-16 Jun-16 Aug-16 Oct-16 Dec-16 Feb-17 Apr-17 Jun-17 SteamEnergy[GJ]
  25. 25. Energy consumption driver Millwide Electrical Energy Consumption vs. Driver - 10,000 20,000 30,000 40,000 50,000 60,000 0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 ElectricalEnergy(GJ) Production-Paper+Tissue+Pulp(tons) Production (Paper + Tissue + Pulp) Electrical Energy 25 Decommissioned Finishing house machines Commissioned will cutter
  26. 26. y = 3.42x + 2440 R² = 0.8584 - 10,000 20,000 30,000 40,000 50,000 60,000 0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 ElectricalEnergy(GJ) Electrical Energy dependence on mill production – FY 2014 Electrical Energy (GJ) Linear (Electrical Energy (GJ)) Energy Performance Indicators 26 0.40 0.60 0.80 1.00 1.20 1.40 1.60 Oct-14 Dec-14 Feb-15 Apr-15 Jun-15 Aug-15 Oct-15 Dec-15 Feb-16 Apr-16 Jun-16 Aug-16 Oct-16 Dec-16 Feb-17 Apr-17 Jun-17 EnPC(EII) -160,000 -140,000 -120,000 -100,000 -80,000 -60,000 -40,000 -20,000 - Oct-14 Dec-14 Feb-15 Apr-15 Jun-15 Aug-15 Oct-15 Dec-15 Feb-16 Apr-16 Jun-16 Aug-16 Oct-16 Dec-16 Feb-17 Apr-17 Jun-17 Aug-17 ElectricalEnergy[GJ]
  27. 27. Energy Savings – Projects Completed ID Description of Opportunity SEU Service 1 Install energy efficient lighting - DSM lighting Millwide Electricity 2 Switch off speedflow IR dryers that is not required Paper Machine Electricity 3 Switch of deflaker when not in use Paper Machine Electricity 4 Install drive in Process water Plant intake pumps Utilities Electricity 5 Install drive on the Effluent booster Pump Tissue Electricity 6 Install drive on tertiary cleaner pump P425 - Pulp Mill Pulp Mill Electricity 7 Install drive on boiler ID and FD fans Utilities Electricity 8 No. 4 compressor Upgrade Utilities Electricity 9 No. 2 compressor Upgrade Utilities Electricity 10 Upgrade of cleaners in the Tissue Machine Tissue Machine Electricity 11 Lagging and cladding of steam lines - Millwide Millwide Steam 12 Upgrade of P102 Paper Machine Electrical More Information available - See ER8 of EnMS Spreadsheet 27
  28. 28. Energy Savings – Projects in Progress 28 ID Task SEU Service 1 Upgrade of IR dryers Paper Machine Electricity 2 Upgrade of Hardwood refiners Paper Machine Electricity 3 Upgrade of Mixed stock refiner Paper Machine Electricity 4 Energy efficient lighting - Phase 1 Milwide Electricity 5 Tissue Machine - Fan Pump drive motor installation Tissue Electricity 6 Decommission of Transfer Chest Pulp Mill Electricity 7 Heat Recovery - Steam Loss - Phase 1 Milwide Steam 8 Gravity feed process water from the clarifier to process plant Water Electricity 9 Switching off non critical items during demand Peak periods Paper Electricity More Information available - See ER8.1 - EnMS Spreadsheet
  29. 29. Continual Energy Improvement o Mill wide - Steam reduction projects for all plants o Use of Executive Summary to monitor energy usage (Steam and Electricity) o Energy awareness communication o Strong implementation of Energy efficient projects o More effective use of SAP Deviations for energy usages. o EnMS Spreadsheet - Populated monthly and reviewed for opportunities 29
  30. 30.  Know your business  Know where your energy is going  Know your products  Understand what “Less than expected” means  Adjust your baseline  Register and track all ideas and project  “This is the boss speaking” 30 Lessons learned
  31. 31.  Equipment specific savings  Fans  Pumps  Steam  …  Bio fuels  New technologies (Turbo blowers vs Vacuum pumps)  Cross industrial co-operation 31 Untapped opportunities
  32. 32. Benefits? 32
  33. 33. Special thanks to Alf Hartzenburg, the NCPC team and Wendy da Cruz for taking this journey with us “In this journey I have not learned much but I have learned to put the knowledge that I have into the right context” 33
  34. 34. 34 Be careful out there!

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