Gavin Puckle at Sustainability Conference 2015, NCPC

1. The Biggest Loser - Industrial Energy
Efficiency Case Studies
July 21st 2015
Gavin Puckle
Engineering Manager
Johnson Matthey – South Africa

2. Confidential 1
Johnson Matthey
• A speciality chemicals company and a world leader in advanced
materials technology
• Origins date back to 1817, floated 1942, FTSE 100 company since
June 2002
• £5.9 billion revenue
• Operations in over 34 countries with 10,000 employees
• 5 Different divisions – Emissions Control Technology
• 14 ECT Manufacturing sites around the globe

3. Confidential 2
Energy Management
What do we do?
Nitrous
Oxide
Carbon
Monoxide
Hydro
Carbons
Water
Nitrogen
Carbon
Dioxide
ENERGY

4. Confidential 3
Energy Management
Implementation/challenges
TIME LINE
2
0
1
1
Poorrecords
Can’tqualifyandquantify
savings
ISO50001Implementation
Measurementchallenge
Behaviourchallenge
TeamCompositionchallenge
ISO50001almost
implemented
R7.7MilSavings
ISO50001Certification
ISO50001Surveillanceaudit
Savingstodate>R15Mil
Newprojects
Sustainperformance
2
0
1
2
2013
2
0
1
4
2
0
1
5
2
0
1
?

5. Confidential 4
Energy Management
• Cost of electricity supply in SA
• Produce more product with less energy
• JM Global sustainability initiative (MJ / LCP)
What is driving the energy initiative at JMSA
0
2 000 000
4 000 000
6 000 000
8 000 000
10 000 000
12 000 000
14 000 000
16 000 000
18 000 000
20 000 000
0
10000000
20000000
30000000
40000000
50000000
60000000
70000000
2011-12 2012-13 2013-14 2014-15
ProductionVolumesinLCP
CostsinRand&energyinkWh
Electrical Energy Cost / kWh
cost (Rand) energy (kWh) Production Vol. LCP

6. Confidential 5
Energy Management
Power x hours ÷ Litres of catalyst produced (LCP)
Awareness and understanding your KPI
Reduce
installed
capacity /
Optimizati
on
Reduce
time
equipment
runs
Increase the
speed that
we run at
Get one right, you make progress.
Get two right, you are good!
Get three right and we will fly!!
ENERGY EFFICIENT USE THEREOF

7. Confidential 6
Energy Management
Know your Significant Energy Users

8. Confidential 7
Energy Management
Measuring and monitoring – What you measure is important
0
200
400
600
800
1000
1200
Apr2013-Mar2014
Apr2014-Mar2015
YTD(Apr2015-
Mar2016)
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
GENERAL USERS POWER OUTPUTS CHART
Power (KW) Power Target
0
50
100
150
200
250
300
350
Apr2013-Mar2014
Apr2014-Mar2015
YTD(Apr2015-Mar2016)
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
TOWER MCC POWER OUTPUTS CHART
Power (KW) Power Target
0
20
40
60
80
100
120
140
160
Apr2013-Mar2014
Apr2014-Mar2015
YTD(Apr2015-
Mar2016)
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
ADMIN BUILDING POWER OUTPUTS CHART
Power (KW) Power Target
0
100
200
300
400
500
600
700
Apr2013-Mar2014
Apr2014-Mar2015
YTD(Apr2015-Mar2016)
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
UTILITIES POWER OUTPUTS CHART
Power (KW) Power Target

9. Confidential 8
Energy Management
Start the cycle again - PDCA
Plan
Do
Check
Act

10. Confidential 9
Energy Management
Lessons learned
• Systematic approach is important
• Focus on functional requirements of equipment (Gap)
• Team Composition
• Awareness for the “User”
• All hands on deck

11. Confidential 10
Energy Management
• Attitude is king
• Awareness and knowledge is the key
• If you don’t know about potential saving opportunities
– you wont look for them
• If you don’t look for savings, you won’t find them
• If you don’t care – the savings will not happen.
Conclusion

12. Confidential 11
Energy Management
Questions