Manufacturing the future
MANUFACTURING THE FUTURE
Working hard to develop innovative, sustainable solutions to current and future challenges. INEOS gives high priority to manufacturing processes optimisation and efficiency.
Waste 75% of Greater Manchester’s waste is diverted to our Runcorn plant
Energy Savings 18% 10 years of energy savings at Runcorn = 250,000 tones a year of CO2
Consumption More than 50% reducing in water consumption and waste in Decatur, Alabama
Energy Demand 47% lower primary energy demand for the VinyLoop process
Operation Clean Sweep ZERO pellet, flake or powder loss – Operation Clean Sweep
EXAMPLES OF INNOVATION successes to date include our patented process for the production of acrylonitrile, which is essential for the world’s carbon fibre, our proprietary membrane cell technology for the production of chlorine, our co-investment in combined heat and power (CHP) production at our major manufacturing sites, and our initiatives to create sustainable PVC.
Through actions such as energy efficiency projects, process integration, business clusters (Antwerp, Köln, Lavéra and Stenungsund) and new developments in cleaner technologies such as clean catalysts, we create the right environment for innovation.
Our Research and Technology centres in various locations around the world are key to the development of our technology and process innovations. Not only are these new solutions essential within our own activities but by working with our customers and providing technical service at a process and product level, we ensure that new developments are implemented safely, to the full extent of their capacity.
THE FUTURE OF LOGISTICS
OUR SUPPLY CHAIN logistics know that the most environmentally friendly mode of transport is nearly always also the most cost effective. Furthermore, the most carbon efficient mode of transport for us also reduces risks from a health and safety perspective. At INEOS we focus on driving down both the cost and the environmental impact of transportation, while maintaining our high quality and safety standards.
The most efficient means of transporting commodity chemicals is to avoid transportation in the first place. Where we can, INEOS will negotiate product “swaps” with other production units of the same commodity closer to a customer to avoid transportation altogether. This can be between our own sites or other suppliers. If this is not possible the next best option is via a pipeline.
Our businesses generally encourage customers to co-locate on the same industrial site or at locations that are connected. This approach means that we can deliver product directly via pipeline. Our next preferred option is to use a ship or barge, then rail and finally road. As part of our work with our transport providers we also strongly advocate training for drivers on fuel-efficient driving.
Cross-business supply chain network
Through our cross-business supply chain network, managers meet regularly to share best practice including how to make the most of low carbon logistics. In addition, all our suppliers are required, through our contractual arrangement with them, to be most efficient in providing a service on our behalf. With large tenders we aim to leverage the size of the contract to drive further fuel and cost efficiencies. This mindset together with efficient transport planning helps us to maintain safety, drive cost down and improve carbon savings across our supply chain.
REDUCING ENERGY CONSUMPTION
SAVING ENERGY has always been a fundamental part of how we operate at INEOS because it makes good business sense. Climate change considerations and legislation in some of our operating countries mean we are also committed to meeting strict targets for CO2 emissions. Our strategy is to first reduce our own energy use as much as possible, then recover and reuse most of the waste energy and last but not least use the lowest carbon sources for energy and feedstock as is feasible.
This approach is illustrated at our Runcorn site in the north of England. By investing in infrastructure and new process technology, the Runcorn plant has been optimised to run in the most energy efficient way possible. Initiatives implemented over the last few years include energy monitoring systems with meters that allow managers to have instant access to real-time data on energy use. The site has also installed high efficiency motors, it has built a new steam plant and invested in a new centralised control room with a cross-site process automation system.
Overall, these changes have led to energy savings in the last ten years of nearly 18% and annual CO2 savings of around 250,000 tonnes per year.
We have invested more than £400 million in new chlorine cellrooms at Runcorn, which use the latest membrane technology. This technology removes the need for mercury in the process and delivers primary energy savings compared to the older mercury cell technology.
Having reduced energy consumption at our Runcorn site we have built what will be the largest energy from waste Combined Heat and Power (CHP) plant in the UK. This new plant will use Solid Recovered Fuel (SRF) from municipal waste. Ultimately the plant will produce 70 MW of electricity and 50 MW of steam heat, which will mean that up to 20% of the Runcorn site’s total energy use will come from renewable sources.
CHP, IMPROVED EFFICIENCY FROM HOUSEHOLD WASTE
STRATEGICALLY LOCATED near to Liverpool, Cheshire and Greater Manchester, the Energy from Waste Combined Heat and Power plant at our Runcorn site, provides efficient energy provision for those located nearby.
With a total capacity to treat 750 ktpa of solid recovered fuel and to produce 83 MW of electricity and 51.2 MW of heat by steam export per year the benefits derived from the plant are huge.
The facility supplies the neighbouring INEOS chemicals manufacturing facility with up to 20% of its total energy needs. It allows users to reduce the reliance on fossil fuels, therefore replacing substantial amounts of it. It helps divert more than 75% of Greater Manchester’s waste from landfill. It presents a more sustainable way of waste disposal than landfills, which produce and emit a lot of GHG. With a well-regulated flue gas treatment system, emissions do not pose a threat to public health and the environment.