Energy and emissions

Energy management

For us, saving energy is an important contribution to environmental protection and therefore influences the corporate decisions. For that reason, for example, we have established an internal energy management system at the headquarters in Munich. This ensures that energy consumption is continuously analyzed and energy-saving projects are implemented. New projects are integrated into a structural plan and are documented in an energy catalog as what are called preliminary projects. The individual preliminary projects are prioritized and their measures are implemented in a timely manner in accordance with cost-effective and energy-saving aspects. The fields of activity here extend, for example, from isolated cases of reducing consumption, to more comprehensive production adjustments and renovation, to completely replacing energy and supply systems.

Another efficient option for reducing our energy consumption is found in preventing or reducing load peaks in the (production-related) power consumption. We record the consumption data in detail using an energy tool in the Building Automation System (BAS); the data is subject to both daytime and weekday fluctuations. Following an analysis, we adjust our production processes to achieve more uniform and more cost-effective utilization of the systems.

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Energy audits

How we benefit from an outside perspective of our energy management systems

Independent energy audits ensure that we comply with valid legal requirements. At the same time, we are also able to achieve improvements in energy efficiency and reduce our energy consumption.

External energy audits were carried out in our European plants in 2015 in accordance with DIN EN 16247. This is how we ensure compliance with the applicable legal requirements of the German power and energy control law. In addition, independent checks identify further areas of potential for improving energy efficiency and reducing energy consumption.

Furthermore, all operational locations are checked internally every one to two years with regard to environmental protection, operating safety and energy-saving criteria.

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Energy consumption

The principal energy sources at our Munich plant

The energy sources used at the Munich plant are electricity, natural gas, technical gases and diesel. Despite energy savings measures already having been implemented, we still see potential for further savings – a topic that will continue occupying us in the years ahead.

The locations of KraussMaffei Technologies GmbH drew a total of about 55 million kWh of energy from various sources. The Munich location is the largest consumer with 52.8 million kWh (95 percent). In the following we present primarily the key performance indicators and measures of this location, because this is where we see the greatest savings potential.

The energy sources used at the Munich location are electricity, natural gas, technical gases and diesel. In 2014 the largest consumption percentages were for natural gas with 29.5 million kWh (56 percent) and electricity with 22.6 million kWh (43 percent). Most of the natural gas is used for producing district heating. The electricity consumption is one of the largest cost drivers of the energy costs (73 percent).

The largest energy sources for electricity at the Munich location in 2014 were the production systems with 11.2 million kWh (54 percent), the conversion systems with 5.9 million kWh (29 percent), with which, for example, district heating is gained from gas, and the lighting for the offices and production halls with 2.8 million kWh (13 percent).

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Energy conservation measures and emissions

How we use modern systems to optimize our energy consumption and our CO2 footprint

We are continually working on reducing our energy consumption. At our Munich plant, we have implemented a number of major projects since 2014 which have made a positive impact in recent years. Further measures have already been kicked off or are being planned for the years ahead.

In recent years, we have already implemented many measures to reduce energy consumption at the Munich location. As part of this, one of the largest projects of 2014 was modernizing the production hall lighting and light control system. For this project, we replaced 1,500 mercury vapor lamps (high-pressure lights) with 1,000 LED overhead and side lights with integrated daylight and presence sensor technology. The intelligently controlled LED technology records movement patterns or daylight intensity, for example, and adjusts the illuminance automatically.

Not only does the company benefit from these measures by saving electricity costs, but employees also enjoy improved light quality and increased work safety. At the same time, CO2 emissions went down by almost 2,000 tons per year. The project was also nominated for the Handelsblatt Energy Award in 2016 for the "Industry" sector due its successful implementation.

Other extensive energy conservation measures that have already been implemented include, for instance, reinforcing the roof insulation and installing new roof hatches in all Munich production halls, a direct digital control system that connects to the building automation system for heating, ventilation, lighting and electrical generation, as well as new well pumps and controls. The ventilation system was equipped with energy-saving motors and cross-flow heat exchangers for heat recovery and a gradual replacement of the windows for better heat insulation has been initiated. In total, more than 700,000 euros have been invested in these energy-saving measures.

Additional projects are planned for the future. For one, energy consumption can be lowered further by purchasing new forced air compressors, which can be aided further through a deliberate approach and adaptation of the application parameters. In another project, we intend to modernize the ventilation system and the control system of the cafeteria.

In 2017, we hope to make a larger purchase and change the district heat supply in Munich over from the four current boilers, which are heated with gas and heating oil, to a block-type thermal power station (BTTP) with an electrical and thermal capacity of 1,000 kWh. In addition to heat, electricity is generated simultaneously in a BTTP. By using energy to generate electricity and heat, utilization rates of more than 90 percent can be reached. At the same time, a BTTP is preferably operated at the site of heat consumption. Due to the short distance, hardly any energy is lost and efficiency increases. We expect a reduction of CO2 emissions of 4,000 tons in a year thanks to the commissioning of the BTTP.

The figures for electricity and gas consumption since 2010 show us that we are on the right path with the conservation measures carried out in recent years. It is because of this that gas consumption could be reduced by more than half at all locations of the GmbH (KMT) from 2010 (86 million kWh) to 2015 (35 million kWh). Power consumption was reduced by about 9.6 million kWh from 2010 to 2015.

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