- What is the distribution of your energy sources (e.g. % of natural gas, electricity, nuclear power, coal usage etc.)?
- What is the percentage of total energy consumption for major operations (e.g. transportation, production process, pollution control, waste treatment, office, or by business Segments)?
- How does your company incorporate energy efficiency into overall business planning? (e.g. strategic planning, resource allocation, department/ group dedicated to improve process/ energy efficiency)?
- What were your energy consumption and your total expenditures on energy in 2007?
- How energy efficient are your production processes?
- Please describe your energy management system and activities.
- A central Headquarters function exists for benchmarking, supporting and auditing the energy performance of each facility. How are these energy initiatives incorporated with sector initiatives?
- Are these energy initiatives and management programs consistently applied throughout the company (e.g. EU standards vs. U.S. standards)?
- How does your company plan to achieve these goals and targets? Please give specific examples – past, present and future projects.
- How do you work with government and other agencies to promote energy efficiency within sectors or to develop new energy efficiency programs and policies?
- How significant does energy efficiency affect the overall financial performance of your company?
- What were Ciba's global CO2 emissions in 2007 and what is the company's contribution to combatting global warming?
What is you distribution of energy source (e.g. % of natural gas, electricity, nuclear power, coal usage etc.)?
Calculated back into primary energy, i.e. the energy used to generate the utilities consumed on our sites, the percentages consumed were as follows:
| Energy | 2003 | 2004 | 2005 | 2006 | 2007 |
| Natural Gas | 43.6% | 42.5% | 40.4% | 40.9% | 39.2% |
| Liquid Fuels | 2.3% | 2.2% | 2.9% | 2.8% | 1.9% |
| Electricity | 35.1% | 35.1% | 34.1% | 33.1% | 35.9% |
| Steam from third parties* | 12.6% | 13.6% | 14.7% | 14.0% | 15.1% |
| Wastes & renewables | 2.7% | 3.1% | 3.4% | 4.5% | 5.3% |
* including steam from waste
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What is the percentage of total energy consumption for major operations (e.g. transportation, production process, pollution control, waste treatment, office, or by business Segments)?
We have no breakdown according to the above criteria. The energy requirements for each production process are included in our product recipes and hence in the production costs. Thus the energy intensity is visible.
In our production sites, the energy consumption in the offices and laboratories amounts to about 8 to 10% of the total consumption. In our Headquarters in Basel, offices and laboratories consume about 75% of the energy used.
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How does your company incorporate energy efficiency into overall business planning? (e.g. strategic planning, resource allocation, department/ group dedicated to improve process/ energy efficiency)?
Energy has become one of the most significant cost blocks of production, and energy saving forms an integral element of business targets, as well as being one of the 5 eco-efficiency indicators published on this website. We have also set a target to increase the proportion of alternative energy sources from 5% to 15% between 2006 and 2010 and the first projects towards achieving this target will become fully operational in 2008. In addition, all major new investments are challenged on energy efficiency, and key personnel have responsibility for reducing energy consumption at each production site.
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What were your energy consumption and your total expenditures on energy in 2003?
Calculated back into primary energy, our energy consumption and costs were:
- 15'756 TJ
- CHF 212 million (excluding water)
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How energy efficient are your production processes?
Since at least 50% of our energy is not directly related to production processes, we also give priority to reducing our “base load” in factory infrastructure, as well as improving the efficiency of utilities generation.
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Please describe your energy management system and activities.
Our Energy Policy is available on the Internet.
In the three-year period 2003 to 2006 we reduced our overall energy consumption by 13% despite a substantial increase in production.
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A central Headquarters function exists for benchmarking, supporting and auditing the energy performance of each facility. How are these energy initiatives incorporated with sector initiatives?
Company-wide energy targets are approved by the Executive Committee, which includes the Heads of our business Segments. The Segments are responsible for the production facilities; they set individual targets for each production site.
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Are these energy initiatives and management programs consistently applied throughout the company (e.g. EU standards vs. U.S. standards)?
Energy targets are applicable worldwide and the methods of achieving them are exchanged and coordinated through a network of production site contacts.
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How does your company plan to achieve these goals and targets? Please give specific examples – past, present and future projects.
Current initiatives include: optimizing internal re-use of waste solvent as fuel; heat recovery in production, especially steam condensate; purchase of the most energy-efficient equipment (E-Labels); improved utilities generation efficiency; computer-aided simulation and optimization of continuous processes; optimization of energy efficiency during process development; studies in collaboration with local universities (doctorates); regional exchange of case studies and success stories; extended use of existing on-line utility management tools; thermo graphic and ultrasonic surveys for energy loss prevention; technical training for administrators of offices and laboratories with optimization projects where appropriat. Specific examples include:
- Application of new technology for burning lightly-contaminated liquid wastes in standard steam boilers: some production sites have more than doubled quantities
- Purchase of low-energy refrigerators, laboratory equipment and copiers, according to energy labels and published energy ratings
- Installation of new boiler level controls to improve utilization levels, and eliminate need for standby heat
- Pooling of utility generation plants with neighbouring companies to increase overall utilization and generating efficiency.
- On-line availability of key energy data for production line managers in production sites with existing energy management systems in Switzerland, Italy, Germany, France and the U.S. Better interpretation and visualization of existing data.
- Replacement of refrigeration equipment which resulted in >20% increase in the refrigeration efficiency
- Savings of 23% steam consumption in 2001 in a major distillation unit by use of Aspen computer simulations to optimize usage. No investment was needed.
- Three Doctorate studies, between 1997 and 2005 modelled patterns of heat, electricity and water consumption in batch production processes
- Regional groups to exchange information and success stories in Central Europe, the U.K. and the U.S.
- Established European and U.S. centers of competence for thermographic surveys
- Use of timber-gasification technology to replace natural gas with clean renewable energy
- Introduction of less energy-intensive production processes
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How do you work with government and other agencies to promote energy efficiency within sectors or to develop new energy efficiency programs and policies?
We have worked in the past on such government initiatives, but are currently concentrating on climate change issues. We regularly respond to government questionnaires, but believe that participation in the chemical industry’s Responsible Care® program is the best method of promoting our success in all aspects of our operations.
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How significant does energy efficiency affect the overall financial performance of your company?
Our energy cost is less than 5% of sales, but over 80% of utility costs are "cash out", so savings contribute directly to net income.
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What were Ciba's global CO2 emissions in 2007 and what is the company's contribution to combatting global warming?
Compared to manufacturers of bulk chemicals, Ciba is not energy- intensive and our global direct CO2 emissions from our 54 production sites were less than 400'000 tonnes in 2007. Considering also our indirect CO2 emissions, e.g. from consumption of electricity from the grid, we increased our production output from 2006 to 2007 by 8% without increasing our CO2 emissions. Further reductions will result from increased use of alternative energy sources. Ciba has many products which make a contribution to limiting global warming.
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