COLUMBUS, Ohio--The American Chemical Council (ACC) has recognized several U.S.-based Hexion Inc. (“Hexion” or the “Company”) sites for sustainability programs focused on improving energy efficiency and waste management as six Hexion programs were recently named Responsible Care® award winners honored for excellence in environmental, health, safety and security performance. In addition, Hexion was nominated as a finalist for Responsible Care® Company of the Year.
“This is a tremendous honor and a testament to the great work happening across the Hexion organization,” said Craig O. Morrison, Chairman, President and CEO, Hexion. “As an organization, we are enthusiastic supporters of Responsible Care and are committed to best practices related to sustainability and safety in the U.S. and at our facilities around the globe.”
The ACC honored four Hexion programs in the Energy Efficiency category and two in Waste Minimization, Reuse and Recycling. The sites and programs honored are:
- Fayetteville, North Carolina: Energy consumption at the Fayetteville formaldehyde plant increased 60 percent in 2014 without a corresponding increase in production. An internal evaluation found a new product mix was requiring additional steam for production. The team devised a solution that included distillation improvements at a second Hexion site, allowing the new mix to be handled there without increasing energy consumption. This production shift resulted in a 50 percent reduction in energy consumption at Fayetteville with no increase at the second site.
- Moreau, New York: The team identified an opportunity to significantly reduce consumption by shifting from two plants operating five days a week, 24 hours a day, to a single plant operating seven days a week around the clock. The shift reduced the need for natural gas for steam production, cutting natural gas use by 51 percent year over year. It also reduced electrical consumption for approximately 700 horsepower of process equipment, improved cooling water efficiency and reduced outside services for security and maintenance. The site added new operators to execute the revised operating schedule.
- Sheboygan, Wisconsin: The Sheboygan site replaced two aging cooling towers – representing 26 percent of total electric usage – with a single replacement tower engineered with significant energy efficiency upgrades. Intelligent controls paired with variable frequency drives on all the motors in the tower yielded a 21.1 percent reduction in cooling tower electric usage on a normalized basis and reduced total site consumption by 6 percent.
- Bedford Park, Illinois (Argo): The site converted high-pressure sodium lights in the process area to 68W LED lights and converted metal halide lights in the warehouse to 78W LED lights, reducing total energy consumption in those areas from 242.4 million kilowatt-hours (MkWh) in 2016 to an estimated 79.7 MkWh in 2017. This is an annual reduction of approximately 67 percent, or approximately 162.7 MkWh, and could result in savings of more than $16 million year over year.
Waste Minimization, Reuse and Recycling
- Deer Park, Texas: The Deer Park team used a combination of hardware and software upgrades and improved employee training to significantly reduce the creation of undesired byproducts in its production processes. The improvements reduced waste by 400,000 pounds in 2016, resulting in a savings of about $400,000. Just as importantly, the project created more ownership from the ground floor in thinking and acting to minimize waste production and helped reduce operational complexity and the potential for mistakes.
- Deer Park, Texas: The Deer Park team implemented several process improvements designed to reduce the 41,000 pounds of disposed crude resin the site produced per month. From the end of 2015 through 2016, crude resin disposals were completely eliminated. This created significant savings related to disposal as well as material costs as the recycled resin was put to use. The improvements required no new equipment or capital costs; rather, the key was creating better operating procedures and improving employee accountability.
The International Council of Chemical Associations (ICCA) coordinates the Responsible Care program, which originated in Canada in 1984 and is practiced today under the oversight of 60 national and regional associations around the world. Responsible Care companies operating in the U.S. have a worker safety rate five times better than the U.S. manufacturing sector as a whole, and three times better than the overall business of chemistry.
In addition, 43 sites within Hexion’s global manufacturing network have achieved ISO9001 certification (Quality Management System) and another 12 sites have achieved ISO 14001 certification (Environmental Management System). The Company also has 7 sites that have earned OHSAS 18001 certification (Health and Safety Management System). In total, Hexion sites have achieved 80 safety, quality and energy management designations globally.
About the Company
Based in Columbus, Ohio, Hexion Inc. (formerly known as Momentive Specialty Chemicals Inc.) is a global leader in thermoset resins. Hexion Inc. serves the global wood and industrial markets through a broad range of thermoset technologies, specialty products and technical support for customers in a diverse range of applications and industries. Hexion Inc. is controlled by investment funds affiliated with Apollo Global Management, LLC. Additional information about Hexion Inc. and its products is available at www.hexion.com.