ATC140313: Report of the Portfolio Committee on Energy on its oversight visit to energy efficiency projects in the Cape Town area on 21st June 2012, dated 12 March 2014
The Portfolio Committee on
Energy, having undertaken an oversight visit to various energy efficiency
projects, report as follows:
Purpose of the report
The purpose of this report is to
report back to the National Assembly on the findings of the PC on Energys
study tour to various energy efficiency projects in the Cape Town area.
Worldwide, nations are beginning to face up to the challenge of
sustainable energy in other words to alter the way that energy is utilised so
that social, environmental and economic aims of sustainable development are
South Africa is a developing nation with significant heavy industry, which
is by its nature energy intensive. This energy intensive economy largely relies
on indigenous coal reserves for its driving force. At first sight there would
appear to be an apparent paradox between using less energy and developing a
healthy and prosperous nation based on energy intensive activities. This is not
the case. In recent years energy efficiency has significantly gained in stature
and has become recognised as one of the most cost effective ways of meeting the
demands of sustainable development.
The benefits of energy efficiency upon the environment are self-evident.
These benefits are of particular relevance, as South Africa remains one of the
highest emitters of the Greenhouse gas CO
per capita in the world.
At a local level the problems of SO
and smoke emissions have been
the focus of concern for many communities living adjacent to heavily
industrialised areas. Energy efficiency can address both the macroscopic and
microscopic aspects of atmospheric pollution.
The economic benefits of improving energy efficiency have been well
documented since the first Oil Crisis in the early 1970s. Many
forward-thinking industrial and commercial concerns have already adopted energy
efficiency as a key policy towards maximising profits. The national electricity
utility, Eskom, has itself embarked upon a Demand Side Management programme to
help reduce the requirements for investment in new power generation capacity.
Such positive contributions to both our physical and economic environments
will inevitably benefit our social well-being also; the alleviation of fuel
poverty, job creation, improvements to human health, better working conditions
- the list goes on. All of these factors will significantly contribute towards
the aims of sustainable social development.
It is for these reasons that South Africa needs an Energy Efficiency
Purpose of the oversight
The committee envisages
scheduling public hearings on energy efficiency, where stakeholders and
interested individuals will be invited to make written and oral presentations
to the committee.
The committee therefore
resolved to undertake a study tour on energy efficiency projects prior the
public hearings, in order to get a sense of what initiatives is being
undertaken and what challenges are being experienced.
The committee identified
several initiatives undertaken by the City of Cape Town, as well as initiatives
undertaken by business.
Plan of development
The report will firstly
describe the initiatives undertaken by the City of Cape Town and secondly those
undertaken by business.
City of Cape Town Energy Efficiency initiatives
Kuyasa Clean Development
Mechanism Pilot Project
The Kuyasa CDM Pilot Project involves the retrofitting of solar water
heater (SWHs), insulated ceilings and energy efficient lighting in over 2 300
low-cost homes in Khayelitsha, Cape Town. The project will see an immediate
impact on the social, health and economic well-being of the targeted
Kuyasa is South Africas first internationally registered Clean Development
Mechanism (CDM) project under the Kyoto Protocol on climate change and was the
first Gold Standard Project to be registered in the world. The project has
generated substantial interest locally and internationally as a pilot for the
energy-efficient adaptation of South African low-cost housing.
Kuyasa is a low-income community in Cape Town. The
particular area within Kuyasa comprises 2,300 low-income RDP households. The
Kuyasa Clean Development Mechanism (CDM) project was developed to address the
inefficient design of the houses, with a particular aim of improving the
quality of life of the Kuyasa residents and reducing the required monthly
expenditure on energy sources. The successful implementation of this project
required finance, buy-in and support from many different parties, notably the
UNFCCC, private sector, as well as national, provincial and local government.
The projects main interventions were the
installation of solar water heaters (SWHs), thermal insulating ceilings,
energy-efficient lighting and improved wiring. Some houses also received
hotboxes (thermal insulation cooking devices), which help to reduce the cost
of cooking. One of the projects key aims was to support local job creation and
skills development, and members of the community were trained and employed
through the project to install the various technologies; this resulted in over
65,000 person-days of labour
Figure 1: Solar Water Heater on one of the houses in Kuyasa
The Kuyasa project was developed by the nongovernmental organisation (NGO)
South South North (SSN) for the City of Cape Towns Environmental Resource
Management Department and Urban Renewal Programme. Ten pilot houses were
adapted in 2005, providing the practical data for an efficiency measuring
With funding from the Department of Environment and Tourism's (DEAT's),
Social Responsibility Programme and Provincial Governments Department of
Housing, the retrofitting of 2,300 houses in Kuyasa, Khayelitsha started in
August 2008 and was completed in October 2010.
members of Kuyasa have been involved from the initial stages, where they
have ownership of the project, i.e. there is community buy-in.
the community involvement there has been no vandalism or break-ins.
to retrofit the houses is around R10 000.
Chinese manufactured solar water heaters were used. Since its inception,
10 has already been replaced.
manufacturer could initially be found in SA, however the City found a
service provider who could manufacture solar water heaters for R6 000 per
span of the Chinese solar water heaters (R3 500) is around 4 to 5 years
(the delegation was informed that these ones rust quickly as well),
whereas the locally produced solar water heaters (R6 000) life span is
around 20 years.
regard to replacing the units, the City does have a maintenance budget and
maintenance plan in place
hundred (100) people are currently employed by the project.
of participants have undergone training as plumbers at Northlink College
for between 2 3 months.
members trained have been accredited as certified plumbers by Eskom.
participants has found employment with the City of Cape Town
This project was the first in
South Africa to access the United Nations CDM and was the first in the
world to be registered as a Gold Standard project.
The Kuyasa project has been
the focus of much interest, both locally and internationally, and is a
good example of the potential that energy-efficiency projects have within
Of the 680 households
surveyed after the completion of the project, 148 had received hotboxes.
Of these households, 123 made use of the hotboxes, most commonly for
cooking samp and rice. The hotboxes are also used for cooking pap (maize),
meat and vegetables. The savings attributed to the hotbox vary
significantly, but those using it on a regular basis have positive
The survey conducted after
the installation of ceilings identified a significant drop in the
incidence of respiratory illnesses. 81% of households indicated that there
had been a decrease in the frequency of illnesses.
3.2. Manenburg Human Settlements Contact
What is a green building?
A green building is energy and resource
efficient and environmentally responsible, and incorporates design,
construction and operational practices that significantly reduce or eliminate
negative impacts on the environment and its occupants.
On a practical level, this involves the use
of design, materials and technology to reduce energy and resource consumption.
Green building measures include careful design to reduce heat loads, maximize
natural light and promote the circulation of fresh air; the use of energy-efficient
air-conditioning and lighting; the use of environmentally friendly, non-toxic
materials; the reduction of waste, and the use of recycled materials;
water-efficient plumbing fittings and water harvesting; the use of renewable
energy sources, and sensitivity to the environmental impact of the development.
3.2.2. Information on the centre
The Citys new Human Settlements contact
centre in Manenberg could be the first municipal building in the country to
receive a Green Star SA rating from the Green Building Council of South Africa.
To earn this prestigious rating, the design
team was asked to create a contact centre that would be sustainable from an
environmental, economic and socially responsible perspective. This meant
designing and building a structure that incorporated sustainable site
development, water saving, energy efficiency, material selection, indoor and
outdoor environmental quality and social connectivity.
There are only a handful of buildings that
carry a Green Star rating in South Africa. The contact centre provides
facilities for two departments, Existing Settlements and Revenue. It has a
public component of cash offices, meeting cubicles and waiting halls, and a
staff component of offices, meeting rooms and planted breakaway courtyards. At
the new offices, Manenberg residents can access the Citys service hotline;
make enquiries regarding the Housing database, tenancy matters, service and
rental accounts; pay municipal accounts and traffic fines; buy prepaid
electricity, and apply for services, rates rebates and indigent benefits.
The bar was set high. The team had to create
a green building in relatively uncharted construction territory within budget
and they had to factor in the challenge posed by its location in an area
notorious for gang activity. The building needed to be secure, yet
approachable, so the design strategy incorporated simple materials and blurred
the distinction between fence lines and building edges.
The public space in front of the buildings
public courtyard has been landscaped for the pleasure of the community. It
consists of lawn areas with shade trees and seats, and beds with indigenous,
locally indigenous and even endemic plants.
Over the next year, a building facilities
manager will monitor and report back on the effectiveness of the environmental
controls used in the centres construction, for later review by both the design
and construction team.
A proud highlight
for the City of Cape Town is that the building will be their first Green Star
rated building - a 4-Star Certified rating that recognises best practice in
the industry. It has been designed to be sustainable, economically and socially
responsible. Ecologically approved building material will be used. Maximum
water saving measures have been incorporated into the design - these will
ensure that 100% of rainwater falling onto the roofs will be recycled, and that
all waste water will be captured and recycled into the ablution facilities and
landscaping irrigation. 75% of the centres electricity usage will be harvested
from the sun and wind, with intelligent electrical systems and task lighting
allowing it to function efficiently, almost independent of the electricity
grid. The indoor office space has also been considered with a plentiful supply
of fresh air, natural light and landscaped courtyards.
The area on the southern and eastern side of the building will be publically accessible and will be landscaped with predominantly indigenous vegetation for the enjoyment of the community. The landscaping will include pathways, pedestrian lighting, bicycle lock-up facilities, seating and lawn areas with shade trees. Bio-retention ponds will form part of the landscaping and help to reduce the annual stormwater load.
seventy five (75) percent of the buildings energy usage will be harvested
from the sun and the wind
rainwater will be captured in collection tanks and recycled.
black water (sewage) treatment system has been implemented, to capture
wastewater and recycle it back into the ablution facilities, with a
portion redirected for landscape irrigation.
goal is zero water wastage, with minimum freshwater use.
sites bio-retention ponds will also reduce the stormwater pollutant load,
which helps meet the Citys sustainable drainage system objectives in
terms of its urban stormwater policy.
used in construction were selected for their eco-friendly content and
low-carbon footprint in manufacture and delivery; Forestry Stewardship
Council (FSC)-certified timber was specified, and recycled plastic bottles
were used as insulation material.
developers also reduced their cement content by substituting industrial
waste products, and a large percentage of all steel specified had to be
re-used or recycled
environmental quality has been enhanced by increasing fresh-air intake
significantly, inviting daylight into the workspace and incorporating
landscaped courtyards that will encourage staff productivity and improve
their general health and well-being.
people worked in the construction, landscaping, civil works and artwork.
3.3. Traffic Management Centre - Goodwood
The Traffic Management Centre (TMC) a
2010 FIFA World Cup project - will integrate
such as Freeway Management, Urban Traffic
, the new
Rapid Transit system(MyCiti)
, Traffic Services and Metro Police in a
single operational environment so that they are able to function side-by-side.
This will improve Cape Towns incident and information management capability
and will ensure effective and efficient traffic and public transport
The new centre operates from Goodwood in a
custom designed building funded by National Government and the City. Council
approved the original plans in May 2008, the ASTII Consortium was appointed in
June 2008 to manage the project, and the building was completed in November
The TMC will enable the City to actively manage traffic flows, public transport, safety and security and incident and information from one central point.
Transport Management Centre (TMC) is a building that houses most of the Cities
Transport department employees. This building was used as an energy
efficient building as the lighting in the building as well the design of the
building all encompasses energy efficient technology.
retrofits in Council buildings and Electricity Saving Campaign
Energy efficiency retrofits in 4 Council buildings
The City has many programmes that its running
that form part of our Energy and Climate Action Plan.
They focus on energy efficiency, renewable
energy and improving the Citys resilience to climate change, through effective
One of these programmes
focuses on energy efficiency retrofits of City owned and operated buildings.
Interventions in these buildings include:
Light & lighting controls, solar water heaters, Power factor
correction, intelligent thermostat control on Air Cons & operating hours
According to the City, o verall, the project is performing better than expected. The guarantee is based on average savings, where the City can see that the guarantee period will be shorter than anticipated, if the performance continues. The City highlighted that they have installed good quality meters as a means to track consumption effectively. This online tool allows the City to monitor electricity consumption in the buildings in real time, half hourly intervals. This will help the City to improve their information on its buildings, and will also serve as a facilities management tool, to help manage behaviour in these buildings.
The City is also utilizing Division of Revenue Act
(DoRA) which has been allocated to the building retrofit project.
This covered 14 buildings in four areas of
The funds will only be spent
on lighting and metering, and the savings that will be guaranteed are
staggering, according to the City. Alongside technical retrofit the City also
embarked on behavioural change interventions, where they will be able to
increase savings even more if staff are included in the process and are
conscious of their consumption habits and impact. Interventions took the form
of workshops, exhibitions, handouts (flyers), and monthly tracking of
consumption through posters in the facilities.
Not only is the City focusing on changing behaviour in the Cape Town municipality, but also looking at a wider audience. According to the City, the electricity saving campaign, launched in 2011, has been a resounding success. The material developed for the campaign has been incredibly well received it is attractive, accessible and provides actual interventions that households across Cape Town can use. The next phase of the campaign, expected to start in September 2012 will be a 2 ½ year campaign. It will also include the commercial sector, through the continuation of the Citys energy efficiency forum, and will help companies to access various EE incentives (like Eskoms standard offer). The City aims to focus its messaging around periods of tariff increases, to help households and businesses to cope with the extra costs.
Division of Revenue Act
(DoRA): Energy Efficiency Demand Side Management (EEDSM) program
The Energy Efficiency Demand Side Management (
EEDSM) program is a grant fund
disbursed to municipalities to implement energy efficient retrofits, which is
managed by Department of Energy (DoE). The program currently only focuses on
lighting interventions, where the City has been a participant in the EEDSM
program since 2009-2012.
Projects implemented and savings realized:
1 406 053 kWh/pa
Street lights: R10 543 848
Traffic lights: R9 456 152
1 669 216 kWh/pa
R14 985 001
R16 144 999
R6 300 000
M&V: R1 769 998
Capacity Building & interns: R400 000
Public awareness & promotion: R400 000
Luminaires to be retrofitted:
1 731 509 kWh/pa
Luminaires to be retrofitted:
4 690 980kWh/pa
4 675 tCO2e
Luminaires to be retrofitted:
148 839 kWh/pa
Source: Presentation by CoCT on 21 June 2012
4. Visits to businesses
Industrial Energy Efficiency Improvement Project (IEE) in South Africa assisted
the committee in identifying the various businesses which can be visited.
project was established in 2010 in response to the growing need to improve the
energy efficiency of South Africa. UNIDO, along with the Swiss Secretariat for
Economic Affairs, the UK Department of International Development and partnered
by the Department of Trade and Industry (dti) and the Department of Energy
(DoE) of South Africa, embarked on a program to address the global drive for
greater energy efficiency; the ultimate goal being to demonstrate the positive
impact of energy management as a means of reducing carbon-dioxide emissions and
to demonstrate the effectiveness and financial impact of in-plant energy
management. The project is hosted by the National Cleaner Production Centre of
South Africa (NCPC-SA) at the CSIR and will be integrated into the centre after
it has completed its 4 year lifespan.
It has been demonstrated, time and time again, that energy-efficiency saves
industrial firms money, increases the reliability of operations and has a
positive effect on productivity and competitiveness. The Department of Trade
and Industry (the dti), the Department of Energy (DoE), the Department of
Environmental Affairs, and Business Unity South Africa (BUSA), in collaboration
with the United Nations Industrial Development Organisation (UNIDO) and the
Swiss State Secretariat for Economic Affairs, have initiated a project to
improve the capacity of the South African industry to use available energy
resources more efficiently and productively.
The project is housed by the National Cleaner Production Centre of South
Africa (NCPC-SA) at its offices in Pretoria and Cape Town. Started in 2010, the
goal of the Industrial Energy Efficiency (IEE) project is to contribute to
South Africas industrial energy-efficiency, reduce carbon-dioxide emissions
and demonstrate the effectiveness of in-plant energy management as a means of
4.1. Nampak - Bellville
Nampak offers the most comprehensive product range, across multiple
industries throughout Africa, manufacturing to the highest commercial and
environmental standards in
glass, paper and plastic.
A positive customer experience is made possible by Nampaks large geographic footprint , extensive value-added services , large infrastructure, significant capacity to deliver , one of the world's leading packaging research and development facility and a proven innovation process .
acknowledge the benefits of corporate driven
strengthen its leading market position. Nampak highlighted that they
believe in a culture that actively recruits, develops and retains talent and
diversity. They value
mutually beneficial long-term partnerships
with both their suppliers and customers, built on a foundation of superior
quality, innovation and service. They continuously drive
asset management and satisfied stakeholders.
committed to operating in an
way. In terms of their environmental policy, any
impact on the environment is minimised by:
environment in all business decisions and actions
environmental awareness internally and externally
improving environmental performance
controls that recognise legislated standards and practices
necessary financial and human resources.
As a group, Nampak have adopted an
environmental management system that is based on the
Nampak has a target of
up to 1%
of profit-after-tax to corporate social investment. Key focus
areas are education, health and welfare and the environment.
produces around 60 000 ton of products, which is 20 percent more than an
costs are currently around R8 million a year.
Johannesburg and Durban factories mostly use natural gas, whereas the Cape
Town factory uses liquefied petroleum gas (LPG), which is more expensive.
a percentage of Nampaks costs: in 2008 it was 8 percent and 2011
increased to 11 percent.
to address the efficiency and to reduce the base load, Nampak embarked on
the following initiatives:
an Energy Water and Waste Committee for the entire Nampak group
of plant level Energy Committees
undertaken to address energy efficiency included:
of a boiler where Nampak aims to save 43 000MWhr per annum, which will
be used from September 2012.
system optimisation techniques
energy intensive procurement policies
of unnecessary and inefficient processing steps
increases in electricity, Nampak is unable to recover the costs from the
largest electricity user in the Western Cape. They used
to be part of the Power User Group
Manufacturing Company - Stikland
Hose manufacturers(Pty) Ltd, is part of an international group spanning
Europe, USA, South America and Australia, which was established in the early
1960s to manufacture fire hose for the Southern African continent.
Their strategy has always been to dedicate time and energy to research and
development, which can be seen in their approach to rapidly changing and
emerging markets where they will find themselves in, while being part of an
overseas company which gives them access to and keeps them abreast of the
latest technologies and developments.
Hose Manufacturers is part of the South African Bureau of Standards
(SABS), where they have all their quality mark of approval for all hoses under
SABS 1456-2 to 5. They have also passed standards required by the countries to
which they export, including Ozone, Fuels, Oils & Chemicals, Foods and
varying temperature tests. Hoses are manufactured according to ISO 9001:2000
Quality Management System.
Hose Manufacturers firehose market has developed over the years, where
they now have a range of six types of firehoses used for various situations.
They have developed hoses for different working environments including
rugged hoses for the mining sector and extra-tough hoses for the industrial
sector. Irrigation hoses for the agricultural sector and submersible hoses for
The electrical tubing in transformers used to be big business for Hose
Manufactures, as this was one of Eskoms capex expenditures. However since
Eskom is not building as many transformers as they use to, business has gone
Hose Manufacturers applied in February 2012 for the installation of a
transformer and in about 2 weeks the transformer was installed. The whole
process took about 5-6 months at a cost of R600 000.
Certain processes at Hose Manufacturing are very energy intensive,
therefore the request to install a transformer, where all the different lines
can be run simultaneously.
The Department of Trade & Industry (thedti) with the Industrial
Development Corporation (IDC) approved an amount of R250 000, to upgrade the
facility to adhere to food and safety standards, in order to export. The
funding received was from the Textile Improvement programme.
Hose Manufacturers employ 40 full-time staff and 7 contractors.
Weaving operations runs for 24 hours, whereas the extrusion and back-up
runs normal working hours.
Hose Manufacturer receives its PVC from Durban, polyurethane from Germany
and polyfibres from Japan.
Other initiatives to address energy efficiency include:
Utilization of heating towers
Lighting savings via Eskom subsidies
Hose Manufacturing also ascertained that they were billed at the incorrect
tariff by Eskom.
Aurecon Building - Century City
Aurecons office building in
Century City, Cape Town, which is nearing completion, is the first building in
South Africa to be awarded a 5 Star Green Star SA Office Design v1 rating by
the Green Building Council of South Africa (GBCSA).
Developed by the Rabie
Property Group at a cost of around R130million, the 7000 square metre office
block is also the first building in Cape Town and only the fifth country-wide
to achieve Green Star accreditation from the GBCSA. The four other buildings
all achieved a 4 Star rating.
Aurecon has 26
offices throughout South Africa, with its first office having opened in Tshwane
in the early 1950s. These also include subsidiary companies such as Geostrada
Engineering Materials Laboratory and the Asprita Microbiological Chemical
involvement in projects in South Africa ranges from the provision of basic
services in rural areas, to the design of multi-modal transportation projects
in metropolitan areas. Aurecon ensures the involvement of local engineers
through our local offices. The result is effective knowledge and technology
sharing and networking. In this way the group ensures local knowledge is
combined with Aurecons international expertise.
Projects undertaken by
Aurecon included the award winning Department of International Relations and
Cooperation Head office and Berg Water Project, the Gauteng Freeway
Improvement Project, and the Peter Mokaba Sporting Complex.
4.3.3. Green measures undertaken
The new building will serve
as the new regional offices for global engineering, management and specialist
technical services group Aurecon who were responsible for the design of all the
engineering services on the project and also the Green Star Rating application,
with documentation assistance from PJ Carew Consulting.
Rabie director Colin
Anderson, who was responsible for the development, says they were ecstatic with
the achievement which was amazing given that they had to complete the building
within a normal commercial budget. Anderson stated that their success is due to
the commitment, hard work and effort put into the project by the entire team.
According to Aurecon it has
become important to demonstrate that their own buildings and facilities have
been built in a sustainable manner. The group is committed to ensuring that
they design and execute sustainable and environmentally responsible
infrastructure projects and they further ensured that their teams include
suitably trained and registered professionals, including environmentalists and
Green Star SA Accredited Professionals.
Aurecon stated that the
building has been built to design, so there is no reason stopping Aurecon from
also applying for an As Built Green Rating from the Green Building Council SA
(GBCSA). Only one other building in the country has so far achieved a Green
Star rating in two categories and this was the Nedbank building in Johannesburg
which achieved a 4 Star Green Star SA Office Design v1 and a 4 Star Green
Star SA As Built v 1.
Aurecon stated that in their
quest for a Green-Star rating the professional team and building owners took
into account the Green-Star SA criteria, namely Management, Indoor
Environmental Quality, Energy, Water, Transport, Materials, Emissions, Land Use
and Ecology and Innovation.
The four storey building,
which has been constructed on a podium covering a naturally-ventilated
semi-basement of covered parking, was designed by MaC Architects and its
orientation ensures maximum indirect sunlight and reduced east and west direct
Other measures undertaken
include the following:
air-conditioning system with a full economy cycle to provide free cooling
when outside conditions are favourable
A state-of-the-art Building
Management System which monitors and controls and energy consumption
Treated effluent irrigation
and the harvesting of rain water for the flushing of toilets
High-performance glazing on
the windows to reduce glare and radiant heat
Innovative measures include
the implementation of a Green Lease, believed to be the first in the
country, in terms of which both the landlord and the tenant have
undertaken to run the building as it was designed in terms of Green
Saint-Gobain, the world leader in the habitat and
construction markets, designs, manufactures and distributes building materials,
providing innovative solutions to meet growing demand in emerging economies.
As one of the top 100 industrial groups in the world,
Saint-Gobain continues to deploy its technological know-how, often in
partnership with the most prestigious universities and laboratories.
South Africa, sustainability is critical where it represents both a daily
responsibility and a fantastic business opportunity. They are committed to
integrating sustainable principles into the very nature of their business, from
the development and manufacture of its products.
global business activities are grouped into four sectors:
1. Construction products:
includes insulation, gypsum, exterior products, piping and industrial mortars.
The complementary nature of these products makes it possible for Saint-Gobain
to meet the needs of every part of the construction industry, from the creation
of new buildings to the renovation of old.
2. Innovative materials:
encompasses flat glass (manufacturing; transformation and distribution for the
building sector; automotive glazing and specialties), as well as
high-performance materials such as ceramics, plastics, abrasives and textile
solutions, applied in the housing, energy and environmental fields.
3. Building distribution:
more than 4 000 outlets, Saint-Gobain is the leading distributor of
construction materials in Europe, and excels in the building standards training
that we provide to our tradesmen.
As the worlds
second-ranking producer of glass containers, they manufacture bottles and jars
for the food and beverage industry.
In South Africa,
Saint-Gobain represents two of the four sectors. The construction products
brands operating locally include Gyproc, Isover, PAM and Weber. These provide
system solutions incorporating plasterboard and gypsum plasters, glasswool and
mineral wool for thermal and acoustic insulation, a variety of foam insulation
products, ductile iron and cast iron products, wall, floor and pool finishes,
and tile adhesives and grouts.
materials sector embodies Saint-Gobains innovation orientated culture. In
South Africa it includes the Norton brand.
Saint-Gobain is a
founding member of the Green Building Council of South Africa (GBCSA), an
independent, non-profit, membership-based organisation that was formed in 2007
by leaders from all sectors of the commercial property industry. GBCSA is a
full member of the World Green Building Council, and the official certification
body of buildings under the Green Star SA Environmental Rating System.
Saint-Gobains activities has silver status membership. The company actively
supports the GBCSA in its goal of ensuring that all buildings are built and
operated in environmentally sustainable ways, so that all South Africans may
work and live in healthy, effective and productive environments.
4.4.3. Targeted energy use
operations in South Africa collectively aim to reduce its total energy usage by
6% by end 2012, measured from 2010. To this end world-class manufacturing
principles have already been implemented in four of the five local
manufacturing sites that have the highest total energy usage.
compelled to purchase electricity from the countrys parastatal power company,
Eskom. This electricity has an inherently high carbon footprint of 968g carbon
per kWh of electricity generated. We therefore ensure that 52% of our
operations energy consumption is in the form of natural gas, which has a far
lower carbon footprint (one third of that of electricity) Another 30% of our
energy usage is in the form of primary fuels, such as oils and coal, as well as
a small but growing percentage of renewable power, such as solar PV and thermal
Using electricity from the national grid is always our last resort.
The results speak
for themselves: in 2011, the energy inflation in South Africa was 30%, while at
Saint-Gobain they kept the increase in energy spend to 17% unlike most hot gas
manufacturing plants that use coalfired and heavy oil-fired systems,
Saint-Gobain in South Africa uses 96% natural gas and light oils.
They further continue to investigate the use
of alternative and renewable energy sources in order to protect the environment
and reduce its reliance on electricity.
Study tour to PetroSA Synthetic
Innovation Centre at the University of the Western Cape (UWC)
PetroSA and the University of the Western Cape (UWC) signed an agreement
on 27 January 2010 in which PetroSA has committed R36 million for a five year
initial project period 2010 2015 at the South African Institute of Advanced
Materials Chemistry (SAIAMC) to further develop COD (conversion of olefins to
distillates) process technology.
The project is focused on improving the efficiency of the COD process and
the possibility of using alternative feed stocks such as alcohols and naphthas.
Since then the PetroSA Synthetic Fuels Innovation Centre (PSFIC) has been
established and a COD pilot plant has been relocated from Mossel Bay to a
custom built laboratory at UWC.
The vision of the centre is to establish the PSFIC as leading research
centre for the creation of marketable technologies for synthetic fuels.
PetroSA operates one of the worlds largest Gas-to-liquid (GTL) complexes
at Mossel Bay, South Africa. With 15 years of operational experience, the GTL
plant and processes are well proven, producing fuels with qualities unrivalled
by those produced by conventional oil refiners. The COD technology itself, as
part the bigger GTL process, originated on a commercial scale at the same time
in an effort to allow PetroSA operational flexibility in changing diesel versus
gasoline yields as market conditions change. The COD technology is thus
strongly supported by a wealth of operational know-how and experience.
5.2. Objectives of the Centre
the IP position of PetroSA by the further development of COD Technology
human capital for the oil and gas industry of SA.
to the scholarly publications output of the UWC
a way forward for the for the development of improved marketable COD
5.3. Current research projects and
The above objectives are being attained via three major research
directions which are alternative feed stocks, catalyst development and process
optimization to improve product quality.
Already promising research results have led to filing of a provisional
patent application and the presentation of some other aspects of the research
progress local scientific conferences.
5.4. PetroSA value proposition
In exploitation of these opportunities and through use of its patented COD
technology, PetroSA is able to increase product value by:
overall diesel to petrol yield
mixed olefins normally targeted for lower value gasoline products to
higher value distillate products
aromatic content of products
cold flow and emission properties of distillate products.
5.5. Research and Development
While PetroSA has commercially operated a COD plant in Mossel Bay, it has
lately invigorated its development drive on COD technology. Proof in case is
the full-time operation of COD pilot plant in the PetroSA laboratories. This
pilot plant is supplemented with laboratory scale reactors allowing full-time
optimisation efforts of the COD processes and catalysts. COD clients therefore
have access to world-class R&D facilities.
The rationale for the establishment of a COD research
facility at the SAIAMC at UWC is that there already exists expertise in
catalysis research and gas conversion technology at the SAIAMC, although not
specifically in COD. Thus the COD facility, which is called the PetroSA
Synthetic Fuels Innovation Centre (PSFIC), includes in its staff compliment
PetroSA COD experts who will transfer their knowledge and skills to both staff
and students at the SAIAMC.
pilot plant is located in a custom built laboratory which also houses a
control room, analytical laboratory, storage areas for gases and fuels,
offices and the PSFIC Board room.
laboratory spaces has also been provided in the adjacent SAIAMC Innovation
currently 3 graduates in training, 2 masters students and 1 PhD student at
addition there are 8 pilot plant operators who are students from the cape
Peninsula University of Technology (CPUT) completing the experiential
learning component of their diplomas. A further 5 students are working as
PetroSA COD technology converts light olefins predominantly into sought
after low aromatic content (<10%) distillate through utilising its
patented COD technology.
process uses catalytic conversion (oligomerisation and isomerisation) by
means of a seolite type catalyst.
is designed to operate between two extreme operating modes, which are
termed the Gasoline and the Distillite Modes, allowing a range of
operating conditions where the yields can be manipulated to a considerable
process produces distillates, gasoline and propane. The distillates can be
hydro-treated and fractionated to produce low aromatic diesel and
kerosene. The gasoline can typically form part of the gasoline blend pool.
Propane will end up in the LPG pool
of the COD diesel is specifically suited to use in niche transportation
fuel markets such as very cold climates and underground environments.
hydro-treated to reduce aromatics content to very low levels, the aromatic
diesel and kerosene are excellent for the following applications, inter
alia: indoor fuels, lubricants, drilling fluids, ecodiesel, copper
extraction fluids etc
from this process is of exceptional quality and already exceeds future
European low sulphur specifications.
process offers flexibility in terms of changing distillate to gasoline
is also in a position to test alternative feedstocks in their pilot plant
and laboratory facilities.
Strong incentives exist for energy efficiency improvement in the South
African industry, namely increased profit, reduction of GHG emissions, and the
need to maintain economic competitiveness. Several case study assessments of
industry leaders in South Africa suggest that South African industry has an
even higher potential for energy cost saving. Organisation structure, financial
controls and culture/attitude can be barriers to the implementation of energy
projects. Further investigation into the extent of energy management in South
African industry may help in estimating the impact of energy efficiency
programs on energy consumption and energy intensity.
The establishment of a fuels innovation centre at pilot-plant
scale represents a new venture as far as technology development partnerships
between industry and academia in South Africa are concerned. The Committee
wishes to congratulate the PetroSA for its vision in funding this important
enterprise, as well as the University of the Western Cape in housing on its
campus a pilot plant facility that is dedicated to technological innovation in
the national interest. The Committee is optimistic that this strategic
partnership, between PetroSA and the University of the Western Cape will grow
from strength to strength.
The Minister of Energy:
Clean Development Mechanism Pilot Project and facilitates its replication in
the rest of the country;
In partnership with the relevant Ministers, ensure that policy development
for all new public buildings to be environmentally sensitive with energy
Ensure promotion of Industrial Energy Efficiency Improvement Project and
increased resourcing of the National Cleaner Production Centre
Promotes gas as an alternative source for industrial use and reviews
policy to facilitate such.
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