Production in the Verbund: using energy efficiently and conserving resources

We aim to prevent emissions and protect the climate in our production processes, especially through the use of energy-efficient plants. Our Verbund system helps us accomplish this through the synergetic interconnection of facilities, logistics, infrastructure and the flow of energy. By the end of 2015, we also intend to have the energy management at our German sites certified in accordance with DIN EN ISO 50001. We have already examined BASF SE’s most energy-intensive production processes.

Antwerp

Second-largest BASF Verbund site
Established: 1964
Production: around 50
Area: 6 km2
Pipelines: 290 km

Geismar

Established: 1958
Production facilities: 22
Area: 9.27 km2
Pipelines: 1,139 km

Freeport

Established: 1958
Production facilities: 24
Area: 1.64 km2
Pipelines: 290 km

Ludwigshafen

Largest chemical complex in the world
and largest BASF Verbund site
Established: 1865
Production facilities: rund 160
Area: 10 km2
Pipelines: 2,750 km

Nanjing

Established: 2005
Production facilities: 16
Area: 2.2 km2
Pipelines: 708 km

Kuantan

Established: 1997
Production facilities: 13
Area: 1.5 km2
Pipelines: 450 km

6.1 million metric tons

of carbon emissions are prevented each year through the highly efficient generation and use of power and steam in our Energy Verbund.

Verbund principle

The Verbund system is one of BASF’s great strengths. With six large Verbund sites and 376 other production sites, we are represented in almost every country in the world. Verbund – this means intelligently linking our sites and creating value as one company. This idea is reflected everywhere in BASF and extends beyond production, as we also combine our expertise and technologies to develop innovative products and solutions for our customers all around the world.

Power plants for the Energy Verbund

How are electricity and steam produced and used? This was the question schoolchildren explored in the “Power4School” project of the Wissensfabrik (Knowledge Factory). A class of students visited our Verbund site in Ludwigshafen and discovered: Combined heat and power plants are responsible for a large portion of BASF’s energy supply. These are plants that use natural gas to produce not only electricity, but also steam. Instead of being lost, the heat is fed into our other production facilities over a steam network. The benefit for climate protection is obvious: Carbon emissions can be avoided thanks to this interconnected production. Furthermore, the utilization rate of natural gas as a fuel can reach up to 90% – so that nearly all the heat is converted into energy. Conventional power plants are only around half as efficient.

BASF’s lifelines

Every day, steam, air and water flow through the pipelines connecting the plants and facilities of our large sites. In the Production Verbund, we use this infrastructure to create efficient value chains. For example, by-products from one plant can serve as raw materials in the manufacture of another product.