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Description
The company is the largest manufacturer of chemical products in Romania with over 60 years of experience in innovating, manufacturing and commercializing inorganic and organic chemical products. They operate the largest chemical plant in Romania, having two industrial platforms in Onesti and Ramnicu Valcea and 7 working points. Its main object of activity is manufacturing of other inorganic basic chemicals, Nace 2013 and as secondary activity manufacturing of other organic basic chemicals, Nace 2014 (activity that held the largest share in the revenues achieved in 2020). One of the main products are polyols for multiple industrial and domestic applications.
The main objectives of the project are to invest in a new production line that will be multifunctional and will allow in principle the synthesis of many other types of polyols. The scope of the project is not only to produce special polyols, but also to optimize them together with customers, adapting the technical specifications according to their specific needs and overall increase in the utilization capacity of the existing production infrastructure. The strategy for development focuses on replacing petrochemical components with less polluting components. The project will reduce both the operational costs and the negative impact on the environment. Key activities of the project include:
- Increase the utilization production capacity.
- Increase product range.
- Acquire, construct, install a new production line.
- Publicity measures to strengthen the brand image.
Expected outcomes increase an annual decrease of CO2 emissions by 3.416 tonnes and annual decrease in energy consumption by 722,29 MWh. The project is expected to generate 5 new jobs.
The project will be implemented in partnership with International development Norway (IDN). Their main tasks will be to build the internal competence for optimization, elaborate a Life Cycle Assessment and deliver a best practice in using LCA in chemical industry.
Summary of project results
The project aimed to address several key issues and challenges. Firstly, it sought to meet the European Union''s stringent standards for polyurethane foams, which require the use of green polyols. The market was under pressure to produce environmentally friendly products, and customers were obliged to incorporate a certain percentage of renewable materials in their products. This necessitated the development of bio-based or "green" polyols as environmentally acceptable alternatives to petrochemical-based polyols.
Additionally, the project aimed to reduce the environmental impact of standard polyols by replacing petrochemical components with less polluting alternatives. This included the use of natural oils such as castor oil, soybean oil, palm oil, and coconut oil, which are known as natural oil polyols (NOPs). These NOPs help reduce carbon emissions by minimizing the use of non-renewable crude oil derivatives.
Furthermore, the European Green Deal was expected to drive an increase in the use of specialist Polyether-Polyols, particularly those based on vegetable oils or other natural materials, to replace petrochemicals. The project also aimed to enhance the company''s competitiveness by reducing operational costs and opening new opportunities in both internal and external markets for greener polyols.
The project undertook several activities aimed at enhancing the production capabilities and environmental sustainability of the Applicant''s operations. The primary focus was on implementing a new production line for special polyols, which involved upgrading the existing technological flow to increase the utilization capacity of the current installations and diversify the polyols portfolio with environmentally friendly options.
Key activities included increasing the production capacity by 17.17%, extending the production capacity of polyols by 17,175 tons per year, and producing new types of special polyols such as those for energy efficiency, vegetable oil-based polyols, and reactive flame retardants. The project also involved acquiring, constructing, and installing a new production line, including a foaming installation, and employing five new full-time personnel.
The outputs of the project included the production of special green polyols. These polyols were designed for various applications, including coatings, adhesives, sealants, elastomers, flexible block foams, standard and CME foams, and rigid foams. Additionally, the project aimed to optimize these polyols in collaboration with customers to meet their specific needs.
Overall, the project resulted in a significant increase in production capacity, a broader product range, and a stronger brand image as an environmentally responsible company by reducing CO2 emissions by 3,416.10 tons per year.
The project achieved several significant results that benefited both the company and its stakeholders. The primary outcome was the successful implementation of a new production line for special polyols, which increased the utilization capacity of the existing installations by 17.17% and extended the production capacity by 17,175 tons per year. This expansion allowed the company to produce new types of special polyols, including those for energy efficiency, vegetable oil-based polyols, and reactive flame retardants.
The project also resulted in the production of environmentally friendly polyols which were designed for various applications, including coatings, adhesives, sealants, elastomers, flexible block foams, standard and CME foams, and rigid foams. These new products helped the company meet the European Union''s standards for green polyols and respond to market demands for environmentally friendly products.
The beneficiaries of the project included the company''s customers, who gained access to a wider range of high-quality, environmentally friendly polyols tailored to their specific needs. Additionally, the project strengthened the company''s brand image as an environmentally responsible entity by reducing CO2 emissions by 3,416.10 tons per year. This not only enhanced the company''s competitiveness in the market but also contributed to global efforts to reduce carbon emissions and promote sustainability.
Summary of bilateral results
The partner aimed to enhance the Applicant''s internal skills in optimizing production processes and products by following circular economy principles. This involved developing a Life Cycle Assessment (LCA) methodology to be integrated into product development, ensuring that environmental impacts are considered from the beginning. By doing so, the company could improve its sustainability practices and reduce waste. Additionally, the project focused on establishing best practices for using LCA in the chemical industry. This included assessing various LCA tools and selecting the most suitable ones for 2-3 product cases. By implementing these tools, the company could better evaluate the environmental impact of its products and processes, leading to more informed decisions and a stronger commitment to sustainability.