Energy and Water Consumption
The most important energy sources are natural gas, electricity and the energetic processing of our waste products (steam production, combined heat and power). Fossil fuels other than natural gas play a very minor role.
Water usage is discriminated into two main classes, industrial process water and non-contact cooling water. Essentially all cooling water cycles are closed loop systems, whereby the exchanged heat is dissipated by airflow and evaporation (cooling tower) or by river water (Visp, Switzerland).
The total energy requirement in 2015 was 9 900 Terajoules (2 750 GWh), 1 % down on the previous year. The essentially stable consumption parallels a similarly stable production volume.
The main energy sources used by Lonza in 2015 were natural gas (35 %), electricity (30 %) and self-generated energy, mainly by incineration of waste (28 %). Liquid, mainly fossil-based fuels, accounted for 1 % of the overall energy consumption.
A number of energy efficiency measures are currently being realized at several prouction sites. Energy consumed to run our manufacturing processes is by far the largest contributor to our climate relevant emissions. We therefore concentrate on energy efficiency measures at all our manufacturing sites - a cornerstone in Lonza's continuous improvement effort.
Energy consumption intensity referenced to production volume (metric tons of finished goods) in 2015 was 16.2 GJ/t (same as in the previous year).
Reporting on water consumption is separated into "industrial water" and "cooling water".
: Water which is polluted by industrial or sanitary processes and installations and which has to be treated in own or external waste water treatment plants.
: Water used for energy transfer (cooling, heating), which is kept in a network separated from industrial water and which can be released back to receiving waters (rivers, lakes) without further treatment.
Industrial water consumption, closely related to production volume, capacity use and product mix, amounted to 6.7 million cubic meters in 2015, up 10 % on 2014. The peak in year 2012 is related a single site in the US with high water use, acquired in late 2011 and divested by end of 2012.
With production volume staying esssentially at pre-year level, water consumption intensity parallels the absolute consumption change and was at 10.9 m3/t of finished goods in 2015 (+11 %).
Industrial water consumption of all Lonza sites active in the respective year.
With one exception, all current Lonza manufacturing sites are using closed-loop cooling water systems with heat dissipation by means of airflow cooling towers. The large chemical complex at Visp (CH) makes use of the waters of the nearby river Rhone to dissipate non-recoverable heat by heat exchangers. This process is strictly regulated and monitored in order to stay within permitted heat levels to protect the river ecosystem.
All cooling water networks are completely separated from any industrial water networks to prevent accidental pollution of water.
Total cooling water used by Lonza in 2015 amounts to 134 million cubic meters, down 11 %. Thereof the 'flow-through' site at Visp absorbs around 133 million cubic meters of river water as heat exchange medium. All other
In order to show trends of the cooling water use over time and unmasked by the large water volumes used at Visp, the graph shows the cooling water consumption of all Lonza manufacturing plants without the 'flow-through' sites of Visp and, in 2012, Brandenburg. Notably after the acqusition of Arch Chemicals Inc. in late 2011, the industrial water use has sharply risen to values short of 1 million cubic meter. We reinforced our water conservation activities where opportunities could be realized, and the decline by -9 % in 2014 and -1.3 % in 2015 are positive signs, that our water conservation efforts show the desired results.