Novus International
About Novus
Part: 01
Collaboration
Part: 02
Community
Part: 03
About this Report
Part: 04

Why Is Environmental Stewardship So Essential to Novus?

Managing Environmental Impacts

We take care to manage the environmental outcomes of all Novus's business activities in a responsible way, striving to optimize resource consumption, while minimizing all associated environmental impacts relating to our use of energy, water, and materials in production and logistics operations around the world.

Novus Headquarters

This approach is founded upon a precautionary approach to product development in which sustainability parameters are included at an early stage and keen attention to planning and implementation of plant location, design, manufacturing processes and logistics from an environmental risk perspective. This is evident, for example, in the achievement of Platinum Leadership in Energy and Environmental Design (LEED) certification by the U.S. Green Building Council of the Novus global headquarters campus located in the Missouri Research Park. In addition, the campus is one of the first pilot projects to be certified by the Sustainable Sites Initiative™ (SITES™) for its sustainable site design, construction and maintenance, and in February 2012, was awarded a 3-star rating by SITES, making it the highest rated landscape project in the world. This accomplishment was made possible due to partners such as SWT Landscape Architects, the University of Missouri, the Missouri Botanical Gardens and the Missouri Deparment of Conservation. In all our production operations, Novus constantly seeks to apply best practices which will reduce the direct environmental impacts of our operations and protect biodiversity. Environmental sustainability is embodied in Novus's adherence to all legal and regulatory requirements with regard to environmental protection as well as several voluntary certification standards in every country in which Novus operates. To date, Novus has not knowingly acted in violation of any environmental legislation in any part of the world.

Direct Energy Consumption

Novus uses natural gas in four out of ten of its manufacturing facilities. The global consumption of natural gas at Novus increased by 18% in 2011 versus 2010, a result of the continuing expansion and increased production output at Novus's Little Rock plant (U.S.), which recorded an overall increase of 62% in tons delivered during 2009-2011.

Direct Energy Consumption in Gigajoules

Direct Energy Consumption in
Gigajoules

Indirect Energy Consumption

Indirect energy consumption from purchased electricity and steam sources for use in Novus manufacturing facilities increased in 2010 by 10%. This is due to overall increased production in several manufacturing facilities, especially at Little Rock (U.S.) as mentioned above. Novus's total indirect energy consumption in gigajoules for 2011 was composed of purchased steam (92%) and electricity (8%).

Indirect Energy Consumption in Gigajoules

Indirect Energy Consumption
in Gigajoules

Total Energy Consumption

Overall, total energy consumption at Novus facilities in 2011 was 11% higher than in 2010. This is just 1% higher than the overall increase in production output during this period, representing improvement in energy control versus prior years in which energy consumption had outpaced production output more significantly.

Total Energy Consumption in Gigajoules

Total Energy Consumption in
Gigajoules

Spotlight on Indaiatuba: Energy Efficiency

At the Novus facility in Indaiatuba, Brazil, local leadership has demonstrated responsible energy management, achieving a massive 42% energy efficiency improvement over a two year period.

This has been accomplished through ongoing, consistent attention to all energy factors in the facility, and relies on the constant engagement and vigilance of all factory personnel. In addition, the Indaiatuba plant uses energyefficient lighting for the internal offices and other spaces, and during daylight hours, the factory is operated without any electric lighting other than natural light which is drawn through the skylights in the environmentally designed factory roof.

Additional environmental initiatives at Indaiatuba include treatment of all domestic sewage achieving 90% efficiency in chemical load reduction before the wastewater enters the public sewage system, manufacture of all packing bags from recyclable materials and rigorous exhaust gases emission testing of all incoming delivery trucks, which are not permitted to enter the property unless they comply with exhaust emissions standards (below level 3 on the Rigelmann scale).

Energy Efficiency
Improvements at Indaiatuba
Plant, Brazil

Spotlight on Little Rock — Improving Environmental Efficiency

In 2011, as in previous years, consistent with ongoing business growth, Novus expanded its manufacturing capabilities to meet increasing demand around the world. In May 2011, Novus welcomed over 300 industry leaders, customers, government officials and employees to a ribbon cutting to commemorate the opening of an expanded Novus Arkansas Facility in Little Rock, Arkansas. The new expansion features a 45,000 square foot manufacturing facility for MINTREX, a unique line of chelated trace mineral products for aquaculture, poultry, pork, beef, dairy and pet nutrition. The new plant was designed to provide optimum flexibility to make multiple products, requiring the construction of new chemical reactor equipment to meet different manufacturing processes. This has resulted in a highly efficient operation that reduces energy, generates no waste water, and reduces materials usage for an improved environmental footprint. In addition, all air streams are routed to a high efficiency air pollution control device.

In addition, MINTREX is manufactured using proprietary Novus technology which requires far less water than traditional slurry-based processes, using reaction heat to dry off the water in the process. The manufacture of MINTREX therefore provides environmental advantages, in addition to the benefits gained from use of the product in animal feed.

The new Little Rock facility earned a Silver LEED Certification from the U.S. Green Building Council, consistent with Novus's commitment to creating environmental, social and economic sustainability in Arkansas and the communities Novus serves around the world. It is estimated that the new office building saves 7% in cooling and 22% in heating costs through the use of a film on external double pane windows.

Accounting for Carbon Emissions

Overall, total energy consumption at Novus facilities in 2011 was 11% higher than in 2010. This is just 1% higher than the overall increase in production output during this period, representing improvement in energy control versus prior years in which energy consumption had outpaced production output more significantly.

Total Energy Consumption in Gigajoules

Total Energy Consumption in
Gigajoules

Spotlight on Indaiatuba: Energy Efficiency

Novus's reporting of carbon emissions is aligned with its reporting to the American Chemistry Council. Novus calculates its greenhouse gas emissions based on the methodology adopted by the Responsible Care® initiative of the American Chemistry Council. Participation in the Responsible Care initiative includes mandatory annual reporting of Greenhouse Gas (GHG) emissions. Responsible Care openly communicates these GHG emission results to the public.

For U.S. plants, data from the U.S. Energy Information Administration's Annual Energy Review is used to derive the CO2 emissions factor attributable to electricity purchased by the chemical industry. Factors used were taken from the most recent 2010 review released in August 2011. For non-U.S. plants, carbon dioxide emissions were determined using the published 2011 edition of the International Energy Agency guidelines.

The methodology used to calculate CO2 emissions from natural gas combustion is consistent with criteria used by the U.S. Environmental Protection Agency in its report, Inventory of U.S. Greenhouse Gas Emissions and Sinks: 1990-2009 (February, 2011).

Novus calculates direct and indirect carbon emissions based on electricity, natural gas and purchased steam consumption. In 2011, total carbon emissions increased from 48,536 tons of CO2 emissions reported in 2010 to 56,808 tons in 2011. This change demonstrates a slight increase in carbon emissions, as a result of increased production efforts and a change in the mix of energy used from different sources. This represents an overall change in carbon efficiency of -4.4% in 2011 versus 2010 (when normalized for production quantities).

Reducing Carbon Emissions in Germany

Novus's plant in Gudensberg, Germany, is one of the smaller Novus plants and its environmental impacts are modest. However, in 2011, in line with our overall objective to improve our environmental impacts, a new warehouse was constructed for finished product in order to avoid finished product being sent for storage in external warehousing. This development avoids logistics for product transfer and saves approximately 1,000 liters of fuel per year. Additionally, the new warehouse was constructed along sustainability principles with no energy-consuming heating system. Insulation was added to prevent the warehouse becoming too cold, even in the very low winter temperatures.

Improving Waste Efficiency

Novus is committed to managing all production operations to achieve minimal waste and all Novus facilities keep detailed records of waste generated and disposal methods. Total waste levels remained constant in 2011, while overall production output increased by over 10% in the same period.

Over 96% of the liquid waste generated by Novus occurs in the Chocolate Bayou Plant in Texas (U.S.) and consists of a salt solution that is disposed of via deep well injection that traps liquid waste in geologic formations isolated from drinking water sources. Novus operates two deep wells under permits issued by the State of Texas Environmental Agency and the United States Environmental Protection Agency (EPA). Remaining liquid waste is routed for treatment at sewage treatment plants. Novus's overall level of solid waste (564 tons in 2011) accounts for less than 0.14% of total waste levels and is primarily disposed of via landfill. This waste is primarily organic, non-hazardous chemical waste, packaging waste and small amounts of paper, plastics and glass.

Total Waste by Disposal Method in Tons

Total Waste by Disposal Method in Tons

NB: The level of liquid waste to waste treatment was overstated for 2010 in Novus's previous report. This has now been corrected following a rigorous check at the Novus Chocolate Bayou facility.

Three Environmental Initiatives in Spain

The Novus plant in Constanti has undertaken several environmental initiatives to improve its overall environmental impacts and control waste levels and recycling. Among the most significant in 2011, are three specific programs:

In-house pigment waste water treatment:

A full remodeling of one of the plant units was executed in order to establish a facility for in-house treatment of waste water in pigment processing. Previously this had been sent out for external treatment. The in-house facility not only avoids the environmental impacts of transportation, but also enables Novus to recover pigment traces for reuse and reduces overall levels of water consumption.

A new recycling facility:

Another initiative at Constanti has been the establishment of a new recycling area in the plant, with facilities for carton, paper and drum recycling.

Use of liquefied natural gas (LNG) in boilers:

The Constanti plant undertook a major refitting program in order to provide the plant with an appropriate gas and cooling tank in order to substitute the use of diesel fuel with natural gas. During 2011, the changeover achieved a level of 60% and the plant continues to convert all required processes to achieve 100% in the near future. LNG has a much lower carbon emission profile than diesel fuel.

Reducing Paper Consumption

Novus continuously seeks to develop processes which reduce our environmental impacts and one area of focus during the past year has been to encourage collaboration with our suppliers to reduce paper consumption. This has resulted in a high success rate of converting Novus suppliers to an electronic payment system. By November 2011, Novus had achieved a sustained level of over 70% of close to 12,000 payments to suppliers per year, which are executed electronically via a paperless system.

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