Environmental Statement Update

Transcription

1 Environmental Statement Update Savaria 217

2 Introduction In the year 215 the environmental management at LuK Savaria has been reviewed according to the actual EMAS regulation (EC No. 1221/29) and the environmental statement 215 has been validated. The site registration of Schaeffler plants is carried out by the Chamber of Commerce in Nuremberg in Germany as a group registration. LuK Savaria is covered under the group registration with the register number DE The present actualized environmental statement, according to requirements of the EMAS III (regulation (EC) Nr. 1221/29), is integral part of the environmental statement 215 and describes the relevant changes, the development of key performance indicators as well as the status of environmental objectives and targets of the plant. Legal requirements are checked and reviewed twice a year. Any violations found are corrected immediately. During the reporting period all relevant limits were met. 2

3 Changes at the Location Dynamic improvements and growth at the site. New construction or reconstruction of buildings Complete reconstruction of cold storage building (G11) started in summer 216. and will be finished in 217. Reconstruction of previous waste yard started to create a new storage and ramp wing (G7) for Logistics during summer, 216. A new Gatehouse building (G24) was created in the end of 216. Security service moves there in 217. New production machines ZMS 15, new dual mass flywheel machine assembly line, complex technology started its production in Plant1 in April, 216. EK18 arrived to Plant 2 in December, 216. and started its operation in 217. New central facilities or storage areas A new waste handling area was constructed during 215. The project was completed in January, 216. A new waste liquid storage tank and pump system was installed in the beginning of 216. to protect waste water pipe network. There were 27 new air pollution sources installed at the site during 216. New products Clutch disk facing production brought a new range of products to LuK Savaria. Extension of production area Clutch disk facing technology started its operation in Plant 3B in March 216 (the technology is originating from Morbach). Dislocation of machines, facilities, products, etc. EK4 machine line was moved from Plant1 to Plant2 in November, 216. Start of the use of new technologies Automated Ammonia system has been operating from February, 216. It supports Heat treatment technology in Plant 3B. Sectioned chamber furnace technology and organic solvent washer has been operating since August, 216. Sectioned chamber furnace belongs also to Heat treatment technology in Plant 3B. Changes in organization The factory doctor has 2 assistants, attendance takes 7 hrs every workday on site and assistants are there from 8: to 18: on site every weekday. An HR specialist joined LuK Savaria in April, 216., sitting with EHS team and taking indirect tasks over from H&S engineers. 3

4 Objectives and targets OUR ACHIEVEMENTS Environmental targets Environmental programs Status Actions Save energy by optimization of compressed air system Increase energy efficiency by 4,5 % (for electricity consumption) Increasing security of water supply and compressed air supply via structured methodology Save yearly 2 % site level energy by optimizing natural gas consumption in Heat treatment area Improvement of the central control system to increase energy efficiency Save energy, improve efficiency by modernizing boilers Improve cooling technology and save compressor coolers Environmental marketing activities Get ISO 51 (energy management system) certification Goal achieved. >> All media shut off via a separate cut-off valve, e.g. a compressed air cut-off valve >> Details are described in LuK Savaria energy report document >> Create water supply and compressed air infrastructure risk assessment, identify possible hazards, define optimization corrective actions and implement them >> This solution makes it possible to set operational parameters with pressure control (while maintaining furnace burners, post-burners and small part replacements) >> The system optimizes the operation of compressors, air equipment, boilers and lighting >> Boiler house No. 1. will have a boiler technology improvement (new machine types, energy saving features, higher efficiency). This project depends on top management decision >> Installation of a dry cooling unit section with dry coolers for Heat treatment technology (for winter period) >> Green office competition >> Eco Spring Fest exhibition participation >> Drawing competition among employees children >> Employee waste collection >> Preparations for the audit and get certified Goal was partly achieved. Goal not achieved. >> Optimization is in parallel with new section installations (large amount of modifications and investments) >> This target was not achieved. Details are described in LuK Savaria Annual Energy Report 217. Alterations will be actioned in the future >> Fulfilled >> Fulfilled requires continuous follow up >> Control and regulation of dress room ventilation, black radiation heaters in production, electrical transformer system, heating network control based on internal temperature >> According to actual Management decision this project has been postponed and depends on further site development >> Additional similar projects come in 217 >> Waste collection did not happen due to bad weather >> Fulfilled 4

5 PLANNING Environmental targets Environmental programs Responsible Deadline Save 1 % yearly site level electricity consumption by optimization of compressed air system Increase energy efficiency by 4,5 % (for electricity consumption) Increase security of central system via structured methodology Improvement of a central control system to increase energy efficiency Improvement of EDMS monitoring system to increase energy efficiency Improve cooling technology and save compressor coolers Save 35 % electrical energy by lighting reconstruction Save ~ 5 % natural gas for Clutch disk facing TNV technology Save energy and apply modern operational accessories for forklift trucks 2% reduction in municipal water consumption >> All media shut off via a separate cut-off valve, e.g. a compressed air cut-off valve >> Details are described in LuK Savaria Annual Energy Report >> Creation of a risk analysis for coolant lubrication system. Integrate results into the existing strategy and action plan >> The system optimizes the operation of compressors, air equipment, boilers and lighting (Plant 3C devices, G11, G23 Schweinfurt Conference room will be integrated) >> Installation of social water and natural gas and technology compressed air and electricity sub meters to identify and analyze main consumers >> Installation of an adiabatic kit for cooling unit section for Heat treatment technology (for summer period) >> Install LED lighting system into G7 (CRS area) and G11 (Versand storage) >> Install heat insulation for suction pipeline network >> Forklift fleet technical modifications: battery charging time monitoring, capacity utilization optimization. >> High frequency charger for new forklifts (energy efficient charging, space saving/ optimization), old chargers replacement >> Identify main consumers and install water meters for significant nodes >> Define actions and optimize consumption Energy coordinator Clutch facing Segment leader Logistics

6 Key Indicators to EMAS III Szombathely Absolute Relative* Database Reference data Added value in Mio. Euro [Mio ] General Data Total headcount [EMP] Size of property [m 2 ] Total sealed surface [m 2 ] [m 2 / Mio ] Biodiversity [%] Input Water [m 3 ] [m 3 / Mio ] Electricity from external supply [kwh] [kwh / Mio ] >> Percentage of renewable energy (only from external supply) [%] ,3 >> Amount of electricity from renewable energy (external supply) [kwh] [kwh / Mio ] >> Amount of electricity generated inhouse (conventional) [kwh] [kwh / Mio ] >> Amount of electricity generated inhouse from renewable energy [kwh] [kwh / Mio ] Electricity [kwh] [kwh / Mio ] >> Percentage of renewable energy with regard to overall consumption [%] Natural gas [kwh] [kwh / Mio ] >> Amount from renewable energy [kwh] [kwh / Mio ] >> Percentage of renewable energy [%] Light fuel oil [l] [l / Mio ] >> Amount from renewable energy [l] [l / Mio ] >> Percentage of renewable energy [%] Fuels for internal logistics Diesel [l] [l / Mio ] >> Amount from renewable energy [l] [l / Mio ] >> Percentage of renewable energy [%] Gasoline [l] [l / Mio ] >> Amount from renewable energy [l] [l / Mio ] >> Percentage of renewable energy [%] District heating [kwh] [kwh / Mio ] >> Amount from renewable energy [kwh] [kwh / Mio ] >> Percentage of renewable energy [%] Propane / LPG [t] [t / Mio ] Metanol [t] [t / Mio ] Energy input [kwh] [kwh / Mio ] >> Amount of renewable energy with regard to total energy input [kwh] [kwh / Mio ] >> Percentage of renewable energy with regard to total energy input [%]

7 Absolute Relative* Database Emulsion concentrates [kg] [kg / Mio ] Processing oils [kg] [kg / Mio ] Solvent - VOC [kg] [kg / Mio ] Solvent - non VOC [kg] [kg / Mio ] Metal raw materials [kg] [kg / Mio ] Metal semi finished products (external supply) [kg] [kg / Mio ] Other raw materials [kg] [kg / Mio ] Output Waste [t] [t / Mio ] non hazardous waste [t] ,74 2,61 23,83 [t / Mio ] >> paper, cardboard [t] ,13 7,39 7,59 [t / Mio ] >> waste wood [t] ,35 7,19 8,6 [t / Mio ] >> domestic waste [t] ,95 4,29 4,97 [t / Mio ] >> others [t] ,31 1,74 3,21 [t / Mio ] hazardous waste [t] ,76 [t / Mio ] >> grinding swarf / sludge [t] ,9,86,69 [t / Mio ] >> waste emulsion [t] ,13 5,73 7,78 [t / Mio ] >> waste oil [t] ,29,13,4 [t / Mio ] >> others [t] ,12 1,76 1,25 [t / Mio ] Scrap (ferrous + non-ferrous) [t] ,72 [t / Mio ] >> Waste for recycling (without scrap) [t] ,93 [t / Mio ] >> Waste for disposal / removal [%] [t] ,4 [t / Mio ] [%] CO 2-equivalents [t] [t / Mio ] >> CO 2-emissions from combustion processes at this site [t] [t / Mio ] >> CO 2-emissions from electricity obtained from external sources [t] [t / Mio ] >> CO 2-emission factor per kwh electricity obtained from external sources [g / kwh] >> CO 2-emissions from district heating obtained from external sources [t] [t / Mio ] >> CO 2-equivalent from the refrigerant agent amount refilled due to leakages [kg] [kg / Mio ] SO 2 - emissions from combustion processes at the site [kg] ,,7,6 [kg / Mio ] NO x - emissions from combustion processes at the site [kg] [kg / Mio ] Particulate matter emissons [kg] ,22 28,64 26,61 [kg / Mio ] >> from combustion processes at the site [kg] 3 2 2,3,2,2 [kg / Mio ] >> from production an other processes [kg] ,19 28,62 26,58 [kg / Mio ] VOC-emissions [kg] [kg / Mio ] * In relation to added value Sources for evaluation of emission factors are the ProBas data bank ( - status: September 22 nd, 211) as well as the GEMIS 4.8 data bank ( 7

8 Input Electricity consumption Electricity consumption has risen compared to previous years. This occurrence can be explained with growing machine park and machine startup and trial run. The specific data show a stable tendency. Plant 3A and Plant 3B received additional new machinery, new machine installations and trial runs are the reason for increased consumption (Clutch disk facing production segment from March, Arc spring heat treatment tunnel and warm setting relaxation machine line and Sectioned chamber furnace technology from August 216. [m 3 ] Gas consumption [m 3 /pcs] ,7,6,5,4,3,2,1, Gas Heating [m 3 ] Gas Technology [m 3 ] Specific Value [m 3 /pcs] [MWh] Electricity consumption [MWh/t] 6.,5 5.,4 4., ,2 1.,1, Electricity [MWh] Specific Value [MWh/t] on). Water consumption Municipal water quantity dropped. On one hand this is because there was no extraordinary event or intervention. On the other hand, shift change timing and public transport dynamism make people not to shower on site but get clean after they arrive home. Natural well was used in similar way than the previous year (mainly in the summer period). Well water is primarily used for indirect technology cooling and for Cooling-lubricating emulsion system. Heat treatment technology requires more support because of technology increase and (garden) watering as site surface got larger. Gas consumption The reason for the positive, stable line of warm water and heat purpose gas consumption is the two compressor waste heat recovery systems. The use of these solutions bring savings for the factory even against capacity increase. As for technology gas consumption, it is heat treatment production s dynamism that shows its impact. There have been three additional heat treatment machine lines (Etageofen2-8, Furnace 676, Sectioned chamber furnace technology) installed in Plant 3B. These changes explain the tendency of the graph. [m 3 ] Water consumption [m 3 /pcs] Water municipal [m 3 ] Water well [m 3 ] Specific Value [m 3 /pcs] Specific values show an increase compared to previous stable tendency. The reason is huge trial run of Sectioned chamber furnace and Etageofen2-8. 8

9 Output Non-hazardous waste The status of specific value has not changed significantly, which means there is no remarkable modification in the ways of working. Technology modifications and trial runs have been regular during 216. It is also typical that a large amount of machining raw materials arrive from China in wooden boxes (with several single use packaging materials). [kg/t produced] Non-hazardous waste Non-hazardous waste [kg/t produced] Hazardous waste The specific value of hazardous waste compared to production quantity has increased in 216. There were 2 significant cooling-lubricant liquid change where the complete system had to be emptied and refilled. One occasion was due to planned maintenance and the other was due to a technical failure (pollutant got into the system). The hazardous waste quantity generated on site caused larger amounts to be managed. Additional reason is cleaning activity precaution measures to protect our waste water pipeline network: the polluted washing water has been collected in the new closed tank system and managed as hazardous waste to spare our waste water infrastructure. In addition, the tank means more precise hazardous waste liquid collection (every batch goes directly into the closed system, there is no leakage or uncertain handling). [kg/t produced] 5, 4,5 4, 3,5 3, 2,5 2, 1,5 1,,5 Carbon-dioxide emission Emission parameters of our boilers, gas operated heat treatment machines and other combustion technology equipment stay safely below end values defined by the environmental authority. Our carbon-dioxide emission has risen visibly in line with the improving combustion based machine park in Heat treatment (Plant 3B). Indirect carbon-dioxide emission linked to our electrical consumption changes in line with increasing electricity usage. [t/co2] Hazardous waste Hazardous waste [kg/t produced] CO 2 Emission Emission from electricity obtained from external sources Emission from combustion processes at the site 9

10 Verifier s Declaration The undersigned, Dipl.-Phys. R. Mirz, EMAS Environmental Verifier, registration number DE-V-26, accredited or authorized for the area designated by NACE code confirms that his inspection of the location at Zanati u. 31, 97 Szombathely as indicated in the updated environmental statement of LuK Savaria Kft., registration number D complies with all requirements stipulated by (EC) No 1221/29 of the European Parliament and of the Council of 25 th November 29 on the voluntary participation by organizations in a community eco-management and audit scheme (EMAS) and of the Regulation (EU) 217/155 from 28 th August 217 (amendments of annexes I, II and III of the Regulation (EC) No. 1221/29). The signature at the end of this statement confirms that >> the verification and validation has been carried out in full compliance with the requirements of Regulation (EC) No 1221/29 and the Regulation (EU) 217/155, >> the result of the inspection and validation confirms that no evidence of non-compliance with valid environmental specifications has been found >> the data and information in the environmental statement (Environmental Protection and Occupational Safety Report) for the location at Zanati u. 31, 97 Szombathely as part of LuK Savaria Kft. represent a reliable, credible and true picture of all activities at this location within the area indicated in the environmental statement. This document is not equivalent to EMAS registration. EMAS registration can only be granted by an authorized agency in accordance with (EU) Directive No. 1221/29. This document shall not be used as a stand-alone piece of public communication. Dipl.-Phys. R. Mirz LuK Savaria Kft., Questions about environmental Protection at the location Savaria: Tamás István Zanati u Szombathely, Hungary tamas.istvan@schaeffler.com Hungary: From other countries: Questions about environmental protection by Schaeffler: Norbert Hörauf Industriestraße Herzogenaurach norbert.hoerauf@schaeffler.com Germany: From other countries: The structure and contents of this report correspond to the requirements stated in Annex IV of Regulation (EC) No / 29 of the European Parliament and the Council dated November 25, 29 regarding the voluntary participation of organizations in the eco-management and audit scheme (EMAS). Moreover, the report contains information about issues pertaining to occupational safety, plant security and fi re protection as well as general information on social benefi ts pr ovided by the company and this location. Schaeffler Technologies AG & Co. KG in 217 This publication or parts thereof may not be reproduced without our permission. The next consolidated (entire) Environmental Statement will be published in April 219. at the latest. In the years between, an annual update of the Environmental Statement will be compiled for validation by the environmental verifier. Print and Design: BRENDLI LAYOUT Tel. +49 () 9131/49732 brendli@t-online.de