Environmental Statement. Report Environmental Protection and Safety. Schaeffler Caldas Up date. Status October

Transcription

1 Environmental Statement Report Environmental Protection and Safety Schaeffler Caldas 214 Up date Status October 214

2 Introduction In the year 213 the environmental management at Schaeffler Portugal has been reviewed according to the actual EMAS III (regulation (EC) Nr /29) and the environmental statement 212 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. Schaeffler Portugal is covered under the group Regulation with the register number DE The present actualized environmental statement, according to requirements of the EMAS III, is integral part of the environmental statement validation year of last consolidated environmental statement and describes the relevant changes, the development of key performance indicators as well as the status of environmental objectives and targets of the plant. Changes at the Location New packaging machine In the beginning of the year, it was acquired a machine for manufacturing air bags to the Bearings Warehouse. This air bags have brought various benefits, due to the reduced weight of the packaged goods (near 8 %): >> reduction of costs associated to goods transportation >> reduced consumption of packaging material compared to the previously used (wood and cardboard, for increase goods protection) >> less waste, resulted from packages, to Schaeffler Group. >> reduction of CO 2 emissions associated with transportation (indirect environmental aspect) New spill control system A control system was purchased for spill containment Drain Blocker to protect the rain water drain at the bottom of the road next to the methanol tank to prevent contamination in the event of leakage during attest. Training was given to employees and created a work instruction. Waste Operators Visit According to an audit recommendation for improvement, it was held in 213, a one day visit at two waste operators / suppliers that have been working with Schaeffler Portugal EGEO and ECOPARTNER.

3 In this visit, EHS Coordinator and Purchasing Responsible, analyzed the conditions on which the different type of waste (LER Code) were managed at waste operator facilities. No deviation was found. Fluorated Gases The automatic extinguishing systems in Technical Facilities that use HFC-23 and HFC 227ea are since 213 submitted to 2 preventive maintenance inspections per year by external certified company, to detect any possible leakage of fluorated gas. Mobility week From 16 to 22 September, took place the European Mobility Week. Each year it focuses on a specific theme related to sustainable mobility. To mark this week in our plant, it was given a eco-award (SIGG Bottle) to 2 employees who traveled by bicycle (conventional or electric) or on foot to work. Environment, Safety and Energy Booth In December 213, there was held the usual annual Quality Week, which include the Environment, Safety and Energy booth. The topic for this year was Prevention. Regarding environment, it was posted information on the booth about Prevention of pollution (air, soil, soil and ozone layer); Prevention of waste and Prevention of energy losses. In the booth day, there were several activities as illustrated in the pictures above: >> Test-drive of electric cars (outdoor) >> Game about smart and eco choices as a consumer (in booth)

4 Objectives and Targets Our Achievements Environmental Goals Environmental Program Achieved? Actions Increase the employee s skills and knowledge on Environment and Safety issues >> Environment and safety training on various topics, in over 5 % hours regarding the last year (from h to 472 hours) Objective accomplished Energy Saving by the electricity system and consequently the reduction of CO 2 emissions (Reduction the Ratio Electricity consumption / Produced bearings from.212 to.19) Reduction of the frequency rate of accidents Reduction of the severity rate of accidents Increase the security on the plant Improve the fire safety on the plant Reduction of oils consumption >> Step 1: Speed variator in pump in Emulsion Central in Building 2 >> Step 2: Replacement of lamps T8 for T5 in Maintenance and Warehouse areas (Building 1) >> Step 3: Elimination of Emulsion Central in Building 1 >> Implement changes, foreseen in Action Plan, in order to reduce risks of accidents (12,5 % reduction: TFA from 45.7 to 4,) >> Implement changes, foreseen in Action Plan, in order to reduce risks of accidents (2 % reduction: TSA from to 18.27) >> Perform a simulation and emergency evacuation >> Install an access tork in the Reception of the plant >> (3 rd step) Installation of an inside hydrant network in Building 2 >> Reduction of the ratio Grinding oil (Ilogrind) consumed / No. of grinded rings from.25 to.195 (5 %) >> All this measures were postponed to 214, the Maintenance Dep. was not able to implement them in due time >> The ratio registered a slight increasing, from.25 to.28 >> The simulation was planed to December but it was postponed to January 214, when it has been performed. >> Objective not accomplished due to delay of the supplier. To be finnished until the end of June 214 Goal has been achieved. Part of goal has been achieved. Additional actions planned. Goal not achieved.

5 Goal Planning Environmental Goals Environmental Program Responsible Completion Increase the employees skills and knowledge on Environment and Safety issues >> Environment and safety training on various topics, with the goal of 1,5 hours per employee, which means around more 37 hours than in 212) Human Resources EHS Department Dec 214 Energy Saving by the electricity system and consequently the reduction of CO 2 emissions (Reduction the Ratio Electricity consumption / Produced bearings from.28 to.198) Reduction of the accidents frequency rate (AccR) Reduction of the accidents severity rate (LTR) Reduction of oil consumption Reduction of air compressed consumption Increase the security at the plant >> Step 1: Speed variator in pump in Emulsion Central in Building 2 >> Step 2: Replacement of lamps T8 for T5 in Maintenance and Warehouse areas (Building 1) >> Step 3: Elimination of Emulsion Central in Building 1 >> WS for Elimination of air leakages >> Implement changes, foreseen in Action Plan, in order to reduce risks of accidents, decreasing one level on AccR classification, i.e, AccR <15 >> Implement changes, foreseen in Action Plan, in order to reduce risks of accidents, decreasing one level on LTR classification, i.e, LTR <2 >> Reduction of the ratio Grinding oil (Ilogrind) consumed / No. of grinded rings on 2 % in comparison with 213 (i.e., from.956 to.937) >> Reduction of the air compressed consumption in 25 % regarding 213, by several elimination of air leakages >> Perform a simulation and emergency evacuation every year >> Install an access torque in the Reception of the plant Maintenance EHS Department May 214 Dec 214 Jun 215 Dec 214 EHS Department Dec 214 EHS Department Dec 214 Production responsible Dec 214 Energy Coordinator Dec 214 Plant manager EHS Department Plant Manager Security Coordinator Jan 214 Jun 214

6 Key Indicators according EMAS III Schaeffler Portugal Absolute Relative* Database Reference data Added value in Mio. Euro [Mio] 13, 13, 17, General Data Total headcount [MA] Size of property [m 2 ] Total sealed surface [m 2 ] [m 2 / Mio ] Biodiversity [%] 22, 22, 22, Input Water [m 3 ] [m 3 / Mio ] Electricity [kwh] [kwh / Mio ] >> Amount of electricity from renewable energy (only external supply) [kwh] [kwh/ Mio ] >> Anteil Eigenerzeugung (konventionell) [kwh],,,,,, [kwh/ Mio ] >> Amount of electricity generated inhouse from renewable energy [kwh],,,,,, [kwh/ Mio ] >> Percentage of renewable energy with regard to overall consumption [%] 39, 39, 29, Natural gas [kwh] [kwh/ Mio ] >> Amount from renewable energies [kwh],,,,,, [kwh/ Mio ] >> Percentage of renewable energies [%],,, Light fuel oil [l],,,,,, [l/ Mio ] >> Amount from renewable energies [l],,,,,, [l/ Mio ] >> Percentage of renewable energies [%],,, Fuels for internal logistics Diesel [l] [l/ Mio ] >> Amount from renewable energies [l],,,,,, [l/ Mio ] >> Percentage of renewable energies [%],,, Gasoline [l],,,,,, [l/ Mio ] >> Amount from renewable energies [l],,,,,, [l/ Mio ] >> Percentage of renewable energies [%] 5.,, District heating [kwh],,,,,, [kwh/ Mio ] >> Amount from renewable energies [kwh],,,,,, [kwh/ Mio ] >> Percentage of renewable energies [%],,, Propane / LPG [kg] [kg / Mio ] Methanol [kg] [kg / 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 [t] , 59, 27, [t / 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] ,15 33,63 2,59 [t/ Mio ] >> paper, cardboard [t] ,77 9,48 7,71 [t/ Mio ] >> waste wood [t] , 9,33 6,71 [t/ Mio ] >> domestic waste [t] ,15 14,22 6,6 [t/ Mio ] >> others [t] 3, 8, 2,,23,6,12 [t/ Mio ] hazardous waste [t] , 38, 27, [t/ Mio ] >> grinding swarf / sludge [t] ,62 19,26 15,43 [t/ Mio ] >> waste emulsion [t] 75, , 5,77 9,1 5,59 [t/ Mio ] >> waste oil [t] 73, 52, 36, 5,62 3,91 2,14 [t/ Mio ] >> others [t] 78, 72, 59, 6, 5,42 3,47 [t/ Mio ] Scrap (ferrous + non-ferrous) [t] ,31 5, 35, [t/ Mio ] CO2-equivalents [t] , 46, [t/ Mio ] >> CO2-emissions from combustion processes at this site [t] , 52, 4, [t/ Mio ] >> CO2-emissions from electricity obtained from external sources [t] 5, 5, 6,,,, [t/ Mio ] >> CO2-emission factor per kwh electricity obtained from external sources [g/ kwh] >> CO2-emissions from district heating obtained from external sources [t],,,,,, [t/ Mio ] >> CO2-equivalent from the refrigerant agent amounts refilled due to leakages [kg] [kg / Mio ] SO2 - emissions from combustion processes at the site [kg] 15, 18, 17, 1,2 1,3 1, [kg / Mio ] NOx - emissions from combustion processes at the site [kg] , 24, 19, [kg / Mio ] Particulate mater emissions [kg] 1, 1, 1,,4,5,4 [kg / Mio ] >> from combustion processes at the site [kg] 1, 1, 1,,4,5,4 [kg / Mio ] >> from production an other processes [kg],,,,,, [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 22nd, 211) as well as the GEMIS 4.8 data bank (

8 Input Notes on selected key performance indicators We present the three major input key indicators for the reporting year Energy (electricity), Water and Production chemical products. [kwh] Evolution of Energy Consumption [pc*1.],35,3,25,2,15,1, Ratio kwh / Bearings Electricity MWh Produced bearings pc* Evolution of Energy Consumption Ratio kwh / Bearings Electricity MWh Produced bearings pc*1. 29, , , , , [m 3 ] Water consumption / Working hours [Working hours *1.],3,25,2,15,1, Ratio Water m 3 / Working hours Total m 3 Working hours * Water consumption vs Working hours Ratio m 3 / Working hours Total m 3 Working hours pc*1. 29, , , , ,

9 Products (querosene, grinding and honing oils) The chemical product which has registered a higher increase of consumption was Querosene. This was because of the increasing of washing effectiveness -more pressure, higher flow resulting on bearings better noise performance. The honing and grinding oil have registered lower ratios compared with the previous year due to a more efficient use. [l] Products (Querosene, Grinding and Honing oils) 2,5 2, 1,5 1,, Querosene l Grinding oil l Honing oil l Querosene Querosene (l) Querosene (l) / Tbearings , , , , ,87 Grinding Grinding oil (l) Grinding oil (l) / Tbearings , , , , ,1 Honing oil Honing oil (l) Honing oil (l) / Tbearings , , , , ,39

10 Output Notes on selected key performance indicators Scrap We registered a decreased of 8.6% on scrap production at the plant, which represents a more efficient use of material. Ratio Produced bearings *1. Scarp 211, , , [t] Scrap production / Produced Bearings [t],12,1,8,6,4, Ratio [t] Produced bearings [t] Scrap [t] CO 2 -Emission The CO 2 emission increase due to 2 factors: increase of electricity ratio and increase of the factor of Kg Co 2 per KWh electricity of our supplier (.354 to.396). CO 2 produced t Kg of CO 2 / kwh of Electricity Electricity MWh 29 3,48, ,9, ,48, ,5, ,68, [t] CO 2-Emissions / Working hours [MWh] 6, 5, 4, 3, 2, 1, CO2 produced t Kg of CO2 / kwh of Electricity Electricity MWh

11 Production Waste In 213, it was produced a total of tones of waste (including urban waste). In the following table, you can check the amount of waste produced in 213 compared to 212. In total, there was a 11 % reduction in total waste produced in 213 (tonnes) in comparison to the previous year, and the types of waste that have been reduced more significantly were wheels and grinding material, chips and production scrap and used oils. Regarding the percentage of recoverable waste versus hazardous waste in 213 there was a 6 % increase in the percentage of recyclable waste, which is positive. The ratio kg waste per 1. pieces also shows a decrease in the past 3 years. Actually, per 1. bearings we produce 18,47 kg of waste, which is the lowest ratio in the past 5 years. Waste Chips, tubes / bars ends, production metal scrap Metal scrap (machines and equipments) 34, 45, Used oils 58, 36, Used emulsions , Paper / plastic / carton non contaminated Paper / plastic / carton and contaminated wastes 38, 36, Mixed urban wastes Production sludge Wood packaging Others 5, 1, [kg] Waste [kg] 3, 25, 2, 15, 1, 5, Ratio (kg waste / 1. pc) Total waste (without urban waste) hazardous waste recyclable waste Quantity (t) % Quantity (t) % , , , ,2 Ratio (kg waste / 1. pc) Total waste (without urban waste) 29 27, , , , ,

12 Environmental Verifier s Statement The undersigned, Dr. Norbert Hiller, EMAS Environmental Verifier, registration number DE-V-21, accredited and authorized for the area designated by NACE Code 28.15, confirms that his inspection of the site at Rua Estrada do Lavradio, Caldas da Rainha has met all of the requirements stipulated by Regulation (EC) No /29 of the European Parliament and Council dated November 25, 29 on the voluntary participation of organizations in an environmental management and audit scheme (EMAS) as indicated in the updated environmental statement (report entitled Environmental Protection and Occupational Safety ) of by Schaeffler Portugal, registration number D The signatures at the end of this statement confirm that >> The inspection and validation have been completed in full agreement with the requirements stipulated in (EU) Regulation No /29 >> 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 (report entitled Environmental Protection and Occupational Safety ) for the site at Rua Estrada do Lavradio, Caldas da Rainha, as part of Schaeffler Portugal represent a reliable, credible and true picture of all activities at this site within the area indicated in the environmental statement. This statement cannot be equated to an EMAS registration. EMAS registration can be completed only by an authorized agency in accordance with Regulation (EC) No /29. This statement must not be used as an independent basis for informing the public. Dr.-Ing. N. Hiller Caldas da Rainha, Questions about environmental protection Questions about environmental protection and and safety at the location: safety at Schaeffler: Schaeffler Portugal Vera Dinis Norbert Hörauf Rua Estrada do Lavradio, 25 Industriestraße Caldas da Rainha 9174 Herzogenaurach Internet Internet Vera.Dinis@Schaeffler.com Norbert.Hoerauf@Schaeffler.com Portugal: In Germany: Phone Phone Fax Fax From other countries: From other countries: Phone Phone Fax Fax 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 fire protection as well as general information on social benefits pr ovided by the company and this location. Schaeffler Technologies AG & Co. KG 214, October This publication or parts there of may not be reproduced without our permission. The next consolidated (entire) Environmental Statement will be submitted for validation in April / 215 at the latest. In the years between, an annual update of the Environmental Statement will be compiled for validation by the environmental verifier.