Environmental Statement

Transcription

1 Environmental Statement Report Environmental Protection and Occupational Safety Taicang and Anting UPDATE Status March 215

2 Introduction In the year 214 the environmental management at Taicang Plant 1, 2, 3, 4 and Anting R&D Center have been reviewed according to the actual EMAS regulation (EC No. 1221/29) and the environmental statement 213 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. Taicang Plant 1, 2, 3, 4 and Anting R&D Center are covered under the group registration with the register number DE The present actualized environmental statement, according to requirements of the EMAS III regulation (EC No. 1221/29), is integral part of the environmental statement 213 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. Changes at the Location NEW CONSTRUCTION AND RENOVATION Taicang Plant 1 None Plant 2 The wheel bearing was located in plant 3 and were relocated to plant 2 in 214. Furthermore, the new investment will be continued to plant 2 after production was relocated to Nanjing plant. Plant 3 Hall 5- Phase I The construction work of plant 3 Hall 5 phase 1 was completed in June 214. The total gross floor space is around 7,38 m 2. Among them, production area is 4,5 m 2. The new production line has been installed in 214 for the torque converters and the wet double clutch assembly line. The wet double clutch assembly line, also known as chaku-chaku line (single-piece flow) is the first manufacturing line at Schaeffler worldwide to process wet double clutches for high-volume, mass production. Plant 3 Hall 5- Phase II The Hall 5 phase 2 will begin to be constructed in March 215, and will be finished in October 215. The total gross floor space is around 14,883 m 2. Among them, production area is 9,1 m 2. Anting The construction for new office building in Anting started in april 213 and were completed in february 215. The new building was located in the west of the existing building. The plot size of the new building is 6,767 m 2. The total gross floor space is around 18,584 m 2. Among them, net office apace is 5, 835 m 2. The new building is mainly for extended R&D center and sales office. 2 new gas tanks 2 new underground gas tanks using for fire engine test rig which started construction in October 213 and were completed in March 214. The 2 double-wall underground tanks with volume 5 m 3 each which one is petrol gas tank and the other is diesel gas tank. All the necessary legal requirements are met before start construction tanks.

3 Objectives and Targets Our Achievements Environmental goals Environmental programs Completed Actions Energy Saving Reduce environmental Impact Increase Employee Health Services provided Enhancing increasing management and employees EHS awareness >> At least 1 ton of oil could be recycled from grinding sludge per year at plant 1 Jun. 214 >> Install frequency converts for the emulsion Dec.214 pumps to reduce the pumps power consumption 262,8 kwh electricity is planned to be saved at plant 2 and 3 >> Reduce hazardous waste amount Dec ton/year at plant 1 >> Support Plant Nanjing to set up medical team Dec. 214 and medical center, and provide on-site health services >> Hold Health Day activity and health lectures Dec. 214 with special medical topics for employees >> 1 safety booklet was created Dec. 214 Goal achieved. Part of the goal has been achieved. Goal not achieved. Planning Environmental goals Environmental programs Responsible Completion Reduce environmental impact Energy Saving Enhancing increasing management and employees EHS awareness Increasing employees security satisfaction Increasing employees health satisfaction against severe air pollution Decreasing security incident rates >> Reduce hazardous waste amount 1 % internally comparing with previous year >> Installing sound proofing wall around chiller >> 1133 MWh electricity is planned to be saved per annual >> To replace the normal fluorescent light with LED light, 1.87 MWh electricity is planned to be saved >> Investing solar panel for company street lighting, about 1,95 KWh electricity is planned to be saved >> Investing a used heat reusable system from furnace chimneys in plant 4. This energy is used to heat the process water >> The water of pure water tank can heat by recovery heat device, then adding to washing machine >> Install energy automatic switch of office air-conditions >> Enhance management and employee s EHS awareness to reduce accidents / incidents / loss EHS & Plant 2 Facility Anting Facility Plant 1 Facility Plant 1,2, 3 and 4 Facility Anting Facility Plant 4 Facility Plant 1 Facility Plant 1 Facility EHS >> Employees satisfaction > 92 % Security dept. >> Creating 1 internal measurement against severe air pollution Medical center and EHS >> The security incident < = 4 issues every year Security dept.

4 Key Indicators to EMAS III Taicang Plant 1 Absolute Relative* Database Reference data Added value in Mio. Euro [Mio] General Data Total headcount [EMP] 1,116 1,355 1,555 Size of property [m 2 ] 41,2 41,2 41,2 Total sealed surface [m 2 ] 27,23 27,23 27, [m 2 / Mio ] Biodiversity [%] Input Water [m 3 ] 23, , ,25 3,92 3,448 2,167 [m 3 / Mio ] Electricity [kwh] 37,33,938 38,821,6 44,32,46 717, ,632 67,129 [kwh / Mio ] >> Amount of electricity from renewable energy (only external supply) [kwh] 7,87,748 8,928,968 1,579, ,33 129,45 144,922 [kwh / Mio ] >> Amount of electricity generated inhouse (conventional) [kwh] [kwh / Mio ] >> Amount of electricity generated inhouse from renewable energy [kwh] [kwh / Mio ] >> Percentage of renewable energy with regard to overall consumption [%] Natural gas [kwh] [kwh / Mio ] >> Amount from renewable energies [kwh] [kwh / Mio ] Light fuel oil [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] Fuels for internal logistics Diesel [l] 17,85 5,95 29, [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] Gasoline [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] District heating [kwh] [kwh / Mio ] >> Amount from renewable energies [kwh] [kwh / Mio ] Propan / LPG [kg] 17,82 87, 17,32 2,73 1,261 1,47 [kg/ Mio ] Methanol [kg] 318,62 339,48 446,86 6,127 4,92 6,121 [kg/ Mio ] Energy input [kwh] 4,592,3 41,837,444 48,413,564 78,621 66,34 663,2 [kwh / Mio ] >> Amount of renewable energy with regard to total energy input [kwh] 7,87,748 8,928,968 1,579, ,33 129,45 144,922 [kwh / Mio ] >> Percentage of renewable energy with regard to total energy input [%]

5 Absolute Relative* Database Emulsion concentrates [kg] 29,26 4, 39, [kg / Mio ] Processing oils [kg] 84,15 72,25 14,55 1,618 1,47 1,432 [kg / Mio ] Solvent - VOC [kg] [kg / Mio ] Solvent - Non-VOC [kg] 12, [kg / Mio ] Metal raw materials [t] 5,4 6,8 8, [t / Mio ] Metal semi finished products (external supply) [t] 2,6 4,16 3, [t/ Mio ] Other raw materials [kg] [kg/ Mio ] Output Waste [t] 8,744 8,13 7, [t/ Mio ] non hazardous waste [t] 1,162 1,871 2, [t/ Mio ] >> paper, cardboard [t] [t/ Mio ] >> waste wood [t] [t/ Mio ] >> domestic waste [t] 862 1, [t/ Mio ] >> others [t] [t/ Mio ] hazardous waste [t] 2,98 2, [t/ Mio ] >> grinding swarf / sludge [t] [t/ Mio ] >> waste emulsion [t] 2,9 2, [t/ Mio ] >> waste oil [t] [t/ Mio ] >> others [t] [t/ Mio ] Scrap (ferrous + non-ferrous) [t] 4,62 3,9 5, [t/ Mio ] >> Waste for recycling [t] 1,162 1,9 1, [t/ Mio ] (without scrap) [%] >> Waste for disposal / [t] 2,98 2, [t/ Mio ] removal [%] CO 2-equivalents [t] 38,348 4,14 45, [t/ Mio ] >> CO 2-emissions from combustion processes at this site [t] , [t/ Mio ] >> CO 2-emissions from electricity obtained from external sources [t] 37,34 38,822 44, [t/ Mio ] >> CO 2-emission factor per kwh electricity obtained from external sources [g/ kwh] 1, 1, 1, >> CO 2-emissions from district heating obtained from external sources [t] [t/ Mio ] >> CO 2-equivalent from the refrigerant agent amounts refilled due to leakages [kg] 185,53 586, ,932 3,568 5,919 8,4 [kg/ Mio ] SO 2 - emissions from combustion processes at the site [kg] [kg/ Mio ] NO x - emissions from combustion processes at the site [kg] [kg/ Mio ] Particulate mater emissions [kg] [kg/ Mio ] >> from combustion processes at the site [kg] [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 (

6 Key Indicators to EMAS III Taicang Plant 2, 3 & 4 Absolute Relative* Database Reference data Added value in Mio. Euro [Mio] General Data Total headcount [EMP] 2,777 3,138 3,57 Size of property [m 2 ] 199, , ,437 Total sealed surface [m 2 ] 68,15 16, , [m 2 / Mio ] Biodiversity [%] Input Water [m 3 ] 228,63 296, ,3 2,236 1,975 1,989 [m 3 / Mio ] Electricity [kwh] 66,45,792 78,28,75 97,38,36 651,37 52, ,661 [kwh / Mio ] >> Amount of electricity from renewable energy (only external supply) [kwh] 12,617,1 17,946,613 23,227,56 123, , ,624 [kwh / Mio ] >> Amount of electricity generated inhouse (conventional) [kwh] [kwh / Mio ] >> Amount of electricity generated inhouse from renewable energy [kwh] [kwh / Mio ] >> Percentage of renewable energy with regard to overall consumption [%] Natural gas [kwh] 19,945,181 19,86,44 27,521,63 195, ,43 151,218 [kwh / Mio ] >> Amount from renewable energies [kwh] [kwh / Mio ] Light fuel oil [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] Fuels for internal logistics Diesel [l] 84,538 72,661 79, [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] Gasoline [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] District heating [kwh] [kwh / Mio ] >> Amount from renewable energies [kwh] [kwh / Mio ] Propan / LPG [kg] 68, , 145, [kg/ Mio ] Methanol [kg] 53,69 756,5 862,62 5,23 5,4 4,74 [kg/ Mio ] Energy input [kwh] 9,938,97 14,28, ,163,16 891, ,22 726,171 [kwh / Mio ] >> Amount of renewable energy with regard to total energy input [kwh] 12,617,1 17,946,613 23,227,56 123, , ,624 [kwh / Mio ] >> Percentage of renewable energy with regard to total energy input [%]

7 Absolute Relative* Database Emulsion concentrates [kg] 115,342 15, 77,784 1,131 1, 427 [kg / Mio ] Processing oils [kg] 276,32 188,7 325,92 2,79 1,258 1,791 [kg / Mio ] Solvent - VOC [kg] 19, [kg / Mio ] Solvent - Non-VOC [kg] 183,29 1,6 [kg / Mio ] Metal raw materials [t] 27,21 35,7 53, [t / Mio ] Metal semi finished products (external supply) [t] 3, 38,8 38, [t/ Mio ] Other raw materials [kg] [kg/ Mio ] Output Waste [t] 26,419 39,77 48, [t/ Mio ] non hazardous waste [t] 2,118 4,257 5, [t/ Mio ] >> paper, cardboard [t] , [t/ Mio ] >> waste wood [t] 1, , [t/ Mio ] >> domestic waste [t] 2,859 3, [t/ Mio ] >> others [t] [t/ Mio ] hazardous waste [t] 2,982 3,75 3, [t/ Mio ] >> grinding swarf / sludge [t] 2,311 2,957 2, [t/ Mio ] >> waste emulsion [t] [t/ Mio ] >> waste oil [t] [t/ Mio ] >> others [t] [t/ Mio ] Scrap (ferrous + non-ferrous) [t] 21,319 31,7 39, ,73 [t/ Mio ] >> Waste for recycling [t] 2,118 1,398 2, [t/ Mio ] (without scrap) [%] >> Waste for disposal / [t] 2,982 3,75 3, [t/ Mio ] removal [%] CO 2-equivalents [t] 71,82 83,689 14, [t/ Mio ] >> CO 2-emissions from combustion processes at this site [t] 5,21 5,66 7, [t/ Mio ] >> CO 2-emissions from electricity obtained from external sources [t] 66,46 78,29 97, [t/ Mio ] >> CO 2-emission factor per kwh electricity obtained from external sources [g/ kwh] 1, 1, 1, >> CO 2-emissions from district heating obtained from external sources [t] [t/ Mio ] >> CO 2-equivalent from the refrigerant agent amounts refilled due to leakages [kg] 24,18 57,2 2,2 314 [kg/ Mio ] SO 2 - emissions from combustion processes at the site [kg] [kg/ Mio ] NO x - emissions from combustion processes at the site [kg] 2,632 3,18 3, [kg/ Mio ] Particulate mater emissions [kg] [kg/ Mio ] >> from combustion processes at the site [kg] [kg/ Mio ] >> from production an other processes [kg] [kg/ Mio ] VOC-emissions [kg] 19, [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 Electricity Consumption Plant 1 electricity consumption in 214 increased by approximately 14 % and the average electricity consumption has increased by 11 % in Plant 1 comparing with 213. The reason is as below: 1 7 sets new machines are installed in 214, its total electric power is 3,7 KW; 2 Including 2 sets furnaces, commissioning 4 months, consumption 5, kwh each furnace every day; 3 Running a waste water treatment machine in 214, consumption 1,5 kwh every day. [MWh] 5, 4, 3, 2, 1, Electricity Consumption Plant 1 [MWh / 6 Electricity Consumption [MWh] Average [MWh / [MWh] Electricity Consumption Plant 2, 3 & [MWh / Plant 2, 3 and 4 electricity consumption increased by 25 % in 214. The average electricity consumption in Plant 2, 3 and 4 has increased by 6 % in 214 comparing with 213 due to increased added value. The reason is as below: 15, 9, 75, 6, P2 Large Size Bearing (LSB) relocated to Nanjing new plant, caused a lot of energy consuming and production added value transfer Nanjing. 2 P4 Soft area installed air condition, started running from Sept Wheel Bearing moving from Plant 3 to Plant 2, more commissioning, less production. 4 Pump bearing moving from Plant 1 to Plant 2. Anting electricity consumption increased by about 12 % in 214 comparing with 213. However, the average electricity consumption remains stably same (3 MWh / headcount) in 212, 213 and 214 refer to headcount. 45, 3, 15, 5 Electricity Consumption [MWh] Average [MWh / [MWh] 5, 4, 3, 2, 1, Electricity Consumption Anting 6 55 [MWh / Head] Electricity Consumption [MWh] Average [MWh / Head]

9 Input Water Consumption Comparing with 213, water consumption decreased by around 28 % in 214 in Plant 1. Meanwhile, the average water consumption is decreased by 3 % refer to the added value in plant 1. That s because plant 1 has improved the water management, such as install a valve time controller in washing station. [m 3 ] Water Consumption Plant 1 25, 2, [m 3 / 45 4 [m 3 ] Water Consumption Plant 2, 3 & 4 4, 35, 3, 25, 2, 15, 1, 5, 2 Water Consumption [m 3 ] Average [m 3 / [m 3 / , 35 1, 5, Water Consumption [m 3 ] Average [m 3 / The total water consumption in Anting increased steadily by approximately 23 % in 214 comparing with 213 due to increased headcount. However, average water consumption refer to headcount is increased by 5 % comparing with 213. Water consumption in Plant 2,3 and 4 increased by 22 % comparing with 213. The average water consumption in 214 increased by around 4 % comparing with 213 refer to the added value. That s because construction water of Hall 5 and some water consumed production expanded. [m 3 ] Water Consumption Anting 35, 3, 25, 2, 15, 1, 5, [m 3 / Water Consumption [m 3 ] Average [m 3 / Head] 1

10 Input Fuel Consumption Input Location Year Consumption 21 59, ,624 Plant , ,95 Diesel Oil (Liter) , , ,898 Plant 2, 3 & , , , ,26, ,318,867 Plant 2, 3 & ,899, ,891,467 Natural Gas (m 3 ) 214 2,621, , ,77 Anting , , , Plant Propane (Ton) Plant 2, 3 & Diesel consumption In 213, the heat recovery was new installed and operated very efficiency. In 214, the diesel consumption in plant 1 increased rapidly, that s because of the heat recovery reduce the efficiency due to several reasons. The heat recovery could be maintained and repaired on a regular basis and kept in a good condition. Natural Gas consumption Comparing with 213, the natural gas consumption in plant 2, 3 and 4 has increased by 38 %. That s because the heat treatment lines expanded their capacity. Propane consumption The consumption of Propane also increased about 2 %. It is also because of new furnaces.

11 Output Waste Management All waste were transferred to external waste management companies. Metal waste was sent to steel factory directly and will not show in the chart. [kg / 3,5 3, 2,5 Waste Management Plant 2, 3 & 4 Most of wastes generated at this location are recycled as per legal specifications. The remainder wastes generated here is also disposed properly. In 214, plant 1 installed a evaporator system, so the waste emulsion quantity decreased dramatically. In 214, plant 2 relocated some production lines to Nanjing plant and some remain production lines expanded their capacity. So the waste components and quantity has changed a little. [kg / 8, Waste Management Plant 1 2, 1,5 1, 5 Waste for Recycling Other Waste Total waste at Taicang location consists of the following types: Waste for Recycling: >> Cardboard >> Wood >> Plastic [%] Non-Hazardous Waste 214 7, 6, 5, 4, 3, Cardboard 49 % Wood 47 % Plastic 4 % 2. 1, Waste for Recycling Other Waste Other waste: >> Liquid waste >> Solid waste [%] Hazardous Waste 214 Waste sludge 77 % Waste oil 2 % Oily water 21 %

12 Output Emissions Indirect CO 2 Emission Most of CO 2 emissions are caused by electricity supplied from outside sources. Taicang and Anting are located in East China that most electricity is generated by burning the coal. An emission factor of 1. kg of CO 2 emitted for every 1 kwh of electricity used. Estimated Direct CO 2 Emissions from Electricity Usage [Tons / Yr] Plant 1 37,34 38,822 44,32 Plant 2, 3 & 4 66,46 78,29 97,38 Anting 3,616 4,236 4,288 Total 17, ,86 145,917 Direct CO 2 Emission We converted usage of diesel oil, natural gas and propane to CO 2 emissions. Diesel oil is used for heating and hot water in Plant 1. Nature gas is used for heat treatment and hot water only in plant 2 & 3. Estimated Direct CO 2 Emissions from fuels [Tons / Yr] Diesel oil Plant ,5 Plant 2, 3 & ,41 Anting Propane Plant ,13 Plant 2, 3 & ,1 Anting Natural Gas Plant 1 Plant 2, 3 & 4 3,69 3,594 4,98 Anting Total 4,741 4,694 6,366 Estimated Direct CO 2 Emissions from the refrigerant agent amounts refilled due to leakages [kg/ Yr] Plant 1 185,53 48, ,932 Plant 2, 3 & 4 24,18 57,2 Anting Total 389,71 41, ,146 R22, R134A, R47C, R44A as refrigerant agent are used in the plant. The consumption of refrigerant is high due to the pipe line of the chiller broken in plant 1. VOC Emission Some solvent has been used for washing machine to clean the parts. However, the VOC emission definition in China is not cleared. Therefore, the EU legislation is adopted and data was collected since 214. >> having at K (= 2 C) a vapor pressure of.1 kpa or more, or >> having a corresponding volatility under the particular conditions (temperature) of use.

13 Verifier s Declaration The undersigned, Dr.-Ing. Norbert Hiller, EMAS Environmental Verifier, registration number DE-V-21, accredited or authorized for the area designated by NACE code 25 and confirms that his inspection of the location at Plant 1 18 Chaoyang Road, Taicang Jiangsu Province, P.R., Plant 2, 3 & 4 No. 1-3 Schaeffler Rd, Taicang, Jiangsu Province, P.R., Anting No. 1 Antuo Rd, Anting, Jiading District Shanghai, P.R. China as indicated in the updated environmental statement (Environmental Protection and Occupational Safety Report) of) Schaeffler China, registration number D complies with all requirements stipulated by (EU) Directive No /29 by the European Parliament and Council dated November 25, 29 on the voluntary participation of organizations in a joint system for environmental management and eco-audits (EMAS). The signature at the end of this statement confirms that >> the inspection and validation have been completed in full agreement with the requirements stipulated in (EU) Directive 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 (Environmental Protection and Occupational Safety Report) for the location at Plant 1 18 Chaoyang Road, Taicang Jiangsu Province, P.R., Plant 2, 3 & 4 No. 1-3 Schaeffler Rd, Taicang, Jiangsu Province, P.R., Anting No. 1 Antuo Rd, Anting, Jiading District Shanghai, P.R. China as part of Schaeffler China represent a reliable, credible and true picture of all activities at this location within the area indicated in the environmental statement. This statement cannot be equated to EMAS registration. EMAS registration can be completed by an authorized agency in accordance with (EU) Directive No /29. This statement must not be used as an independent basis for informing the public. Dr.-Ing. Norbert Hiller Done at Schaeffler China, on 16/3/215 Questions about environmental Protection at the location: Schaeffler China Corporation Questions about environmental protection by Schaeffler: Li You No. 1-3 Schaeffler Road, Taicang, Jiangsu Province, li.you@schaeffler.com China: From other countries: 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 fire protection as well as general information on social benefits pr ovided by the company and this location. Schaeffler Technologies AG & Co. KG im Dezember 215 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 February 216 at the latest. In the years between, an annual update of the Environmental Statement will be compiled for validation by the environmental verifier.