Metall Sustainability Report 2014 Diehl Metall Röthenbach
Contents Introduction 3 Brass Material Cycle 3 Environmental Goals and Measures 4 Energyefficiency 5 Watersupply and Wastewater 6 Air Pollution Control 7 Packaging Semi-finished Products 8 Waste/Waste Separation 9 Reach 11 Environmental Initiatives 11 2
Introduction Brass Material Cycle Smelting furnace (from top left), cast billets, bar and tube material, scrap The stringent requirements of our customers and the importance of quality, reliability and sustainability with respect to products guide our actions at Diehl Metall. Diehl Metall maintains open communication with authorities and the public. Protecting the environment and the health of our employees is always at the center of attention right from the initial product idea. The material used is subjected to intensive checks to fulfill the highest quality standards from the cast part to the finished product. Modern waste gas purification facilities ensure that the legal limit values are not merely observed but are significantly below them. The products are characterized by ecological safety. The production processes are environmentally friendly. As an important representative of copper materials, brass is characterized by a large array of properties and has become indispensable in daily life. Copper materials are environmentally sound, very valuable and are 100 % recyclable. Diehl Metall thus accepts all the chips and leftover pieces generated during further processing from our customers and feeds them back into the production process again. In this way, valuable raw materials are protected and approx. 60-70% energy is saved compared to the primary process. This is due to the fact that when recycling copper, it is no longer necessary to consume the same level of energy that is associated with ore mining as well as with the processing and transport of ores and ore concentrates. Diehl Metall Röthenbach is certified according to the DIN EN ISO 14001 environmental management system and the DIN ISO 50001 energy management system. To safeguard and further develop attained goals, the energy and environmental management systems undergo regular checks by independent experts. 3
Environmental Goals and Measures In day-to-day work, the highest value is placed on energy efficiency and a caring approach to the environment. Idea management, an employee suggestion scheme and expert panels are established to identify savings and improvement measures. To uncover energy savings potential and check the effectiveness of the measures, a high level of transparency and good availability is required with respect to the consumption data. This is supported by energy management software. All production processes at Diehl are assessed with respect to their environmental effects. Assessment criteria include the type and volume of wastewater and waste, energy needs and emissions. From this assessment, measures may be derived, prioritized and implemented. Energy-saving measures Examples of measures undertaken recently include eliminating leakages in the compressed air system, exchanging the circulating pump in the boiler house, installing a new control system for the hydraulic unit of the indirect extrusion press for bar material, overhauling another hydraulic system, and the installation of energy-efficient illuminants in reflector lamps.these measures enabled approx. 300,000 kwh of electricity to be saved. 4 Measures for environmental protection To reduce noise, sections of the road on the company premises were renewed. Besides this, parts of the sewer system and the oil separator facilities were modernized.
Energy Efficiency 1999 until 2014 at the Röthenbach Location Energy use for the production of bar and tube material. Reference year 1999 = 100 % The consumption of electricity and natural gas has decreased by approx. 25 % over the past 10 years. To achieve this, existing facilities were modernized and investments made in new plant technology. Measures for increasing energy efficiency were implemented consistently. 5
Watersupply and Wastewater Wastewater treatment plant Water is supplied by the company s own well. The water is controlled regularly by an independent measuring institute. Wastewater from production is processed in a wastewater treatment plant and is directly discharged into the Pegnitz River. An in-house laboratory and the water authority carry out regular checks to ensure that the limit values are being adhered to. Wastewater discharge volumes in m³ 184,317 129,852 85,600 94,600 81,362 91,813 69,642 69,845 99,740 102,682 64,650 59,500 74,405 105,812 98,959 98,959 2007 2008 2009 2010 2011 2012 2013 2014 6 Sanitary wastewater Production wastewater
Air Pollution Control Exhaust stack of the dust extraction unit The dust generated during smelting and casting brass is extracted and retained in filter systems. Each year, 1.3 billion Nm³ of raw gases are extracted and filtered. The electricity requirement of the dust extraction unit amounts to 2.0 million kwh. Regular maintenance of the measuring equipment ensures that no faults occur. Emissions are monitored continuously. Measuring data of air pollutants: The limit value according to the Technical Instructions on Air Quality from 2002 amounts to 5 mg/m³ total dust content for cleaned exhaust gases. The total dust content in the cleaned exhaust gases was always below 1 mg/m³ and thus far beneath the legal limit value. Cyclone separator Filter chamber 7
Packaging Semi-finished Products Great importance is attached to reliable and environmentally sound packaging solutions. As far as possible, bars and tubes from semi-finished production are dispatched in wood packaging which can be used several times in circulation. Forgings supplied to the automotive industry are usually transported in reusable packaging. Automotive manufacturers have introduced a container management system. Other forgings are dispatched in returnable packaging such as pallet cages, wooden crates or plastic containers. For disposable packaging, cardboard and wood are used. These packaging materials can be easily recycled. 8
Waste/Waste Separation In-house recycling center Diehl Metall takes care to avoid waste with respect to auxiliary and operating materials during production processes. Where waste is unavoidable, the materials are recycled. By separating waste on a daily basis, all employees play their part. Waste is collected in the designated containers and properly disposed of. The goal is to avoid waste or else to reduce and recycle it. Recycling protects the environment and contributes to protecting resources. For this purpose, a recycling center was set up. In the recycling center, reusable waste is separated. Here, auxiliary production materials such as lubricoolants from machining, soap baths for tube drawing and the contents from oil separators are treated. Cardboard, straps and foil from packaging is compacted into bales by means of a press. This enables homogenous separation for recycling. The baling press reduces the waste volume, thereby decreasing the number of times waste needs to be transported by truck to the recycling plant. 9
Classifying waste Types of waste in t 2013 2014 136 128 134 94 105 99 74 44 56 63 49 64 55 13 14 16 13 21 Grease Foil/Plastic Road sweepings Cleaning cloths/ Solvents Waste oil Waste paper Furnace linings Wood Industrial waste The waste recycling rate amounts to 97 %, i.e. almost all waste generated at Diehl is fed back into the reusable material cycle. Metallic production waste is recycled completely. Hazardous waste refers to waste which, due to its composition or nature, requires special monitoring and care during transport, storage and recycling. These materials are handled by trained specialists. During disposal and recycling of hazardous waste, Diehl Metall works with certified waste management facilities. 88 % of all waste generated at Diehl Metall is classified as non-hazardous. Checks are regularly carried out to determine whether materials can be replaced by more environmentally sound alternatives. Classifying waste Recycling/Disposal Hazardous/Non-Hazardous Disposal 3% 12% hazardous waste 10 Recycling 97% 88% non hazardous waste
Environmental Initiatives As an importer of copper and zinc, Diehl Metall has registered all important materials at the European Chemicals Agency (ECHA) under REACH. The alloys produced by Diehl Metall do not contain any materials which are classified as those of very high concern according to the REACH regulation and which are listed in Annex XIV of this regulation, which is known as the candidate list. We always keep an eye on this list, as it is continuously updated. In the event that the constituents of our products need to be taken up into the list, Diehl Metall would inform its customers along the supply chain and change its production process if necessary. Diehl Metall is a founding member of Metals pro Climate (Metalle pro Klima), an initiative of leading companies in the non-ferrous metal industry. In this initiative, the contributions which companies are making to climate protection are rendered transparent. Diehl Metall has published Best Practice examples from the areas of recycling, production and products on the website of Metals pro Climate. With its plant in Röthenbach, Diehl Metall participates in the Bavarian Environmental Package (Umweltpaket Bayern). The Bavarian Environmental Package is a voluntary agreement between the Bavarian government and Bavarian industry. At the forefront of the agreement is the conviction that the natural basis for life may be better protected with voluntary and reliable cooperation between state and industry than by laws and regulations alone. 11
Contact data: Diehl Metall Stiftung & Co. KG Heinrich-Diehl-Str. 9 D-90552 Röthenbach a.d. Pegnitz Contact partner: Dr. Claus Heubeck Environmental officer Diehl Metall Stiftung & Co. KG Tel. + 49 911 5704-405 V-Oe/11/2014/Au