environmental statement 2012 - wieland plumbing...nickel as well as chromium, titanium and silicon....
TRANSCRIPT
Environmental Statement 2012Vöhringen works
Preface................................................................................................3
Environmental policy....................................................................4
Origins and environmental policy milestones........................5
Description of location.................................................................6
Copper as raw material – the most sustainable metal........7
Metals and Casting Division.......................................................8
Rolled Products Division.............................................................9
Extruded and Drawn Products Divison.................................10
The environmental management system..............................12
Legal conformity..........................................................................12
Input diagram...............................................................................13
Output diagram............................................................................15
Organisation of environmental protection
at Wieland-Werke AG................................................................17
Identification and review of environmental aspects...........18
Supplies.........................................................................................19
Waste Disposal............................................................................21
Indirect environmental aspects..............................................23
Contingency precautions and activities................................23
Organisational structure of Wieland-Werke AG..................24
Validation certificate...................................................................25
Enviromental performance 2009 to 2011............................26
Enviromental programme 2012..............................................27
Contents
3
Preface
Our Vöhringen works is the largest loca-tion within Wieland-Werke AG and has plant whose operation requires high energy input. This explains our special commitment to environmental and cli-mate protection.
The works site is situated in the imme-diate vicinity of the town of Vöhringen and the river Iller. This very fact brings with it a high degree of responsibility for the protection of water resources, the air and the soil.
To achieve our environmental goals, we promote the environmental awareness of our employees. In addition, we also employ the very latest technology to enable us to conserve valuable resour-ces and use energy efficiently.
Wieland-Werke AG
Ulrich Altstetter and Dr. Ulrich Hartmann, Members of the
Executive Board
4
Environmental and
energy policy of Wieland-Werke AG
Wieland-Werke AG is conscious of its responsibility to nature and to society. Our environmental and energy policy aims to contribute towards protecting our environment and sustaining its quality for the life of the community in general. Environmental protection and the economical use of energy and resources are a managerial task. Environmental interests and the economical use of energy are considered in all the decisions taken in the Company.
In essence, this means:
• We undertake to continually improve environmental protection within the Company. This includes the prevention of pollution, such as emissions and waste, as well as the improvement in the energy efficiency of our processes.
• From the development stage on, we ensure that our products are manufactured in as ecologically sound a manner as possible. Thanks to the technical properties of our products, their use frequently leads to an improvement in the energy efficiency of processes. Since copper and copper alloys are 100 % recyclable, our products are infinitely recyclable.
• We meet all legal obligations as well as other commitments undertaken by us regarding environmental protection, energy use, energy consumption and energy efficiency.
• In accordance with the principles of this policy, we define concrete goals in order to realise the above mentioned improvements. To this end, we provide any information and resources necessary.
April 2012
• We conduct an open dialogue with our customers, suppliers, public authorities, trade and professional organisations and cooperate with them in a constructive manner. This includes the publication of the principles of our environmental and energy policy.
• We expect our service providers and suppliers to act in accordance with the principles defined in this policy. This equally applies to the delivery of products and services.
• We review our divisions and processes on a regular basis in order to determine whether we have achieved our goals and to ascertain whether the management systems are effective. We continually improve our environmental and energy management system.
Wieland-Werke AG
5
Environmental policy milestones
1966 Start-up of an acid concentration unit for
regenerating pickling concentrates and a
facility for treating wastewater from produc-
tion processes
1973 First dedusting plant set up in the casting
plant
1976 Construction of a scrubber for cleaning the
exhaust air from mixed acid pickling baths
together with a treatment unit for the resultant
scrubbing waters
1977 Installation of three ion exchanger systems for
reducing the rinse water required in the pick-
ling processes
1978 Establishment of a large central wastewater
treatment facility for wastewaters from our
production processes
1981 Construction of a second dedusting plant
1990 Construction of the third dedusting plant
1999 Two new dedusting facilities replace the 1973
plant; waste material preparation and loading
bay built
2000 Coal-fired and heavy oil-fired boilers for
in-plant power generation decommissioned
2002 Chip unloading and transport to the casting
plant optimised
2002 Abfallverbrennungsanlage stillgelegt
2003 Introduction of an environmental management
system
2008 Construction of an electro-tinning line for strip
with its own wastewater treatment facility
2008 New flood dyke completed along the southern
works boundary
2010 Construction of a fifth dedusting plant for a
new billet casting line
2011 Construction of a dross sorting line for the
recovery of metals
2012 Integration of an energy management system
into the existing environmental management
system; introduction of an occupational safety
and health management system
Origins
In 1820, Philipp Jakob Wieland took over the fine art and bell foundry in Ulm from his uncle Thomas Frauenlob. After only a few years he ventured to establish the first brass plate rolling mill in the kingdom of Württemberg, as it was then, and by 1828 he had made a name for himself as
an innovative manufacturer of brass plate and wire. In 1864 he acquired the Krauss Mill in Vöhringen, 17 km south of Ulm, where he set up a brass rolling and wire drawing works. The site on the river Iller allowed the exploitation of water power, which is still used to this day.
Krauss Mill at Vöhringen
6
Description of location
The Vöhringen works at Wielandstr. 26, 89269 Vöhringen, lie in the Iller valley some 17 km south of Ulm in the southern German state of Baden-Württemberg. The site includes the casting plant, the metal store and the central research and development establishment. Manufacturing facilities for tube and pipe, rolled products and extruded and drawn products are also situated here. The works premises extend along the western edge of the town of Vöhringen and are divided by the Vöhringen-Illerrieden road, Illerstrasse, into a southern and a northern section. The northern section is designated as a business park, the southern section as an industrial zone. In all, the Vöhringen site covers approx. 560,000 m², with buildings accounting for some 265,000 m², surfaced yards and roads about 165,000 m² and unsurfaced areas some 130,000 m². Some 2,400 people are employed at the Vöhringen works.
7
Copper is 100 percent recyclable. Currently, recycled materials already account for about half of Germany’s annual copper requirements. It is estimated that 80 percent of all copper ever extracted is still in use today. Copper recycling produces little or no waste. Not only that, it consumes only about 25 percent of the energy required for extracting the metal from copper ore. Copper and its alloys can be recovered from waste materials without any loss of quality. But energy is saved in other ways in addition to recycling. After silver, copper is the best electrical conductor, so copper in engines, power lines and electrical appliances ensures high energetic efficiency. Copper is also an excellent heat conductor, outstripping all other industrial metals. In particular, copper boosts the efficiency of alternative energy sources such as solar and wind power, geothermal energy and
fuel cells. Another benefit is the extreme longevity of products made of copper: whether in roofing, tubing, electric cables and wires or water pipes — as a rule they last for decades. This is not a recent finding – even the water supply system at Cheops' Pyramid in Egypt was made of the "red metal". More than 5,000 years on, it is still intact and usable. As far as sustainability goes, our material is indispensable: With the help of copper, we can preserve resources, avoid waste and use energy more economically.
Copper as raw material – the most durable metal
8
Copper is the main component in our products. Our casting plant produces a large number of conventional and innovative alloys, with the main alloying components being zinc, tin and nickel as well as chromium, titanium and silicon. We use new copper, for example in the form of copper cathodes, as well as high-quality secondary raw materials which are obtained from our own and customers' manufacturing processes. At the metal store we record, check and packet all incoming metal deliveries. From intermediate storage and weighing out, the charge metals required for the alloy recipes go to the casting shop, where they are melted down in induction furnaces. Our employees monitor the chemical composition of the alloys by taking ladle samples from each melt for spectrometric analysis. Following clearance, the melt is transferred to the casting furnaces. We still use the Wieland-Junghans casting process developed in our Company in 1933: an automatic flow control system feeds the melt from the furnace into water-cooled moulds. The cast strands are then withdrawn either continuously or semi
continuously and allowed to cool. Precision casting produces near-net shape rods, tubes or sections in copper alloys in a continuous process. Spray forming is a process that allows the production of billets from materials which are difficult to cast. As the melt leaves the tundish, it is nitrogen-atomized into small droplets, on average 60 to 80 µm in diameter. Following a preset trajectory, the droplets deposit on a collector plate, where they solidify under the effect of their kinetic energy. Spray forming produces a finer grain and more homogeneous structure than conventional casting. The Metals Division is the starting point of our production process. Continuously cast rounds are processed into rods and bars, tubes, wire and sections. Rectangular products are the prematerial for strip, sheet and plate.
Metals and Casting Division
9
Rolled Products Division
Semi continuously cast slabs in unit weights of up to 15 tonnes form the starting material for our Rolled Products Division. These ingots are first heated in a gas-fired walking beam furnace to the optimum shaping temperature, between 600 and 1,000 °C, depending on the material. Reversing hot-rolling reduces the slab thickness to between 10 and 18 mm. After that, both the casting skin and any oxides generated during hot rolling are removed by milling. The slab is now ready for the first cold rolling step, followed by the first intermediate anneal. Repeated rolling, annealing and pickling (to remove the oxide layers) alternate until the strip achieves its final thickness and strength as ordered by the customer. Finally, slitting shears cut the strip lengthwise to the specified width. If required, we
weld several strips together in order to provide our customers with a convenient delivery form. The strip is supplied either as coils or as several stacked and interconnected rings called a multicoil. A hot-dip tinned surface is frequently specified for electrical applications. Many copper alloys can also be supplied in the form of sheet, which is cut on cut-to-length lines from strip or, alternatively, rolled piece by piece to customised sizes. Application areas for strip and sheet are the electronic and electrical industry, the automotive, cutlery and jewellery industries, and the building trade.
In our electroplating plant we can also apply “intelligent” surface coatings to the finished strip in line with customer specifications. The manufacturing programme of the Rolled Products Division also includes special alloys for the production of current carrying components for electronic applications. Based on these materials the use of natural resources in production can be significantly reduced.
Slitting (strip)
Intermediate and finish rolling
Cutting to length (sheet)
Preheating Hot rolling Milling
Cold rolling
Inspection
Intermediate annealing
Manufacturing process for strip and sheet
InspectionDrying Rinsing Pickling
InspectionDryingRinsingPickling
Continuous annealing
10
Continuously cast or spray formed billets are the starting material for our extruded and drawn products. The first processing step involves heating the billets to the material-specific forming temperature between 600 and 1,000 °C. Hydraulic extrusion presses then form them into cross sections of varying degrees of near-net dimensions. While alloys with good hot-forming characteristics can be formed to the final dimensions in a single drawing process, more difficult materials need repeated rolling and drawing passes until the desired cross section
a) Rods and wire
Anwärmen
Beizen/Spülen
Ziehen
Ablängen
Stangen angefast und angespitzt
Richten
Prüfen
Pressen
Schema der Fertigung von Messingstangen
is achieved. Recrystallization annealing may also be called for, depending on the extent of cold hardening. Once the final dimensions have been reached, the section or rod is cut to the desired length and then straightened or sized as required. Alternatively, cross sections can be delivered as wire coiled with or without overlap, as specified by the customer. The surface is pickled as required both after extruding and after intermediate and final annealing. Rods and wire are processed by our customers into a wide range of
different products which are used, for example, in the electrical, automotive, metal optical and jewellery industries, in the building and construction trade and in arts and crafts. In addition the Extruded and Drawn Products Division develops lead-free copper alloys for the manufacture of components for drinking water installations.
Extruded and Drawn Products Division
11
Production in the Tube Division starts from continuously cast billets. These are heated to a hot forming temperature of about 950 °C and then extruded to form copper tubing for further processing by cold working on bull blocks or chain-type drawing machines. This takes place in multiple consecutive steps during which the tubing is drawn through round dies, with a mandrel serving as internal tool to reduce the wall thickness. Copper's excellent forming properties mean intermediate annealing is not necessary. Depending on the specified strength, however, heat treatment may be required when the final dimensions have been reached or almost reached. Finally, the tubing is
b) Tubes for plumbing and industrie
straightened, degreased as appropriate and delivered straight or as coils or level-wound coils to customer specifications. Copper tubing for certain applications may require further special treatment. Tubing for industrial use, for instance, must meet particularly high standards of internal cleanliness. Such tubing is cleaned and its ends are closed with plastic caps if requested. Pipe for drinking water supply systems is protected against corrosion using a special process. Pipe used for panel heating elements is protected with a thin plastic coating. We also produce insulated pipe, thickly coated to prevent heat loss. The most important domestic engineering uses of copper tubing and
Anwärmen
Fertigziehen
Richten
Richten
Prüfen
Prüfen Spulen
Ablängen
Rohre in geraden Längen
gespulte Rohre
Vorziehen
Pressen Abkühlen
Schema der Fertigung von Kupferrohren
pipe include conventional and panel heating systems as well as drinking water and oil and gas installations. In the industrial sector, copper tubing is utilised in heating/refrigeration and air conditioning (HVAC) systems and in the construction of vehicles, machinery, plant and process equipment. This includes in particular tubes for the manufacture of solar heat absorbers for solar thermal equipment. Due to the basic material copper these tubes are characterised by outstanding heat resistance and excellent thermal conductivity.
12
Fulfilment of the elements set out in the control cycle on the left is required for successful certification in accordance with DIN EN ISO 14001:2005 and validation according to EU Regulation No. 1221/2009 "EMAS". The responsibilities, processes and procedures called for in the implementation of these elements are regulated by process descriptions and working instructions. These are integrated into the Wieland-Werke AG QM Manual. The processes which are relevant and essential to environmental management are determined by systematic "Identification and Review of Environ-mental Aspects" (see p. 18). Employee involvement is based on close co-operation with the Works Council and on the Employee Suggestion Scheme which also includes an Environmental suggestions category. In addition, in line with our LEAN Management policy, many employees are committed to the group-wide continuous improvement process which also ecompasses environmental protection issues.
The Environmental Management System
A large number of environmentally relevant laws and ordinances and various sets of rules apply to the Vöhringen location and the facilities in it which are subject to licensing. Compliance with the related requirements is monitored and reviewed at regular intervals.
All additionally applicable rules and requirements follow from the environ-mental legislation and approvals. Supervision of compliance with them has been assigned to authorised officers. The related responsibilities are shown in the following organisation chart (page 17).
Legal conformity
The most important German laws are:
• the Federal Immission Control Act (BImSchG)
• the Water Act (WHG)
• the German Closed Substance Cycle Act (KrWG),
• the Federal Soil Protection Act (BBodSchG)
Status report (Environmental review)
Environmental and energy policy
Implementation and operationResponsibilities
Training
Communication
Documentation
Emergency preparedness
PlanningEnvironmental aspects
Legal requirements
Environmental programme, targets
Management review
CheckingAudit System
Monitoring and measurement
Continuous improvement
13
Diagramme Input
2008 2009 2010
473,900
112,000
5,700
356,200
2011
333,400
82,400
4,000
247,000
454,500
90,600
6,400
357,500
442,800
73,700
5,400
363,700
Raw material input (t)
Total material used
New metals
Intermediate alloys
Scrap
2008 2009 2010
186.9
183.0
3.9
2011
155.3
129.9
25.4
188.4
178.6
9.8
188.1
187.9
0.2
Gas consumption (million kWh)
Total gas consumption
Natural gas
Butane gas
2008 2009 2010
10,062
4,249
5,363
450
2011
8,614
2,933
5,341
340
11,096
4,181
6,447
468
10,593
3,766
6,458
369
Inert gas consumption (thousand m³)
Total inert gas consumption
HNx
Nitrogen N2
2Hydrogen H
Natural gas and butane are alternative energy sources. Which one is used depends on the current price situation. Owing to the price of high butane, demand in 2011 was met almost entirely with natural gas.The share of gas consumed for heating purposes rose slightly from 35 to 38 percent.
Inert gas is employed at the annealing furnaces to prevent the formation of oxide layers. The inert gas known as HNx is generated in our own inert gas plants with natural gas or butane as the primary energy source.Remaining needs are covered with gases bought in as technical gases (N or H), which are mixed on site to create the desired ratio. In some cases, annealing is performed in an atmosphere of pure hydrogen.
New metals and intermediate alloys have fallen from 21 percent of total material input in 2010 to 18 percent.
14
2008 2009
Hilfs- und Betriebsstoffe
Chemikalien fest und flüssig incl. Entfettungsmittel t
Bearbeitungsflüssigkeiten,Öle und Fette t
Diesel und Heizöl t
2010
955
2011
1,6942,102
326486
738
2,339
430
1,046
2,575
406
1,060
2008 2009 2010
9.846*
9.792
0.048
0.006
2011
8.121*
8.079
0.028
0.014
9.236
9.192
0.041
0.003
8.962
8.919
0.040
0.003Drinking water of the townof Vöhringen
Drinking water (=groundwater)
Service water (=groundwater)
Total water cosumption
Water consumption (million m3)
2008 2009 2010
406.0
398.9
7.1
2011
324.0
317.1
6.9
399.0
392.0
7.0
396.1
389.5
6.6
Electric power consumption (million kWh)
Total power consumption
Bought-in electicity
Hydro-electric power(in-plant generation)
Water consumption relative to quantity output fell by approximately 1 percent.
The increase in chemical consumption is attributable to the higher consumption of pickling acids and regeneration chemicals for the generation of deionized water in strip production. In this sector, customers are demanding ever higher quality standards, and this in turn necessitates additional pickling and flushing processes.
Electric power consumption relative to quantity output remained almost unchanged.
* Values have been adjusted.
15
Diagramme Output
2008 2009 2010
40,909
8,939
18,608
250
13,112
2011
32,797
7,100
14,680
90
10,927
35,264
8,854
18,399
92
7,919
33,437
10,199
19,273
137
3,828
Waste (t)
Total waste
Waste for recycling
Scrap from metal stock for recycling
Waste for disposal
Debris
2008 2009
9.846*
0.266
9.232
0.2940.054*
2010 2011
8.121
0.266
7.601*
0.2110.043*
9.236
0.266
8.690
0.2360.044
8.962
0.267
8.372
0.2790.044
Wastewater disposal (million m³)
Total water disposal
Sanitary wastewaterTreated wastewater
Cooling water
Evaporation characteristicCasting plant cooling towers
2008 2009
434,700
149,900*
150,800
61,700
362,400
2010
306,400
100,100*
95,600
55,800
251,500
2011
415,505
148,700*
133,100
58,400
340,200
404,400
138,000
139,200
57,700
334,900
Finished products (t)
Total finished products
Rolled products
Extruded/drawn products
Output casting plant
Tubes
The 33,437 t of solid waste in 2011 included 5,773 t of hazardous waste.The largest contributors of this were:
- Zinc oxide filter dust - Emulsions and scrubbing liquids containing oil- Sludge from the wastewater treatment plants
The quantity of wastewater in relation to quantity output fell slightly overall (–1 percent). The increase in treated wastewater is attributable to larger quantities of cooling water from wire production as a consequence of higher capacity utilization in production. Because the cooling circuits are not all closed-loop, the cooling water arising there has to be treated via oil trap systems.
* The values have been adjusted over those in the last Environmental
Statement.
16
2010
27,235
10,198
37,433
2008 2009 2011
20,741
10,983
31,724
26,939
10,725
37,664
26,505
11,094
37,599
CO2-emissions (t/a)
thereof for process heat
thereof for heat generation(steam boiler)
Total t CO2
(excl. transport and works traffic)
(directly from fossil fuel combustion)
2008 2009 2010
36,109
56,048
1,226
2011
28,548
40,262
997
45,417
60,469
1,413
37,441
58,301
1,424
Air emissions (kg)
Total C
Nitrogen oxides as NO2
Dust
1) Other greenhouse gases are
not relevant at the location.
2) Other emissions, such as
SO2, are insignificant at the
location
Core indicators 2009 2010 2011
related to output of finished products
related to output of finished products
related to output of finished products
Energy efficiency:
Total energy consumption 479,300 MWh 1.905 MWh/t 587,600 MWh 1,727 MWh/t 584,200 MWh 1.744 MWh/t
Thereof renewable energies 109,932 MWh 0.437 MWh/t 138,030 MWh 0.406 MWh/t 65,900 MWh 0.197 MWh/t
Material efficiency:
Raw material input, casting shop 333,400 t 1.325 t/t 454,500 t 1.336 t/t 442,800 t 1.322 t/t
Water:
Total water consumption 8,121,000 m3 32.277 m3/t 9,236,000 m³ 27.149 m³/t 8,962,000 m³ 26.760 m³/t
Waste:
Total waste generation 32,797 t 0.130 t/t 35,264 t 0.104 t/t 33,437 t 0.100 t/t
thereof hazardous wastes 4,068 t 0.016 t/t 8,223 t 0.024 t/t 5,773 t 0.017 t/t
Biodiversity:
Use of land 432,754 m2 1.72 m²/t 432,754 m² 1.27 m²/t 432,754 m² 1.29 m²/t
Emissions:
CO2 emissions (electricity and gas) 1) 163,935 t 0.652 t/t 170,210 t 0.500 t/t 224,005 t 0.669 t/t
Dust and NO2 emissions 2) 41,259 kg 0.164 kg/t 61,882 kg 0.182 kg/t 59,725 kg 0.178 kg/t
The emission loads are based on the three-year emission measurements ac-cording to sect. 28 BImSchG calculated on the basis of the actual operating hours in the respective emission sources.Emissions were last measured at most facilities in 2010. Despite the requirement that emissions are always to be measur-ed at maximum plant utilization, these measurements are merely snapshots.As a result, variations in the emissions measured result in considerable fluc-tuations in the calculated emission loads.
We are participating in CO2 emissions trading with our heat generating plants (steam boilers 1, 2, 7 and 8).The allowance allocated for the second trading period 2008–2012 is 11,666 tonnes CO2 per year.
The reduction in the core indicatorsenergy efficiency, water and waste ischiefly attributableto the increase in plant utilization during the fiscal year 2009/2010.
Input and output data relate to the respective fiscal years from 1 October to 30 September.
17
Occupational safety and health, environmental
protection and energy at Wieland-Werke AG
Your contacts for environmental issues at the Vöhringen works:
Immission protection, hazardous incidents:Oswald AblerPhone +49 731 944 3005Fax +49 731 944 [email protected]
Water law, water protection:Reimar BaumPhone +49 731 944 6417Fax +49 731 944 [email protected]
Waste disposal, hazardous goods:Dieter JechlePhone +49 731 944 3564Fax +49 731 944 [email protected]
Executive Board
Occupational safety and health, environmental
protection and energy management officer
AZ/Zimmermann
Senior safety expert: ASI/Schuster
Environmental protection officer: AZU/Abler
Plant officers for:
- Solid waste: AZU/Jechle
- Hazardous goods: AZU/Jechle
- Water protection: AZU/Baum
- Immission protection: AZU/Abler,
AZU/Hutzel
Energy officer/energy team: AZV/Gaus
Technical Management
Corporate Division Metal, Casting, Research & Development Herr Dr. Müller
Operating Division Rolled Products Herr Cüppers
Operating Division Extruded and Drawn Products Herr Ulm
Operation Division Tubes Herr Graßhof
Operation Division Slide Bearings and System Components Herr Vorndran
Ulm worksWorks Manager
S/Vorndran
Vöhringen worksWorks ManagerAZ/Zimmermann
Langenberg worksWorks Manager
WK/Blässing
Villingen worksWorks ManagerWM/Dambietz
Safety experts:
ASI/Vizzutti
ASI/Schuster
Company doctor:
PGAU/Dr. Müller-Nübling
Officer for:
- Radiation protection
(as per RöV (X-ray Ordinance)
+ StrlSchV (Radiation Protection
Ordinance)) ASI/Linner
- Laser protection ASI/Walter
- Hazardous incidents AZU/Abler
- Fire protection ASI/Linner
Contacts for:
- Environmental protection AZU/Abler
- Energy team AIS/Jacob
Safety experts:
ASI/Schuster
ASI/Walter
ASI/Yilmaz
ASI/Linner
Company doctor:
PGAV/Wörner
Officer for:
- Radiation protection
(as per RöV (X-ray Ordinance)
+ StrlSchV (Radiation Protection
Ordinance)) ASI/Linner
- Laser protection ASI/Walter
- Hazardous incidents AZU/Abler
- Fire protection ASI/Linner
Contacts for:
- Environmental protection AZU/Abler
- Energy team AZV/Gaus
Safety experts:
WKA/Lins
Hr. Küpper (ext.)
Company doctor:
Hr. Keßel
Officer for:
- Radiation protection
(as per RöV (X-ray Ordinance)
+ StrlSchV (Radiation Protection
Ordinance)) WKQ/Preick
- Laser protection WKA/Lins
- Hazardous incidents –
- Fire protection WKA/Henzel
- Deputy officer for water
protection WKA/Lins
Contacts for:
- Environmental protection WKA/Lins
- Energy team WKA/Lins
Safety experts:
WMA/Bodamer
Hr. Hey (ext.)
Company doctor:
Dr. Fritzer
Officer for:
- Radiation protection
(as per RöV (X-ray Ordinance)
+ StrlSchV (Radiation Protection
Ordinance)) WMT/Vural
- Laser protection WMI/Rapp
- Hazardous incidents –
- Fire protection WME/Hofmann
- Deputy officer for water
protection WMA/Epting
Contacts for:
- Environmental protection WMA/Epting
- Energy team WMA/Epting
18
A key instrument in our environmental management system is the systematic “Identification and Review of Environ-mental Aspects” for all plant and equipment with subsequent evaluation and prioritisation according to fixed criteria. The review is documented on an ongoing basis in comprehensive schemes. The following significant environmental aspects were identified in the various divisions and business areas:
•energyconsumption•emissions(airandnoise)•coolingwaterconsumption•wastewater•handlingsubstanceshazardousto water•useoforganicsolvents•handlingsubstancessubjectto the Hazardous Incident Reporting Ordinance (12th BImSchV)
Identification and Review of
Environmental Aspects
19
Wieland canal
Power supplies
The manufacture of semifinished pro-ducts in copper and copper alloys is based on very energy-intensive processes. Today, our power supplies are based on a 110 kV incoming line and a branched 20 kV/6 kV distribution network. The water turbines built in 1904 on the Iller canal are also still in operation, although they now only meet about 2 percent of the plant’s power needs.Two stand-by generators are available to assure supplies in the event of an external power failure.The heat for heating and production purposes is generated by four low-emission, energy-efficient gas boilers. The heat supply is also supported by a large number of heat recovery systems in which waste heat from production processes is used among other things to heat buildings, halls and service water. This way, considerable quantities of climatically harmful CO2 can be saved.For the cooling of our production facilities, a variety of systems are employed. New plants are mainly equipped with open- or closed-loop cooling systems, while older units are still operated with once-through cooling.
All installations are kept in good condition with proactive and computer-aided maintenance and monitored continuously for malfunctions by means of a central building management system. Proactive and computer-assisted maintenance ensures that all the plant and machines are kept in good repair and are continuously monitored for faults via a central building management system. Thanks to our continual improvement process, our plant is optimized on an ongoing basis, thus assuring the efficient use of energy.
Supplies
Water
We use water to cool the material in the casting plant and to rinse the pickling facilities, so its supply is especially important to us. Since mid-2002, process water needs have been met
exclusively from our own groundwater wells. Drinking water is partly supplied by treated groundwater and partly sourced from Vöhringen’s drinking water supply.
Transformer station
20
Safety relevant substances covered by the Hazardous Incident Reporting Ordinance (12th BImSchV)
Various plant and equipment areas at Wieland are subject to the Hazardous Incident Ordinance. Extended obligations, e.g. procedures for informing the public, apply particularly to the liquid gas store. A list of all safety-relevant areas and facilities is included in a continuously updated safety report.
VOC Directive (31st BImSchV)
The VOC Directive, which establishes limits for volatile organic compounds emissions, was transposed into German law by the 31st Solvents Ordinance (BImSchV) in August 2001. The surface cleaning systems in our Extruded and Drawn Products Division and in the Tube Division falls within the scope of this Ordinance. We prove compliance with the threshold values for diffuse emissions through conducting solvent audits for all the plant and equipment areas concerned.
Handling water-polluting substances
We operate many units in which water-polluting substances are used: storing, filling and handling equipment as well as facilities for production, treatment and utilization. We operate many units in which water-polluting substances are used: storing, filling and handling equipment as well as facilities for production, treatment and utilization. They are assigned a hazard rating according to their risk potential and our organisation and technology ensure that they are reliably operated and monitored. We are a recognized specialized establishment as defined by Section 19 (i) of the Water Act (WHG) and are regularly checked by an approved monitoring agency. The company is also fortunate to have a large skilled and qualified monitoring team, so we are able to maintain and service our own plant and equipment which handle water-polluting substances.
Raw materials
Primary metals used as input stock in the casting plant are procured worldwide. They include in particular cathode cop-per, pure zinc and pure tin. In addition, unmixed metal waste, chips and scrap which are generated on the customer’s premises or within our own production process are remelted. The ratio of metals used is 25–30 percent primary metals to 70–75 per cent recycled metals.
Operating supplies
Operating supplies are mainly delivered to the central operating supplies store where they are stocked and managed for production and maintenance purposes. Some facilities have external stores which are supplied directly (e.g. for oils, acids, and chemicals for wastewater treatment). Environmentally relevant operating supplies are transported within the works on pallets with drip trays to collect any spills.
Radiation protection
All x-ray and laser equipment is operated with the best possible protective measures for our employees' safety. In addition, detectors screen incoming returns from our customers on railway wagons and trucks for radioactivity. The equipment can even detect values which are only slightly above the natural background radiation levels.
Flood protection
The river Iller has flooded twice recently, in 1999 and 2005, and the Vöhringen works came precariously close to being under water, which would have brought incalculable damage and environmental hazards. Now the flood danger for the Vöhringen works has been eliminated as far as possible through the construction of a flood dyke, the purchase of sub-stantial flood protection equipment and a whole range of organisational measures including a contingency plan for a large part of the workforce.
Liquid hydrogen storage tank and butane
storage sphere
Chemical transfer point
Detector system for trucks
21
Waste groups
The production processes generate three groups of waste:
• wastes made up of various metal alloys, so-called “returns”. These are (re)melt- ed in the casting plant.• other waste that occurs during the production and auxiliary processes• commercial waste similar to domestic refuse.
We fulfil the requirements of the German Closed Substance Cycle and Waste Management Act (KrW-/AbfG) by avoiding waste wherever possible. This is our primary objective, before recycling and disposal. Where waste cannot be avoided, we seek alternative ways of recycling it which themselves satisfy ecological aspects. Waste is rigorously collected and separated so that as little as possible has to be disposed of. In all, the Vöhringen works collects some 120 different kinds of waste. Disposal is through about 30 certificated specialist firms.
Waste Disposal
Heat utilisation/ Energy efficiency
These days, with resources increasingly scarce and energy prices rising, the use of heat is a highly topical matter. Wise use of heat means, for one thing, exploiting waste heat from production processes. It also covers the principle that primary energy required for the individual production stages must be used as efficiently as possible. Moves in this direction, therefore, are urgent not only for ecological but also for economic reasons. After the energy crises of the 70s, in-dustry recognised the need for a more efficient use of heat. Wieland-Werke AG developed the exploitation of waste heat for further industrial heating processes and for room heating. As a result, many production facilities were equipped to turn waste heat to good use.Today we examine new production plant right at the planning stage to see how far waste heat can be exploited and, where possible, used effectively in the actual production process itself.
Filling a paper press container
Cooling tower group
Wastewater disposal
Where necessary, cooling and process wastewater (e.g. from the pickling lines) is treated and then discharged into the Iller canal together with precipitation water.In accordance with the provisions of the law, we subject the treated wastewater to tightly meshed analyses for in-plant monitoring.
22
Results of most recent emission measurements (dust)
Limit acc. to notice of approval
Measured value
Year
EA1 4 mg/m3 0,07 mg/m3 2011
EA2 4mg/m3 0,08 mg/m3 2011
EA5 4 mg/m3 0,08 mg/m3 2011
EA6 4 mg/m3 0,07 mg/m3 2011
EA9 4 mg/m3 0,09 mg/m3 2011
Air emissions
The most significant source of emissions is the casting plant, where exhaust air is cleaned in four dedusting systems. Dust meters monitor emissions continuously to ensure that limits are observed. In addition, dust and dioxin emissions are checked at regular intervals by recognised measuring institutes. In recent years all the measured values have been well below the permissible limits.
EA9 dedusting plant
Noise barrier Truck park
Noise emissions
The works premises are situated in the west of Vöhringen, immediately adjoined by a residential district. Protection from noise pollution is therefore of key importance. New buildings are designed with noise protection façades to take account of this. Furthermore, to screen off noise caused by internal movements of materials, noise barriers with a total length of 300 metres have been set up at three different points. Stationary noise meters have been installed along the works fence so that exceptional levels of noise can be responded to directly.
Internal transport operations are forbidden between 10 pm and 6 am on the eastern works road adjoining the residential area. All windows and doors in the works have to be kept closed during this period. Measurements carried out by TÜV-Süd (the South German technical inspection agency) in 2005 verified observance of the ambient noise guide values in the residential area adjacent to the works.Measurements carried out in April 2012 have again confirmed this.
The use of fossil fuels (gas and diesel fuel) leads to CO2
emissions, which are measured and disclosed in the context of CO2 emission reduction. The basis here is the industry‘s self-commitment and the Kyoto Protocol on the reduction of greenhouse gas emissions, primarily carbon dioxide emissions. Our heat generating facilities together produce about 33 MW nominal power in four steam boilers, so we also participate in the EU-wide CO2 Emissions Trading Scheme with its statutory obligation to cut emissions.
23
Indirect Environmental
Aspects
Traffic
About 75 percent of our goods are delivered and distributed by road and some 25 percent by rail. The environmental aspects relevant to transport are known and are being optimised in a logistics project (depot management). It has led to the construction of a new materials preparation bay in conjunction with additional truck parking space in the north of the works, which will allow internal truck traffic to be significantly reduced.
Our works fire service is the most important pillar of emergency precautions. Recognised under sect. 15 of the Bavarian Fire Service Act (BayFwG), it is on call 24 hours a day, 365 days a year. Fire fighter training, regular fire practices and excellent equipment ensure a high standard of precautionary and defensive fire protection. A practice plan is arranged by the works fire service commander in coordination with the authorities, the District Office in Neu-Ulm. The hazard prevention organisation which we have implemented is an essential element in our contingency precautions and activities. It forms the basis of the external disaster prevention plan in the Neu-Ulm administrative district. The safety report on potential incidents is fundamental to emergency precautions and actions (including environmentally relevant accidents and emergencies) for the plant and facility areas subject to the extended obligations of the Hazardous Incident Ordinance.
Emergency precautions and actions
Waste disposal
We engage only certified specialist disposal firms to dispose of our residual wastes from the production and auxiliary processes. The same applies to commercial wastes similar to domestic refuse. Furthermore, we check our main waste disposal contractors regularly for compliance with our environmental requirements and we document the results.
Service providers
Suppliers and service providers are included in our efforts to protect the environment. We obligate service providers working on our premises to meet our environmental standards. This is an integral part of contracts concluded with them.
Truck park
Fire service depot on the works premises
Driveway to the new truck parking lot
24
July 2012
Organisation chart Wieland-Werke AG
Executive Board
Chairman
Harald Kroener
Sales and Marketing
Werner T. Traa
Engineering and Production
Dr Ulrich Hartmann
Engineering and Production
Ulrich Altstetter
Corporate Units
Corporate Communications, Internal Audit
Sales Processes and Tools
Occupational Safety,Quality Systems
Energy Management,Environmental Protection
Legal Affairs and Insurances
Corporate Divisions
Finance and Controlling
Human Resources
Service and Sales Companies
Metal Division, Foundry, Research and Development,Standards and Associations
Engineering and Logistics
Information Systems
Corporate Functions
Corporate Development Lean-ManagementManufacturing Companies
and Participations
Operational Divisions
Rolled Products Extruded and Drawn Products High Performance Tubes Slide Bearings and Components
Organisational Structure of Wieland-Werke AG
25
Validation certificate
Statement of the environmental verifier on the verification and validation activities
The undersigned Thomas Schneider, EMAS environmental verifier, registration number DE V 0178, accredited or licensed for the scope NACE 24.44, declares that he has verified whether the Vöhringen works location as indicated in the updated Environmental Statement of Wieland-Werke AG, registration number DE-104-00108, meets all the requirements of Regulation (EC) No 1221/2009 of the European Parliament and of the Council of 25 November 2009 on the voluntary participation by organizations in a Community eco-management and audit scheme (EMAS).
With the signing of this declaration, it is confirmed that
•verificationandvalidationwereperformedinfullcompliancewith the requirements of Regulation (EC) No. 1221/2009,
•the outcome of verification and validation confirms thatthere is no evidence of non-compliance with the applicable environmental regulations,
•the data and information of the updated environmentalstatement of the location present a reliable, credible and
correct picture of site activities within the scope mentioned in the Environmental Statement.
Vöhringen, 24 April 2012
Thomas SchneiderEnvironmental Verifier Reg. No. D-V-0178
26
Objective Individual targets Individual actionsOrganizational unit responsible
StatusCost (in €)
Process optimization
Protect climate: Use renewable energy sources and reduce CO2 emissions
Truck park North: generate approx. 36 MWh/year solar energy
Construction of a 260 m² photovoltaic system on the southern noise barrier wall of the truck park
Logistics Department Completed in spring 2009
150,000 (environmental
content)
Reduce air emissions: new dedusting concept for the K3 billet caster
Reduce direct and diffuse dust emissions from the casting shop
Construction of a new, enclosed casting shop and an additional dedusting facility
Plant Planning Department – Metal
Construction and installation completed end of 2010
7,900,000 (total cost
of EA9 dedusting
facility)
Protect water: avoid risk when draining tanks
Create a secure chemicals drainage area
Build a tank drainage site for pickles and brines at building 17
Energy/Waste Management Departments
Construction and installation completed end of 2010
30,000
Protect water:Reduce water pollution in tube drawing shop
Improvements in water protection through closed circuit cooling water system at extrusion press P15
Re-cool cooling-water tank with external heat exchanger
Energy Management and Tube Drawing Departments
Project completed end of 2010
200,000
Reduce primary energy consumption and CO2 emissions: Push up heat utilization
Dismantle plant steam network and replace with a hot water network with improved waste heat feed
Set up new central steam / hot water transformer station in building 17
Energy Management Departments
Completed in March 2011
500,000
Save energy:push up the waste heat percentage of the casting shop's energy consumption
Raise waste heat utilization in the casting shop by up to 5,000 MWh through setting up a central NT network in the area of billet casting shop K3
Set up a central closed-circuit recooling system for the new billet caster feeding into the air-intake system
Energy Management Depart-ment and Plant Planning Department – Metal
Verification of energy savings completed end of 2011
approx. 1,000,000
(environmental content)
Heat new office building (building 86) with waste heat
Extract waste heat from continuous furnace DO48
Energy Management Department
Completed in November 2011
100,000
Continuous Improvement Process
Reduce risk potential related to fire protection
Implement fire protection measures in buildings 50 and 83, tube drawing shop
Implement stages 4 and 5 Tube Production Departments, Construction Planning Department
Completed in September 2009
400,000
Reduce emissions Reduce nitrogen oxide emissions from suction channels on pickling tanks
Optimize NA4 detoxification plant in line with the existing concept
Plant Planning Department,Rolling Mill
Completed in September 2009
20,000
Reduce noise impact on near-by residential areas in line with noise measurement evaluation
Carry out appropriate constructional, plant organi-zational measures
Change storage of multiple billet lengths in the southern section of the premises
Extruded and Drawn products Division
Completed end of 2009
100,000
Reduce waste volumes at the Vöhringen Works
Push up recycling quota by increasing metal recirculation in the casting plant
Construct and start up a dross sorting facility for dross from the casting process
Plant Planning Department – Metal
Completed in May 2011
1,175,000
Reduce CO2 emissions Determine Wieland-Werke AG's corporate carbon footprint (CCF)
Project with external consulting agency
Trade Association Work Department
Completed in September 2011
13,000
Organizational Measures
Improve plant and materials management at Wieland-Werke AG
Build up shared database for materials and plant for the four Wieland-Werke AG works
Set up an Environ-mental Information Management System (EIMS) based on a procured software solution
Environmental Protection Department
Software installation and implementation across works com-pleted in September 2011
50,000
Environmental performance:
Implementation of environmental protection improvement measures 2009 to 2011
27
Objective Individual targets Individual actionsOrganizational unit responsible
StatusCost (in €)
Process Optimization
Cut primary energy consumption and CO2emissions through increasing plant heat utilization
Extrusion press P 21: improve heat utilization in billet heating to save 24 % energy over old presses
Replace obsolescent billet induction heating furnaces by two innovative gas furnaces and one HTS furnace
Extruded and Drawn Products Division
September 2012 1,000,000 (environmental
content)
Save energy:push up waste heat percentage of energy consumption
Push up waste heat utiliza-tion in the casting shop by raising the temperature level of the furnace coil cooling system from 40 °C to >70 °C
Carry out tests with furnace O33 which has been modified for this purpose
Energy Management and Maintenance Departments, Casting Plant
December 2012 20,000
Improve energy efficiency of continuous furnace DO50
A new energy concept has been developed for the furnace section with cooling line to be replaced. Examples: heat recovery from gas burners and cooling zone, inert gas savings through optimized charging / discharging locks
Plant Planning Department, Rolling Mill
September 2012 approx. 500,000
(environmental content)
Increase energy efficiency:conduct a new energy saving project at the Vöhringen Works
Reduce specific energy consumption of individual plants
Conduct at least five energy saving workshops per fiscal year. Continue energy efficiency programme of 2009
Energy Management Department
September 2012 100,000 (additional
costs)
Reduce heat losses in buildings
The new maintenance work-shop will feature excellent heat insulation (30 % up on EnEV2009 specifications) as well as controlled ventilation with heat recovery.
Construction Planning Department
December 2012 400,000 (overall project)
Resource efficiency:recover copper from wastes
Copper recovery from used pickles and copper-bearing scrap / recyclables
Cooperation project with BIFA and the Knittel com-pany; on verification in the laboratory the process is now being tested in the pilot plant.
Energy / Waste Management Departments
Project started in March 2012
400,000 (complete
project)
Reduce noise emissions Modify or replace noise-emitting units to reduce immission levels
- Retrofit scrubber chimney of building 61 with sound absorbers- Replace exhaust system of building 1 and relocate it to the interior - Repair, optimize or replace laboratory exhaust system on the roof of building 78
Maintenance Department, Extruded and Drawn products Division
April 2012 50,000
Continuous Improvement Process
Optimize Wieland-Werke AG's Environmental Management System
Heighten benefits through revised presentation
Reduce number of working instructions and present "also valid" documents more clearly as such
Environmental Protection Department
– –
Improve climate protection Improve thermal insulation in buildings
For 2012, thermal insulation measures are planned for buildings 97, 13 and 21
Construction Planning Department
April 2012 approx. 100,000
Organizational Measures
Improve plant and materials management at Wieland-Werke AG
Centralized processing of all individual requirements under approval notices for all plant subject to approvals
Introduce software for monitoring approval deadlines as part of the Environmental Information Management System
Environmental Protection Department
December 2012 20,000
Improve information flow to Environmental Information Management System
In-depth training of selected employees
Nomination of an internal environmental officer for every department
Environmental Protection Department
September 2012 –
Environmental Programme 2012
0541
-01
261/
06.
09
Ab
0,5
OD
H (G
SW
/Al)
Wieland-Werke AG www.wieland.de
Graf-Arco-Str. 36, 89079 Ulm, Deutschland, Telefon +49 731 944 0, Fax +49 731 944 2772, [email protected]