Environmental Indicators
2003/2004
Performance In 2004, we published our first Environmental report with the aim of communicating our environmental efforts and results. The current publication shall be seen as a follow-up of the Environmental Report, with the aim of updating the 2004 performance indicators, as well as communicating the environmental objectives for 2005.
João Ferra Silva
Planning, Environment and Infrastructures Business Manager
Environmental Indicators (Comparison 2003/2004)
Automotive Production 2003 2004
Vehicles
14000 12000 10000 8000 6000 4000 2000
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Nov
Dec
ENVIRONMENTAL INDICATORS | PERFORMANCE
Main Pollutants in the Waste Waters
(Values obtained at the discharge point of the VW Autoeuropa WWTP, before the biological treatment performed by the Palmela Municipality) 2003 2004
2003 2004 Tons/year
0,16 0,12 0,08
0,008 0,006
2 3
0,004
0,04
0,002
Tot P Cd
Cr
Cu
Ni
Pb Phenols
As
Hg
Pollutants
2003 2004
2003 2004 6
120
5
100
Tons/year
Tons/year
Tons/year
0,2
4 3
80 60
2
40
1
20
Tot N
TOC
Pollutant
Pollutant
Tot P – Total phosphor Cd – Cadmium Cr – Total chromium
Cu – Copper Cr VI – Hexavalent chromium TOC – Total organic carbon
Ni – Nickel Pb – Lead As - Arsenic
Hg - Mercury Tot N – Total nitrogen
Cyanide Cr VI
Pollutants
Amounts of the Main Waste Types
Hazardous Wastes (tons)
2003
2004
Paint sludge, including enamels, organic solvents or other hazardous materials
669
451
Water-based suspensions, containing paint, enamel, organic solvents or other
62
56
Sealer waste, containing solvents or other hazardous materials
120
167
Phosphate sludge
105
84
Hydrocarbons wastes
114
111
WWTP sludge
663
429
hazardous materials
Non-hazardous Wastes (tons) Ferrous metal chips and fillings Cardboard and paper packaging Plastic packaging Wood packaging and pallets Office paper
2003
2004
36788
33855
1164
767
53
45
846
756
16
20
ENVIRONMENTAL INDICATORS | PERFORMANCE
Atmospheric Emissions Note: The considered air emissions refer to measurements conducted at the incinerators and exhausts. Since the yearly emission is calculated with two campaigns only (as requested by law), it’s natural to have fluctuations. Anyway, the measured concentrations are far below the legal limits.
2003 2004
Tons/year
30 25 20 15 10 5
TSP
TSP – Total suspended particles CO – carbon monoxide VOCʼs – Volatile organic compounds NOx – Nitrogen oxides
CO
VOCʼs
NOx
Pollutants
Specific Water Consumption 2003 2004 14,00
240,00 200,00
10,00
160,00
8,00
120,00
6,00
80,00
4,00
40,00
2,00
0,00
0,00
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Nov
2003
Dec
2004
12%
13%
55% 33%
4 5 m3/Vehicle 2004
m3/Vehicle 2003
12,00
54% Water from municipal network Water from bore holes, industrial use Water from bore holes for irrigation
33%
Specific Electricity Consumption 2003 2004 1800
kWh/Vehicle 2003
1600
20000
1400 1200
15000
1000 800
10000
600 400
5000
200 0
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Nov
Dec
Specific Natural Gas Consumption 2003 2004 380
340
Nm3/Vehicle
300 260 220 180 140 100 60 20 0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Nov
Dec
kWh/Vehicle 2004
25000
ENVIRONMENTAL INDICATORS | PERFORMANCE
Steel Consumption 2003 2004
6000
4000
2000 0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Common note to the previous four charts: Since we are reporting the consumptions per manufactured vehicle, the August peaks are due to very low volumes (annual shutdown). This is why the steel consumption in those months is very low. Refer to the production volumes, presented in the chart on page 2.
Paint Process Raw-Materials Consumption 2003 2004 1400 1200 1000 800 600 400
Cleaning solvents
Waxes
Enamel
Base colors
Primers
Sealers
200
Electrocoat
Tons/year
Tons
8000
Nov
Dec
6 7
Objectives and Results
Environmental Running Costs 2003 2004 Costs (X1000 €) External ISO14001 Audits (VCA)
6,7
12,2
Air emissions monitoring
20,0
27,0
WWTP operation and maintenance
106,0
99,9
WWTP chemicals and materials
194,8
152,1
Effluent analyses
23,0
23,0
Waste management
1717,9
1533,6
TOTAL
2068,4
1847,8
Environmental Investments 2003 2004 Costs (X1000 €) Replacement of incinerators in paint area
835
Replacement of membranes in the cataphoresis ultra-filtration unit
98
Improvements in the WWTP ultra-filtration unit
23 43
Residual heat recovery project (incinerators) Several actions to save energy and fluids consumption TOTAL
78 956,0
121,0
ENVIRONMENTAL INDICATORS | OBJECTIVES AND RESULTS
Environmental Objectives and Results 2004 Maintain Environmental Certification according to ISO14001:1996
On-going
Maintain compliance with legal requirements
On-going
Improve environmental communication and information to Autoeuropa workers
Achieved
and external contractors Tuning of the Energy Management System and several actions to reduce consumption of
On-going
electricity, natural gas and compressed air Reduce the natural gas consumption in Paint area by 400 m3/production day, when
Achieved
compared to 2003 Influence the activities of the Suppliers Park and promote implementation of their own
On-going
Environmental Management Systems and continuous improvement of their environmental performance Reduce packaging waste by:
Achieved
0.15 kg/vehicle (cardboard) 0.30 kg/vehicle (wood) Implementation of a segregation system to recover plastic waste in the Final Assembly area No external complaints received about environmental issues
View over the Sado River Estuary
Achieved
8 9
Arrábida mountain
Environmental Objectives 2005 Adapt the Environmental Certification to ISO 14001:2004 Maintain compliance with legal requirements New external communication and awareness actions Tuning of the Energy Management System and several actions to reduce consumption of electricity, natural gas and compressed air Reduce the natural gas consumption in Paint area by 900 m3/production day Influence the activities of the Suppliers Park and promote implementation of their own Environmental Management Systems and continuous improvement of their environmental performance Replace pneumatic tools by electric tools in the Final Assembly area, in order to reduce compressed air consumption Environmental awareness via TPM training in more areas of the plant Reduce sealer consumption in Body area by 1%/car in all MPV models Reduce oil leaks and conclude the Ecostamping Project in the Stamping area
ENVIRONMENTAL INDICATORS | OBJECTIVES AND RESULTS
10 11
Environmental Management System Certificate
1st Edition VOLKSWAGEN Autoeuropa, Automóveis Lda Planeamento, Ambiente e Infra-estruturas Quinta da Marquesa 2951-510 Quinta do Anjo www.autoeuropa.pt
Design: MIL Cenas - Lda Rua Lopo Homem nº2 A 2910 -788 Setúbal Tel.: +351 265 591 003 Fax: +351 265 591 006
Technical Direction: Controlo Ambiental Tel.: +351 21 211 2917/ 3053/ 3146
Printed by: Armazém de Papéis do Sado, Lda Praça do Quebedo, 14 2900 -575 Setúbal Tel.: +351 265 528 400 Fax: +351 265 238 702
Photographs: VW Autoeuropa, Automóveis Lda MIL Cenas - Lda
Nr. of exemplars: 250 Exemplares
Environmental Indicators, January 2005
Printed in recycled paper