EnvironmentalStatement HUBERSE - HUBER SE - HUBER SE...9.Eco-balance2008–2010 2008 2009 2010 Unit...

Environmental Statement

HUBER SE

HeadquartersIndustriepark Erasbach A192334 Berching

WASTE WATER Solutions

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Contents1. ‘A commitment to the environment’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. Company profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3. Environmental policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4. Environmental protection – a review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5. Environmental protection within the company organisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6. The use of stainless steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7. Production processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8. Integrated product policy (IPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9. Eco-balance 2006 – 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9.1 Approach and reasons for major deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

9.2 General evaluation of all environmental aspects and selection of ecologically relevant materials . . . . 28

9.3 Key indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

10. Environmental program 2009 – 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10.1 Organisational and technical goals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.2 Environmental statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

List of figuresFig. 1: HUBER SE Board of Directors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fig. 2: Stainless steel input / operating performance, development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fig. 3: Environmental protection goals and program – a review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fig. 4: Recovery-Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fig. 5: ReUse Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fig. 6: Specific disposal costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fig. 7: Plate cutting waste development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fig. 8: CO2 emission / operating performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fig. 9: Power and gas / operating performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

List of tablesTable 1: Input 2008 – 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 2a: Output products / energy / wastewater 2008 – 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 2b: Output waste 2008 – 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 2c: Output exhaust air / emission 2008 – 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 3: Evaluation of pollutants according to their risk potential x quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 4: Evaluation of the plants by their environmental aspects (extract) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Table 5: Overview of key indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 6: Environmental goals and program 2009 – 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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➤➤➤ 1. ‘A commitment to the environment’

Environmental protection as a guiding principle hasbecome an important part in the moral concept of oursociety. Both politics and economy as well as citizensregard environmental protection as an important futurechallenge.The developed industrial states all over the world aregenerally expected to make great efforts in order tosecure our basis of existence in the long run and preserveour natural resources.The frequently described antagonism between economyand ecology no longer exists. Especially in highlyindustrialised countries, great efforts have been made toproduce in an environmentally sound manner and launcheco-friendly products on the market. New industrybranches have developed which produce innovativeproducts for environmental protection and generate newjobs.Particularly in Germany, environmental engineering has avery high standard. German products and technologiestake a leading position on international markets and aresold globally.We, HUBER SE, understand ourselves as a technologycompany committed to environmental protection. Withour products and solutions we provide innovative andefficient services for the field of water supply, wastewaterdisposal, process water and sludge treatment. Ourresponsibility for the environment is not limited to theconception of our products but includes also state-of-the-art manufacturing technology to relieve the environmentand be sparing with our resources.

This is an idea all HUBER employees are committed to.Our environmental statement describes the strategiesand measures we have taken for the purpose ofenvironmental protection.We want to show the interested public, our customers andsuppliers that environmental protection is possible withinan industrial company and success can be achievedwhich improves in the long run both our quality of life andour economic efficiency.It will therefore remain our endeavour to set standardsnot only with our production processes.HUBER SEBerching

Board of Directors:Georg Huber, Dr.-Ing. Oliver Rong, Dr.-Ing. JohannGrienberger, Rainer KöhlerEnvironmental officer: Dr.-Ing. Johann Grienberger

Fig. 1: HUBER SE Board of DirectorsLeft to right: Rainer Köhler, Georg Huber (CEO), Dr.-Ing. Oliver Rong, Dr.-Ing. Johann Grienberger

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➤➤➤ 2. Company profileWe are a medium-sized machine and plant manufacturingcompany with decades of tradition in the water technologysector. From the original coppersmithy, which has beenowned exclusively by the Huber family since 1834, thecompany has since developed into a state-of-the-artmanufacturing company that enhances the furtherdevelopment of environmental products for water throughinnovation.Today HUBER processes exclusively stainless steel andmanufactures machines and equipment for water supply,wastewater disposal and solids/liquid separation, andoffers specific, complete solutions. Huber products areused on municipal wastewater treatment plants andwater works as well as in industries for process andcirculation water treatment. The products are mainly usedin the following applications:➤ Manhole equipment➤ Object protection➤ Drinking water and elevated reservoir equipment➤ Equipment for water supply and wastewater disposal

facilities (railing, enterings, crossings, etc.)

HUBER machines and plants are applied for example inthe following fields:➤ Complete mechanical pre-treatment (screens, grit

trap)➤ Screenings and grit trap material treatment➤ Mechanical sludge treatment (thickening, dewatering,

drying)➤ Equipment for circular and rectangular secondary

clarification tanks➤ Membrane technology➤ Decentralised wastewater treatment➤ Heat recovery from wastewater

For the purpose of optimal product management ourorganisation is made up of business units:➤ Mechanical pre-treatment, disposal, sewerage

program, incl. heat recovery from wastewater➤ Sludge treatment➤ Membrane technology with Filtration & ReUse➤ Decentralised wastewater treatment➤ Industry➤ Stainless steel products➤ Global service➤ Research & development incl. recovery plant

for a safe environment

As an innovative company we develop new solutions inthe field of water reuse. We make wastewater a resource.

A main pillar of HUBER’s product range are the internallymanufactured and mainly standardised products, whichare developed in close cooperation with the users. As apioneer HUBER has introduced various patentedinnovations on the German market and is selling themsuccessfully all over the world. Our expert support anddesign preparation complete our extensive supplyprogram of package solutions. Appropriate after-salesservice and maintenance of our supplied products is amatter of course for us.About 900 employees worldwide work in the HUBERGroup and its about 20 subsidiaries, 550 of them at thecompany headquarters in Berching, Germany.We are committed to➤ the environment according to ISO 14001 and EMAS➤ top quality according to ISO 9001➤ observing occupational safety rules➤ integrated product policy (IPP)

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➤➤➤ 3. Environmental policyIn 1997, we decided to set the stage for the certificationof our production according to ISO 14001 and EC OrganicRegulation (official journal of the European Communitiesfor the environmental management system and eco-auditNo. L 168/1 of 10 July 1993, No 1836/93 of 29 June 1993on the voluntary participation of business enterprises inan eco-management and audit scheme).The reasons why we have an environmental managementsystem:➤ Our general attitude towards environmental concerns

is basically positive.➤ Possible weak points in environmental protection

should be analysed in order to develop solutions forthe problems found.

➤ We sell products and services in environmentalsectors and actively contribute to environmentalprotection, not least with our own products,particularly in the field of wastewater treatment anddisposal. This gives us reason to show our customers

and the public that we are anxious also in terms of ourproduction (product and process technology) toundertake what is technically and economicallyfeasible for environmental protection.

➤ It is our commitment to keep our staff and the socialbusiness environment actively informed about thestatus quo and our plans concerning environmentalprotection.

➤ We meet in this way the guidelines for ourenvironmental policy derivable from the company’soperating principles.


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➤➤➤ We declare our commitment to the following environmentalpolicy guidelines

➤➤➤ Our maxim is ’commitment to the environment’.

1. The responsibility for environmental protection startsat the company management level.

2. We consider environmental protection as a measurenecessary to achieve our business goals. Therealisation of the environmental goals should takeplace within the scope of the financially andtechnically feasible. Environment-related aspects aretherefore integrated in the decision and actionstructure of our management system. We commitourselves to observe environmental laws andregulations.

3. Environmental protection is a substantial managerialfunction. Superiors have an important exemplaryfunction and carry responsibility.

4. The cooperation of all employees is required to beable to implement the environmental policy.Extensive information is therefore provided for theemployees in all company divisions and the completestaff is integrated in the environmental protectionconcept.

5. Ecology is an integral part of all our training andprograms. We inform our employees aboutenvironmental protection activities in the companyand encourage them to show personal responsibilityand ecological awareness within the scope of their job.Environmental protection is part of our employeesuggestion system.

6. Within the scope of our planning and control systemthe progress in internal environmental protection isconstantly verified, as much as possible in aquantified form, and checked against our goals andprograms. Also evaluated and monitored are theeffects of the activities on the local environment.

7. We undertake regular environmental audits in order tosecure our internal environmental protection andverify the efficiency of our policy, goals and programs.

8. It is our aim to still more include environmentalaspects in our product developing processes. In doingso we pay attention to the improvement of productfunctionality and at the same time minimisedconsumption of resources and increasedenvironmental compatibility of the productionprocess. The whole product life cycle is checked forweak points. Provisions are made early enough in ourwork flows, activities and processes (IPP).

9. As to the few activities and processes that are criticalin ecological terms but unavoidable, we work outemergency plans, wherever possible in cooperationwith authorities and the institutions involved. We takethe organisational and technical measures that arenecessary to prevent the emission of dangeroussubstances.

10. All new processes we plan and implement are state-of-the-art processes. Continuous improvement of theinternal environmental protection is achieved byapplying appropriate measures and implementing therespective projects.

11. With appropriate technical and organisationalmeasures we minimize the volume of waste andresidual materials, polluting emissions andwastewaters. The effects of activities beingundertaken are constantly monitored.

12. We exert influence on our suppliers and serviceproviders in terms of our environmental policy.

13. We provide our customers with information aboutenvironmental compatibility of our products related totheir handling, use, recycling and disposal.

14. We rely on the fruitful cooperation we maintain withauthorities, other companies and the public. All theinformation required to understand the impacts of thecompany’s activities on the environment is available.We regularly provide information about ourenvironmental activities.

15. Ecology is a basic principle of our production.

Environmental commitment is incorporated in ourVision & Mission Statement (point 6)Responsibility for the environment and societyClean water is essential for life. Not only are weactive in this market segment and contribute with oursolutions to the benefit and protection of ourenvironment, we are also focused on acting inaccordance with ecological principles in our externalenvironment. This is an integral part of our socialresponsibility and is communicated externally.

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➤➤➤ 4. Environmental protection – a reviewWhen we shifted our production facilities and erected anew factory at Industriepark Erasbach-Süd near Berchingin 1993, we could incorporate the latest standard ofknowledge in the field of environmental protection.An overview of our goals and the progress achieved isprovided in the chapter Environmental program 2009-2011.

Choice of location:➤ Acting socially responsibly, we shifted our production

facilities from a mixed zone to an industrial zone.➤ The new company location provided the pre-

conditions for planning and erecting state-of-the-artproduction facilities, particularly with regard to theminimisation of the environmental impact.

Choice of materials:➤ The main material processed is stainless steel, which

is completely reused.➤ All other materials used are eco-friendly and the

majority of them can be reused.

Water pollution control:➤ The majority of the production processes that need

water use recirculation water (particularly the picklingplant).

➤ Unavoidable wastewaters are treated (centrifuged,filtered, precipitated, etc.) and regularly monitored.

➤ The water consumption in the new office building isminimized by using water saving fittings and toiletflushing systems as well as waterless urinals. As aresult, the amount of wastewater generated isreduced.

Immission and emission protection:➤ The flue gas generated in the production by welding

processes is sucked off (for health and safety of theworkers) and treated prior to being discharged to theenvironment. The results of the check measurementscarried out in 2006 confirmed the efficiency of thesuck-off systems.

➤ A study on 200 welding work places with theparticipation of 10 HUBER employees that we do notexceed any limit values. The study was conducted in2009 by the German BG Institute (institute forstatutory accident insurance and prevention.

➤ The same applies to the emissions caused by thepickling plant, which are in addition measuredexternally. The washing tower for NOx was updated tothe latest state of technology.

➤ Noise emissions to the environment were reduced tobelow the permissible level of 52 dB(A) by means ofthe specific hall design and noise insulation.

Waste avoidance and reduction:➤ Systems for separate collection of valuable materials

and waste materials are used. As far as possible,valuable materials are recycled.

➤ The stainless steel plasma cutting waste requiringspecial supervision is analysed and authorityapproved owing to its positive properties.

➤ By proprietary development, the stainless steelplasma cutting waste is dewatered to up to 45 % DSand the amount of waste reduced in this way. A furtherreduction of this waste was achieved through theintroduction of laser cutting.

➤ The raw material consumption related to operatingperformance does not show any substantial change.The increase in 2009 was due to a reduced operatingperformance.

➤ The shape cutting chipping technology machines areequipped with closed circuits for lubrication andcooling emulsions. Pump sump tightness is ensured.The used emulsions are collected, cleaned and reusedafter regeneration.

➤ Suppliers are instructed to supply their products withas little packing material as possible.

➤ The systems for waste collection available within thecompany are at the employees’ disposal.

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Energy saving:➤ When planning the new building great importance was

attached to thermal insulation and use of state-of-the-art heating technology.

➤ Small decentral, gas-fired heat generation plants areapplie d in the production process.

➤ Process exhaust heat is used to heat the productionhall.

➤ The entire vehicle fleet consists of vehicles with three-way catalytic converters or modern diesel vehicles.The number of diesel vehicles is increasedsuccessively.

➤ The University of Applied Sciences Amberg-Weidenworked out an energy efficieny concept for HUBER SEin 2010 and came to the result that we are on a goodlevel. Reasonable proposals have been implemented.

Under the guidance of our environmental protectionmanager an environmental management system wasdeveloped for our company and implemented in 1999.Additional support is provided by the regionalenvironmental working group 'Neumarkter ArbeitskreisUmwelt’, which we have been a member of for 19 years.

It should also be mentioned that our employees arerewarded for positive suggestions for environmentalprotection. Within the scope of a prize competition ourtrainees investigated in 2007 the subject ‘environmentalprotection in HUBER SE.

New legal regulations are checked annually vialogin method on www.umwelt-online.de.

Worldwide environmental protection throughwastewater treatment with HUBER screens:➤ With the number of HUBER screens sold until 2010 up

to 12,000,000,000 m³ of wastewater per year can becleaned worldwide.

Fig. 2: Stainless steel input / operating performance, development

Stainless steel raw material / operating performance rate (kg/€)

2000-01 2001-02 2002-03 2003-04 20062004-05 2005-06 2007 20102008 2009

0,06

kg/€

0,05

0,04

0,03

0,02

0,01

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Environment: Review of targets and 2010 programWe set ourselves the following targets in order to further improve environmental protection within our factory.

No. Environmental target Measures taken Statusachieved?

Results achieved

1 a) Raw material cutting wastereduction from 27.5 % tobelow 26% (weight)– Waste related to raw

material consumptionb) Raw material cutting waste

reduction from 24.96 % to≤ 24% (related to surface)

➤ Improved nesting➤ Combine orders

no a) 27.6 %

-

b) 24.81 %

2 Reduce re-pickling work; optimalpickling concentration: constantpickling efficiency taking intoaccount the temperature;reduction of pickling pasteconsumption related to rawmaterial usage.Status: 0.78 kg/to

Continuous plant cleaning (grease-free); seasonal adjustments;sufficient pre-treatment; re-picklingonly if actually required

yes 0.65 kg/toantox consumptionincreasedby 3 %

3 Generally avoid overstepping ofwastewater limit values

Process improvement and control yes No exceedance

4 Replace environmentally harmfulmaterials. Avoid newenvironmentally harmfulmaterials.

Search for alternative materials,approval test for new materials

yes The search has notidentified any alternative.

5 Current consumption related tooperating performance, as wellas cos factor 0.98

Continue with previous measures(lighting control, etc.)

yes High operatingperformance – reducedconsumption

6 Integration of IPP in all newproducts

Take over the systematic procedurefrom RoS3 5Q.

yes IPP standards have beenimplemented.

7 Reduction of CO2 operatingperformance to below 32 g/EUR

Consider the fuel and currentconsumption particularly whenmaking new investments. Individualcar types, motorisation andespecially limited motorspecifications are defined in therespective company car guidelines.

no 32 g/€, not achieved butimproved (previously 34g/€)

Fig. 3: Environmental protection goals and program – a review

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We deliberately incorporated in our environmental policyguidelines that environmental responsibility must beginat the company management level and extend down toevery single workplace. The implementation of theecological idea in all areas is supported by our

environmental protection manager Eugen Hini.We want to achieve this by distributing the tasks in theenvironmental protection sector onto all fields ofresponsibility.

New employees are introduced into the environmentalprotection issues and function of our environmentalmanagement system by their superiors.

Our water protection and waste management officerErwin Meyer is employed in the production division. Anaspect we consider particularly positive is the integrationof environmental safety, quality and occupational safety.

➤➤➤ 5. Environmental protection within the company organisation

Board of Directors– Georg Huber– Dr.-Ing. Oliver Rong– Dr.-Ing. Johann Grienberger– Rainer Köhler

Definition of environmental targets and efficiency controlDefinition of responsibilitiesAnnual information of the public and employees by means of an environmentalreport and environmental statement

Company management– Anton Neger– Reinhold Fischer

The production management is functionally responsible for environmentalprotection in production. Elaboration and control of environmentalmanagement guidelines; authority to set policy guidelines on the division level.

Division managers,production foremen

Definition of responsibilities on the division levelCompliance with division guidelinesAny production-related environmental issues to be agreed with the productionmanager. As to new products, it is mainly the development department thatdecides on the materials used and their environmental compatibility.

Group managers Responsibility for the implementation of environmental standards concerninghis group

Operative employees Responsibility for environmental protection at their own workplace

Environmental protectionmanager Mr. Eugen Hini

The environmental protection manager is directly responsible to the board ofdirectors. He is responsible for the implementation of the environmentalmanagement system and has an advisory and supporting function for allemployees. He reports directly to the board of directors.

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At this point, let us turn from the production as thesubject under consideration to the raw material ourproducts are made of: stainless steel (according to ENstandards). A basic product balance sheet is provided.The material stainless steel has a long tradition in ourcompany. In 2010 we processed approx. 3,800 tons ofstainless steel in our production. For us, the mostimportant properties of stainless steel are the following:➤ Corrosion resistant to air, water and aggressive media➤ Hygienic up to sterility➤ Environment and resource-preserving through long

material life and 100% recyclability➤ Fully recyclable

The two latter mentioned properties are dealt with indetail in the following.A live cycle inventory analysis (input and output analysis)was published for steel products1. With regard to theprimary energy required for its production, steel is eco-friendlier than competitive metallic and syntheticmaterials. The energy demand for steel production forexample amounts to only 10 – 17 % of the energy neededfor the production of aluminium. Compared to plasticmaterials, the ratio of 1:4 is also an argument in favour ofsteel. Recycling of steel required only half the energyrequired for recycling aluminium. The energy consumedfor the production of 1 t aluminium plate is 179.5 GJ. Acomparable, well-proven and worldwide working recyclingsystem exists for hardly any other material.Approximately 80 - 90% can be reused.

The reduction of dusty and gaseous emissions hastraditionally been in the focus of environmental protectionefforts. In the course of the past 30 years the dustemissions of the steel industry could be reduced byapprox. 90%. There are similar figures for the specificenergy consumption (approx. 20 GJ/t raw steel)2 and thespecific water usage (approx. 22 m3/t raw steel)3.We have always been aware of the fact that we must beeconomical also with stainless steel and preserve alsothis resource. We therefore implemented in 1998 asoftware for optimised operation of our cutting plants toreduce cutting waste. The software was further developedin 2004. Prius Consult GmbH analysed this process in2007 and rated our optimisation system as ’very good’.We are in regular contact with other software producersand keep in touch in order to take over potentialimprovements.Note:Stainless steel is fully recyclable and is indeed generallyrecycled.

1 Technical journal ’Stahl und Eisen’ 114 (1994) no. 11, page 71-782 18.5 GJ/t according to Steel Institute VDEh, status 1992, unpublished3 Since no eco-balances have been created yet especially for stainless

steel, we have to resort to those for raw steel, however most probablywithout a significant impact on the data basis.

➤➤➤ 6. The use of stainless steel

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In terms of ecological relevance particularly thoseprocesses require continuous control and improvement,➤ which have a high energy consumption;➤ which generate noteworthy amounts of waste or

hazardous waste;➤ which must be pointed out in terms of wastewater

pollution and gas or dust emissions;➤ which involve hazardous materials;➤ which produce CO2 (cars, heating).

Such processes are explained in detail hereunder:

Plasma cutting, water jet cutting, laser cuttingPlasma cutting is applied to cut 2 - 70mm thick stainlesssteel plates. The plasma cutting process demands a highenergy input. Underwater plasma cutting producesstainless steel containing sludge and wastewater.Both mixtures are recycled. By using a proprietarydevelopment, the stainless steel plasma cutting waste isdewatered to up to 45 % DS and the amount of wastereduced in this way. Through introduction of laser cuttingthis waste is further reduced, but on the other hand thelaser operation is energy-intensive and consumes highamounts of nitrogen gas. Water jet cutting of plasticmaterials is environmentally friendly as toxic gases areavoided. The generated water jet sludge is dewatered toup to 45 % DS and disposed of separately.

WeldingThe dust and gaseous emissions produced when weldingstainless steel are harmful to health due to their chromeand nickel content if taken in large quantity. Welding fumeis therefore sucked off at its source of production byintegrated suction nozzles. The dust is filtered out by anautomatically controlled central filter plant prior to beingemitted into the ambient air.To increase occupational safety, the air is not returneddirectly despite exhaust heat losses. This was confirmedby measurements carried out at workplaces in 2009 bythe professional association.

PicklingWelding seams of stainless steel parts are treated in anacid bath of hydrofluoric and nitric acid with an acidconcentration of about 20%.Gaseous emissions, wastewater and sludge fromwastewater treatment are produced in the picklingprocess. We apply methods for efficient wastewater pre-treatment and acid regeneration and thus reduction ofpickling acid demand. This prevents the release of wasteacid. The exhaust air is sucked off and cleaned in awasher prior to being emitted into the ambient air.The pickling plant is state-of-the-art technology in termsof technique, circulation of welding acid, as well aswastewater and exhaust air treatment, and clearlyexceeds legal standards. With our optimised acidregeneration plant we eliminate the need for aciddisposal. All processes in the pickling plant are controlledfully automatically.Cars: The general goal is the reduction of petrol anddiesel fuel consumption.Co2 emissions (current, gas, fuel) related to operatingperformance could be kept constant in the past yearseven in spite of the expansion of facilities. See diagram 8.

➤➤➤ 7. Production processes

20

Today, 1.1 billion people do not have access to cleanwater and 2.6 billion have to live without adequatesanitary facilities. Particularly critical are the livingconditions in countries like Asia, Africa and Latin Americawhere also the availability of nutrients for agriculturalneeds is frequently limited. Due to the enormousinvestment and operating costs, high water consumptionand elimination of nutrients, conventional wastewatertreatment systems are not an adequate solution.

A sustainable development in areas still unserved withadequate sanitation is rendered possible by theapplication of alternative sanitary concepts that arebased on separate collection and treatment of theindividual wastewater flows. The main focus is on reuse ofthe treated water and the nutrients contained within thewastewater. Promising technologies, which provide for thesuccessful implementation of the innovative approachesto solving the problems, are the following:

➤ Membrane filtration: The HUBER membrane systemprovides for both treatment of wastewater andproduction of a virtually germ-free effluent, which issuitable to be reused as irrigation water for example.

➤ Precipitation, stripping and absorption:The combination of precipitation, stripping andabsorption in the new HUBER modules is suitable fortreatment of undiluted urine. The aim of this processis recovery of the nutrients phosphorus and nitrogen.

➤ Anaerobic treatment technology: The anaerobictreatment system produces biogas from faeces andbio-waste. Process control at high temperaturesenables the production of very hygienic fermentationresidues, which can be used as an agricultural soilimprover.

The ReUse concept implemented in the HUBERoffice building

Within the scope of the HUBER Re-use Project at theHUBER headquarters innovative sanitary systems withintegrated biowaste disposal are applied and differentoptions for reuse of treated wastewater and the valuablematerials contained are tested. The standard equipmentof the HUBER office building with no-mix toilets, waterlessurinals and three different wastewater lines provides forseparate collection of the individual wastewater flows atsource (yellow, brown and grey water). Differenttechnologies can be developed and tested for the specifictreatment of the separated or partially collectedwastewater flows.The purpose of wastewater treatment in the HUBERRecovery Plant is the recovery of valuable materialcontained within the individual substance flows and theproduction of safe water for reuse. To demonstrate thereuse options, the differently treated wastewater flowsare used for irrigation of the company park and fruitorchard and for a fish pond in the company’s ReUse Park.The recovered material can be reused as fertiliser fororchard meadows and plant beds. Besides, the treatedgreywater, together with the collected rain water, is usedfor toilet flushing. With this innovative demonstrationproject HUBER proves that wastewater is not waste but arecyclable resource from which valuable water, nutrientsand energy can be recovered.

Separate collection and individual treatment in the Recovery PlantReuse of water and nutrients in the ReUse Park

➤➤➤ HUBER ReUse Park – Wastewater is a resource!

➤➤➤ 8. Integrated product policy (IPP)Wastewater – A source of water, nutrients and energy!


21

➤➤➤ Recovery Plant und ReUse Park

precipitation reactor

stripping column

adsorption column

hydrolysis

anaerobic reactor

RecoveryPlant

MBR

servicewaterenergy

fertilizerfertilizer

pond managementirrigation

grey waterbrownwater

urineunseparated sewage

ammonium-sulfate fermentation

residuebiogas

fertilizer

MAP

bio-waste

MBR

Fig. 4: Recovery Plant

Fig. 5: ReUse Park

22


23

➤➤➤ Input

➤➤➤ 9. Eco-balance 2008 – 2010

2008 2009 2010 UnitRAW MATERIALSV2A stainless steel 2,767 2,338 2,830 tV4A stainless steel and other 943 1,191 1,001 tNE metals 9.0 10.9 6.0 tPVC 0.56 0.42 0.42 tOther plastics 27.4 31.2 29.5 tSEMI-FINISHED PRODUCTSAuxiliary materialsColours, paints, surface sprays 1,257 1,064 1,066 pcs.Solvents, machine cleansers 618.8 584.0 658.8 kgWood packing 398.9 499.5 533.5 m3

PU foams 7,600.0 6,450.0 5,400.0 kgPolystyrene (B94) 218.4 185.3 224.8 m3

Adhesives 79.0 100.7 77.0 kgOperating mediaPickling paste 2,480.0 2,250.0 2,505.0 kgHydrofluoric acid (HF) 26.4 29.0 14.1 m3

Nitric acid (HNO3) 37.1 42.7 34.5 m3

Sodium hydroxide solution (NaOH) 5.8 5.6 5.4 m3

Hydrogen peroxide 10.8 12.5 14.7 m3

Hydrochloric acid (HCl) 0.4 0.24 0.24 m3

Chlorine bleaching lye 13.6 11.4 9.5 m3

FE II sulphate (FeSO4) 4.0 3.0 4.0 tLime 41.4*** 34.2 31.8 tEnergyNatural gas 1,573,367 1,578,003 1,725,590 m3

Electric energy 3,089,358 3,172,734 3,464,950 kWhFuelsDiesel (company cars) 271,177 261,502 257,601 lUnleaded petrol Super(company cars) 33,551 26,989 22,439 l

WaterDrinking water (Erasbach) 10,260 9,061 9,528 m3

Air n.q. n.q. n.q n.q.

Increases to be regarded as increase related to operating performance:Operating performance in 2008 91 Mill. €Operating performance in 2009 84 Mill. €Operating performance in 2010 96 Mill. €

Table 1: Input 2008 – 2010

24


25

2008 2009 2010 UnitProductsStainless steel products 2,593,500 2,511,373 2,655,535 kgWood packing 398.9 499.5 533.35 m3

EnergyNatural gas 1,573,367 1,578,003 1,725,590 m3

Electric energy 3,089,358 3,172,734 3,464,950 kWhDiesel (company cars) 271,177 261,502 257,601 lUnleaded petrol Super (company cars) 33,551 26,989* 22,439 l

Water

Wastewater (Erasbach) 10,260 9,061 9,528 m3

of which wastewater / ww treatment plant 2,497 2,742 3,033 l

Waste codenumber Specification

QuantitiyUnit

2008 2009 2010Hazardous waste for disposal

13 05 02* Sludge from oil/water separators 27.9 20.8 19.3 m3

13 02 05* Non-chlorinated machine, gearbox and lubricatingoil on the basis of mineral oil 1.26 1.26 1.26 t

19 02 05* Metal hydroxide sludges 108.8 92.4 85.9 t20 01 21* Fluorescent tubes, batteries 0 820 726 pc.12 01 09* Drilling emulsion 6.8 5.5 3.9 t15 02 02* Absorption & filter materials: contain.oil 380 540 540 kg

11 01 05* Pickling solution (HF, HNO3) 41.5 21.7 0 t

* hazardous waste according to AVV, § 43 of KrW/AbfG (German Recycling Management and Waste Law)

Waste for reuse20 02 01 Bio-degradable waste, construction waste 42 55 0 m3

15 01 02 Foils, plastic residues, mixed plastics 1.54 5.78 3.56 t12 01 01 St. st. waste: iron-containing chips, machines 1,116.45 1,002.9 1,248.0 t16 01 17 Steel scrap 14.7 40.4 t

20 01 01 Waste paper 47.0 37.75 49.2 tWaste for disposal

19 09 02 Water jet sludge 60 49 81 t20 03 01 Municipal waste / commercial waste 75.7 70.4 69.0 t

➤➤➤ Output

➤➤➤ Waste

* Switch from petrol to diesel cars

Table 2a: Output products / energy / wastewater

Table 2b: Output waste

26


9.1 Approach and reasons for major deviationsOur eco-balance in form of an input-output balance showson the one side the operational inputs with the materialsand energies listed separately. The products and materialor energy emission are shown on the output side. Thisquantitative analysis identifies not only the marketedproduct but also the produced by-products, wastes andemissions.In the case of wastewater from the pickling plant, thevalues achieved were far better than the permitted limitvalues.How the energy sources are treated under the input-output analysis depends on where they are consumed.Super petrol and diesel are therefore treated as transititems, on the majority, since both energy carriers areconsumed virtually exclusively outside the location forbusiness trips and travelling to sites for equipmentinstallation.

Significant yearly deviations are likely to occur in coolantsand oil-containing wastes since their disposal is veryirregular over the year. A positive development is the slowincrease in raw material consumption since 1999compared to the higher increase in turnover.

27

Plant 2010 Unit

Flue gas suction plant 6,730 m3/h

Suction plant in pickling department 4,059 m3/h

Grindery suction plant 1,850 m3/h

Roof ventilators 312,000 m3/h

Total CO2 emission at Erasbach(fuel, electricity, gas) 3,054 t

Table 2c: Output exhaust air / emissions

28

9.2 General evaluation of all environmental aspectsand selection of ecologically relevant materialsAn important aspect with the creation of an eco-balanceis the knowledge about so-called ecologically relevantmaterials. These materials were analysed by using theIÖW1 eco-balance approach (ABC/XYZ method).Qualitative selection was made according to substances➤ U the use of which is legally regulated;➤ G the use or handling of which is an issue of public

discussion;➤ L and their risk potential for air➤ W and their risk potential for water➤ B and their risk potential for soil➤ M their risk potential for humans (toxicity);➤ S which harbour a significant risk for incidents;

➤ H the production of which is ecologically relevant;➤ E the disposal of which is problematic.

The 9 evaluation criteria are graded A, B, or C:A = negative, need for actionB = medium, need for medium-term actionC = safe.To have a basis of comparison, A = 100, B = 10, C = 1.To obtain the evaluation mark, the individual criteria aresummed up, e.g. 3xA, 5xB, 1xC = 351 B = evaluationmark. The materials with the highest evaluation marksare most pollutive.The quantitative selection was made by additionallytaking into account quantity consumptions, i.e.multiplying the quantity of the material with its ABCevaluation mark.

The results of this priority order in 2010 are presented in the following table.

Material U G L B W M S H E A+B+C... Evaluation Q.in kg

Nitric acid HNO3 B B C A A A A A A 621 28,923,075 46,575

Hydrofluoric acid HF B B C A A A A A A 621 9,964,566 16,046

Pickling paste B B C B B A B B A 261 653,805 2,505

PU hard foam B component B B B B B A B B B 180 612,000 3,400

Loctite express cleaner 70636 B B B C B B C B A 162 58,126 358,8

PU hard foam A component C C C C B B C C C 27 54,000 2,000

Tangit cleaner, 1 l B B B B B B B B A 180 46,368 257.6

Silicone cartridge Novasil S 27 C B C C C B B B B 54 28,836 534

Quick degreaser C C C C B C C C C 18 11,340 630

Epple 22 sealant B B A B A B B B B 270 7,128 26.4

Table 3: Evaluation of pollutants according to their risk potential x quantity

1Cf. (N.N.): Company eco-balances, if applied properly, are a chance for organisational development: Ecological letters no. 48 dated 1994-11-30, page 12-13.Institut für ökologische Wirtschaft (institute for economy and the environment).


29

The materials have been arranged on the horizontal axisaccording to ABC criteria. The quantity consumption ofunsafe quality materials was the second evaluationcriterion. For evaluation, the danger level was multipliedwith the quantity and then sorted by height.We see here a combination of high consumption andunsafe ecological properties at the same time. Thestrategy is substitution of consumption. If substitution isimpossible, it is ensured that the material is used undercontrolled conditions.

General evaluation of environmental aspectsWhen purchasing environment-relevant plants the buyingdepartment takes into account environment-relevantparameters, such as current consumption, operatingmedia consumption, etc.The plants were systematically evaluated, similar to thehazardous materials, by means of the ABC/XYZ method.Existing plants, environmental aspects and indirectenvironmental aspects are evaluated according to thesame principle. See extract in table 3, and chapterproduction processes and IPP. The efficient use of the rawmaterial stainless steel is continuously further optimised.Transport, packing and development are elements of theenvironmental management system with continuousimprovement.

Area

Mac

hine

s

Emiss

sions

Was

te

Was

tewa

ter

Exha

usth

eat

Powe

r

Pres

sure

air

Wat

er

Cool

ing

wate

r

Inte

rnal

noise

Exte

rnal

noise

Wat

erha

zard

class

Tech

n.ru

lesf

.flam

m.liq

uids

Ordi

nanc

eon

haza

rd.s

ubst

.

Num

bero

fent

ries

Crite

rion

sum

Num

bero

fent

ries

Crite

rion

sum

Asse

mbl

y

Forming press B B C 3 B

Foam device B C C C B 4 C

RoD balancing machine C C C 3 C

IPE suction TT B A C C C 5 B

Pick

ling

RoD test stand C C A B C 5 B 5 B

Acid pump C B C 3 C

Wash water pump C B C 3 C

High pressure cleaner C C A C 3 B

High pressure cleaner C C A C 3 B

Wastewater treatment A A C C C

Exhaust air treatment A A C C C

Sandblaster B C B C 4 C 5 C

Cent

ral Fume and heat discharge C C C 3 C

Compressor plant B A A C 4 B

Heating plants 10 * 15 A A C C 4 B 3 B

Environmental aspects evaluation 2010: Average = 2.43 = B

ABC method

Table 4: Evaluation of the plants by their environmental aspects (extract)

30


31

9.3 Key indicatorsWasteThe following curve (fig. 6) describes the specific costs forthe disposal of hazardous waste related to operatingperformance.

At the turn of the year 2008/2009 the pickling bath wasrenewed and the Eco-Tec plant optimised. This resulted inan increase of the specific costs. In 2010, we couldvirtually achieve the 2007 level.

Fig. 6: Specific disposal costs

➤➤➤ Specific disposal costsHazardous waste for disposal / operating performance

0.05 %

0.04 %

0.03 %

0.02 %

0.01 %

0.000 %

-0.01 %2008 2009 2010

Fig. 7: Plate cutting waste development

2000 2002 2004 2006 2008 2010

40

35

30

25

20

15

Was

te[%

]

➤➤➤ Cutting waste factor

actualtarget

Constructive measures were taken in and after 2006 toimprove plate wastage but no substantial change could

be observed. The potential seems to have been exploitedto a great extent.

Business year

2002 2003 3004 2005 2006 2007 2008 2009 2010

power / operatingperformance

gas / operatingperformance

2003 2004 2005 2006 2007 2008 2009 201039 41 39 36 32 32 34 32

0

5

10

15

20

25

30

35

40

45

50

32

Emissions / energy efficiencyThe following diagrams show the ratio of CO2 emission /power / natural gas to operating performance. Thegeneral development is a reduction compared to theyears 2005/2006, with a negative influence caused in2009 by unusually low operating performance.

HUBER SE commissioned the University of AppliedSciences Amberg-Weiden to work out an energy efficiencyconcept. Reasonable proposals have been implemented.

Fig. 8: CO2 emission / operating performance

Fig. 9: Power and gas / operating performance

➤➤➤ Total Erasbach CO2 emission / operating performance

CO2

/ope

ratin

gpe

rform

ance

(g/l

)

g/EUR

➤➤➤ Power & natural gas consumption /operating performance ratio

0.050

0.045

0.040

0.035

0.030

0.025

0.020

0.015

0.010

0.005

0.000

natural gas m3, electric energy kWh


33

Table 5: Overview of key indicators

Input / Effects Description Result Unit

Energy efficiency / operating performance 0.056 kWh / €

Energy Natural gas 1,906,951 kWh

Power 3,464,950 kWh

Renewable energy sources: 17.03 %

Material efficiency, see table 1

Raw materials(stainless steel, plastic)

Annual consumption after purchasedate / operating performance 0.00004 t / €

Water efficiency

Water Drinking water / operating perform. 0.000099 m3/€

Waste, see table 2b

Specific disposal costs Waste for disposal /operating perform. 0.036 %

Biodiversity

Built-up area at Erasbach:25,553 m2 m2

Emissions

CO2 emission, see fig. 8 CO2 emission / operating perform. 31.79 g / €

Total emission in air*

SO2 433.2 kg

NOX 929.1 kg

Dust emissions (PM) are negligible.

Regular maintenance of climate control units is ensured. No cooling agent was refilled in 2010.

* SO2 Und NOX emissions are caused with the combustion of natural gas.

Overview of key indicators

34

➤➤➤ Environment: Goals and program 2009 – 2011We set ourselves the following targets in order to furtherimprove environmental protection within our factory:

No. Subject Action Responsibility Goal Plannedcompletion

1 Efficiency of resourcesa) Raw material cutting waste

reduction from 27.5 % to below26% (related to weight)– Waste related to raw

material consumptionb) Raw material cutting waste

reduction from 25.0 % to <24% (related to surface)

CO2 reduction / operatingperformance 32 g/€

- Current, gas, fuel consumptioncontrol

– Improve nesting / NC program– Improve nesting of several

orders– Combine orders and cut

parts of same plate thicknessConsider the fuel and current

consumption particularlywhen making newinvestments. Individual cartypes and motorisation aredefined in the company carguidelines.

NC teamDesign

ro, jg, hg, koe

<26 %≤ 24 %

< 30 g/€

2011

2 Reduce re-pickling work; optimalpickling concentration: Constantpickling efficiency taking intoaccount the temperature;Constant pickling pasteconsumption related to rawmaterial usage.

Continuous plant purification(free of grease); seasonaladjustments; sufficient pre-treatment; Re-pickling only ifactually required

nd/mey/eh

0%even with

increasing rawmaterialusage

2011

3 Generally avoid overstepping ofwastewater limit values

Process improvement andcontrol

eh, mey Nooversteppingof limit values

2011

4 Replace environmentally harmfulmaterials. Avoid newenvironmentally harmfulmaterials.

Search for alternativematerials, approval test fornew materials

eh, mey, kr,blo

Eco-friendlymaterials

2011

5 Keep current consumptionconstant related to operatingperformance, as well as cos factor0.98

Continue previous measures fi Constantcurrent

consumptionrelated tooperating

performance

2011

6 Implementation of GHS guidelinesfor hazardous materials.

Meet the requirements eh, mey, ns Implementation 2011

Table 6: Environmental goals and program 2009 - 2011


➤➤➤ 10. Environmental program 2009 – 2011In our environmental program we define the projects andschemes we plan in the course of the next years for theimprovement of internal environmental protection.The maxim of our actions is the goals defined in ourenvironmental policy. It is thereby our endeavour to gobeyond the standards prescribed by law.According to the EU directive we defined the responsibi-lities for achievement of the goals in each task area andon each company level. We defined also the means howto achieve the goals.Concerning the organisational and technical goalsspecified below, it is a matter of particular concern for usboth to explain the measures how to achieve our goalsand to specify when individual measures will beimplemented.In our next environmental statement we will report towhat extent we have achieved our ambitious aims.

10.1 Organisational and technical goalsThere are seven goals we especially plan to achieve 2009– 2011. (See table below.)By reducing the stainless steel scrap to 26 % we expectalso an economic success, in addition to the preservationof raw material resources. We continuously optimise theeffective material usage through development inaccordance with IPP. Further improvements are expectedas a result of measures with regard to plate nesting bymeans of state-of-the-art NC software and designmodifications.

10.2 Environmental statementThe next consolidated environmental statement will bepresented for validation by May 2012 at the latest.

Environmental expert / expert organisationCommissioned environmental expert / expert organisation:Dr.-Ing. N. Hiller (license no. DE-V-0021)Intechnica Cert GmbH (license no. DE-V-0279)Ostendstr. 18190482 Nuremberg

Validation confirmationThe undersigned, Dr. Norbert Hiller, EMAS environmentalexpert, registration no.DE-V-0021, accredited / certifiedfor the area 28.96 (NACE code rev. 2) confirms he hasvalidated whether the complete HUBER SE organisation,as stated in its updated environmental statement, meetsall requirements of EC Ordinance no. 1221/2009 of theEuropean Parliament and Council dated 25 November2009 related to the voluntary participation oforganisations in a community eco-management and auditscheme (EMAS).

The signature under this declaration confirms that➤ the assessment and validation procedure has been in

full compliance with the requirements of EC Ordinanceno. 1221/2009;

➤ the results of assessment and validation confirm thatthere is no proof of any non-compliance withapplicable environmental regulations;

➤ the data provided in the Environmental Statement /updated environmental statement of the organisation/ place of organisation provide a reliable, trustworthyand true image of all activities of the organisation /place of organisation within the field specified in theEnvironmental Statement.

Nuremberg,

Dr.-Ing. N. HillerEnvironmental Expert

10.3 Outlook

HUBER SE participates in the Clean DevelopmentMechanism (CDM) Initiative Bavaria, an innovativeproject of co2ncept plus that supports small andmedium-sized companies in climate protection.

The aim is to identify the corporate carbonfootprint (CCF) of HUBER SE at its Berchingheadquarters on the basis of the GreenhouseGas (GHG) Protocol.

We will continue our commitment to theenvironment also in the future and keep youinformed.

35

HUBER SEIndustriepark Erasbach A192334 BerchingPhone + 49 - 84 62 - 201- 0Fax + 49 - 84 62 - 201- [email protected]: www.huber.de

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