Environmental Report 2011-2014 - vinnolit.com · Vinnolit Environmental Report 2011-2014 7 Vinnolit...

Environmental Report 2011-2014

Vinnolit GmbH & Co. KG

3Vinnolit Environmental Report 2011-2014

We are committed to combining economic success with social and environmental responsibility.

At all times, we take our responsibility for people and the environment very seriously. Safety, the protection of human health and the environment are the primary goals of our corporate policy. This commitment demands compliance with high standards of safety and environmental protection in production, conservation of resources in the operation of our production facilities, and the sale of products only when we are convinced of their safety and environmental compatibility. Because we are an energy-intensive company, our attention focuses on the improvement in the efficiency of our energy consumption. In the last several years, Vinnolit has made substantial invest-ments in related efforts that have been highly successful. Regular audits by impartial assessors confirm our reliable compliance with the requirements established by standards for quality, safety, environmental protection and energy conservation.

When challenges related to environmental sustainability that can be mastered most effectively by the PVC or plastics industry as a whole arise, we cooperate with other companies in the plastics industry, especially in the PVC value chain, within the framework of associations and initiatives to find solutions. Among other activities, Vinnolit is actively involved in VinylPlus (the voluntary sustainable development program of the European PVC industry), the Euro Chlor sustainability program, and the worldwide Responsible Care initiative of the chemical industry. The industry has made tremendous success in recent years, especially in PVC recycling, the more sustainable use of PVC additives, and the conversion to the environmentally friendly membrane cell process for the production of chlorine and caustic soda.

This environmental report, which supersedes the annual environmental protection declarations and their updates of the past years, de-scribes the company’s goals, actions and past successes in environmental protection. However, we have no intention of resting on our laurels. We will continue, now as a member of the Westlake group, to set demanding targets and to face the coming challenges in the future. Come along with us!

Acting Responsibly

Dr. Josef Ertl Managing Director


Inhalt

The company 6

Responsibility for people and environment 8

Associations and initiatives 10

Products 12

Processes 14

Environmental targets 18

Figures 20

Contact 20

6 Vinnolit Environmental Report 2011-2014

The company

Vinnolit

With an annual capacity of 780,000 met-ric tonnes (1.7 billion lbs) Vinnolit is one of the leading PVC producers in Europe and, worldwide, is the market and technical lea-der in specialty PVC.

The six production sites are in Burghausen, Gendorf, Knapsack, Cologne, Schkopau, and Hillhouse (UK); company headquarters are located in Ismaning near Munich. With 1,400 staff, Vinnolit has an annual turnover of ca. €900 million.

Since mid-2014, Vinnolit has been a part of Westlake Chemical Corporation, a leading international producer of petrochemicals, polymers and PVC building products.

Vinnolit produces and markets a broadly diversified range of PVC products encom-passing all of the common PVC applica-tions, e.g., in construction, the automotive industry and medical technology. No mat-ter whether PVC is required for flooring, wallpaper, window profiles, pipe, rigid film, technical coatings, vehicle underbody pro-tection, cable sheathing, or infusion bags — Vinnolit has solutions to match the requi-rements for any product.

Vinnolit is also a leading producer and supplier of intermediate products such as caustic soda, vinyl chloride, and tin tetra-chloride that are required for further pro-cessing in the chemical industry and many other sectors.

The world market and technology leader for PVC specialties

Sites

Vinnolit has production plants at six sites in Germany and Great Britain.

Burghausen

Vinnolit produces suspension and emul-sion PVC as well as PVC copolymers at the Burghausen site. The Vinnolit plants are lo-cated on the premises of the Burghausen site belonging to Wacker Chemie AG. The PVC raw material vinyl chloride (VCM) is supplied to the PVC plants via pipeline from Vinnolit´s Gendorf site.

Burghausen is also the location of the Vin-nolit application technology center where all important PVC processing methods can be replicated and customers can get advice about formulation and processing techno-logy.

Vinnolit headquarters in Ismaning

Silo storage of PVC at the Cologne site


Vinnolit converted to the environmentally friend-ly membrane cell process for the production of chlorine and caustic soda back in 2009.

Gendorf

Vinnolit produces emulsion PVC and PVC copolymers, the preliminary products chlo-rine, ethylene dichloride (EDC) and VCM, as well as caustic soda and tin tetrachloride at the plants in the Industrial Park "Werk Gendorf". The VCM is transported via closed-system pipelines to the PVC plants in Gendorf and Burghausen.

Gendorf is also home to Vinnolit´s Innova-tion Management with its research labo-ratory and technical center. Here work on the ongoing improvement of products and manufacturing processes as well as the development of new products takes place. Increases in energy efficiency, reduction of emissions and conservation of raw materi-als and supplies are examples of the objec-tives for process improvements. Production processes can be replicated on a trial scale in the technical center as a way to test im-provements in processes and products wit-hout disrupting normal production.

Knapsack

The Vinnolit plants in Knapsack are inte-grated into the Chemical Park Knapsack. Suspension PVC, the preliminary products chlorine, EDC and VCM, as well as caustic soda are produced here. VCM is supplied to the Cologne site from Knapsack.

The internal chlorine network of the Chem-ical Park is an example of modern material flow management. Vinnolit plays a major role in the interlinked material loops, in which other companies producing at the site participate, too. Cologne

Microsuspension and suspension PVC are produced in the Vinnolit plants on the pre-mises of the Cologne site of Wacker Che-mie AG. Deliveries of VCM are accepted at a ship unloading facility in the petroleum port Cologne-Niehl or alternatively at a rail-

road tank car unloading facility in the plant and transferred via closed-system pipelines to the VCM tank farm. The raw material is supplied to the PVC plants from here.

Schkopau

The plant, which manufactures emulsion PVC in Schkopau is located on the premi-ses of the Dow ValuePark. VCM is supplied from Dow by pipeline.

Hillhouse (UK)

Vinnolit operates a plant for the production of emulsion and microsuspension PVC at the Hillhouse International Business Park in Hillhouse. Supplies of VCM are brought to the site by tank trucks.

Site services

Various services such as • the supply of energy,• the disposal of waste water and waste,• environmental protection, safety and

health protection services,• engineering services, and• vocational and advanced trainingare purchased at the sites, for the most part, from the local site service provider.

Energy sources such as steam, electricity, cooling water, compressed air, or natural gas which Vinnolit requires for the heating and cooling of product flows, the operation of motors, the drying of our products, and other purposes are procured from the ser-vice units of the plants. They are subject to environmental protection standards com-parable to those found at Vinnolit.


Responsibility for people and environment

Safety and the protection of human health and the environment are the primary goals of the Vinnolit corporate policy and are fi rm-ly anchored in the company’s vision and values. Effective environmental management en-sures compliance with laws and voluntary obligations undertaken by the industry and defi nes the standards required for this com-pliance. Environmentally compatible pro-cesses, technical safety, and the protection of human health are fi xed components of our objectives beginning at the product de-velopment stage.

Our principles also include the implementa-tion of ongoing improvements aimed at the reduction of any possible negative impact on the environment.

For instance, numerous measures have been implemented in the production and further processing of the raw material chlo-rine to make the processes even safer. Companies in the industry share their expe-rience within the framework of Euro Chlor, the association of European chlorine pro-ducers organized as part of the European Chemical Industry Council (CEFIC), and within the German Federation of the Chem-ical Industry (VCI).

Strict standards also apply to the product-ion of the chlorine daughter products EDC, VCM and PVC. Producers of these pro-ducts are organized in the European Coun-cil of Vinyl Manufacturers (ECVM).

“Safety and protection of human health and the environment are the primarygoals of the Vinnolit corporate policy.”

Integrated management system

Vinnolit maintains an integrated manage-ment system for quality, safety, environ-mental protection, and energy management that ensures the trackable and continuous improvement of products and work proces-ses in the company. Vinnolit is certifi ed in accordance with DIN EN ISO 9001/14001 and 50001 and with BS OHSAS 18001 and OHRIS. Compliance with the requirements is confi rmed by impartial assessors in the course of regular audits. The issued certifi -cates can be viewed on the company web-site under Company/Integrated Manage-ment System.

Organization

The Vinnolit organizational structure, the as-signment of responsibilities regarding qua-lity, safety, environmental and health pro-tection, and energy, and the names of the responsible offi cers at each of the product sites are listed in the corporate manual.

In accordance with Section 52 b of the Ger-man Federal Emissions Control Act (BIm-SchG), one member of top management performs the duties and obligations of an operator of plants subject to approval. Di-rect responsibility for environmental protec-tion is situated in the chain of delegation from the operations director to the relevant heads of the production divisions and plant managers.

The organizational chart is set forth in

manuals and in process and operating in-structions. Training is conducted at regular intervals to ensure that employees are fa-miliar with these instructions and comply with them.

Idea management

One of the important pillars for the ongo-ing improvement of our work procedures, occupational safety, environmental protec-tion, and energy management is provided by the employee suggestion system (idea management).

Emergency management system

Vinnolit is integrated into the emergency management system at each of the sites. Primary contact in case of an emergency is the plant fi re department, which is staffed around the clock. The Cologne Professio-nal Fire Department is responsible for fi re protection and the protection of the popu-lation at the Cologne site. It is supported


by personnel, technical and organizational measures in the plant.

As necessary, various on-call services of the plant are notified in accordance with a ranking system to provide support to the fire department personnel. Well-equipped measurement squads are able to detect possible local immissions outside of the plant boundaries.

The reporting channels to government au-thorities and the issue of information to the general public are precisely defined. Pos-sible emergency scenarios are the subject of regular discussions and are simulated during realistic drills involving personnel from outside the plant and with the parti-cipation of representatives of government authorities.

Any and all deviations from normal oper-ations are documented and reviewed to determine possible means to prevent the occurrence of similar incidents in the future.

Incidents

Incidents within the sense of the Incident Reporting Ordinance (12th BImSchV [Ger-man Federal Emissions Control Ordinance]) are any events resulting in a major hazard, whether inside or outside of the plant premi-ses, or serious material damage. The com-pany is insured for environmental pollution caused by such incidents. The policies also include coverage of possible environmental pollution from proper operations.

No incidents occurred at Vinnolit during the reporting period.

Dr Josef Ertl (left) and Dr Ralph Ottlinger (right), Vinnolit managing directors, with Dr Hubert Martin, TÜV-Süd auditor.

Chemical Park Knapsack maintains readiness for emergencies by conducting a large-scale emergen-cy drill every year.


Plus and Vinyl 2010, its predecessor pro-gram. For instance, more than 481,000 me-tric tons of PVC were recycled in Europe in 2014 within the scope of VinylPlus. The use of lead stabilizers has been reduced by 86%, and they are to be completely re-placed by alternative stabilizer systems by 2015. Short-chain phthalates are being re-placed in more and more applications with alternative, non-hazardous plasticizer sys-tems. Of no less importance is the increase in energy efficiency along the full length of the value chain. The advances are docu-mented in an annual progress report. (www.vinylplus.eu)

Responsible Care

Vinnolit participates in the Responsible Care program of the chemical industry, which seeks the continuous improvement of safety and protection for human health and the environment.

PlasticsEurope

PlasticsEurope represents the political and economic interests of plastics producers in Germany and Europe, serving as a contact for all subjects relevant for plastics. Envi-ronmental and sustainability topics are at the special focus of the work done in the division „People and Environment“. Vinnolit participates in the Zero Pellet Loss initiative of PlasticsEurope, which aims to prevent the entry of plastics into the environment.

ECVM

The European Council of Vinyl Manufactu-rers (ECVM) represents the specific inte-rests of the European PVC producers. One important focus is on the sharing of expe-rience related to environmental and safety issues.

Associations and initiatives

VinylPlus

Vinnolit is an “Official Partner” of VinylPlus, the voluntary sustainable development pro-gram of the European PVC industry, and supports the program financially, through commitment to its principles, and through active participation.

VinylPlus defines the obligations under-taken by the PVC industry: • Expand PVC recycling• Help to ensure that persistent organic

componds do not accumulate in nature and to reduce emissions further

• Drive the environmentally more sustai-nable use of PVC additives

• Protect the climate through energy ef-ficiency and responsible utilization of resources and raw materials

• Foster integration and sensitization of the entire PVC value chain for environ-mentally sustainable business opera-tions

The industry has made major progress in environmental protection by realizing Vinyl-

Vinnolit is a founding member of the Bavarian Environmental Pact for the continuous impro-vement of operational environmental protection. In 2011, Dr. Ralph Ottlinger (right), managing director, accepted a certificate from Dr. Markus Söder, Minister of the Environment, in recogni-tion of this.

EuroChlor

Vinnolit is also a member of Euro Chlor, the association of European chlorine pro-ducers, and supports the Euro Chlor envi-ronmental sustainability program. Vinnolit had in 2009 already fulfilled the voluntary commitment of the Euro Chlor members to convert chlorine production from the mer-cury cell to the environmentally friendly membrane cell process by 2020.

AGPU

Vinnolit is an active member of the Working Group PVC & Environment e.V. (AGPU), a joint environmental initiative of business and academics, which has been working successfully for the sustainable develop-ment of PVC in Germa-ny for 25 years.

Organochlorineemissions

Controlled-loop management

Sustainableenergy & climate

stability

Sustainable use of additives

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SUSTAINABILITY AWARENESS


There are recycling systems available for many PVC appli-cations, e.g., for window profiles. More than 481,000 metric tons of PVC were recycled in Europe as part of the environ-mental sustainability program VinylPlus in 2014.


Products

PVC

Chlorine, which is produced from rock salt, a virtually inexhaustible resource, using an electrolysis process, makes up about 57% of PVC. Since the raw material com-ponent rock salt plays such a major role, the manufacture of PVC requires relatively small quantities of raw materials from non-renewable fossil sources — a long-term benefit from both economic and ecological perspectives. PVC products conserve re-sources and are especially economical, ef-ficient, and low-maintenance. And they lend themselves well to recycling.

Thanks to its quality and versatility, PVC is an ideal material for an enormous ran-ge of applications. Floor coverings made of PVC are especially easy to maintain and are available in many different designs. De-corative vinyl wallpaper create special at-mosphere, and PVC window profiles have outstanding qualities for energy-saving window systems. In the construction indus-try, PVC is also used for long-lasting pipes, cable sheathing, or sturdy tarpaulins. We encounter this versatile material in our daily lives as credit cards, artificial leather, wear-resistant rain clothing, in car interiors, and in many other areas, including blister packs for pills and life-saving blood bags.

The first patent for PVC was issued 100 years ago, and further development of the material has steadily continued ever since. Today, it consistently compares well, eco-nomically and ecologically, with alternative materials:

• Through the relatively low quantities

of raw materials from non-renewable fossil sources, PVC helps to conserve resources.

• About 70% of the products fabricated using PVC (windows, flooring, pipes, etc.) are very durable and have a life cycle exceeding ten years - in some cases even 50 years. The low level of required maintenance and the good recyclability offer ecological and eco-nomic benefits.

• Important ecological criteria (e.g. ener-gy consumption or greenhouse gas emissions) can be quantified by life cycle assessments. As a rule, PVC products score well in these assess-ments as shown in a comparative EU ecological assessment study in 2004.

• In general, PVC products are charac-terized by significant cost advantages in comparison with alternatives. Their use saves money, which can be spent for other ecological or social improve-ments.

PVC is a well-studied, safe plastic that has proven its value for many years. As such, it is used in medical technology, food pa-ckaging, drinking water pipelines, and other applications.

It is shipped to customers in silo tank cars, as palletized sacks, or in large containers (big bags).

Caustic soda

Caustic soda is a co-product of the produc-tion of chlorine, the raw material for PVC. It is an important basic chemical and its uses include the manufacturing of paper, glass and ceramics, aluminum, detergents and cleaning agents, or viscose fiber. In addi-

PVC is a modern and innovative material which is constantly evolving.

PVC is the ideal material for a broad range of applications — from floor coverings and car inte-riors to blister packaging and wallpaper.


tinuous development of our product techno-logies and PVC raw materials to meet the demands and markets of tomorrow. Our work in this area includes cooperation bey-ond the boundaries of our company and in-volves customers and universities.

Vinnolit is one of the most innovative com-panies in our industry. More than half of our PVC products for paste applications now being sold have been developed and laun-ched on the market in the last ten years. On average, two new developments are added each year.

The Innovation Management division is lo-cated at the Gendorf site. Our employees in the laboratory and pilot facility develop new products for our customers.

All of the important PVC processing tech-nologies can be replicated at the Vinnolit application technology center in Burghau-sen. This unit cooperates closely with In-novation Management in Gendorf and with

our customers to work continuously on the optimization of processing technologies and products. This collaborative effort cul-minates in creative solutions for special customer requirements.

tion, caustic soda is used as a neutralizati-on agent, a precipitation agent, a cleaning agent, and a food additive.

The product is shipped to customers in tank cars, tank trucks, and ships. It is conveyed in pipelines at the respective sites.

Hydrogen

Hydrogen, a co-product of chlor-alkali elec-trolysis, is used primarily as an energy source replacing natural gas, but it is also utilized in chemical processes or as an energy source for hydrogen stations.

Tin tetrachloride

Tin tetrachloride is produced from chlorine and tin and is the base product for tin-based special chemicals, especially tin stabilizers used in the processing of PVC. In addition, it is used for coating glass surfaces or as a hardener for polyurethane systems. The packaging of tin tetrachloride is fully auto-matic, and it is shipped mostly in railroad tank cars.

Research and development

Vinnolit invests multi-million-euro amounts in research, development, and application technology every year. We work on the con-

Loading caustic soda in Knapsack

All of the important PVC processing technologies (here the extrusion of window profiles) can be repli-cated at the application technology center in Burghausen.

Vinnolit laboratory


Processes

Production and technology

The Vinnolit plants are subject to the pro-visions of the German Federal Emissions Control Act (BImSchG) and the “extended obligations” of the “Incident Reporting Or-dinance” (12th BImSchV [German Federal Emissions Control Ordinance]). The latter includes the preparation of a comprehen-sive safety report. All of the plants have obtained operating permits issued by the relevant government authorities. During the approval process for the permits, all of the plants were examined by impartial experts or by the relevant government authorities in accordance with the extensive legal requi-rements.

Regular inspections and maintenance work are carried out on all of the equipment in the plants to ensure disruption-free operation. Compliance with all legal regulations, the lowest possible impact on the environment, and the highest possible level of energy efficiency using state-of-the-art technology are never in question during the procure-ment of new technical equipment and the improvement of existing facilities.

Emissions

The process chain for the production of chlorine, dichloroethane, and finally vinyl chloride releases small quantities of emis-sions (inorganic and organic gases, parti-culate matter) into the air. Although filters have been installed, these emissions are technologically unavoidable. Process water is treated in the central biological treatment facilities at the chemical sites. Emissions into the air and water are limited by legal regulations or voluntary commitments and are monitored to ensure compliance with these limits. Thanks to the conversion to modern, environmentally friendly membrane cell electrolysis, mercury has not been used for the production of chlorine since mid 2009.

The production of PVC and the prelimina-ry products takes place within closed sys-

tems. Monomer, which is not converted, is returned to the manufacturing process to prevent its emission into the air. Material and durability demands made on the con-tainers and pipelines used in these systems are naturally high as well. The equipment is freely ventilated only during drying and reprocessing.

Low emissions of particulate matter occur at dedusting filters and cannot be comple-tely eliminated technologically. We have been able to reduce these emissions signi-ficantly by installing new filter systems.

The actual emissions are regularly repor-ted to government authorities in emissions statements and in the European pollutant register E-PRTR.

Raw materials

The most important raw materials are de-livered to the Vinnolit plants via closed pipeline systems; salt is delivered as a bulk product by rail. Packaging materials play a role only for the relatively small quantities of auxiliary supplies. Generally speaking, all possible actions are taken to reduce consumption.

Suppliers of raw materials and technical

materials are requested to avoid superflu-ous packaging and to offer recycling sys-tems. Plastic packaging and plastics are recycled and utilized in cooperation with RIGK GmbH. In 2013, the recycling led to an saving of more than 65 metric tons of greenhouse gases. Environmental con-cerns are elements of our supplier assess-ments.

Raw materials are stored in containers or rooms approved for this purpose in confor-mity with legal requirements. As many of the raw materials we use are hazardous substances within the sense of the Ha-zardous Substances Regulations, we pay special attention to the environmental re-levance of the required raw materials and auxiliary supplies right from the product de-velopment stage and look for environmen-tally compatible substances that can serve as substitution.

Waste

All of the Vinnolit facilities take steps to prevent the occurrence of waste. Compa-red to the quantities of raw materials used, the manufacture of PVC produces very little waste. All of our processes have been op-timized to prevent as much waste as pos-sible for economic and ecological reasons.

PVC waste resulting from the processes is utilized. Most of this waste results during the cleaning processes. Collection systems for different recycling and disposal chan-nels are operated at the plants and used by Vinnolit. In addition to using the facilities operated by the plants themselves, we take advantage of the opportunity for thermal re-covery outside of the plant as well. Emplo-yees receive regular training for handling waste products during safety instruction sessions.

Suspension PVC powder from Vinnolit


Rock salt — raw material for the manufacture of PVC


pollution during shipment to customers as low as possible:

• Avoidance of packaging by using silo vehicles whenever the customers’ fa-cilities permit

• Return of the rock salt quantities which are unusable to the mine on the same train

• Use of railway silos and railway silo containers whenever the customers’ facilities permit

• Use of recyclable paper for bagged goods and participation in the Repa-sak model

• Shrinking of bagged goods with recyc-lable shrink wrapping

• Stacking of bagged goods on standar-dized chemistry pallets for which there is a circulation and repair system

Environmental aspects are also taken into consideration during the selection process for forwarding agents. For instance, Vinnolit has been participating in the Eco-Plus pro-gram of its logistics partner DB Schenker Rail since the beginning of 2012; the pro-gram features the utilization of renewable energies for the rail transport of rock salt to the Gendorf site. This has enabled Vinno-lit to reduce CO2 emissions every year by about 5,900 metric tons in comparison with road shipment and by about 1,000 tons in comparison with rail shipment without Eco-plus.

as protection from possible soil pollution when working with potential water pollu-tants.

Energy efficiency

The ongoing modernization and optimiza-tion of plant equipment has substantially reduced the consumption of electricity, steam, and cooling water. Specific energy consumption has also been significantly re-duced since 2009 by the conversion of the electrolysis technology from mercury cell to membrane cell technology. By taking these steps, Vinnolit has made an important con-tribution to increasing energy efficiency and reducing CO2 emissions.

The further improvement in energy effici-ency remains an important corporate tar-get. With this in mind, Vinnolit continually invests in the modernization of equipment and the improvement of process procedu-res. The company-wide project “VinSavE” encouraged employees to develop ideas for energy conservation that can reduce energy consumption in the company by more than 10%. Many of the proposed ac-tions have been implemented - others will follow in the coming years. After the con-clusion of the project, the instruments were implemented as permanent elements of the management system.

In an international comparison of energy consumption, Vinnolit posts excellent re-sults based on experience from past indust-ry benchmarks. Fluctuations in energy con-sumption are possible as a consequence of shifts in the product mix.

Traffic and transport

Vinnolit consciously relies on environmen-tally friendly “green” logistics, both when procuring raw materials and shipping its products, and to the greatest possible ex-tent uses railroads, ships, and pipelines for transport. The following principles are observed as a way to keep environmental

Water and waste water

Programs for conserving water have resul-ted in a substantial reduction of water con-sumption. For instance, the company has been operating “PVClean”, the first large-scale technology facility for recycling pro-cess water from a suspension PVC plant, in Knapsack since 2008. Ultrafiltration and water recycling have made it possible to re-duce water consumption by 200,000 cubic meters annually.

The polymerization of VCM to PVC in wa-ter and the cleaning of the equipment with high-pressure water produces contamina-ted waste water; it is collected and, after se-paration of the solids it contains, conveyed to the waste water treatment plants via the pipeline systems maintained by the plants.

Noise and odor

Noise protection concepts are in place for the plants. Noise levels at the workplaces are monitored on the basis of a plant noi-se register. Work to eliminate the sources of noise is ongoing. Noise protection con-cerns are a major element of the terms and conditions of purchasing whenever new equipment is procured.

As a rule, the Vinnolit plants do not produce any disagreeable odors.

Soil

Whenever there is suspicion that pollution has occurred, special soil or groundwater samples are taken and, if necessary, the appropriate monitoring, security, or restora-tion concepts are coordinated with govern-ment authorities. Tests for soil contamina-tion are conducted whenever excavation work is done.

All of the relevant filling/transfer facilities are equipped with liquid-tight floor troughs, collecting pits, etc. Special floor coverings and cups in the production facilities serve


Environmentally relevant facilities at the production sites

Residue incineration Incineration of solid, liquid, and gaseous waste ■ ■ ▲ ■Waste water stripper Cleaning of process water contaminated with VCM ▲ ▲ ▲ ▲ ▲ ▲Flocculation Separation of solids from process water ■ ■ ■ ■ ▲Waste water cleaning Mechanical, chemical, and/or biological cleaning of plant waste water

with analytical testing■ ■ ■ ■ ■ ▲

Water retention Emergency basin for incidents/water for fighting fires ■ ■ ■ ■ ■ ■Dumps Storage of construction rubble and similar waste ■ ■ ■ ■

HCl recycling/central exhaust gas recycling

Thermal recycling of exhaust gases ■ ▲ ■

Recycling facilities Utilization/recycling of by-products from VCM/PVC production ▲ ■ ■Exhaust gas cleaning plant

Recycling of VCM from exhaust gases ■ ▲ ▲ ▲ ▲

Rain water utilization Utilization of collected and cleaned rain water as cooling water ■

Ultrafiltration facilities Concentration of PVC latex and conservation of steam;Recycling of water

▲ ▲ ▲ ▲

The ultrafiltration facility “PVClean” in the Knap-sack S PVC plant

Occupational safety

Appropriate actions to ensure occupational safety have been implemented on the basis of extensive risk assessments pursuant to the Occupational Safety Act and the Ha-zardous Substances and Industrial Safety Regulations. Equipment and tools are pro-vided, safely used and regularly inspected by trained personnel to ensure that they are in good operating condition. Employees receive operating instructions and regula-tions, and managers monitor compliance with their provisions. Whenever necessa-ry, employees wear the required personal protection equipment. Instruction regarding risks and measures at the workplace based on an annual schedule is given to emplo-yees.

Workplace area and noise measurements are carried out to ensure compliance with limits on hazardous substances and noise

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at the workplaces so that employees’ ex-posure is minimized. Employees are exa-mined regularly by the company physician in accordance with the Regulations for Oc-cupational Health Screening. The program Sicherheit PLUS (dealing with behavioral risk components) secures the participation of employees and their direct supervisors in the risk assessments and accident reviews.

Environmentally relevant equipment

The Vinnolit plants make use of the exten-sive environmental protection equipment at the plant sites, ensuring an environmentally friendly on-site treatment and disposal of waste water and waste that for the most part does not require any transport. In ad-dition, Vinnolit operates its own facilities for this purpose.

■ Facilities at the plant sites ▲ Vinnolit facilities


Environmental targets

Energy consumption, emissions, waste, and waste water are environmental effects that are the inevitable consequences of all human action and thus of all industrial processes and activities. The assessment of these environmental effects is an essen-tial element of our integrated management system and is used as the starting point for setting targets for our environmental pro-grams.

The production divisions concentrate large-ly on the areas of energy, efficient use of re-sources, and emissions, but do not neglect other environmental aspects. Conservation of heating energy and electricity, reduction in the use of paper, and separation of waste in offices are relevant for the administrative departments.

Achievement of targets 2009–2011

Vinnolit set itself the objective of reducing specific energy consumption (steam, natu-ral gas, electricity) by 5% over the period between 2009 and 2011.

This target was exceeded when, due to the conversion of the electrolysis processes from mercury cell to modern, power-saving membrane cell technology and the conser-vation program VinSavE, a figure of -7.8% was recorded. About 242 million kilowatt-hours are saved in electricity alone every year during the annual production of 2 milli-on metric tons of products.

Natural gas consumption has been reduced by the use of hydrogen from chloralkali electrolysis as a fuel gas in EDC cracking.

The company-wide project VinSavE (“Vin-nolit Saves Energy”) contributed to further improvement in energy efficiency. Over the course of the program, the company’s employees contributed numerous ideas ai-med at reducing energy consumption even further. Savings were consequently achie-ved for compressed air, electricity, steam,

Energy efficiency has been improved significantly since 2008.

Energy efficiency (steam, electricity, natural gas) 2008 - 2014per t output

The optimization of the insulation on steam ducts conserves 710,000 kWh per year.

Improvement of energy efficiency in % (Basis 2008 = 100%)


and cooling water at various points of the production processes.

Achievement of targets 2012

Based on the assessment of environmental effects, Vinnolit concentrated primarily on the subject of energy conservation in 2012 as well. Through conservation measures for electricity and steam and the reduc-tion of heat loss, the 2012 target has been achieved and energy efficiency has been improved by further 0.44%.


In 2013, a number of projects culminating in annual savings of 16,452,300 kWh of energy were successfully carried out on the basis of the energy saving program VinS-avE. The energy-relevant sectors electri-city, cooling water, steam, compressed air, natural gas, and demineralized water were involved. Outstanding results came from one project that saved 6,966,000 kWh of steam and demineralized water annually by recovering condensation not otherwise used from an evaporation plant and retur-ning it to the process.

The constant assessment of environmental impact in the production facilities also made it possible to reduce emissions by about 3.4 metric tons, waste by 22.8 metric tons, and waste water by 155,000 m³. The reduction of the waste water volume came from the aforementioned reutilization of the conden-sation from the evaporation plant.


In 2014 more measures based on the energy saving program VinSavE were im-plemented that led to an annual saving of 2,825,536 kWh energy. It involved the are-as of electricity, steam and compressed air through the use of more energy efficient compressors, the optimization of insulati-ons and improved operation modes.

Emissions 2009 - 2014

Significant reductions have already been achieved in emissions; further progress will therefore be in very small steps. Nevertheless, it was possible to lower the specific emissions still further in the period between 2009 and 2014.

664,000 kWh of electric power are saved annually after the replacement of a hydrogen compressor with a rotary compressor.


Figures

Vinnolit Group 2008 2009 2010 2011 2012 2013 2014

Energy efficiency (GJ/t) 4.65 4.59 4.50 4.29 4.27 4.25 4.23

Water consumption (m³/t) 1.28 1.31 1.23 1.20 1.18 1.11 1.10

Biological diversity (m²/t) 0.0655 0.0686 0.0602 0.0604 0.0597 0.0587 0.0627

Emissions Particulate matter (kg/t) 0.0213 0.0259 0.0205 0.0203 0.0162 0.0151 0.0170

Nitrogen oxides (kg/t) 0.0735 0.0837 0.0700 0.0553 0.0630 0.0615 0.0583

Sulfur dioxide (kg/t) 0.000145 0.000168 0.000124 0.000097 0.000081 0.000141 0.000191

Carbon dioxide equivalents (kg/t) 62.4 77.1 74.2 65.5 63.8 66.0 68.2

Inorganic gases (kg/t) 0.0608 0.0674 0.0733 0.0619 0.0654 0.0774 0.0844

CHC/HC (kg/t) 0.0477 0.0456 0.0405 0.0383 0.0386 0.0388 0.0381

Waste (kg/t) 14.49 14.12 16.95 13.31 8.28 8.49 9.45 1

Waste water (m³/t) 1.10 1.14 1.07 1.09 1.05 1.00 1.00

Core indicators according to EMAS III (EG) No. 1221/2009

The values are subject to inevitable fluctuations owing to changes in the utilization of plant capacities or the product mix, technological modifications, and fluctuations in weather conditions. t = metric ton of total output from production.

Dr. Oliver MiedenHead of Environmental Affairs & Corporate Communications

Phone: +49 89 96103-282E-Mail: [email protected]

Michael SüßSTEM Sicherheit, Technik, EnergiemanagementEHS Environmental Health Safety

Phone: +49 8679 7-5860E-Mail: [email protected]

In case of any incident you will receive information via the community helpline:

Burghausen site: +49 8677 83-6111Gendorf site: +49 8679 7-6111Schkopau site: +49 3461 49-1111Cologne site: +49 221 31086-226Knapsack site: +49 2233 48-6001Hillhouse site: +44 1253 864123

Contact

Brochures containing information for the general public required pursuant to Section 11 Incident Reporting Ordinance were prepared at all production sites and distributed at all of the households in the vicinity. They have been prepared in consultation with the relevant government authorities and contain information about proper conduct in the event of the occurrence of incidents.

1 Increase of waste due to construction measures in 2014

© Vinnolit 2015; Version 1.1 (10/13/2015)Vinnolit GmbH & Co. KG, Corporate CommunicationsCarl-Zeiss-Ring 25, 85737 Ismaning, GermanyPhone: +49 89 96103-0E-mail: [email protected]

Photos: Vinnolit GmbH & Co. KG, Benecke-Kaliko AG, Bilcare Research GmbH, Heiner Heine, Marburger Tapetenfabrik, Schüco International KG, Tarkett Holding GmbH. Cover: Kathrin Frischemeyer/Pixelio.

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