Stahlwerk Thüringen GmbH

Sustainability and Environmental Management

www.stahlwerk-thueringen.de Stahlwerk Thüringen GmbH Since the foundation of the “Maximi- The certified integrated Management lianshütte” 140 yeas ago, there has System ensures all customer require- been a traditional iron and steel ments can be met as well as satisfying production facility on the Unterwellen- exacting standards for health, safety born site in . and the environment. Stahlwerk Thüringen GmbH (SWT) In 1999, 2000, 2001 and 2007 the com- was established on the 1st of July 1992 pany was awarded the prize “Workplace on the site of the former Maxhutte, Seal” of the Evangelic Church of Unterwellenborn. This marked the (EKD) “Arbeit plus” for its beginning of a complete modernisation exemplary workplace policies and programme for the Unterwellenborn social commitment. site. In November 2002 SWT was awarded In 1995 the new steel manufacturing the Thuringian state prize for quality facility with electric arc furnace and (“Thüringer Staatspreis für Qualität”). continuous casting was brought into In 2005 and 2012 the company recei- operation. The modernisation of the ved the prestigious health and safety more important plant equipment of the award “Johannes Bube”. rolling mill was completed in 2002. The de-dusting plant in the steel works was modernised in 2006 and the waste products disposal site was expanded in 2009. The most recent major moderni- sation project was the installation and commissioning of the new “break- down” stand in the rolling mill. In February 2012 SWT became part of the Brazilian steel group CSN (Com- panhia Siderúrgica Nacional). CSN is a leading steel manufacturer who also own iron ore mines, cement works, electrical power companies and logistics infrastructures, such as railway networks and sea ports. The SWT product range includes sectional steel (IPE, HE and U- channels) and steel railway sleepers. The products are sold all over the world by the company's sales organisation CSN Steel Sections. Stahlwerk Thüringen GmbH currently has approx. 700 employees. White steam over the casting shop

2 www.stahlwerk-thueringen.de Sustainability – Expectations and Reality Stahlwerk Thüringen GmbH is commit- modernization in the rolling mill, are ted to the principle of the “sustainable important steps to guarantee employ- development” and meeting this chal- ment and to reduce the environmental lenge successfully with the aim of burden in our region. improving the economic and social Thanks to these modern plants we are living conditions and to protect the able to supply products to our custo- natural conditions for future genera- mers with a minimal impact on the tions in the long term. environment. Sustainable development is only Management decisions at Stahlwerk possible using this principle to meet the Thüringen GmbH are always based on needs of future generations. social and environmental considera- Since 2000 Stahlwerk Thüringen tions as well as on economic aspects. GmbH has been working as the first This means that the company objective metallurgical company in Germany with is not only high product quality and an integrated Management System service but also to achieve improve- comprising of the Quality Management ments for the regional and the social Standard (DIN ISO 9001:2008), environment. Environmental Management Standard Stahlwerk Thüringen recognises the (DIN ISO 14001:2004) and Occupatio- importance of training its own apprenti- nal Health and Safety Standard (BS ces in-house. OHSAS 18001:2007). Since 1994 the company has trained Stahlwerk Thüringen GmbH joined the apprentices as industrial mechanics, Sustainability Agreement of Thuringia electronic technicians and industrial which is a logical continuation of our clerks. business philosophy. Since then more than 120 young skilled Together with other German steel workers have been given full time manufacturers, Stahlwerk Thüringen contracts. At the moment there are 53 GmbH works within the framework of trainees. Every year the company “bauforumstahl” on a uniform environ- takes on 10 apprentices. mental product declaration (UPD) in line with ISO 14025. The UPD describes the specific environmental influences of sectional steel and heavy plates in Germany and supports the development and realization of environmentally friendly and sustainable buildings and con- structions. Numerous investments in modern technologies, such as the commissio- ning of the electric steel works with Our administration building, in the fore- continuous casting in 1995 and the ground some IPE sections

www.stahlwerk-thueringen.de 3 Sustainability with Targeted Environmental Measures and Energy Aware Processes

The certificates of the DQS (German society to the certification of management systems)

The Environmental Management to established for legal provisions and is DIN EN 14001 and Energy Manage- continuously being developed. This ment to DIN EN 50001 are central to the legal data bank encompasses all the integrated Management System. relevant current legislation for the Compliance with current legislation is individual areas of responsibility in a up an important cornerstone of the to date format for information, ack- company's environmental protection nowledgement and implementation. and energy management. Therefore This information system is complemen- the responsible members of staff (for ted by an internal authorization register emissions and water protection, listing and reporting all company hazardous material, dangerous relevant authorization documents. The material, radiation protection etc.) aforementioned system, with regard to regularly attend training courses to the applicable legislation, forms the ensure they are up-to-date with the basis for observing the latest legal latest legislation. requirements and for the sustainable In 2008, to ensure the compliance with development of the company. legal provisions and in cooperation with VISTRA, a web based schedule was

4 www.stahlwerk-thueringen.de In order to document and demonstrate resource preservation as well as the commitment of Stahlwerk Thürin- energy efficient technologies and gen GmbH to a sustainable and equipment and the recycling of residual ecological approach, Stahlwerk material. Intensive communication Thüringen GmbH joined the “Sustaina- between the Federal State Govern- bility Agreement of Thuringia 2009 to ment, administrative bodies and 2011 (NAThüringen)” in August 2009, businesses ensures the further this has been extended for the period development of the sustainability from 2012 to 2014 and Stahlwerk process. Thüringen GmbH has also extended its Since its formation Stahlwerk Thürin- membership of this agreement. The gen GmbH has been working intensive- members of this agreement, consisting ly to optimize the production process of the Federal State Government and with regard to the use of materials and Thuringian Businesses, have voluntari- energy, and to invest in the state-of-the- ly committed to the objective of art technologies. This long-term achieving a high level of natural targeted effort has enabled us to resource preservation, energy efficien- become the leading company with cy as well as environmental and climate regard to reduction of carbon dioxide protection. Central to this are the emissions in our industry (production of introduction of ecological non-alloy steel profiles). As a result, we are making a significant contribution to climate protection.

Steel sections and channels in different dimensions are produced at Stahlwerk Thüringen, here HE beams being loaded

www.stahlwerk-thueringen.de 5 Sustainability in the Production Process Recycling material scrap Burner System Electric Arc Furnace Recycled scrap is used almost exclu- State of the art burners ensure that gas, sively for the production of steel oxygen and energy costs are kept to a sections in Stahlwerk Thüringen. Less minimum. than 1.5 % scrap is produced on site (separation and pig iron) and is also Use of Scale in the Building Material reused in the production process. Industry Scale resulting from the manufacturing process is used in the building material industry.

Beam Blank The production of beam blanks of various sizes and cross-sections (pre- formed) reduces the energy consump- tion of the rolling mill.

Steel scrap is our most important raw Hot Charging material A high percentage of beam blanks are transferred in a hot condition to the De-dusting Plant pusher type furnace resulting in gas Emissions from the furnace exhaust efficient processing. gases are kept to a minimum using a de-dusting facility with coke particle Conversion of Pusher Type Furnace injection filtration system. The conversion from city gas to natural gas has reduced both gas consumption Recycling of Zinc from Filter Dust and CO2 emissions Dust from the de-dusting plant is used as a primary material for the production De-dusting Stands of zinc. A de-dusting plant at the tandem stands ensures that dust levels in the rolling Slag Recycling mill are kept to a minimum. Slag from the electric arc furnace is recycled and used in the construction Rail Transport Company (EVU) industry, for example road building. The foundation of an internal rail transport company means that a large proportion of shipments are made by rail.

6 www.stahlwerk-thueringen.de Environmental Management

In 2004 it as decided that measures replaced by one which is three times would be taken to further reduce the larger, a third extraction fan and a larger dust emissions produced by the exhaust stack were also installed. The production processes and the resulting associated pipework was adapted dust emissions in the area surrounding accordingly. Stahlwerk Thüringen. The existing The new coke particle injection system steel works de-dusting plant was enables emissions to be consistently comprehensively overhauled using the below the legal limit by a factor of ten. most modern technology available. The The dust emissions have been reduced new plant was commissioned in with the increased filtration surface October 2006. area from 3.5 mg/Nm³ to less than 1.0 Two new filtration systems were mg/Nm³ which is significantly less than installed, doubling the existing filter the legal limit of 5.0 mg/Nm³. surface area to 24,000 m². Further optimisation of the system is an Additionally, the mixing chamber was ongoing process.

Dedusting Plant - Trend 2003 - 2011 (Annual average of dust concentration)

www.stahlwerk-thueringen.de 7 Dedusting plant of the Electric Steel Plant Old plant New plant partly finished Completed new plant

Before 2008 the transfer of hot electric Magnetic separation removes the furnace slag to the containers for metallic residues out of the slag for transportation to the disposal site of reuse in the electric arc furnace. SWT took place outdoors. In 2008 a Stahlwerk Thüringen GmbH is continu- large roof hood was installed and the ously improving the recycling of its area in front of the “Clean Pit” was waste and by-products in line with the enclosed on three sides resulting in a recycling and waste management significant reduction of dust emissions, regulations(KrW-/AbfG). especially in the areas adjacent to the The recycled electric furnace slag is steelworks. recycled as an alternative material (e.g. In 2012 improvements and process road construction). The recycling changes were made for the reduction of proportion is currently approx. 90 %. dust emissions at the residual slag box The remainder (oversized pieces) is area of the casting process as well as deposited on the waste disposal site. for the transfer of the slag from the ladle Trials are currently being carried out furnace. (2011-2013) to improve the recycling The slag from electric arc furnace and properties of the ladle furnace slag ladle furnace is temporarily stored on using a “shock cooling” process which, the SWT disposal site for subsequent if successful, will be implemented at the recycling by the separation plant. end of the test period.

Disposal site for slag Before beginning of Installation of mineral Almost completed 1st construction works sealing layer construction stage

8 www.stahlwerk-thueringen.de In co-operation with the college Anhalt (Bernburg), the ladle furnace slag is currently being checked for its suitabil- ity for use as a fertilizer. Stahlwerk Thüringen GmbH started the construction of the new waste product disposal site in spring 2009 to guaran- tee the safe long term disposal (about 50 years) of the metallurgical waste products, having completed the project approval procedure in 2008. The waste System for wastewater treatment product disposal site meets the standard for category 1 disposal and oil detection and extraction technology as well as pH-value stabilization. Measuring systems permanently monitor the typical waste water parameters. The company works within the Euro- pean REACh-Regulations for the Registration, Evaluation, Authorisation and Restriction of Chemicals. In line with this, Stahlwerk Thüringen pre- registers the relevant substances and Disposal site for slag (view from south) has joined the corresponding consor- tiums for substances arising at the company. The “REACh-Ferrous Slag- has been designed to the correspond- Consortium (RFSC)” is for the slag from ing environmental safety measures the electric furnace and ladle furnace, (e.g. mineral sealing layer) and was and for scale it is the “Iron Platform”. commissioned in 2010. Stahlwerk Thüringen GmbH is con- stantly aware of the importance of responsibly associated with the discharging industrial waste water directly into a natural water source and that is why the prevention of water pollution is of the utmost priority. In 2003 the company voluntarily con- structed an additional waste water retention basin just before the dis- charge area. This waste water retention basin is equipped with the most modern At the cold sawing unit the sections are cut for the customers

www.stahlwerk-thueringen.de 9 Energy Management Stahlwerk Thüringen is an energy An example of this reduction is the total intensive company. Our production energy consumption for the DC electric processes require a high level of arc furnace with the introduction of electrical and gas energy for the injection blowing technology. Further manufacture of our customer's prod- improvements to the electric arc fur- ucts. This means that an energy aware nace process management were pos- approach to our production methods is sible with the use of exhaust gas an important component of our com- analysis systems. The consumption of pany strategy. The energy manage- natural gas for the continuous casting ment has been taken to the next level plant has been reduced with the use of with the implementation and maintain- a special coating which has lengthened ing the standards set out in DIN ISO the service life of the fireproof lining of 50001 as a goal for the company. the tundish. Since the formation of Stahlwerk Thü- The total energy consumption of the ringen GmbH a variety of new technolo- rolling mill has also been reduced with gies have been introduced, resulting in the commissioning of new equipment significant energy savings. and machinery as well as the introduc- tion of frequency controlled drives. New pumps and valve technology in the hydraulic station H1b have substan- tially improved the efficiency of the plant. In 2012 a research project was under- taken in cooperation with a plant equip- ment manufacturer for a heat recovery system from the exhaust gas of the electric arc furnace. A further energy saving measure is the planned equip- ping of the pusher type furnace com- bustion gas plant with a frequency converter. The energy management system as per DIN EN ISO 50001 has been approved by the German Association for the Certification of Management Systems (DQS). Thus committing the company to comply with its own energy policies. This is implemented by systematically analysing and evaluating the energy The electric arc furnace is our biggest consumption, the recording and pre- consumer of electric energy (> 100 MVA) sentation of energy flow, the planning,

10 www.stahlwerk-thueringen.de preparation and implementation of Within the framework of the energy energy saving measures as well as management policy Stahlwerk Thü- regular evaluation and updating of the ringen GmbH must comply with the results. relevant national laws and regulations, Every 3 months the appointed respon- to actively involve the employees in the sible employees report on energy implementation of the energy policies management activity. and to carefully check and evaluate energy efficient solutions and propos- als. The long term goals of Stahlwerk Thüringen GmbH are, to use energy resources as economically as possible and to reduce the greenhouse gasses produced by the steel production in the steel works and by the pusher type furnace of the rolling mill to a minimum. We aim to eliminate all unnecessary energy usage by ensuring the highest The pusher type furnace for the rolling mill possible output efficiency and the runs on natural gas lowest possible failure rate.

Assurance of Contamination Free Deliveries of Steel Sections The following measures have been and documented within the framework made to ensure that all products and of the Quality Management System. by-products produced by Stahlwerk To prevent any radioactive materials Thüringen GmbH are free of radioac- reaching the production process there tive contamination: are checks made before goods • Contractual agreements with supp- (especially scrap) are allowed on site, liers of scrap, alloys and additives these are: that the deliveries are not contami- • permanent monitoring equipment nated. for all deliveries by road (HGVs). • Checking of all goods inwards for • permanent monitoring equipment radioactivity. for all deliveries made by railway • Testing of all steel sections and by- wagon. products for radioactive contamina- • additional independent check made tion. using detectors on the crane grabs SWT have installed modern highly sen- used for material transfer in the sitive measurement equipment for the scrap yard. detection of radioactive substances. A comprehensive monitoring of goods inwards and outwards is carried out

www.stahlwerk-thueringen.de 11 Checks for radioactivity are made using To achieve the full and complete a Nal detector positioned in a lead monitoring of all materials leaving SWT shielded measuring point at the ladle the by-products, slag and filter dust, are furnace to guarantee that all steel also checked for radioactive contami- sections delivered to our customers are nation. free of contamination.

12 www.stahlwerk-thueringen.de Environmentally Aware Logistic Management in Stahlwerk Thüringen With a total transport volume of about caused by movements and transporta- 3 million tons, equally distributed bet- tion of material. ween goods inwards (scrap, additives, · About 70 % of the produced steel and spare parts) and goods outwards sections is shipped by rail from the (sections, scale, by-products) the lo- dispatch department of the rolling gistic management plays an important mill directly to the customer. role in our environmental management. · 75 % of steel sections are transpor- Successful environmental manage- ted to destinations within Germany ment includes avoiding unnecessary or the bordering countries (short material movements, optimization of distances for transportation) transport distance and orientation to- · The layout of the production within wards environmentally friendly mode of SWT has been logistically optimised. transportation. All material movements between the In recent years, SWT has introduced steel works and the rolling mill/ and optimised logistics projects. dispatch department are made with The results being: electrically powered cranes or · 90% of the scrap brought into SWT permanently installed roller tables. (1.1 million tons per year) travels a · Two thirds of the journeys made by distance of no more than 250 km the Stahlwerk Thüringen GmbH in- · Over 55% of this scrap is transported ternal rail company are bidirectional by rail. (scrap – steel sections – logistics) · In 2001 SWT founded its own rail which means the number of journeys transport company to ensure a without loads are kept to a minimum. reliable supply of scrap by rail · All the locomotives used in SWT are (approx. 450,000 tons per year). equipped with the most modern · SWT produces steel sections spe- engines available, reducing con- cifically for customer orders, mini- sumption of diesel fuel and engine oil mising the environmental influences as well as substantially lowering noise and exhaust emissions.

A train delivery scrap to Stahlwerk Finished sections on their way to the Thüringen customer

www.stahlwerk-thueringen.de 13 Sustainability of the Personnel

Since its foundation Stahlwerk Thürin- These safety management measures gen GmbH has been committed to the are complemented by a yearly day of training and safety of its employees by health and the participation in the promoting and supporting the training health and safety competition organi- of their own skilled workers. sed by the French steel industry Due to the occupational training and (GESiM). The company's commitment apprenticeships carried out in partners- to health and safety has been demon- hip with training institutes, it has been strated by the frequent honour of possible to welcome 120 highly receiving the GESiM award as well as qualified and motivated members of the Thueringian workplace safety staff into the Stahlwerk Thüringen award “Johannes Bube”. GmbH team. In 1999, 2000, 2001, and 2007 the Furthermore, we encourage the company received the workplace seal internal promotion of existing employe- of approval from the Evangelical es by offering organisational and Church of Germany “Arbeit Plus” for financial support for further education exemplary working policies and social as master craftsmen, technicians and commitment. degree qualifications. We also offer financial grant support to graduate students in partnership with colleges and universities. There are only professionally trained qualified personnel currently working for the company. As well as occupational training, the company also regards health and safety in the workplace as an important component of the company policy. Regular occupational related medical examinations are made by the compa- ny doctor. There are also numerous organisational measures, such as Works Safety Committee in addition to the tasks carried out by the appointed departmental safety representatives. So that the company is prepared for most eventualities, further training courses for the first aid staff and the works fire brigade are carried out regularly.

14 www.stahlwerk-thueringen.de Regional Integration and Social Commitment From the very beginning Stahlwerk image and the trust placed in the Thüringen GmbH has valued the company in the Unterwellenborn intensive and direct contact with the region. members of the local community, local Stahlwerk Thüringen GmbH plays an council and their representatives. important role in supporting the social Each year the company welcomes programme of the immediate local area more than 2500 visitors and customers as well as that of the wider region. for tours of the works who regularly Through sponsorship of a variety of provide positive feedback with referen- clubs and associations, with sporting or ce to the importance Stahlwerk cultural objectives, the company is able Thüringen GmbH places on sustaina- to make the life of the members of the ble development. local community and wider region more This has been a particularly important varied and interesting. aspect for the development of the

Aerial view of Stahlwerk Thüringen works with Kamsdorf at the upper right and Unterwellenborn at the lower left of the picture

www.stahlwerk-thueringen.de 15 How to find us:

Niedersachsen

4

Nordhausen 80 247 80 85 Sondershausen 88 80 249 247 4 Sachsen-Anhalt Mühlhausen 84 176 249

n 176

e Sömmerda

s Bad Langensalza 87 85 93 s Apolda 84 4 180 e 4 247 Weimar 88 7 Erfurt Altenburg 7 H Gotha 7 Jena 7 180 Eisenach 4 93 19 Gera Arnstadt 85 9 Bad Salzungen 175 84 Thüringen 247 4 87 88 281 92 Pößneck 2 Greiz 285 19 88 94 71 Unterwellenborn Ilmenau Meiningen Suhl 4 85 Schleiz Sachsen

19 89 281 2 4 90

4 Sonneberg 89 Bayern

to Langenschade to Saalfeld

Ernst-Thälmann-Straße

Supermarket, Petrol station

Uploading to Pößneck trucks

to Kleinkamsdorf

to Kamsdorf Stahlwerk Thüringen GmbH Kronacher Straße 6 07333 Unterwellenborn Phone +49 3671 - 4550 0 Fax +49 3671 - 4550 7107 Pictures: Archive Stahlwerk Thüringen GmbH Mail [email protected] Print: SDC Satz+Druck Centrum Saalfeld Web www.stahlwerk-thueringen.de GmbH

www.stahlwerk-thueringen.de