Situation

The site is located in an industrial zone, 12 km from the sea and 8 km north of the centre of Bursa. The nearby River Nilüfer crosses the plain of Bursa. The nearest homes are immediately next to the site (around 150 m to the east). The Renault Oyak plant occupies a total surface area of 51 ha, of which 25.6 ha of buildings.

Initial ISO 14001 certification earned in 1999. 

The site renewed its ISO 14001 certification in 2002 and 2005.

Download : 

  Environmental Statement 2006 (Turkish/English)

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Water consumption

Considerable efforts have been made to cut water production.

Action has been taken in several areas:

• quality assurance of the wastewater treatment facility,

• meters at different stages of the process, to reduce the quantity of rinsing water,

• development of inter-stage rinsing processes. 

The higher consumption observed since 2003 can be attributed to a strong increase in output (+100% since 2003). However, calculated per vehicle produced, consumption fell from 3 m3/veh. to 2 m3/veh between 2002 and 2007.

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Water-borne effluents

The increased output of the plant and the extensive work on infrastructure have led to a rise in emissions to water. The replacement of lead in the electrocoating process cut daily flows of lead by 92% between 2001 (0.397 kg/day) and 2007 (0.0298 kg/day).

The strong increase in output, in 2003, 2004 and 2007 explains the variations in daily flows of suspended solids (SS) and organic matter (OM).

At the plant outlet, discharges are sent to the treatment plant in the industrial zone.

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SO2 and greenhouse gas emissions

SO2 emissions fell as a result of a significant decrease in the consumption of fuel-oil, which has been replaced by natural gas.

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Volatile organic compounds emissions from paint process

The following steps have been taken to reduce emissions of volatile organic compounds (VOCs):

• recovery of automatic purges from application machines,
• accountability of cleaning companies for the use of solvents,
• introduction of technologies making paint application more efficient,
• use of a distillation column to recycle dirty solvents.
• switch to water-based paint in September 2007.

Through these developments, the plant achieved its VOC reduction target. VOC emissions fell 32% from 7.34 kg/veh. in 2003 to 5.0 kg/veh. in 2007. In order to keep cutting VOC emissions, the plant will pursue research, kaizen, etc.

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Waste

An increase in OIW tonnage was observed in 2000. This can be attributed to the development of the on-site spare parts activity (increased part packaging waste).

Due to technical problems in the waste processing sector, HIW piled up in the HIW storage area. As a result, the quantity of HIW increased. The other cause of the higher volume of HIW was the increase in production.

However, in terms of volume per vehicle, OIW and HIW tonnages fell by 25% between 2003 and 2007. As a result of the investment in durable packaging, the plant reduced tonnage of packaging waste by 46% between 2003 and 2007.

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Energy

Practical measures have been taken to save energy:

• programming of heating appliances in large workshops,
• shutdown of transformers operating outside working hours,
• precise mapping of leakage points to determine energy losses,
• shutdown of facilities (machinery, processes, etc.) outside working hours,
• investment in monitoring energy consumption by each department,
• benchmarking with other Renault group sites.

As a result of energy-saving studies conducted on the boiler plant and industrial paint process, energy consumption (electricity and natural gas) – calculated per vehicle – fell by 29% respectively between 2003 and 2007.

Efforts to save energy have reduced GHG emissions, which fell from 186.42 kg/veh. in 2003 to 133.95 kg/veh. in 2007.

 

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Highlights

 

 Özlem Sönmez, Environment Manager:

"The highlights of 2007 were:

- the switch to water-based paints;

- an increase in capacity from 43 vehicles an hour to 60 vehicles an hour;

- extension of the site to cover an area of roughly 97 ha;

- and the relocation of assembly facilities for increased capacity."

• Risk prevention

Like all plants in the Renault group, Oyak-Renault has put in place a plan to manage the risks of fire, explosion and natural disasters. Earthquakes are a major risk for the site. An in-depth study has been carried out to identify the necessary reinforcements with, in particular, a campaign to attach all industrial process equipment to the floor or the structure of the building.