Situation

Located in Yvelines, 45 km west of Paris, the Flins plant spans the municipalities of Flins and Aubergenville, above a water table that provides drinking water and on the edge of a nature reserve. Enjoying excellent access – via the A13 motorway, the Paris/Le Havre railway line and the River Seine, which borders the site to the north – the plant can ship via three modes: road (62%), rail (21%) and river (17%).

First Iso 14001 certification earned in 2000.

The site renewed its certification for three years in 2003 and 2006.

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Water consumption

The plant cut water consumption by 70% between 2000 and 2007, mainly by altering the operation of turbo-machines (turbo-compressors and turbo-alternators) with once-through cooling systems (discontinuation of peak shaving and start-up of cogeneration). Once-through cooling systems were installed for turbo-machines at end-2005.

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Water-borne effluents

The total increase in liquid effluent is due to a change in the calculation method for flows discharged into the environment (application of the new prefectoral decree). Until 2001, flows were evaluated in relative terms. Pollution inflows via the water pumped from the Seine before use on the site were subtracted from pollution outflows in order to obtain the impact of the Flins plant.

In August 2002, the plant introduced a lead-free electrocoating process. The change between 2003 and 2004 can be attributed mainly to the average increase in outflows (practically 200 m3 a day) to the Seine. 

At the end of 2004, the confinement system for the site’s main wastewater outfall was completed.  Confinement and settling tanks were installed in 2005, making it possible to keep polluted water on the site if an accident or fire occurs, and also to treat stormwater.  As a result, SS and OM concentrations have dropped considerably.

The reduction in 2006 can be attributed to the fall in flow rate due to the operation of the closed-loop cooling towers for a full year.

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SO2 and greenhouse gas emissions

The programme to replace the power plant's fuel-oil boilers with gas-fired boilers began in 2004. This work will continue in phases until 2007, and will reduce emissions of dust, SO2 and NOx, as well as improving energy efficiency. 

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Volatile organic compounds emissions from paint process

VOC emissions into the atmosphere were reduced by 15% between 1998 and 2002 per vehicle, as a result of efforts made at every stage of the body paint application process and the installation of an incinerator in 2002. The increase in 2003 can be attributed to operating incidents with the incinerator, which was out of order in the first half of the year.

The start-up of the water-based line (September 2004) and more reliable incinerator operation explain the reduction in waste in 2004. In 2005, the replacement of Clio II (with solvent-based paints) by Clio III, which uses water-based paints, and the implementation of continuous progress actions in 2006 made it possible to continue the reductions begun in 2004.

At end-2007, shutting down the 100% solvent-based Twingo paint line enabled us to reduce VOC emissions to below the threshold of 30g/m².

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Waste

Tonnages of Ordinary Industrial Waste (OIW) increased significantly in 1999. This increase can be attributed to growth in the spare parts business on the site (increase in packaging waste) and to growth in industrial activity in that year generating a proportional increase in metal waste . A 35% reduction in Hazardous Industrial Waste (HIW) was achieved between 1998 and 2003.

This result was achieved by various actions to reduce waste at source, such as rational use of cleaning products, etc. In 2004, the decrease in HIW tonnage can be attributed mainly to a lower tonnage of metal offcuts (from vehicle manufacturing). HIW tonnage increased due to activities not related to manufacturing, such as soil remediation work on the site.  Higher tonnages in 2005 and 2006 are directly caused by the increase in site output due to Clio III and other stamped parts shipped to other Group sites.

In 2007, the tonnage of metal offcuts fell following the discontinuation of Twingo and of the ranges of stamped style parts, which were transferred to Sandouville.

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Energy

Since the start-up of cogeneration in 2000, fuel-oil consumption has been reduced in favour of gas, which has a lower impact on atmospheric emissions. Changes in the plant’s energy needs are determined by the site’s activity but also by weather conditions (the outside temperature has a considerable impact). In 2003, low temperatures at the beginning and end of the year are partly behind the increased consumption of heating energy. By contrast, the site noted a reduction of almost 10%  in electricity and gas consumption.

The main energy-related event in 2005 was the start-up of two gas-fired boilers to replace the fuel-oil boilers.  In 2006, although production of vehicles and parts increased, an energy saving campaign conducted throughout the plant made it possible to reduce energy consumption.

In 2007, progress actions were sustained (such as work on compressed air leakage, and switch-off warnings at the end of a shift via a telephone alarm) helped continuously reduce energy consumption.

Note: consumption of steam produced by cogeneration is included in gas consumption.

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Highlights

 

 Silva Bernardi, environment manager:

 “Flins reported a substantial reduction in atmospheric emissions in 2007, especially in VOCs, after we shut down the 100% solvent-based paint line for Twingo, and in sulphur dioxide after the last fuel-oil boiler was taken out of service. The continuous progress actions set up to reduce energy and water consumption brought positive results."