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News Release from: Volvo Europa Truck
Edited by the Manufacturingtalk Editorial
Team on 16 February 2007
Truck plant is CO2 emissions-free
Volvo Europa Truck has invested some EUR 10 million in on-site alternative energy supply systems and expects to see payback within two years as oil and gas prices continue to rise.
The Volvo Europa Truck plant at Ghent, Belgium, is believed to be the world's first carbon dioxide emissions-free vehicle plant in the world, said its manager of Facilities, Environment and Safety, Marc Seghers He was speaking at a recent automotive manaufacturing conference 'AMS Europe' in Leipzig Germany, organised by the UK-based Ultima Media company, publishers of the magazine 'Automotive Manufacturing Solutions'
This article was originally published on Manufacturingtalk on 6 Jan 2004 at 8.00am (UK)
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His paper 'Heat and Energy savings - reduction of costs and usage' said the Ghent plant produces one-third of Volvo's trucks - 35,035 units in 2006 and forecasts nearer 50,000 units for 2007.
The plant employs 3500 and turns over around EUR 1,777 million.
Seghers said that the company was following the 1997 'Kyoto Protocol' in terms of reducing energy usage by adopting carbon dioxide (CO2) neutral processes.
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He said that the plant had ceased to use oil and coal heating for many years, relying on natural gas.
Between 2001 and 2006 the plant had reduced the flat rate of energy consumption by 23% - in a period when production of trucks rose 33%.
Seghers said they achieved it by introducing buildings temperature control - including frequency control on paint booth fans.
And by maximising the use of daylight in factory buildings.
On the topic of CO2 emissions, he said that in 2005, the plant produced 4020 tonnes of CO2 direct emissions and 6,900 tonnes of indirect emissions (such as taking electricity from external power stations).
To reduce or eliminate CO2 emissions, the company installed three 2MW wind turbine generators on the site.
These are 100m tall (ground level to turbine) and use rotors of 80m diameter.
Installation was carried out following full approval - after close liaison - with the local populace and employees.
Note that the closest residential property to a wind turbine is 300m.
Seghers did not mind admitting that negotiations had been tough concerning rotor noise, bird routes, shadows and other concerns.
Volvo took great care to inform and educate the populace and approval was eventually given.
He made the point that the company took pains to ensure that the same information and data was given to the local populace as was given to the local and national media.
A biomass boiler plant and a rebuilt existing boiler converted to burn bio-oil are serving the remainder of energy consumption not covered by the turbines - around 70%.
The biomass plant burns pelletised wood dust supplied by local sawmills.
Seghers commented that some discussion is taking place over choice of bio-oil for the rebuilt boiler.
At present, the unit is burning palm oil, but three other oils are being considered.
This boiler is used for peak and summer demands and covers 30% of needs.
Are zero CO2 emision profitable? The amount of investment involved in the exercise is around EUR 10 million.
Seghers said that the company had found the solutions for achieving zero CO2 emissions from energy, heating and lighting.
He commented that initially, the company had though 'pay-off' period would be 5-10 years.
Now, with energy costs continuing to rise (coal, oil and natural gas), the pay-off period will now be under two years.
It was in late 2005 that the company had taken the decision to reduce CO2 emissions.
It had decided that the technology - wind power, biomass and bio-oil heating and control systems - was readily available.
Seghers said: "We had found the solutions - it was a case of 'daring to do it'.".
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