Shotton Works is located in Deeside, North Wales, and manufactures approximately 600,000 tonnes of pre-finished steels per year for building envelope, domestic and consumer applications.
Key focus areas for reduction in CO2 relate to the efficient use of natural gas on furnace operations and electrical efficiency. Initiatives include:
- A focus on operational energy reduction initiatives such as installation of variable speed drives on some equipment.
- Upgrading energy efficient lighting.
- Installation of two regenerative thermal oxidisers to reduce natural gas consumption on process lines, whilst simultaneously abating solvent emissions from coating processes
- Receiving 100% feedstock from South Wales by rail rather than road.
Shotton is covered by a new energy efficiency governance process established within Tata Steel Europe, whereby its energy performance has been compared to a benchmark as part of a gap analysis exercise.
The site has generated a range of schemes aimed at bridging the gap with best practice. Internal targets for improvement have been established and Tata Steel Europe’s Chief Technical Officer and his direct reports review the progress of each site towards these on a quarterly basis.
In line with our objective to reduce / eliminate wastes to landfill, we have enacted a number of waste reduction strategies at our plant in Shotton, including:
- Reducing the amount of waste going to landfill. We have improved waste segregation for plastic, wood and paper across the site. Balers have been put in place for the recycling of plastic and card. Where it is not possible to recycle wood because it is damaged, broken pallets are sent to a local steam raising plant to be incinerated to provide an energy source.
- Recycling of Dry Mixed Recyclable (DMR) office wastes was introduced in 2011, whereby paper and recyclable office and canteen wastes are processed by a licenced waste processor.
- Coil packaging materials have been significantly changed so they can be recycled and the amounts used reduced. On site packaging is no longer disposable and has been changed to reusable magnetic bindings. Coil protectors are reused on site and only disposed of once they are beyond repair.
- Reusable isolated bulk containers (IBCs) have replaced paint being delivered and stored in one use drums.
Our actions to improve resource efficiency go beyond the actions we take in our own manufacturing operations. A key element of resource efficiency is durability; products don't have to be replaced so often and societal consumption is reduced.
We offer the most comprehensive guarantee for pre-finished steel products in Europe for up to 40 years. Unlike other guarantees, Confidex® covers cut edges for the entirety of the guarantee period and does not require any inspections or maintenance during this time.
At the end of the working life of our modular products, there are a number of options that are beneficial in terms of reducing the full life cycle impacts of the buildings they are used in:
- They can be refurbished: by re-painting or replacing the outer sheet, they can be given an extra life of between 10 and 30 years.
- They can be re-used: when removed from the underlying steel structure they can be re-used in another weather-proofing application.
- They can be recycled: our coated steel sheets are fully recyclable through the Basic Oxygen Steelmaking (BOS) route. We have done detailed studies to demonstrate that this can be done without increasing harmful emissions from the process.
In addition to the inherent durability, re-usability and recyclability of our products, we have taken actions to increase the rate at which they are recycled at the end of life. We have done detailed studies to demonstrate that recycling through the BOS process can be done without increasing harmful emissions from the process.
We are continually investing in the UK's steel collection and recycling infrastructure, enhancing our own recycling capabilities at plants in Port Talbot and Rotherham.
We provide education in schools about steel recycling and we provide technical literature for customers about the life cycle impacts of our products and the steps that can be taken to minimise these impacts throughout the life of the applications in which they are used.
Shotton has enacted a number of improvements to optimise its water consumption and have an objective to reduce the amount of process water being used, to reduce the impact that our water emissions have on the environment, as we discharge into ecologically sensitive areas, for example:
- Local treatment of incoming waters.
- Processing contaminated waters through our effluent treatment plant.
- Directing non-effluent process waters, away from wastewater treatment, and discharged into the site lagoons.
- Identifying opportunities for water reuse through the installation of chillers and cooling towers.
- Implementing process improvements to reduce the use of water, use of closed loop cycles, use of no-rinse technologies.
Transport impacts are managed centrally within Tata Steel and, as such, it is not possible to disaggregate the transport impacts associated with the production and delivery of specific products from specific locations from the total estimate of Tata Steel transport impacts.
- As shipping and logistics activities are managed centrally within Tata Steel it is not possible to disaggregate the CO2 emissions associated with the production and delivery of specific products from specific locations from the total estimate of Tata Steel transport impacts. See the general page for information on Tata Steel’s transport impacts and some of the steps we are taking to reduce these.
We apply a common approach to employment and skills at all, of its sites. See the general page for information on what Tata Steel is doing to advance the learning and development of its employees.
The Shotton site has developed strong links with the local community over the years. The main community activities include:
- Work closely with schools and colleges in the area to help young people prepare for further training and employment.
- Employees can opt to donate £1 of their monthly salary which then goes on to support local charities and good causes.
- Offer nature walks around the areas of environmental interest on site to local schools.
- Work closely with the Flintshire Rangers to expand our involvement in local nature interests
- Support local events such as the "Big Dee Clean Up" where employees volunteer to help with the clean-up of marine and coastal litter along the River Dee.
As a site we monitor the numbers of people from the local community who have been involved in such activities and the number of days of support provided, with the aim of increasing year on year. The table below shows our involvement in the community for the last complete calendar year – this will be updated in the first quarter of the following year (i.e. 2014 data will be updated during Q1 2015).
|Activity type||Employees |
|Total Support |
given in days
|Number of local |
|Family visits and nature walk||3||22||170|
|CO2 emission (t)||Direct scope||66,997||64,587||54,206|
|Water use (m³)||484,538||484,538||453,254|
|Waste disposed (t) (% of waste produced)||1,515||11%||14,217||53%||1,778||14%|
|Waste recovered (t) (% of waste produced)||12,702||89%||12,702||47%||11,224||86%|
|Justified complaints (n)||0||0||0|