C282 - Tranz Rail Ltd - Wellington Region
Summary
Tranz Rail Ltd has a pro-active environmental strategy that
aims to minimise the effects of its operation on the environment.
Recycling systems have been set up for all the major waste
materials and cleaner production work is also being undertaken
in: the cleaning area, where chemicals with reduced environmental
impact are used. 15-20% savings have been made in power consumption.
Business Profile
Tranz Rail Ltd is the leading transport provider of rail,
shipping and truck services in New Zealand. The company owns
and operates rail track and stock throughout the country.
Two main workshops repair, maintain and refurbish locomotives
and carriages, one in Dunedin and the other in Lower Hutt.
The Lower Hutt workshop employs about 250 people (mid-1997)
to service, clean, repair and refurbish locomotives and carriages.
The company has undergone a series of restructuring and downsizing
operations in the previous 5 years, reducing numbers working
on the Lower Hutt site by over 90%.
Type of Project
Energy efficiency; good housekeeping; material recycling and
substitution; process modification; reduction in use of hazardous
substances; waste reduction; workplace reform.
Reasons for Project
Cost savings; improved environmental performance; waste management
efficiency.
The Project
Recycling Programme
The Tranz Rail Hutt site achieved a solid waste reduction
(by volume) of 65-70% in a series of stages over 14 months:-
- Trial recycling scheme introduced in May 1996, initially
taking paper and cardboard from three key areas. Half a
tonne of cardboard was collected in the first month. This
was in addition to traditional recycling of metal.
- June 1996 - two main recycling stations were set up in
Plant One, taking separated paper, cardboard, cans & glass.
Waste is emptied into 1.5m3 bins, but by the end of July
1996, the number of these in Plant One had been reduced
from thirteen to six.
- By January 1997, Plant Two was operating a similar recycling
system, reducing waste generation still further.
- A new solid waste collection contract came into operation
in March 1997. Tranz Rail's waste disposal costs are now
approx. $7.50 per m3. Previously they stood at approx. $14
per m3.
Specially designed lifting gear, using the plants' cranes
and pulleys, empties wheelie bins into the main collection
bins. Research into improved collection bins for the 32 teams
is on-going, including bins made from recycled plastic.
The combination of a new recycling operation and re-negotiation
of the disposal contract has brought cost savings of approximately
80%, or almost $50,000 per annum in waste disposal. Recycling
non-ferrous as well as scrap metal generates around $1m per
annum. Costs of setting up the recycling system to mid-July
1997 were $23 000. This was paid off in the first year of
operation.
Cleaning Systems
Parts are cleaned at a central site where hazardous chemicals
are being phased out, waste products are being reduced, and
energy and water are being used more efficiently as part of
Tranz Rail's environmental improvement programme.
Until recently, a toxic phenolic product was used to clean
parts in the workshop. This was contained in 20,000 litre
tanks and had a limited lifespan, requiring problematic disposal.
A number of alternative systems were tested, including baking
ovens and caustic cleaning chemicals before one was settled
on. The strongly alkaline product selected is relatively easy
to use, has a much lower impact on the environment than its
predecessor and does not compromise worker health & safety
to the same extent. It is also reusable in a wide range of
secondary cleaning applications.
An oil separation system is used to clean wastewater, which
is re-circulated through a water blasting unit. This unit
benefits from the water containing low concentrations of cleaning
solution, reducing the need for added product. It has also
been retrofitted with an applicator which enables the operator
to use exactly the amount of cleaner needed and has been designed
to minimise energy use by utilising waste heat. 75% less cleaning
solution is used as a result and the time taken to clean parts
has been reduced.
A number of cleaning machines have been bought new or relocated/repaired
for use in the cleaning area. These use a combination of hot
water and hot alkaline cleaning solution (another product
selected for its reduced environmental impact). The lifespan
of these solutions has been extended to the extent that sludge
removal is only required once or twice a year. Previously,
disposal occurred monthly.
Each locomotive can be cleaned for $800 less than previously
(without taking into account the reduction in time spent or
energy consumed).
Energy
Efficiency Capacitors have been installed to increase power
efficiency for all workshops on site. These store electrical
energy and allow better control in its release for operations.
Power factor ratings have increased from about 0.7 to over
0.9, giving cost savings of 15-20% throughout the site.
For additional information contact:
Wayne Johns,
Recycle & Disposal Store Co-ordinator
Tranz Rail Hutt
Private Bag
Wellington
Phone: (04) 498 2086
Fax: (04) 498 3157 |
Kirsty Ferguson,
Environmental Manager
Tranz Rail
Wellington
Private Bag
Wellington
Phone: (04) 498 2089
Fax: (04) 498 2039 |
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