Transcript
Recycling A pure bonus Roland Scharf-Bergmann Head of Recycling
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• 1 Recycling • 2 Market Outlook • 3 Recycling in Hydro
• 1 Recycling • 2 Market Outlook • 3 Recycling in Hydro
Recycling – a pure bonus Utilizing aluminium as an energy bank
5% of initial energy to recycle
75% still in use
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Aluminium recycling, a viable business
High rates of recycling
• 95% Transport • 95% Buildings • 55% Packaging (64% Cans)
RECYCLING GLOSSARY Pre-consumer scrap process scrap generated before the product‘s use phase
Post-consumer scrap product scrap from used products at end of product life
Long lifetime for aluminium in use
• 15-20 years for vehicles • 40-50 years for buildings
Primary aluminium aluminium generated from bauxite ore, via alumina refining and electrolysis
Recycled aluminium aluminium generated from scrap sources
Remelter recycling plant producing extrusion and rolling ingot
Refiner recycling plant producing foundry alloys
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3 types of scrap are created in the regional aluminium flow Post-consumed (PCS), fabrication scrap and clean process scrap (CPS) Primary production
Bauxite
Al₂O₃
Trade Casthouse shapes Trade (primary and remelt)
Semis trade
Final product trade
Casthouse shapes
Semis Shipments
Final products
End-of-life product trade
Primary shapes (EI,SI,PFA,WR,IN)
Remelt shapes (EI,SI,SFA)
Clean process scrap
Total consumed products in use
PCS
End-of-life products
Fabrication scrap
Melt loss
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Unable to collect
Various scrap sorting techniques & technologies
Shredding
• Cutting scrap in pieces without separating various metals
• Taking out some easy parts before shredding e.g. Wheels and engines from cars is usual
• The shredded metal can then go on to be sold as shredded scrap or be treated by sorting techniques to increase its value
Steel, Fe
Plastics, foam
Mg, Cu, Zn, Pb
Wrought vs Casting
Metals & alloys
Metals & alloys
Magnetic & Eddy current
Air seperation
Sink float
Hot crush
Color sorting
Spectroscopy
• Magnets separating ferrous and nonferrous metal scrap
• Heavy metals like steel and iron is sorted out
• Used extensively for Secondary production
• Eddy Current: Rotor with magnets to throw scrap at different distances in relation to their eddy current
• Utilizing the different conductivities of various metals
• Using air to separate scrap streams
• Also called windsifting, air-knives, elutriation, winnowing and air columns
• Conveyor belt system with air flows pushing away light weight materials like e.g. plastics
• This technique could result in loss of light and small aluminium scrap such as UBC scrap
• Separates scrap in
• Thermal-mechanical
various baths with various specific gravities
separation method
• Possible to sort based on the various metal’s density, but also based on alloy (Scrap will sink or float based on density)
• Separating heavy and light materials from the wrought and casting aluminium scrap
• Successfully separates wrought and casting alloys by looking at the eutectic temp. as castings has a lower melting temp (because of higher Si content)
• First warm, then crush to separate whether the metal breaks or not
• 96% effective in separating the scrap
• Hand sorting based on different colors of metals. Can also sort wrought vs. casting alloys
• Only possible with low labor costs. 99% accuracy estimated for China
• Can also be done by a computer, can sort by alloy when using etching chemicals making alloys stand out in color
• Environmental and
• X-ray, neutron flux or pulse laser detectors scan the metal (must be free of lubricants, paint and coating)
• The metal returns various emissions when hit by the detector source. The differing emissions are read and forms the basis for the scrap sorting
• The system can then direct the piece of scrap to an appropriate bin using a mechanical arm or air flow
economic barrier
• Recently possible at high speeds
Source: Improving aluminum recycling: A survey of sorting and impurity removal technologies (Gabrielle Gaustad et. Al.) (7)
• 1 Recycling • 2 Market • 3 Recycling in Hydro
Europe is the world leader in recycling • 10,5 million mt recycling production in 2014. • An increase of 6,1% from the year before, • Primary production in Europe fell by 3,0%
There are more than 220 plants in 24 countries in Europe
5%
3%
7% 29% 7%
7%
11%
15% 7%
Germany UK Scandinavia Other Countries
Source: EEA
9% Italy Eastern Europe BeNeLux
France Austria/Switzerland Spain/Portugal
89% of scrap is used in Europe (EU27+EFTA) 11% of the scrap generated in Europe in 2014 was exported Use of scrap 11% 19%
17%
~7 million mt 53%
Scrap consumption in Europe
Pre consumer casting alloys
Post consumed casting alloys
European scrap exports
Pre consumer wrought alloys
Post consumed wrought alloys
Source: EAA
Advanced modelling reveals long term supply growth
Old Scrap Collected (Europe) 6.0
Aluminium in million tonnes
5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 2010
2015
2020 Rolling
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Extrusion
2025 Casting
2030
Available post-consumed scrap expected to increase. China as main source of old scrap generation growth CAGR:
GARC: Global old scrap to scrap market (Before trade and remelt loss) 38
Figures in million tonnes (mio.t)
Other
36
Other Producing Countries
34 +5%
32
Region
10-15
15-20
20-25
25-30
7%
6%
5%
4%
-1 %
2%
2%
2%
Other Asia
6%
7%
7%
7%
North America
3%
2%
1%
3%
Middle East
8%
8%
6%
6%
South America
6%
5%
4%
4%
Japan
2%
1%
2%
2%
Europe
4%
3%
2%
2%
12 %
11 %
10 %
8%
Other (Residual)
Other Asia
30 28
North America
26 24
Middle East
+5%
22
Other Producing Countries
South America Japan
20 +5%
18
Europe
16 14 +5%
12 10 8
China
6 4
China
2 0 1990
Source: IAI
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1995
2000
2005
2010
2015
2020
2025
2030
Current scrap trade levels not sustainable due to shrinking Chinese imports Declining US exports as an effect of this China scrap import
US scrap export
Figures in kt
Figures in kt
3 000
3 000
-5%
2 500
2 500 -2% Others
+26%
2 000
2 000 +17%
Malaysia 1 500
Others
1 500
Canada
Australia 1 000
Hong Kong
500
Mexico Korea
1 000
China
500 USA
Source: UN COMTRADE: 7602 Aluminium waste and scrap
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2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
2003
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0
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Scrap and alloy prices principally follow LME Time-lags for scrap may cause imbalances Price development in € 2013 - April 2015 € 2,500 € 2,300 € 2,100 € 1,900 € 1,700 € 1,500
€ 1,300 € 1,100 € 900 € 700 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN 2013 LME in €
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DIN 226
2014
LME + billet premium
LME + ingot premium
postconsumed profiles (ACL + WAZ)
Feb
Mar
2015
High grade FA
Apr
• 1 Recycling • 2 Market (UBC) • 3 Recycling in Hydro
UBC scrap market in Europe
280 kmt of UBC are collected in Europe from a variety of collection systems based on EAA figures.
Deposit based Kerbside collection Bring system Residual Waste Sorting
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Volumes from different collection systems
Added value from sorting Cleanliness of scrap Residual Waste Sorting (RWS)
Kerbside collection separated
Bring system
Waste treatment plant
Sorting facility
Sorting facility
Annual volumes:
44 kmt (15%)
77 kmt (28%)
Export
Non-ferrous metal concentrate
Downgrading
Metal treatment plant
Deposit based system
60 kmt (22%)
96 kmt (35%)
Hydro UBC processing line
Competitors Estimated annual volume based on EAA data
More than 80% of European UBC come from return systems with elevated levels of mix up and contamination.
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• 1 Recycling • 2 Market Outlook • 3 Recycling in Hydro
The industry’s most ambitious climate strategy: Carbon-neutral by 2020 Supported by the three pillars of Hydro’s technology strategy
Energy and primary production Reduce emissions, increase efficiency
Aluminium in use Maximize userphase benefits
‘End-of-life’ Increase recycling, back to the loop
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Hydro’s recycling facilities Holmestrand, Norway • 2014 production: 47,000 tonnes
Karmøy, Norway
WMR, Dormagen, Germany
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• 2014 production: 30,000 tonnes
2014 production, 23,000 tonnes
Deeside, UK
Neuss (Alunorf), Germany
• 2014 production: 51,000 tonnes
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2014 production: 347, 000 tonnes
Rackwitz, Germany Texas and Kentucky, USA
• 2014 production: 87,000 tonnes
• Commerce, 2014 production: 104,000 tonnes • Henderson, 2014 production: 79,000 tonnes
Hamburg, Germany • 2014 production: 104,000 tonnes
Neuss (Rheinwerk), Germany • 2014 production: 87,000 tonnes
Lucé, France • 2014 production: 52,000 tonnes
Clervaux, Luxembourg • 2014 production: 90,000 tonnes
Azuqueca, Spain • 2014 production: 75,000 tonnes
Cisterna di Latina, Italy • 2014 production: 44,000 tonnes
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Hydro has developed leading scrap capabilities the last years
Key elements in scrap procurement and handling Material Flow Analysis Scrap availability modelling based on dynamic stock analyses and growth scenarios
Scrap Receival & Sampling Best practices for receival and sampling, supplier evaluation, chemistry and recovery database
Tools Scrap portal
System optimization long term
Charge optimization on batch level
Technology Scrap processing: Shredding, magn. & EC separation, X-ray sorting
Continuous delacquering & hot transfer
Furnace concept: Cont. feeding, submerged melting, electromagn. stirring
Hydro leading in state-of-the-art scrap flow model development Best practice sharing across plants on scrap receival and sampling Hydro in-house developed tools are differentiating elements
Leading competence in furnace operation Significant scrap processing competence built last years
Our Recycling Strategy – in short
Build on leading remelt capability to expand use of post consumed and lower priced scrap
Enablers • •
Access to processing capacity for post consumed and difficult scrap Increased sales of Recycling Friendly Alloys (RFA)
• • •
Better (improved margins) Bigger (increased capacity utilization) Greener (Recycling/RFA)
Establish cooperation models for scrap sourcing and processing, possibly with asset ownership Alt 4: Hydro investing in own processing capabilities
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Strategic Objectives
Increased used of post consumed scrap
source
collector
processor (by recycler)
recycler
extruder
Flow-sheet post-consumed scrap recycling Mixed End of Life scrap fines
shredder
bunker
ferrous metals
magnetic separator
decoating kiln
screen (size split approx 40mm)
sieve
plastics, minerals
eddy current separator
melting furnace
heavy metals cast alloys
x-ray sorter
casting furnace
plastics, organics
eddy current separator
DC casting
billet / sheet ingot
fines
Strengthening of recycling position through UBC* recycling line
Establishing strong recycling position
• Fulfilling customer needs and strengthening beverage can market position • € 45 million investment • Start of production end 2015 • Contribution towards 2020 carbon neutrality target
* UBC: Used beverage can (25)
UBC shredder unit Overview Shredding the cans for optimal sorting • contamination such as "plastic widgets" in special beer cans must be exposed by the shredding (Guinness / bitter beer) Shredding the cans for optimal delacquering • both sides of the aluminium can (inside / outside) must be open • target grain size: 50mm Technical challenge • scrap composition • shape and density of scrap bales and packages
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Bale braker and hammer mill
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Sorting line, furnace and delaquering
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Acquisition of WMR Recycling GmbH Superior patented shredding & sorting technology Two-stage scrap processing Step 1:
• • • •
Scrap shear Hammer mill Magnetic & eddie-current-sorting, sieving Particle size 150 – 250 mm
Step 2:
• • • •
2 parallel cutting mills X-ray transmission sorting eddie-current-sorting, sieving Particle size 30 – 80 mm
Throughput (extrusion & sheet scrap)
• 12 t/h input • Particle weight 15 – 40 g • Sorting of 1,000 particles per second
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