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Recycling A Pure Bonus

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Recycling A pure bonus Roland Scharf-Bergmann Head of Recycling (1) • 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 (4) 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 (5) 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 (6) 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 (12) 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 (13) 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 (14) 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 2002 0 2001 0 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 € (15) 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 (17) 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. (18) • 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 (20) Hydro’s recycling facilities Holmestrand, Norway • 2014 production: 47,000 tonnes Karmøy, Norway WMR, Dormagen, Germany • • 2014 production: 30,000 tonnes 2014 production, 23,000 tonnes Deeside, UK Neuss (Alunorf), Germany • 2014 production: 51,000 tonnes • 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 (21) 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 (23) 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 (26) Bale braker and hammer mill (27) Sorting line, furnace and delaquering (28) 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 (29) (30)