US E FA B R I C AT I O N R E C YC L I N G

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1 US E FA B R I C AT I O N R E C YC L I N G PRIM ARY COPPER PRODUC TION Environmental Report 2012

2 2 Foreword of the Executive Board Chairman, Peter Willbrandt 4 Aurubis company portrait Copper the material of modern life 8 Foreword of the Head of Group Environmental Protection, Dr. Karin Hinrichs-Petersen 11 Company guidelines and Group environmental protection guidelines 14 Copper resource-efficient production, energy-efficient applications, recycling without a loss of quality Examples of our commitment: 16 Improved multi-metal recycling in our recycling center in Lünen 17 Developing products together at our sites in Hamburg and Stolberg 18 Environmental protection and education at our site in Pirdop, Bulgaria 20 Implementing REACH at Aurubis 21 New EU directives define future environmental requirements in the Aurubis Group 22 Climate protection and energy management: energy optimizations, energy management systems 26 Aurubis AG, Hamburg 28 Aurubis AG, Lünen 30 Aurubis Bulgaria AD 32 Aurubis Belgium nv/sa 34 CABLO Metall-Recycling & Handel GmbH 36 Elektro-Recycling NORD GmbH 38 Aurubis Buffalo Inc. 40 Aurubis Finland Oy 42 Aurubis Italia Srl 44 Aurubis Netherlands BV 46 Aurubis Stolberg GmbH & Co. KG 48 Aurubis Sweden AB 50 Deutsche Giessdraht GmbH 52 Schwermetall Halbzeugwerk GmbH & Co. KG 54 RETORTE GmbH Selenium Chemicals & Metals 56 Peute Baustoff GmbH 58 Slitting Centers 59 Glossary 62 Photo credits, contact information

3 Our Sites Production sites and Slitting Centers Aurubis AG, Hamburg 1 Hamburg, headquarters (D) 26 Elektro-Recycling NORD GmbH 1 Hamburg E. R. N. (D) 36 Peute Baustoff GmbH 1 Hamburg (D) 56 CABLO Metall-Recycling & Handel GmbH 2 Fehrbellin (D) 34 Aurubis U.K. Ltd. 3 Smethwick / Birmingham (UK) 58 Aurubis Netherlands BV 4 Zutphen (NL) 44, 58 Aurubis Belgium nv/sa 5 Olen (B) 32 Deutsche Giessdraht GmbH 6 Emmerich (D) 50 Aurubis AG, Lünen 7 Lünen (D) 28 Aurubis Stolberg GmbH & Co. KG 8 Stolberg (D) 46 Schwermetall Halbzeugwerk GmbH & Co. KG 8 Stolberg (D) 52 RETORTE GmbH Selenium Chemicals & Metals 9 Röthenbach (D) 54 CABLO Metall-Recycling & Handel GmbH 10 Nersingen, Strass (D) 34 Aurubis Slovakia s.r.o. 11 Dolný Kubín (SK) 58 Aurubis Mortara SRL 12 Mortara (I) 58 Aurubis Bulgaria AD 13 Pirdop (BG) 30 Aurubis Italia Srl 14 Avellino (I) 42 Aurubis Sweden AB 15 Finspång and Västerås (SE) 48 Aurubis Finland Oy 16 Pori (FI) 40 Aurubis Buffalo Inc. 17 B u ff a l o ( US) 38 Raw materials used Concentrates Recycling material Copper products Cathodes Continuous cast wire rod Continuous cast shapes Strips/foils Specialty wire, shapes, shaped wire By-products Precious metals Sulfuric acid Iron silicate stone/sand Other metals and products Services Slitting Centers Sales offices Page

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5 Copper from people for people High environmental standards at Aurubis for the material of modern life You can find further information on our website:» Or read the additional publications that are available in our download center: EMAS Environmental Statements for Aurubis AG s Hamburg and Lünen sites» Aurubis Sustainability Report 2011

6 Dear readers, I am pleased to present to your our Environmental Report 2012, which describes our group-wide performance in environmental protection at all of the production sites. Aurubis is broadly positioned along the copper value-added chain. With the addition of Luvata s Rolled Products Division to the Group this past year, we took a decisive step in becoming more international, expanded our product range and strengthened processing. We view ourselves as an attractive employer and a good neighbor. We believe that economy, ecology and social responsibility build on one another. Good economic development is the precondition for capital expenditure on state-of-the-art plant technologies with the highest environmental protection standards. The extraction and use of non-ferrous metals are required for technical progress and a high standard of living. Copper produced in an environmentally friendly manner is also a significant problem solver when it comes to climate protection. Without copper there are no efficient technologies for renewable energies and thus no energy turnaround. This sustainable use of copper as a material from people for people and for modern life is reflected in its excellent properties, from resource-efficient production and energyefficient applications to recycling without a loss of quality. For a country like Germany that lacks raw materials, copper recycling is therefore an important pillar of copper production for Aurubis. Copper can remain in the value-added chain indefinitely, so Aurubis has a leading position with respect to resource efficiency as well. The ongoing growth in copper demand cannot be covered by recycling alone, however. Primary copper production will thus form the basis for covering copper demand in Europe in the future. Environmental and climate protection are enshrined in our company guidelines. We want to continue to improve and steadily expand our position as an international leader at all sites. People take priority. It is important to us that our employees develop a high level of environmental awareness and that environmental protection is a way of life in the Group. 2

7 Increasingly complex and high requirements in environmental and climate protection nevertheless present considerable challenges. New European and national obligations are incredibly detailed and lead to conflicting targets for protected resources in some cases. For example, stricter regulations in water pollution control could lead to environmental protection measures that cause additional emissions to air. Environmentally friendly companies in Europe always bear higher costs than their international competitors. CO₂ certificates, high electricity prices, the energy turnaround and the implementation of the industrial emissions directive negatively affect companies in Germany in particular. Copper is quoted on the metal exchange, so the copper price is the same worldwide. There is strong international competition in copper production, and Aurubis cannot pass on additional costs resulting from national or European legislation to customers but must instead compensate for this with continuous increases in productivity and efficiency. However, efforts to enhance productivity and efficiency are increasingly reaching the limits of technological possibility. Therefore, we call on policymakers to act with sound judgment in the development of instruments to improve environmental and climate protection and not to burden industry in Europe and Germany with dramatic increases in additional costs which our international competitors do not have to bear. Only then can it be ensured that copper production and multi-metal recycling take place in state-of-the-art facilities with the highest environmental protection standards like those in Germany. You are cordially invited to see Aurubis environmental protection performance for yourself. I hope you enjoy reading the report. Best regards Peter Willbrandt Chairman of the Executive Board August 2012 AURUBIS ENVIRONMENTAL REPORT

8 Aurubis company portrait: our business, our Business Units COMPANY PORTRAIT Aurubis AG is a leading international integrated copper group with a strong foundation in Europe. Our portfolio includes copper production, metal recycling and copper product fabrication. We are therefore represented in central areas of the industrial metal s value-added chain. The production of precious metals and specialty products completes the range of services. Aurubis produces at sites in Europe and the USA and has a broad service and sales system that supports product sales in Europe, Asia and North America. About 6,300 employees work for Aurubis worldwide. We are oriented towards sustainable growth and increasing value: the main focuses of our strategy are on strengthening the business, utilizing growth opportunities and responsibility towards people, resources and the environment. Aurubis shares are part of the Prime Standard segment of the Deutsche Börse and are listed in the MDAX, the European Stoxx 600 and the Global Challenges Index. HISTORY Aurubis was founded in 1866 as Norddeutsche Affinerie Aktiengesellschaft in Hamburg. Following various changes in the ownership structure, the company went on the stock exchange in Several subsidiaries and affiliated companies belong to the Group, as does the Belgian copper rod and semi-finished product fabricator Cumerio acquired in The company was renamed Aurubis in The product business became stronger and more international with the acquisition of the Luvata Rolled Products Division on September 1, With this acquisition, Aurubis has addi - tional production sites in Buffalo (USA), Finspång1 (Sweden), Pori (Finland) and Zutphen (Netherlands) as well as service centers in Zutphen, Mortara (Italy) and Shanghai (China) and sales offices in the USA, Europe and several Asian countries. OUR BUSINESS MODEL Our business model combines the production, recycling and processing of metals under one roof. This provides us with a great deal of flexibility in controlling raw material procurement and production. Our product and service spectrum is strongly oriented towards the needs of the market. Both standard and specialty product solutions are offered in addition to comprehensive services. We produce copper first and foremost from copper concentrates but also from intermediate products from other metal producers, copper scrap and other recycling materials, including metal production residues and electronic scrap. A broad range of by-elements are extracted and processed into products such as precious metals, bymetals like lead, tin and selenium as well as sulfuric acid and iron silicate. The copper cathodes produced at our sites in Hamburg, Lünen, Olen and Pirdop are of an excellent quality that exceeds the requirements of the metal exchanges. We primarily process the cathodes into copper products, but they can also be sold on the London metal exchange and to trade and industry. We have provided an overview of our sites on the inner front flap. 1 The plan is to re - locate production from Finspång to other Aurubis Group sites (Buffalo, Zutphen) in the next two years. Full production will continue in Finspång until summer

9 OUR BUSINESS SEGMENTS The Aurubis Group is managed from the corporate and administrative headquarters in Hamburg, where significant production plants are also located. The group structure is oriented towards the copper value-added chain. Three operating Business Units (BUs) form the Group s organizational framework and the basis for reporting. Furthermore, several group-wide departments that support the operating sectors with their services and administrative functions make up the Corporate Functions. Primary Copper Recycling/Precious Metals The Business Unit Primary Copper handles The main activity of the Business Unit all activities associated with the production of pure, high-quality copper in the duction of high-purity copper cathodes Recycling/Precious Metals is the pro- form of marketable copper cathodes made from a very wide range of recycling raw of the primary raw material, copper concentrates. This includes smelting and at various sites in the Group, the most materials. Recycling activities take place refining activities at the sites in Hamburg, significant of which are the Group s recycling center in Lünen and the secondary Olen (Belgium) and Pirdop (Bulgaria) as well as marketing the by-product sulfuric smelter in Hamburg. Copper scrap and, acid and iron silicate products. The subsidiaries Peute Baustoff GmbH and Retorte materials like electronic scrap are pro- increasingly, more complex recycling raw GmbH Selenium Chemicals & Metals, cessed in an environmentally friendly the world s leading selenium producer, fashion with innovative technology. In the are also part of the Business Unit. Business Unit Recycling/Precious Metals we also produce precious metals contained in copper raw materials as well as other by-metals and by-products. For copper production in both sectors, our income is determined in large part by treatment and refining charges, which are agreed on with the raw material suppliers as a processing fee. Our copper cathodes strictly fulfill the metal exchanges very high quality requirements. Copper Products Our own and external copper cathodes are processed in the Business Unit Copper Products. Continuous cast copper wire rod, which is delivered to the cable and wire industry, is of central importance. We also produce continuous cast shapes for the market and for internal processing as well as pre-rolled strip, rolled products and specialty products. The main production sites are located in Europe, including Hamburg (Germany), Olen (Belgium), Zutphen (Netherlands), Finspång1 (Sweden), Pori (Finland) and Avellino (Italy). Outside of Europe, Aurubis produces strips made of copper and copper alloys in Buffalo (USA). Service centers in the United Kingdom, Slovakia, Italy, the Nether lands and China and a global sales network round off the service profile of BU Copper Products. The industries that use copper, the material of the future, include the electrical and electronics industry (including telecommunications), construction, industrial machines and plants, transport and consumer goods. Our revenues in copper processing are determined by premiums and shape surcharges, which cover the processing of pure copper into products and reflect the value added. AURUBIS ENVIRONMENTAL REPORT

10 EVERYWHERE, IRREPLACEABLE: COPPER FROM AURUBIS Copper the material of modern life Air conditioners Wind turbines Engines Transport Cars Cable Construction Machinery and plant engineering Electrical engineering and electronics Water pipes Formability Alloying capability Outstanding electrical conductivity Excellent thermal conductivity Corrosion resistance Recyclability Consumer goods Coins Non-ferrous metals are necessary for technical progress and a high quality of life. As a central component of innovative technological developments, our highquality copper contributes to modern life and to the energy turnaround: without copper there would be no technologies for renewable energies, no efficiency increases in these energies and no improvement in the CO₂ balance. 6

11 Fig. 1: Global copper demand by industries for % Consumer goods 13 % Transport 13 % Industrial machines and plants 34 % Electrical and electronic applications 31 % Construction Source: Wood Mackenzie, Copper, June 2012 Fig. 2: Sales structure of the Aurubis Group by industries for fiscal year 2010/11 11 % Consumer goods 12 % Transport 20 % Industrial machines and plants 36 % Electrical and electronic applications 21 % Construction Today, copper is used in sectors where its material properties are important. It is the best electrical and thermal conductor after silver. The intelligent use of resources in one area, for example copper production, can lead to efficiency increases in another area, for instance more effective wind energy plants. At Aurubis, we view copper as an irreplaceable material for sustainable economic activity. AURUBIS ENVIRONMENTAL REPORT

12 Dear readers, The Aurubis Group is currently one of the most environmentally friendly copper producers in the world. Energy efficiency and climate protection are constantly developed and improved at all of the Group sites. Sustainability, resource efficiency and environmental and climate protection are key targets of Aurubis corporate strategy and are firmly established in our company guidelines. We are developing innovative and energy-efficient plant technologies in environmental protection that set new benchmarks worldwide. We keep the effects on the resources water, air and soil to a minimum with the use of the best available technologies and high environmental standards. Nearly all of the raw materials are processed into marketable products and waste is effectively avoided and recycled if possible. Environmentally friendly copper production from primary raw materials, such as copper concentrates, and multimetal recycling form the basis for an adequate copper supply in Europe. Our motto: Copper is made by people for people. Aurubis uses the highest environmental standards for the material of modern life. The corporate environmental protection guidelines were developed in order to live up to this motto. They describe environmental protection targets and significant areas of activity, define responsibilities, provide a framework for information and reporting, establish the tasks of Group Environmental Protection and outline the cooperation with the local environmental officers and managing directors or plant managers. This ensures uniform procedures for environmental protection within the Group and in our public image. The new Group sites in particular are supported by the Hamburg Group headquarters with knowhow and technology transfer. We have defined both group-wide targets in environmental protection as well as concrete targets for the individual sites (see Fig. 3, p. 10). Environmental protection successes On average, about one-third of total capital expenditure in the Aurubis Group has been used for environmental protection (see Fig. 4, p. 10). Because of this and the operation of state-of-the-art, innovative plant technologies, Aurubis has a leading global position in climate and environmental protection in primary and secondary copper production as well as processing copper into products such as rolled sheets, rod and cast products. As an energy-intensive company, Aurubis feels especially committed to climate protection. We therefore invest in energy-efficient plant technologies, individual measures to save additional energy and volunteer projects like the city of Hamburg s climate protection program at all sites. This long-term involvement has been successful: we have significantly reduced our specific CO₂ emissions at all sites. 8

13 The figure on the following page (see Fig. 5, p. 10) illustrates this with our sulfur dioxide emissions compared to other primary copper producers. To achieve these kinds of results, Aurubis has consistently pursued the objective of further improving environmental protection with continuous investments. The success is evident in the emissions trend in Aurubis primary copper production they have decreased by 84 % since 2000 (see Fig. 6, p. 10). The goal is now to maintain this level in the long term and to continue reducing it if possible. Aside from reductions in air emissions, there were also improvements in water pollution control. For example, metal emissions to water in Aurubis copper production have decreased from 7.2 to 2.9 g per ton of copper output since 2000, or by 60 %. The goal is to achieve a roughly 70 % reduction by Aurubis tries to recycle as much of the generated waste as possible. The recycling rates at all sites reached up to 99.9 % in We have established emergency plans at all sites for emergencies and accidents. They describe how to react so that environmental effects can be prevented or effectively limited. Furthermore, there are alarm and danger prevention plans for the individual production sites. We regularly test their functionality in emergency drills. The plants in Hamburg and Lünen also fulfill the requirements of the Hazardous Incident Ordinance. Targets and challenges in Group environmental protection The new industrial emissions directive, which will be implemented in EU countries by 2013, sets new benchmarks and standards for industrial plants in Europe. This directive poses significant additional challenges for industry. For example, new limit values are defined for air and water on the European level by stipulating the best available technology (BAT). Our 17 production sites across Europe have to achieve these limits within four years. Most of our plants are already part of the best available technology and set benchmarks in the BAT process (Seville Process).1 As a growing group with new sites, Aurubis is harmonizing environmental protection at a very high level. This process is cost-intensive and requires strategic planning for environmental investments. We will also continue to deal with the issue of resource efficiency. Indicators should be developed now in order to make resource efficiency successes visible. It is important to establish them in a way that strengthens environmentally friendly copper production and multi-metal recycling in Europe. We would like to inform you about what we have achieved, the detailed targets and additional measures for the individual sites in this Environmental Report. We hope you enjoy reading it. Best regards Dr. Karin Hinrichs-Petersen Head of Group Environmental Protection 1 See Glossary, p. 59 AURUBIS ENVIRONMENTAL REPORT

14 Fig. 3: Targets in Group environmental protection until 2015 Noise Target: Reducing noise emissions Example: Erecting a noise barrier in Olen Climate protection Target: Continued reduction in CO₂ emissions Examples:» Constructing turbines to use waste heat in Hamburg and Lünen» Optimizing suction plants at Schwermetall Halbzeugwerk Air Target until 2015:» Reducing SO₂ emissions1 in primary copper production by over 80 % compared to 2000» Reducing dust emissions in copper production by over 90 % compared to 2000 Waste Target: Increasing the recycling rates Examples:» Stronger marketing of fayalite in Pirdop» Optimizing the separation plant at E. R. N. Water Target until 2015: Reducing metal emissions to water2 in copper production by about 70 % compared to 2000 Example: Operating new water treatment plants in Pirdop and Lünen Fig. 4: Capital expenditure for environmental protection measures in copper production in the Aurubis Group in million Fig. 5: Highest environmental protection standard worldwide Source: Brook Hunt, Copper Smelter Cost Service 03/2011; certified data SO₂ emissions of copper smelters in kg SO₂/t of copper output International copper smelters: 307 kg SO₂ / t Cu European copper smelters: 41 kg SO₂ / t Cu Aurubis Hamburg: 4.3 kg SO₂/t Cu Aurubis Pirdop: 7.6 kg SO₂/t Cu Fig. 6: Specific SO₂ emissions in primary copper production in the Aurubis Group in kg/t of copper output Fig. 7: Dust emissions in copper production in the Aurubis Group in g/t of copper output 1,291 1, % since % since

15 Company guidelines and Group environmental protection guidelines 1 Sulfur dioxide emissions in primary copper production and dust emissions in copper production have decreased considerably since Now the target is to maintain this level and to continue reducing it if possible. 2 There are plans to reduce metal emissions to water from direct discharge in copper production. There has been a 60 % reduction compared to 2000 and the goal is to reach about 70 % by The former Luvata sites, which joined the Group in 2011, were integrated into Group environmental protection. After the good experience with the integration of the former Cumerio sites in 2008, it is» The continuous improvement of water conservation, soil conservation and immission control is a key aim of environmental protection.» For reasons of accountability, environmental and climate protection should be developed in such a way as to preserve natural resources and avoid or minimize the burdens on the environment and our employees. now important to analyze how the environmental protection situation can be further developed at the new sites as well. The following principles are laid out in our company guidelines:» Issues of environmental protection should be taken into account equally in the planning and development of new products and production processes.» Processed raw materials and intermediate products should be brought into the economic cycle as completely as possible and unavoidable waste should be properly recycled or harmlessly disposed of. Raw material suppliers are advised on issues related to environmental protection if needed.» Essential precautions to avoid accidents and operational disruptions are in place to prevent or minimize environmental hazards for our employees and neighbors as well as effects on the environment.» Our employees sense of responsibility in environmental protection should be strengthened and an objective, open and respectful dialogue should take place with them, the relevant authorities and the public.» Our customers are appropriately informed about the features of our products and necessary safety measures and are advised on questions related to product disposal.» External companies working for us must be selected, informed and advised in such a way as to ensure that laws and our environmental protection standards are observed. Compliance with these legal regulations is the basis and minimum standard of our activities. AURUBIS ENVIRONMENTAL REPORT

16 Aurubis assumes responsibility for environmental and climate protection, which are key issues in the company s strategy. Metals are necessary for technical progress and a high standard of living. Rising demand worldwide is met with limited resources, however. Metal recycling is therefore an important source of raw materials especially for a country like Germany that lacks natural resources. It makes an important contribution to supply security, sustainability and resource protection. Aurubis obtains raw materials from more than 50 countries worldwide, with a focus on Europe for secondary raw materials. A number of recycling raw materials, for example circuit boards, copper pipes and electronic scrap, are purchased and processed as part of Aurubis multi-metal recycling. High volumes of recycling raw materials are processed into cathode copper and precious metals at the Hamburg site as well. Since copper concentrate processing is an exothermic process, recycling materials can be melted when processing primary raw materials in Hamburg, practically without any addi tional energy. We assume responsibility for environmentally friendly production with the highest energy efficiency standard for climate protection and have established these targets in our company guidelines. Alignment with the market, orientation towards growth, a clear commitment to efficiency and continuous improvement processes, high quality awareness in all sectors and ecological and social responsibility: all of these factors secure the future of the Group. We pursue goal-oriented environmental protection with state-of-the-art technology. Expanding recycling in the Group helps to close material cycles in an environmentally sound manner and therefore makes an important contribution to sustainable development. Beyond legal requirements, voluntary agreements like the chemical industry s Responsible Care initiative are important instruments for Aurubis to continuously improve its environmental and health protection performance. Chairman of the Executive Board Peter Willbrandt oversees Group Environmental Protection. Fig. 8: Organizational chart Chairman of the Executive Board Peter Willbrandt Business Unit Primary Copper Group Environmental Protection Plant Managers/Managing Directors at the production sites Dr. Karin Hinrichs-Petersen Head of Group Environmental Protection and Environmental Protection Hamburg Environmental Officers at the production sites 12

17 1 See Glossary, p. 59 Chairman of the Executive Board Peter Willbrandt and Head of Group Environmental Protection Dr. Karin Hinrichs-Petersen are responsible for the strategic orientation of environmental protection in the Group. Environmental Officers oversee the environmental duties at the individual sites. With the involvement of employees, Plant Managers/Managing Directors and the Executive Board, uniform environmental protection standards were developed, established with Group guidelines and implemented across the Group as part of the environmental management system (ISO or EMAS1). The key environmental protection factors, which are uniform within the Group, are reviewed and certified annually. An environmental exchange takes place across the Group and employees are trained on environmentally relevant topics regularly. Emergency plans or alarm and danger prevention plans have been established at all sites for emergencies and accidents. They ensure that environmental impacts are effectively avoided and that employees and the community are protected. We carry out training sessions and emergency drills regularly, documenting and evaluating the procedures. Emergency plans are developed in coordination with the responsible authorities. The Group environmental protection guidelines also include the tasks to implement the European chemical directive, REACH.1 Fig. 9: Environmental management in the Aurubis Group Legal environmental requirements and standards Group environmental policy ISO 14001/EMAS Environmental management Formulating standards by means of Management handbook Process and operating instructions Process descriptions ISO 14001/EMAS Environmental inspection Environmental management system Implementing standards by means of Planning (environmental targets/measures) Implementation (e. g., via process changes or training) Correction, adjustment Monitoring (e. g., via environmental audits) Publishing the environmental performance AURUBIS ENVIRONMENTAL REPORT

18 ENVIRONMENTALLY SOUND: COPPER FROM AURUBIS Copper resource-efficient production, energy-efficient applications, recycling without a loss of quality A VALUABLE CYCLE Non-ferrous metals like copper are not used up but instead pass through the recycling process, therefore completely fulfilling sustainability and resource efficiency requirements (see Fig. 10). Shorter and shorter product lifecycles lead to a recycling raw material supply that is growing constantly and changing quickly. New technologies, legal standards and product requirements lead to smaller and smaller amounts of recyclable raw materials being used in products. Even marginal quantities of copper and precious metals, for example from electronic scrap, can be almost completely recycled. Recycling alone is not enough to cover the raw material demand, however (see Fig. 11). Aurubis currently covers about 27 % of its raw material demand with recycling material.1 The use of new technologies like electric cars increases copper demand; secondary raw materials alone are not sufficient. The copper needed is still in use or is in the recycling process in some cases, so there is a lack of raw materials. Primary raw materials must first be fed into the system for recycling to take place after they are used, which can lead to a delay of several years or even decades. 1 Increase from 19 % to 27 % since Buildings, infrastructure and vehicles have a limited lifespan. Every city changes; urban mining basically means that freed-up resources are exploited and returned to the material cycle. THE RAW MATERIALS A good two-thirds of our copper production results from the use of primary raw materials that we purchase worldwide mainly from South America and Asia. Our suppliers include the largest international companies, such as Xstrata, Anglo American, Vale, Teck and Newmont. We prefer to develop long-term cooperation by means of contracts that often continue for many years. We try to obtain declarations from our suppliers stating that the material they deliver was produced and or exported in compliance with valid laws, regulations, statutes or requirements of the country of origin and that they adhere to UN sanctions or trade restrictions and UN conventions related to human rights, environmental protection and safety. We mainly purchase our secondary raw materials from Germany and other EU countries. In contrast to primary raw materials, procurement is largely based on short-term delivery agreements. Secondary raw materials now increasingly include complex end-of-life materials in addition to copper and copper alloy scrap and copper processing residues. In order to be able to use as many of the local secondary resources as possible in the scope of urban mining 2, but also the growing quantity of electronic scrap from the IT and telecommunications sectors, we are expanding the processing capacities for these kinds of scrap and investing in state-of-the art facilities for multimetal recycling (see p. 16, Lünen example). Most of our suppliers are part of the International Council on Mining and Metals (ICMM), which is actively committed to sustainable raw material extraction. 14

19 FA B R I C ATION Fig. 10: A valuable cycle No metal besides silver has higher electrical or thermal conductivity than copper. Copper therefore plays a key role in the switch to sustainable energy production as well as increasing the efficiency of products and applications. Copper as an efficiency-increasing material U S E Collecting, separating, sorting, treating Aurubis processes a number of different recycling raw materials and has environmentally friendly and efficient recycling options as part of the company s multi-metal recycling. Copper production End-of-life products Urban mining R E C YC L IN G PRIMARY COPPER PRODUCTION Aurubis works with innovative and energy-efficient plant technologies in environmental protection, which set new benchmarks worldwide. The effects on the resources PRIMÄRKUPFERERZEUGUNG water, air and soil are kept to a minimum with the use of the best available technologies and high environmental protection standards. Fig. 11: The European copper market traditionally exhibits cathode deficits Copper production and demand by region Copper surplus and deficit by regions in » With an average copper product lifespan of about 30 years, even recycling 100 % of the production volume from 30 years ago would not cover 50 % of today s copper demand Source: Wood Mackenzie, March 2012 AURUBIS ENVIRONMENTAL REPORT

20 AN EXAMPLE OF OUR COMMITMENT: IMPROVED MULTI-METAL RECYCLING IN OUR RECYCLING CENTER IN LÜNEN KRS-Plus project: an intelligent solution for increasingly complex raw materials A wide range of secondary raw materials are recycled in an environmentally sound and energy-saving process with the Kayser Recycling System (KRS) in our recycling center in Lünen. Apart from copper, precious metals, nickel, tin, lead and zinc are recovered as by-products. The use of increasingly complex raw materials, continuous optimization of the metal yield, including by-metals, and a flexible raw material input that is the strategy behind Aurubis multi-metal recycling, which combines resource and energy efficiency. The KRS was expanded to include a top blown rotary converter (TBRC) in 2011 as part of the KRS-Plus project. The three furnaces process a larger volume of complex secondary materials such as electrical and electronic scrap, improve the overall metal yield and enable an additional input of up to 100,000 t of material containing low amounts of copper. How long was the preparation for this project? Dr. Mehmet Ayhan: The first ideas started in 2005/2006. Because of the extent of the capital expenditure, details about the material flows and the necessary changes to the previous process were specified in Construction ended in 2011 and the first melt was processed. What was your function during the implementation of the project? Stefan Schmidt: Dr. Mehmet Ayhan is the process licensor. He oversaw all of the preliminary calculations regarding material balances, energy and metal distribution. At the same time, he led TBRC trials in Hamburg as well as at the RWTH Aachen to review the theory and substantiate the metallurgical process. I was responsible for the concept development, the personnel and the operating procedure for the new facility. The organizational and technical integration of the new furnace into the melting operations existing process was especially important. How was the start-up of the facility? Dr. Mehmet Ayhan: The start-up was very good. The facility reached about 85 % of its design capacity within two months. The plant s design target was achieved consistently after six months. A team made up of engineers from the melting operations, research and the Lünen tankhouse was formed for the start-up. They oversaw the plant in threeshift operation. What is the status of the project today and what are the next steps? Stefan Schmidt: The key now is further optimizing the plant with respect to its metallurgical results. At the moment, trials are being carried out to produce a special, highly enriched anode alloy. Stefan Schmidt, Production Manager of Melting Operations at the Lünen Recycling Center and Dr. Mehmet Ayhan, Head of R&D Recycling, Production Management Lünen 16

21 AN EXAMPLE OF OUR COMMITMENT: DEVELOPING PRODUCTS TOGETHER AT OUR SITES IN HAMBURG AND STOLBERG Successfully increasing efficiency: copper in high-performance LEDs 1 In addition to its use in DBC circuit boards, copper is used in copper-based alloys, leadframes and heat sinks in LED technology. These strip products with special surface quality standards are also a central element of Aurubis Stolberg s product range. Because of their much lower energy consumption (71 % CO₂ savings potential) and considerably longer lifespan compared to conventional lighting, LED lamps are becoming more and more important, especially for lighting streets and open spaces. In cooperation with Aurubis Hamburg, Aurubis Stolberg developed solutions to produce strip made of special copper alloys1 specifically for this use. High-performance LEDs are operated with high currents, so good heat dissipation is very important. This requirement is fulfilled with so-called DBC (direct bonded copper). Thin copper strips are mounted on ceramic substrates on special circuit boards. In some designs, the copper conducting paths are then coated with gold or nickel. The copper strips used in DBC fabrication have to be produced from high-purity copper alloys. This required completely new procedural solutions for production. Only these special fabrication processes ensure the highest quality requirements for DBC circuit board processing. Dr. Michael Hoppe: I ve worked at Aurubis since 1994 and have participated in many projects and supervised a number of technological developments. This project was very special, however, because we were able to make a high-performance product ready for production in only 18 months together with an inter-site team. We fulfilled the technological requirements of a DBC world market leader in this short time. I m especially proud of that. But it s a well-known fact that research work never really ends, so we re currently working on developing and optimizing this application. Dr. Michael Hoppe, Operations and Technology Development, Business Line Flat Rolled Products & Specialty Wire AURUBIS ENVIRONMENTAL REPORT

22 AN EXAMPLE OF OUR COMMITMENT: ENVIRONMENTAL PROTECTION AND EDUCATION AT OUR SITE IN PIRDOP, BULGARIA Environmental protection does not end at our plant boundaries. At the end of 2011 we opened two information centers in the neighboring cities of Pirdop and Zlatitsa, not only to give people an understanding of our work and to strengthen our dialogue with them, but also to create educational opportunities to raise awareness about environmental issues and encourage people to save resources. We would like to present two of these projects. SPARE1: International educational project on energy, climate and environmental sustainability An update on the Green Project : My Green City painting contest for children Environmental protection is a challenge. Climate change on our planet is a serious concern and each person is responsible for the Earth s future. The greater the energy efficiency, the lower the CO₂ emissions that end up in the atmosphere. Changes have to be made in order to save electricity. We took on this task in 2011 as part of an EU program with 26 students in their final year at the Savo Savov school (Pirdop): together with our colleagues in the Environmental Protection Department, they developed solutions to improve energy efficiency at the Pirdop site and they were so successful that the project was awarded a prize within the program. Our target was to introduce the students to a real situation and let them work on a real project. Employees gave them the responsibility of reducing the energy consumption resulting from office lighting, the flotation plant and the green area in front of the administrative building. They quickly found a solution: replacing the lighting with LED lamps reduces electricity costs and is environmentally friendly (see p. 17). The lamps are recyclable and do not create any hazardous gases or dangerous emissions like ultraviolet or infrared rays, which are harmful for the eyes and surrounding objects. In 2010 Aurubis Bulgaria started the Green Project with the purpose of creating stronger environmental awareness with a number of projects.2 Green Month took place in April 2012 as part of this project, which included the painting contest My Green City for children in 5th to 7th grade. They transferred their ideas to paper with bright colors. Beauty and harmony abound in the cities that they showed. We fully achieved our goal of helping children think about the environment in an artistic way. The Environmental Protection Department also uses the information centers in Pirdop and Zlatitsa to intensify the dialogue with the plant s neighbors. Angel Kostov, Head of Environmental Protection at Aurubis Bulgaria. (below left) Bulgarian students did outstanding climate protection work for Aurubis Bulgaria. (below center) The proud artists and their artwork on the theme My Green City. 1 SPARE: School Project on Application of Resources and Energy 2 In 2010 Aurubis Bulgaria started the Green Project, which allows employees to contribute to successful environmental protection work. The purpose of the project is to raise awareness of environmental protection in the long term with the help of effective communication, including a logo, training sessions and activities. 18

23 AURUBIS BULGARIA INFORMATION CENTERS Dialogue with neighbors How long have you participated in this project? How long have you worked for Aurubis? Draga Sapundjieva: I ve been working on this project since December I ve been at Aurubis for over six years, and I ve been responsible for our company s social projects in the region for four years now. Do you have the feeling that people s view of Aurubis has changed? Draga Sapundjieva: There has been a very positive reaction to the information centers. We want to approach people openly and engage in a dialogue. This makes the local citizens more receptive to us. What influence do the information centers have on the projects? Does the work get easier as time goes on? Are there any new contacts? Draga Sapundjieva: The information centers are the heart of the projects. Everything is easier because Aurubis approaches people and listens to them. This has led to a number of new contacts. What successes motivate you? Have there been any setbacks? Draga Sapundjieva: It s motivating to meet with people every day and answer their questions and address their concerns. Aurubis has become an involved citizen that makes me proud. Visitors who have a negative attitude and don t trust the information centers are frustrating. But I still believe in the necessity of this initiative and its positive effect. What about the children? Do they appreciate the projects? Draga Sapundjieva: The children view all of our projects positively and participate actively in them. I m happy when they say, Aurubis is my friend. What s planned for next year? Draga Sapundjieva: We re planning new projects for students. Our priority is always the environment. We will of course continue to maintain contact with the local citizens and inform them about what we do. Draga Sapundjieva, Coordinator for Social Projects and Information Centers, Aurubis Bulgaria

24 DR. JÖRN MÜHLENFELD AND DANIELA CHOLAKOVA, REACH TEAM, HAMBURG SITE Implementing REACH at Aurubis The REACH directive went into force in the European Union on June 1, REACH stands for Registration, Evaluation, Authorization and Restriction of Chemicals. The objective of the directive is to collect information on all of the materials on the market in the EU following the principle of no data, no market and to protect people and the environment using appropriate measures. Producers and importers have to register their chemicals in accordance with REACH. Data on the physical, chemical, human toxicological and ecotoxicological properties must be compiled as part of the registration process. The registration deadlines and requirements for the registration dossiers depend on the produced or imported material quantities and the properties of the materials. December 1, 2010 was the first registration deadline for the REACH directive. Aurubis submitted the registration dossiers for all sites successfully and on time to the European Chemical Agency (ECHA). Preparations are currently being made for the second registration deadline in June Daniela Cholakova: Implementing REACH poses a big challenge for the next few years. I ve been part of Aurubis since the acquisition of the Belgian copper producer Cumerio in 2008 and have been working on this issue since then. At the moment we re continuing to implement the experience and proven approaches from the first registration phase; we re expanding documentation and leading an intensive exchange with downstream users, associations and the ECHA. Dr. Jörn Mühlenfeld: We re coordinating the group-wide fulfillment of the REACH requirements centrally in Hamburg. In addition, we have contacts at the individual sites who are responsible for on-site implementation. This is incredibly important in an expanding group; the Group just grew again last year with the acquisition of the former Luvata sites. What has really stood the test of time during the first registration phase: Aurubis was already organized early on in a number of consortia on the European level together with other companies. I think this exchange is very exciting and rewarding. (from l. to r.) Dr. Jörn Mühlenfeld, Group Environmental Protection, Hamburg site; Daniela Cholakova, Group Environmental Protection, Hamburg site; Georgi Nikolov, General Secretary, Aurubis Bulgaria, Pirdop site; Dr. Günther Leuprecht, Production Manager for the Tankhouse and Chemical Plants, Hamburg site; Dr. Andreas Specht, Head of Primary Copper, Hamburg site 20

25 DR. HANNO HINTZE, HEAD OF ACID PLANTS, HAMBURG SITE New EU directives define future environmental requirements in the Aurubis Group Directive 2010/75/EU on industrial emissions dated November 24, 2010 forms the basis of permits for industrial plants in Europe with particular environmental relevance. This new directive develops the guiding principle of sustainable production. The target is to achieve a high level of protection for the environment overall. To establish the best available technologies (BAT) and new environmental standards, the European Commission has organized an informational exchange between the EU Member States, the industries affected and environmental associations (Seville Process).1 The BAT fact sheet for the non-ferrous metals industry is currently being revised. Since the emission values described in the conclusion will be binding in the future (see p. 10), it must be ensured that it is possible for companies to adhere to them in practice. The BAT fact sheets include detailed information on the technologies used, their operating conditions and the emission values that can be achieved with them. This makes them very complex. Aurubis is actively helping to shape this process; experts from the entire group from administration and the plants are intensively working on them, applying their expert knowledge. Some of these employees are featured in the photo above. Dr. Hanno Hintze: A critical issue so that old and new industrial plants consistently fulfill the BAT implications and can be operated legally is appropriate consideration of the individual processes of the plants, which are very different in some cases. Many plants are operated under variable process conditions, so in contrast to constant conditions, an ideal value cannot always be achieved. Practical regulations are therefore absolutely essential. 1 See Glossary, p. 59 (from l. to r.) Dr. Hanno Hintze, Head of Acid Plants, Hamburg site; Christian Plitzko, Head of Recycling/Precious Metals, Hamburg site; Christiane Henke, Group Environmental Protection, Hamburg site; Arne Schilling, Group Environmental Protection, Hamburg site; André Weishaupt, Group Environmental Protection, Hamburg site; Filip Lecomte, Head of Environmental Protection and Plant Security, Aurubis Belgium, Olen site

26 Climate protection and energy management: energy optimizations, energy management systems Environmental and climate protection are guiding principles in Aurubis company strategy and are consistently established at all of the Group sites. Aurubis holds a leading position in energy efficiency when compared internationally (see Fig. 12). Intensive work is being carried out to utilize accumulated waste heat at all Aurubis sites. In this way, waste heat can almost completely cover the heat and process steam supply at the Pirdop, Lünen and Hamburg sites. The Energy Affairs department was formed and comprehensive energy management systems (EMS) were developed in order to use additional energy optimization potential. Individual sites are connected to each other so that there can be an informational exchange across site boundaries. For the three sites currently certified in accordance with EMAS, an additional certification in accordance with DIN EN ISO is planned for 2013, which serves as a guide for sustainably increasing energy efficiency with the help of an energy management system (see Fig. 13, p. 23). A steam turbine for electricity production has been installed in Hamburg to utilize waste heat and the pressure gradient between steam pressure levels. A second turbine is under construction. A similar turbine is in the implementation phase in Lünen, while in Pirdop, work continues on optimal waste heat use. Fig. 12: From anode to cathode: energy efficiency comparison of the copper industry s tankhouses in MJ/ t of cathodes in ,359 2,839 1,487 2,442 3,285 2,265 3,333 1,867 2,341 North America Latin America Aurubis Aurubis Hamburg Europerope Africa Africa Rest Rest of of Asia China Japan Australia Source: Brook Hunt, a Wood Mackenzie Company, Copper Refinery Cost Service Summary and Analysis February

27 Energy team at Aurubis (from l. to r.): Thorsten Stölcken, Energy Management Officer; Ulf Gehrckens, Head of Group Energy Affairs; Christian Hein, Energy Affairs EMISSIONS TRADING The European Union introduced European emissions trading at the company level on January 1, 2005 as an instrument to fulfill the joint emission reduction obligation. In addition to the Hamburg site, the sites in Emmerich, Lünen, Olen, Pirdop and Stolberg (Schwermetall) will take part in CO₂ emissions trading starting in An application for free allocation for direct CO₂ emissions was submitted on time and notification is expected in late Only then will it be clear whether sufficient free certificates can be issued or an additional purchase is necessary. Article 10a no. 6 of the CO₂ emissions trading directive states that arrangements may be made for complete compensation of indirect CO₂ costs in the individual Member States electricity prices for industries endan- gered by carbon leakage (the relocation of CO₂ emissions). The copper sector is generally recognized as an industry subject to this risk. The EU assistance guideline explicitly mentions the copper sector. Benchmarks still have to be defined by the European Commission s Directorate General for Competition. The development of an electricity efficiency benchmark does not make sense, however, as the European copper industry uses a broad variety of production processes. The copper industry would thus be part of the fallback area1 as in the allocation rules for direct CO₂ emissions. Aurubis therefore advocates for the selection of reasonable compensation criteria for the copper sector. Fig. 13: Sites with energy management systems (EMS) Site EMS established EMS certified Certificate Schwermetall Halbzeugwerk EMAS Aurubis AG, Hamburg site EMAS Aurubis AG, Lünen site EMAS Aurubis Bulgaria 2010 Aurubis Stolberg DIN EN ISO 50001:2011 Deutsche Giessdraht DIN EN ISO 50001:2011 CABLO Metall-Recycling & Handel, Fehrbellin site DIN EN ISO 50001:2011 CABLO Metall-Recycling & Handel, Strass site DIN EN ISO 50001: A general factor of 70 % is currently being discussed, which would reduce compensation by 30 %. AURUBIS ENVIRONMENTAL REPORT

28 Fig. 14: Reinforcing and adding to the grid in Germany Lead Scenario B 2022 of the grid development plan Grid expansion Grid reinforcement» The accelerated energy turnaround requires grid capacities to be expanded. Source: NEP 2012, August 2012, THE EFFECTS OF THE ACCELERATED ENERGY TURNAROUND Following the Fukushima disaster, a resolution on an accelerated energy turnaround was passed in Germany in summer Significant elements include phasing out nuclear energy by late 2022, expanding the proportion of renewable energies to make up at least 35 % of gross electricity production and reducing greenhouse gas emissions by 40 %. At the same time, eight nuclear power plants (including Brunsbüttel, Unterweser and Krümmel in Northern Germany) were shut down completely. The German Federal Network Agency s report on the situation of the electricity grid in winter 2011/12 states that the situation was very tense and that the supply was only secured with significant interventions by the grid operator. The number of interventions by the grid operator that were required to maintain grid stability in both power plant schedules and in the electricity feed have increased drastically. It was impossible to cover domestic demand with domestic production facilities in some cases. Therefore, power plants (socalled cold reserves) in other European countries were involved in stabilizing the German electricity grid. In Northern Germany, the grid situation in Hamburg in particular is problematic because Brokdorf is the only power plant on the grid after the shutdown of the power plants Krümmel, Brunsbüttel and Unterweser. The coal power plant Moorburg will only be able to close the gap starting in 2014 due to construction delays. Because of the existing grid problems, it must be ensured that net capacity is expanded at the same time that production capacity is increased. According to an estimate from the German Energy Agency (dena), Germany will lack at least 3,600 additional grid kilometers as well as 1,550 kilometers of undersea cable for connections to offshore wind farms until The gap between Schwerin and Hamburg/Krümmel in the 380 kv grid is largely responsible for the lack of grid stability in Northern Germany (see Fig. 14). In winter 2011/12 Aurubis took measures to prevent large-scale damages to its facilities so that operations could be started up again after the supply had been restored. For example, Aurubis rented emergency power generators to secure the electricity supply in the case of a blackout, mainly in order to empty the furnaces so that the liquid melt does not harden in them, which would lead to irreversible damage. For winter 2012/13 the German Federal Network Agency expects a similarly critical situation in the electricity grid like in the past winter. Aurubis is therefore reviewing suitable protective measures again. 24

29 Site Reports Aurubis Group production sites and Slitting Centers Page 1 Aurubis AG, Hamburg Hamburg, headquarters (D) 26 1 Elektro-Recycling NORD GmbH Hamburg (D) 36 1 Peute Baustoff GmbH Hamburg (D) 56 2 CABLO Metall-Recycling & Handel GmbH Fehrbellin (D) 34 3 Aurubis U. K. Ltd. Smethwick / Birmingham (UK) 58 4 Aurubis Netherlands BV Zutphen (NL) 44, 58 5 Aurubis Belgium nv/sa Olen (B) 32 6 Deutsche Giessdraht GmbH Emmerich (D) 50 7 Aurubis AG, Lünen Lünen (D) 28 8 Aurubis Stolberg GmbH & Co. KG Stolberg (D) 46 8 Schwermetall Halbzeugwerk GmbH & Co. KG Stolberg (D) 52 9 RETORTE GmbH Selenium Chemicals & Metals Röthenbach (D) CABLO Metall-Recycling & Handel GmbH Nersingen, Strass (D) Aurubis Slovakia s. r. o. Dolný Kubín (SK) Aurubis Mortara SRL Mortara (I) Aurubis Bulgaria AD Pirdop (BG) Aurubis Italia Srl Avellino (I) Aurubis Sweden AB Finspång and Västerås (SE) Aurubis Finland Oy Pori (FI) Aurubis Buffalo Inc. Buffalo (US) 38

30 Aurubis AG, Hamburg located in Hamburg, Germany Hamburg, Germany» Largest site and administrative headquarters» Site size: 870,000 m2» Certification: EMAS1, ISO , ISO 50001, ISO Employees Main products at the site by Business Unit 2,200 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals Cathodes 367,000 t BU Copper Products Continuous cast wire rod 249,000 t Sulfuric acid 1,037,000 t Silver, gold and selenium 1,600 t Continuous cast shapes 179,000 t Iron silicate 676,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing dust emissions by 9 t per year A bulk goods warehouse will be built in the northern storage area. In addition, the crusher will be integrated into the warehouse concept. The objective of this measure is to reduce fugitive emissions from the northern storage area. Authorization was issued. The warehouse was completed in fall 2011, integration of the crusher in the warehouse concept in summer 2012 Feasibility study on further reducing fugitive emissions in the primary copper production sector Analyses until 2012; assessment in 2013 Constructing and operating a turbine to produce electricity from waste heat in the primary copper production sector (CO₂ reduction of 5,000 t annually) Start of construction in December 2011; to be completed in 2013 Energy efficiency and climate protection: Lowering the energy demand in precious metal recovery Pilot scheme supported by the German Federal Environment Ministry: Use of a membrane filter press that can be heated and evacuated for drying metallurgical slimes Lowering the energy demand by up to 35 %; reducing CO₂ by about 460 t annually Implementation in 2013 successfully completed in progress not achieved 1 See Glossary, p

31 Thoralf Schlutzkus (Plant Manager) Orhan Cekel (Environmental Officer) Aurubis AG, Hamburg We are committed to conserving and maintaining resources; in our integrated copper production plant in the middle of the city of Hamburg, 99 % of all input materials are converted into products at the highest environmental protection standard. The Hamburg site s detailed EMAS Environmental Statement is available on our website (in German): responsibility/environment/ The largest Aurubis AG production site and the Group headquarters is located on the Elbe island Peute, only about four kilometers as the crow flies from Hamburg s city hall. The plant was constructed in 1908 on an area of about 870,000 m2 in Peute, an industrial inland harbor area in the Veddel district. Following reconstruction after World War II, the production facilities were continuously expanded and steadily modernized. Today Aurubis AG s Hamburg site is one of the world s most state-of-the-art primary and secondary copper smelters and has an authorized production capacity of 450,000 t of copper cathodes each year. About 2,200 personnel are employed at the Hamburg site, including around 180 apprentices. The main raw materials in copper production are copper concentrates (processed copper ores) and recycling materials (including electrical and elec - tronic scrap). Pure copper results from the different raw materials following the smelting process in the tankhouse. Additionally, precious metals, nickel, lead and zinc as well as iron silicate products and sulfuric acid are obtained from in some cases very complex input materials in the scope of multi-metal recycling. Aurubis uses the properties of copper and other metals to enable recycling without a loss of quality. Dust emissions at the Hamburg site in g/t of copper output » Projects to reduce fugitive emissions currently take top priority following the focus on direct emissions in the 1990s. It is therefore crucial for Aurubis to develop innovative environmental protection technologies, breaking new technical ground in the process.»the nominal increase in dust emissions in 2011 is based on arithmetical grounds; it can be attributed to the authorities new nationwide calculation standards. Dust emissions did not actually increase. 1 The main energy sources at the Hamburg site are electricity and natural gas Specific energy consumption at the Hamburg site in MWh/t of copper output » Specific energy consumption1 has stagnated at the Hamburg site during the past few years due to the increase in the proportion of facilities producing products other than copper. This leads to higher total energy consumption but not a higher copper quantity.» In the long-term view, specific energy consumption, which is the main indicator for energy-efficient production, has decreased significantly at the Hamburg production site in the last several years by 51 % compared to AURUBIS ENVIRONMENTAL REPORT

32 Aurubis AG, Lünen located in Lünen, Germany Lünen, Germany» Largest copper recycling site worldwide» Site size: 316,000 m2» Certification: EMAS1, ISO , ISO Employees Main products at the site by Business Unit BU Primary Copper BU Recycling/Precious Metals BU Recycling/Precious Metals 550 Site employees Group total 6,300 Cathodes 211,000 t Iron silicate sand 166,000 t Other by-metal products 29,000 t (nickel sulfate, tin-lead, etc.) KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing fugitive emissions from the tin-lead furnace by more than 90 % In connection with the primary smelter s additional filter and TBRC2 filter 7, there are now plans to completely close the ridge turret. The anode smelter s suction line was extended over the entire primary smelter roof to the tin-lead furnace in mid Since the primary smelter s additional filter has had limited availability up to now, only part of it was connected over the tin-lead furnace. Emissions: Optimizing wastewater currents Developing a wastewater/process water concept based on rainwater retention The rainwater retention concept is finished and the authorization process is in progress. Separate treatment of sanitation water There is already a concept and detailed planning is underway. Energy efficiency and climate protection: Increasing energy efficiency The objective is to cover at least 10 % of the plant s electricity demand by using the KRS waste heat steam; after analyzing the individual alternatives, the plan is now to use a steam turbine to produce electricity internally. Planning has been completed; the authorization process is in progress and start-up is planned for See Glossary, p. 59 successfully completed in progress not achieved 2 Top blown rotary converter 28

33 Dr. Franz-Josef Westhoff (Plant Manager) Dr. Claus Meyer-Wulf (Head of the Environmental Protection Department, Environmental Officer) Dr. Hendrik Roth (Deputy Head of the Environmental Protection Department) Aurubis AG, Lünen The outstanding event in 2011 was the successful implementation of the KRS-Plus project, which significantly increased the capacity and range of multi-metal recycling at the Lünen site yet again. Furthermore, we were able to set new benchmarks with respect to progressive environmental protection with state-of-the-art facilities. The Lünen site s detailed EMAS Environmental Statement is available on our website (in German): responsibility/ environment/ production-sites/ luenen/ Aurubis AG s Lünen plant was commissioned in 1916 as a branch plant of Hüttenwerke Kayser. Norddeutsche Affinerie AG acquired the majority of Hüttenwerke Kayser AG shares in 2000 and the plant was expanded to become the Group s recycling center. In the meantime, the site has 550 employees, including more than 40 apprentices. Today Aurubis AG s Lünen site is the largest secondary copper smelter in the world with an annual production capacity of 210,000 t of copper cathodes. In addition to the usual recycling raw materials like copper scrap and other scrap, slimes and residues, complex materials are increasingly used in copper production, especially electrical and electronic scrap. The core facility for metallurgical processes has been the Kayser Recycling System (KRS) since 2002, which was supplemented by a so-called TBRC 1 in mid Zinc-bearing KRS oxide, iron silicate sand (slag granules), lead-tin alloy, nickel and copper sulfate as well as anode slimes are produced as by-products of multimetal recycling. Dust emissions at the Lünen site in g/t of copper output 1, » Emissions of dust and dust components (Cu, Pb, As, etc.) have decreased significantly at the Lünen site due to reduction measures during the past few years. The figures shown also in - corporate fugitive emissions, including storage and transshipment. The moderate increase in 2011 is a result of more recent recordings and a change in the evaluation process.» Only about 1 % of the total emissions of dust and dust components originate from the TBRC1. 1 Top blown rotary converter 2 See Glossary, p. 59 Specific energy consumption at the Lünen site in MWh/t of copper output » Energy is primarily used to heat the metallurgical plants (mainly heating oil) and for the tankhouse (electricity). The KRS and anode furnace waste heat boilers produce most of the steam for the leaching plant and tankhouse. There are also two extra boilers fueled with light oil or natural gas.»the energy consumption for the throughput increases in KRS2 and the anode furnaces was largely compensated for by increasing energy efficiency.» 30 % of the electricity demand at the Lünen site is required for environmental protection measures. AURUBIS ENVIRONMENTAL REPORT

34 Aurubis Bulgaria AD located in Pirdop, Bulgaria Pirdop, Bulgaria» Link to the Southeast European markets» Site size: 4,000,000 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit 800 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Cathodes 226,330 t Sulfuric acid 1,060,079 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing air emissions Investment project Aurubis Bulgaria 2014 with a capital expenditure volume of 44.2 million, 26 million of which is allocated to environmental protection measures: (1) increasing the concentrate drying plant s filter capacity; (2) extensive capture and cleaning of fugitive emissions in a filtration plant Implementation by 2014; detailed planning mostly finished New mobile vacuum cleaning system In operation since 2011 Emissions: Optimizing water conservation Renovating and expanding domestic and process water treatment Completed in 2011 Constructing an additional treatment plant for cleaning surface water Construction starts in 2013 Resource protection: Increasing the recycling rate Stronger marketing of fayalite, e. g., as an aggregate in cement production Ongoing successfully completed in progress not achieved 1 See Glossary, p

35 Nicolas Treand (Executive Director of Aurubis Bulgaria) Angel Kostov (Environmental Officer) Aurubis Bulgaria, Pirdop At the end of 2011 we opened information centers in Pirdop and Zlatitsa to provide the local community with information about our environmental protection successes in a direct dialogue. A plant having contact with its neighbors is still very rare in Bulgaria, which made people even more receptive to our efforts. This is just as important to us as the fact that we fulfill all of the environmental requirements. The site in Pirdop, Bulgaria provides Aurubis with access to the Southeast European market. The smelter has been in existence since 1958 and has meanwhile been expanded into a state-of-the-art plant. Nearly 800 employees produce anodes, cathodes and sulfuric acid. The entire plant has been audited and certified in accordance with the ISO standard since March In 2012 the certificate was once again renewed by LRQA1 and is valid until March Significant progress has been made in the environmental sector in recent years at the Pirdop site. The production processes have become more efficient, and modern off-gas cleaning and wastewater treatment facilities have been installed. These efforts have reduced the plant s specific energy consumption and emissions to air and water. Aurubis Bulgaria s highest priority is continuous production process optimization in order to reduce environmental impact. In December 2011 Aurubis Bulgaria opened two information centers in the neighboring cities of Pirdop and Zlatitsa to promote dialogue with local citizens. The project serves to implement the company s communication and social principles.2 1 Lloyd s Register Quality Assurance 2 The information centers are open daily to answer people s questions and strengthen communication with them, for example with event programs. Find more information on our website: bulgaria/responsibility/ information-centers/ 3 IPPC stands for Integrated Pollution Prevention and Control. The target of the EU directive: to pursue a high level of environmental protection (air, water, soil) using the best available technologies. Sulfur dioxide emissions at the Pirdop site in kg/t of copper output Dust emissions at the Pirdop site in kg/t of copper output 8, »The low level of air pollution in the Pirdop plant area today is a result of the continuous development of the production processes and the permanent operation of the gas cleaning system. The secondary off-gases sulfur dioxide values (all captured emissions) are well below the limits established in the EU s IPCC directive.3» Specific emissions of SO₂, dust and the metals contained in it have been reduced by 95 % since The 2011 results confirm that the values are still low and comply with the established standards. AURUBIS ENVIRONMENTAL REPORT

36 Aurubis Belgium nv/sa located in Olen, Belgium Olen, Belgium» Central location for the West European markets» Site size: 328,218 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit BU Primary Copper BU Recycling/Precious Metals BU Copper Products 470 Group total 6,300 Cathodes 347,000 t Rod 235,000 t Specialty rod 21,000 t Bars & Profiles 5,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing air emissions Improving the capture of the Contimelt facility s fugitive emissions (the off-gas systems were already optimized in 2010) Partially implemented, completion in late 2013 Energy efficiency and climate protection: Reducing CO₂ emissions Constructing a heat recovery system for the Conform1 facility System currently being installed, completed at the end of 2012 Controlling the volume flow of the wastewater treatment plant s feed pumps Emissions: Improving water conservation The rinse water treatment in the Contirod facility was switched from lime to sodium hydroxide as a neutralizing agent. Successfully implemented in 2011 Emissions: Reducing noise emissions Constructing a noise barrier along the main public road Construction started in late 2011; successfully completed in April 2012 successfully completed in progress not achieved 1 See Glossary, p

37 Jo Rogiers (Plant Manager) Filip Lecomte (Environmental Officer) Aurubis Belgium, Olen In the past few years, Aurubis Belgium has intensively worked to reduce emissions to air and water. In addition to these important factors, we also addressed other environmental areas. For example, a noise barrier was built to reduce the impacts of noise on the surrounding neighborhood. Additional measures to reduce fugitive emissions will follow. Aurubis Belgium in Olen is the gateway to the West European market. About 470 personnel are employed at Aurubis Belgium, some of whom do administrative work in Brussels. In 2011 the Olen plant produced 186,000 t of anodes, 347,000 t of cathodes, 235,000 t of rod and 21,000 t of specialty rod. There are plans to install three wind turbines in Olen; a joint project involving Electrabel (an electricity producer) in cooperation with Umicore and Aurubis started in At the moment (summer 2012), the application files for the building and environmental permits are being made up. In 2009 an environmental permit valid for 20 years was issued for all activities at the Olen site. Aurubis views this as an incentive to continue improving environmental protection in the future. Since June 2011 two automatic measuring devices in the plant s entryway have inspected delivered scrap for radioactivity. In spring 2012 the noise barrier was completed, which shields the nearby residential areas from noise emissions from the scrap yard. Metal emissions in water at the Olen site in g/t of copper output »The ongoing optimization of wastewater treatment and a new chemical reactor have considerably reduced the metal emissions in surface water in the past few years.» s to lower the influence of wastewater on the Olens Broek natural reserve are being discussed with local authorities. Direct CO₂ emissions at the Olen site in t CO₂/t of copper output » Natural gas, electricity and steam are the most important energy sources for the processes.» Many projects, including projects that extend beyond the plant, are dedicated to energy efficiency and CO₂ reduction. For example, a new combined heat and power plant was built in cooperation with Umicore and started up in June AURUBIS ENVIRONMENTAL REPORT

38 CABLO Metall-Recycling & Handel GmbH located in Fehrbellin and Strass, Germany Fehrbellin, Germany Strass, Germany» Specialist in cable recycling» Site size: about 47,500 m2 (Fehrbellin: 32,500 m2, Strass: 15,000 m2)» Certification: ISO , ISO 50001, ISO Employees Main products at the site by Business Unit 582 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Copper products 13,000 t Plastic products 6,000 t Aluminum products 1,100 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Modernizing water pollution control facilities After restoring the wastewater network at the Fehrbellin site (2011), a similar overhaul is planned at the Strass site. Concept developed; details are being planned Emissions: Reducing fugitive dust emissions at the Fehrbellin site Building an additional warehouse for dry storage of PVC-bearing plastic mill feed; this will avoid fugitive dust emissions during transshipment despite higher external delivery volumes. Under construction Completion was put off due to delays in the authorization procedure; September 2012 Optimizing environmental protection processes Introducing an environmental management system in accordance with ISO at both CABLO sites System introduced and certified Introducing an energy management system in accordance with ISO at both CABLO sites System introduced and certified Energy efficiency and climate protection: Optimizing environmental protection procedures Electronically recording the dismantling facilities energy consumption Electronically recording the trucks fuel consumption; data analysis to minimize fuel consumption Fehrbellin: Currently being implemented Strass: In the planning stage Recording devices commissioned successfully completed in progress not achieved 1 See Glossary, p Fehrbellin, 16 Strass 34

39 Dr. Michael Liesegang (Managing Director) Arne Senftleben (Management Representative) CABLO Metall-Recycling & Handel GmbH, Fehrbellin Some welcome changes have taken place here during the last year: we successfully started the environmental and energy management systems and have had the external audit certificates since July. We have come significantly closer to our target of increasing energy efficiency and environmental performance. An automated device for recording the energy consumption of the cable dismantling facilities will be set up this year since these facilities are our biggest electricity consumers. We re already looking forward to reporting additional successes next year. CABLO Metall-Recycling und Handel GmbH (CABLO) is a 100 % Aurubis Group subsidiary specializing in metal-plastic separation. Cable product waste and used cable scrap in particular are recycled at the two sites in Fehrbellin and Strass. CABLO closes material cycles with its services by supplying the cable industry with raw materials recovered in the Group in a usable form such as copper cathodes, copper wire rod and conductive aluminum. CABLO produces limited emissions due to the mechanical work processes. The focus of the environmental work is therefore reducing specific energy consumption while simultaneously increasing material recovery rates. The existing quality management system in accordance with ISO 9001 was thus expanded to an integrated system. In 2012 an environmental and energy management system in accordance with ISO and ISO 50001, respectively, was implemented and successfully certified. There are still plans to set up data recording systems in the energy sector in Dust emissions at the Fehrbellin and Strass sites in g/t of metal output » In dismantling facilities, the cable insulation is separated from the metal core with cutting and grinding processes. The facilities exhaust air is completely suctioned off and filtered before being discharged into the ambient air.»the strong decrease in emissions, especially in 2010, is due to new recordings2 which prove the success of the emission reduction measures carried out in the past several years. Plastic waste recycling 1 In contrast to past reporting, the emissions are related to product quantities instead of input quantities. 2 The values for the previous years were calculated based on earlier recordings. at the Fehrbellin and Strass sites in t 1,976 1,907 3,641 5,228 5,950 1,840 1,750 2,249 3,091 3, ,392 2,137 2, PVC-bearing plastic waste from internal cable dismantling PVC-bearing plastic waste from other companies» In the internal recycling process, PVC-bearing mill feed is processed into standardized products for the transport sector, for example base plates for delineator posts. In addition to internal mill feed, residues from other companies are also recycled.» After dismantling the cable, non-pvc-bearing plastic and residual waste are directed to an external recycling or disposal company. The recycling rate was over 99 % in AURUBIS ENVIRONMENTAL REPORT

40 Elektro-Recycling NORD GmbH located in Hamburg, Germany Hamburg, Germany» Specialist in recycling electrical and electronic devices» Site size: 6,417 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit 13 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Electrical and electronic scrap 17,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Resource efficiency: Reducing residual waste and improving options for further utilization Modifying the separation technology: Achieving a higher sorting quality by sorting with state-of-the-art separating equipment (optic, sensory) Discharging the plastic parts and cleaning the aluminum parts, concentrating the non-ferrous metal fraction Reducing energy consumption by modernizing operations Normal operations started up in Emissions: Protecting employees from hazardous materials Voluntary hazardous substance recordings on the entire plant property, taking the Technical Rules for Hazardous Substances into account Carried out in 2012 Recording the separation plant s emissions after the renovation (BlmSchG, German immission control law ) Carried out in 2012 Emissions: Reducing fugitive dust emissions Building stone partition walls in all outside storage areas First part completed in 2011, second step in 2012 successfully completed in progress not achieved 1 See Glossary, p

41 Oliver Carstens (Managing Director) Norbert Barth (Environmental Officer) E. R. N., Hamburg We take electrical and electronic scrap and make raw materials that are returned to the material cycle. This contributes to environmental protection and resource conservation, just like the measures in our environmental program. Since being certified in accordance with DIN EN ISO in 2004, we have compiled a new catalogue of measures each year. The improvements must make sense from both an ecological and an economic perspective. Elektro-Recycling NORD (E. R. N.) is a 100 % Aurubis subsidiary that specializes in recycling all kinds of electrical and electronic devices. The extensive serviceoriented solutions for waste issues guarantee conformity with the provisions of waste and recycling management law. The company s customers include large international firms, small enterprises and private individuals. E. R. N. is a member of the Quality Association for Electronic Scrap in the Federation of German Metal Traders and follows the principles of comprehensive resource recycling. E. R. N. makes raw materials out of scrap, returning the valuable substances to the material cycle in an environmentally friendly manner. E. R. N. s service catalogue consists of disassembling, recycling and disposing of all kinds of electrical and electronic devices as well as industrial products. Picking up individual devices and components and dismantling installations are also included in the services. Recycling at E. R. N. at the Hamburg site Input Processing Output Plastic fraction Used electrical devices E. R. N. Internal material recycling Iron (Fe) Aluminum (Al) Precious metal-bearing circuit boards AURUBIS ENVIRONMENTAL REPORT

42 Aurubis Buffalo Inc. located in Buffalo, USA B u ff a l o,usa» Producer of flat rolled products made of copper and brass for over 100 years» Site size: 290,000 m2» Certification : TS Employees Main products at the site by Business Unit 630 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Copper and brass flat rolled products 99,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Resource conservation: Reducing sulfuric acid consumption by recovering it Installing facilities to clean used sulfuric acid Two facilities have been installed and three more are planned. Resource conservation: Reducing water consumption Analyzing water consumption in all of the plants The analysis is currently being carried out; on top of this, technical solutions for optimization are being reviewed. Waste and recycling: Implementing a recycling program at the site Establishing a collection area for separating and recycling batteries, computers, monitors and light bulbs An estimated 90 % of these materials are now collected and recycled thanks to the collection area. successfully completed in progress not achieved 1 See Glossary, p

43 Ray Mercer (Managing Director) Paul Bodekor (Environmental Officer) Aurubis Buffalo Inc., Buffalo In Buffalo we have always proactively ensured that our activities are in strict conformity with all regional regulations and national laws. More importantly, one of our basic values is to do the right thing for our employees, our neighborhood and the environment. This is especially important to us. Aurubis Buffalo, located in the state of New York, is about a half-hour away from Niagara Falls by car. Copper products have been fabricated here since A total of about 100,000 t of rolled copper and brass products were produced here in The completely integrated plant with 630 employees includes a copper and brass foundry, a hot rolling and cold rolling mill, an annealing furnace and a longitudinal slitting machine to produce strips with a variety of copper alloys, for example for connectors, telecommunications and electrical applications. In 2003 the plant became the first rolling mill for copper alloys in North America to earn TS certification, a quality management certificate based on ISO The investment program to modernize the plant is continually updated. At the moment, the authorities are reviewing the renewal of the emission license, which was expected in summer All of the foundry s off-gases are cleaned with filters before entering the atmosphere. The filter dust that accumulates in the process is recycled due to its zinc content. The acid cleaning plants off-gases are directed to a wet cleaning system to remove the sulfuric acid. The acidic wastewater that results is neutralized in the wastewater treatment plant. Schematic production process at the Buffalo site Casting Hot rolling Milling Cold rolling Inter. GA Rolling Annealing Slitting Tinning Customer AURUBIS ENVIRONMENTAL REPORT

44 Aurubis Finland Oy located in Pori, Finland Pori, Finland» Producer of copper strips, sheets and plates» Site size: 78,070 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit 200 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Copper billets 25,578 t Copper strips, sheets and plates 22,936 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Optimizing off-gas cleaning in the shaft furnace Emission recordings for the shaft furnace s different modes of operation Developing an implementation concept to optimize off-gas cleaning Recordings completed in late 2012; concept to be finished by September 2013 Energy efficiency and climate protection: Reducing energy consumption in the foundry Developing a new cover for the casting launder to lower heat losses, thus being able to reduce the number of burners. Integrating the temperature control in the process control system, cutting energy consumption during casting by more than half. Cover has been installed on the casting launder. To be completed in late 2012 following tests and optimization. Emissions: Improved soil protection in the unroofed storage areas Cleaning, installing a wall and sealing the non-roofed storage area in the scrap storage yard to prevent rainwater in unsealed areas Completion in 2012 successfully completed in progress not achieved 1 See Glossary, p

45 Minna Eerola (Environmental Officer) Hannu Heiskanen (Plant Manager) Aurubis Finland Oy, Pori At Aurubis Finland Oy, we see ourselves as part of society and assume the environmental responsibility that comes along with this role. Our central concern is continuously finding new ways to lower energy and resource consumption and emissions. For example, we considerably reduced the dust emissions at our site; the challenge now is to maintain this success and continue improving it. Our current capital expenditure for environmental protection aims to reduce energy consumption and copper emissions. We have successfully optimized our waste management system in the meantime, which has reached the excellent recycling rate of almost 100 %. The Aurubis Finland production site is located in Western Finland in Pori on the Kokemäenjoki River. The copper foundry and rolling mill are in a copper industrial park on an area of 100,000 m2, where other companies such as Luvata, Boliden, Outotec and Cupori are also located. The first industrial buildings emerged here in The Pori plant was part of Outokumpu until 2005, when the company sold its copper business to Nordic Capital. The rolling mill in Pori is a state-of-the-art warm and cold rolling mill. The high-quality copper products include copper plates, sheets, strips and circles. The selection covers a wide range of copper and copper alloys. In 2011 about 200 employees produced around 22,936 t of strips, sheets and plates as well as 25,578 t of copper cakes. Copper scrap is used first and foremost for production. The waste heat that arises in the foundry is sold to the local power plant Porin Energia. The waste heat produced during the hot rolling process is reused to preheat combustion air during processing. Emissions of dust and volatile organic compounds (VOCs) are reduced to a minimum using afterburning andfilters. The wastewater that results from the melting process circulates internally, while the rolling line s wastewater is treated. Dust emissions at the Pori site in g/t of copper products sold »The dust emissions vary but remain at the low level of previous years. Production waste: Recycling and disposal at the Pori site in t Recycling 1,737 1,811 1,880 1,727 1,857 Disposal 1,671 1,742 1,847 1,690 1, » Production waste is almost completely recycled the recycling rate was 98 % in AURUBIS ENVIRONMENTAL REPORT

46 Aurubis Italia Srl located in Avellino, Italy Avellino, Italy» The only copper rod producer in Southern Italy» Site size: 58,000 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit 107 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Continuous cast wire rod 156,251 t Wire 2,883 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Optimizing environmental protection processes Establishing a system to record environmental data Optimization in 2011 Emissions: Optimizations in water conservation Installing a continuous water sampling process prior to releasing water into the sewer system Set-up in 2011 Emissions: Protecting scrap from radioactive radiation Purchasing measuring equipment for radioactivity Portable Geiger counters acquired; special training for employees carried out in April 2012 Emissions: Optimizing the water treatment plant Increasing the water treatment plant s capacity The improvements in the water treatment plant were scheduled for September Emissions: Reducing fugitive emissions Reducing fugitive emissions from the rolling mill Study on the most significant fugitive emission sources has started after reducing the use of alcohol in the emulsion: routine recordings and tests currently being carried out successfully completed in progress not achieved 1 See Glossary, p

47 Antonio de Blasio (Plant Manager) Gianpaolo Antonacci (Environmental Officer) Aurubis Italia, Avellino In Avellino we are always looking for new possibilities to optimize environmental protection. Our system for recording environmental data allows us to see our environmental protection successes directly: our emissions have decreased significantly in the last few years. However, we are especially proud of the fact that we process almost 100 % of the input materials into products. Furthermore, we use a great deal of the waste heat that arises during the production processes, which helps us save even more energy. Aurubis Italia is located in Avellino and is the only copper rod producer in Southern Italy. 107 employees produce 156,251 t of rod and 2,883 t of wire for special applications. Thanks to the high effectiveness of Aurubis Italia s production processes, nearly 100 % of the raw materials used can be processed into products. Modern cleaning and filter facilities keep off-gas and wastewater to a minimum. Since 2011 the wastewater has been subject to continuous monitoring before entering the sewer system. Most of the waste heat generated during operations is harnessed by stateof-the-art facilities. Volatile organic compounds (VOCs) from the rolling mill are collected and treated. A system for recording environmental data was implemented in The fugitive emissions in the foundry were considerably lowered. Routine recordings indicate that emissions have decreased and the ambient air quality has improved. Portable Geiger counters measure radioactivity and ensure a high level of safety for employees. Dust emissions at the Avellino site in g/t of rod output »The two main off-gas cleaning systems in Avellino are (1) a filter for cleaning the off-gases that arise during the melting process and (2) a facility that collects and treats volatile organic compounds (VOCs) that are generated in the rolling train when surface-treating wire. Disposal and recycling of production waste at the Avellino site in t Recycling Disposal »The waste produced during the processes is largely recycled. The recycling rate rose again to over 90 %. AURUBIS ENVIRONMENTAL REPORT

48 Aurubis Netherlands BV located in Zutphen, Netherlands Zutphen, Netherlands» Brass strip producer» Slitting Center and sales in the Netherlands» Site size: 100,000 m2» Certification: ISO , ISO Employees Main products at the site by Business Unit 150 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Brass strips 23,939 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing metal contents in wastewater Optimizing wastewater treatment Implementation 2011, optimization 2012 Resource protection: Reducing water consumption Reusing water from the vaporizer that treats the tinning plant s wastewater Implementation 2011, optimization 2012 Energy efficiency and climate protection: Increasing energy efficiency Analyzing the possibility of increasing efficiency in compressor operations Study started in 2011, to be completed in early 2014 Using waste heat from the annealing furnace by installing a heat exchanger Implementation by late 2012 successfully completed in progress not achieved 1 See Glossary, p

49 Raymond te Riele (Environmental Officer) Theo Mimpen (Plant Manager) Aurubis Netherlands BV, Zutphen In Zutphen we produce brass strips for the entire world with a unique continuous casting technology. Our strip production process is incredibly efficient. Protecting the environment and resources is a matter of course for us, as is the annual review of the related measures. An important environmental project began in 2011 with the wastewater treatment optimization, which is already showing considerable success. Aurubis Netherlands BV in Zutphen produces brass strips for the entire globe, mainly for the automotive and connector industry. In 2011 about 150 employees produced 23,939 t of brass strip. Copper scrap is the main raw material used, supplemented by copper cathodes and zinc. Aurubis Netherlands BV began optimizing and improving the wastewater treatment plant in This led to a notable decrease in heavy metal contents in wastewater. The plant is located in an industrial area with an established noise limit. According to an official recording from 2011, the noise level does not exceed the standard of 50 db (A) per day. An official recording of NO X and SO₂ values at the end of 2011 indicated that Aurubis Netherlands BV completely fulfills the guidelines. Water use at the Zutphen site in 1,000 m »The water demand is covered by groundwater to a large extent (245,000 m3 in 2011), which is primarily used for cooling.» Potable water is used first and foremost for the processes (30,000 m3). Production waste: Recycling and disposal at the Zutphen site in t Recycling 2,217 1,779 1,138 1,892 2,167 Disposal 2,112 1,666 1,067 1,845 2, » Production waste is almost completely recycled the recycling rate was 99 % in AURUBIS ENVIRONMENTAL REPORT

50 Aurubis Stolberg GmbH & Co. KG located in Stolberg, Germany Stolberg, Germany» Supplier of strips, foils and shaped wires for various applications» Site size: 40,300 m2» Certification: ISO , TS Employees Main products at the site by Business Unit 396 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Shaped wires, strips 60,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Optimizing water pollution control Restoring the plant s sewer network Restoration of the plant s sewer network continued. Three additional parts were overhauled during the reporting period, leaving only one part left before completion. All measures will be completed by Energy efficiency and climate protection: Reducing energy consumption Establishing an energy management system in accordance with ISO First-time certification in June 2012 Adequately controlling the hall suction system in the foundry Commissioned in spring 2012 Modernizing the plant s internal cooling circuit with the newest energy-efficient technology Detailed planning is finished, implementation started summer 2012, to be completed by the end of 2013 Resource efficiency: Reducing rolling oil losses Installing more efficient oil stripping equipment on the cold rolling mill to reduce rolling oil losses and oily waste Delay due to delivery bottlenecks, implementation now planned for the end of 2013 successfully completed in progress not achieved 1 See Glossary, p

51 Martin Maiwald (Environmental Officer) Dr. Jürgen Jestrabek (Managing Director) Aurubis Stolberg, Stolberg Only when companies independently push environmental protection forward can real progress be achieved. We promote awareness for using resources efficiently and are excited about every innovative idea here. That extends from large-scale energy-saving product developments carried out together with customers to internal measures to reduce rolling oil losses, for example. We work with our employees to identify and implement potential that hasn t been utilized yet. Aurubis Stolberg has been part of the Aurubis Group since 2002; the company was called Prymetall until The site supplies high-precision strips, foils and shaped wires for many different applications. Its customers include companies in the electrical engineering, electronics, automotive, construction, telecommunications and mechanical engineering industries. In the foundry, rolling mill and pressing and drawing mill, about 400 employees fabricate up to 60,000 t of products made of copper, copper alloys and scrap for the global market each year. The process technology for the foundry furnaces exhaust air cleaning system uses state-of-the-art technology and operates according to the principle of hose, textile and cassette filtration. The mass concentration of dust recorded at the chimney outlet is < 0.1 mg/m³, which is well below the total dust limit prescribed in the TA Luft regulations. Since the value is even below the detection limit, this warm air can also be used to heat the halls in the raw material warehouse and foundry area an example of efficient energy use. The metal-bearing waste from wire and strip production, which contains copper, brass and/or bronze, for example, is completely recycled at the Stolberg site which is especially important in a country like Germany, which lacks raw materials. Other waste such as used rolling emulsion or filter material is disposed of appropriately by an external service provider. Production process in the rolling mill at the Stolberg site Pre-rolling Annealing & pickling Rolling Longitudinal strips Packaging Production process in the wire drawing mill at the Stolberg site Casting Pressing Pickling Annealing Drawing Packaging AURUBIS ENVIRONMENTAL REPORT

52 Aurubis Sweden AB located in Finspång and Västerås, Sweden Finspång, Sweden Västerås, Sweden» Producer of copper strips» Site size: 40,000 m2» Certification: ISO , TS Employees Main products at the site by Business Unit BU Primary Copper BU Recycling/Precious Metals BU Copper Products Group total 6,300 Copper strips 24,900 t Finspång 200 Västerås 35 Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Energy efficiency and climate protection: Increasing energy efficiency in the casting plant Implementing a new furnace lining method with improved physical properties in the casting plant Completed in 2011 New burner with lower energy consumption in the casting plant Completed in 2011 Energy efficiency and climate protection: Increasing energy efficiency in the annealing furnace Renovating an annealing furnace to increase efficiency and lower propane consumption Preparations currently underway; to be completed in February 2013 Waste and recycling: Reducing rolling oil consumption Testing new seals in the rolling mill to prevent hydraulic oil from infiltrating the emulsion The first tests started in 2011 and will continue in successfully completed in progress not achieved 1 See Glossary, p

53 Patrik Sivesson (Managing Director) Malin Ribbenhed (Environmental and Quality Officer) Aurubis Sweden AB Constantly improving environmental protection at the site is a natural part of our daily work. We re working on making the complete production chain more efficient including with respect to energy consumption and resource efficiency. That improves our result not only from an economic perspective, but it is also better for the environment. The basis of our work is our environmental management system, which has been in operation since 2000 and is certified in accordance with ISO Aurubis Sweden AB operates a production plant in Finspång and an office in Västerås. The area in Finspång has been used for copper production since Thin copper sheets for engine cooling, heat exchangers and electrical appliances are produced here. The production processes include melting, casting, rolling, annealing and slitting copper strips. An internal strip casting technology was developed in which cold rolling immediately follows casting, making this production method particularly energy-efficient. The environment and quality take priority at Aurubis Sweden. The production processes have been certified in accordance with the environmental management system ISO since An external audit in 2011 confirmed that the site complied with all of the requirements of environmental law. Production is quality-certified in accordance with TS This standard was developed by leading automotive engineers and was originally intended for component fabricators in vehicle manufacture. Aurubis Sweden AB works continuously on optimization processes for wastewater and off-gas treatment, chemical storage and energy efficiency. In the next two years, production will be moved from Finspång to other Aurubis Group sites. Production will continue at full volume in Finspång until summer 2013 and then be relocated gradually. Supporting measures have already been initiated for the employees and are still being carried out. The Technical Center in Finspång will remain. Amount of recycling material in total material input at the Finspång site in % » Finspång began using recycling materials to produce copper strips in This has expanded since then. Copper scrap meanwhile makes up more than one-fourth of the input materials. Production waste: Recycling and disposal at the Finspång site in t Recycling 1,677 1,776 1,310 1,578 1,378 Disposal 1,594 1,675 1,274 1,540 1, » Production waste is almost completely recycled the recycling rate was 97 % in AURUBIS ENVIRONMENTAL REPORT

54 Deutsche Giessdraht GmbH located in Emmerich on the Rhine, Germany Emmerich, Germany» Specialist in producing continuous cast wire rod for special applications» Site size: 32,000 m2» Certification: ISO , ISO 50001, ISO Employees Main products at the site by Business Unit 1152 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Continuous cast wire rod 300,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Energy efficiency and climate protection: Reducing specific electricity consumption Reducing electricity consumption by redesigning the emulsion plant The emulsion plant was renovated in August The number of pumps needed was significantly reduced by changing the filtration technology, therefore further decreasing electricity consumption (see Fig. Specific electricity consumption, p. 51). Emissions: Minimizing fire hazards Switching to a carbon-free additive in the dust removal facility, reducing the fire hazard in the filter The new additive has been used since early 2011 Emissions/energy efficiency and climate protection: Cathode transport by rail Relocating transport services from roads to railways More cathode transports between Lünen and Emmerich have been moved to the railways since early 2011, reducing CO₂ emissions, noise and road traffic 1 See Glossary, p. 59 successfully completed in progress not achieved 2 Number of employees: 60 % Aurubis 50

55 Dr. Stefan Schneider (Managing Director) Richard Hoch (Environmental Officer) Deutsche Giessdraht, Emmerich Environmental protection and energy efficiency go hand in hand. Reducing specific energy consumption has therefore been one of our most important targets in production for many years. Because of this, we are an international leader in energy efficiency among rod plants. This year we commissioned the energy management system in accordance with ISO 50001, which allows us to better analyze our processes and push systematic improvements forward. We will thus continue to completely fulfill our ecological and economic responsibility. Deutsche Giessdraht GmbH is a 60 % Aurubis subsidiary that produces high-quality continuous cast copper wire rod. The company, which was founded in 1975, is in Emmerich on the Rhine with optimal connections to shipping and the roadway and railway network. The company s 115 employees produce up to 300,000 t of rod annually. The production process consists of melting, casting, rolling, pickling and coiling the copper. The rod production facilities are state-of-the-art from a technical standpoint and fulfill all product quality and environmental protection standards. Specific energy consumption primarily natural gas and electricity are used has been reduced little by little in the last several years thanks to continuous improvements in the production process. About 1,200 t of waste are generated each year during production. Two-thirds of this amount is copper-bearing materials that are recycled at Aurubis AG s Lünen site. Deutsche Giessdraht GmbH s waste management is so efficient that more than 99 % of the waste is recycled. The certification of the environmental management system in accordance with ISO was confirmed again in April Water consumption at the Emmerich site in m3/t of rod output » Water is mainly used for cooling purposes.» Cooling water withdrawal from the industrial harbor in Emmerich is constantly adjusted to current consumption. Specific water consumption fell by 20 % due to the start-up of pumps with a variable rotational speed in Specific electricity consumption at the Emmerich site in kwh/t of rod output » Electricity is primarily used in the rolling mill but also in the drives for pumps, compressors, fans, etc. Extensive component modernization and the strict use of energy-efficient drive systems have led to a decrease in specific electricity consumption from 67 to 62 kwh/t of rod output since AURUBIS ENVIRONMENTAL REPORT

56 Schwermetall Halbzeugwerk GmbH & Co. KG located in Stolberg, Germany Stolberg, Germany» Specialist in prefabricating strips» Site size: 231,500 m2» Certification: EMAS1, ISO , ISO Employees Main products at the site by Business Unit 2602 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Pre-rolled strip 194,900 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Energy efficiency and climate protection: Reducing electricity consumption and the corresponding emissions Renovating and installing a suitable suction system on a filter and the milling machine Delay in implementation, now planned for the end of 2012 Energy efficiency and climate protection: Increasing energy efficiency Constructing and starting up a new bell-type annealing furnace to replace an old plant Successfully implemented in early 2011 Emissions: Reducing fugitive emissions Constructing a hall for shipping dross Construction will start as soon as authorization is issued and should be completed in mid-2013 Emissions: Reducing emissions to air Improving the emissions situation in the shaft furnace by building a new filter To be completed in fall 2012 successfully completed in progress not achieved 1 See Glossary, p Number of employees: 50 % Aurubis 52

57 Dirk Harten (Managing Director) Georg Janssen (Environmental Officer) Schwermetall Halbzeugwerk, Stolberg Since the company was founded in 1972, protecting the environment and resources has been an integral part of our daily work at Schwermetall. We are a leading hot rolling mill in Europe that introduced an environmental management system in accordance with EMAS in 1995, one of the first European companies to do so. It has been certified in accordance with the standard ISO since Clear success factors that enable our high level of environmental protection: investments in modern technologies and our well trained and motivated employees. The 50 % Aurubis subsidiary Schwermetall Halbzeugwerk produces pre-rolled strip made of copper-based alloys. Virgin metals and scrap are melted in the foundry and cast into cakes, which are processed into pre-rolled strip in the rolling mill. The site has five filter facilities and two wastewater treatment plants. management system is regularly reviewed by an external expert. The company s main environmental issues include saving energy and re ducing fugitive dust emissions. Environmental protection has been an important element of corporate policy since the company was founded in 1972 because the plant is surrounded by nature preserves. In 1995 Schwermetall Halbzeugwerk was one of the first companies in Europe to introduce an environmental management system in accordance with EMAS, which has also been certified in accordance with the international standard ISO since Comprehensive information on environmental protection can be found in the annually updated Environmental Statement.1 The environmental Process chain for pre-rolled strip made of copper materials at Schwermetall Halbzeugwerk in Stolberg Melting & casting Inspection & milling Heating & hot rolling Cold rolling Annealing Pickling & inspection Inspection & slitting Customer Production waste: Recycling and disposal 1 The Environmental Statement can be sent upon request. at Schwermetall Halbzeugwerk in Stolberg in t Recycling Disposal 5,310 4,769 3,110 4,791 5,516 4,944 4,341 3,069 4,759 5, » About 70 % of the waste generated is made up of metalbearing materials whose valuable contents are recovered in recycling processes. The recycling rate among all production waste rose to over 99 % in 2011.»The amount of waste is mainly proportional to production. In addition, changes in the product mix have led to more metal-bearing residues with higher value added. AURUBIS ENVIRONMENTAL REPORT

58 RETORTE GmbH Selenium Chemicals & Metals located in Röthenbach, Germany Röthenbach, Germany» Produces selenium products1 for the glass, solar and animal feed industries» Site size: 13,000 m2» Certification: ISO Employees Main products at the site by Business Unit 40 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Mineral premixtures 1,800 t Selenium products 750 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Energy efficiency and climate protection: Reducing specific energy consumption Renovating and expanding the selenium reduction plant as well as overhauling the exhaust air system and connecting the area s heating system to the central heat supply Finished in 2011 Resource efficiency: Using raw materials more effectively Improving selenium recovery in the wastewater collection equipment Planning phase; implementation by the end of 2013 Energy efficiency and climate protection: Saving energy and better air pollution control Adding a heat recovery unit to the new air inlet and outlet facility Brainstorming phase until the end of 2012 Emissions: Saving water Developing a concept for using process water multiple times Brainstorming phase, implementation by the end of 2013 successfully completed in progress not achieved 1 See Glossary, p

59 Bernd Treiber (Managing Director) Robert Jahn (Environmental Officer) RETORTE, Röthenbach Even good things can always be improved. We have achieved a lot in the past several years, but that s no reason for us to let up in our efforts to protect the environment and conserve resources in our production. We ll be focusing on water in particular in the near future. We want to decrease specific water consumption and continue improving the wastewater quality. That s no easy task, but with the help of innovative processes, we think there are good opportunities to achieve this goal. RETORTE GmbH specializes in producing pure selenium, selenium chemicals and selenium alloys. We supply various industrial sectors with these products, from glass and solar cell production to animal feed and pharmaceutical applications. At our site about 10 km east of Nuremberg near the city of Röthenbach and the Pegnitz River, we have special responsibility when it comes to keeping air, water and soil clean. With a variety of measures we ensure that our industrial operations do not have any negative impacts on our surroundings. We constantly look for and exploit potential to conserve resources. Apart from the classic environmental aspects of air, water, energy and waste, parameters such as CO₂ equivalents, land use and resource renewability are increasingly becoming the center of attention. Production at RETORTE at the Röthenbach site Raw material input On-site processing Products Customer markets Standard selenium Batteries, glass production Pure selenium Solar and electro-optical applications Raw selenium RETORTE Sodium selenite Feed and pharmaceuticals Glass production Zinc selenite Glass production Selenium dioxide Electroplating AURUBIS ENVIRONMENTAL REPORT

60 Peute Baustoff GmbH located in Hamburg, Germany Hamburg, Germany» German market leader in the iron silicate products sector» Site size: 68,000 m2» Iron silicate products are registered with REACH for all intended applications» Certification: ISO for iron silicate granules for blasting abrasive production Employees Main products at the site by Business Unit 12 Group total 6,300 BU Primary Copper BU Recycling/Precious Metals BU Copper Products Iron silicate stone 450,000 t Iron silicate granules 270,000 t Site employees KEY ENVIRONMENTAL TARGETS AND MEASURES Emissions: Reducing emissions to air Enlarging the dust removal facility; optimizing the suction points Concept drawn up in 2011 Emissions: Reducing dust emissions Optimizing surface drainage Concept drawn up by the end of 2012; implementation during fiscal year 2013/14 Optimizing the existing overhead sprinkler system Concept to be drawn up and implemented in fiscal year 2012/13 successfully completed in progress not achieved 1 See Glossary, p

61 Thomas Zantz (Works Manager) Manfred Hamann (Managing Director) Peute Baustoff GmbH, Hamburg We have produced iron silicate products for 20 years. We want our production processes to save even more energy in the future and make an important contribution to resource conservation. But that s not all that we ve undertaken in environmental protection. Our objective is to improve our performance in dust emissions and water pollution control. 1 Federal Immission Protection Law: law to protect against harmful environmental impacts due to air impurities, noise, vibrations and similar factors. Peute Baustoff GmbH (PBG) is a 100 % Aurubis AG subsidiary that emerged from the construction materials department in It is responsible for marketing the iron silicate products produced at Aurubis AG in Hamburg. These are recovered in the course of copper production in two forms with consistent material properties in accordance with the DIN 4301 standard: as crystalline iron silicate stone and amorphous iron silicate granulates. After processing it in a crushing/screening plant, iron silicate stone is used in different grain sizes and weight classes in hydraulic engineering, road construction and as a stone additive in concrete. Iron silicate granules are used as a blasting abrasive in cement production under the brand name NAstra. The iron silicate products fulfill the requirements of the relevant national and international regulations for the different applications, e. g., EN ISO norms or technical delivery conditions. PBG s operations are authorized in accordance with BImSchG1 and are subject to monitoring accordingly. The use of dust removal and overhead sprinkler facilities as well as sweepers to reduce dust ensures that applicable environmental provisions are observed. Product lifecycle of iron silicate stone: from formation to use as hydraulic construction stone Molten iron silicate Flash smelter Slag cleaning furnace Cooling process (3 days) Truck transport Forklift transport stockpiling Crusher Screening station Sifting 7 fractions Transport with truck or ship Construction site Bank reinforcement AURUBIS ENVIRONMENTAL REPORT

62 Slitting Centers Aurubis U. K. Ltd., United Kingdom Aurubis Mortara SRL, Italy Aurubis Netherlands BV, Netherlands Aurubis Slovakia s. r. o., Slovakia Smethwick, United Kingdom 2 Zutphen, Netherlands 3 Dolný Kubín, Slovakia 4 Mortara, Italy Main products at the sites by Business Unit Employees BU Copper Products Aurubis U. K. Ltd. Strips made of copper and copper alloys ~ 4,400 t 30 Aurubis Mortara SRL Strips, thin strips in coils and sheets ~ 3,000 t 25 Aurubis Netherlands BV Strips made of brass and other alloys, galvanic tin plating ~ 2,800 t 16 Aurubis Slovakia s. r. o. Strips made of copper and copper alloys ~ 1,300 t 11 The Aurubis Group has four Slitting Centers around the world: Slovakia, the United Kingdom, the Netherlands and Italy. The Slitting Centers process the copper produced at Aurubis, fabricating a wide variety of strips and sheets from copper and copper alloys according to customer requirements. Aurubis Slovakia has 11 employees and primarily supplies customers in Central and Eastern Europe. This plant has the largest area at 5,900 m2. It was certified in accordance with the environmental management standard ISO for the first time following a successful audit in Aurubis UK in Smethwick near Birmingham has about 30 employees and mainly fabricates products for the automotive, electrical and electronics industry. This Slitting Center plans to fulfill standard ISO with an environmental management system that is already being worked on. The Slitting Center in Zutphen at the Aurubis Netherlands BV rolling mill (see p. 44) specializes in fabricating strips made of brass and other alloys as well as galvanic tin plating. Sixteen employees achieved an output of 2,800 t in Aurubis Mortara has 25 employees and produced almost 3,000 t of copper strips and other copper products for further processing in Apart from copper strip, coils and sheets are also produced here. Aurubis Mortara is currently a well-known actor in Italy when it comes to copper and products with copper alloys. Furthermore, the company has its own sales office to support sales activities on the Italian market. Both sites are 100 % subsidiaries of Aurubis Stolberg. The scrap generated during the production processes is sent back to Stolberg together with the pallets, where it is recycled or re-used. 1 See Glossary, p

63 Glossary Anode furnace» A unit used in pyrometallurgical copper refining in which copper is cleaned in a combined rinsing and reduction process (known as poling) and anode copper is produced by reducing the copper s oxygen content. Aurubis fiscal year» A fiscal year at Aurubis is the period between October 1 of one year and September 30 of the following year. Blister copper» Unrefined porous copper, an intermediate product of copper production that contains about 98 % pure copper. Molten copper absorbs gases more easily than copper in solid form. During solidification, dissolved gases form small blisters in the copper. CLP Regulation» Regulation (EC) No. 1272/2008 on classification, labeling and packaging of substances and mixtures, which went into effect on January 20, 2009, introduced a new system for classifying hazardous chemicals and implemented the United Nations global harmonized system (GHS) in Europe. Collected emissions» Collected emissions are emitted by directed emission sources (e. g., smokestacks). In contrast, fugitive emissions are emitted by undirected emission sources (e. g., storage areas). Conform» A continuous forming process in which the source material wire (12 25 mm in diameter) is shaped into special profiles. The wire is pressed in a chamber over a wheel with a groove. The copper exits the chamber through a shaping instrument and thus achieves the desired profile shape. The material gets very hot up to about 700 to 800 ºC during the process due to friction and forming energy. Converter» A metallurgical unit in which oxidizing metal extraction or refining processes are generally carried out. Copper cathodes» In metallurgical parlance, the copper cathode is the high-purity tankhouse product with a copper content of more than %. Copper concentrates» A product resulting from processing copper ores. Since ores generally only have a copper content of 0.5 % to 3 %, they are enriched after extraction from the mine into concentrates with a copper content of less than 20 % to 40 %. Copper concentrates are Aurubis main raw material by quantity. Copper matte» A mixed phase of copper sulfide and iron sulfide (ncu₂s x FeS) arising during the pyrometallurgical processing of sulfidic copper concentrate. The copper (crude) matte produced in Aurubis flash smelter with a copper content of about 65 % is initially processed in the converter by selective oxidation into white metal (Cu₂S) and then into blister copper. Copper recycling» Describes the industrial recovery of copper. Copper is regarded as an extremely sustainable raw material since it is virtually inexhaustible as a material and can be recycled again and again without loss of quality. Copper tankhouse» The copper tankhouse, a hydrometallurgical process for the electrochemical refining of copper, is the last refining stage in copper recovery. Anodes and cathodes are hung in a cell containing a sulfuric acid solution (electrolyte) and connected to an electric current. During the process the copper contained in the anodes is dissolved in the electrolyte together with baser elements (arsenic, nickel, etc.). Precious metals and the non-soluble elements (e. g., lead, selenium) sink to the cell bottom and form the anode slimes. Copper from the solution is deposited on the cathode with a purity of more than %. EMAS» The acronym stands for Eco-Management and Audit Scheme, a system for environmental management and eco-auditing for organizations. EMAS was developed by the European Union. Participating organizations must publish an environmental declaration in which they describe their influence on the environment, their environmental performance and their environmental goals, among other things. This is reviewed by an independent environmental consultant and must be updated every year. At least every three years the consultant assesses the environmental management system, compliance with environmental policy, compliance with legal provisions and consolidated environmental declaration. Emissions» In general, the discharge of disruptive factors into the environment e. g., by-products and chemical substances that are a hazard to health or the environment. An important aim of environmental protection is to suppress or reduce hazardous emissions as far as possible in order to avoid environmental pollution, such as air, soil or water contamination and at the same time to protect people from pollution in their homes and workplaces. Environmental management» The environmental management or environmental management system in a company is concerned with operational and regulatory environmental (protection) requirements. Its purpose is to ensure the sustained environmental compatibility of the company s products and processes as well as the conduct of its employees. EU Emission Trading System» The European Union Emission Trading System (EU ETS) limits CO₂ emissions within the EU, where companies are allocated emission rights in the form of tradable certificates. Fine dust-pm10» Suspended particulates Flash smelter» The first step of the pyrometallurgical process in copper concentrate processing takes place in the flash smelter. Concentrate falling (floating) in a reaction shaft reacts with oxygen. The concentrate melts due to the released heat. Sulfur and iron are separated as intermediate products. The copper in copper matte is enriched to about 65 % copper content. Fugitive emissions (KRS)» Fugitive emissions are emitted by undirected emission sources (e. g., from storage areas). In contrast, collected emissions are emitted by directed emission sources (e. g., smokestacks). AURUBIS ENVIRONMENTAL REPORT

64 Immissions» Environmental impacts affecting people and the environment (air, atmosphere, soil, water, plants, animals, etc.), such as impurities, noises, vibrations, light, heat, radiation, etc. Iron silicate stone» A solidified product of the copper smelting process. During the process the iron contained in the copper concentrate is combined with silicate flux (SiO₂) to yield iron silicate (2 FeO x SiO₂). Although its structure is similar to natural rock, this artificially produced stone has a substantially higher density and weathering resistance. ISO » This global standard provides the criteria for establishing and auditing the environmental management of a company. If the external auditor confirms the adherence to the criteria, the company receives a certificate which is proof of a functioning environmental management system. ISO 9001» This standard describes the requirements of a quality management system. It is process-oriented and contains basic principles for structured processes and measures within a company. Its aim is the ongoing improvement of internal processes, helping the company to ensure and increase customer satisfaction. Kayser Recycling System (KRS)» A plant for secondary copper production at the Lünen site. In the KRS, converter copper is produced from recycling materials, such as copper-bearing residues, alloys and electronic scrap, which is then processed further in the anode furnace. Metallurgy» Refers to all processes for extracting and using metals as well as metallurgically relevant semimetals and non-metals from ores, soils, salts and secondary raw materials. Primary copper production» Copper production from copper concentrates (primary raw material). Pyrometallurgy» The thermal processing of ores or already extracted metals, either by oxidizing, i. e., heating with oxygen (roasting), or by reductive means, i. e., in an oxygenfree furnace. Secondary copper production» Copper production from copper-bearing recycling materials (secondary raw materials). Sulfuric acid (H₂SO₄ )» A strong acid used by the chemical industry as a basis for numerous products and processes. Sulfuric acid is produced at Aurubis as a by-product of primary copper production. The sulfur dioxide (SO₂) arising during concentrate processing is oxidized further by adding oxygen in a catalyzed reaction and is then dissolved in water, which results in sulfuric acid. Suspended particulates, dust emissions» (also fine dust-pm10) Dust is a natural component of the air, but it is also released through manmade emissions. Due to improved recording technology, particles that are smaller than 10 µm can now be measured (medical reports have determined that particularly the small, respirable particles pose a health hazard). This measurement is referred to internationally with the abbreviation PM10 (PM: particulate matter). Sweeps» A metal-bearing product that results when copper, copper alloys and precious metals are melted and processed. It is recycled as a secondary raw material. TS 16949» This standard combines existing general provisions for the automotive industry s quality management systems. It was developed by members of the International Automotive Task Force and published together with the ISO as a Technical Specification (TS) based on EN ISO TÜV» The Technical Control Board, TÜV, a German certification authority that carries out technical safety checks, in particular those that are required by laws or state regulations. Virtual slice of a power plant» As an energy-intensive company, we depend on a long-term electricity supply. Aurubis therefore implemented a constructive industrial solution with the energy provider Vattenfall and purchased a virtual slice of a power plant. This arrangement ensures an annual energy supply of a billion kwh starting in 2010 and secures the overall energy supply for the whole Aurubis Group in Germany for decades. Through this cooperation we also contribute to environmental protection due to the fact that the coal-fueled power plant, which is exceptionally modern from an environmental perspective, replaces outdated power plant capacities. Selenium» A semi-metal in Group 16 that is closely related to sulfur. It is finely distributed all across the earth and is mainly found in sulfidic ores. Copper ores contain between 0 and 20 ppm of selenium. Selenium follows the same path as precious metals in copper reprocessing and is separated from the anode slimes as raw selenium. Although selenium is an essential trace element vital for health, it is highly toxic in large amounts. Seville Process» The exchange regarding the establishment of best available technologies is referred to as the Seville Process because the European office organizing it is located in Seville (European Integrated Pollution Prevention and Control Bureau EIPPCB). 60

65 Contact information and imprint Publisher Aurubis AG Hovestrasse Hamburg Telephone: Fax: Your contacts at Aurubis AG Environmental Protection Dr. Karin Hinrichs-Petersen Head of Environmental Protection Telephone: Translated into English by Sara St. John Conception and design Lithography Frische Grafik, Hamburg Printing gutenberg beuys feindruckerei, Hannover Editorial deadline: September 2012 Group Communications Michaela Hessling Head of Group Communications Telephone: Matthias Trott Telephone: Kirsten Kück Telephone: Photo credits Alfred van Baal p. 51 Stefan Bauer p. 17, p. 47 Alfonso De Biasio p. 43 Jörg Hempel Photodesign p. 5 (right) Todor Ivanov p. 19 Julie Jelonek p. 39 Jelena Kurilova p. 49 Andreas Nolte p. 16, p. 29 Rolf Otzipka title page, p. 2/3, p. 8/9, p. 18 (top right), p. 20/21, p. 23, p. 37 Paul Peters p. 33 Andreas Schmidt-Wiethoff p. 5 (left), 27, 31, 35 Other photos PR Aurubis AG Title photo Patinated roofing copper from the Hamburg church St. Jacobi from Aurubis donated the copper needed for the church roof, gave parts of the old roofing copper to Hamburg artists to process and recycled the rest of the copper scrap. The production of the Aurubis Environmental Report 2012 and the recycled paper Circle Silk Premium White are certified according to the criteria of the Forest Steward Council (FSC ). The FSC issues stringent criteria for forest management and thus prevents uncontrolled logging, human rights violations and environmental strain. Since the products with the FSC seal are passed through various steps of trade and processing, the paper processing plants, e. g. printing presses, are also certified according to FSC standards. carbon neutral natureoffice.com DE print production

66 Our Copper for your Life