Aurubis Environmental Protection

Transcription

1 Aurubis Environmental Protection Aurubis AG Angel Kostov Head of Environment, Aurubis Bulgaria Daniela Cholakova Corporate Environment Sofia, 5th of October

2 Agenda 1. Aurubis 2. Environmental protection and recycling 3. Aurubis Bulgaria 2

3 Aurubis strengths include productivity, efficiency, environmental protection and processing expertise Aurubis: an integrated copper producer Raw materials Concentrates Blister BU Primary Copper» Cathodes» Sulfuric acid» Precious metals» Tramp metals» Iron silicate Processors and end users Scrap no. 1 Copper scrap E-scrap BU Copper Products» Cathodes» Wire rod» Shapes» Flat rolled products» Specialty profiles 3

4 Aurubis production sites and recycling facilities Hamburg» Concentrates» Copper scrap» Intermediates» E-scrap» Others Olen» Blister, Copper scrap BU Primary Copper: Hamburg (DE); Pirdop (BG) Aurubis has a service and sales network in more than 20 countries (Europe, Asia and North America) Fehrbellin» Cable scrap Lünen» Copper scrap» Alloy scrap» Shredder materials» Industrial residues» E-scrap» Copper-iron material» Others Pirdop» Concentrates» Copper scrap BU Copper Products: Avellino (IT); Buffalo (US); Dolný Kubín (SK); Emmerich (DE); Fehrbellin (DE); Hamburg (DE); Lünen (DE); Mortara (IT); Olen (BE); Pori (FI); Röthenbach (DE); Smethwick (GB); Stolberg (DE); Zutphen (NL) 4

5 Aurubis is a world leader in the copper value chain FY 2014/15 Position Concentrate processing 2,294,000 t No. 2 worldwide Copper scrap processing 294,000 t No. 1 worldwide Cathode production 1,138,000 t No. 3 worldwide Rod production 764,000 t No. 1 worldwide Shape production 170,000 t No. 1 in Europe Strip production 216,000 t No. 1 worldwide Sulfuric acid production Gold production Silver production 2,200,000 t 45 t 958 t April

6 Aurubis holds a leading position in the raw material supply markets Copper concentrate Recycling materials Others 20 % Chile 21 % Eastern Europe 10 % Others 5 % Canada 6 % Argentina 11 % Peru 12 % Bulgaria 15 % Brazil 15 % North America 13 % Rest of Western Europe 30 % Germany 42 % Source: Aurubis FY 2013/14 6

7 Aurubis Recycling processes a variety of complex materials into first class products Raw Material Processing Products Copper scrap Copper cathode Grade A Residues Nickel-sulfate Shreddermaterials SnPb Alloy Printed circuit boards Precious Metals Copper Iron KRS-Oxide (Zinc oxide) Metal bearing Sludges Ferro-silicate sand 7

8 Agenda 1. Aurubis AG 2. Environmental protection and recycling 3. Aurubis Bulgaria 8

9 Aurubis Reports th Sustainability Report th Group Environmental Report th Sustainability Report, Sustainability Strategy 2013 Development of a Sustainability Strategy Since 2010 Group Environmental Report (every two years) Since 2009 Group Sustainability Report (every two years) 2008 First Aurubis AG Sustainability Report Since 2002 Annual Aurubis AG Environmental Reports 9

10 Participation in Life Cycle Assessment and European Environmental Footprint pilot phase» Market and regulatory demand for life cycle data is increasing» Introduction of Environmental Footprint method for products (PEF) and organisations (OEF) by EU Commission as a basis for policy incentives» Activities by competing sectors» plastics industry (TEPPFA) comparative study between copper and plastic household installations used for misleading promotional messages» address substitution risks from aluminum in the power cable sector» Promote robust and scientific LCA practice and harmonized methodology» OEF can support EMAS / ISO management systems as a measurement tool 10

11 Aurubis Group environmental targets have been reached securely Climate protection» Target: Continuous reduction in CO 2 emissions» Examples: Constructing turbines to use waste heat in Hamburg and Lünen» Optimizing suction plants at Schwermetall Halbzeugwerk Noise» Target: Reducing noise emissions» Example: Erecting a noise barrier in Olen Waste» Target: Increasing the recycling rates» Examples: Stronger marketing of fayalite in Pirdop» Optimizing the separation plant at E.R.N. Air Targets until 2015:» Reducing SO 2 emissions in primary copper production by over 80 % compared to 2000 (85 % reduction achieved in 2015)» Reducing dust emissions in copper production by over 90 % compared to 2000 (96 % reduction achieved in 2015) Water Target until 2015:» Reducing metal emissions to water in copper production by about 70 % compared to 2000 (87 % reduction achieved in 2015)» Examples: Operating new water treatment plants in Pirdop and Lünen Soil» Target: Reducing input of harmful substances into soil» Example: Extensive securing of the plant premises in Lünen and collection of rainwater 11

12 12 More than 530 Mio. capital expenditure in environmental protection measures since 2000 Capital expenditure environment, copper production (in million ) 83,4 81,5 51,6 33,3 30,7 10,4 11,7 10,0 23,1 38,4 19,6 27,5 29,6 27,4 34,4 15,

13 13 Air protection is a main driver for Aurubis Group Successful reduction of emissions Dust emissions in g/t of copper output % since

14 14 Environmental protection is a core competency and a competitive advantage of Aurubis SO2 emissions from the copper smelter (in kilograms of SO2 per t produced copper) 3,500 3,000 2,500 2,000 1,500 1, Hamburg 4 Pirdop 6 Copper smelters: - European Ø 42 - International Ø 174 Pirdop Primary copper Hamburg SO2 emissions at Aurubis (In kilograms per t of copper produced) 34,8 35,4 19,4 10,6 7,3 8,0 7,6 8,1-85 % since ,0 6,8 6,7 5,5 5,6 5,6 4,7 5,1 0 Quelle: Wood Mackenzie, 2015 / zertifizierte Daten, Aurubis Aurubis achieves outstanding successes in environmental protection and is now considered one of the world's most environmentally friendly copper producers

15 Specific metal emissions to water in copper production in Aurubis Group Metal emissions to water (g / t produced copper) ,2 5,2 5,9 6,3 5,2 4,7 4,9 5,6 4,6-87 % since ,6 3,2 2, ,2 1,8 1,3 1,

16 Modern copper recycling is part of a sustainable raw material supply Recycling is essential overall:» It returns copper, precious metals and trace elements back to the economic cycle» Copper and most other metals can be recycled an unlimited number of times without losses» Preserves natural resources» Saves energy» Is basically politically accepted» Continuous investments and adaptations to changing recycling materials are required» High EHS requirements must be implemented on a continuously ambitious level The Aurubis solution: primary and secondary copper production complement one another and ensure the highest flexibility 16

17 Robust metallurgical infrastructure is a key to extracting many elements from dynamically changing product compositions Base metals Cu, Pb, Ni, Sn and Zn and their processing infrastructure all play a crucial part in present society acting as enablers in any recycling efforts, as they carry and release important and vital minor elements. Of importance is not only the criticality of elements but also the criticality of the metallurgical infrastructure and technology that enables the economically viable recovery of elements and compounds from complex products and materials. (Markus A. Reuter, Prof. Dr. Dr. h.c., Lead author of the UNEP report on metal recycling) UNEP (2013) Metal Recycling: Opportunities, Limits, Infrastructure

18 REACH Authorization of metals in recycling streams is in conflict with objectives to encourage recycling Facts» Complexity of modern recycling materials is increasing. Miniaturisation results in less metal weight» Recycling of complex materials is a challenge Objectives» Develop and implement a value-based industrial network» Multi-metal recycling has a key role 18

19 Closing the loop a mutual give and take Example: Telekom Aurubis and Telekom: Aurubis subsidiary CABLO extracts highpurity copper granules from cable scrap» Aurubis receives cable scrap with a copper content of abut 50 % and processes it in a professional and environmentally sound manner» After separating the copper core from the plastic fraction, the material is processed into high-purity copper granules» The copper granules are re-processed at Aurubis into copper products such as continuous cast rod, which is necessary for electric lines, among other things the copper cycle comes full circle» Using injection molding technology, the plastics are used to produce products with a high surface quality that hold their shape well, e.g. bases for traffic signs 19

20 Closing the loop beyond an example of a mutual relationship between Aurubis AG and Grillo Werke AG» Aurubis Lünen s Kayser Recycling System (KRS) produces KRS oxide, a complex, zincbearing (approx. 50 % Zn) residue» Grillo Werke AG takes KRS oxide as a raw material to process environmentally friendly zinc sulfate (fiber, feed and fertilizer industries)» Additional elements are chemically separated. Considered from e-scrap recycling bromine from flame retardants returns to the economic cycle» A resulting residue with copper, tin and lead is again taken back into Aurubis facilities Aurubis and Grillo: Cooperation on the highest standard for implementation of a transparent, consistent value chain cycle 20

21 Agenda 1. Aurubis AG 2. Environmental protection and recycling 3. Aurubis Bulgaria 21

22 AB Plant Site (and NATURA 2000 sites)

23 AB Plant Site (landscape view) 2,000 m DMD 720 m OKS ODZ MBAL 23

24 AB Plant Site (general view)

25 Air Emissions (LRQA, SGS, TUV Nord and CAs) SO 2, kg/t

26 Air Emissions (LRQA, SGS, TUV Nord and CAs) Dust, g/t

27 Air Emissions (LRQA, SGS, TUV Nord and CAs) Metals (Cu/Pb/As/Cd), g/t

28 Ambient Air Quality Monitoring Sites (SO2 and PM10) 28

29 Ambient Air Quality Data (DMD Zlatitsa ) DMD monitoring station Exceedings of the daily SO 2 AAQS threshold value [number] Exceedings of the hourly SO 2 AAQS threshold value [number] » 2015 is the 3 rd consecutive year when the SO 2 AAQS are sustained 29

30 Ambient Air Quality Monitoring Site (DMD Zlatitsa) Daily Exceedings (Zlatitsa) vs concentrate treatment DMD ODZ Conc smelted (t/y) Threshold

31 Past actions (emission abatement) Exceedings of the threshold value for the daily SO2 AAQ Standard in Zlatica vs concentrate treatment / 2002 PS converter equipped with secondary hoods Replacing HFO dryers with steam dryers Commissioning Secondary Gas Cleaning Plant / rd. Stationary hood CPS Sealing FSF tapping hole tunnels New drag chain conveyor and crusher WHB Change of dust transport system NEW control philosophy SAP and Smelter DMD ODZ Conc smelted (t/y) Threshold 31

32 Last Major Emission Abatement Action (Add/New SULPHACIDE secondary waste gas treatment plant)» Construction stated Jun 2013» IPPC is amended to allow its operation Jun 2014» Official commissioning (Act 16) Mar 2016» Additional adjustments for optimal performance Jul-Dec

33 Ambient Air Quality (PM10 ODZ Zlatitsa ) ODZ monitoring station Average annual PM 10 [µg/m 3 ] Aurubis contribution is between 2 and 4% depending on the season (according to the actual municipal AAQAM programmes from 2013/2014) 33

34 PM 10 and HMs AAQ monitoring sites (AB, EEA and RHI) 34

35 AB Plant Site (incl. Gypsum and Tailings Ponds)

36 New Sludge Landfill (WWTPs and 1 st GCS)» Construction started Apr 2015» End of construction Jun 2016» IPPC permit reissuing Jul 2016» Current sludge landfill recultivation start 2017 Q1 36

37 Water Emissions (HMs ) kg/y Total water emissions Rainwater emissions IWWTP 37

38 Water Emissions (HMs) 4,5% 4,2% Exceedings / samples (%) 4,0% 3,9% 3,5% 3,1% 3,1% 3,0% 2,5% 2,0% 2,0% 2,6% 2,1% 1,5% 1,0% 0,5% 0,0% 0,4% 0,2% 0,02%

39 Rain/Surface Water Emissions (HMs ) Heavy Metals, kg/y Rainwater emissions IWWTP 39

40 Waste Water Emissions (Status by mid 2008) 40

41 Selected scheme for conducting surface/rain water to the new RWTP (2010) 41

42 Sites connected to the Domestic Sewerage 42

43 Scheme of Domestic Sewerage branches 43

44 Critical sections and interconnections to other sewerages (for Industrial and Rain-Surface water) 44

45 Reconstructed sections from the Domestic Sewerage 45

46 New WWTP for Rain/Drainage Sewerage (2014) 46

47 New RWTP (proposed technology) Rain water flow рн=6,5-8,2 Metals Precipitator NaOH Coagulant Electrolyte HCL Precipitator Collecting reservoir with removal of floating substances and free oil products (globules 150 μm) Reservoir for collecting floating substances and free oil products Filtrate I-st Reactor Increasing of ph = 9-10 II-nd Reactor Coagulation ph = 9-10 III-rd Reactor Flocculation Precipitation Connection ph = 6 8,5 IV-th Reactor Last рн control Reservoir Wastes Collecting sediments Filter press Filtrate Filter cake 47

48 Water Quality Monitoring of Bio-indicators (EEA and RBD)

49 2016 Shut Down» Duration: (52 days)» Total budget: 43M» Main projects:» Smelter: FSF & WHB repair, Steam Dryer 2 replacement» SAP: Converter 2, Cooling tower 1 & catalyst replacement 49

50 Major ongoing investment projects» Fit For Future (FFF 2018)» New pre-converter at SAP (Line 2)» New (9 th ) Storage Tank for H 2 SO 4» Reserve AF» New 2 MW Steam Turbine 50

51 Aurubis AG The Leading Integrated Copper Producer 51

52 Company profile» Founded in 1866 as Norddeutsche Affinerie AG in Hamburg» IPO in 1998» Renamed in 2009 after the acquisition of Cumerio Aurum + Rubrum = the red gold = Aurubis» Production sites in European countries and North America with about 6,300 employees» Third largest producer of copper cathodes in the world with an annual output of about 1.1 million t of copper cathodes» No. 1 copper recycler in the world» Largest rod producer in the world» One of the world s leading copper foil and flat rolled product manufacturers» Production capacities for approx. 1.3 million t of different copper products» Global leader in environmental protection 52