Updated Aurubis AG Environmental Statement 2013 Hamburg and Lünen Sites

Transcription

1 Updated Aurubis AG Environmental Statement 2013 Hamburg and Lünen Sites

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3 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. 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 is extracted and processed into products such as precious metals, by-metals 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. 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 additional production sites in Buffalo (USA), Finspång (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. This Environmental Statement applies to Aurubis AG, which comprises the Hamburg and Lünen sites. aurubis ag, Hamburg Updated Environmental Statement

4 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 Business Unit Primary Copper handles all activities associated with the production of pure, high-quality copper in the form of marketable copper cathodes made of the primary raw material, copper concentrates. This includes smelting and refining activities at the sites in Hamburg, Olen (Belgium) and Pirdop (Bulgaria) as well as marketing the by-products sulfuric acid and iron silicate products. The subsidiaries Peute Baustoff GmbH and Retorte GmbH Selenium Chemicals & Metals, the world s leading selenium producer, are also part of the Business Unit. Recycling / Precious Metals The main activity of Business Unit Recycling / Precious Metals is the production of high-purity copper cathodes from a very wide range of recycling raw materials. Recycling activities take place at various sites in the Group, the most significant of which are the Group s recycling center in Lünen and the secondary smelter in Hamburg. Copper scrap and, increasingly, more complex recycling raw materials like electronic scrap are processed in an environmentally friendly fashion with innovative technology. In 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 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), Finspång (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 Netherlands 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 should cover the processing of pure copper into products and reflect the value added. 2

5 Company guidelines and Group environmental protection guidelines 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 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: The continuous improvement of water pollution control, 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 mini mize strain on the environment and our employees. 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 legal regulations is the basis and minimum standard of our activities. aurubis ag, Hamburg Updated Environmental Statement

6 Aurubis assumes responsibility for environmental and climate protection, which is a key issue 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. 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. 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 multimetal 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 additional energy. 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. Fig. 1.0: Group Environmental Protection 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 4

7 The Group Environmental Protection Department is responsible for the strategic orientation of environmental protection and directly reports to Chairman of the Executive Board Peter Willbrandt. Environmental Officers oversee the environmental protection duties at the individual sites (see Fig. 1.0). 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 EMAS). The key environmental protection factors, which are uni form 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 regulation, REACH. aurubis ag, Hamburg Updated Environmental Statement

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9 Updated Aurubis AG Environmental Statement 2013 Hamburg Site 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 2,280 personnel are employed at the Hamburg site, including around 151 ap prentices. The individual production sectors at Aurubis AG in Hamburg are divided into three plant areas (see also Fig. 1.7, p. 17): the secondary smelter (RWN) is mainly comprised of the administration, the workshops, secondary copper and smelter production (secondary copper smelter) and precious metal production. The South Plant (WS) includes the sludge decomposition plant, the cracking acid cleaning facility, the wastewater treatment facility, the concentrate delivery area, the chemical plants and the casting lines in particular. The primary smelter sector includes the main primary copper production facilities: the RWO, the sulfuric acid production plants and the tankhouse. This section also houses the rod plant. Aurubis is an integrated copper producer that operates copper production and processing facilities at the Hamburg site (see Fig. 1.1). Fig. 1.1: Aurubis, an integrated copper producer Mines and recycling markets Copper production Copper processing Downstream/ final processing BU Primary Copper BU Copper Products Concentrate Sulfuric acid Iron silicate Pre-rolled strip and strips Electrical and electronic applications Automotive engineering Cathodes Shapes Energy sector BU Recycling/Precious Metals Shaped wire Telecommunications Continuous cast wire rod Construction/ architecture Recycling materials Precious metals Other metals Specialty profiles aurubis ag, Hamburg Updated Environmental Statement

10 Fig. 1.2: From copper concentrate to cathode Flash smelter SO₂ Copper concentrate Off-gas cleaning Copper matte (64 % Cu) Copper scrap Converter SO₂ Sulfuric acid plant Sulfuric acid Blister copper (98 % Cu) Copper anodes with about 99.2 % purity are produced from copper concentrates and recycling materials in a pyrometallurgical process in the primary smelter. The iron contained in the copper concentrate is recovered from the process and marketed as iron silicate stone or granules. The sulfur found in the raw materials initially occurs as gaseous sulfur dioxide (SO₂) in the process off-gas and is converted in the so-called contact plant into high-purity sulfuric acid, which is primarily sold to the fertilizer and chemical industry (see Fig. 1.1, p. 7). The main raw materials for copper production are copper concentrates (processed copper ores) and recycling materials (including copper scrap and electrical and electronic scrap). Pure copper is produced from the various raw materials after the smelting process in the tankhouse. The copper can be traded on the international metal exchanges. However, Aurubis only sells a small proportion of the copper cathodes on the exchange. Most of the cathodes are processed into copper products such as continuous cast wire rod, shapes, strips, sheets, foils, wires and profiles at the different Group sites. As part of multi-metal recycling, precious metals, nickel, lead and zinc as well as iron silicate products and sulfuric acid are produced from input materials which are very complex in some cases. Aurubis uses the properties of copper and other metals to enable recycling without a loss of quality (see Fig 1.2). Commitment to the environment Aurubis is an environmental partner of the city of Hamburg and was recognized as an environmentally friendly company as part of Hamburg European Green Capital. This environmental partnership was extended for another five years in April The focuses of the joint work program in the context of the environmental partnership in this period are the topics raw material efficiency, recycling management, air pollution control and climate protection. Furthermore, Aurubis and 11 other companies of different sizes and from different industries signed the Partnership for Air Quality and Low-emission Mobility initiated by the city of Hamburg. The objective of the partnership is to reduce nitrogen dioxide emissions, which are caused by transport in particular. To develop ideas to fulfill the targets of the air quality partnership, open workshops were carried out for all employees in May 2013 together with Innovation Management. They focused on the topics employee mobility and efficient vehicle fleets. Under the motto Let s Make Our Plant Greener, Aurubis carried out a tree-planting project together with the German Association for the Protection of Forests and Woodlands (Schutzgemeinschaft Deutscher Wald). The Senator for Urban Development and the Environment, Jutta Blankau, also participated. Aurubis employees, their families, children and guests planted a total of 50 trees and 3,000 shrub cuttings, including mountain-ash, ash, oak, beech, poplar and alder trees. The shrub cuttings included hazelnut, elderberry, olive, hornbeam, honeysuckle and buckthorn. The joint tree-planting project strengthened environmental awareness among employees and their families and contributed to nature conservation. Planting trees and cuttings helps reduce emissions as well. 8

11 Anode furnace Anode casting plant Tankhouse Copper (99.5 % Cu) Anode Raw materials Copper products By-products Nickel sulfate Cathode (> % Cu) Anode slime Precious metal refining Aurubis also takes part in the Voluntary Hamburg Industry Agreement to implement company CO₂ reductions from 2013 to The goal is for the 15 companies that have signed the agreement to cut a total of at least 150,000 t of CO₂ annually. Aurubis has pledged to carry out a key project to continue using off-heat in primary copper production. By implementing all of the planned projects, Aurubis will cut 12,000 t of CO₂ each year. Continued improvements in water pollution control, soil conservation, emissions, energy efficiency and natural resource conservation for future generations are among the management s main responsibilities at Aurubis. In the past several years, an average of one-third of total capital expenditure has gone to environmental protection measures. Total capital expenditure at the Hamburg site since 1981 has amounted to 1,118 million 384 million of which was devoted to environmental protection. By implementing these measures and operating state-of-the-art, innovative plant technologies, Aurubis AG is a leader in climate and environmental protection in primary and secondary copper production as well as wire and continuous cast material (processing). The facilities operated at the Hamburg site are an example for Europe and are listed under Best Available Techniques in the BAT document Non-Ferrous Metals. Aurubis has reduced its specific emissions by up to 90 % since At Aurubis, copper and by-products are produced as sustainably as possible using state-of-the-art, energyefficient plant technologies with very high environmental standards in order to conserve natural resources and to maintain a clean environment for future generations. Raw materials and recycling products (such as copper scrap and computer scrap) are almost completely converted into marketable products. Cathode copper that is no different from copper from primary raw materials in terms of quality is produced from various recycling raw materials after processing them in the tankhouse. Aurubis does more, however: as part of multi-metal recycling, precious metals, nickel, tin, lead, zinc and iron silicate products are also produced from input materials which are very complex in some cases. Aurubis uses the properties of copper and other metals to facilitate recycling without a loss of quality. Aurubis is developing innovative technologies in the Hamburg plant which have a multiplier effect. One example is the use of a new membrane filter press to dry slimes in an energy-efficient way. aurubis ag, Hamburg Updated Environmental Statement

12 The anode slime processing building The membrane filter press, which is partly funded by the Federal Ministry of Education and Research, is part of an overall concept for anode slime preparation with the goals of energy-related optimization, recovering resources and reducing emissions. With this sub-project alone, a CO₂ reduction of 460 t is possible each year with maximal utilization of the production facility. Innovations like these contribute to improving our environmentally friendly multi-metal recycling, which is fundamental for future-oriented, resource-efficient recycling management. With the implementation of this project, environmentally friendly multi-metal recycling will be stabilized and expanded at the Hamburg site. This creates the basis for future-oriented, sustainable and resource-efficient recycling management. Sustainable copper production at Aurubis contributes to environmental and climate protection and helps conserve resources for future gen - erations. Additional measures are planned to improve environmental and climate protection at the Hamburg site. They are described in the environmental program in this Environmental Statement (starting on p. 31). THE ENVIRONMENTAL MANAGEMENT SYSTEM Aurubis has had an environmental management system at the Hamburg site since 2002, which is certified in accordance with ISO and EMAS. The annual TÜV review is a good opportunity for Aurubis to have its effective implementation of environmental protection and the resulting successes inspected and verified by an external third party. The energy management system at the Hamburg site was implemented in It has been reviewed within the scope of environmental protection up to now. Because of the increasing significance of the certified energy management system and the current energy policy conditions, it was successfully certified separately in May Targets and tasks of the environmental management system The environmental management system helps us to confidently control production processes. In particular, targets and measures are defined and their implementation is monitored. The environmental management system includes the documentation of operational processes, external environmental reviews, internal audits, routine recordings and site inspections. Inventories form the basis for decisions about the type, extent, suitability and execution of environmental protection measures. Our environmental protection management system en sures that the applicable legal requirements are fulfilled with respect to environmental protection. Furthermore, it supports the continuous improvement of our environmental protection efforts with economically reasonable product and process design that takes the environment and occupational safety into account. Saving energy is also part of environmental protection for us, so we also 10

13 Fig. 1.3: Environmental protection organization at the Hamburg site Executive Board Plant Manager Health Protection Environmental Protection Radiation Protection Officer General Services Technical Services Occupational Medicine Immission Protection Officer Radiation Protection Representative Hazardous Materials Officer Energy Management Officer Occupational Safety Water Pollution Control Officer Occupational Safety Specialist Waste Officer Environmental Management Officer Accident Officer Officer for Specialized Companies, 62 WMA had our energy management system certified in accordance with DIN EN ISO The energy flows are presented transparently and optimization potential is documented. The systems and organization of environmental management and health protection are described extensively and understandably in a handbook available to employees. This management handbook guarantees that all activities that concern environmental aspects and occupational safety issues are planned, managed, monitored and continuously improved with due regard to legal requirements. Environmental management organization As the operator of the approved facilities in accordance with 52a Federal Immission Protection Law and 53 Recycling Management and Waste Law, the Aurubis AG Executive Board or the appointed member of the Executive Board is responsible for observing environmental protection and radiation protection regulations. The head of the Environmental Protection Department assumes the position of Environmental Management Officer and reports to the Executive Board. As part of the environmental management system, the Environmental Protection Department tracks changes in legal requirements, reviews their effects on the different areas of our company and ensures that our facilities are operated in conformity with the law. Furthermore, the department updates the legal directory and provides employees with information and training. The management has appointed officers for the following issues or specified individuals responsible for them in order to fulfill corporate duties (see Fig. 1.3): Immission protection Water pollution control Waste management Radiation protection Hazardous materials Environmental management Officer for Specialized Companies pursuant to the Water Management Act (WMA) Occupational Safety Specialists Medical Department Energy Management Officer aurubis ag, Hamburg Updated Environmental Statement

14 All environmental protection issues are coordinated, organized and monitored in the Environmental Protection Department to support the different business sectors. In addition, the Environmental Protection Department is responsible for implementing the requirements of the new Regulation (EC) No / 2006 (REACH) for the Aurubis AG sites in Hamburg and Lünen as well as advising the Aurubis Group. Monitoring and internal auditing of environmental management The environmental management system s effectiveness is reviewed with internal audits pursuant to EMAS regulations and ISO The approach for the internal audits is defined in specific process instructions. Internal and external audits take place annually in compliance with the EMAS and ISO requirements. Emergency measures and crisis management Because of the type and quantity of materials handled, the Hamburg production site is subject to the obligations of the German Accident Regulation. The existing safety report in accordance with 9 Accident Regu - lation was updated for the entire Aurubis AG plant in Hamburg in 2010 / The inspections in the safety report are based in particular on the relevant technical facility data and the composition of the materials handled. According to this safety report, serious danger within the meaning of the Accident Regulation can be ruled out for the facilities. Furthermore, the measures provided to protect the general public and the surrounding area from other dangers, substantial disadvantages and significant disturbances pursuant to 4b paragraph 1 no. 2 of the 9th German Federal Immission Protection Law prevent or limit large-scale damages. The external audit involves verifying the description of operating processes and reviewing the environmental data provided. The results of the company environmental audits and internal audits are compiled in a report and presented to the Executive Board for assessment (Management Review). The Executive Board evaluates how suitable, appropriate and effective the management system is and whether our principles for environmental protection, health protection and occupational safety are being successfully implemented. All of the additional safety sub-reports were updated up to The Executive Board also evaluates the energy management system as part of a Management Review. 12

15 Fig. 1.4: Quantity of hazardous materials transported at the Hamburg and Lünen sites Mode of transport in t p. a. FY 06/ 07 FY 07/ 08 FY 08/ 09 FY 09/ 10 FY 10/ 11 FY 11/ 12 Road 64,736 95,925 57,311 69,145 87,960 97,280 Rail 164, ,420 83, , , ,155 Inland waterways 949, ,636 1,081, , , ,896 Sea 7,334 7,055 10,465 5,924 5,781 7,573 Air <1 Total 1,185,737 1,134,036 1,232,816 1,016,900 1,072,961 1,118,904 Emergency plans are in place for emergency situations and accidents. They describe how to react to prevent or limit environmental effects. We routinely carry out emergency drills, documenting and evaluating the processes. Moreover, we have developed an alarm and danger prevention plan in coordination with the responsible authorities, which describes emergency measures for our plant premises. The individual plant divisions also have alarm and danger prevention plans. These documents are issued by the Plant Fire Department or the plant divisions in cooperation with the Environmental Protection Department and are accessible to all parties involved in the emergency. Our Plant Fire Department works around the clock in Hamburg. Employees are on call for each plant division and for all of the relevant departments. An engineer on duty who can also be reached at any time coordinates the required measures. The engineers rotate weekly. In an emergency, the individuals listed in the emergency plan are responsible for passing on information to the public. INDIRECT ENVIRONMENTAL EFFECTS Indirect environmental effects are effects that are not directly caused by our production processes on site. Therefore, Aurubis cannot directly influence them. These include our products in the upstream and downstream value-added stages. We cannot directly influence transports of hazardous materials which we have commissioned, either. Transporting hazardous materials A joint Hazardous Materials Officer was appointed for the Hamburg and Lünen sites and the relevant au thorities have been informed. This issue is thus handled jointly for the Hamburg and Lünen sites. In fiscal year (FY) 2011 / 12, a total of 1,118,900 t of hazardous materials were consigned for delivery at the Hamburg and Lünen sites, of which 97 % was various sulfuric acid products (UN 1830 and UN 1831) from dangerous goods class 8, Corrosive Substances, from the Hamburg site (see Fig. 1.4). No accidents with hazardous material leakage occurred during the reporting period. Isolated irregularities were corrected immediately before transport in compliance with the relevant regulations on hazardous materials. Internal consultations, monitoring and training were carried out repeatedly in order to maintain this high safety standard. aurubis ag, Hamburg Updated Environmental Statement

16 Fig. 1.5: Origin of copper concentrates for the Hamburg site in percent, fiscal year 2011/12 Other countries 7 Canada 9 Australia 5 Indonesia 4 Brazil 13 Concentrate throughput at Aurubis Hamburg > 1,000,000 t 23 Peru 21 Chile 18 Argentina Origin of the raw material copper concentrate Our raw material for primary copper production, copper concentrate, is mainly extracted on-site at mines, where the ores with about 0.5 % to 4 % copper content are concentrated to an average copper content of 30 % to reduce transport volumes. Our primary ore concentrate suppliers are the mining companies Xstrata, BHP Billiton, Rio Tinto, Vale, Teck and Newmont. These global mining companies have committed themselves to a sustainable corporate policy and to releasing environmental reports, which can be found on the companies websites. Aurubis is currently developing a business partner screening process. In this context, options for integrating environmental pro - tection and social aspects into the screening are being reviewed. We obtain most of the copper concentrate from South America (75 %), 4 % from Asia, 9 % from Canada, 5 % from Australia and small quantities from other countries (see Fig. 1.5). The concentrate is transported almost exclusively by sea in bulk carriers via Brunsbüttel. Special ships suitable for inland waterways are used to deliver the concentrate mixtures. They drop off their cargo in the Müggenburger Canal with a crane. In fiscal year 2011 / 12, 1.1 million t of copper concentrates were delivered to our plant in this way. Indirect CO₂ emissions Copper production is an energy-intensive process for which a reliable electricity supply is very important in particular. Aurubis therefore has a long-term share in a coal power plant being constructed by Vattenfall Europe AG in Hamburg-Moorburg by means of a virtual power plant slice. This is the most state-of-the-art and efficient power plant of its kind. Electricity production in this power plant leads to CO₂ emissions. CO₂ emissions of this kind are considered indirect environmental effects at Aurubis. In 2012, these indirect CO₂ emissions totaled 476,600 t. Several projects are being implemented at the moment in order to continue reducing indirect CO₂ emissions. Electricity from regenerative energy sources is not used in the production processes at the moment. One important project in this context is the continued use of offheat to generate electricity in primary copper production. This project alone reduces indirect CO₂ emissions by 5,000 t. A total of 9,955 MWh of electricity were produced from waste heat in 2012, or 1.5 % of total electricity consumption. Furthermore, landfill gas was used in the production processes instead of natural gas (2012: 3,870 MWh). Steam is required for copper production processes. This steam was produced in large part from waste heat; in 2012, 79 % of the necessary steam was produced from waste heat and only 21 % was produced from fossil fuels. 14

17 ENVIRONMENTAL AND CLIMATE PROTECTION DATA AND FACTS The production facilities operated in Hamburg are licensed pursuant to immission protection law. With respect to water pollution control, cleaned rainwater, wastewater and cooling water are fed in in compliance with existing water law permits. Data is collected at the Hamburg plant on the basis of data in the SAP system, the PI system, internal recordings and the results of comprehensive measuring programs. Calculation methods and data collection are documented so that data is always traceable and verifiable. Environmental aspects and data are reviewed, analyzed and evaluated as part of routine quality circles, management discussions and audits. Environmental protection focuses and environmental targets can be established this way. The key indicators required by EMAS III are also redefined annually in this process. During the internal audits, the company s 2012 environmental targets were reviewed to see if they had been fulfilled. This was confirmed for all of the relevant environmental targets with a direct influence on environmental effects. Several additional targets were updated and new targets were defined and documented. The focus of the new environmental program is on further improving emission reduction and climate protection. Environmental quality circles and continued employee training were arranged to strengthen environmental awareness and implement the environmental protection targets. Division targets were set in 2012, and their implementation is being reviewed and documented. In the context of an authorization process with participation of the public, which Aurubis applied for on a voluntary basis, an environmental compatibility inspection was carried out for the entire site for the first time. The issuance of the authorization with the environmental compatibility inspection safeguards the existing site facilities and forms the basis for all future authorization processes. The public contract Aurubis signed in 2011 with the city of Hamburg addresses the issue of air pollution control. It includes a 9 t reduction in dust emissions per year based on the Emissions Declaration of The measures agreed on in the contract were incorporated in the new environmental program. aurubis ag, Hamburg Updated Environmental Statement

18 Fig. 1.6: High capital expenditure for environmental protection measures leads to higher operating costs Capital expenditure at the Hamburg site in mill. Operating costs for environmental protection in Hamburg in mill /00 01/02 03/04 05/06 07/08 09/10 11/12 99/00 01/02 03/04 05/06 07/08 09/10 11/12 Technology Environmental protection Credit for products Net operating costs 1 Because of a change in the accounting procedure, the information starting in 2010 / 11 deviates significantly from the previous years. 2 Credit for products without rounding: 58.5 mill., net operating costs without rounding: 18.8 mill. The main measures are as follows: In secondary copper production, the new crusher will be connected to the recently constructed North Plant warehouse. In primary copper production, a turbine will be built to produce electricity from waste heat (CO₂ reduction of 5,000 t per year). A feasibility study will show if it is possible to close the ridge turrets in primary copper production and whether a suction system can be installed. The new agreement includes environmental protection measures with a capital expenditure volume of about 20 million; the agreement runs until In addition, Aurubis successfully took part in the first Hamburg climate protection program from 2007 to CO₂ emissions were permanently reduced by 32,000 t per year. A number of individual measures with a capital expenditure volume of around 22 million were implemented for this purpose. INVESTMENTS IN ENVIRONMENTAL PROTECTION At Aurubis, copper and by-products are produced as sustainably as possible with the use of state-of-the-art plant technologies with very high environmental protection standards in order to conserve natural resources and maintain a clean environment for future generations. We therefore continuously invest in modern plant and environmental protection technology. Our most important tasks include constantly improving air quality, energy efficiency and water pollution control as well as conserving natural resources for future generations. An average of about one-third of the Aurubis Group s total capital expenditure has gone to environmental pro - tection measures over the years. Since 1981, total capital expenditure has amounted to over 1.1 billion, of which 384 million was capital expenditure for the environment. By implementing these measures and operating stateof-the-art, innovative plant technologies, Aurubis AG is a leader in climate and environmental protection in the primary and secondary copper production sectors and the production of wire and continuous cast material (preliminary stages of processing). Today, only comparatively smaller improvements can be achieved with continued high capital expenditure on environmental protection because a leading international environmental standard has been reached and emission reduction is subject to technological limitations. Because of a change in the accounting procedure, the data on the operating costs for environmental protection is not directly comparable with the data from the previous years starting in fiscal year 2010 / 11. This is highlighted by the dashed line (see Fig. 1.6). Investments in environmental protection lead to higher operating costs as a matter of course. 16

19 Fig. 1.7: Aurubis AG plant premises Elbinsel Kaltehofe Prevailing wind direction 1 North Plant 2 South Plant 3 East Plant Veddel measuring station Fig. 1.8: Drastic reduction in immission values (suspended particulates) on the Elbe island Kaltehofe¹ As pollution at measuring site Kaltehofe in ng / m³ Cd pollution at measuring site Kaltehofe in ng / m³ EU target value: 6 ng / m³ 1 gram (g) = 1 billion nanograms (ng) Heavy metal immissions considerably below EU target value 1 Suspended particulate measurements in Kaltehofe stopped when the area was transformed into a water conservation area. The new measuring station is located in the residential area of Veddel. The arsenic level there in 2012 was 3.4 ng/m³ and the cadmium level was 1.1 ng/m³. EU target value: 5 ng / m³ Source: Hamburg Institute for Hygiene and the Environment aurubis ag, Hamburg Updated Environmental Statement

20 Fig. 1.9: Further reduction in emissions of dust and dust components in secondary copper production Expected emission reduction in kg p. a. Storage area Crusher/conveyor Dust 6,000 1,050 3,270 Copper % 1, % The new crusher/conveyor connected to the bulk material warehouse will reduce fugitive emissions in this area by more than 70 %. The data has been estimated based on the Emission Statement from The reduction in net operating costs for environmental protection in 2011 and 2012 is a result of very good revenues from the sale of sulfuric acid products. The projects to reduce fugitive emissions in particular are milestones for environmental protection. As a leading copper production company, it is important for Aurubis to develop innovative technologies for environmental protection and to enter new technical territory in the process. Relevant projects include the house-in-house project in the secondary smelter (capital expenditure of about 7 million) and the project to encapsulate and suction off fugitive emissions in the anode furnaces and the casting machine in the primary smelter with a capital expenditure volume of about 7 million. The success of measures to reduce fugitive emissions is illustrated by the fact that the suspended particulate recordings taken by the Hamburg environmental authority have remained at a constant, low level for years on the Elbe island Kaltehofe, which lies in the prevailing wind direction. The immission value was already 5 ng/m³ for arsenic and 1.0 ng/m³ for cadmium. Measurements commissioned by Aurubis confirm that the values are below the European reference values in the 4th daughter directive of the Air Quality Framework Directive. Aurubis has observed the EU target values for arsenic (6 ng/m³) and cadmium (5 ng/m³) that went into effect in 2013 for years already. No additional measurements have been taken at the Elbe island Kaltehofe since it was declared a water protection area. However, the measurement values at the Veddel measuring station are also far below the EU limit values (see Fig. 1.7 and 1.8). The best available plant technologies are in operation at Aurubis AG, offering a very high standard of environmental protection. Further emission reduction measures therefore require disproportionately high capital expenditure. At the same time, operating facilities that provide environmental protection (e. g. filter facilities) incur substantial costs. This trend has increased in the last few years due to higher energy prices, as environmental protection measures (e. g. operating filter facilities with fans) are very energy-intensive. AIR One of the most important environmental protection milestones in the 1990s was the use of state-of-the-art filtering technologies for all directed emission sources, or smokestacks. Projects to reduce fugitive emissions currently have high priority. It is therefore crucial for Aurubis to develop innovative technologies for environmental protection and to enter new technical territory in the process. The new 5,000 m² bulk material warehouse in the North Plant (North Plant warehouse) went into operation in September The crusher/conveyor was integrated in The project, which had a capital expenditure volume of about 7.5 million, reduced fugitive emissions from this area by more than 70 %. Separated flue dusts can be processed within the smelter to recover the metals contained in them, so there is no additional waste (see Fig. 1.9). Specific emissions to the air have been reduced significantly since This is illustrated in the following figures. 18

21 Fig. 1.10: Dust emissions at the Hamburg site Dust emissions in g/t of copper output Fig. 1.11: Copper emissions at the Hamburg site Copper emissions in g/t of copper output Fig. 1.12: Lead emissions at the Hamburg site Lead emissions in g/t of copper output Dust emissions have been reduced by 80 % since The slight nominal increase in dust emissions starting in 2011 is due to calculation reasons; it can be attributed to new national calculation requirements issued by the authority for data from continuous measuring devices (the so-called validation value is not taken into account). There was not an actual increase in dust emissions (see Fig. 1.10). More than 70 % of the remaining metal emissions from the Hamburg production site come only from fugitive sources, the majority of which stem from hall ventilation facilities. Specific lead emissions have been reduced considerably (by 85 %) compared to 1990 and are therefore still at a low emission level (see Fig. 1.12). Copper is the main metallic substance in the dust in Hamburg. Specific copper emissions have been reduced by 77 % since This low level was maintained, as the changes compared to the previous year were in the expected range (see Fig. 1.11). The figure provided for specific lead emissions is in the range typical for the last few years. The slight increase is based on current recordings of fugitive emissions taken on the ridge turrets of the lead production facility, which result in an optimized collection level in the recordings. Lead emissions did not actually increase in aurubis ag, Hamburg Updated Environmental Statement

22 Fig. 1.13: Arsenic emissions at the Hamburg site Arsenic in g/t of copper output Fig. 1.14: SO₂ emissions at the Hamburg site SO₂ in kg/t of copper output Fig. 1.15: Highest environmental standards worldwide SO₂ emissions from copper smelters in kg SO₂/t of copper output Ø International copper smelters: 232 kg SO₂ / t Cu Ø European copper smelters: 49 kg SO₂ / t Cu Aurubis Hamburg: 4 kg SO₂/t Cu Aurubis Pirdop: 7 kg SO₂/t Cu Source: Brook Hunt 2012 / certified data Arsenic is a natural component of copper concentrates. Arsenic emissions have been reduced by about 90 % since 1990 in various steps of the copper refining process (see Fig. 1.13). Apart from copper, sulfur is one of the main components of copper concentrates. The gaseous sulfur dioxide produced when ore is smelted is converted into sulfuric acid in the sulfuric acid plant using the modern double catalysis process. The sulfuric acid is mainly used in the chemical industry. Specific sulfur dioxide emissions have been reduced by nearly 60 % since Sulfur dioxide emissions are largely influenced by the feed materials in the primary smelter and the utilization of the contact plant. Specific sulfur dioxide emissions have remained at the same low level as the past years (see Fig. 1.14). When compared internationally, the Aurubis Hamburg site is a forerunner in reducing specific sulfur dioxide emissions (see Fig. 1.15). 20

23 View of the new North Plant warehouse With an annual output of 456,800 t of copper, specific emissions for 2012 are as follows: Specific emissions related to: Emissions input material copper output SO₂ kg/t Dust g/t Copper g/t Lead g/t Arsenic g/t The emission limits established in the relevant permits for sources of collected emissions were strongly complied with. Only about half of the approved freight limits* for fugitive emissions** were utilized. NOISE We regularly measure the noise level that emanates from our plant premises. The noise level at the plant boundaries is less than the existing reference values. Detailed noise recordings were carried out and a noise register was developed in These recordings continued in 2011 to evaluate how effective the implemented measures were. Additional recordings are planned for 2013 to evaluate the effectiveness of the noise reduction measures executed in water The wastewater from Aurubis AG s entire Hamburg plant is composed of precipitation, indirect and direct cooling water, condensate, process wastewater and desludging water. All of the plant s precipitation (406,000 m³ in 2012) is collected and cleaned together with other wastewater (e. g. from the anode casting machine in the primary smelter) and discharged into the Elbe River. Precipitation is also used as cooling water in some cases. Accumulated process water is cleaned in a separate stateof-the-art wastewater treatment facility. The Hamburg plant has water law permits and observes their requirements. The sanitary water (especially wastewater from kitchens, cafeterias, showers and social rooms) is discharged into the city sewer system to be treated by the city s wastewater treatment plant (see Fig. 1.16). * Freight limit: max. mass flux of an emission permitted over a defined period ** 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). aurubis ag, Hamburg Updated Environmental Statement

24 Fig. 1.16: Metal emissions in water at the Hamburg site Metal emissions in g/t of copper output The proportion of heavy metals discharged by Aurubis in the Elbe s total load is less than 0.1 %. Aurubis has reduced the heavy metal load that is discharged with the wastewater into the Elbe by over 60 % since Today s emission value of 1.5 g/t of copper products is evidence of Aurubis top position in environmental protection, as the company was well below the limits stipulated in the Wastewater Ordinance. The specific wastewater quantities related to input materials and copper production are given in the following table. Specific data on metal emissions in water at the Hamburg site Specific metal emissions in water related to: Year input material in g / t copper output in g / t Aurubis operates an extensive monitoring network for cooling water discharge. In the process, the discharge temperature, temperature increase and cooling water quantity are measured and recorded at all discharge points. Moreover, the oxygen concentration in discharges that are relevant in terms of quantity must be measured continuously. An evaluation system that statistically assesses and documents the parameters determined for the cooling water started up in Monitoring heat emissions through the cooling water is another measure for improving water pollution control. Potable water usage from the Hamburg Water Works in 2012 was at a low level similar to that of the past few years. Potable water consumption at Aurubis has been reduced by up to 400,000 m³ annually by treating water from the Elbe River for use in the plant (see Fig. 1.17). This facility for producing pure water primarily fulfills the rising water demand in the boilers and acid production and serves as a technical benchmark. It reduces the use of potable water from Hamburg s reservoir by up to 400,000 m³. 22

25 Plants handling substances hazardous to water The specialized audit of the relevant plants under the Act on Plants Handling Materials Hazardous to Water was carried out by TÜV Nord pursuant to the established audit cycles. The specialized company inspections in accordance with 19 Water Management Act were also performed by TÜV Nord. New plants and renovations in the plants were also constructed and/or inspected pursuant to the applicable state ordinances. WASTE A total of 310,095 t of waste were accepted and recycled at the Hamburg site last year, of which 24,491 t were classified as hazardous waste. A total of 1,716 t of this came from other countries and was registered with the authorities. The increase in the amount of waste accepted for recycling is a result of the higher use of copper scrap in the secondary smelter. A total of 64 % of the waste accepted was used as a slag former (ash from sludge and other incineration plants, spent abrasives, sand and excavation residues and spent potlining from Lünen) and 36 % was used for metal recovery (dust, slimes, slags and precious metal-bearing sweeps). In the last calendar year, 38,911 t of waste were gene rated and passed on to waste management at the Hamburg site. Of this amount, 20,278 t (52 %) were classified as hazardous waste. The total was once again about 30 % higher than in As in 2011, this is due in particular to a higher amount of construction waste (29,619 t), which amounts to 76 % of the total waste volume. Only 9,292 t of waste were related to production, of which 2,861 t were directed to waste disposal and 6,431 t to external recycling. The ratio of production-related waste and waste directed to recycling is comparable with Fig. 1.17: Preserving potable water resources is also one of Aurubis long-term targets Potable water consumption at the Hamburg plant in 1,000 m³ p. a Ca. 60 % reduction aurubis ag, Hamburg Updated Environmental Statement

26 Fig. 1.18: Waste production at Aurubis Hamburg in t p. a. Waste containing arsenic/ Recycling Trash from Waste for above-ground underground waste disposal the lot/burning disposal (construction work) 8,444 10,085 4,564 5,745 27,332 15,390 12,516 15,393 12,761 20,069 16,724 29,683 38,812 38, The reason for the increase in the total waste volume in 2012, which is comparable to 2011, is yet again the higher amount of construction waste due to the implementation of various building projects (see Fig. 1.18). Most of the waste that is disposed of is slimes from offgas cleaning, which were significantly reduced in 2012 due to a modified composition of the feed materials. Moreover, slimes from the East and South washing and cooling facilities were processed internally in the primary smelter and were not disposed of. The slime separation process was also optimized and less lime was used for neutralization, which significantly lowered the amount of slime. With an output of 456,800 t of copper output for the year, the specific waste level is 85 kg per ton of product (comparison: 79 kg/t in 2011, 63 kg/t in 2010). A total of 99.4 % of the 1.6 million t of material input was transferred to products in ,459 t of olivine pyroxene rock from the secondary smelter and 68,062 t of slag material from the primary smelter were not marketed as substitute construction material and were directed to recycling as a construction material for landfills. ENERGY AND CLIMATE PROTECTION We act responsibly towards future generations by economically and efficiently using raw materials and energy. Our main energy sources are electricity and natural gas. In total, Aurubis AG consumes about 1.1 billion kwh of energy at its Hamburg site annually. With an annual copper output of 456,800 t, this means specific energy consumption of 2.5 MWh per ton of copper output (comparison: 2.3 MWh/t in 2011, 2.4 MWh/t in 2010). With a material input of 1.6 million t in 2012, this corresponds to energy consumption of about 0.71 MWh per ton of feed material. Specific energy consumption has stagnated at the Hamburg site in the past few years. An important reason for this is the higher level of multi-metal recycling, which leads to higher total energy consumption. As a result, energy consumption related to copper production also rises without a significant increase in the copper volume. If primary copper production from ore concentrates to copper shapes or wire is considered exclusively, specific energy consumption in this sector has remained constant in the past few years. 24

27 Fig a: Specific energy consumption at Aurubis Hamburg in MWh/t of copper output % Fig b: Specific fuel-related CO₂ emissions at Aurubis Hamburg in t CO₂/t of copper output % Reducing energy consumption ensures that we stay competitive and makes an important contribution to climate protection. Taking a longer term view, specific energy consumption as a yardstick for energy-efficient production has been significantly reduced at the Hamburg production site in the last several years, falling by 46 % compared to Fuel-related specific CO₂ emissions have been reduced by about 71 % since 1990 due to the economical and efficient handling of energy. With an output of 456,800 t of copper in the calendar year, specific CO₂ emissions from fuels amounted to 0.24 t of CO₂ per ton of product (comparison: 0.24 t CO₂/t in 2011, 0.25 t CO₂/t) (see Fig. 1.19a and 1.19b). Aurubis uses process waste heat to heat buildings and for the production processes as far as possible. The buildings at the Hamburg site are thus 80 % heated by waste heat. An example of an effective energy-saving measure in the framework of the climate protection concept is the energy network concept that Aurubis developed and installed: a new off-heat boiler and a steam turbine. This new collaborative energy concept permanently reduces emissions by 12,500 t of CO₂ annually. Copper production from ore concentrates begins in a flash smelter. Its exhaust gases have a temperature of 1,400 C and contain about 35 % sulfur dioxide, which is processed into liquid sulfuric acid in a so-called contact plant. The smelting furnace s hot exhaust gases are initially cooled in a waste heat boiler, producing valuable steam to heat the plant and the office buildings. This steam is also used as process steam for various metallurgical processes. The entire heat content of the acid plants hot exhaust air is to be used year-round thus the idea was developed to convert the excess heat into electricity by reducing the steam s pressure in a turbine. This so-called collaborative system consists of a two-stage turbine and a waste heat boiler, which work together and mutually complement each other. The new waste heat aurubis ag, Hamburg Updated Environmental Statement

28 Fig a: Energy efficiency comparison in the copper industry in MJ/ t of cathodes European copper producers are world Source: Brook Hunt 2006 North America Latin America EU-15 Aurubis Hamburg Africa Rest of Asia Japan Australia leaders in energy efficiency boiler generates about 60,000 t of steam from waste heat annually and thus reduces CO₂ by about 4,500 t each year. The steam turbine achieves about twelve million kilowatt hours by generating electricity from waste heat and thus reduces CO₂ production by 8,000 t per year. The result is remarkable: the environmental strain is reduced by about 1,500,000 m³ annually owing to reduced use of natural gas since electricity is generated from waste heat and not in a power plant. Overall, the collaborative concept has steadily reduced the environmental strain by around 12,500 t of CO₂ emissions annually (see Fig. 1.20a, 1.20b and 1.21). This energy efficiency comparison is based on the copper production cycle, which comprises only the production steps up to the cathode. The cycle was selected to ensure that the copper producers can be compared. CO₂ EMISSIONS TRADING The third trading period of the EU emissions trading for greenhouse gases starts in Energy-intensive companies in the production industry, such as Aurubis, will now be included in this trading period. These companies were excluded from emissions trading up to now. The allocation application for the third certificate trading period 2013 to 2020 was submitted on time to the German Emission Trading Office in January New data was recorded for this in Emissions were determined on the basis of individual processes consumed energy sources. There are various calculation bases that are to be used in an established order. These calculation bases relate to utilized waste heat (heat benchmark), direct process heat (fuel benchmark) and direct CO₂ process emissions (process benchmark). However, the other specific energy consumption data reported in this chapter is related to the entire Hamburg site (including all production, auxiliary and processing facilities). Furthermore, a monitoring plan was developed and submitted to the German Emission Trading Office. It was approved in February 2013 and will be used to monitor CO₂ emissions in the future. 26

29 Fig b: Comparison of electricity prices in the industry in / MWh incl. grid but an unequal distribution of costs can lead to competitive distortions. 20 Germany Bulgaria France Spain China Sweden Italy USA South America Source: Hamburg Industry Association 2009 Thermal power plant The thermal power plant at the Hamburg site has been part of the CO₂ emissions trading system since 2005, as the installed combustion efficiency is more than 20 MW. The Hamburg plant is heated 80 % with the waste heat from the smelting process in the RWO s flash smelter. Only the additional volumes due to weather conditions are generated from natural gas. There are strong fluctuations during cold winters. The CO₂ emissions from the thermal power station amounted to 12,804 t of CO₂ emissions in 2012 compared to 9,210 t of CO₂ in 2011 due to the much higher level of steam consumption resulting from the construction of additional production facilities. Climate protection agreement with the Hamburg Senate In August 2007 the Hamburg Senate approved the Hamburg Climate Protection Concept and presented it to the public. A major part of the concept was based on the participation of Hamburg industry. Aurubis AG was one of the first companies to participate in this climate protection concept and implemented a number of projects between 2007 and 2012 that cut CO₂ by 32,000 t each year. Aurubis is also participating in the new follow-up agreement and has pledged to carry out projects to reduce annual CO₂ emissions by 12,000 t by Because of the five-year trading period ( ), it is possible for the higher emissions in 2010 to be balanced by lower emissions in the other years. Fig. 1.21: CO₂ reduction potential is reaching its technological and physical limits. Specific fuel-related CO₂ emissions at Aurubis Hamburg in t of CO₂/t of copper output 78 % total 82 % Advance payment until 2007: 16 million CO₂ reduction: 80,000 t CO₂ p. a climate protection concept: 18 million Planned CO₂ reduction: 32,000 t CO₂ p. a Cutting 120,000 t of CO₂ corresponds to the electricity consumption of 100,000 households. aurubis ag, Hamburg Updated Environmental Statement

30 Fig. 1.22: Interplant turbine project: generating additional electricity from the primary smelter s off-gas Installation of a 60/20 bar back pressure turbine in the primary smelter using overheated 60 bar steam»» The relaxation enthalpy between the two pressure levels 60/20 bar is transferred into electrical energy via a turbine/generator and fed into the 6 kv plant network. The decompressed and overheated 20 bar steam is fed into the plant network and used completely as heating and production steam. Generator capacity: 2.8 MW Electricity generated: ca. 13,000 MWh p. a. CO₂ emission reduction: ca. 5,000 t p. a. New climate protection measures The operation of the new heat exchanger that uses the waste heat from the flash smelter off-gases was optimized in fiscal year 2011 / 12. The reduction of CO₂ emissions will amount to more than 2,000 t of CO₂ annually after the optimization phase and will be verified as part of the energy management system. Future RWO, the authorization process with public participation and an environmental compatibility inspection, was successfully concluded in February The proportion of electricity from these kinds of renewable sources should be doubled in the future from ca. 2.4 % to ca. 5 % of total energy consumption owing to the installation of the new steam turbine (see Fig. 1.22). An innovative pilot project in anode slime preparation, which was funded with 328,000 by the German Federal Environment Ministry, will reduce energy demand in this area by 35 %. The new processes will lower CO₂ emissions by 460 t per year at the same time. Environmental compatibility inspection As part of the authorization process with public participation, an environmental compatibility inspection was carried out for the Hamburg site and successfully reviewed by the authorities. Pursuant to 1a of the 9th Federal Immission Protection Law (BlmSchV), the following protected resources were reviewed in an environmental compatibility inspection in 2010 and 2011 concerning expected effects: Climate Air Soil Water Plants and animals Landscape Cultural and other material goods Humans (indirect and direct effects) A membrane filter press that can be heated and evacuated is planned to dry slimes in an energy-efficient way. The process technology follows the principle of a normal filter press with a packet made of membrane plates. However, the slimes are actually dried using integrated heating plates through which 120 ºC process steam flows. The steam-saturated air that forms (the so-called exhaust vapor) is suctioned off and condensed using a vacuum, so subsequent gas cleaning is no longer necessary. 28

31 Overall, it was determined that the operation of Aurubis production plants does not have any significant adverse effects on humans, animals and plants, soil, water, the atmosphere or cultural and other material goods. Aurubis AG has grown over time at the location in Hamburg-Veddel. Measures to increase efficiency and reduce environmental influences have been carried out continuously over the last several decades. The industrial use of space surrounding the site and the use of the site itself affect isolated protected resources. These effects of the whole Aurubis plant were considered in the completed environmental compatibility inspection. Polluted areas There are soil impurities typical for industrial areas at the Hamburg plant owing to many years of industrial use. The heavy metal pollution values are so low that no clean-up is required from the authorities view. The plant premises are mostly paved so that soil impurities cannot mobilize. Furthermore, the groundwater is protected from soil impurities by a water-resistant layer of clay. A sheet pile wall has also been erected in the primary smelter that effectively prevents backwater from flowing beyond the plant premises. aurubis ag, Hamburg Updated Environmental Statement

32 REACH: the new EU chemicals regulation The new EU regulation on the registration, evaluation, authorization and restriction of chemical substances (REACH), which came into force on June 1, 2007, stipulates that materials must be documented in detail and registered when they are produced or imported into the EU in quantities of more than one ton p. a. Data on the physical, chemical, human toxicological and ecotoxicological properties must be compiled as part of the registration process. December 1, 2010 was the first registration deadline for the REACH regulation. Aurubis submitted the registration dossiers for all sites successfully and on time to the European Chemical Agency (ECHA). Preparations are currently taking place for the second registration deadline in June Additional materials must be registered by this date. The registration process was carried out successfully until May Special occurrences There were no incidents or malfunctions with significant environmental effects during the reporting period. In the fourth quarter of 2012, the informational brochure on incidents, Safety for Our Neighbors, was revised and updated in collaboration with 30 other companies in Hamburg to provide information to the public. The brochure, which was coordinated by the Hamburg Chamber of Commerce, was sent to all of the households concerned in February Aurubis is also hosting informational events at the Hamburg plant for neighboring companies in the first half of A total of 88 registration dossiers were submitted for all the sites in the first registration phase, including 24 material dossiers with a complete, maximum data set. The safety data sheets with the data from the REACH process are currently being updated and prepared in accordance with the requirements of the Classification, Labeling and Packaging of Substances and Mixtures (CLP) Regulation. Extensive exposition scenarios must be prepared for the expanded safety data sheets and provided in all of the customers languages. These expanded safety data sheets can be very complex and comprehensive and, like the dossiers, are prepared in consortia on the European level together with competitors in some cases. 30

33 ENVIRONMENTAL PROGRAM The targets set in the context of the Environmental Statement 2012 were reviewed to determine the extent to which they had been achieved and implemented. Discussions with employees, training, audits and quality circles served as a basis for discussing and evaluating the environmental protection measures as well as developing a new environmental protection program for The results are presented in the following environmental program: aurubis ag, Hamburg Updated Environmental Statement

34 Strengthening environmental awareness Target Planned measure Degree of implementation/date Environmental quality circle Routine discussions and review with works management and the plant and/or production managers Every two months and as needed Training employees in the primary smelter Annual training sessions for employees in the primary smelter Seminar was successfully carried out again and will be continued annually as part of general continuing education. Training employees in all areas relevant to environmental protection in the plant Annual training sessions for employees in the secondary smelter, lead plant, precious metal recovery, casting lines, rod plant and logistics Implemented in 2012; to be repeated annually Training in environmental protection Carrying out an annual seminar for production and plant managers on the legal situation and correct implementation of provisions as well as clarifying the consequences of non-compliance Seminar was successfully carried out again; the seminars will continue in 2013 as part of general continuing education. Plant tours by employees in the Environmental Protection Department Monitoring operations with regard to environmental effects and compliance of Environmental Protection Department with requirements 4 5 tours per month; information is provided to the works and plant management in short reports including implementation controlling Documentation and reporting Providing information about environmental and climate protection, documenting key environmental figures Repeated annually; this year s audit took place in May Strengthening environmental awareness All employees should be reached by distributing the Environmental Report and providing the environmental handbook with the relevant instructions on the intranet. The current Environmental Report is on display at the main entrance in English and German for employees and visitors to take; in addition, the Environmental Report and the Environmental Statement can be downloaded from the homepage. Repeated annually. 32

35 Reducing dust emissions by 9 t each year Public contract with the city of Hamburg; timeframe Target Planned measure Degree of implementation/date Increasing energy efficiency Constructing and operating a turbine to produce electricity from waste heat in the primary copper production sector (CO₂ reduction of 5,000 t p. a.) Target was carried over from Construction started in December 2011, completion scheduled for 2013; start-up in the first quarter of 2014 Reducing fugitive emissions Improving off-gas capture and cleaning in the primary smelter Implementation until 2012; auxiliary hood filter on the Big Bag feed is in trial operation. Reducing fugitive emissions A bulk warehouse is being erected in the northern storage area. The crusher will also be integrated into the hall concept; the target of the measure is to reduce fugitive emissions in the northern storage area. Authorization was issued. The hall was completed in fall 2011 and the crusher was integrated into the hall concept in fall Reducing fugitive emissions A sprinkler system will be installed in the intermediate product warehouse (RWN) to prevent fugitive emissions The intermediate product warehouse was completed in Reducing fugitive emissions from open spaces and roadways Program to optimize cleaning of roadways, halls and storage areas Implementation until October 2013 Reducing hall emissions in the primary smelter Feasibility study on closing the primary smelter s ridge turret and installing a suction system for the area Assessment will be issued in Reducing fugitive emissions Fugitive emissions are to be further reduced in the slag pot area (RWO) by installing additional optimized sprinkling devices for the roads. Trials were successfully carried out in 2009; new overhead sprinkler systems were installed in 2011 / 12; crusher was integrated into the hall concept in fall aurubis ag, Hamburg Updated Environmental Statement

36 Air pollution control and authorizations Target Planned measure Degree of implementation/date Participation in the Hamburg Senate s climate protection concept Voluntary pledge to permanently cut 40,000 t of CO₂ p. a.; implementing various measures (e. g. integrating the interplant turbine into the primary smelter) Voluntary pledge among Hamburg industrial companies Implementing projects to cut 12,000 t of CO₂ Reducing emissions Preparing a concept for a new steam dryer to replace the directly heated drying drum used up to now The project has been delayed for now. Reducing fugitive emissions So-called copper matte is transported from the flash smelter in buckets to charge the converter. During transport, a solid layer forms on the copper matte surface which has to be broken before charging, resulting in fugitive emissions. This has to be covered with suitable material to prevent the layer from forming. Trials were carried out. No effective option was found to cover the copper matte. The project was discontinued. Energy optimization Target Planned measure Degree of implementation/date Increasing energy efficiency Installing a new heat exchanger to use the waste heat from the flash smelter s off-gases. CO₂ emission reduction will amount to more than 2,000 t of CO₂ p. a. This should be proven in the context of the energy management system. Installation 2010 Optimization in the course of 2011 Increasing energy efficiency Innovation Campaign on saving energy Innovation Campaign took place in Increasing energy efficiency Feasibility study on the construction of a CHP gas turbine Feasibility study developed in 2012; implementation delayed in favor of other projects. Reducing energy demand in precious metal recovery Pilot project funded by the German Federal Environment Ministry: use of a membrane filter press that can be heated and evacuated when drying metallurgical slimes. Reducing energy demand by up to 35 %; reducing ca. 460 t of CO₂ p. a. Completed in

37 Water pollution control Target Planned measure Degree of implementation/date Reducing the authorized heat input via the cooling water Measurements of heat-relevant parameters including a data analysis unit (classification unit) to record and assess the heat-relevant data (discharge quantity, temperature increase, discharge temperature, volume measurement, heat input and oxygen content or oxygen saturation for the discharge point Norderelbe and two points in the Müggenberger Canal) as an hourly average or 6-hour moving average Measurement program has been implemented since March 2011; continuation in Requirements of the thermal load plan implemented starting Safety aspects Target Planned measure Degree of implementation/date Revising existing safety sub-reports for facilities in accordance with the Hazardous Incidents Ordinance using hazard source analyses The revision of the existing safety sub-reports concluded in Precautionary concept to prevent emissions in the case of a large-scale blackout Precautionary concept implemented in Environmental management system Target Planned measure Degree of implementation/date Recording the environmental targets for the individual plants and separate schedule tracking Department-specific target documentation since April 2011; additional optimization in 2013 Business partner screening Target Planned measure Degree of implementation/date Developing a business partner screening process for raw material suppliers Concept developed in 2013 aurubis ag, Hamburg Updated Environmental Statement

38 Key figures for Aurubis AG, Hamburg site, in calendar year 2012 Input Output Raw materials Products Copper concentrates 1,118,100 t Copper 456,800 t Copper scrap/refining material 58,600 t Sulfuric acid products as H₂SO₄ 1,053,700 t Other Cu-bearing raw materials 117,600 t Iron silicate stone (incl. granules) 661,900 t PM-bearing raw materials incl. scrap 24,500 t Silver and gold, selenium 1,400 t Lead scrap and waste 14,100 t Metal compounds (Ni, As) 2,300 t Waste for recycling 31,900 t Lead 14,400 t Total TC/RC-earning raw materials 1,364,800 t Total products 2,190,500 t Auxiliaries Sand and additives incl. cyclone sand 204,100 t Iron as an additive 14,400 t Total input materials 1,583,100 t Input material per t copper 3.4 t/t Cu Energy Electricity consumption 517,200 MWh Additional electricity consumed to produce oxygen 128,200 MWh Natural gas 412,500 MWh Coke 50,127 MWh Other energy sources 22,200 MWh Total energy consumption 1,130,200 MWh Energy consumption per t copper 2.5 MWh/t Cu Water withdrawal/uptake River water 72,650,000 m³ Potable water 277,000 m³ Precipitation 406,000 m³ Total water usage 73,300,000 m³ Water consumption per t copper 161 m 3 /t Cu Waste Recycling Disposal Construction waste Total waste of which hazardous waste Waste per t copper output Waste per t input material 6,400 t 2,800 t 29,620 t 38,900 t 20,300 t 85 kg/t Cu 25 kg/t Conversion into products 99.1 % Emissions Dust Dust per t copper SO₂ NOx per t copper Indirect CO₂ emissions CO₂ from fuels CO₂ from fuels per t Cu Metal discharge in water Metal discharge in water per t Cu Water discharge 48 t 105 g/t Cu 2,000 t 390 g/t Cu 476,600 t 108,000 t 0.24 t/t Cu 670 kg 1.5 g/t Cu Direct discharge 70,953,500 m³ Indirect discharge 56,000 m³ Total water discharge 71,009,500 m³ Water discharge per t copper 155 m 3 /t Cu Area used at the Hamburg site: Total plant area 678,000 m² Buildings and paved area 570,000 m² (equivalent to 84 %) 36

39 Updated Aurubis AG Environmental Statement 2013 Lünen Site Aurubis AG s recycling center is located in the south of the city of Lünen about one kilometer from the town hall. The plant was built and commissioned on undeveloped land between the Cologne-Minden railway and the Datteln-Hamm Canal in 1916 as a branch plant of Hüttenwerke Kayser in Berlin. After the loss of the Berlin plants and reconstruction after the end of World War II, the production facilities were continuously expanded and modernized. After the then Norddeutsche Affinerie AG acquired the majority of Hüttenwerke Kayser shares in 2000, the plant was initially integrated into the company structure and expanded to become the Group s recycling center. Today Aurubis AG s Lünen site is the largest secondary copper smelter in the world with a production capacity of 210,000 t of copper cathodes annually. Primarily recycling raw materials are used in the smelting units in Lünen, including traditional recycling raw materials such as copper scrap and other scrap, slimes and residues as well as increasingly complex materials, in par - ticular electrical and electronic scrap. The feed materials, which are largely delivered by truck, are first sampled, in some cases crushed and separated in a material preparation plant, and then processed in a multi-step metallurgical process. The copper anodes produced in this way are then refined electrolytically into cathodes, which are the final product at the Lünen site. Additional anode quantities from other Aurubis sites are also processed in the copper tankhouse. The core facility for metallurgical processes has been the Kayser Recycling System (KRS) since 2002, which gained a TBRC (top blown rotary converter) in 2011 as part of the KRS-Plus project. The converter copper produced in the TBRC is refined together with copper scrap in the anode furnace and cast into anodes in a casting plant. The anodes are dissolved electrochemically and precipitated as cathodes. Zinc-bearing KRS oxide, iron silicate sand (slag granules), a lead-tin alloy, nickel and copper sulfate as well as anode slimes are produced as by-products of multi-metal recycling. The anode slime is processed in the Hamburg site s precious metal recovery process (see Fig. 2.1). There are about 590 employees at the Lünen site, more than 40 of whom are apprentices. aurubis ag, Lünen Updated Environmental Statement

40 Fig. 2.1: Multi-metal recycling at the Lünen site Sampling, material preparation Slimes Residues Electronic scrap Kayser Recycling System (KRS) Submerged lance furnace Copper alloy scrap Black copper (80 % Cu) Iron silicate sand Zinc-bearing KRS oxide TBRC Converter copper (95 % Cu) Tin-lead rotary furnace Tin-lead alloy The environmental management system An environmental management system exists at the Lünen site as well. It has been certified in accordance with ISO and EMAS and incorporated in a TQM (total quality management) system in connection with quality management pursuant to ISO The TQM system fulfills the requirements of the waste disposal regulation (EfbV) and the law on circulation, withdrawal and environmentally sound disposal of electrical and electronic devices (ElektroG) for the material preparation plant as well as energy management in accordance with 41 Renewable Energy Law (EEG) and the Data Collection Regulation An energy management system pursuant to DIN EN ISO is being prepared and was successfully certified in April Targets, tasks and organization of the environmental management system The targets and tasks of the environmental management system correspond to those at the Hamburg site, while the organization takes site-specific features into account. In this respect, the management handbook and its process and work instructions, etc. are related not only to the environmentally relevant issues including accident prevention and health protection, but also quality assurance measures. The TQM team consists of the Quality and Energy Management Officer, the Environmental Management Officer and other delegated individuals and employees. The officer functions for immission protection and accident prevention waste management radiation protection specialist companies in accordance with the Water Management Act (WMA) hazardous materials Fig. 2.2: Capital expenditure of Aurubis AG at the Lünen site in million/fiscal year About 200 million has been invested in technology and environmental protection since 2000, of which roughly 100 million went to environmental protection alone Environmental protection Technology 38

41 Copper scrap Anode furnace Anode casting plant Tankhouse Anode (~ 99 % Cu) Raw materials Copper products By-products Nickel sulfate Cathode (> % Cu) Anode slime Precious metal production are carried out by the employees mentioned above. The same applies to the Occupational Safety Specialist, while the health protection measures that extend beyond this are the responsibility of Aurubis AG s company Medical Department. The officer function for REACH and Classification, Labeling and Packaging of Substances and Mixtures (CLP) is carried out centrally for all of Aurubis AG from Hamburg. Capital expenditure on environmental protection Capital expenditure on environmental protection also has a high level of significance in Lünen. The Kayser Recycling System (KRS) initially set new precedents with a capital expenditure volume of around 40 million. Additional capital expenditure followed, especially for reducing fugitive emissions in metallurgical facilities and in the storage and handling of feed materials. The emission reduction concept agreed on with the authorities for the period 2005 to 2009 was initially estimated at about 10 million but was then supplemented with additional capital expenditure of 25 million with additional measures. Significant projects included the e-scrap warehouse and warehouse 4 for dust-forming KRS input materials, comprehensive paving of storage areas and the new KRS filter 5. Further more, environmental protection accounted for 17.5 million of the investment costs of the KRS-Plus project, which has been implemented in the meantime. In addition, the renovated anode furnace filter 2 was completed in Overall, around 100 million has been invested in environmental protection in the fiscal years 1999 / 2000 to 2011 / 12 (see Fig. 2.2). Renovation of anode furnace filter 2 In fall 2012, the renovation of anode furnace filter 2 was completed in connection with various improvements to the anode furnace off-gas system. The main components of the project were as follows: Renovation of the filter, which was more than 30 years old, with a highly effective, state-of-the art bag filter. Increase in the total capacity of the anode furnace filtration plant, which consists of three filters, from 150,000 m³/h to 300,000 m³/h. Installation of an off-gas mixer (similar to the mixer installed on the KRS in 2010) in which the individual off-gas branch currents are combined, mixed and directed to filters 1 and 2 (filter 3 continues to function purely as an auxiliary hood filter). Inclusion of the exhaust vapors from the anode casting plant, which had previously been cleaned in the primary smelter s extra filtration plant, in the new system. Installation of new recording equipment on the chimney; the entrance to the Sampling Department is 35 m above the ground and can be reached with outer stairs. aurubis ag, Lünen Updated Environmental Statement

42 (left) New anode furnace filter 2, chimney with outer stairs (right) Off-gas mixer Additional emission reductions can also be expected in this area in the future owing to improved collection and more efficient dedusting of anode furnace off-gases. Moreover, the relocation of exhaust vapor dedusting opens up free capacities in the smelter s extra filtration plant used up to now, which increases efficiency in the roof suction system there. This is intended as described in the permit for the anode furnace filter 2 project to be used to expand the primary smelter s roof suction system. In order to design this as optimally as possible, it was decided to renovate the primary smelter s extra filtration plant as well and to use its maximum possible capacity of 500,000 m³/h. Environmental effects Air Emissions The emissions from directed sources (chimneys) are monitored by continuous measuring devices in connection with emission data transfer. Aside from dust, sulfur dioxide, nitrogen oxides, hydrogen chloride, hydrogen fluoride and mercury in the KRS are measured continuously depending on relevance. Other off-gas and dust components are measured manually. The measurements comply with all limit values or fall significantly below them in some cases. Emissions of dust and especially dust components (copper, lead, arsenic, etc.) have been considerably reduced at the Lünen site in the past several years due to reduction measures. The following figures incorporate the fugitive emissions including storage and handling. A very low level of about 1 % of total emissions of dust and dust components originated in the TBRC (see Fig. 2.3 to Fig. 2.6). Fig. 2.3: Dust emissions at the Lünen site Dust in g/t of copper output 1,

43 View of the off-gas cleaner in the TBRC facility and the newly constructed chimney Note on the selection of the years presented here: Fugitive emissions in particular have been determined or calculated since 2004 in accordance with the methods used at the Hamburg site. The values for 1990, 2002 and 2003 were estimated in a comparable manner, while there are no reliable values for the missing years. Fig. 2.4: Copper emissions at the Lünen site Copper in g/t of copper output Fig. 2.5: Lead emissions at the Lünen site Lead in g/t of copper output Fig. 2.6: Arsenic emissions at the Lünen site Arsenic in g/t of copper output aurubis ag, Lünen Updated Environmental Statement

44 Fig. 2.7: Immissions of PM10 suspended particulates and metallic components on Viktoriastrasse Immission Limit Target value value LANUV¹ MBBM² LANUV MBBM LANUV MBBM LANUV MBBM LANUV MBBM PM 10 ⁴ in µg/m³ ³ Lead in µg/m³ ³ Arsenic in ng/m³ ³ Cadmium in ng/m³ ³ Nickel in ng/m³ ³ NRW State Agency for Nature, the Environment and Consumer Protection 2 Müller-BBM 3 Not measured yet in 2008 ⁴ Dust with particle size <10 µm (inhalable particulate matter) Dust emissions decreased again in 2012, due in part to the improved cleaning of streets, pathways and other areas that have been paved in the meantime. In contrast to the positive trend in dust emissions, copper and lead emissions have increased. A significant reason for this is the emissions from the primary smelter s additional dedusting process. As previously mentioned, this is currently being renovated, so a considerable improvement is expected starting in 2014 after the new filter has been finished and commissioned. Arsenic emissions have been at a very low level since With an annual output of 201,000 t of copper cathodes and a material input of 387,600 t, the following specific quantities result for 2012: Specific emission Specific emission Emission related to input related to products SO₂ kg/t Dust g/t Copper g/t Lead g/t Arsenic g/t The measurements comply with all of the limit values in the permits or fall significantly below them in some cases. The same is true for the other materials listed in the permits, e. g. NOx, HCl, HF, etc. Immissions To measure the immissions of dust precipitation including metallic components, the LANUV (NRW State Agency for Nature, the Environment and Consumer Protection) operates a network of twelve so-called Bergerhoff measurement points in the area surrounding the Lünen plant, which was established after the TA Luft (Technical Instructions on Air Quality Control) went into effect in 2002 and has been expanded little by little (LÜNE 001, etc.) (see Fig. 2.7 and 2.8). While the deposition values of TA Luft 2002 for lead (100 µg / (m² d)), arsenic (4 µg / (m² d)), cadmium (2 µg / (m² d)) and nickel (15 µg / (m² d)) are currently still exceeded at some measurement points, the following reductions are evident on average for the measurement points that were continuously operated in the period from 2006 to 2012 (1 to 3, 5 to 7 and 9 to 11): Development Immission in % Lead 55 Arsenic 74 Cadmium 58 Nickel 40 Note: The deposition values result from a variety of different factors and thus are not binding limit values for the operation of individual facilities. 42

45 Fig. 2.8: Locations of immission measurement points near the Aurubis plant in Lünen MP 1 Viktoriastrasse (see Fig. 2. 7) Bergerhoff measurement points in Lünen 1 Buchenberg / city harbor 2 Kleine Bergstrasse 3 Bergstrasse 48 5 Bebelstrasse / Süggelbach 6 Rail line / mosque 7 Lünen South freight yard 8 Kurt-Schumacher-Str. / Kamener Strasse 9 B 236 / Lippebrücke 10 Im Wiesengrund 11 Builders association / building yard 12 Rail line / Kantstrasse 13 Im Engelbrauck / north side Aurubis plant building The data pool for a comparable assessment is not sufficient yet for measurement points established by LANUV in 2006 at areas that were subject to more pollution. Moreover, there has been a LANUV measurement station for suspended particulates (PM10) including components on Viktoriastrasse (ca. 100 m northeast of LÜNE 12). The position corresponds to that of the cal culated immission maximum. In connection with the KRS-Plus authorization procedure, a supplementary measurement station for Müller-BBM GmbH was established close by starting in In contrast to the deposition values, which are not yet satisfactory, the suspended particulate measurements fall distinctly under the limit values for PM10 and lead as well as the EU target values for arsenic, cadmium and nickel that go into effect starting aurubis ag, Lünen Updated Environmental Statement

46 Fig. 2.9 a: Water consumption and wastewater discharge at the Lünen site Water consumption in m³ p. a. Wastewater discharge in m³ p. a.* 609, , , , , , , , , , * Calculation formula in accordance with the Lippe Association While the level of suspended particulates (PM10) is about 30 % below the limit, the level of lead is more than 90 % lower than the limit. The continued improvement for arsenic is especially positive: it was initially 35 % below the limit in 2008 and is now more than 50 % below. Cadmium is 90 % below the limit in the meantime, while nickel is 80 % below. Noise Noise protection measures take high priority in the conception of new facilities in particular. The additional noise pollution in the area in terms of TA Lärm should be marginal, i. e. the levels should be at least 10 db(a) lower than the TA Lärm immission reference values. This requirement was fulfilled in the last few years in all projects, and noise reduction measures were carried out at existing facilities as well. The differences between the LANUV measurements and the Müller-BBM measurements are within the range of measurement uncertainty; overall, a downward trend has been apparent for the metals since The measurements carried out in 2012 showed that the reference values relevant for the respective applications are observed at all assessment points predetermined by the authorities. In the areas classified as mixed use areas, this is 60 db(a) maximum during the day and 45 db(a) maximum at night. Fig. 2.9 b: Illustration of planned rainwater retention basins at the Lünen site Layout (section from p. 43) m³ service water storage tank 2 Treatment plant hall 3 3,000 m³ rainwater retention basin 4 6,000 m³ rainwater retention basin 44

47 Fig. 2.10: Waste generated at the Lünen site in t p. a Packaging and other waste 1,084 1,189 1,318 1,533 1,276 Construction waste ,701 44,487 41,531 23,740 Spent potlining 1,089 1,279 1, Retail products and waste products from the material preparation facility 7,890 7,190 4,737 5,410 5,713 Total 10,305 29,359 52,045 49,464 30,993 of which was hazardous waste , Water Water is used in the Lünen plant for various cooling purposes, including anode cooling and slag granulation, as feed water for the steam boiler, for operating several sweepers as well as sprinkling driveways, plant/storage surfaces and input materials. Because of the increases in water consumption for the latter measures to reduce dust emissions, the water supply and the resulting wastewater volume rose again in 2012 (see Fig. 2.9a). Waste The waste from the Lünen plant mainly results from packaging from delivered materials, from construction measures and from spent potlining from the KRS, anode furnaces, etc. The externally marketed contingents of the material preparation plant, e. g. aluminum and separated plastics for continued recycling, are also inevitably among the waste from the site, as they do not lose their waste properties due to preparation (see Fig. 2.10). To decrease the use of city water, there are plans to retain and utilize rainwater or surface water. The permit application was submitted in fall 2012 after planning ended. The contract was issued and construction started in spring Packaging and other waste are at the level of the past few years. As in the previous year, construction projects were the predominant source of waste in The plans were changed so that now two rainwater retention basins (6,000 m³ and 3,000 m³ large) and a 500 m³ large service water storage tank are being built northeast of the new plant entrance. Two additional 100 m³ large service water storage tanks that both use treated rainwater and excess water from the steam supply are being constructed in the central plant area. The main consumers of the service water will be KRS granulation, anode cooling and the sweepers (see Fig. 2.9b). Some spent potlining was recycled internally, i. e. in the KRS, so the volume disposed of externally in 2012 was lower than before. The volume of hazardous waste was therefore also lower. All of the quality-tested KRS slag granules (iron silicate sand) produced at the site were marketed as a product for various construction purposes and thus are not included in the table. aurubis ag, Lünen Updated Environmental Statement

48 Fig. 2.11: Raw material procurement: The supply is concentrated in Europe despite global purchasing activities. Supplier and purchasing structure Sources of recycling materials in FY 2011/12 in % Very broad supplier base with about 550 sources in (Lünen and Hamburg) more than 60 countries Rest of Mainly spot transactions with individual annual Western Europe 30 contracts in the last several years, but also long-term cooperation with the industry Dual purchasing organization with central procurement in Lünen and agency network/subsidiaries/holding North America 11 companies (USA, CDN, E, GB, I, Eastern Europe) Other 3 5 Eastern Europe 51 Germany Soil conservation Restoration measures Since the plant opened in 1916, facilities producing nonferrous metals have been operated continuously at the site. In conjunction with war damages, this led to a strain on the soil in the past. On the basis of comprehensive tests, a restoration plan was developed, which was coordinated with the responsible authorities and has been partly implemented. The restoration concept includes encapsulating the contaminated area with the help of a sealing wall as well as a drainage facility that requires the discharged water to be purified. Part of the sealing wall and some flowing wells have already been completed in the run-up to construction measures. The treatment of the restored water was optimized again with additional tests. Because of the sulfate content, the water cannot be discharged via the city sewer system, so direct discharge into the Lippe is required. The licenses still pending are currently being discussed with the Unna district. Preventative measures Preventative and protective measures have been developed for several decades in order to eliminate future strains on the soil. They are primarily related to the facil ities dealing with materials hazardous to water, e. g. the tankhouse and oil storage. Furthermore, the storage spaces for input materials are being designed so that even traces of deposits and components of input materials hazardous to water cannot end up in the soil. Indirect environmental impacts Delivery traffic is one of the main indirect environmental impacts. We strive to relocate this as much as possible from roads to railways and waterways (see Fig. 2.11). With the extension of the plant railway and the two-track expansion on the northern plant premises completed in 2011, the anodes delivered to the plant and the cathodes delivered from the plant by train increased distinctly again in Nevertheless, the delivery of most input materials and auxiliary materials with trucks cannot be avoided. The main reason is that the type of delivery is the supplier s choice. About 70 % of deliveries arrive through the Buchenberg entrance, which is completely located in an industrial area of the Lünen city harbor and is separated from residential areas with an effective noise protection wall. Energy / climate protection Energy is required first and foremost to heat the smelting facilities (primarily heating oil) as well as for the tankhouse (electricity). Steam for leaching and electrolysis is mainly produced in the KRS waste heat boilers and anode furnaces. There are also two auxiliary boilers fueled with light oil or natural gas. Their output is under 20 MW, so the site has not been subject to the conditions of the Greenhouse Gas Emission Trade Law (TEHG, 2nd trading period). Production increases in the KRS and anode furnaces were compensated for by more efficient energy input, so the absolute consumption of heating oil, coal and coke did not change significantly. In the period from 2008 to 2012, the throughput of recycling raw materials rose from about 255,000 t to 367,000 t, or by 40 %. 46

49 Fig. 2.12: Energy consumption1 at the Lünen site in GWh p. a Heating oil Coal, coke etc Natural gas Electricity Total Calculated using DEHSt (German Emissions Trading Authority) standards 2 Exclusively external electricity at the moment. The use of internal electricity from waste heat steam is planned for the future, which will cover some of the demand. Fig. 2.13: Environmental protection measures account for 33 % of electricity demand. 49 % Tankhouses 75,000 MWhel Total consumption 154,000 MWhel 16.5 % 33 % 1.5 % Production and processes 25,900 MWhel Other environmental protection 19,900 MWhel Large filters 30,700 MWhel Administration, social areas, lighting 2,500 MWhel Fig. 2.14: Reduction of specific energy demand due to new technologies and throughput increase Primary energy input at the Lünen site in GWh Specific energy demand at the Lünen site in kwh / t of secondary raw material input Start of KRS procedure 2,700 2, , KRS significantly reduces the energy input. Multi-metal recycling requires more absolute energy.»» With respect to the use of recycling raw materials, the primary energy demand is decreasing continuously. Fig. 2.15: CO₂ emissions at the Lünen site in t p. a Total CO₂ 140, , , , ,870 Biogenic CO₂ CO₂ subject to DEV , , , , ,870 1 Data Collection Ordinance 2020 for the third emissions trading allocation period aurubis ag, Lünen Updated Environmental Statement

50 Fig. 2.16: Specific energy consumption at the Lünen site in MWh/t of copper output The raw material-related energy demand decreased notably (see Fig. 2.14). The higher natural gas consumption is a result of the TBRC, and the higher electricity consumption is due to additional drives, filters, etc. One-third of the electricity demand is necessary for environmental protection measures (see Fig and 2.13). On the left-hand curve, the graphic (see Fig. 2.14) shows that the site s absolute energy demand has been relatively constant for 10 years and rising slightly. When the energy input is shown together with the throughput of recycling raw materials, a more than 30 % reduction in the specific energy demand is evident for the same period. This figure shows the multi-metal recycling strat egy selected for the Lünen site very concretely. With the same cathode copper output, metal should be produced from a high and continuously increasing input of recycling materials. The average copper content in the raw materials is decreasing, while the proportion of by-metals such as tin, nickel, gold and silver is increasing. Projects such as injecting electronic scrap into the KRS smelting furnace contribute to using raw materials energy content more efficiently with as low an input of primary energy sources as possible. For the future, we expect CO₂ emissions to stagnate or continue decreasing with an increasing quantity of low-grade recycling materials (see Fig and 2.16). In this respect, specific CO₂ emissions have also increased since (see Fig. 2.17). CO₂ emissions trade The third trading period of EU emissions trading for greenhouse gases starts in 2013, which is relevant for secondary copper production at the Lünen site. The allocation application pursuant to 9 TEHG and the monitoring plan were submitted to the DEHSt on time. The latter was approved in February The CO₂ emissions were also determined in accordance with DEHSt standards. The increase in the absolute figures is mainly a result of a higher quantity of complex input materials with low copper contents. This longterm trend led to an increase of more than 10,000 t in 2011 due to the implementation of the KRS project is the first complete year of operation for the Kayser Recycling System, which was expanded with the TBRC. As described already with the energy input, the CO₂ emissions trend reflects the corporate strategy of increasing the amount of raw materials containing low levels of copper and decreasing the amount of scrap con taining high levels of copper. Additional climate protection measures Improvements in energy use have been a focus of technical development at the Lünen site for a long time. One milestone was replacing the coke-operated shaft furnaces with the modern Kayser Recycling System about 10 years ago. Specific energy consumption decreased again in the course of additional optimizations. It should be noted that the increasing use of complex recycling raw materials with comparably low copper contents requires more energy than traditional scrap as a matter of course. 48

51 Fig. 2.17: Specific CO₂ emissions at the Lünen site in t of CO₂/t of copper output In this respect, measures for the efficient use of the organic material inevitably contained in the input materials as a carbon supply for smelting and reduction processes is becoming more important. The silo and injection facility conceived for this purpose started up in March Communication with the general public / special occurrences There were no incidents or malfunctions with significant environmental effects within the meaning of the Hazardous Incidents Ordinance in Lünen during the reporting period. Another project is the efficient use of steam from waste heat. After reviewing different alternatives, electricity production with the help of a steam turbine turned out to be the best solution. After the planning process concluded, the permit application was submitted in fall Construction started in early 2013 and the turbine is expected to start up in mid The turbine will produce an average of 3.8 MWel (the energy demand of about 7,500 households) in the future. This can be used within the plant or distributed externally. The results of the immission measurements made by LANUV (NRW State Agency for Nature, the Environment and Consumer Protection see the Immissions section) and analyses of leafy greens in local gardens were presented and discussed on November 27, 2012 at an informational event hosted by the city of Lünen. The LANUV experts highlighted improvements in deposition values at the measuring points that are primarily influenced by Aurubis. Construction of silo 2 aurubis ag, Lünen Updated Environmental Statement