Circular economy in Eramet Norway

Transcription

1 Circular economy in Eramet Norway B. Ravary R&D director Eramet Norway EIT raw Material metal processing event, Indutry Futurum, Oslo Nov ALLOYS, ORES AND PEOPLE.

2 ENK Our strategic goals Health and Safety first! The smallest environmental footprint in our industry The world s leading producer of refined Mn-alloys Among the most cost competitive producers of Mn-alloys To achieve this we need to ensure that we are a learning organization 2 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

3 ERAMET NORWAY GOALS WITHIN CLIMATE AND ENVIRONMENT Climate Energy Environment [DRAFT] Circular economy [DRAFT] Long term goals We shall reduce CO 2 emissions by at least 43% within 2030 and 80% within 2050, compared agiainst the reference year We shall increase energy efficiency by at least 27% within 2030, compared against the reference year We shall avoid negative environmental impacts to the local societies we are located in. (No breach of permits) We shall improve resource efficiency by increasing value creation linked to byproducts and waste materals and reduce level of depositing by 50% within Parameters CO 2 emissions per sellable ton (Electricty consumption less Energy recovery) / Sellable tons Measurements according to permit Measurements vs internal goals (ISO14001) Neighbor complaints Negative articles in media Internal and external audits Sales of byproducts and waste materials Utilizationyields of Mn (and other resources) Depositing volumes Reduced costs Level ENO Total and by product ENO Plant total and by product ENO Total and by Plant Per plant and ENO Total Per plant and ENO Total Reference for goals EU: 2030: 40% vs : 80-95% vs 1990 EU ETS:: 2030: 43% vs 2005 Norsk Industri: According to EU ETS EU: 2030: 27% vs 2005 International and national directives, conventions, laws and regulations, e.g. EU s Industrial Emission Directive ENO emission permits (by plants) International and national directives, conventions, laws and regulations, e.g. EU s Industrial Emission Directive ENO emission permits (by plants) Framework The framework was adopted by EU leaders in October It builds on the 2020 climate and energy package. It is also in line with the longer term perspective set out in the Roadmap for moving to a competitive low carbon economy in 2050, the Energy Roadmap 2050 and the Transport White Paper On the basis of the Energy Efficiency Directive, the European Council has endorsed an indicative energy savings target of 27% by This target will be reviewed in 2020 having in mind a 30% target. Statement: «We shall comply with and contribute to further develop BAT» Other references Paris COP UN Sustainability goals UN Sustainability goals UN Sustainability goals UN Sustainability goals «Drivers» Reduce absolute emissions Increase production efficiency Reduce electricity consumption for furnaces and aux.systems Recover and utilize energy Increase production efficiency Reduce environmental emissions -Optimize equipment/tech -Increase competence -Improve routines/procedures Increase production efficiency Optimize procedures Optimize technology and processes 3 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

4 VALUE CHAIN & MAIN RECYCLING LOOP STEEL Recycling of steel (FeMn, SiMn) Purpose of Mn in steel: Hardness, abrasion resistance, elasticity, ease of working steel, weldability 4 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

5 A WORLD LEADING PRODUCER OF MANGANESE ALLOYS A COMPANY IN THE ERAMET GROUP Eramet Norway Sauda Eramet Norway Porsgrunn Built in 1915 Built in 1913 Built in 1974 Eramet Norway Kvinesdal Eramet Norway acquired ENS and ENP in 1999 from Elkem ENK acquired from Tinfos i 2008/2009 With three production sites and one common administration we will be among the worlds most efficient Mn alloy producer. 2016: 517 employees, Turnover 4. 5 billions Eramet NOK Operating Norway result - Circular 722 Economy MNOK - EIT Raw 5 Materials 2018

6 Production process at plant and circular economy Eramet Norway Porsgrunn Plant Raw materials FeMn process FeMn Filter dust FeMn Distribution Sizing Casting Refining Tapping SiMn process Raw materials incl. HC slag SiMn Filter dust Distribution Sizing Casting Refining Tapping SiMn Status circular economy % circulated % circulated Distribution Sizing Casting Bi-product SiMn slag <50 % circulated 6 Our main principle for sustainably is to produce in the most efficient way and also try to reuse/recycle all waste or develop by-products. ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

7 Case 1: Mn-units and the by-product SiMn slag Applications of SiMn slag: Stones in jewelry ton/year Mn ore 40% Mn Traditionally and still Filling mass in construction ground work (at land) Filling mass in sea for land creation Introduced last couple of years Filler in asphalt (P14306B Asfalt) Raw material in concrete (CE Ytelseerklæring Betong 8-16) On going development: Covering of contaminated sea bed (P17054A Tildekkingsmasse,M- 441) Bilde av SiMn slagg + Bilde av øredobber ton/year SiMn slag 2-5% Mn ton/year FeMn alloy 80% Mn ton/year FeMn slag 30 % Mn ton/year SiMn alloy 70% Mn 7 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

8 Case 2: Energy in furnace gas, and CO 2 emissions Open furnaces 1953 Worlds fist sealed FeMn furnace CO CO 2 In open furnace: the furnace gas from the reduction process will burn on top of the furnace all CO is transformed to CO All furnaces closed Furnace gas delivery to Hydro (Yara) Small scale /low regularity used for : Calcination of limestone and dolomite Raw material production of formic acid CO CO 2 Sealed furnace: the furnace gas is captured and can be used as a resource New facilities for furnace gas delivery to Hydro (Yara) built, Gas used as energy in N 2 production 2001 First FeMn furnace to install mercury removal unit (MRU) on the unburned furnace gas. improved the gas quality Continuously increase in gas sales CO 2 CO Utilization: the more we utilize the smaller carbon footprint and the more we get paid 15 MNOK in ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

9 Case 2 resulting carbon footprint: Refined FeMn with the worlds smallest carbon footprint Refined FeMn from Porsgrunn has the smallest carbon footprint in the world. 1 t CO 2 / t metal Global MC & LC ferromanganese production ranked by CO 2 emissions, 2015 Tonnes CO 2 /tonnes Refined FeMn Sauda Porsgrunn 9 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

10 Case 3: Sludge from off-gas, looking for better solutions Treatment Zn/Pb returne d to SAF K/Na returned to SAF Waste to be deposited % Mn Recovered to process Product Technological risk / recent studies Landfill (current) None None Mountain cavern None None Hydrometallurgy Mn 2 SO 4 unknown Briquetting Mn alloy Poor furnace operation Direct injection Mn alloy Poor furnace operation Sintering Mn alloy Poor furnace operation Agglomeration & Partial recycling costs Mn alloy recycling x % (2018) Solid state Mn ore RHF operation not reduction substitute known for Mn Oxyfines burner High Mn slag Expensive Melting slag HC FeMn slag Too expensive (2011) Melting alloy Mn alloy Too expensive (2011) 10 ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS 2018

11 Some conclusions circular economy Efficiency is key To be located in an industrial area/cluster is an advantage when it comes to finding and implementing circular solutions It has to be profitable to get done Circular economy is politically wanted, but to go from waste to value involves a huge bureaucracy, and very limited help... We have to speed up ERAMET NORWAY - CIRCULAR ECONOMY - EIT RAW MATERIALS Circular economy helps us meet future changes by combining technology and economy.