ENVIRONMENTAL PROFILE REPORT

Transcription

1 ENVIRONMENTAL PROFILE REPORT Life-Cycle inventry data fr aluminium prductin and transfrmatin prcesses in Eurpe February 2018 EXECUTIVE SUMMARY

2 THE ALUMINIUM EFFECT 80+ members acrss the aluminium value chain 600 plants in 30 Eurpean cuntries 39.5 billin eurs annual turnver 1 millin+ direct and indirect jbs 75% f all aluminium ever prduced is still in use Recycling saves 95% f the energy needed fr primary prductin Cmpared t steel, 200kg f aluminium in a car can save up t 16g f CO 2 per km

3 Executive summary Intrductin This Eurpean Aluminium Envirnmental Prfile Reprt cvers the envirnmental impact f the entire aluminium value chain in Eurpe, frm metal supply - primary and recycling - t semi-fabricatin - rlling, fil and extrusin. It prvides accurate and reliable data n aluminium industry s envirnmental perfrmance in Eurpe. The 2015 data demnstrate strng imprvement by the industry. First, the envirnmental impact f the primary prductin has decreased significantly (by 21 per cent fr Glbal Warming Ptential) while the envirnmental perfrmance f the primary aluminium cnsumed in Eurpe has remained stable. Fr the semi-fabricatin (rlling and extrusin) and the recycling industry there has been a strng imprvement in the envirnmental perfrmance f thse prcesses in Eurpe. The Eurpean aluminium industry has been a leader in imprving envirnmental perfrmance fr many years. Since 1990, the industry has reduced the carbn intensity f its primary prductin by mre than half. This has led t Eurpe being able t bast ne f the lwest primary prductin carbn ftprints in the wrld; less than half the glbal average and almst ne-third that f China. This is imprtant, nt simply frm an envirnmental perspective but als frm that f meeting grwing public interest and cncern. Stakehlders rightly want t knw the impact f the prducts they use and cnsume t infrm their behaviur. Hwever, when assessing the full envirnmental impact f aluminium prducts, it is vital t cnsider the full life-cycle f the prduct, including the use and recycling phases. These steps are essential t fully reflect the intrinsic prperties f aluminium prducts such as light weighting and recyclability). As highlighted in ISO and 14044, nly the envirnmental aspects f a prduct system r a service in a life-cycle perspective, i.e. frm cradle t grave r frm cradle t recycling, are scientifically sund. This Eurpean Aluminium Envirnmental Prfile Reprt has been reviewed by tw renwned Life Cycle Assessment experts, Prf Dr Matthias Finkbeiner and Prf Dr. Walter Klöpffer. An essential verview, it recgnises the nging effrts by the aluminium industry n LCA as stressed in the fllwing statement: T sum up, this prject is an excellent example fr generic data acquisitin, cnslidatin and presentatin. It cntributes t the Life Cycle Assessment develpment by prviding reliable data fr ne imprtant material and cntinues a traditin f ne and a half decade in an exemplary way. Highlights frm the reprt Primary aluminium Eurpean Aluminium is prviding tw envirnmental datasets fr primary aluminium: ne fr dmestic prductin in Eurpe (representing the Eurpean prductin mix) and the ther fr aluminium cnsumed in Eurpe (representing the Eurpean cnsumptin mix), i.e. including net imprts. In fact, Eurpe (EU28+EFTA) imprts arund half f its supply f primary, mainly frm Russia, Africa and the Middle East. Primary aluminium prductin in Eurpe In cmparisn with the previus LCI data cllectin exercise in 2010, fur smelters lcated in EU have been clsed. EFTA cuntries (i.e. Iceland and Nrway) represent arund 50 per cent f EUROPEAN ALUMINIUM Envirnmental Prfile Reprt

4 Eurpean prductin in 2015, up frm arund 40 per cent five years ag. As a result, the electricity mix f Eurpean smelters has shifted frm apprximately 50 per cent renewable energy (e.g. hydr and gethermal) in 2010 t arund 70 per cent in In additin, Eurpean smelters cntinue t imprve their envirnmental perfrmance. Fr example, PerFlurCarbn (PFC) emissins (CF4 has drpped by 50 per cent and C2F6 by 52 per cent cmpared t 2010), have drpped significantly. Ttal PFC emissins have nw fallen by 97 per cent cmpared with In alumina prductin in Eurpe, there has als been a significant reductin in thermal energy cnsumptin (dwn 13 per cent cmpared t 2010). This reflects a switch frm heavy fuel t natural gas calciner technlgy within alumina refineries. This has made a significant imprvement t air emissins quality. Fr example, sulphur dixide (SO2) particulates emissins decreased by mre than 90 per cent and nitrgen dixide (NOx) by arund 74 per cent in cmpared with Ultimately, all envirnmental indicatrs fr primary prductin in Eurpe have significantly imprved. Fr example, the Glbal Warming Ptential (GWP) i.e. the Green Huse Gas (GHG) emissins decreased by 21 per cent t 6.7 kgco2 equivalent (CO2e) per kg f primary aluminium. Fr illustratin, this saving f 7.6 millin tnne CO2e is equivalent, n an annual basis, t arund ne-third f the GHG emissins f Cratia 1. Primary aluminium cnsumptin in Eurpe This dataset is based n the Eurpean prductin f primary aluminium (see abve), plus net imprts. Eurpe is increasingly dependent n imprts f primary aluminium. In 2015, imprts f primary metal represented arund 49 per cent f Eurpean cnsumptin up frm 44 per cent in In additin, the surces f primary metal have slightly changed. Russia remains the main exprter f primary metal t Eurpe with 39 per cent f ttal imprts, fllws by Africa with 23 per cent. Hwever, the Middle East nw prvides arund 21 per cent f Eurpean imprts up frm nly 11 per cent in Meanwhile, the share f imprts frm Nrth America decreased significantly frm 11 t 6 per cent in This situatin explains the decrease f the imprts derived frm hydrelectricity (67 per cent in 2015 vs. 79 in 2010) and an increase f the imprts derived frm natural gas (22 per cent in 2015 vs. 12 in 2010). This has slightly increased all envirnmental indicatrs relating t Eurpean imprts f primary aluminium. Fr example, the carbn intensity f the electricity mix f Eurpean imprts increased frm 203g CO2e/kWh in 2010 t 267g CO2e/kWh electricity in In terms f ttal cnsumptin, the verall envirnmental impact f the primary aluminium used in Eurpe remains relatively stable at 8.6kg CO2e per kg f primary aluminium. This is explained by the strng decrease in the envirnmental impact f dmestic prductin (dwn 21 per cent) being balanced by an equivalent increase in the envirnmental impact f imprts. Semi fabricatin The aluminium industry is prviding three envirnmental datasets fr semi fabricatin (i.e. prductin mix) in Eurpe: ne fr rlling prductin, ne fr extrusin prductin and ne fr fil 1 In 2015, Cratia emitted apprximately 24 millin tnnes CO2-equivalent (Surce: Eurpean Envirnmental Agency) 4 EUROPEAN ALUMINIUM Envirnmental Prfile Reprt 2018

5 prductin (via EAFA 2 ). Fr these datasets, imprts f semis have nt been cnsidered due t the absence f ther reginal datasets and the limited trading flw f semis entering Eurpe, i.e. n average arund 10 per cent f the dmestic prductin. Rlling The envirnmental impact f rlling mill prcesses fell significantly in cmparisn with Fr example, the ttal energy cnsumptin decreased by 9 per cent. The same trend is seen in ther inputs materials used in the prcess, such as ancillary prducts r packaging. The prcesses shwed a strng decrease in the utputs f mst air emissins and in the vlume f hazardus waste generated. As a result, the envirnmental impact f the aluminium rlling mill prcess has decreased fr mst indicatrs. Fr example, the Glbal Warming Ptential (GWP) decreased by arund 25 per cent while ttal energy cnsumptin fell by 16 per cent. Other indicatrs such as acidificatin (related t SO2 emissins) and eutrphicatin (related t NOx emissins) have als decreased, by 52 per cent and 25 per cent respectively. Extrusin The envirnmental impact f extrusin prcesses imprved significantly cmpared with Fr example, ttal energy cnsumptin fell by 8 per cent. Cnsumptin f ancillary materials has remained stable in the same perid even if there seems t have been a slight increase in the cnsumptin f materials fr packaging. Regarding the utputs frm the prcess, the main air emissins (i.e. NOx and SO2) have decreased. The ttal vlume f waste generated increased, hwever, mst f this increase is directed fr recycling and nt fr landfill. As a result, the verall envirnmental impact f the aluminium extrusin prcess decreased fr mst indicatrs. Fr example, the Glbal Warming Ptential (GWP) fell by 11 per cent. In additin, indicatrs such as acidificatin (i.e. related t SO2 emissins) als decreased significantly, falling 37 per cent. Fil The LCI dataset relating t fil prductin was develped by EAFA (the Eurpean Aluminium Fil Assciatin) and cvers the entire prcess, i.e. prductin f fil stck (bth ht-rlling and cntinuus-casting rutes), fil rlling plus recycling f prcess scraps. Cmpared with 2010 data, the ht-rlling prcess, which generates the fil stck fr the ht-rlling rute was directly include in the LCI dataset. Fr this reasn, there is n direct cmparisn with 2010 in this reprt. Recycling Eurpean Aluminium is prviding tw envirnmental datasets fr recycling in Eurpe: ne fr remelting prductin (i.e. fr wrught ally ingts) and ne fr refining prductin (i.e. fr casting allys ingts). Remelting The verall envirnmental impact f remelting imprved significantly cmpared t Fr example, ttal energy cnsumptin decreased by 12 per cent. Otherwise, ancillary materials cnsumptin is stable. There was a significant fall in utputs frm the prcess, with a strng decrease f mst air emissins (e.g. dwn 15 per cent fr NOx and 19 per cent fr SO2) and vlume f 2 Eurpean Aluminium Fil Assciatin (EAFA) EUROPEAN ALUMINIUM Envirnmental Prfile Reprt

6 waste generated. As a result, the verall envirnmental impact f remelting has decreased fr mst envirnmental indicatrs. Glbal Warming Ptential (GWP) decreased by 9 per cent and ttal energy cnsumptin by 4 per cent. In additin, indicatrs such as acidificatin (related t SO2 emissins) als fell by 19 per cent. Refining Recycling efficiency and recycling rutes are heavily dependent n scrap rigin and quality. Therefre, fr specific aluminium applicatins r prducts, the recycling scenari(s) and the recycling rutes shuld be clsely analysed in rder t develp better-adapted mdels and assciated LCI datasets. This Eurpean mdel fr recycling is being refined by Eurpean Aluminium members. Hence, this reprt relies n 2010 results. The updated LCI results will be part f a future publicatin. Fcus n Glbal Warming Ptential (GWP) results As an example f the envirnmental indicatrs in this reprt, the Glbal Warming Ptential (i.e. Greenhuse Gas emissins expressed in CO2 equivalent - CO2e ) is reprted belw fr the varius datasets. Eurpean Aluminium datasets Value (in kg CO2e per kg f prductin) Primary aluminium prduced in Eurpe (cradle t gate) 6,7 Primary aluminium used in Eurpe (cradle t gate) 8,6 Sheet prductin (gate t gate) 0,4 Extrusin prductin (gate t gate) 0,7 Fil prductin (gate t gate) 1,3 Remelting prductin (gate t gate) 0,3 Refining prductin (gate t gate) 0,5 Backgrund Sciety is increasingly sustainability cnscius and aware. Grwing numbers f stakehlders seek infrmatin and data n the envirnmental impact f the prducts they use and cnsume. T meet this demand, cmpanies are increasingly turning t Life-Cycle Assessments 3 (LCAs) as a cmmunicatin tl. Plicy makers als use LCA cncepts in certain envirnmental legislatins. Fr example, at Eurpean level, legislatin n ec-design and envirnmental prducts plicies (e.g. MEErP 4, PEF 5 ) are based n LCA cncepts. This is als the case fr the Envirnmental Prducts Declaratins (EPDs) cmmnly used in the building sectr. Aluminium ffers numerus intrinsic prperties (e.g. lightness, strength, recyclability) that match the grwing demand fr mre sustainable prducts in several applicatins such as transprt, building and packaging. Thrugh its use and prmtin f life-cycle thinking fr mre than 20 years, Eurpean Aluminium supprts custmers in assessing the envirnmental impact f prducts using aluminium. This has highlighted the clear need fr rbust and reliable data t make these assessments. 3 Life-cycle assessment (LCA) is a technique t assess the envirnmental aspects and ptential impacts assciated with all the stages f a prduct s, prcess r services life. 4 Methdlgy fr the Ec-design f Energy related Prducts (MEErP) 5 Prduct Envirnmental Ftprint (PEF) 6 EUROPEAN ALUMINIUM Envirnmental Prfile Reprt 2018

7 Scpe f the reprt This reprt aims t: Update the envirnmental data (e.g. energy cnsumptin) n the varius prcesses f aluminium prductin in Eurpe. Prvide accurate and reliable generic industry Life-Cycle Inventry (LCI) datasets fr the key prcess steps essential fr calculating the envirnmental impact f prducts using aluminium. These new datasets, based n 2015 prductin data, update the 2010 versins. The reprt is aimed at LCA practitiners, researchers and envirnmental managers wrking in, and interested in, the aluminium value chain, particularly thse experts that are part f aluminium cmpanies, their custmers (such as in transprt, building and cnstructin and packaging), cnsultancies (e.g. LCA databases suppliers), research centres (e.g. university, R&D centres) r administratins (e.g. EU institutins). This reprt prvides seven envirnmental datasets cvering the entire aluminium value chain prductin in Eurpe: 1. Primary aluminium prduced in Eurpe (cradle t gate 6 ): this dataset includes the envirnmental impact f prducing a primary aluminium ingt in Eurpe ready fr delivery t the user as well as the impact f surcing the raw materials frm the smelters (i.e. alumina and bauxite mining). The data uses 2015 figures. 2. Primary aluminium cnsumed in Eurpe (cradle t gate): this dataset includes the envirnmental impact f the cnsumptin (i.e. prductin and net imprts) f a primary aluminium ingt in Eurpe ready fr delivery t the user. It als captures the impact f surcing the raw materials frm the smelters (i.e. alumina and bauxite mining). The data uses 2015 figures. 3. Rlling mill prcess in Eurpe (gate t gate): this dataset includes the envirnmental impact f the aluminium rlling mill prcess, frm ingt (i.e. slab) t aluminium sheet (i.e. flat-rlled prducts) ready fr delivery t the user. The data uses 2015 figures. 4. Fil prcess in Eurpe (gate t gate): this dataset includes the envirnmental impact f the aluminium fil prcess in Eurpe, i.e. frm the strip-casting prcess and frm the cldrlling prcess t the aluminium fil ready fr delivery t the user. The data uses 2014 figures. These datasets are prepared in cllabratin with the Eurpean Aluminium Fil Assciatin (EAFA). 5. Extrusin prcess in Eurpe (gate t gate): this dataset includes the envirnmental impact f the aluminium extrusin prcess, frm the ingt (i.e. billet) t the aluminium prfile ready fr delivery t the user. The data uses 2015 figures. 6. Remelting prcess in Eurpe (gate t gate): this dataset includes the envirnmental impact f the aluminium remelting prcess, frm pre-r pst-cnsumer scrap t the wrught ally ingt ready fr delivery t the user. The data uses 2015 figures. 7. Refining prcess (gate t gate): this dataset includes the envirnmental impact f the aluminium refining prcess frm pre-r pst-cnsumer scrap t casting ally ingt ready fr delivery t the user. The data uses 2010 figures. An update t these datasets is under 6 Mining t primary ingt casting EUROPEAN ALUMINIUM Envirnmental Prfile Reprt

8 develpment, as they require deeper analysis as explained belw. These new data will be published separately at a later date. Prductin manufacturing f final prducts (e.g. mtr vehicles, aluminium cans, etc.) and the use phase f the prducts are nt included in this assessment, as these datasets are mre specific t aluminium custmers. Hwever, these shall be included when assessing the full life-cycle assessment f final prducts cntaining aluminium, as emphasised belw. Emissins reprting scpe These seven LCI data include the direct emissins relating t aluminium prcesses (Scpe 1), the indirect emissins (e.g. frm electricity) related t energy cnsumptin (Scpe 2) and all ther indirect emissins (Scpe 3) frm ther ancillary materials. A simplified definitin f the prject scpe is prvided belw. Gegraphical scpe The gegraphical area cvered by Eurpean Aluminium s dataset is cmpsed f the 28 EU Member States and the EFTA cuntries (Nrway, Switzerland and Iceland) unless therwise stated (e.g. Turkey fr rlling). Methdlgy This reprt, and the assciated LCI data have been develped in full cmpliance with the tw relevant ISO standards ISO and [8-9]. The 2015 envirnmental data have been cllected and develped by the aluminium industry based n inputs prvided by its members. The cmpleteness f the data is cnsidered excellent fr mst segments and representative f the aluminium industry. Fr example, fr the electrlysis step, which cntributes significantly t the envirnmental impact f the value chain, the industry data cllected cvers arund 85 per cent f Eurpean prductin. Fllwing cnslidatin, the data cllected have been integrated in LCA sftware (i.e. Gabi) t 8 EUROPEAN ALUMINIUM Envirnmental Prfile Reprt 2018

9 generate the full envirnmental impact assessment f aluminium prcesses (i.e. reprting Scpes 1, 2 and 3). Fr primary aluminium industry, which is electricity intensive, a specific mdel has been develped reflecting real energy surcing f the primary aluminium prduced and used in Eurpe. Finally, this reprt has been reviewed by tw renwned LCA experts, Prf. Matthias Finkbeiner (Technische Universität Berlin, Chair f Sustainable Engineering, Managing Directr f the Department f Envirnmental Technlgy) and Prf. Dr. Walter Klöpffer (Editr-in-chief, Internatinal Jurnal f Life-Cycle Assessment). Reviewers acted as independent experts and nt as representatives f their rganisatins. Hw t use these aluminium LCI datasets The aluminium industry develps envirnmental datasets fr varius aluminium prcess steps (primary, recycling, rlling, fil and extrusin). T determine the life-cycle prfile f the respective prducts, these datasets need t be cmbined in a mdular way. Fr example, the LCI f an aluminium sheet made frm primary aluminium needs t cmbine the cradle t gate LCI f the primary step (prductin r cnsumptin) and the gate t gate LCI f the rlling mill prcess. Hwever, when assessing the full envirnmental impact assessment f aluminium prducts, ne must als cnsider the full life cycle f the prduct, by including, fr example, the benefits r burdens the prduct prvides during its use phase and at its end f life (e.g. recycling). In additin, the Eurpean aluminium industry recmmends crediting the envirnmental benefits frm recycling using the s-called substitutin methdlgy. This apprach is explained in detail in the technical paper aluminium recycling in LCA, which can be dwnladed frm ur website. These steps are essential t be able t fully reflect the intrinsic prperties f aluminium prducts (e.g. lightweighting, recyclability) when assessing their envirnmental impact. As highlighted in ISO and 14044, nly the envirnmental aspects f a prduct system r a service frm a lifecycle perspective, i.e. frm cradle t grave r frm cradle t recycling, are scientifically sund. EUROPEAN ALUMINIUM Envirnmental Prfile Reprt

10 INDUSTRY OVERVIEW ANNUAL TURNOVER ~39.5 Billin 8% 1 millin indirect direct and jbs f the wrld s annual primary aluminium prductin is made in Eurpe TONNES RECYCLED 4.9 millin in ~600 plants in 30 Eurpean recycling cuntries (EU28 + EFTA and Turkey) % saves 95% f the energy needed fr the primary prductin 53% f the Eurpean aluminium industry s utput cmes frm recycled surces surce: Eurpean Aluminium 2017 (estimates) MAIN END-USES FOR ALUMINIUM PRODUCTS IN EUROPE IN 2017 CONSUMER DURABLES CONSTRUCTION 6% MOBILITY 23% 42% 12% 17% HIGH TECH ENGINEERING PACKAGING 10 EUROPEAN ALUMINIUM Envirnmental Prfile Reprt 2018

11 Bauxite mining Use phase Alumina prductin Recycling ALUMINIUM VALUE CHAIN Prductin manufacturing Primary aluminium prductin Semi-fabricatin 8g 61% 50% 73% 34% the reductin in CO 2 emissins per km btained by cutting 100Kg frm a car s mass the amunt f aluminium allys in the structure f an Airbus A380 the ptential energy saving frm buildings with intelligent façades incrprating aluminium systems. the recycling rate fr used aluminium beverage cans in Eurpe in 2014 the average reductin f fil thicknesses in the last 30 years withut jepardising the quality f the cntents the fil prtects TRULY SUSTAINABLE ~75% f the aluminium ever prduced is still in use EUROPEAN ALUMINIUM Envirnmental Prfile Reprt

12 ABOUT EUROPEAN ALUMINIUM Eurpean Aluminium, funded in 1981 and based in Brussels, is the vice f the aluminium industry in Eurpe. We actively engage with decisin makers and the wider stakehlder cmmunity t prmte the utstanding prperties f aluminium, secure grwth and ptimise the cntributin ur metal can make t meeting Eurpe s sustainability challenges. Thrugh envirnmental and technical expertise, ecnmic and statistical analysis, scientific research, educatin and sharing f best practices, public affairs and cmmunicatin activities, Eurpean Aluminium prmtes the use f aluminium as a material with permanent prperties that is part f the slutin t achieving sustainable gals, while maintaining and imprving the image f the industry, f the material and f its applicatins amng their stakehlders. Our 80+ members include primary aluminium prducers; dwnstream manufacturers f extruded, rlled and cast aluminium; prducers f recycled aluminium and natinal aluminium assciatins are representing mre than 600 plants in 30 Eurpean cuntries. Aluminium prducts are used in a wide range f markets, including autmtive, transprt, high-tech engineering, building, cnstructin and packaging. Fllw us n Cntact details Eurpean Aluminium Avenue de Brqueville Brussels, Belgium Phne cmmunicatins@eurpean-aluminium.eu February 2018