Recycling A Pure Bonus: Roland Scharf-Bergmann
Recycling A Pure Bonus: Roland Scharf-Bergmann
Recycling A Pure Bonus: Roland Scharf-Bergmann
A pure bonus
Roland Scharf-Bergmann
Head of Recycling
(1)
• 1 Recycling
• 2 Market Outlook
• 3 Recycling in Hydro
• 1 Recycling
• 2 Market Outlook
• 3 Recycling in Hydro
Recycling – a pure bonus
Utilizing aluminium as an energy bank
5%
of initial energy
to recycle
75%
still in use
(4)
Aluminium recycling, a viable business
Remelter
recycling plant producing extrusion and rolling ingot
Refiner
recycling plant producing foundry alloys
(5)
3 types of scrap are created in the regional aluminium flow
Post-consumed (PCS), fabrication scrap and clean process scrap (CPS)
Primary shapes
(EI,SI,PFA,WR,IN)
(6)
Various scrap sorting techniques & technologies
Steel, Fe Plastics, foam Mg, Cu, Zn, Pb Wrought vs Casting Metals & alloys Metals & alloys
Magnetic &
Shredding Air seperation Sink float Hot crush Color sorting Spectroscopy
Eddy current
• Cutting scrap in • Magnets separating • Using air to separate • Separates scrap in • Thermal-mechanical • Hand sorting based • X-ray, neutron flux or
pieces without ferrous and non- scrap streams various baths with separation method on different colors of pulse laser detectors
separating various ferrous metal scrap various specific metals. Can also sort scan the metal (must
metals • Also called gravities • Successfully wrought vs. casting be free of lubricants,
• Heavy metals like windsifting, air-knives, separates wrought alloys paint and coating)
• Taking out some easy steel and iron is elutriation, winnowing • Possible to sort based and casting alloys by
parts before sorted out and air columns on the various metal’s looking at the eutectic • Only possible with • The metal returns
shredding e.g. density, but also temp. as castings has low labor costs. 99% various emissions when
Wheels and engines • Used extensively for • Conveyor belt system based on alloy (Scrap a lower melting temp accuracy estimated hit by the detector
from cars is usual Secondary production with air flows pushing will sink or float based (because of higher Si for China source. The differing
away light weight on density) content) emissions are read and
• The shredded metal materials like e.g. • Can also be done by forms the basis for the
• Eddy Current: Rotor
can then go on to be plastics • Separating heavy and • First warm, then a computer, can sort scrap sorting
with magnets to throw
sold as shredded scrap at different light materials from crush to separate by alloy when using
scrap or be treated by distances in relation • This technique could the wrought and whether the metal etching chemicals • The system can then
sorting techniques to to their eddy current result in loss of light casting aluminium breaks or not making alloys stand direct the piece of scrap
increase its value and small aluminium scrap out in color to an appropriate bin
scrap such as UBC • 96% effective in using a mechanical arm
• Utilizing the different
scrap separating the scrap • Environmental and or air flow
conductivities of
various metals economic barrier
• Recently possible at
high speeds
Source: Improving aluminum recycling: A survey of sorting and impurity removal technologies (Gabrielle Gaustad et. Al.)
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• 1 Recycling
• 2 Market
• 3 Recycling in Hydro
Europe is the world leader in recycling
3%
5%
7%
29%
7%
7%
11%
15%
7% 9%
Source: EEA
89% of scrap is used in Europe (EU27+EFTA)
11% of the scrap generated in Europe in 2014 was exported
Use of scrap
11%
19%
17%
~7 million mt
53%
Scrap consumption in Europe Pre consumer casting alloys Post consumed casting alloys
European scrap exports Pre consumer wrought alloys Post consumed wrought alloys
Source: EAA
Advanced modelling reveals long term supply growth
(12)
Available post-consumed scrap expected to increase.
China as main source of old scrap generation growth
GARC: Global old scrap to scrap market (Before trade and remelt loss) CAGR:
38 Figures in million tonnes (mio.t)
Other
36 Region 10-15 15-20 20-25 25-30
Other
34 Producing
Other
+5% Countries 7% 6% 5% 4%
32 (Residual)
Other Asia
30 Other Producing
Countries
-1 % 2% 2% 2%
28
North America
26
Other Asia 6% 7% 7% 7%
24 Middle East
+5%
22 South America
North America 3% 2% 1% 3%
20 Japan
+5%
18 Middle East 8% 8% 6% 6%
Europe
16
14 South America 6% 5% 4% 4%
12 +5%
10
Japan 2% 1% 2% 2%
8
China Europe 4% 3% 2% 2%
6
4
China 12 % 11 % 10 % 8%
2
0
1990 1995 2000 2005 2010 2015 2020 2025 2030
Source: IAI
(13)
Current scrap trade levels not sustainable due to shrinking Chinese imports
Declining US exports as an effect of this
2 500 2 500
-2%
+17%
Malaysia Others
1 500 1 500
Canada
Australia
Mexico
Korea
1 000 Hong Kong 1 000
0 0
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
Source: UN COMTRADE: 7602 Aluminium waste and scrap
(14)
Scrap and alloy prices principally follow LME
Time-lags for scrap may cause imbalances
€ 2,300
€ 2,100
€ 1,900
€ 1,700
€ 1,500
€ 1,300
€ 1,100
€ 900
€ 700
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN Feb Mar Apr
2013 2014 2015
LME in € DIN 226 LME + billet premium LME + ingot premium postconsumed profiles (ACL + WAZ) High grade FA
(15)
• 1 Recycling
• 2 Market (UBC)
• 3 Recycling in Hydro
UBC scrap market in Europe
Deposit based
Kerbside collection
Bring system
(17)
Volumes from different collection systems
Competitors
Estimated annual volume based on EAA data
(18)
• 1 Recycling
• 2 Market Outlook
• 3 Recycling in Hydro
The industry’s most ambitious climate strategy: Carbon-neutral by 2020
Supported by the three pillars of Hydro’s technology strategy
Energy and
primary production
Reduce emissions,
increase efficiency
Aluminium in use
Maximize user-
phase benefits
‘End-of-life’
Increase recycling,
back to the loop
(20)
Hydro’s recycling facilities
Holmestrand, Norway
• 2014 production: 47,000 tonnes
Karmøy, Norway WMR, Dormagen, Germany
• 2014 production, 23,000 tonnes • 2014 production: 30,000 tonnes
Deeside, UK
• 2014 production: 51,000 tonnes Neuss (Alunorf), Germany
• 2014 production: 347, 000 tonnes
Rackwitz, Germany
Texas and Kentucky, USA • 2014 production: 87,000 tonnes
• Commerce, 2014 production: 104,000 tonnes Hamburg, Germany
• Henderson, 2014 production: 79,000 tonnes • 2014 production: 104,000 tonnes
Neuss (Rheinwerk), Germany
• 2014 production: 87,000 tonnes
Lucé, France
• 2014 production: 52,000 tonnes
Clervaux, Luxembourg
• 2014 production: 90,000 tonnes
Azuqueca, Spain
• 2014 production: 75,000 tonnes
Cisterna di Latina, Italy
• 2014 production: 44,000 tonnes
(21)
Hydro has developed leading scrap capabilities the last years
Tools
Hydro in-house developed tools are
System optimization Charge optimization differentiating elements
Scrap portal
long term on batch level
Technology
Leading competence
Scrap processing: Furnace concept: in furnace operation
Continuous
Shredding, magn. Cont. feeding,
delacquering Significant scrap processing competence
& EC separation, submerged melting,
& hot transfer
X-ray sorting electromagn. stirring built last years
Our Recycling Strategy – in short
Build on leading remelt capability to expand use of post consumed and lower priced scrap
Establish cooperation models for scrap sourcing and processing, possibly with asset ownership
(23)
Flow-sheet post-consumed scrap recycling
Mixed End of Life
scrap
screen
sieve fines
(size split approx 40mm)
plastics,
eddy current separator melting furnace
minerals
plastics,
eddy current separator DC casting
organics
(25)
UBC shredder unit
Overview
Technical challenge
• scrap composition
• shape and density of scrap bales and packages
(26)
Bale braker and hammer mill
(27)
Sorting line, furnace and delaquering
(28)
Acquisition of WMR Recycling GmbH
Superior patented shredding & sorting technology
(29)
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