Capítulo 2. La tendencia verde
2.3 Publicidad Verde .1 Eco branding
Energy is required first and foremost to heat the smelting facilities (primarily heating oil) as well as for the tank- house (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.
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 2013, the throughput of recycling raw materials rose from about 255,000 t to over 400,000 t. As shown in Fig. 2.15 "Specific energy consumption at the Lünen site", this reduced the raw material-related energy demand notably. The higher natural gas consumption is a result of the TBRC, and the higher electricity consumption is due in particular to a number of new and expanded filters and additional drives, etc. One-third of the electricity demand is necessary for environmental protection measures. On the left-hand curve, the graphic (see Fig. 2.13) 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 strategy selected for the Lünen site very concretely. With the same cathode Fig. 2.10: Strong presence on the international recycling raw material markets contributes to Aurubis’ supply security
45 Germany
Other 4 10 Eastern Europe North America 11
Rest of Western Europe 30
Sources of recycling materials in FY 2012/13 in % Recycling raw materials
Copper scrap
Printed circuit boards
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Large number of suppliers with long-term customer relationshipsFig. 2.11: Energy consumption1 at the Lünen site
in GWh p.a. 2008 2009 2010 2011 2012 2013
Heating oil 329 288 295 302 291 266
Coal, coke, etc. 13 16 10 10 6 13
Natural gas 47 52 49 77 81 77
Electricity2 139 137 144 151 154 156
Total 528 493 498 540 532 512
1 Calculated using DEHSt (German Emissions Trading Authority) standards
2 Exclusively external electricity at the moment. The use of internal electricity from waste heat is planned for the
future, which will cover some of the demand.
Fig. 2.14: CO2 emissions at the Lünen site
in t p.a. 2008 2009 2010 2011 2012 2013
Total CO2 140,622 150,027 152,696 166,304 172,870 168,297
Biogenic CO2 517 454 653 457 0 568
Fig. 2.12: Environmental protection facilities – including those at the Lünen site – are very energy-intensive
Tankhouses 75,000 MWhel
Production and processes 30,000 MWhel
Other environmental protection 21,000 MWhel
Large filters 28,000 WMhel
Administration, social areas, lighting 2,000 MWhel 48 % 19 % 31.5 % 1.5 % Total consumption 156,000 MWhel
Fig. 2.13: Successful reduction of specific energy demand due to new technologies and throughput increase
About 30 % of electricity at Aurubis is used for environmental protection measures.
»
Demand for primary energy was reduced by 40 % per ton of secondary raw material input during the period 2005 to 2013.»
The KRS significantly reduces the energy input; multi-metal recycling requires a higher absolute amount of energy»
In relation to the recycling raw material input, the specific primary energy demand has been falling consistently Primary energy input at Aurubis Lünen (in GWh) Specific energy demand at Aurubis Lünen sitein kWh/t secondary raw material input Start of KRS procedure 00 02 03 04 05 06 07 08 09 10 11 12 13 00 02 03 04 05 06 07 08 09 10 11 12 13 700 600 500 400 2,700 2,000 1,300
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 decreas- ing, while the proportion of by-metals such as tin, nickel, gold and silver is increasing.
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 long-term trend led to an increase of more than 10,000 t in 2011 due to the implementation of the KRS project. The figure for total CO2 includes biogenic emissions and emissions from mobile production equipment, i.e. the diesel consumption of plant vehicles which are not considered in emissions trading (see Fig. 2.14).
CO2 EMISSIONS TRADING
The third EU emissions trading period for greenhouse gases started in 2013 and applies to 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 2013.
Communication with the general public/special occurrences
There were no incidents or malfunctions with significant environmental effects within the meaning of the Hazard- ous Incidents Ordinance at the Lünen plant during the reporting period.
As in past years, LANUV analyzed leafy greens from Lünen gardens in 2012 as well. One focus of the latest analyses was comparing vegetables from cultivated patches to vegetables from containers with unpolluted topsoil. LANUV is trying to obtain better insights into the influence of soil routes on pollution.
The results were published in summer 2013 and an in- formational event with the local gardeners affected took place on August 7, 2013. One insight from the analyses is that a significant proportion of the pollution is trans- ferred not through the air but through the soil. The authorities maintained their recommendation to avoid cultivating and consuming leafy greens due to the ongoing increased lead contents. The analysis program will continue in the coming years.
Fig. 2.15: Specific energy consumption at the Lünen site in MWh/t of copper output
5.5 3.7 2.9 2.5 2.5 2.6 2.5 2.4 2.6 2.65 2.6
1990 2000 2005 2006 2007 2008 2009 2010 2011 2012 2013
Fig. 2.16: Specific CO2 emissions at the Lünen site in t of CO2/t of copper output
1.63 1.00 0.77 0.68 0.68 0.68 0.76 0.72 0.79 0.86 0.86
ENVIRONMENTAL PROGRAM
The targets set in the context of the Environmental Statement 2013 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 2014. The results are presented in the following Environmental Program:
Air pollution control
Target Planned measure Degree of implementation/date
Reducing fugitive emissions from the tin furnace by more than 90 %
There are plans to completely seal off the ridge turret in connection with the RHZ filtra- tion plant and TBRC filter 7.
The entire hall of the smelting operations was closed in late 2013 and will be suctioned off with the primary smelter’s auxiliary filter, which has been renovated.
Renovating and expanding the RHZ filtration plant
The former shaft furnace filtration plant that is used as an extra filter in the primary smelter should be replaced by a new, modern filtration plant.
The baghouse cartridge filter with a capacity of 500,000 m³/h was constructed in 2013 and started up according to plan.
Completely closing the storage area on the west side of the plant
Connection and storage hall 2A to close the gap between halls 2 and 3
The project was delayed to 2017/18 due to new prioritization.
Continued paving of storage areas
New measure: paving the “gap closure”/area 24 between silo 2 and plant tracks pursuant to the Water Management Act
The measure has been completed. In the me- antime, nearly all storage areas and transport focuses have been implemented in Water Management Act quality. Additional areas will be improved as needed.
Improvement measures for off-gas treatment in the anode furnace
Off-gas treatment in the anode furnace with a new additive for effective material output as well as a test for post-combustion of off-gas to reduce carbon
The test operation with a new C-based ad- ditive blown into the off-gas was successful. Permanent operation is in the planning stage. Off-gas post-combustion is currently in test operation.
Water pollution control
Target Planned measure Degree of implementation/date
Optimizing wastewater flows
Developing a wastewater/process water concept based on rainwater retention
The rainwater retention system has been con- structed and will go into regular operation in summer 2014. The wastewater/process water concept was submitted to the authorities as part of a new indirect discharge permit. Optimizing
wastewater flows
Separate treatment of sanitation water Details are currently being coordinated for environmental remediation with the respon- sible authorities. The concept is still being adjusted as part of this coordination process.
Energy optimization
Target Planned measure Degree of implementation/date
Increasing energy efficiency, using the steam from KRS waste heat
After reviewing individual options, the use of a steam turbine is planned to generate elec- tricity internally. The aim is to cover at least 10 % of the plant’s electricity needs.
The processing facility and the steam turbine have been authorized and constructed. However, the turbine has only been operated at partial load so far due to start-up problems.
Plant safety
Target Planned measure Degree of implementation/date
Improved organization
Revising the company alarm and hazard prevention plans
The plans were revised; the external effects of possible accidents (domino effects) were discussed with the relevant plants in the surrounding area in coordination with the authorities. A routine discussion group comprising the Accident Officers of these plants (Aurubis, Petrotank and Lünen Municipal Utilities) was initiated. Environmental management system
Target Planned measure Degree of implementation/date
Improved organization
Computerized integrated management system
1st step: data and document management
Document management is currently being implemented and adjusted for the site.
KEY FIGURES FOR AURUBIS AG, LÜNEN SITE,