Water Presentations

1. Think future. Think alulminium.
NCPC Conference 2017
Water Efficiency Case Study
@NCPC_SA

2. Think future. Think alulminium.
Agenda
1 Introduction to Hulamin
2
Optimising the use of water3
NCPC Water Assessment
4 Risk Mitigation
5 Summary

3. Think future. Think alulminium.
• 100% recyclable – has a high scrap value.
• Low melting point – save 95% of energy and
carbon footprint on recycling.
• Non-corrosive – high aesthetic durability and
structural integrity
 High conductivity:
 Heat – beverage cans and heat exchangers.
• Electrical – cables and windings.
• Lightweight – reduce transport costs and
• carbon footprint.
• Bright and shiny – preferred by customers.
• Superior printing qualities.
Aluminium – The Wonder Metal

4. Think future. Think alulminium.
Aluminium value chain (in Southern Africa)
PRIMARY INPUT:
• Imported alumina
• Labour
• Electricity
PRIMARY INPUT – Hulamin (excl. metal):
• Labour 35%
• Energy 29%
• Consumables 16%
• Maintenance 11%
• Other 9%
Hulamin and others
275 000 tons p.a.
Fabricators /
Distributors
e.g. Mahle Behr, Nampak
180 000 tons p.a.South 32
720 000 tons p.a.

5. Think future. Think alulminium.
• Made up of 3 divisions:
 Hulamin Rolled products:
o An independent rolling mill.
o Annual capacity 220 000 tons.
 Suppling into over 50 countries.
 Hulamin Extrusions.
 Hulamin Containers.
The Hulamin Business

6. Think future. Think alulminium.
Hulamin’s Products and Markets
General Engineering
Automotive and
Transport
Building and
Construction
Packaging
44%
2%14%
40%

7. Think future. Think alulminium.
Some of our major market successes
Major supplier to Automotive heat exchanger industry SA and global Brazing sheet
Major supplier to Tesla Motors USA 6-series plate
Largest supplier of Colour coated beverage tab stock Global Beverage tab stock
Major supplier of vacuum chamber plate in Silicon Valley USA 6-series plate
Major supplier of Solar panel frameworks SA Extrusions
Machined vacuum chamber componentAutomotive heat exchangersTesla chassis

8. Think future. Think alulminium.
Local Market Development
Aluminium Cans and closed Loop Recycling
Scrap
processing
Can stock rolling
Can maker
Filler
(brand owner)
Post-consumer
scrap collection
Scrap consolidation
and procurement
Primary metal
99.7%
aluminium
Cans not
recycled
(target <15%)

9. Think future. Think alulminium.
• ISO 9001:2008 – Quality Management Systems
• ISO TS16949:2009
• PAS 223-2011 – Food Safety Requirements
• ISO 14001 – Environmental Management System
• ISO 22000 – Food Safety Management Systems
• OHSAS 18001: 2007
• Other Certifications:
• DNV
• ABS
• BBALloyd's
• TUV
Quality Assurance Certification

10. Think future. Think alulminium.
NCPC Water Assessment

11. Think future. Think alulminium.
• Project Sponsor: National Cleaner Production Centre – SA.
• Project Manager: Ngoanathari Maja.
• Consultants: Bryan Maytham and Warwick Hayes (Fulfil Energy),
Jason Vardy and Jenna Harris (PuraPlan).
• Project Objectives:
 To perform an assessment of water usage and effluent generation with a view to reduce, reuse
and/or recycle water where possible.
 Opportunities that are identified will be costed at a high level to determine the financial viability.
 Opportunities will be presented to guide a high level Water Strategy and provide a means to
prioritise and plan implementation.
NCPC Water Assessment

12. Think future. Think alulminium.
• In its Environmental policy, the company states, “Hulamin is committed to responsible
environmental stewardship of its resources and to ensuring that all its activities result in minimal
harm to the environment.”
• Hulamin sources all its water requirements from the local Municipality (Umsunduzi) which
distributes an average of 160 million liters of water to companies/institutions and to over
600,000 people each day.
NCPC Water Assessment
Production
MT
Water
kl
Water intensity
kl/MT production
Effluent Water
kl
Effluent water intensity
kl/MT production
2010 203,582 774,930 3.81 193,485 0.95
2011 222,783 647,813 2.91 169,181 0.76
2012 209,124 598,172 2.86 153,732 0.74
2013 204,880 578,459 2.82 154,195 0.75
2014 205,955 621,780 3.02 165,347 0.8
2015 191,987 637,713 3.32 183,461 0.96
2016 221,775 589,993 2.66 144,111 0.65
2017 YTD 152,175 372,133 2.45 90,300 0.59
Water Consumption

13. Think future. Think alulminium.
• Annual spend on resources is 30% of primary inputs.Water is a small, but critical,
percentage of this.
• Water is used throughout the manufacturing cycle for cooling, lubrication and cleaning.
Resource split

14. Think future. Think alulminium.
• Current Status
• Moving Forward
• Establishment of Resource Management Team - complete
• Measurement / Monitoring system - WIP
• Development of Baseline – Define KPI’s - complete
Approach to water management

15. Think future. Think alulminium.
• Identified wasteful water use practises corrected.
• Extrusions anodising tank uncontrolled make up.
• An annual saving of 14 000 m3.
• Cooling tower sump level control.
• An annual saving of 12 000 m3.
Optimising the use of water

16. Think future. Think alulminium.
• Cooling towers.
• Significant user, 18% of total use.
• Review of Remelt cast water temperature control.
• VSD’s installed on Remelt and Hot line fans.
• Implementation of automated control of TDS and
hence blow down.
Optimising the use of water

17. Think future. Think alulminium.
• Recovery of Remelt cast water.
 Potential annual saving of 28 800 m3.
 Removal of aluminium hydroxide required
for reuse.
 Successful test plant trials using
precipitation.
 RFQ issued for submission in September.
Optimising the use of water

18. Think future. Think alulminium.
• Coil Coating Lines
• Installing conductivity control for make-up water.
• Review opportunities for reverse cascading.
• Annual potential saving of 20 000m3.
Optimising the use of water

19. Think future. Think alulminium.
• Emulsion optimisation.
 Investigation to
improve water
efficiency highlighted
process inefficiencies.
• RO Brine Recovery.
 Recovery of system
improved from 70% to
80%.
 Potential to recover
brine identified.
Optimising the use of water

20. Think future. Think alulminium.
• Awareness has led to a decrease in demand.
• Effluent plant performance
 Reducing discharge
 Good compliance
Optimising the use of water

21. Think future. Think alulminium.
• Measure and account for all water consumption.
• A significant amount of incoming water still remains unidentified.
• An extensive water metering and monitoring initiative is being implemented throughout the plant.
Risk Mitigation

22. Think future. Think alulminium.
• Site water storage
 Necessary to mitigate against short term supply risks.
o Water disruptions stopped production in 2016, 2017.
o Require 3 days water storage per site.
o Construction of 2 reservoirs in progress.
• Borehole water
 Test borehole drilled and tested, 3 will be required.
 Isotope tests conducted, waiting report.
 If a WUL is possible apply for CAPEX.
• Rain water harvesting, separate investigation required
Risk mitigation

23. Think future. Think alulminium.
• Hulamin is committed to improving its
resource efficiency.
• It has invested in and will continue to
invest in:
 Water consumption reduction.
 Recycling of water, with the
objective of zero discharge
 Energy consumption reduction.
• Sponsored UKZN in its solar car
project.

24. Think future. Think alulminium.
The End
Questions