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The aluminium beverage can going full circle - Recycling aluminium


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Presentation made by Catherine Athènes, Constellium Sustainability Council Leader, during the Canadean Beverage Packaging Congress 2015

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The aluminium beverage can going full circle - Recycling aluminium

  1. 1. THE ALUMINIUM BEVERAGE CAN GOING FULL CIRCLE Canadean Beverage Packaging Congress 2015 Brussels, October 28, 2015 Catherine Athènes, Constellium Sustainability Council Leader
  2. 2. Agenda 2 Constellium and sustainability Life Cycle Assessment Recycling is more than a driver for sustainability What matters is End-of-life Recycling Improving sorting and recycling by working together
  3. 3. Constellium: a long and rich experience in aluminium 3 1855 Pechiney 1888 Alusuisse 1902 Alcan 2000 Alcan Aluminium Limited merges with Algroup/ Alusuisse 2003 Alcan Inc. acquires Pechiney 2007 Rio Tinto acquires Alcan More than a century of growth May 2013 Constellium commences trading on the New York Stock Exchange and NYSE Euronext Paris May 2011 Alcan Engineered Products is renamed to Constellium January 2011 Rio Tinto sells 51% of Alcan Engineered Products to Apollo, 10% to FSI and keeps the remaining 39% stake January 2015 Constellium acquires Wise Metals
  4. 4. Constellium is a leader in innovative aluminium-based solutions 4 Over 10,000 employees* €4.7 billion in sales (incl. €997 million from Wise Metals)* 22 manufacturing sites* C-TEC, our world-class Technology Center Headquartered in Amsterdam, The Netherlands. Corporate offices in Paris, France, Zurich, Switzerland and New York, USA *ThecombinedunauditedproformarevenueinformationfortheyearendedDecember31,2014 presentedgiveseffecttotheacquisitionofWiseasifithadoccurredonJanuary1,2014.Thisinformationis presentedforinformationpurposesonlyanddoesnotpurporttorepresentwhatConstelliumactual revenueswouldhavebeenhadtheacquisitionoccurredonthedateindicated,norisitnecessarilyindicative offutureresults. 2014 pro forma figures including Wise Metals acquisition
  5. 5. Structured into 3 Business Units 5 Aerospace and Transportation  € 1.197 billion in revenues  #1 worldwide for aerospace plates  #1 in the USA for large coils Packaging and Automotive Rolled Products  € 2.573* billion in revenues  #1 worldwide in closure stock  #2 in Europe for can body stock and #3 in North America  Major player in auto body sheet: #4 worldwide Automotive Structures and Industry  € 921 million in revenues  #1 in Europe for large profiles  #1 in Europe for hard alloy extrusions  #2 worldwide in crash management systems * The combined unaudited pro forma revenue information for the year ended December 31, 2014 presented above gives effect to the acquisition of Wise as if it had occurred on January 1, 2014. This information is presented for information purposes only and does not purport to represent what Constellium actual revenues would have been had the acquisition occurred on the date indicated, nor is it necessarily indicative of future results.
  6. 6. C-TEC: a world-class technology center fully dedicated to innovation 6 Unique rapid prototyping capabilities, simulation tools and advanced joining technologies such as friction stir welding Over 150patent families and trademarks 22Nationalities 223Employees 58PhDs 93Engineers including
  7. 7. Our sustainability program: Altogether more sustainable, 4 objectives, 12 targets OBJECTIVES PRODUCTS TARGETS PROGRESS PEOPLE OPERATIONS GOVERNANCE ■ 75% beverage can recycling rate in Europe by 2015 ■ All major new innovation projects through LCA by 2015 ■ 10% of sales from innovative products by 2015 ■ 60% improvement in recordable cases by 2014 ■ No serious injuries in 2015 ■ 50% improvement in employee contributions by 2014 ■ 75% participation rate in the employee survey in 2014 ■ 10% decrease in energy consumption per processed unit by 2015 ■ Major European sites reaching ISO 50001 certification by 2015 ■ 75% total landfill reduction by 2020 ■ 100% of key suppliers joining the UNGC by 2015 ■ 6-point improvement in the employee satisfaction rate in 2014 Developing, producing and selling sustainable products: meeting needs and reducing the environ- mental impact of our customers now and in the future. Ensuring our employees are safe, skilled and motivated, with ethical practices, and that they comply with regulations. minimizing the environmental impact of all our operations in the following key areas: energy, water and waste. Subscribing to the highest levels of transparency and ensuring a responsible supply chain. 7 Needs improvement On trackMissedAchieved
  8. 8. Agenda 8 Constellium and sustainability Life Cycle Assessment Recycling is more than a driver for sustainability What matters is End-of-life Recycling Improving sorting and recycling by working together
  9. 9. Life-Cycle Assessment (LCA) is key to evaluating the environmental impact of aluminium products Life-Cycle Assesment (LCA) is a technique to assess the environmental impacts of a given product throughout its life, from raw material extraction for the original manufacturing process through to its usage and end-of- life. It is a key tool for aluminium which has impacts upstream and brings benefits downstream. 9 We performed third-party- verified LCA-done by Quantis- on an aluminium beverage can.
  10. 10. Focus on Greenhouse Gas Emissions How does it work for a beverage can? (per T) CO2 emissions 0.6 t CO2 emissions 2-4 t CO2 emissions 0 t CO2 emissions 0.5 t 8,5 t Gap 10 CO2 emissions / t of primary alu produced 9 t
  11. 11. 0 20 40 60 80 100 120 140 0% 20% 40% 60% 80% 100% Climate change [g CO2 eq. / can] Verified LCA for an aluminium beverage can: Recycling is key! Life Cycle Assessments 28/10/2015 11 European Aluminium average primary Even better with higher recycling rates Actual result for 2012 recycling rate- 69,5% 1. 69.5% is the EU+EFTA average recycling rate for 2012 (most recently published). 2. Germany, Belgium, Luxembourg, Sweden, Norway, Finland and Switzerland all perform at 90% or higher recycling rates, according to the most recent data currently available (2012) – press release from European Aluminium,March 16, 2015. Aluminium Beverage Can Recycling rate gCO2eq/can Target MPE reycling rate 80% in 2020
  12. 12. Agenda 12 Constellium and sustainability Life Cycle Assessment Recycling is more than a driver for sustainability What matters is End-of-life Recycling Improving scrap collection and sorting by working together
  13. 13. Recycling aluminium makes economic and environmental sense  Recycling is a business imperative due to aluminium’s intrinsic economic value as scrap.  Aluminium can be endlessly melted down and recast with no loss of its inherent properties or downgrade in material integrity. =>No difference between aluminium made of scrap or virgin material!  Creating new metal from recycled aluminium only requires 5% of the energy needed to produce primary aluminium from bauxite ore. => Unique position of aluminium for primary versus secondary source  Once collected and sorted, aluminium can be recycled and reused, avoiding the use of primary metal and thus saving CO2 emissions. 13
  14. 14. Aluminium, a permanent material  Permanent materials are not consumed, they are merely used.  Permanent materials are moved from the ground or manufactured and used in a range of applications and then “lent” to other applications after their previous use.  They can be recycled, over and over again, without loss of properties. 14 Comparison with other materials ■ Plastic and paper recycling damages molecules / fibres  Hence lowering properties  These materials cannot be infinitely recycled. ■ Glass can also be infinitely recycled, even though it can also lose some properties (colour, transparency). Constellium is part of Metal Packaging Europe which has developed the permanent material concept.
  15. 15. Agenda 15 Constellium and sustainability Life Cycle Assessment Recycling is more than a driver for sustainability What matters is End-of-life Recycling Improving scrap collection and sorting by working together
  16. 16. Recycling takes place at all three stages of the aluminium life-cycle. End-of-life recycling is key  Internal process scrap created during transformation.  Customer scrap produced during stamping, milling and other processes Recycling the scrap produced during all production stages is essential due to its cleanliness and value. As it goes throughout the complete production flow, this runaround scrap does not replace primary metal and therefore its usage does not avoid CO2 emissions. 16  The end-of-life scrap from products containing aluminium such as Used Beverage Cans is a clear substitute for primary metal, especially when recycling it requires only 5% of the energy otherwise used to produce primary metal.  End-of-life recycling therefore delivers clear CO2 savings.  End-of-life recycling is the most efficient way to significantly improve the CO2 footprint of aluminium beverage cans. Process scrap End-of-life scrap
  17. 17. The recycled content in a given product does not reflect its environmental performance. Here is why. 1 2 3Recycled content includes industry process scrap and the part of end of life scrap versus process scrap is rarely or never mentioned! Recycled content can only work if there is enough available scrap, which is essentially dependent on scrap produced many years ago Increasing recycled content of a product is highly likely to happen by decreasing the recycled content of another one! 17
  18. 18. Is increasing process scrap intake good for the planet? NO! What matters is end of life scrap! Metal sourcing Rolling/ Remelting Can Mfg Reference Recycled Content 20% process scrap recycled content 1.0 1.0 Metal sourcing Rolling/ Remelting Can Mfg Higher Recycled Content 40% process scrap recycled content 1.0 1.67 1.0 0.67 Sameoutput More scrap generated  more material to be remelted  more energy used – more recycled content 0.25 1.25 When Recycled Content includes process scrap, it can be seen as a metrics for industrial inefficiencies with no environmental value. 1 18
  19. 19. End-of-life scrap intake is limited by its availability 19 75% of the aluminium ever produced is still in use Due to the long lifespan of most (especially larger) aluminium applications such as buildings and transport vehicles, the available quantity of end-of-life aluminium scrap today is limited to what was put on the market many years ago. Calling for higher recycled content will not change scrap availability Aluminiumintperyear 0 2 000 000 4 000 000 6 000 000 8 000 000 10 000 000 12 000 000 14 000 000 1980 1983 1986 1989 1992 1995 1998 2001 2004 2007 2010 2013 Average product life ≈ 20 years Available for recycling now 20 years ago production 2
  20. 20. Producer 1 Increasing the recycled content of one product may happen by decreasing the recycled content of another 20 Producer 2VS. Products 1 Products 2 3
  21. 21. In which case higher recycled content brings no environmental benefit. VS. Average recycled content for every product Limited availability: one product getting more doesn’t change the overall environmental impacts, as others get less Can 1 Can 2 Can 3 Can 1 Can 2 Can 3 21 3
  22. 22. Recycled content may be a good marketing incentive to recycle paper or plastic but is not suited for metal.  Keeps same properties after recycling  Cannot be distinguished from virgin metal  Infinitely recyclable!  Has value which pays for recycling ■ Loses its properties after recycling ■ Low value of scrap/high cost of recycling Recycled content provides an incentive to recycle and is not limited by unsorted scrap availability Recycled content is not the right incentive 22 Paper & Plastic Metal
  23. 23. For packaging, good progress has been made, but still more is needed: 23 What really matters is END-OF-LIFE RECYCLING 69,5% Beverage can recycling rate End of life recyling of aluminium products is already very good: But more needs to be done in terms of quality. 95% Recycling in building 95% recycling in automotive and transportation 25% Beverage can recycling rate 1992 2012
  24. 24. Agenda 24 Constellium and sustainability Life Cycle Assessment Recycling is more than a driver for sustainability What matters is End-of-life Recycling Improving scrap collection and sorting by working together
  25. 25. Constellium aims to boost the overall sustainability of our industry through end-of-life recycling We make sure that as much aluminium as possible is re-used at the end of the life of a product 25
  26. 26. Why improving collection and sorting?  To improve recycling practices, the focus must shift to improving the recycled scrap collection and sorting process as a whole.  Once collected and sorted, scrap can be easily used in one product or another.  Good sorting enables an alloy to be recycled in the same alloy category, thus avoiding dilution or down-cycling.  This would increase the overall volume and quality of the available content, rather than concentrating on the content of individual products.  At Constellium, we believe that we can only achieve this through collaboration and partnership with all relevant stakeholders, within and outside the aluminium industry. 26
  27. 27. Constellium recycling priorities 27
  28. 28. Joint recycling programs Sustainability training-ON 28 The ONLY way to improve the CO2 footprint of aluminium products through recycling is to increase end-of-life recycling through industry-led programs and cooperation with adequate organizations. Every Can Counts MPE CR3/ IRT M2P EA/IAI Aluminium Stewardship Initiative Canibal (Collection Machine)
  29. 29. Thank you! 29 We are Constellium. We are a global leader in aluminium solutions whose business is to materialize today’s and tomorrow’s ideas. For us, aluminium is more than a metal. it is part of the solution for tomorrow’s lighter, faster economy. Abundant, endlessly recyclable and reusable, aluminium’s unique properties mean that, together with our partners, we can shape a future of infinite possibilities