Aluminium and Energy in the EU

Karl-Heinz von Zengen, EAABrussels, 27 March 2006

Aluminium End Uses - Europe 2001

Building26%

Transport32%

Engineering14%

Packaging19%

Others9%

Passenger-km per Person per Year

382

188140

8021092

10024

1

10

100

1000

10000

100000

Walking Cycling Tram/Metro Railway Bus/Coach Pass. Car

Source: DG TREN, European Commission

EU 15, 2000

1990 2005 2010 20151995 2000

300

100

150

200

250

50

0

year

kg a

lum

iniu

m p

er v

ehic

le

Aluminium Use in EU Cars

Al in Cars - Relative and absolute Shares

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

0 50 100 150 200 250 300 350

Ford Fiesta

Skoda Fabia

Fiat Stilo

Peugeot 307

Nissan Micra

Nissan Tino

Opel Corsa

Chrysler PT

Citroen C3

Ford Mondeo

Mini

Renault Laguna

Peugeot 607

Toyota Prius

Citroen C5

Opel Vectra

Mercedes E class

Renault VelSatis

Audi A4

Audi A2

Source: Mavel

1970

1972

1974

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

2000

1998

2002

750

950

1050

1150

1250

1350

850

1450

1550

FordEscort MK2 Ford

Escort MK3

FordEscort MK4

FordEscort MK5

FordFocus

VWGolf Mk1

VWGolf Mk2

VWGolf Mk3

VWGolf Mk4

2004

Citroen GS

Citroen BX

VWGolf Mk5

Citroen ZX

Citroen XsaraToyota

Corolla

ToyotaCorolla

ToyotaCorolla

ToyotaCorolla

ToyotaCorolla

ToyotaCorolla

AstraMk1

AstraMk2

AstraMk3

AstraMk4

AstraMk5

VauxhallCavalier Mk1 Cavalier

Mk2

Cavalier Mk3

Vectra 1

Vectra 2

YEARS

Kg

Vehicle Weight by Generation

Source: Jaguar

European Cars - Equipment Rates

0

10

20

30

40

50

60

70

80

90

100

Airbags ABS Anti Theft A/C Ewindow

1992199619982002

European Cars - relative Material Shares

Fiat Audi Skoda Nissan Peugeot Audi Renault Opel Ford Mercedes Punto A2 Fabia Tino 607 A4 Laguna Corsa Mondeo C2001,9 JTD 1,4 1,9 Sdi 2,0 2,2 HDI 2,0 1,9 dci 1,2 16v 2,0 DI Sedan

Steel 64,5 26,5 64,1 60,4 54,9 52,1 53,5 62,4 55,2 54,2Cast Iron 6,7 1,8 8,8 in steel 6,3 5,1 8,5 in steel 11,4 10,7Aluminium 6,4 36,3 4,9 11,5 11,0 15,7 9,9 7,2 8,3 10,8Magnesium 0 0,2 0,6 0,1 0,1 0,5 0,1 0,1 0,1 0,2Plastics 11,4 22,5 11,4 11,2 14,0 14,6 13,7 13,6 13,2 13,3Glass 2,8 3,4 2,7 2,4 2,8 2,3 2,9 2,7 2,2 2,6Rubber 4,0 5,0 4,1 3,3 5,4 4,8 5,9 4,3 5,3 4,7Ceramic 0,2 0,1 0,2 0,2 0,2 0,2 0,2 0,2 0,1 0,1Misc. 4,0 4,2 3,2 10,8 5,4 4,8 5,3 9,4 4,3 3,4

Material Shares in selected Passenger Cars

Aluminium helps light weighting Cars

887785

9281003

1229

0

200

400

600

800

1000

1200

1400

Ref.- Car Primary state-of-the-art

weight

Primary latest-technology

weight

Upper finalweight(Al-Car)

Lower finalweight(Al-Car)

wei

gh

t [k

g]

Minimum secondary weight saving Maximum

secondary weight saving

Primary state-of-the-art weight reduction

Primary latest-

technology weight

reduction

Source: fka Aachen

Energy Balance of one Material CycleAudi A3; 200.000 km driving distance

effort for ELV dismanteling, logistics, melting, ...0,2%

=

+ service + spare parts (3%)

= fuels consumption (84,5%)= mainly weight driven !

87,5 %

6%production effort =

recycling efficiency2 % benefit = 100,2 % effort

- recycling bonus == benefit from ELV recycling

4%

6%

2%

Mat‘l prod. on base of primary energy =

Source: Audi

Lifecycle Energy: Audi A2

0

400 GJ

50.000 km

cum

ula

ted

pri

mar

y en

erg

y u

se

driving distance / km

200 GJ

100.000 km

break even after~ 55.000 km

Audi A2, 55 kW; 895 kg; 6 ltr/100 km

virtual Audi A2; 1047 kg; 6,57 ltr/100km conventinal concept

Audi A2 with secondary aluminium

database: IfE / TH München and AUDI AG, I/ES & I/EG-34

disadvantage decreaseswith lifetime

ASF advantage increasing

Source: Audi

Aluminium Sector in Europe*, 2004

15.6 mio tonnes

10.1 mio tonnes

11.7 mio tonnes

MINING

ALUMINA

METAL

4.6 mio tonnesBAUXITE

6 plants

11.0 mio tonnesBauxite

Net import

5.2 mio tonnesPRIMARY Metal

Production

38 plants

7.8 mio tonnesALUMINA

12 plants

2.3 mio tonnes Alumina

import

4.2 mio tonnesRECYCLED Metal1

276 plants

2.3 mio tonnesNet import

SEMI’S1.1 mio tonnesWire, powder,

slugs...

3.1 mio tonnesEXTRUDED

4.3 mio tonnesROLLED

Foil (22%)

333 plants64 plants

* West and Central Europe (Former CIS excluded, except Baltic states)1 In-house scrap remelting excl. 2 Integrated automotive producers incl.

+2200 plants

3.0 mio tonnesCASTINGS2

TOTAL = PRODUCTION + IMPORTS

Reduction of Electrolysis Energy for Aluminium

End Uses for Recycled Aluminium, 2003

* EU-25. Semis-fabrication scrap excluded

Casting Alloys = +/- 2.7* million tonnes Wrought Alloys = +/- 1.2* million tonnes

Evolution of Recycled Aluminium, EU-15

0

500

1.000

1.500

2.000

2.500

3.000

3.500

4.000

1980 1984 1988 1992 1996 2000 2004

Year

Alu

min

ium

rec

ycle

d in

thou

sand

tonn

es

per

year

TREND

Includes refining production and tolled and purchased scrap intake of remelters. Foreign material excluded.

0

2000

4000

6000

8000

10000

12000

14000

16000

1950 1960 1970 1980 1990 2000 2003 2004 2010 2020

Old

scr

ap (

thou

sand

tonn

es)

Other

Consumer Durables

Engineering

Packaging

Building

Other Transport

Automotive

Global Old Scrap

Source: GARC, 24.01.05

Aluminium in scrap

FORECAST

x2

Global Aluminium Energy Flow, 2003

Source: GARC, 24.01.05

Values in PJ (1015J)

Net Addition 2003: 1,700

Total EnergyStored in UseSince 188846,000

FinishedProducts (output)2,900

Lost toApplication

10

Fabricated andFinishedProducts (input)4,900

TradedNewScrap 540

InternalScrap1,200

TradedNew

Scrap 56

Ingots 4,700

Metal Losses 17 Landfill 150 Under Investigation 230

OldScrap

530

Bauxite 11

Bauxite Residues 4and Water

Alumina 650

PrimaryAluminium

2,200

RecycledAluminium

2,300

Emissions Primary vs Secondary

Transport

Bauxite mining and alumina production

Electrolysis and Cast house

melting and refining

0.00

2.00

4.00

6.00

8.00

10.00

12.00

Primary Recycled

Scrap preparation

kg CO2 per kg AL

Millions tonnes of CO2

Best Practice and Transport Savings

202

242

290

345

411

327337 333

345 339

200

250

300

350

400

450

2000 2005 2010 2015 2020

GHG Emissions

Transport Savings

Best Practice

The potential for Al Industry to be “Climate Neutral” by 2020 could be accelerated implementing everywhere today’s best practices

Lirecar – Importance of Use phase for total emissionsG

reen

hou

se G

as E

mis

sio

ns

MAX MAX MAX MIN MIN MIN

Ref. 900kg 750kg Ref. 900kg 750kg

-20%

-10%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

CREDIT

PROD

USE

End - of -Life

MAX and MIN are representing

the range of different vehicle

scenarios

Facts about Energy Intensive Industries• Energy intensive industries, which cannot pass on costs,

have already invested in energy efficiency for decades – like the aluminium industry

• Aluminium industry is working globally

• „Incentives“ like ETS, RES etc. encourage the delocating of energy intensive industries

• Energy intensive industries find new homes in countries with less environmental legislation

• Final result will be more pollution in the world

• Finally, the energy efficiency policy in the EU has succeeded by closing down energy intensive industries

Aluminium Recycling

• Aluminium recycling saves up to 95% of the energy versus primary aluminium

• Export of scrap means export of energy

• Export of scrap means - on a global basis - higher pollution