Norsk Hydro Asa · OSL:NHY
Norsk Hydro Asa — Technical Presentation (2015)
42 slides from Norsk Hydro Asa's technical presentation, 2015
Slide 1: Rheinwerk Neuss: An integrated, flexible metal source
Rheinwerk Neuss: An integrated, flexible metal source Jan Peterlic Plant Manager (1)
Slide 2: Welcome to Rheinwerk!
Welcome to Rheinwerk! (2)
Slide 3: An introduction to primary production
An introduction to primary production (3)
Slide 4: Transforming the way we use energy
Transforming the way we use energy Energy efficient, Zero energy Increase solar Packaging that Recycling low-emission Lighter vehicles buildings energy efficiency reduces waste and reuse electrolysis Reduce energy Reduce fossil Reduce energy Reduce fossil Reduce GHG Reduce waste consumption, fuel co
Slide 5: Raw materials to produce 1 kg aluminium
Raw materials to produce 1 kg aluminium Al2O3, Electrolyte + x C 2 Al + mCO2 + nCO 4 - 5 kg Bauxite CO2 1,5-2 kg 2 kg + 0.5 kg + Aluminium-oxide Carbon = 50 g 50 g 13 - 15 kWh 1 kg Aluminium fluoride + Cryolite + Electrical energy Aluminium (5)
Slide 6: Aluminium cell
Aluminium cell Alumina Carbon anode Electrolyte Liquid Carbon cathode aluminium (6)
Slide 7: Rheinwerk Neuss: An integrated, flexible metal source
Rheinwerk Neuss: An integrated, flexible metal source (7)
Slide 8: Unique «Aluminium triangle» utilizing logistical, cost and process synergies
Unique «Aluminium triangle» utilizing logistical, cost and process synergies (8)
Slide 9: Rheinwerk Neuss: The biggest aluminium smelter in Germany
Rheinwerk Neuss The biggest aluminium smelter in Germany • First green field smelter in BRD − Start-up in 1962 − Expansions in 1970 and 1981 − Continuous modernizations • Part of Rolled Products • Production capacities installed: − 190 kt baked anodes − 230 kt primary aluminium − 400 kt sheet ingots
Slide 10: Investment in additional recycling
Electrolysis Carbon New Al-recycling € 45 mln investment for additional recycling Casthouse Existing Al-recycling (10)
Slide 11: Rheinwerk today
During 2009 and 2012 mothballed down to 20% Partly restarted as a result of: Rheinwerk today • 2012 directive on CO2 cost in power • Capturing synergies with Rolled • 155 kt Primary Aluminium Products (of 230 kt) • Good operational efficiency • 230 kt Sheet Ingots • 45 kt Liquid Metal from Recycling
Slide 12: 50 years Rheinwerk
1962 – 2012 50 years Rheinwerk
Slide 13: Rheinwerk Carbon Plant
Rheinwerk Carbon Plant Efficient and sustainable supply of anodes to our electrolysis Customers Internal: Rheinwerk External potential: 45.000 t/a surplus capacity installed Capacity 200,000 mtpy green anodes (production 120,000) 190,000 mtpy baked anodes (production 95,000) 130,000 mtpy rodded anod
Slide 14: Rheinwerk Electrolysis
Rheinwerk Electrolysis 155.000 t/a liquid aluminium delivered to our casthouse with clear value chain benefits Capacity • 230,000 kt (production 155,000) Energy • Amperage: 180 kA • Current efficiency: 94 % • Energy consumption: 13.8 kWh/kg Al Set up • Potlines: 3 • Pots: 474 Employees • Approx. 200
Slide 15: Electrolysis production 2008 – 2015
Electrolysis production 2008 – 2015 Successful restart of mothballed capacity to 67% of installed capacity finalized in 2014 Tonnes 250,000 225,000 200,000 175,000 ~ 80% of capacity mothballed due to 150,000 increased power prices 125,000 and low LME 100,000 75,000 50,000 25,000 0 Jan. 08 Jan. 09 Ja
Slide 16: Current situation of Electrolysis
Current situation of Electrolysis Up to 75.000 t/a capacity still mothballed Potline 3 Potline 1 Potline 2 Still Back in In operation< mothballed operation (16)
Slide 17: Benchmark Rheinwerk Electrolysis
Benchmark Rheinwerk Electrolysis: Operational parameters in comparison with peers demonstrate position and further potential Current efficiency Energy consumption Net anode consumption Gross anode consumption Anode effect frequency Anode effect duration Anode effect minutes Age of cells in operation
Slide 18: Rheinwerk participates in regulation of interruptable load (AbLaV)
Rheinwerk participates in regulation of interruptable load (AbLaV) Our contribution to Germany’s energy turnaround: virtual “power plant capability” Stabilization of public grid in times of huge variations 235 MW in up to 15 minutes Further flexibility: Peak shaving, power modulation and secondary r
Slide 19: Stabilization of German power grid during Solar eclipse March 20th 2015
Stabilization of German power grid during Solar eclipse March 20th 2015: Rheinwerk demonstrated flexibility and was called to shut down and start four times (19)
Slide 20: Rheinwerk Casthouse
Rheinwerk Casthouse High quality products combined with short lead times and flexibility for optimized metal flow Customers • Hydro Rolling Mills (AluNorf & Grevenbroich) Capacity • 400,000 kt (production 230,000) Sheet Ingot • Max. l = 9,100 mm • w = 2,200 mm • h = 600 mm Employees • Approx. 120 Lo
Slide 21: Our final product: Sheet ingots
Our final product: Sheet ingots ready for further processing: portfolio to be high-graded with auto and can alloys (21)
Slide 22: Production in casthouse also impacted by electrolysis
Production in casthouse also impacted by electrolysis Focus in the recent years on high flexibility regarding metal sources and balance downstream Thousand tonnes 400 350 300 250 200 150 100 50 0 2007 2008 2009 2010 2011 2012 2013 2014 Sheet Ingots Liquid Metal to AluNorf (22)
Slide 23: Casthouse: Today's metal balance
Casthouse: Today’s metal balance + 155,000 mt primary metal from electrolysis + 20,000 mt external used scrap in + 45,000 mt process scrap from downstream + 30,000 mt ingots - 230,000 mt sheet ingots out Rheinwerk casthouse - 20,000 mt liquid transport to AluNorf (23)
Slide 24: Continuous Improvements
Continuous Improvements (24)
Slide 25: Safety, our number one priority!
Safety, our number one priority! Equipment • Reduce or remove underlying risks by updating and upgrading critical equipment and systems Processes • Reduce the operational risks through systematic analysis of risks, elimination of unnecessary processes and reduction of instability through the impleme
Slide 26: Loyal, motivated and competent employees are the best guarantee to achieve our goals
Loyal, motivated and competent employees are the best guarantee to achieve our goals (26)
Slide 27: Aluminium Metal Production System (AMPS)
Aluminium Metal Production System (AMPS): A fundamental philosophy for continuous improvements First class production requires stability Precision culture: Organisation can achieve quantum jumps Stability and predictability Inaccuracy, instability and “fire fighting” actions AMPS (27)
Slide 28: Utilization of AMPS as a platform to continuously improve our processes
Utilization of Aluminium Metal Production System as a platform to continuously improve our processes through our people (28)
Slide 29: Rheinwerk close to European CO2 Benchmark
Rheinwerk close to European CO2 Benchmark Further improvement potentials identified to meet or beat the benchmark in the future CO2-equivalent in kg/mt primary metal 4,000 3,811 3,500 3,335 3,000 EU Benchmark 2,502 2,500 Peak 2013 due to restart 2,000 1,858 1,828 1,812 1,784 1,737 1,769 1,759 1,673
Slide 30: Concrete measures in place to further reduce energy consumption
Concrete measures in place to further reduce energy consumption Developing the next generation electrolysis cell for Rheinwerk MWh/mt primary metal 15.5 15.0 15.0 15.0 14.6 14.5 14.2 14.2 14.2 14.2 Further vision down to < 13.0 MWh/mt 14.0 14.0 13.9 13.9 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.7
Slide 31: Increase recycling of aluminium through new investments and synergies
Increase recycling of aluminium through new investments and synergies UBC line and remelt capability in existing assets will more than double recycling volume in 2016 2007: Recycling furnace S2 Tonnes 150,000 125,000 2012: Liquid metal to AluNorf 100,000 75,000 50,000 2016: Used beverage cans (UBC)
Slide 32: UBC-Line Rheinwerk Used Beverage Cans Recycling Plant
UBC-Line Rheinwerk Used Beverage Cans Recycling Plant (32)
Slide 33: Strengthening of recycling position through UBC recycling line
Strengthening of recycling position through UBC* recycling line The new plant will replace ~50.000 t/a imported primary ingots through recycling of UBCs Establishing strong recycling position • Fulfilling customer needs and strengthening beverage can market position • Improving metal cost position •
Slide 34: Process Layout UBC-Line
Process Layout UBC-Line UBC´s Pre-shredding/ shredding Storage Sorting Shredding Thermal delacqering Melting Sorting Melting Liquid-Al Leg. 1005 (34)
Slide 35: UBC shredder unit
UBC shredder unit Overview a. Shredding the cans for optimal sorting i. contamination such as "plastic widgets" in special beer cans must be exposed by the shredding (Guinness / bitter beer) b. Shredding the cans for optimal delacquering i. both sides of the aluminium can (inside / outside) must be
Slide 36: Bale braker and hammer mill
Bale braker and hammer mill (36)
Slide 37: Sorting line, furnace and delaquering
Sorting line, furnace and delaquering (37)
Slide 38: UBC-Centre: Laying of the foundation stone (April 27th 2015)
UBC-Centre: Laying of the foundation stone (April 27th. 2015) (38)
Slide 39: Strategy and aspiration Rheinwerk
Strategy and aspiration Rheinwerk (39)
Slide 40: Rheinwerk strategic goals until 2016
Rheinwerk strategic goals until 2016 • 1 Safety as culture • 2 Further develop synergies with rolling operations • 3 Continuously develop human capital • 4 Fit for automotive • 5 Successful commissioning of UBC • 6 Process & system stabilization • 7 Cost stabilization • 8 Developing „Next Generation
Slide 41: Our vision 2020
Our vision 2020 With competent and engaged staff, we are the sustainable, most flexible metal source in Rolled Products, contributing to become the No. 1 in Europe. (41)
Slide 42: Infinite Aluminium - Hydro
INFINITE ALUMINIUM HYDRO