Aluminium recycling: from Material Flow Analysis to optimal recycling

1. Olivier Néel
ALUMINIUM 2016
11th World Trade Fair & Conference
November 30, 2016
Aluminium recycling: from Material
Flow Analysis to optimal recycling

2. An introduction to Constellium 2015
Constellium is a leader in innovative aluminium-based
solutions
Over 10,000 full-time employees
€5.2 billion in sales
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
2015 key figures
2An introduction to Constellium 2016

3. An introduction to Constellium 2015
Structured into 3 business units
3
Aerospace and Transportation
€ 1.355 billion in revenues
#1 worldwide for aerospace plates
#1 in the USA for large coils
Packaging and Automotive Rolled Products
€ 2.748 billion in revenues
#1 worldwide in closure stock
#2 in Europe and North America for can body stock
Major player in auto body sheet: #4 worldwide
Automotive Structures and Industry
€ 1.047 billion in revenues
#1 in Europe for large profiles
#1 in Europe for hard alloy extrusions
Joint leader worldwide in Crash Management Systems
An introduction to Constellium 2016

4. An introduction to Constellium 2015
The life cycle of aluminium products
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Recycling
Collecting
and sorting
Product design
and manufacturing
Product
use
Casting/rolling
and extrusion
Aluminium
smelting
Alumina
refining
Bauxite
extraction
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

5. An introduction to Constellium 2015
Challenges arising
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Increasing focus on a value chain approach
(circular economy, life cycle approach,
responsible purchasing...)
Increasing concern on environmental aspects
(climate change, water & resources depletion…)
Need for evidence of environmental performance,
hence dedicated assessment tools
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

6. An introduction to Constellium 2015
Tools to assess environmental performance
Complementary tools are available
From a PRODUCT perspective
Life Cycle Assessment (LCA)
Commonly used in many areas
From a MATERIAL perspective
Material Flow Analysis (MFA)
Less widely used, but gaining momentum
In both cases, recycling is key
6Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

7. An introduction to Constellium 2015
Life Cycle Assessment (LCA):
environmental impacts from a product perspective
Examples of impact categories
Water (use, eutrophication,
acidification…)
Air (ozone layer depletion, acidification,
smog)
Land (use, deforestation,
acidification…)
Resources depletion
Ecosystems or Human Toxicity
Energy (total, from non renewable
sources…)
Global warming (greenhouse gas –
GHG - emissions)
Life Cycle Assessment summarize environmental impacts of a product throughout its
production, usage and end-of-life (incl. recycling) phases
7Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

8. An introduction to Constellium 2015
0
1
2
3
4
5
6
7
8
9
10
Glass Steel Copper PE PP Primary Al Recycled
Al
GHGemissions(kgCO2eq./kg)
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LCA: effect of aluminium recycling
on greenhouse gases (GHG) emissions
Recycling is the cornerstone of Aluminium Sustainability
Primary Al GHG
Impact is highest
Recycled Al GHG
Impact is lowest
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

9. An introduction to Constellium 2015
0
20
40
60
80
100
120
140
0% 20% 40% 60% 80% 100%
Climate change [g CO2 eq. / can]
Effect of recycling rate for an aluminium beverage can
2020 European
target
Actual result for
2013 recycling rate
Including Can
manufacturing.
9Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

10. An introduction to Constellium 2015
0,00E+00
1,00E-04
2,00E-04
3,00E-04
4,00E-04
5,00E-04
6,00E-04
7,00E-04
0% 20% 40% 60% 80% 100%
Terrestrial acidification [kg SO2 eq.]
0,00E+00
5,00E-06
1,00E-05
1,50E-05
2,00E-05
2,50E-05
0% 20% 40% 60% 80% 100%
Freshwater eutrophication [kg P eq.]
0,00E+00
2,00E-06
4,00E-06
6,00E-06
8,00E-06
1,00E-05
1,20E-05
1,40E-05
1,60E-05
0% 20% 40% 60% 80% 100%
Marine eutrophication [kg N eq.]
0,00E+00
2,00E-04
4,00E-04
6,00E-04
8,00E-04
1,00E-03
1,20E-03
1,40E-03
1,60E-03
1,80E-03
0% 20% 40% 60% 80% 100%
Ecotoxicity [kg 1.4-DB eq.]
Freshwater ecotoxicity
[kg 1.4-DB eq.]
Marine ecotoxicity [kg
1.4-DB eq.]
Terrestrial ecotoxicity [kg
1.4-DB eq.]
Effect of recycling rate on other indicators
Except for one, clear positive effect.
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Rare case
where recycling
doesn’t reduce
impacts.
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

11. An introduction to Constellium 2015
Material Flow Analysis principle (MFA):
mapping material flows along the life cycle
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Building
Rolling
Wire
Extrusion
Casting
Packaging
Cable
Transport
Other Appl.
Recycling
In Use
Primary
Aluminium
End of
Life
ManufacturingSemi-production
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

12. An introduction to Constellium 2015
Material Flow Analysis: Constellium approach
Existing work from International Aluminium Institute (IAI)
European model
Applications, lifetime & recycling rates included
Allows for estimate of future recycling flows
Need for a more detailed model to better understand recycling flows
Location
Composition
Developing a more detailed model
Finer geographical granularity: down to countries
Split into alloys families
Design allowing for scenarios (parameters can vary with time)
12Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

13. An introduction to Constellium 2015
Constellium MFA model:
System boundaries & data categories
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Different data categories:
This complexity is necessary:
• Understanding of scrap flow composition (alloy, origin, location) and volumes contributes
to recycling strategy.
31 countries
EU27 + Turkey +EFTA)
4 Semi-Products
Extrusion / Rolling /
Casting / Semi-other
Automotive
Car
Transportation
Rail Marine
Aerospace
Commer
cial
Space
Packaging
Cans
Skyline
Building
House
12 product categories 10 alloys family
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

14. An introduction to Constellium 2015
MFA first use: why we will still need primary metal
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AnnualconsumptioninEurope(t)
0
2 000 000
4 000 000
6 000 000
8 000 000
10 000 000
12 000 000
14 000 000
1980 1985 1990 1995 2000 2005 2010 2015
Average product lifetime: ≈ 20 years
Available for recycling
today
Production
20 years ago
Source: European Aluminium
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

15. An introduction to Constellium 2015
More detailed MFA results:
recycling flow depends on recycling rate & lifetime:
15
2015 European production and end-of-life flows by application domain
50 y. lifetime
< 1 y. lifetime
No EOL
recycling
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

16. An introduction to Constellium 2015
If we were to consider recycled content for LCA
VS.Can 1 Can 1
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LCA could possibly show
this to be « greener », is it
correct?
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

17. An introduction to Constellium 2015
MFA can help getting a more relevant picture
VS.
Average recycled content for every
product
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
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MFA shows that it doesn’t
improve the big picture…
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

18. An introduction to Constellium 2015
Example of MFA use:
Evolution of Automotive EOL scrap vs. castings demand
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In the long run,
EOL scrap may exceed demand
Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

19. An introduction to Constellium 2015
Conclusion and perspectives
LCA & MFA are complementary tools to assess environmental performance
LCA can assess the benefits for recycling from a product perspective
Evaluating where efforts are most needed to improve a products life cycle
Calculating how recycling helps avoiding environmental impacts
MFA provides insight on key issues from a material perspective
Detailed timeline and composition of recycling flows
Sustainable material flows implies
EOL recycling is a sound performance indicator
Need for better sorting in the future
Selecting the most efficient way to sort by addressing the right flows.
19Aluminium recycling: from Material Flow Analysis to optimal recycling – ALUMINIUM 2016 - O. Néel – 2016-11-30

20. THANK YOU!

21. An introduction to Constellium 2015
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Visit us: www.constellium.com