Excellence in recycling
Excellence in recycling
Excellence in recycling
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<strong>Excellence</strong> <strong>in</strong> recycl<strong>in</strong>g…<br />
October 2006
Explor<strong>in</strong>g Umicore
Umicore: a history of transformation<br />
1887 1900 1960 1970 1980 1990 2001 2003<br />
Asturienne<br />
Vieille-Montagne<br />
Acec<br />
Société m<strong>in</strong>ère du Bécéka (Sibeka)<br />
Union M<strong>in</strong>ière<br />
Metallurgie Hoboken<br />
Us<strong>in</strong>e de désarg (Degussa)<br />
Compagnie des Metaux d’Overpelt<br />
Société Générales des M<strong>in</strong>erais<br />
Méchim<br />
MDK Komb<strong>in</strong>at Pirdop<br />
Sogem<br />
Degussa (precious metals, automotive catalysts, fuel cells) dmc² PMG<br />
3
Umicore:<br />
a world leader <strong>in</strong> specialty materials<br />
Umicore’s activities are centred <strong>in</strong> 4<br />
bus<strong>in</strong>ess areas: Advanced<br />
Materials, Precious Metals Products<br />
& Catalysts, Precious Metals<br />
Services and Z<strong>in</strong>c Specialties.<br />
Umicore’s expertise <strong>in</strong> materials<br />
science, chemistry and<br />
metallurgy can make a real<br />
difference, be it <strong>in</strong> products that are<br />
essential to everyday life or those at<br />
the cutt<strong>in</strong>g edge of new<br />
technological developments.<br />
4
Umicore: activities <strong>in</strong> four bus<strong>in</strong>ess groups<br />
Precious<br />
Metals<br />
Management<br />
Precious<br />
Metals<br />
Services<br />
Precious<br />
Metals<br />
Ref<strong>in</strong><strong>in</strong>g<br />
Automotive<br />
Catalysts<br />
Electro-<br />
Optic<br />
Materials<br />
Precious Metals Products & Catalysts<br />
Precious<br />
Metals<br />
Chemistry<br />
Specialty<br />
Oxides &<br />
Chemicals<br />
Technical<br />
Materials<br />
Eng<strong>in</strong>eered<br />
Metal<br />
Powders<br />
Advanced Materials<br />
Th<strong>in</strong> Film<br />
Products<br />
Element 6<br />
Abrasives<br />
(40%)<br />
Z<strong>in</strong>c<br />
Specialties<br />
Jewellery<br />
& Electroplat<strong>in</strong>g<br />
Z<strong>in</strong>c<br />
Alloys<br />
Z<strong>in</strong>c<br />
Chemicals<br />
Build<strong>in</strong>g<br />
Products<br />
Padaeng<br />
Industry<br />
(46%)<br />
Additional<br />
<strong>in</strong>fo<br />
5
Precious<br />
Metals<br />
Services<br />
§ Umicore is the world leader <strong>in</strong> the<br />
recycl<strong>in</strong>g of precious metals. It<br />
provides recycl<strong>in</strong>g and ref<strong>in</strong><strong>in</strong>g<br />
services at its plant <strong>in</strong> Hoboken,<br />
Hanau and <strong>in</strong> Brazil.<br />
§ Recovers approximately 20 metals<br />
<strong>in</strong>clud<strong>in</strong>g: gold, silver, plat<strong>in</strong>um,<br />
rhodium and palladium.<br />
§ Metals Management function for,<br />
among others, the hedg<strong>in</strong>g,<br />
leas<strong>in</strong>g, purchas<strong>in</strong>g and sale of<br />
precious metals.<br />
The ma<strong>in</strong> feed materials are byproducts<br />
of the non-ferrous metal<br />
and photographic <strong>in</strong>dustries, spent<br />
automotive and <strong>in</strong>dustrial catalysts<br />
and electronic scrap<br />
<strong>in</strong> mio € H1 2005 H1 2006<br />
Revenue 117.5 166.6<br />
EBIT (recurr<strong>in</strong>g) 28.9 62.6<br />
EBITDA 52.2 77.3<br />
ROCE % 23.6 44.8<br />
6
Precious<br />
Metals<br />
Products &<br />
Catalysts<br />
§ Umicore is one of the world’s<br />
lead<strong>in</strong>g producers of automotive<br />
catalysts and the lead<strong>in</strong>g producer<br />
of catalysts for diesel eng<strong>in</strong>es.<br />
§ Other products and services are<br />
based on precious metals (most often<br />
PGMs) and used <strong>in</strong> a wide variety of<br />
<strong>in</strong>dustries <strong>in</strong>cl. jewellery,<br />
electroplat<strong>in</strong>g, glassmak<strong>in</strong>g,<br />
electronics and <strong>in</strong> various chemical<br />
processes.<br />
§ Th<strong>in</strong> Film Products provides target<br />
materials for a wide range of<br />
applications.<br />
The bus<strong>in</strong>ess has a global reach with<br />
production sites on four cont<strong>in</strong>ents.<br />
This bus<strong>in</strong>ess group is mostly made up<br />
of units acquired as part of the PMG<br />
acquisition which was f<strong>in</strong>alised July ‘03.<br />
<strong>in</strong> mio € H1 2005 H1 2006<br />
Revenue 375.4 426.7<br />
EBIT (recurr<strong>in</strong>g) 71.6 71.7<br />
EBITDA 91.3 94.6<br />
ROCE % 24.2 20.8<br />
7
Advanced<br />
Materials<br />
§ Lead<strong>in</strong>g global position <strong>in</strong> cathode<br />
materials for lithium –ion batteries,<br />
cobalt powders for hard metal,<br />
applications, germanium<br />
substrates for space solar cells.<br />
§ Produces high-purity metals,<br />
alloys, compounds and eng<strong>in</strong>eered<br />
products for a wide range of other<br />
specialist applications.<br />
§ Advanced Materials has <strong>in</strong>dustrial<br />
operations around the world.<br />
Synthetic diamond and superabrasives<br />
activities are conducted<br />
<strong>in</strong> a jo<strong>in</strong>t venture with Element Six.<br />
<strong>in</strong> mio € H1 2005 H1 2006<br />
Revenue 138.6 143.7<br />
EBIT (recurr<strong>in</strong>g) 27.7 24.3<br />
EBITDA 37.5 36.4<br />
ROCE % 13.7 13.0<br />
8
Z<strong>in</strong>c<br />
Specialties<br />
§ Umicore’s strategy is to pursue<br />
leadership positions <strong>in</strong> specialty<br />
products with added value: z<strong>in</strong>c<br />
chemicals, alloys and build<strong>in</strong>g<br />
products.<br />
§ Umicore is also the world’s<br />
foremost z<strong>in</strong>c recycler.<br />
§ Primary production <strong>in</strong> Belgium,<br />
France and <strong>in</strong> 46% owned<br />
Padaeng Industries <strong>in</strong> Thailand.<br />
Umicore’s focus on recycl<strong>in</strong>g is<br />
central to its closed loop bus<strong>in</strong>ess<br />
model.<br />
<strong>in</strong> mio € H1 2005 H1 2006<br />
Revenue 229.1 207.0<br />
EBIT (recurr<strong>in</strong>g) 16.9 27.2<br />
EBITDA 37.3 47.2<br />
ROCE % 8.3 10.8<br />
9
Umicore has <strong>in</strong>dustrial applications on all cont<strong>in</strong>ents<br />
& serves an <strong>in</strong>ternational customer base<br />
10
Umicore: Committed to susta<strong>in</strong>able<br />
development<br />
Turnover<br />
Revenues<br />
EBIT<br />
EBITDA<br />
Net Consolidated Profit<br />
Capital Employed<br />
Workforce<br />
H1<br />
2005<br />
€<br />
million<br />
3,263.5<br />
861.1<br />
121.7<br />
203.8<br />
1,707.0<br />
13,193<br />
77.2<br />
H1<br />
2006<br />
€<br />
million<br />
4,521.0<br />
944.4<br />
160.5<br />
251.3<br />
109.6<br />
1,937.0<br />
15,956<br />
In June 2005 Umicore was ranked<br />
<strong>in</strong> world’s top-50 companies for<br />
comb<strong>in</strong>ed f<strong>in</strong>ancial and corporate<br />
social responsibility performance.<br />
Umicore ranked 8th <strong>in</strong> terms of<br />
corporate social responsibilities.<br />
Umicore recognizes that its<br />
commitment to f<strong>in</strong>ancial success<br />
must also take <strong>in</strong>to account the<br />
broader economic, environmental<br />
and social impact of its operations.<br />
11
Explor<strong>in</strong>g<br />
Umicore<br />
Precious Metals Ref<strong>in</strong><strong>in</strong>g
UPMR Worldwide<br />
UAR,<br />
Cov<strong>in</strong>gton,<br />
USA<br />
UPMR,<br />
Guarulhos,<br />
Brazil<br />
Cycleon, Paris, France<br />
UAR, Hoboken, Belgium<br />
UPMR, Hoboken, Belgium<br />
UPMR, Hanau, Germany<br />
UAR, Alzenau, Germany<br />
UMS,<br />
Shanghai,<br />
Ch<strong>in</strong>a<br />
13
UPMR Worldwide<br />
Hoboken Hanau Guarulhos<br />
§ UPMR’s largest <strong>in</strong>dustrial<br />
activities are located at<br />
Hoboken, near Antwerp<br />
(Belgium).<br />
§ Around 1,150 people active <strong>in</strong><br />
sampl<strong>in</strong>g & assay<strong>in</strong>g activities,<br />
<strong>in</strong> smelt<strong>in</strong>g & ref<strong>in</strong><strong>in</strong>g<br />
operations and <strong>in</strong> commercial<br />
& support<strong>in</strong>g services.<br />
§ First operations started <strong>in</strong> 1887<br />
as a desilver<strong>in</strong>g plant and is<br />
now the world’s largest<br />
precious metals recycl<strong>in</strong>g<br />
facility.<br />
§ UPMR Hanau (Germany)<br />
<strong>in</strong>cludes a sampl<strong>in</strong>g & sales<br />
department<br />
§ Particularly the autocatalyst<br />
recycl<strong>in</strong>g facilities are run out<br />
of Hanau.<br />
§ 20 people are active <strong>in</strong> Hanau.<br />
§ UPMR operates <strong>in</strong> Guarulhos,<br />
near Sao Paulo (Brazil) and has<br />
silver & gold ref<strong>in</strong><strong>in</strong>g activities.<br />
§ The sales department is serv<strong>in</strong>g<br />
the South-American market <strong>in</strong><br />
order to supply our Brazilian<br />
ref<strong>in</strong>ery as well Hoboken’s<br />
plant.<br />
§ Employment: 50 people<br />
14
UPMR: the lead<strong>in</strong>g precious metals recycler<br />
• Unique and <strong>in</strong>novative<br />
technology<br />
• Outstand<strong>in</strong>g services to<br />
an <strong>in</strong>ternational customer<br />
basis<br />
• A wide range of complex<br />
precious metals bear<strong>in</strong>g<br />
materials<br />
• Efficient recovery of 17<br />
different metals<br />
• Apply<strong>in</strong>g world class<br />
environmental standards<br />
15
Umicore Precious Metals Services*<br />
Key Figures<br />
EBITDA<br />
EBIT<br />
Average Capital Employed<br />
ROCE<br />
Capital Expenditure<br />
Workforce<br />
Surface<br />
* Bus<strong>in</strong>ess units Precious Metals Ref<strong>in</strong><strong>in</strong>g & Precious Metals Management<br />
H1 2005<br />
€ million<br />
52.2<br />
28.9<br />
245.1<br />
23.6%<br />
4.8<br />
1,279<br />
H1 2006<br />
€ million<br />
77.3<br />
62.2<br />
277.7<br />
44.8%<br />
9.8<br />
1,294<br />
116 hectares<br />
16
Umicore Precious Metals Ref<strong>in</strong><strong>in</strong>g<br />
SMELTERS &<br />
REFINERS INDUSTRY MARKET<br />
e.g.<br />
tankhouse<br />
slimes<br />
ref<strong>in</strong>ed metal e.g. computers<br />
production<br />
scrap<br />
precious<br />
metals<br />
e.g. copper scrap<br />
e.g.<br />
electronic<br />
scrap<br />
precious<br />
metals<br />
17
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
18
Raw Materials Supply<br />
Each year UPMR processes around<br />
300,000 tonnes of more than 200<br />
different types of raw materials<br />
conta<strong>in</strong><strong>in</strong>g lead/copper/nickel and<br />
precious metals.<br />
19
Types of raw materials<br />
By-products Recyclable products<br />
By-products<br />
from nonferrous<br />
<strong>in</strong>dustry<br />
e.g. drosses from<br />
lead smelters,<br />
slimes from copper<br />
<strong>in</strong>dustry,…<br />
Spent<br />
Industrial<br />
Catalysts<br />
Industrial<br />
catalysts from oil<br />
ref<strong>in</strong><strong>in</strong>g &<br />
petrochemical<br />
<strong>in</strong>dustry<br />
Electronic<br />
Scrap<br />
e.g. pr<strong>in</strong>ted circuit<br />
boards<br />
Spent<br />
Automotive<br />
Catalysts<br />
end-of-life<br />
car catalysts<br />
Precious metal<br />
bear<strong>in</strong>g raw<br />
materials<br />
e.g. fuel cells,<br />
photographic<br />
residues<br />
20
Supply distribution<br />
Spent<br />
Catalysts<br />
12%<br />
Electronic<br />
Scrap<br />
10%<br />
Others<br />
5%<br />
By-products<br />
73%<br />
21
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
22
Sales<br />
We recover and sell precious,<br />
special & base metals, chemicals &<br />
derivated products.<br />
23
Umicore Precious Metals Ref<strong>in</strong><strong>in</strong>g has<br />
flexible capacity for PM’s …<br />
Capacity t/y<br />
Output t/y<br />
From<br />
recyclables<br />
Ag Au Pt Pd Rh<br />
2,400<br />
1,200<br />
25%<br />
100<br />
25<br />
25%<br />
16<br />
12<br />
65%<br />
24<br />
15<br />
65%<br />
4<br />
3<br />
30%<br />
24
Precious Metals added value products<br />
§ Besides the production of ref<strong>in</strong>ed precious metals Umicore<br />
produces a range of complex precious metal bear<strong>in</strong>g<br />
materials serv<strong>in</strong>g a wide range of <strong>in</strong>dustries <strong>in</strong>clud<strong>in</strong>g<br />
automotive, jewellery, electronics, pharmaceutical and<br />
optics.<br />
§ Umicore Precious Metals Products & Catalysts with its<br />
headquarters <strong>in</strong> Hanau (Germany) generates added value<br />
to Hoboken ref<strong>in</strong>ed metals<br />
Additional<br />
<strong>in</strong>fo<br />
25
Precious Metals<br />
Silver<br />
(Ag)<br />
Gold<br />
(Au)<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
tankhouse and various slimes, lead sulphate, ashes, …<br />
silver 99.9+ % & 99.99 % granules<br />
jewellery, co<strong>in</strong>s, electronic & imag<strong>in</strong>g <strong>in</strong>dustries,<br />
catalysts, batteries<br />
tankhouse and various slimes, electronic scrap,<br />
sweeps & bullions<br />
gold 99.99 % gra<strong>in</strong>s & <strong>in</strong>gots (12.5 kg bars or smaller)<br />
jewellery, <strong>in</strong>vestment, co<strong>in</strong>s, electronic <strong>in</strong>dustries, …<br />
26
Precious Metals<br />
Plat<strong>in</strong>um<br />
(Pt)<br />
Palladium<br />
(Pd)<br />
Rhodium<br />
(Rh)<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Residues from the PGM m<strong>in</strong><strong>in</strong>g, slimes, catalysts,<br />
electronic scrap<br />
99.95 % powder (sponge)<br />
Jewellery (Pt), <strong>in</strong>dustrial & automotive catalysts,<br />
electronic <strong>in</strong>dustry, …<br />
27
Precious Metals<br />
Iridium<br />
(Ir)<br />
Ruthenium<br />
(Ru)<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Various slimes and precious metal bear<strong>in</strong>g products<br />
High grade salt (Ru > 75%)<br />
Hard metal and heat resistant alloys, electronic<br />
<strong>in</strong>dustry, …<br />
28
Base & special metals<br />
Pb<br />
125,000t<br />
Cu<br />
40,000t<br />
Sb<br />
3,000t<br />
Capacities for other non - PM elements<br />
Sn<br />
1,000t<br />
Bi<br />
400t<br />
Ni<br />
2,000t<br />
In<br />
30t<br />
Se<br />
600t<br />
Te<br />
150t<br />
Slags<br />
140,000t<br />
Additional<br />
<strong>in</strong>fo<br />
29
Base Metals<br />
Lead<br />
(Pb)<br />
Copper<br />
(Cu)<br />
Nickel<br />
(Ni)<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
drosses, lead sulphates, slags, …<br />
HER 99,97%, Crystal Pb 99,99%, PbCu<br />
Batteries, build<strong>in</strong>g products, …<br />
drosses, tankhouse slimes, copper cement, electronic<br />
scrap, …<br />
see www.cumerio.com<br />
cables, wires …<br />
drosses, slimes, electronic scrap, …<br />
nickel sulphate<br />
batteries, sta<strong>in</strong>less steel, …<br />
30
Chemicals & derivated products<br />
Sodium<br />
Antimonate<br />
Aggregate<br />
for<br />
concrete<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Applications<br />
drosses, slags, tankhouse slimes, …<br />
Sodium antimonate<br />
flame retardant, decolor<strong>in</strong>g agent, oxygen removal<br />
additive (TV-glass)<br />
the slag is the rema<strong>in</strong>der of our metallurgical process<br />
additive for concrete & dyke fortification<br />
31
Special Metals<br />
Indium<br />
(In)<br />
Selenium<br />
(Se)<br />
Tellurium<br />
(Te)<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
Orig<strong>in</strong><br />
Grade<br />
Applications<br />
z<strong>in</strong>c & lead ores<br />
In foil & InH<br />
Indium T<strong>in</strong> Oxide (ITO) for use <strong>in</strong> flat screens,<br />
electronics & semiconductors, solders & low melt<strong>in</strong>g<br />
po<strong>in</strong>t alloys, batteries, …<br />
tankhouse slimes<br />
SeHP 5N, SeHP 5N+, NaSe, SeTG 2N5, SeTG, 3N,<br />
SeSG 4N5 & Se Crude Wet<br />
<strong>in</strong> glass <strong>in</strong>dustry as color<strong>in</strong>g agent, pigments, animal<br />
feed, photo electric cells, …<br />
by-products from copper & lead <strong>in</strong>dustry, tankhouse<br />
slimes<br />
TeTG & TeHP<br />
steel, brass & copper alloys, solar cells<br />
32
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
33
Customer support<br />
UPMR provides a complete range of<br />
commercial and f<strong>in</strong>anc<strong>in</strong>g services for<br />
an optimal match with our costumers<br />
needs.<br />
Logistical assistance is provided as<br />
well as cross border transports and all<br />
legislative related matters.<br />
34
Comprehensive customer service<br />
§ UPMR is present worldwide to provide all<br />
necessary support.<br />
§ UPMR provides its clients complete<br />
<strong>in</strong>com<strong>in</strong>g and outgo<strong>in</strong>g logistical assistance<br />
for raw materials and for ref<strong>in</strong>ed metals &<br />
products.<br />
§ UPMR assists the customer <strong>in</strong> tak<strong>in</strong>g care of<br />
all environmental and adm<strong>in</strong>istrative<br />
obligations result<strong>in</strong>g from <strong>in</strong>ternational waste<br />
regulations and shipments, such as the Basel<br />
Convention, the Decision of the OECD<br />
Council and the Council Regulation (EEC).<br />
§ UPMR’s VAT warehouse allows our clients to<br />
trade with their metal credit loco Hoboken<br />
without VAT registration <strong>in</strong> Belgium and<br />
without declaration to the related EU Tax<br />
authorities.<br />
35
Metals Management service<br />
Basel Convention<br />
LBMA<br />
§ Optimal metal valorisation is ensured by<br />
UPMR’s expertise team, watch<strong>in</strong>g<br />
closely London fix<strong>in</strong>gs and market<br />
<strong>in</strong>formation.<br />
§ Supplier ‘s Risk management can be<br />
facilitated through forward pric<strong>in</strong>g,<br />
transmission of limit orders or more specific<br />
solutions.<br />
36
Metals Management service<br />
§ Our metals management ensures an optimal valorisation of raw<br />
materials. Ref<strong>in</strong>ed metals can be returned or can be repurchased at<br />
the best available market conditions.<br />
§ Clear <strong>in</strong>dividual metal accounts reflect all of the results of the metal<br />
transactions.<br />
§ UPMR offers special services like f<strong>in</strong>anc<strong>in</strong>g, leas<strong>in</strong>g, swaps, metal<br />
account transfers, pledges, early metal returns, market <strong>in</strong>formation,<br />
regular metal statement, ...<br />
37
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
38
A unique metallurgy…<br />
In<br />
Bi<br />
Ag<br />
Pb<br />
Sn<br />
Au<br />
Te<br />
As<br />
Pd<br />
Cu<br />
Sb<br />
Se<br />
Pt<br />
Ni<br />
Ir<br />
Rh<br />
Ru<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Pb, Cu & Ni are the base metals<br />
that drive our unique recycl<strong>in</strong>g<br />
process.<br />
By us<strong>in</strong>g the specific properties of<br />
these collector metals, precious<br />
and other secondary metals are<br />
recovered with the greatest<br />
efficiency.<br />
Our <strong>in</strong>-house developed precious<br />
metals ref<strong>in</strong>ery is one of the<br />
world’s largest and most efficient<br />
ref<strong>in</strong><strong>in</strong>g facility.<br />
39
H 2 SO 4<br />
Sulphuric Acid<br />
Nickel Ref<strong>in</strong>ery<br />
Ni<br />
SO 2<br />
PMresidue<br />
Sampl<strong>in</strong>g<br />
Smelter<br />
Raw Materials<br />
Precious Metals Operations<br />
Cu-bullion<br />
Leach<strong>in</strong>g & Electro W<strong>in</strong>n<strong>in</strong>g<br />
PM-residue<br />
Precious Metals Ref<strong>in</strong>ery<br />
Pb-slags<br />
Cu-matte<br />
Ni-speiss<br />
Agresidue<br />
Seresidue<br />
Base Metals Operations<br />
Blast Furnace<br />
Lead Ref<strong>in</strong>ery<br />
Pb-bullion<br />
Special Metals Ref<strong>in</strong>ery<br />
In-Te-residue<br />
Cu Ag, Au, Pt, Pd, Rh, Ir, Ru In, Se, Te Pb, Bi, Sb,<br />
Sn, As<br />
Additional<br />
<strong>in</strong>fo<br />
Slags 40
Precious Metals Operations<br />
Smelter<br />
§ Unique Isa smelt, submerged lance combustion technology, <strong>in</strong>ject<strong>in</strong>g oxygen<br />
enriched air and fuel <strong>in</strong> a molten bath.<br />
§ Separat<strong>in</strong>g precious metals, <strong>in</strong> a copper bullion, from mostly all other metals,<br />
concentrated <strong>in</strong> a lead slag.<br />
§ Operat<strong>in</strong>g at 1,000 mt/day at an availability > 92%. Brick rel<strong>in</strong><strong>in</strong>g period over<br />
14 months.<br />
§ Highly flexible technology for PM recycl<strong>in</strong>g<br />
q variability of physical aspect (lumps, f<strong>in</strong>es, wet,<br />
dry, shredded material, ...)<br />
q variability of feed mix (e.g. volume e-scrap vs.<br />
total volume)<br />
q ratio PM/ PGM’s and impurities <strong>in</strong> the feed mix<br />
41
Precious Metals Operations:<br />
Leach<strong>in</strong>g and Electro W<strong>in</strong>n<strong>in</strong>g<br />
§ Leach copper to collect precious metals <strong>in</strong> a residue for further ref<strong>in</strong><strong>in</strong>g <strong>in</strong> the<br />
precious metals ref<strong>in</strong>ery.<br />
§ Increase PM-content <strong>in</strong> residue from <strong>in</strong>take (Cu-granules) with factor 10.<br />
§ Wax- less Cu Electro W<strong>in</strong>n<strong>in</strong>g process, operat<strong>in</strong>g at 270A/m², actual current<br />
efficiency > 92%, produc<strong>in</strong>g 99.99% pure Cu-cathodes.<br />
§ Highly flexible technology<br />
q Ratio copper / other metals<br />
q PM and PGM content<br />
42
Precious Metals Operations<br />
Precious Metals Ref<strong>in</strong>ery<br />
§ Comb<strong>in</strong>ation of classical methods (e.g. cupellation) and unique <strong>in</strong>-house<br />
developed processes (e.g. silver ref<strong>in</strong>ery).<br />
§ Unique flexibility on ratio of gold, plat<strong>in</strong>um, palladium and secondary<br />
PGM’s versus silver, vary<strong>in</strong>g substantially accord<strong>in</strong>gly raw material feed.<br />
§ High purity metal production:<br />
q Ag: 5N<br />
q Au: 4N+<br />
q Pt, Pd, Rh: 3N5, catalytic grade<br />
q Ir, Ru: concentrates<br />
43
Base Metals Operations<br />
Blast Furnace<br />
The gases are further treated <strong>in</strong>to<br />
gas clean<strong>in</strong>g <strong>in</strong>stallation.<br />
The gases leave the furnace at<br />
around 200 °C.<br />
At the middle of the furnace the gas<br />
temperature is about 400 °C<br />
The warm gases heats-up the<br />
“cold” feed.<br />
The burned cokes produce gases<br />
with a temperature up to 1700 °C<br />
Reaction between hot air and<br />
cokes.<br />
Blow<strong>in</strong>g hot air at 600 °C <strong>in</strong>to the<br />
furnace.<br />
GASES<br />
Feed<br />
Gases<br />
- The feed is a mixture of more than 20 different products<br />
-Smelt<strong>in</strong>g capacity up to 1000 ton/day<br />
- Productions:<br />
200 - 250 ton lead / day<br />
FEED<br />
Feed<strong>in</strong>g the furnace with a<br />
mixture of cokes and lead<br />
conta<strong>in</strong><strong>in</strong>g products.<br />
Dry<strong>in</strong>g of the feed by the hot<br />
gasses.<br />
Heat<strong>in</strong>g up of the feed to 400 °C.<br />
Heat<strong>in</strong>g up of the feed to 800 °C.<br />
Smelt<strong>in</strong>g of the feed. Due to a<br />
complex set of metallurgical<br />
reactions different liquid and<br />
gaseous phases are formed.<br />
Liquid phases are tapped at<br />
1200 °C.<br />
44
Base Metals Operations<br />
Lead Ref<strong>in</strong>ery<br />
§ The Lead ref<strong>in</strong>ery treats the lead-bullion from the blast furnace<br />
q 95% Pb with As, Sn, Sb, In, Te, Ag, Bi<br />
§ In a batch type process these impurities are <strong>in</strong>dividually separated<br />
q As- salt retrograded to the Blast Furnace<br />
q Sn- salt for third party treatment<br />
q Sb- salt for sales<br />
q In & Te- residue for treatment <strong>in</strong> the Special Metals Ref<strong>in</strong>ery<br />
q Ag-skimm<strong>in</strong>gs for treatment <strong>in</strong> the Precious Metals Ref<strong>in</strong>ery<br />
q Bi-skimm<strong>in</strong>gs for third party treatment<br />
§ The ma<strong>in</strong> f<strong>in</strong>al product is ref<strong>in</strong>ed lead<br />
q 99.99 % Pb, at a capacity of 90,000 ton/year<br />
45
Base Metals Operations<br />
Special Metals Ref<strong>in</strong>ery<br />
Selenium, tellurium and <strong>in</strong>dium form the product<br />
portfolio of UPMR Special Metals. These metals are<br />
extracted from side-streams of the PMO and the Leadref<strong>in</strong>ery.<br />
In Se Te<br />
Selenium is often present <strong>in</strong> copper ore and is recovered from tankhouse slimes. It is<br />
used <strong>in</strong> the glass and pigment <strong>in</strong>dustry, <strong>in</strong> reprography applications, <strong>in</strong> <strong>in</strong>frared optics and<br />
solar cell technologies. UPMR has a production capacity of 600 tonnes per year.<br />
Tellurium is also ma<strong>in</strong>ly generated <strong>in</strong> a by-product of the copper <strong>in</strong>dustry. Tellurium<br />
improves the mach<strong>in</strong>ability of steel, is used <strong>in</strong> rubber vulcanisation and catalysts, as well<br />
as <strong>in</strong> thermoelectric applications. UPMR has an annual production capacity of 150 tonnes.<br />
Indium is not found <strong>in</strong> the native state, but is associated with lead and z<strong>in</strong>c <strong>in</strong> many ores.<br />
80% of the <strong>in</strong>dium consumption is dedicated to the production of Indium-T<strong>in</strong>-Oxide (ITO),<br />
which is a transparant conductive oxide used <strong>in</strong> flat screen displays. Applications of <strong>in</strong>dium<br />
also <strong>in</strong>clude low melt<strong>in</strong>g po<strong>in</strong>t alloys, control rods for nuclear reactors and hermetic seals<br />
for cryogenic applications. UPMR has a production capacity of 30 tonnes per year.<br />
46
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
47
Sampl<strong>in</strong>g & Assay<strong>in</strong>g<br />
The wide variety and complexity of<br />
<strong>in</strong>com<strong>in</strong>g materials mean that<br />
sampl<strong>in</strong>g & assay<strong>in</strong>g are<br />
Key Succes Factors <strong>in</strong> determ<strong>in</strong><strong>in</strong>g<br />
our customer’s f<strong>in</strong>ancial yield.<br />
UPMR allocates more than 15% of<br />
its operat<strong>in</strong>g budget to these<br />
services.<br />
48
Raw materials flow<br />
Arrival of raw<br />
materials<br />
Physical reception<br />
Primary sample<br />
Weigh<strong>in</strong>g <strong>in</strong>formation<br />
Moisture determ<strong>in</strong>ation<br />
F<strong>in</strong>al sample<br />
preparation of<br />
primary sample<br />
W&S report<br />
Samples for customers<br />
Loss of identity<br />
Bulk Smelter<br />
Laboratory Assay Exchange<br />
Determ<strong>in</strong>ation of<br />
metals content<br />
Settlement of results<br />
between customer &<br />
UPMR<br />
49
Sampl<strong>in</strong>g<br />
§ Unique state-of-the-art facilities<br />
§ Dedicated to process all raw materials<br />
§ Key drivers:<br />
q maximiz<strong>in</strong>g automations<br />
q adequate capacities <strong>in</strong> grow<strong>in</strong>g segments (e-scrap, auto catalysts, …<br />
q shorten<strong>in</strong>g the lead times<br />
q respect<strong>in</strong>g environmental, health & safety standards<br />
§ Investment of 15 Million € <strong>in</strong> last 10 years<br />
§ Employment: 90 people<br />
§ Secured area, ± 5000 lots & 300,000 t/y<br />
50
Ma<strong>in</strong> sampl<strong>in</strong>g processes<br />
Autocatalysts<br />
Decann<strong>in</strong>g & sampl<strong>in</strong>g<br />
of ceramic convertors<br />
<strong>in</strong> Hoboken (Belgium),<br />
Hanau-Alzenau<br />
(Germany).<br />
Shredd<strong>in</strong>g & sampl<strong>in</strong>g<br />
of metallic convertors<br />
<strong>in</strong> Alzenau (Germany)<br />
Electronic scrap<br />
Two seperate l<strong>in</strong>es<br />
for shredded and<br />
unshredded<br />
electronic scrap<br />
F<strong>in</strong>e free-flow<strong>in</strong>g<br />
material<br />
Sampl<strong>in</strong>g via<br />
blend<strong>in</strong>g<br />
e.g. sweeps,<br />
<strong>in</strong>dustrial<br />
catalysts<br />
Metallic material<br />
Sampl<strong>in</strong>g after<br />
remelt<strong>in</strong>g<br />
F<strong>in</strong>al sample preparation<br />
Wet material Lumpy material<br />
Homogenisation<br />
by mix<strong>in</strong>g<br />
Automatic spear<br />
sampl<strong>in</strong>g<br />
e.g. leach<br />
products, slimes<br />
Sampl<strong>in</strong>g via<br />
mill<strong>in</strong>g<br />
51
Laboratory<br />
§ Recognized leadership <strong>in</strong> the precious metals <strong>in</strong>dustry<br />
§ An up-to-date analytical equipment, supported by<br />
§ Key drivers:<br />
q a robust quality assurance system<br />
q a laboratory <strong>in</strong>formation and management system (LIMS)<br />
q Customer orientation<br />
q Respect for short lead times<br />
q Cont<strong>in</strong>uously <strong>in</strong>vestment <strong>in</strong> analytical research and method improvement<br />
§ Employment: 75 chemists<br />
§ Workload: 70,000 samples/y<br />
52
Assay<strong>in</strong>g process<br />
§ Internationally recognised by our customers <strong>in</strong><br />
precious metals assay<strong>in</strong>g us<strong>in</strong>g conventional<br />
fire assay & chemical procedures. Highly<br />
experienced <strong>in</strong> Pb, Cu and NiS collection.<br />
§ In-house developed technologies/processes.<br />
§ Extensive wet chemistry experience.<br />
§ Environmental analysis, <strong>in</strong>clud<strong>in</strong>g diox<strong>in</strong>s (by Gas<br />
Chromatography – Mass Spectrometry).<br />
§ Trace metals determ<strong>in</strong>ation.<br />
§ Broad range of <strong>in</strong>strumental techniques:<br />
q X-Ray Fluorescence (XRF)<br />
q Inductive Coupled Plasma (ICP)<br />
q Optical Emission Spectrometry (OES)<br />
q Graphite Furncace Atomic Absorption Spectrometry<br />
(GFMAS)<br />
53
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
54
Susta<strong>in</strong>able Development:<br />
For Umicore Precious Metals Ref<strong>in</strong><strong>in</strong>g, susta<strong>in</strong>able<br />
development implies:<br />
§ Cont<strong>in</strong>uous improvement of environmental<br />
performance.<br />
§ Social responsibility especially towards the local<br />
community.<br />
§ A challeng<strong>in</strong>g and support<strong>in</strong>g policy towards our<br />
personnel.<br />
§ Economic sound management <strong>in</strong> a Total Quality<br />
approach.
Environment:<br />
cont<strong>in</strong>uous reduction of air emissions<br />
45<br />
40<br />
35<br />
30<br />
25<br />
20<br />
15<br />
10<br />
5<br />
0<br />
20<br />
18<br />
16<br />
14<br />
12<br />
10<br />
8<br />
6<br />
4<br />
2<br />
0<br />
Stack emission of lead (t/y)<br />
80 85 90 93 94 95 96 97 98 99 00 01 02 03 04 05<br />
Diffuse emission of lead (t/y)<br />
81 83 85 87 89 91 93 95 97 99 01 03 05<br />
Substantial<br />
reduction<br />
from 2008<br />
Test with<br />
w<strong>in</strong>d screens<br />
for further<br />
reduction<br />
56
Environment:<br />
well perform<strong>in</strong>g waste water treatment<br />
§ All site waters (process water, cool<strong>in</strong>g water, ra<strong>in</strong><br />
water, spr<strong>in</strong>kl<strong>in</strong>g waters,…) are treated; there is no direct dra<strong>in</strong> away to<br />
the River Scheldt.<br />
§ 2/3 of all treated water is reused <strong>in</strong> the plant<br />
§ Emission standards are largely observed<br />
50<br />
45<br />
40<br />
35<br />
30<br />
25<br />
20<br />
15<br />
10<br />
5<br />
0<br />
Concentrations <strong>in</strong> % of emission standard<br />
93 94 95 96 97 98 99 00 01 02 03 04 05<br />
Pb Cd Cu NO2+NO3<br />
57
Environment:<br />
contribution to “Kyoto Protocol”<br />
3500<br />
3000<br />
2500<br />
2000<br />
1500<br />
1000<br />
500<br />
0<br />
2002 2003 2004 2005<br />
(budget)<br />
Energy Consumption (<strong>in</strong> TJ) Energy Recovery (<strong>in</strong> TJ)<br />
Energy Recovery (<strong>in</strong> %)<br />
12%<br />
10%<br />
8%<br />
6%<br />
4%<br />
2%<br />
0%<br />
§ UPMR strives to respect the climate<br />
change/CO 2 objectives:<br />
q Heat recover<strong>in</strong>g facilities at smelter, blast<br />
furncace and lead ref<strong>in</strong>ery.<br />
q Efficiency <strong>in</strong>crease at LEW.<br />
q Several improvement projects<br />
§ Covenant with the authorities with<br />
pledge to stay with<strong>in</strong> the world top for<br />
energy efficiency.<br />
58
Social responsability<br />
Soil remediation project <strong>in</strong> adjacent<br />
residential area “Moretusburg”:<br />
q Replacement of 30 cm of historical<br />
contam<strong>in</strong>ated soil by clean earth<br />
q 700 houses and public area<br />
q Activities will start <strong>in</strong> September 2006<br />
59
Social responsibility:<br />
communication and <strong>in</strong>formation<br />
§ Yearly environmental report, distributed on 7,000 copies<br />
§ Yearly <strong>in</strong>formation session to <strong>in</strong>habitants<br />
§ Consultation Committee with representatives of residentials and<br />
authorities<br />
§ Free telephone number 7/7 and 24/24<br />
§ Visits, open house, …<br />
§ Special <strong>in</strong>formation efforts for soil remediation project of Moretusburg<br />
60
Rehabilitation of historically polluted areas<br />
After 6 mio € clean-up costs: 2001 ><br />
< 1998: Before the clean-up<br />
61
Health & safety<br />
43<br />
38<br />
33<br />
28<br />
23<br />
18<br />
Lead <strong>in</strong> blood [µg/dl]<br />
40 = norm UPMR<br />
95 96 97 98 99 00 01 02 03 04 05<br />
UPMR cont<strong>in</strong>uously improves its occupational<br />
health & safety performance<br />
§ Occupational health monitor<strong>in</strong>g:<br />
q Bio-monitor<strong>in</strong>g<br />
q Workplace analysis<br />
q Vacc<strong>in</strong>ation<br />
§ Health:<br />
q Own medical service<br />
q Reduction program for lead <strong>in</strong> blood of<br />
employees<br />
§ Comfort:<br />
q Ergonomics<br />
q Advice & tra<strong>in</strong><strong>in</strong>g for use of computers<br />
§ Well-be<strong>in</strong>g:<br />
q Alcohol & drug policy / smok<strong>in</strong>g policy<br />
q Stress management<br />
62
Health & safety<br />
1,6<br />
1,4<br />
1,2<br />
1<br />
0,8<br />
0,6<br />
0,4<br />
0,2<br />
0<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
Severity<br />
97 98 99 00 01 02 03 04 05<br />
Frequency<br />
97 98 99 00 01 02 03 04 05<br />
UPMR has a safety policy focussed on three ma<strong>in</strong> areas:<br />
1. Technique:<br />
- Risk analysis of <strong>in</strong>stallations (via HAZOP:<br />
Hazard & Operability Study)<br />
- Identification & follow up of critical components.<br />
- Reliability of safety circles (via SIL:<br />
Safety Integrated Level)<br />
- Fire & explosion restriction (via ATEX:<br />
Atmosphères Explosives)<br />
2. Organization:<br />
Set up & audit of safety procedures (contractors,<br />
licenses, …).<br />
3. Human:<br />
Sensitivity & motivation of all employees <strong>in</strong> order<br />
to work <strong>in</strong> a safe environment.<br />
63
A Total Quality approach<br />
Our Total Quality system is driven by the<br />
European Foundation of Quality Management<br />
(EFQM) model. The EFQM approach is<br />
formalized <strong>in</strong> one <strong>in</strong>tegrated management<br />
system certified aga<strong>in</strong>st <strong>in</strong>ternational<br />
standards.<br />
§ Environmental care system certified<br />
accord<strong>in</strong>g to ISO14001: “… very well<br />
designed and implemented …”<br />
§ ISO 9001: Quality management.<br />
§ Safety certificate OSHAS 18001: due for<br />
October 2006.<br />
64
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
65
www.preciousmetals.umicore.com<br />
www.electronicscrap.umicore.com<br />
www.autocatalyst-recycl<strong>in</strong>g.umicore.com<br />
www.<strong>in</strong>dustrialcatalyst-recycl<strong>in</strong>g.umicore.com
Electronic Scrap Recycl<strong>in</strong>g<br />
www.electronicscrap.umicore.com<br />
67
Recycl<strong>in</strong>g is more complex than it appears on the<br />
1st look: Several cha<strong>in</strong> l<strong>in</strong>ks have to cooperate<br />
E-scrap<br />
Collection<br />
Dismantl<strong>in</strong>g<br />
Preprocess<strong>in</strong>g<br />
Separated components & fractions<br />
Materials<br />
recovery<br />
Recycled<br />
metals/<br />
elements<br />
reuse<br />
Handl<strong>in</strong>g of<br />
f<strong>in</strong>al waste<br />
• The entire cha<strong>in</strong> has to be considered. All steps are closely <strong>in</strong>terl<strong>in</strong>ked.<br />
• Dismantl<strong>in</strong>g & preprocess<strong>in</strong>g (often called „recycl<strong>in</strong>g“ by itself) is important, but only<br />
an <strong>in</strong>termediate step.<br />
• Endprocess<strong>in</strong>g (physical materials recovery) is a crucial step <strong>in</strong> value generation &<br />
toxic control.<br />
• Reuse is only an <strong>in</strong>terim solution and f<strong>in</strong>ally will lead to EOL-material.<br />
• In every process some f<strong>in</strong>al waste streams will occur, they have to be considered<br />
both <strong>in</strong> the environmental and economic process evaluation.<br />
68
E-waste: structure of recycl<strong>in</strong>g cha<strong>in</strong> and<br />
potential losses<br />
typical numbers of participants per country<br />
some 1.000<br />
(local)<br />
some 100 (local)<br />
Ma<strong>in</strong>ly<br />
Some 10 locally<br />
(partly <strong>in</strong>ternational)<br />
< 5 globally<br />
(3 <strong>in</strong> Europe)<br />
Entire EOL-devices<br />
Collection<br />
Sort<strong>in</strong>g/dismantl<strong>in</strong>g/component pick<strong>in</strong>g<br />
Ma<strong>in</strong>ly<br />
globally<br />
Large scale metallurgical<br />
& chemical technologies<br />
Stripped equipment & components<br />
Mechanical preprocess<strong>in</strong>g<br />
Circuit boards & highly<br />
complex materials<br />
Complex metals<br />
ref<strong>in</strong><strong>in</strong>g<br />
Magnitude of losses <strong>in</strong> materials and value<br />
Not collected<br />
Landfill, <strong>in</strong>c<strong>in</strong>eration<br />
or other losses<br />
Lost <strong>in</strong> sidestreams<br />
and wrong fractions<br />
(e.g. Au <strong>in</strong> Al-fraction)<br />
Transfer <strong>in</strong> slags or<br />
other sidestreams<br />
69
Significant losses of valuable raw materials still<br />
occur due to non-collection and exports to Asia<br />
About 40% of WEEE from<br />
Europe (on all levels) is<br />
exported, ma<strong>in</strong>ly to Asia, and<br />
treated <strong>in</strong> the <strong>in</strong>formal sector*<br />
Bulk collected<br />
(white, brown,<br />
grey):<br />
≈ 1,200 kt/y<br />
Total EOL-Waste Electronical<br />
and Electronic Equipment<br />
(WEEE) ≈ 5,000 kt/y <strong>in</strong> the EU<br />
Dismantl<strong>in</strong>g<br />
Pre-process<strong>in</strong>g<br />
Collection (communities,<br />
schemes, others)<br />
... Of which bulk<br />
with circuit boards<br />
≈ 450 kt/y<br />
Integrated metal<br />
smelters & ref<strong>in</strong>ers<br />
Precious Metals<br />
bear<strong>in</strong>g WEEE-parts:<br />
» 45 kt/y<br />
Total amount of Waste Electrical and Electronic Equipment ( WEEE) <strong>in</strong> the EU: » 5 million t/y (14 kg/person) but:<br />
- only some 25% of WEEE is collected so far<br />
- if collected, a substantial part is exported to Asia & Africa (ma<strong>in</strong>ly computers and telecommunication scrap)<br />
- white goods – free of precious metals (PM) - represent biggest quantity of WEEE-collected<br />
- only grey goods and brown goods bear PM’s and are of <strong>in</strong>terest for <strong>in</strong>tegrated metal smelters & ref<strong>in</strong>ers<br />
- WEEE usually requires adequate pre-process<strong>in</strong>g to separate it <strong>in</strong>to different fractions<br />
- PM-bear<strong>in</strong>g fractions <strong>in</strong> grey and brown goods only make up 5 – 10 % of the total weight.<br />
*exports often falsely labelled as<br />
„reuse“. Very low environmental<br />
standard and <strong>in</strong>efficient processes.<br />
Lack of control on exports and local<br />
operations.<br />
70
Material composition of e-scrap:<br />
not too sexy on a closer look<br />
E- scrap, a complex mix of:<br />
w Ag, Au, Pd, … (precious metals)<br />
w Cu, Al, Ni, Sn, Zn, Fe, … (base metals)<br />
w Hg, Be, Pb, Cd, As, Sb, Bi, … (metals of concern!)<br />
w Halogens (Br, F, Cl, ...)<br />
w combustibles (plastics)<br />
high risk of environmental damage if landfilled or if not treated<br />
<strong>in</strong> an environmentally sound way<br />
e-scrap conta<strong>in</strong>s valuable metals & resources and as such<br />
represents a true surface m<strong>in</strong>e, which must not be wasted<br />
Most toxic & most valuable metals are conta<strong>in</strong>ed <strong>in</strong> the circuit boards<br />
71
Examples: Material composition of<br />
circuit boards and some small<br />
electrical devices<br />
TV-boards<br />
Cu<br />
10%<br />
Calculator (without battery)<br />
Fe<br />
3%<br />
Al<br />
10%<br />
Al<br />
5%<br />
Others<br />
18%<br />
Plastics conta<strong>in</strong> halogenated<br />
flame retardants and/or Sb<br />
Cu<br />
3%<br />
Glass<br />
13%<br />
Ag [ppm] 280<br />
Au [ppm] 17<br />
Pd [ppm] 10<br />
Ni [%] 0,3<br />
Pb [%]<br />
Sn [%]<br />
1,0<br />
1,4 PC-boards<br />
Others<br />
15%<br />
Fe<br />
28%<br />
Plastics<br />
28%<br />
Glass<br />
6%<br />
Ag [ppm] 260<br />
Au [ppm] 50<br />
Pd [ppm] 5<br />
Ni [%] 0,5<br />
Pb [%] 0,1<br />
Sn [%] 0,2<br />
Plastics<br />
61%<br />
Others<br />
27%<br />
Cu<br />
20%<br />
Al<br />
5%<br />
Cell Phone 1999<br />
Cu<br />
13%<br />
Others<br />
22%<br />
Al<br />
1% Fe<br />
5%<br />
Glass<br />
2%<br />
Note: <strong>in</strong>dicative numbers only; value can differ significantly also with<strong>in</strong> one category!<br />
Ag [ppm] 1000<br />
Au [ppm] 250<br />
Pd [ppm] 110<br />
Ni [%] 1<br />
Pb [%] 1,5<br />
Sn [%] 2,9<br />
Fe<br />
7%<br />
Plastics<br />
23%<br />
Glass<br />
18%<br />
Ag [ppm] 1340<br />
Au [ppm] 350<br />
Pd [ppm] 210<br />
Ni [%] 0,1<br />
Pb [%] 0,3<br />
Sn [%] 0,5<br />
Plastics<br />
57%<br />
72
Plastics & steel contribute most to the weight, but<br />
precious metals usually dom<strong>in</strong>ate the material<br />
content value<br />
Note: <strong>in</strong>dicative numbers only; value can differ significantly also with<strong>in</strong> one category!<br />
weight-% plastics Fe Al Cu Ag [ppm] Au [ppm] Pd [ppm]<br />
TV-board 28% 28% 10% 10% 280 20 10<br />
PC-board 23% 7% 5% 20% 1000 250 110<br />
mobile phone 56% 5% 1% 13% 1380 350 210<br />
calculator 61% 4% 5% 3% 260 50 5<br />
value-share Fe Al Cu Ag Au Pd sum PM<br />
TV-board 4% 12% 43% 7% 27% 7% 41%<br />
PC-board 0% 1% 15% 4% 68% 12% 84%<br />
mobile phone 0% 0% 7% 4% 71% 18% 93%<br />
calculator 0% 6% 11% 6% 74% 3% 83%<br />
70%<br />
A high recovery of precious metals (PM) is crucial for maximis<strong>in</strong>g value<br />
return. Any PM-losses <strong>in</strong> dismantl<strong>in</strong>g and preprocess<strong>in</strong>g should be<br />
avoided, and metallurgical ref<strong>in</strong><strong>in</strong>g processes must show high recovery<br />
efficiencies and a well controlled handl<strong>in</strong>g of hazardous substances.<br />
73
Metal prices can be extremely volatile and heavily<br />
impact the <strong>in</strong>tr<strong>in</strong>sic metal value of e-scrap<br />
USD / tonne<br />
4500<br />
4000<br />
3500<br />
3000<br />
2500<br />
2000<br />
1500<br />
1000<br />
500<br />
1985<br />
1986<br />
USD / troz<br />
1987<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
Cu<br />
0<br />
1988<br />
1989<br />
1990<br />
1991<br />
1992<br />
Pd<br />
1993<br />
1994<br />
1995<br />
1996<br />
88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05<br />
1997<br />
1998<br />
1999<br />
2000<br />
2001<br />
2002<br />
2003<br />
2004<br />
2005<br />
USD/troz<br />
US cents/troz<br />
500<br />
450<br />
400<br />
350<br />
300<br />
250<br />
800<br />
750<br />
700<br />
650<br />
600<br />
550<br />
500<br />
450<br />
400<br />
350<br />
300<br />
1988<br />
1988<br />
1989<br />
1989<br />
1990<br />
1991<br />
Ag<br />
1990<br />
1991<br />
Au<br />
1992<br />
1992<br />
1993<br />
1993<br />
1994<br />
1994<br />
1995<br />
1995<br />
1996<br />
1996<br />
1997<br />
1997<br />
1998<br />
1998<br />
1999<br />
1999<br />
2000<br />
2000<br />
2001<br />
2001<br />
2002<br />
2002<br />
2003<br />
2003<br />
2004<br />
2004<br />
2005<br />
2005<br />
74
Some observations and conclusions<br />
• Toxic or other harmful substances are usually concentrated <strong>in</strong> the circuit<br />
boards, the same applies for the material content value.<br />
• Any major loss of precious metals (PM) decreases drastically the net<br />
recoverable value from electronic goods.<br />
• Material composition can have a significant impact on recycl<strong>in</strong>g<br />
requirements and adequate technical processes (<strong>in</strong>cl. emission control).<br />
• Mix<strong>in</strong>g different qualities <strong>in</strong> collection/preprocess<strong>in</strong>g can negatively<br />
<strong>in</strong>fluence recycl<strong>in</strong>g returns (dilution, technical constra<strong>in</strong>ts).<br />
• Legislation impacts material composition (and recycl<strong>in</strong>g requirements),<br />
e.g. ROHS → ban on Pb, <strong>in</strong>stead more Sn, Cu, Bi, Ag.<br />
• M<strong>in</strong>iaturisation & technological progress impact material composition.<br />
Tendency of decrease of absolute precious metals content <strong>in</strong> new models<br />
(m<strong>in</strong>iaturisation), but relative PM-% (per tonne) often more stable.<br />
• New products can br<strong>in</strong>g new compositions (e.g. MP 3 players, digital<br />
cameras).<br />
• New product generations can drastically change recycl<strong>in</strong>g requirements<br />
(e.g. CRT glass → flat screens; video recorders → DVD recorders).<br />
75
Electronic scrap <strong>in</strong> a global environment<br />
• Today, large quantities of old cell phones, computers and other IT-equipment are<br />
exported from Europe, North-America and Japan to Asia and <strong>in</strong>creas<strong>in</strong>gly also to<br />
Africa.<br />
• Many of these exports are falsely labelled as “reuse” (to circumvent restrictions<br />
on waste exports). Controls of real physical streams are low.<br />
• Every reuse is a temporary solution only and f<strong>in</strong>ally will lead to electronic-scrap<br />
that needs to be recycled.<br />
• Recycl<strong>in</strong>g requires awareness, an adequate <strong>in</strong>frastructure and some m<strong>in</strong>imum<br />
technology & experience. If this is not available, exports of electronics even for<br />
”real reuse” <strong>in</strong> such regions can be environmentally counterproductive.<br />
• More control and enforcement is needed to make sure that such exports are<br />
really recycled <strong>in</strong> the import<strong>in</strong>g country under high ESM standards.<br />
• Small scale, “backyard” metals recovery from computer scrap us<strong>in</strong>g open sky<br />
<strong>in</strong>c<strong>in</strong>eration and acid stripp<strong>in</strong>g methods release toxic<br />
substances while yield<strong>in</strong>g only low metal recoveries.<br />
They impose considerable damage to the environment<br />
and the health of local workers and neighbourhood.<br />
• Transparency of material flows until the f<strong>in</strong>al dest<strong>in</strong>ation is a key element.<br />
76
Sampl<strong>in</strong>g of electronic scrap at Umicore<br />
Example: the value of circuit<br />
boards can differ significantly:<br />
high grade: Au > 400 g/t<br />
medium grade Au 200 - 400 g/t<br />
low grade Au 100 - 200 g/t<br />
very low grade Au < 100 g/t<br />
Other precious metals conta<strong>in</strong>ed: Ag, Pd, (Pt)<br />
77
Digest<strong>in</strong>g the element cocktail <strong>in</strong> a complex<br />
separation process, us<strong>in</strong>g a unique metallurgy<br />
...<br />
Zn Ir HC Rh Fe<br />
Hg Pt Ni SiO2 Te Se<br />
Ru<br />
AgCo<br />
Au Cu<br />
As<br />
Pb<br />
S Bi Sn Pd<br />
Sb C Cd In Al2O3 Clean off gas Clean waste water<br />
Sulfuric<br />
Acid<br />
Base & Special Metals<br />
Pb, Cu, Ni,<br />
Sb, Sn, Bi, Se, In, Te, As<br />
Umicore Process<br />
Recovery of<br />
Metals & Energy<br />
Precious Metals<br />
Ag, Au,<br />
Pt, Pd, Rh, Ir, , Ru ,<br />
Dykefill<br />
Betogr<strong>in</strong>d<br />
… to turn a difficult feed systematically <strong>in</strong>to<br />
recycled, useful products, while safely<br />
recover<strong>in</strong>g or isolat<strong>in</strong>g toxic substances<br />
Controlled<br />
depot<br />
In<br />
Bi<br />
Ag<br />
Pb<br />
Sn<br />
Au<br />
Te<br />
Pd<br />
Cu<br />
Sb<br />
As<br />
Se<br />
Pt<br />
Ni<br />
Ir<br />
Rh<br />
Ru<br />
78
Umicore’s IsaSmelt process can efficiently cope<br />
with complex mixes of metals and plastics.<br />
Stack<br />
Bag<br />
house<br />
filter<br />
Monthly<br />
measurement of<br />
dust, metals,<br />
SO 2 , NO X , CO,<br />
C tot<br />
Filter dust Dust<br />
HygienicIsaSmelt<br />
Process Radiation<br />
gasses furnace gasses chambre<br />
Heat recovery:<br />
High pressure<br />
steam for <strong>in</strong>ternal<br />
use<br />
Adiabatic<br />
cooler<br />
Electrostatic<br />
precipitator<br />
Quench<strong>in</strong>g<br />
Water to Water<br />
Treatment Plant<br />
Sulphuric<br />
Acid<br />
Plant<br />
Stack<br />
Cont<strong>in</strong>uous<br />
measurement<br />
of SO 2 , NO X<br />
Cont<strong>in</strong>uous<br />
sampl<strong>in</strong>g for<br />
diox<strong>in</strong><br />
detection<br />
Periodic<br />
measurement of<br />
dust, metals,<br />
H 2 SO 4 , NO X , CO,<br />
C tot, , HF, HCl<br />
Plastics <strong>in</strong> the smelter feed can partially substitute<br />
coke & fuel (feedstock recycl<strong>in</strong>g), an extensive offgas<br />
treatment safely prevents any emission of diox<strong>in</strong>es.<br />
79
The scope for recycl<strong>in</strong>g optimisation is the<br />
entire WEEE recycl<strong>in</strong>g cha<strong>in</strong><br />
WEEE<br />
maximise<br />
ecoefficiency<br />
awareness<br />
optimise<br />
environmental<br />
balance<br />
optimise<br />
economical<br />
balance<br />
Process technologies<br />
Material composition<br />
Information/<br />
communication<br />
Bus<strong>in</strong>ess ethics<br />
legislation<br />
Reuse,<br />
Recycled materials,<br />
energy recovery<br />
w maximise material recycl<strong>in</strong>g (ga<strong>in</strong> 1)<br />
w m<strong>in</strong>imise environmental damage (burden)<br />
w consider environmental f<strong>in</strong>gerpr<strong>in</strong>t of material (ga<strong>in</strong> 2)<br />
(Fe < Al < Au)<br />
w maximise revenues from material recycl<strong>in</strong>g<br />
w m<strong>in</strong>imise total recycl<strong>in</strong>g costs (<strong>in</strong>cl. sidestreams)<br />
80
Interface optimisation to cope with technical<br />
conflicts <strong>in</strong> metal recycl<strong>in</strong>g<br />
Dismantl<strong>in</strong>g<br />
& preprocess<strong>in</strong>g<br />
Concentration rate* %<br />
Smelt<strong>in</strong>g &<br />
ref<strong>in</strong><strong>in</strong>g<br />
Investigate<br />
for optimisation<br />
The “concentration dilemma”<br />
e.g. separat<strong>in</strong>g Cu + PM<br />
from feed <strong>in</strong>to own fraction<br />
Recovery rate %<br />
* <strong>in</strong> output stream<br />
highest value & environmental impact for WEEE:<br />
circuit boards with Au, Pd, Ag, Cu, (special metals)<br />
=> m<strong>in</strong>imise total cha<strong>in</strong> losses of these metals<br />
<strong>in</strong>tegrated smelters recover Cu, PM, NF- & special metals,<br />
but Al is lost<br />
Al-smelters recover Al, but Cu & PM are lost<br />
all (NF-) metals are lost <strong>in</strong> landfill, <strong>in</strong>c<strong>in</strong>eration, plastic<br />
recycl<strong>in</strong>g and steel plants<br />
For complex, <strong>in</strong>tensely <strong>in</strong>terl<strong>in</strong>ked „high grade“ materials, metallurgical<br />
processes offer advantages over mechancial separation <strong>in</strong> efficiently<br />
extract<strong>in</strong>g precious & special metals as well as toxics<br />
81
Avoid deep mechanical treatment of<br />
“high grade” materials<br />
PM-loss %<br />
Fe Al<br />
Recovery rate per<br />
plastics<br />
<strong>in</strong>dividually separated material %<br />
100% 100% 100%<br />
Every separation step bears the risk of coseparat<strong>in</strong>g<br />
(los<strong>in</strong>g) precious metals. This can<br />
add up to significant PM-losses.<br />
Accept<strong>in</strong>g higher impurities of Fe, Al and<br />
plastics <strong>in</strong> the Cu/PM-fraction generated <strong>in</strong><br />
pre-process<strong>in</strong>g can boost the overall precious<br />
metal recovery and thus the generated value.<br />
High & medium grade boards, mobile phone<br />
handsets etc. should directly enter <strong>in</strong>to an<br />
efficient, <strong>in</strong>tegrated metals smelter process.<br />
Plastics conta<strong>in</strong>ed there<strong>in</strong> can be utilised as<br />
coke substitute (feedstock recycl<strong>in</strong>g).<br />
Mutual <strong>in</strong>terface optimisations by pre-processors and <strong>in</strong>tegrated smelters<br />
leads to w<strong>in</strong>/w<strong>in</strong>-situations and an <strong>in</strong>creased eco-efficiency<br />
82
F<strong>in</strong>d out the right w<strong>in</strong>dow of optimisation<br />
between preprocess<strong>in</strong>g and smelt<strong>in</strong>g/ref<strong>in</strong><strong>in</strong>g<br />
Costs<br />
Area of optimisation<br />
smelt<strong>in</strong>g costs<br />
preprocess<strong>in</strong>g costs (<strong>in</strong>cl. landfill)<br />
Preprocess<strong>in</strong>g Intensity<br />
precious<br />
metal losses<br />
83
Impact of metal losses along the<br />
recycl<strong>in</strong>g cha<strong>in</strong><br />
USD/t<br />
8000<br />
7000<br />
6000<br />
5000<br />
4000<br />
3000<br />
2000<br />
1000<br />
0<br />
TVboards<br />
PCboards<br />
cellphone<br />
1999<br />
cordless<br />
phone<br />
Metal prices for calculation (Oct. 2005, rounded)<br />
Ag $/troz 7,4 = $/kg 238<br />
Au $/troz 460 = $/kg 14789<br />
Pd $/troz 190 = $/kg 6109<br />
Cu $/mt 4000 = $/kg 4,00<br />
Al $/mt 1100 = $/kg 1,10<br />
Fe $/mt 140 = $/kg 0,14<br />
* gross metal value without consider<strong>in</strong>g<br />
any losses dur<strong>in</strong>g recycl<strong>in</strong>g nor any<br />
recycl<strong>in</strong>g costs. The more efficient the<br />
recycl<strong>in</strong>g cha<strong>in</strong> is, the more of this value<br />
can be recovered → net value.<br />
Fe<br />
Al<br />
Cu<br />
Pd<br />
Au<br />
Ag<br />
Assumption: loss of 20% of Ag, Au, Pd, Cu, Al, Fe<br />
Note: <strong>in</strong>dicative numbers only; value can differ significantly also with<strong>in</strong> one category!<br />
gross <strong>in</strong>tr<strong>in</strong>sic<br />
value*<br />
value share per metal<br />
USD/tonne Ag/Au/Pd Cu Al Fe<br />
TV boards 900 41% 43% 12% 4%<br />
PC-boards 5400 84% 15% 1% 0%<br />
cell phones 6400 93% 7% 0% 0%<br />
metal loss<br />
20% total loss loss per metal <strong>in</strong> USD / tonne<br />
USD/tonne Ag/Au/Pd Cu Al Fe<br />
TV boards 180 74 77 22 7<br />
PC-boards 1080 907 162 11 0<br />
cell phones 1280 1190 90 0 0<br />
For many electronic devices, los<strong>in</strong>g Al or Fe has only a marg<strong>in</strong>al impact on net<br />
value. Highest attention has to be placed on avoid<strong>in</strong>g losses of precious metals!<br />
84
How realistic is a 20% (precious) metal<br />
loss along the e-scrap recycl<strong>in</strong>g cha<strong>in</strong> ?<br />
E-scrap / circuit boards - a highly complex material, especially valid with respect to<br />
precious metals distribution.<br />
Occurrence of PMs with:<br />
• metallics: contacts, connector, solders, hard disk drives,...<br />
• ceramics: Multi layer capacitors (MLCC), ICs, hybrid ceramics, ...<br />
• plastics: ICs, PCB-tracks, <strong>in</strong>ter-board layers, ...<br />
→ Most of the PM conta<strong>in</strong><strong>in</strong>g parts on circuit boards and small devices (cell phones etc.) are<br />
closely <strong>in</strong>terl<strong>in</strong>ked with one another and PMs are highly dissem<strong>in</strong>ated.<br />
→ Shredd<strong>in</strong>g cannot really liberalise the different materials/metals. Shredded parts still are a<br />
partial mix of plastics, Fe, Al, Cu and PMs.<br />
→ Sort<strong>in</strong>g of these shredded parts by traditional separation technics (magnetic, eddy current,<br />
etc.) leads automatically to often substantial losses of PMs <strong>in</strong> the Fe-, Al-or plastic fractions.<br />
→ F<strong>in</strong>e shredd<strong>in</strong>g can improve the liberalisation but generates even more dust which is difficult<br />
to handle and also carries PM.<br />
If circuit boards or small devices are preprocessed by shredd<strong>in</strong>g & sort<strong>in</strong>g, a loss of 20% PMs<br />
is realistic, also higher losses do occur.<br />
If shredd<strong>in</strong>g cannot be avoided (low grade materials), a coarse shredd<strong>in</strong>g process followed by<br />
manual or optical sort<strong>in</strong>g could be a valid alternative.<br />
85
Example:<br />
Eco-efficiency of mobile phone recycl<strong>in</strong>g<br />
The „direct smelter route“ was proven<br />
to be the most eco-efficient solution<br />
(source: J. Huisman, TU Delft)<br />
Environmental weight: how much<br />
environmental impact/burden by<br />
produc<strong>in</strong>g 1 kg of a metal?<br />
86
An example for Umicore’s solution<br />
for complex materials recycl<strong>in</strong>g<br />
Umicore output<br />
Recovered as<br />
metal<br />
Chemical use<br />
as process<br />
additive<br />
Transfer <strong>in</strong>to<br />
an <strong>in</strong>ert slag<br />
(product)<br />
Neutralised<br />
<strong>in</strong> effluents<br />
Isolation and<br />
safe deposit<br />
87
Some observations and conclusions<br />
• Dismantl<strong>in</strong>g, mechanical preprocess<strong>in</strong>g and smelt<strong>in</strong>g/ref<strong>in</strong><strong>in</strong>g of e-scrap are<br />
highly <strong>in</strong>terdependent.<br />
• Interface optimisation is needed to m<strong>in</strong>imise value losses (= PM-losses).<br />
Metallurgical liberalisation and sort<strong>in</strong>g (=smelt<strong>in</strong>g) is a valid alternative to deep<br />
mechanical preprocess<strong>in</strong>g of circuit boards and small “high grade” devices.<br />
• Economies of scale are the more important the more one goes downstream <strong>in</strong><br />
the recycl<strong>in</strong>g cha<strong>in</strong>.<br />
• State-of-the-art technology requires considerable <strong>in</strong>vestments <strong>in</strong> equipment,<br />
process and <strong>in</strong>frastructure, aga<strong>in</strong> the higher the more downstream it is.<br />
• Specialisation and expertise is key to a successful operation. Investment risks<br />
and technical risks are high.<br />
• An (<strong>in</strong>ternational) share of labour has<br />
resulted thereof, emphasis<strong>in</strong>g <strong>in</strong>dividual<br />
core competencies. While collection,<br />
dismantl<strong>in</strong>g, preprocess<strong>in</strong>g usually takes<br />
place on a national/regional level, smelt<strong>in</strong>g<br />
& ref<strong>in</strong><strong>in</strong>g is conducted globally by a<br />
handful of specialised companies.<br />
Ma<strong>in</strong>ly<br />
locally<br />
Sort<strong>in</strong>g/dismantl<strong>in</strong>g/component pick<strong>in</strong>g<br />
Ma<strong>in</strong>ly<br />
globally<br />
Large scale metallurgical<br />
& chemical technologies<br />
Collection<br />
Entire EOL-devices<br />
Stripped equipment & components<br />
Mechanical preprocess<strong>in</strong>g<br />
Circuit boards & highly<br />
complex materials<br />
Complex metals<br />
ref<strong>in</strong><strong>in</strong>g<br />
88
It needs a global network of partners ...<br />
... to offer much more than just technical solutions.<br />
We <strong>in</strong>vite other market participants to jo<strong>in</strong> us <strong>in</strong> the development of<br />
appropriate measures to further <strong>in</strong>crease recycl<strong>in</strong>g efficiency, promot<strong>in</strong>g<br />
best-practice quality standards and environmentally sound operations.<br />
89
Conclusion<br />
• Integrated smelters offer unique, eco-efficient possibilities to recover precious, base<br />
and special metals, while us<strong>in</strong>g organic residues as substitute for coke & fuel, and<br />
safely handl<strong>in</strong>g toxic elements. Sufficient capacity is available.<br />
• For such plants high <strong>in</strong>vestments, state-of-the-art technology and extensive efforts <strong>in</strong><br />
offgas- & waste water treatment are required. Umicore’s Hoboken plant has been<br />
developed to the most advanced processor of precious metals conta<strong>in</strong><strong>in</strong>g WEEE.<br />
• Not any „copper smelter“ can treat e-scrap - only a handful of <strong>in</strong>tegrated smelters<br />
worldwide have all the necessary <strong>in</strong>stallations.<br />
• Integrated smelters can contribute significantly to further optimise the WEEE recycl<strong>in</strong>g<br />
cha<strong>in</strong>, <strong>in</strong> close cooperation with pre-processors (<strong>in</strong>terface optimisation).<br />
• Grow<strong>in</strong>g exports of WEEE and its fractions are a threat to the European recycl<strong>in</strong>g<br />
<strong>in</strong>dustry - valuable recourses are lost and often exported materials are treated <strong>in</strong><br />
environmentally non-compliant ways.<br />
• Future availabilties of e-scrap <strong>in</strong> Europe will be much lower than expected due to large<br />
WEEE-export streams to Asia and Africa.<br />
• Monitor<strong>in</strong>g & control of material streams, transparency and bus<strong>in</strong>ess ethics are key.<br />
90
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
91
Spent Auto Catalysts Recycl<strong>in</strong>g<br />
www.autocatalyst-recycl<strong>in</strong>g.umicore.com<br />
92
Spent automotive catalysts: Scope<br />
Umicore Precious Metals Ref<strong>in</strong><strong>in</strong>g has been active <strong>in</strong> spent<br />
autocatalyst recovery for many years.<br />
It is currently process<strong>in</strong>g material from all over the world.<br />
Transactions may imply “as is” purchase or toll ref<strong>in</strong><strong>in</strong>g.<br />
A state-of-the-art weigh<strong>in</strong>g and sampl<strong>in</strong>g comb<strong>in</strong>ed with a<br />
unique smelt<strong>in</strong>g and ref<strong>in</strong><strong>in</strong>g process guarantees optimum yield<br />
to the supplier.<br />
Additional services such as forward pric<strong>in</strong>g, f<strong>in</strong>anc<strong>in</strong>g etc can<br />
be offered as well.<br />
93
Some history<br />
For more than 20 years, Umicore Precious Metals has been active <strong>in</strong><br />
the recovery of autocatalysts from North America, where the first<br />
mandatory use of catalytic converters was implemented <strong>in</strong> 1975.<br />
S<strong>in</strong>ce 1991, Umicore’s supply also <strong>in</strong>cludes material from its own<br />
subsidiary, Umicore Bowden (Cov<strong>in</strong>gton, TN).<br />
In Europe, first volumes showed up at the end of the 80ies<br />
(Germany, Scand<strong>in</strong>avia) and have cont<strong>in</strong>uously grown s<strong>in</strong>ce<br />
then.<br />
By the late n<strong>in</strong>eties, volumes have started to emerge from<br />
other cont<strong>in</strong>ents as well.<br />
94
Modes of operation<br />
or<br />
“AS IS” basis<br />
= outright sale of converters or monolith material<br />
(per piece, per kg, …)<br />
“ASSAY” basis<br />
= precious metal recovery on toll ref<strong>in</strong><strong>in</strong>g transaction<br />
95
“AS IS” - Fundamentals<br />
Pric<strong>in</strong>g (spot) per unit converter or unit weight,<br />
as a function of estimated weight of monolith,<br />
precious metal assay,<br />
precious metal prices,<br />
costs.<br />
In practice, use of a regularly updated price list, with<br />
or without brand/size/type differentiation.<br />
96
“AS IS” - Pros and Cons<br />
+ Very simple formula: price/unit<br />
+ Easy adm<strong>in</strong>istration<br />
+ Immediate payment: no fluid assets problems<br />
+ No price risk<br />
+ No expertise necessary for sale of precious metals<br />
- The supplier has to develop an expertise on his own<br />
regard<strong>in</strong>g the quality of the various converters.<br />
- Little transparency: the supplier has no real idea of the<br />
different components <strong>in</strong>fluenc<strong>in</strong>g the price offered.<br />
- There is more than just the price ...<br />
97
“ASSAY” - Fundamentals<br />
Recovery of Pt, Pd, Rh on toll treatment :<br />
weigh<strong>in</strong>g / count<strong>in</strong>g+decann<strong>in</strong>g+weigh<strong>in</strong>g,<br />
crush<strong>in</strong>g,<br />
sampl<strong>in</strong>g,<br />
assay<strong>in</strong>g,<br />
allow<strong>in</strong>g actual determ<strong>in</strong>ation of Pt, Pd, Rh content.<br />
This is followed by credit to metal account,<br />
for subsequent account-to-account transfer,<br />
sale to Umicore Precious Metals,<br />
physical delivery,<br />
subject to payment of contractual process<strong>in</strong>g costs.<br />
98
“ASSAY” - Pros and Cons<br />
+ Transparency: customer knows the exact metal content and<br />
receives correspond<strong>in</strong>g return.<br />
+ Potential for highest yield: no cushion for cover<strong>in</strong>g aga<strong>in</strong>st<br />
quality and price risks, s<strong>in</strong>ce the settlement is based on the<br />
actual weight and precious metal assay.<br />
- Wait<strong>in</strong>g for metal credit means long f<strong>in</strong>anc<strong>in</strong>g period.<br />
- Market<strong>in</strong>g the precious metals requires some expertise.<br />
- Price risk until actual sale of the recovered metals, unless<br />
estimated metals content have been hedged.<br />
- More complicated formulas and adm<strong>in</strong>istration.<br />
99
Converter reception & decann<strong>in</strong>g<br />
Weigh<strong>in</strong>g (if required)<br />
Count<strong>in</strong>g<br />
Grad<strong>in</strong>g (full, half, empty)<br />
Sort<strong>in</strong>g (if required)<br />
Decann<strong>in</strong>g,<br />
with proper attention to safety and<br />
dust collection<br />
100
Weigh<strong>in</strong>g & Sampl<strong>in</strong>g<br />
Tailor-made, dedicated weigh<strong>in</strong>g<br />
and sampl<strong>in</strong>g l<strong>in</strong>e for broken<br />
honeycomb<br />
A thorough sampl<strong>in</strong>g procedure to<br />
guarantee maximum representativity<br />
of the reta<strong>in</strong>ed sample.<br />
Presence of customer representative<br />
or <strong>in</strong>dependent witness<br />
ISO 9001 certified<br />
Generally recognised as ‘first <strong>in</strong> class’<br />
Weigh<strong>in</strong>g<br />
Empty<strong>in</strong>g &<br />
separation of waste<br />
Shredder 6 mm<br />
< 6 mm<br />
Primary Sampler<br />
7 - 10%<br />
Secondary Sampler<br />
1 – 2%<br />
101
Process<br />
2<br />
1<br />
3<br />
Cu-smelter (1):<br />
collection of precious<br />
metals on Cu<br />
LEW (2):<br />
Leach<strong>in</strong>g and ElectroW<strong>in</strong>n<strong>in</strong>g of Cu<br />
Precious Metals ref<strong>in</strong>ery (3)<br />
High flexibility <strong>in</strong> terms of<br />
- quality (PGM, carrier, impurities)<br />
- quantity<br />
102
Spent autocatalyst operations with<strong>in</strong> UPMR<br />
Who<br />
Where 1<br />
Where 2<br />
Cycleon SA Asnières France X<br />
Contract<strong>in</strong>g<br />
Umicore Autocatalyst Recycl<strong>in</strong>g Belgium NV Hoboken Belgium X X<br />
Umicore Autocatalyst Recycl<strong>in</strong>g USA Cov<strong>in</strong>gton, TN USA X X<br />
Decann<strong>in</strong>g<br />
Umicore Autocatalyst Recycl<strong>in</strong>g GmbH Alzenau Germany X X<br />
UPMR Hanau (Umicore AG & Co KG) Hanau Germany X X<br />
UPMR Brasil (Umicore Brasil Ltda) Sao Paulo Brasil X X X<br />
UPMR Hoboken (Umicore NV) Hoboken Belgium X X X X<br />
W&S<br />
Smelt<strong>in</strong>g<br />
PGM Ref<strong>in</strong><strong>in</strong>g<br />
103
Umicore serves the complete PGM life-cycle<br />
PGM Compounds<br />
Precious Metal<br />
Management<br />
New Catalyst Production<br />
PGM Ref<strong>in</strong><strong>in</strong>g<br />
New Vehicle Production<br />
End of life Scrap<br />
Catalyst Collection<br />
104
Additional services<br />
Precious Metals Management :<br />
metal accounts<br />
geographical metal swaps<br />
leas<strong>in</strong>g (early metal outturn)<br />
purchase<br />
forward pric<strong>in</strong>g<br />
f<strong>in</strong>anc<strong>in</strong>g<br />
Assistance with <strong>in</strong>-bound shipp<strong>in</strong>g<br />
Global presence<br />
105
Conclusion: Why us ?<br />
General<br />
“AS IS”<br />
“ASSAY”<br />
Committed - Long term vision<br />
Flexible<br />
Reliable<br />
F<strong>in</strong>ancially stable<br />
Fair grad<strong>in</strong>g<br />
Fair price<br />
Transparent<br />
State-of-the-art weigh<strong>in</strong>g and sampl<strong>in</strong>g<br />
Best overall value<br />
106
Contact: Philippe Van Maele<br />
Manager Raw Materials Supply, Spent Catalysts<br />
address: Adolf Gre<strong>in</strong>erstraat 14<br />
2660 Hoboken<br />
Belgium<br />
Tel: +32 3 821.79.85<br />
Fax: + 32 3 821 78 07<br />
Mobile: +32 475 64.47.12<br />
e-mail: philippe.vanmaele@umicore.com
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
108
Spent Industrial catalysts Recycl<strong>in</strong>g<br />
www.<strong>in</strong>dustrialcatalyst-recycl<strong>in</strong>g.umicore.com<br />
109
Spent Industrial catalysts: Scope<br />
Umicore’s unique smelt<strong>in</strong>g and ref<strong>in</strong><strong>in</strong>g capabilities allow the<br />
recovery of precious metals from a wide variety of <strong>in</strong>dustrial<br />
spent catalysts.<br />
Its high flexibility makes it possible to cope with any type of<br />
carrier and with unregenerated catalysts, conta<strong>in</strong><strong>in</strong>g a high<br />
level of impurities.<br />
Additional services can be offered <strong>in</strong> the form of a package.<br />
110
Process<br />
2<br />
1<br />
3<br />
Cu-smelter (1):<br />
collection of precious metals on Cu<br />
LEW (2):<br />
Leach<strong>in</strong>g and Electrow<strong>in</strong>n<strong>in</strong>g of Cu<br />
Precious Metals ref<strong>in</strong>ery (3)<br />
High flexibility <strong>in</strong> terms of<br />
- quality (impurities, carriers, PM)<br />
- quantity<br />
111
Acceptable Spent Catalyst Properties<br />
Include<br />
A high presence of coke (no trashburn) and/or hydrocarbons<br />
Nuisance elements<br />
F<strong>in</strong>es<br />
Support balls<br />
by catalyst design, eg Cl -<br />
caused by process contam<strong>in</strong>ation, eg Fe, As<br />
Base metal catalyst fractions<br />
Any type of carrier<br />
112
Weigh<strong>in</strong>g & Sampl<strong>in</strong>g<br />
113
Weigh<strong>in</strong>g & Sampl<strong>in</strong>g<br />
A thorough sampl<strong>in</strong>g procedure to guarantee maximum<br />
representatively of the reta<strong>in</strong>ed sample.<br />
Presence of customer representative or <strong>in</strong>dependent<br />
witness<br />
No pretreatment losses<br />
ISO 9001 & ISO 14001 certified<br />
Generally recognised as ‘first <strong>in</strong> class’<br />
114
Additional Services<br />
Precious Metals Management:<br />
metal accounts<br />
Assistance with Transfrontier Movement of Waste<br />
Global presence<br />
geographical metal swaps<br />
leas<strong>in</strong>g possibilities (early metal outturn; bridge lease…)<br />
forward pric<strong>in</strong>g<br />
115
Conclusion<br />
Flexible<br />
complex multiple precious metal catalysts<br />
unscreened & unregenerated ‘polluted’ catalysts<br />
Process Reliability<br />
fast, efficient & representative sampl<strong>in</strong>g<br />
adequate assay<strong>in</strong>g<br />
possible to use umpire laboratory <strong>in</strong> case of discrepancies<br />
116
Conclusion<br />
F<strong>in</strong>ancial Reliability<br />
Service<br />
Competitive<br />
sound balance sheet<br />
long tradition<br />
a wide variety of precious metal related services<br />
117
Contact: Frank Bastenie<br />
Michel Verhelst<br />
Address: Adolf Gre<strong>in</strong>erstraat 14<br />
2660 Hoboken<br />
Belgium<br />
Tel: +32 3 821.74.13 / +32 3 821.73.06<br />
e-mail: frank.bastenie@umicore.com<br />
michel.verhelst@umicore.com
Industrial by-products<br />
Tankhouse slimes from the copper, lead and t<strong>in</strong> <strong>in</strong>dustry<br />
Dross, matte & speiss from the lead <strong>in</strong>dustry<br />
Lead sulphate and copper cement from the z<strong>in</strong>c <strong>in</strong>dustry<br />
Flue dust from the nickel and precious metals <strong>in</strong>dustry<br />
119
Our Core Bus<strong>in</strong>ess<br />
Sampl<strong>in</strong>g &<br />
Assay<strong>in</strong>g<br />
Metals Sales<br />
Recycl<strong>in</strong>g & Ref<strong>in</strong><strong>in</strong>g<br />
Raw Materials<br />
Supply<br />
Customer Support<br />
SUSTAINABLE<br />
DEVELOPMENT<br />
120
Tree Structure Bus<strong>in</strong>ess Presentation<br />
Level<br />
0.<br />
Umicore<br />
1.<br />
UPMR general &<br />
core bus<strong>in</strong>ess<br />
2.<br />
Sub bus<strong>in</strong>ess<br />
3.<br />
Details<br />
Byprod.<br />
1<br />
A. Supply<br />
Ind.<br />
cats<br />
Auto<br />
cats<br />
B. Sales<br />
Escrap<br />
1 1 1<br />
Homepage<br />
Explor<strong>in</strong>g Umicore<br />
Explor<strong>in</strong>g UPMR<br />
Our core bus<strong>in</strong>ess<br />
C. Customer<br />
Support<br />
D. Recycl<strong>in</strong>g<br />
& Ref<strong>in</strong><strong>in</strong>g<br />
Flow<br />
sheet 1<br />
E. Sampl<strong>in</strong>g<br />
& Assay<strong>in</strong>g<br />
F. Susta<strong>in</strong>able<br />
Development<br />
1 1 1<br />
1<br />
1 1<br />
PM<br />
2<br />
BM &<br />
SM 1<br />
Additional <strong>in</strong>fo<br />
121
Detailed structure Bus<strong>in</strong>ess Presentation (1)<br />
Base presentation<br />
(pages)<br />
1<br />
2 to 5<br />
6 to 7<br />
8 to 13<br />
14<br />
Sub presentation<br />
(pages)<br />
5.1 to 5.4<br />
Content<br />
Homepage<br />
Explor<strong>in</strong>g Umicore, part 1<br />
Additional <strong>in</strong>fo Umicore<br />
Explor<strong>in</strong>g Umicore, part 2<br />
Explor<strong>in</strong>g UPMR<br />
Pivot page “Core<br />
Bus<strong>in</strong>ess” for further<br />
presentation<br />
Comments<br />
By click<strong>in</strong>g on the “additional <strong>in</strong>fo” button of slide 5<br />
you will turn up at the additional <strong>in</strong>fo. Once this<br />
sub-presentation comes to an end you will arrive to<br />
part 2 of Explor<strong>in</strong>g Umicore.<br />
By click<strong>in</strong>g on the grey boxes of the specific<br />
presentations (and on the green text for Susta<strong>in</strong>able<br />
Development) you will turn up at right presentation.<br />
There is no particular order to follow <strong>in</strong> het choice<br />
of the presentations. Once a specific presentation<br />
comes to an end, you will automatically return to the<br />
122<br />
pivot page “Core Bus<strong>in</strong>ess”.
Detailed structure Bus<strong>in</strong>ess Presentation (2)<br />
Base presentation<br />
(pages)<br />
A1<br />
A2<br />
A3<br />
Sub presentation<br />
(pages)<br />
A. RAW MATERIAL SUPPLY<br />
A2.BP.1<br />
A2.IC.1-?<br />
A2.ES.1-?<br />
A2.AC.1-?<br />
Content<br />
Home page<br />
Types of raw materials<br />
Add. <strong>in</strong>fo By-products<br />
Add. <strong>in</strong>fo Industrial cats<br />
Add. <strong>in</strong>fo E-scrap<br />
Add. iInfo auto cats<br />
Supply distribution<br />
Comments<br />
By click<strong>in</strong>g on one of the pictures you will turn up at<br />
the right sub-presentation and automatically return<br />
to the pivot page “Core Bus<strong>in</strong>ess” once the specific<br />
presentation comes to an end.<br />
123
Detailed structure Bus<strong>in</strong>ess Presentation (3)<br />
Base presentation<br />
(pages)<br />
B. METALS SALES<br />
B1<br />
B2 to B3<br />
B4<br />
C1<br />
C2 – C4<br />
Sub presentation<br />
(pages)<br />
B3.PM.1-3<br />
B4.BM.1-3<br />
C. CUSTOMER SUPPORT<br />
Content<br />
Home page<br />
Precious Metals<br />
Add. <strong>in</strong>fo Precious Metals<br />
Base & Special Metals<br />
Add. Info Base & Special<br />
Metals<br />
Home page<br />
Info Customer Support<br />
Comments<br />
By click<strong>in</strong>g on the “additional <strong>in</strong>fo” button you will<br />
turn up at the specific presentation.<br />
By click<strong>in</strong>g on the “additional <strong>in</strong>fo” button you will<br />
turn up at the specific presentation.<br />
124
Detailed structure Bus<strong>in</strong>ess Presentation (4)<br />
Base presentation<br />
(pages)<br />
D1<br />
D2<br />
E1<br />
E2 – E6<br />
F1<br />
F2 – F10<br />
Sub presentation<br />
(pages)<br />
D. RECYCLING & REFINING<br />
D2.FS.1-6<br />
E. SAMPLING & ASSAYING<br />
F. SUSTAINABLE DEVELOPMENT<br />
Content<br />
Home page<br />
Flow sheet<br />
Add. <strong>in</strong>fo Flow sheet<br />
Home page<br />
Info Sampl<strong>in</strong>g & Assay<strong>in</strong>g<br />
Home page<br />
Info susta<strong>in</strong>able Development<br />
Comments<br />
By click<strong>in</strong>g on the “additional <strong>in</strong>fo” button you will<br />
turn up at the specific presentation. Be aware that<br />
you will not return to the flow sheet, but to the pivot<br />
page “Core Bus<strong>in</strong>ess”.<br />
125