Von Zengen

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Aluminium and

Energy in the EU

Karl-Heinz von Zengen, EAA

Brussels, 27 March 2006

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Aluminium End Uses - Europe 2001

Building

26%

Transport32%

Engineering

14%

Packaging

19%

Others

9%

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Passenger-km per Person per Year

382

188140

8021092

10024

1

10

100

1000

10000

100000

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

Source: DG TREN, European Commission

EU 15, 2000

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1990 2005 2010 20151995 2000

300

100

150

200

250

50

0

year

kgaluminiump

erv

ehicle

Aluminium Use in EU Cars

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Al in Cars - Relative and absolute Shares

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

0 50 100 150 200 250 300 350

Ford Fiesta

Skoda Fabia

Fiat Stilo

Peugeot 307

Nissan MicraNissan Tino

Opel Corsa

Chrysler PT

Citroen C3

Ford Mondeo

Mini

Renault Laguna

Peugeot 607

Toyota Prius

Citroen C5

Opel Vectra

Mercedes E class

Renault VelSatis

Audi A4

Audi A2

Source: Mavel

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1970

1972

1974

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

2000

1998

2002

750

950

1050

1150

1250

1350

850

1450

1550

Ford

Escort MK2 Ford

Escort MK3

Ford

Escort MK4

Ford

Escort MK5

Ford

Focus

VW

Golf Mk1

VW

Golf Mk2

VW

Golf Mk3

VW

Golf Mk4

2004

Citroen

GSCitroen

BX

VWGolf Mk5

Citroen

ZX

Citroen

XsaraToyota

Corolla

Toyota

Corolla

Toyota

Corolla

Toyota

Corolla

ToyotaCorolla

Toyota

Corolla

Astra

Mk1

Astra

Mk2

Astra

Mk3

Astra

Mk4

Astra

Mk5

Vauxhall

Cavalier Mk1 Cavalier

Mk2

Cavalier

Mk3

Vectra

1

Vectra

2

YEARS

Kg

Vehicle Weight by Generation

Source: Jaguar

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European Cars - Equipment Rates

0

10

20

30

40

50

60

70

80

90

100

Airbags ABS Anti Theft A/C Ewindow

1992

1996

1998

2002

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European Cars - relative Material Shares

Fiat Audi Skoda Nissan Peugeot Audi Renault Opel Ford Mercedes

Punto A2 Fabia Tino 607 A4 Laguna Corsa Mondeo C200

1,9 JTD 1,4 1,9 Sdi 2,0 2,2 HDI 2,0 1,9 dci 1,2 16v 2,0 DI Sedan

Steel 64,5 26,5 64,1 60,4 54,9 52,1 53,5 62,4 55,2 54,2

Cast Iron 6,7 1,8 8,8 in steel 6,3 5,1 8,5 in steel 11,4 10,7

A l u m i n i u m 6,4 36,3 4,9 11,5 11,0 15,7 9,9 7,2 8,3 10,8

Magnesium 0 0,2 0,6 0,1 0,1 0,5 0,1 0,1 0,1 0,2

Plastics 11,4 22,5 11,4 11,2 14,0 14,6 13,7 13,6 13,2 13,3

Glass 2,8 3,4 2,7 2,4 2,8 2,3 2,9 2,7 2,2 2,6Rubber 4,0 5,0 4,1 3,3 5,4 4,8 5,9 4,3 5,3 4,7

Ceramic 0,2 0,1 0,2 0,2 0,2 0,2 0,2 0,2 0,1 0,1

Misc. 4,0 4,2 3,2 10,8 5,4 4,8 5,3 9,4 4,3 3,4

Material Shares in selected Passenger Cars

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Aluminium helps light weighting Cars

887 785928

1003

1229

0

200

400

600

800

1000

1200

1400

Ref.- Car Primary state-

of-the-artweight

Primary latest-

technologyweight

Upper final

weight(Al-Car)

Lower final

weight(Al-Car)

weight[kg]

Minimum

secondary weight saving Maximum

secondary weight saving

Primary

state-of-the-

art weight

reduction

Primary

latest-

technology

weight

reduction

Source: fka Aachen

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

effort for ELV

dismanteling,

logistics, melting, ...0,2%=

+ service + spare parts (3%)

= fuels consumption (84,5%)

= mainly weight driven !

87,5 %

6%production effort =

recycling

efficiency2 % benefit

= 10

0,2 % effort

- recycling bonus == benefit from ELV recycling

4%

6%

2%

Matl prod. on base of primary energy =

Source: Audi

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Lifecycle Energy: Audi A2

0

400 GJ

50.000 km

cum

ulatedprimaryenergyuse

driving distance / km

200 GJ

100.000 km

break even after~ 55.000 km

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

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

conventinal concept

Audi A2 with secondary aluminium

database: IfE / TH Mnchen and

AUDI AG, I/ES & I/EG-34

disadvantage decreases

with lifetime

ASF advantage

increasing

Source: Audi

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Aluminium Sector in Europe*, 2004

15.6 mio tonnes

10.1 mio tonnes

11.7 mio tonnes

MINING

ALUMINA

METAL

4.6 mio tonnes

BAUXITE

6plants

11.0 mio tonnes

Bauxite

Net import

5.2 mio tonnes

PRIMARYMetal

Production

38plants

7.8 mio tonnes

ALUMINA

12plants

2.3 mio tonnes

Aluminaimport

4.2 mio tonnes

RECYCLEDMetal1

276plants

2.3 mio tonnes

Net import

SEMIS

1.1 mio tonnes

Wire, powder,

slugs...

3.1 mio tonnes

EXTRUDED

4.3 mio tonnes

ROLLED

Foil (22%)

333plants64plants

* West and Central Europe

(Former CIS excluded, except Baltic states)

1 In-house scrap remelting excl.2 Integrated automotive producers incl.

+2200plants

3.0 mio tonnes

CASTINGS2

TOTAL = PRODUCTION + IMPORTS

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Reduction of Electrolysis Energy for Aluminium

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End Uses for Recycled Aluminium, 2003

* EU-25. Semis-fabrication scrap excluded

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

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Evolution of Recycled Aluminium, EU-15

0

500

1.000

1.500

2.000

2.500

3.000

3.500

4.000

1980 1984 1988 1992 1996 2000 2004

Year

Aluminiumrecycledinthousandtonnes

peryear

TREND

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

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0

2000

4000

6000

8000

10000

12000

14000

16000

1950 1960 1970 1980 1990 2000 2003 2004 2010 2020

Oldscrap(thousandtonnes)

Other

Consumer Durables

Engineering

PackagingBuilding

Other Transport

Automotive

Global Old Scrap

Source: GARC, 24.01.05Aluminium in scrap

FORECAST

x2

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Global Aluminium Energy Flow, 2003

Source: GARC, 24.01.05Values in PJ (1015J)

Net Addition 2003: 1,700

Total Energy

Stored in Use

Since 1888

46,000

Finished

Products (output)

2,900

Lost to

Application

10

Fabricated and

FinishedProducts (input)

4,900

Traded

New

Scrap 540

Internal

Scrap

1,200

Traded

New

Scrap56

Ingots 4,700

Metal Losses 17 Landfill 150 Under Investigation 230

Old

Scrap

530

Bauxite 11

Bauxite Residues 4

and Water

Alumina 650

Primary

Aluminium

2,200

Recycled

Aluminium

2,300

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Emissions Primary vs Secondary

Transport

Bauxite mining and

alumina production

Electrolysis and Cast

house

melting and refining

0.00

2.00

4.00

6.00

8.00

10.00

12.00

Primary Recycled

Scrap

preparation

kg CO2per kg AL

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Millions

tonnes

of CO2

Best Practice and Transport Savings

202

242

290

345

411

327 337 333

345 339

200

250

300

350

400

450

2000 2005 2010 2015 2020

GHG Emissions

Transport Savings

Best Practice

The potential for Al Industry to be Climate Neutral by 2020 could beaccelerated implementing everywhere todays best practices

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Lirecar

Importance of Use phase for total emissions

Greenho

useGasEmissions

MAX MAX MAX MIN MIN MIN

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

-20%

- 10%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

CREDIT

PROD

USE

End - of - Life

MAX and MIN are representing

the range of different vehicle

scenarios

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Facts about Energy Intensive Industries

Energy intensive industries, which cannot pass on costs,

have already invested in energy efficiency for decades

like the aluminium industry

Aluminium industry is working globally

Incentives like ETS, RES etc. encourage the delocating

of energy intensive industries

Energy intensive industries find new homes in countrieswith less environmental legislation

Final result will be more pollution in the world

Finally, the energy efficiency policy in the EU has

succeeded by closing down energy intensive industries

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Aluminium Recycling

Aluminium recycling saves up to 95% of the energy

versus primary aluminium Export of scrap means export of energy

Export of scrap means - on a global basis - higher

pollution