1 Steel Recycling This report covers production years 26 to
2 211 Contents 1 Message from the General Manager 2 CELSA Group 3 CELSA Steel UK 4 Our products 8 6 Environmental profile Meeting the requirements of sustainability 7 Sustainability and sustainable manufacturing 1 Significant environmental aspects 12 Emissions and Legal compliance 16 Environmental performance indicators Resource efficiency (raw materials and production) Energy efficiency (including CO2) Melt Shop case study Energy reduction Atmospheric emissions Water consumption Water quality Waste management Transport Biodiversity 14 Environmental objectives and targets Sections Mill case study Oil reduction Health, Safety & employee engagement Community & stakeholder engagement 33 Environmental statement verification Cover image: CELSA Rod & Bar Mill from Bute East Dock.
3 Message from the General Manager 211 business growth has to be integrated with environmentally sustainable decisions and practices This is our second Environmental Statement, following registration to the EMAS scheme last year, and covers the year of 21. Through its pages you will see that despite an exceptionally difficult market, we have not lost our focus of continual improvement in our Health, Safety and Environmental performance. Nearly all of the objectives and targets that we set ourselves for 21 have been met and those that haven t been met were, in the main, directly related to market performance effects, which is a testament to the commitment of all of our employees and that of our service contractors. Business growth has to be integrated with environmentally sustainable decisions and practices so it is right to look at our business performance through economic, social and environmental lenses and to seek synergies between these facets as we develop and grow the business. CELSA is a recycling business, turning end of use ferrous scrap into new steel for use in the construction industry, and as such plays an important part in the UK Governments Sustainable Construction Policy. EMAS registration and the publication of this statement is demonstration of our environmental focus, and this coupled with our certification to the Eco Reinforcement and BES 61 standards enables users of our products to specify them with confidence. Our process makes new steel by melting steel scrap in an Electric Arc Furnace (EAF). Steel produced in this way consumes only a third of the energy and emits only one sixth of the CO2 when compared with other steelmaking processes, and typically, 95% of the waste arisings from the processes are useful by-products that are either recycled or reused. The process produces relatively little true waste for disposal. The use of modern and best available techniques, employing and nurturing the right people, and continually improving our processes will enable us to achieve ambitious environmental performance targets for our business and our continued development in this field is not only my personal wish, but our strategic goal for an environmentally responsible business. Luis Sanz Villares General Manager Appointed November 21 1
4 211 Introduction we believe in people and are committed to the health, safety and development of our employees and communities we operate in EMAS This document has been prepared by UK Ltd (CELSA Steel UK) in accordance with the requirements of the Eco Management & Audit Scheme (EMAS) as set out in European Council Regulation 761/1. EMAS is a voluntary scheme designed to recognise and reward those organisations that go beyond minimum legal compliance and continuously improve their environmental performance, therefore demonstrating green credentials. It was initially established by European Regulation 1836/93, although this has been replaced by Council Regulation 1221/29. It is a requirement of the scheme that participating organisations regularly produce a public that reports the organization s environmental performance clearly and accurately. The accuracy and reliability of the information in this voluntary publication must be checked and certified by an independent environmental verifier. This document is the Environmental Statement of CELSA s environmental attributes and environmental performance for the period 26 to 21. All the information is independently verified for accuracy, and a statement of confirmation is provided by the verifier at the end of the document. Image above right: High Yield Coil for reinforcement. 2 Eco-Reinforcement & BES 61 As part of CELSA s contribution to sustainable construction practices and sustainable development objectives, CELSA s products are accredited to the Eco-Reinforcement Responsible Sourcing Standard (Issue 2, Eco- Reinforcement Ltd 29) and to the Eco-Reinforcement parent standard, BES 61, the BRE Environmental & Sustainability Standard for the Responsible Sourcing of Construction Products (Issue 2, BRE Global Ltd 29). This has also been written in accordance with the higher level requirements of both the Standards. In November 21, Celsa improved its Eco-Reinforcement certification rating, rising from Pass to Good, whilst also attaining BES 61 certification for all other steel products manufactured in Cardiff, which also achieved a Good rating. The improvement in rating is an indicator of the continuous improvement Celsa has accomplished following its commitment to implementing EMAS, and the progress realised through certification to the Eco-Reinforcement standard. CELSA Group CELSA was founded in Barcelona in 1967 with its first rolling mill. A decade later an electric arc furnace started producing steel at the Barcelona plant. The CELSA GROUP grew through reinvestment and successive acquisitions to become a well recognised brand in steel manufacture. CELSA now ranks amongst the top 3 steel-producing companies in the World as well as one of the most diversified European long products producer. CELSA has a diverse range of steel production and processing operations strategically positioned across Europe to both maximise our competitive spread and to reduce our transportation impacts. The CELSA group of companies employ over 8 people across Europe, operating from 7 steel plant locations and numerous downstream fabrication units. At CELSA we take our responsibilities seriously. We believe in people and are committed to the health, safety and development of our employees and communities we operate in. We believe in sustainable development and are committed towards ongoing improvement in managing our environmental impact in supplying sustainable products. We believe in integrity and are committed to managing all aspects of our business with honesty and transparency.
5 Introduction 211 CELSA Group mission CELSA group is the most diversified European private steelmaking group in long products. Our purpose is: To satisfy all its customers with quality products and excellent and direct service. To be a competitive, profitable and innovative group leading the target markets and achieving sustained growth, by being an efficient, flexible and dynamic organisation. CELSA Group vision Our people, their effort and professional and personal development and teamwork. Continuously improving all our processes and activities and the permanent updating of our technology. Managing and operating our business in an ethical, safe and environmentally responsible manner. By working together in this way, we will achieve a sustainable company and maintain international presence for benefit of all concerned. CELSA Group values We live for our customers We feel like owners We respect people and teamwork We are sharp and flexible We lead as ground-breakers We fight for results! UK (Ltd) (UK) Ltd (CELSA) was acquired by the CELSA Group in 23. CELSA is the largest producer of steel reinforcement in the United Kingdom and one of the largest producers of other long steel products. Our facilities at Cardiff comprise a new state of the art melt shop built in 26, and two hot rolling mills: one for rolling reinforcing products and wire rod, the other for rolling merchant bar and light sections. We manufacture and deliver approximately 1 million tonnes of finished product annually, mostly for the UK and Irish markets. 6 We employ approximately 45 staff as well as several hundred sub-contractors in South Wales and see our business as an important supporter and member of the local community. CELSA is dedicated to being a sustainable producer. All of the steel we produce in our melt shop is produced from scrap metal using the electric arc furnace (EAF) process we are a steel recycling plant. 7 8 Steelmaking sites 1. Celsa Barcelona, Barcelona, Spain 2. Celsa Nervacero, Vizcoya, Spain 3. Celsa Global Steel Wire, Santander, Spain 4. Celsa Atlantic, A Coruña, Spain 5. Celsa France, Bayonne, France 6. Celsa UK, Cardiff, Wales 7. Celsa Armeringsstål, Mo i Rana, Norway 8. Celsa Huta, Ostrowiec, Poland UK Fabricators BRC / Express Reinforcements / ROM Group 3
6 211 Our products Sourcing, manufacture and supply Primary raw materials The primary raw material used in the production of our steel is ferrous scrap metal which contributes in excess of 98% of the constituent raw materials by mass and volume. Secondary raw materials Other consumables include the mineral additions of ferro-alloys, coke and lime, which are added to control the chemistry and remove impurities from the molten steel. Energy The use of energy in the form of electricity, natural gas and carbon additions is significant and is central to the process of recycling steel. Scrap Melting Refining Casting By-products By-products formed during the melting process include lime slag which is utilised as a secondary aggregate, dust utilised for zinc extraction and mill scale which is used in the manufacture of ferro-alloys and cement. Waste Whilst we generate large volumes of waste, both hazardous and nonhazardous we currently recycle or reuse over 95% of the wastes that we generate. Emissions to air Emissions of CO 2 are significant due to the combustion of carbon bearing sources such as natural gas, coke and carbon. Also, the consumption of natural gas in our processes results in the release of SOx, NOx, and CO. Finished products Reinforcing bars For the reinforcement of concrete (Grade 5C) High Yield Coils For the reinforcement of concrete (Grade 5C) Flat bars With various applications including construction, transport and machinery. 4
7 Rolling Finished products Emissions to water The water used in our cooling systems undergoes chemical treatment to prevent corrosion, the formation of legionella and to remove sludge. Stringent limits are placed on the quality of the water released from our systems and regular monitoring enables us to meet these requirements. Finished products We produce a range of steel products predominantly for the construction sector, but also with various other applications. Transportation Our raw materials and our finished products require transport either by road, rail or sea. We are constantly working on ways to minimise the impact of transport by using rail wherever possible. Channels, Parallel, Tapered Flange & UPN Typically used in composite steel construction. Wire Rod For the production of reinforcing mesh & other applications including wire drawing. Plain round bars With various applications including construction. Equal & Unequal Angles Typically used as a structural steel element in construction. 5
8 211 Environmental profile Electric Arc Furnace Steel The Process Steel Scrap Coke Lime Oxygen Natural Gas Carbon Electricity Ferro-Alloys Argon Electricity Natural Gas Natural Gas Electricity Scrap Bay Scrap Charge Basket Electric Arc Furnace Ladle Furnace Billet Caster Billets Rolling Mills EAF Dust Slag Handling Millscale Zinc Aggregate Material Reuse in Ferro-Alloys Steel is almost 1% recyclable and can be recycled indefinitely without losing its quality. It can be efficiently and easily recovered for recycling from mixed waste streams. There are currently two technologies for producing steel: that used in blast furnace plants which utilise iron ore to create new steel, and that used in electric furnaces which recycles steel scrap metal into new products. One tonne of steel that is made from recycled scrap using an electric furnace, compared with primary steel manufacture saves: 1,35 tonnes of Iron ore; 45kg of coal; and 2kg of limestone compared to primary steel manufacture from iron ore 2. Typically, the electric furnace process: Emissions to air and water are reduced by approximately 8%. CELSA has one of the lowest Carbon Dioxide per tonne of Carbon Steel (CO2 / tcs) rates for EAF steelmaking in Europe. CELSA 21 Direct emissions.54 ton CO2 / ton steel Direct and Indirect emissions.288 ton CO2 / ton steel The arithmetic average of the top 1% most efficient installations (9.6), after verification, is as follows: Direct emissions.61 ton CO2 / ton steel Direct and Indirect emissions.285 ton CO2 / ton steel 1OO %RECYCLED 2. CELSA Armeringsstål AS Mo I Rana 29 in accordance with EMAS Regulations 3. CELSA Armeringsstål AS Mo I Rana 29 in accordance with EMAS Regulations 4. Source Eurofer Project number: Verification Report for CO 2 Benchmarking Data Steel Sector Summary Report 5. Source Eurofer Project number: Verification Report for CO 2 Benchmarking Data Steel Sector Summary Report 6
9 Sustainability and sustainable manufacturing 211 whereas achieving this accreditation was a long and sometimes arduous process, the ability to now differentiate ourselves as not just market leaders, but sustainable market leaders has put CELSA in a prized and invaluable position when it comes to winning major contracts in which sustainability and responsible sourcing are key drivers. Luis Sanz, CELSA s General Manager What is sustainability? Sustainable development/sustainability is based on the commitment to meet the needs of today without compromising the quality of life for society today and tomorrow. Sustainability focuses on the balance of three areas: Maintenance of economic growth and employment Social progress, recognising the needs of everyone (employees and community) Effective protection of the environment, now and in the future, including preserving natural resources for future generations What does sustainability mean to CELSA UK? For the companies operating under the CELSA GROUP brand it means taking into account the environmental, social and economic consequences of the strategic decisions taken in our day to day tasks. The principles of sustainability have been adopted into the CELSA UK business strategy and are reflected in the CELSA UK Mission, Vision and Values. CELSA UK mission CELSA is a steelmaking company, part of the CELSA Group, a major European supplier of steel long products. Our aim is to be a dynamic total quality company where we are all responsible for and committed to: Operate in a safe and environmentally responsible manner Satisfy our customers by gaining a full understanding of their needs and providing an excellent service and a wide range of quality products Empower people by involvement, participation and teamwork to be an innovative, flexible and highly responsive organisation Continuously improve our process, activities and technology in order to be a low cost producer CELSA UK vision Our aim is to be: The employer of choice in the UK The safest steel manufacturer in Europe The most environmentally friendly steel organisation in the UK The supplier of preference for our products and markets The lowest cost producer in the CELSA Group To be 5 years ahead of our competitors CELSA UK Values are a reflection of CELSA GROUP Values We live for our customers We feel like owners We respect people and teamwork We are sharp and flexible We lead as ground-breakers We fight for results! 7
10 211 Meeting the requirements of sustainability How does CELSA meet the requirements of sustainability? At CELSA we see sustainability and sustainable practices as an integral part of our business strategy. We consider the environment, people and community in balance with the economics of our business and this is demonstrated in the following manner: CELSA is committed to continual improvements in all of its activities, products and services to minimise or eliminate any adverse impacts to the environment. We have operated an Environmental Management System (EMS) certified to ISO 141 since July 25. CELSA is registered under the Eco-Management and Audit Scheme (EMAS), which is a voluntary scheme designed to improve companies environmental performance. As a sustainable steel producer, CELSA is committed to responsible sourcing of constituent materials, by manufacturing and supplying products to customers in a responsible manner. Our merchant bar and light section products are certified to the BES 61 standard, and our reinforcing products are certified to the Eco-Reinforcement Responsible Sourcing Standard both of which have been developed by the Building Research Establishment (BRE). Environmental Policy Responsible Sourcing Policy 8
11 Meeting the requirements of sustainability 211 CELSA recognises that its people are paramount to the success of the company and are committed to ensuring the highest standards of Health, Safety and welfare for our employees. We have operated a Safety Management System certified to British Standard (BS) OHSAS 181 since March 29. CELSA is committed to providing its customers with a diverse range of high quality steel products. Each product and process is subject to stringent quality control to ensure that products conform to British and European Standards through CARES approval and CE marking. CELSA s Quality Management System is certified to ISO91. Aerial of Tremorfa site with Melt Shop and Sections Mill Health & Safety Policy Quality Policy 9
12 211 Significant environmental aspects we currently recycle or reuse over 95% of the wastes that we generate CELSA recognises that, like any manufacturing business, its activities can have both direct and indirect impacts upon the environment and in some cases these impacts have the potential to be significant if not properly managed. CELSA has carefully evaluated and identified through its ISO141 Environmental Management System the aspects of its business activities that could have an environmental impact. CELSA aspects are evaluated to determine their significance and reviewed on an ongoing basis. These are summarised as follows: Use of raw materials We produce over 1,, tonnes of steel every year and this utilises large volumes of raw materials in the process, including ferrous scrap, and mineral additions such as ferro-alloys and lime, as well as consumables like refractories and electrodes. CELSA carefully manage their raw materials to ensure that they are responsibly sourced taking account of their environmental impact and used efficiently to avoid waste. Use of energy As part of the metal recycling process a significant amount of energy is used in the form of electricity, natural gas and carbon additions. We are careful to ensure that our processes are efficient so as to minimise the use of energy and to avoid waste. Use of water During the production process of recycling steel water is used for process and product cooling. Some cooling water is lost by evaporation in cooling towers. This is an unavoidable loss but we work hard to minimise the use of water to ensure that we exceed the standards laid down for our processes, by harvesting as much rainwater as possible. Emissions to air During the process of recycling steel scrap into new steel, large quantities of dust laden fumes are generated. These fumes are captured and filtered to remove as much dust as possible but some particles will escape to air. Natural gas is also used in our processes and products of combustion (SOX, NOx, and CO) are released to air. 1
13 Significant environmental aspects 211 Cardiff Bay Emissions to water Process water cooling systems normally involves closed circuit cooling systems, which minimise releases to water. However these systems require the use of chemical treatment to prevent corrosion, stop the formation of legionella and allow the removal of sludge. Periodically we have to drain the systems down to the sewer system or to controlled waters which we try to keep to a minimum. Production of CO2 The on site production of CO2 is significant and comes from the combustion of carbon bearing sources such as natural gas, coke and carbon. We also have to consider the CO2 that is created from the generation of the electricity that we use in our processes. Use of oils and greases As with most mechanical processes we have to use lubricants and hydraulic oils. As these are mostly hydrocarbon based we try to minimise their use to avoid the depletion of natural resources, and to avoid the disposal impact of hazardous waste. Generation of waste Invariably waste, both hazardous and non-hazardous, is generated from the processing of scrap metal. Over 95% of the wastes produced are recycled, recovered or re-used. Transportation All our raw materials and finished products require transport either by road or by rail. We continuously evaluate ways to minimise the impact of transport and use rail wherever possible. Impact of noise Our processes are that of heavy industry and can generate some noise. We continuously work to reduce the impact of noise on the local community. 11
14 211 Emissions and legal compliance CELSA recognises that its business has a potentially large environmental footprint that could impact upon the environment if not managed effectively. Due to the nature of the manufacturing process there is a requirement for each operation to be permitted under the UK Environmental Permitting regime and is regulated by the Environment Agency Wales. CELSA monitors it s compliance against emission limit values and discharge consents in accordance with each of the permit requirements. CELSA holds the following permits/ authorisations: New Melt Shop: Environmental Permit (TP3639BH) Trade Effluent Discharge Consent (TE147G) Rod and Bar Mill: Environmental Permit (EPR/BV759IC) Licence to Abstract Water (21/57/25/48) Sections Mill: Environmental Permit (BV767) Trade Effluent Discharge Consent (TE147F) Mineral Site: Environmental Permit (EPR/WP3699FQ) Licence to Abstract Water (21/57/25/78) Environmental data relating to CELSA s Environmental Permits is reported to the Environment Agency. Information can be found from the Environment Agency s web site at: Whilst CELSA has not had any significant environmental incidents there have been a small number of Schedule 1 incidents which, in accordance with the Environmental Permits require notification to the Environment Agency. These events have been limited to fugitive releases of dust from the Melt Shop, breaches of permitted limits for carbon monoxide and particulates. CELSA in all such cases has been proactive in identifying the cause of such incidents and for investigating and implementing corrective measures. For those aspects of CELSA s operations that represent the greatest potential for negative environmental interaction (emissions to air, land and water and energy consumption), the table opposite shows typical levels of these emissions and discharges relative to our permitted limits. View of Melt Shop with Sections 12 Mill in foreground.
15 Emissions and legal compliance 211 performance against process emission limits Typical Emmissions Emissions to Air Units Process Limit Steelmaking Particulates CO NOx SOx Dioxins VOC mg/m 3 mg/m 3 mg/m 3 mg/m 3 ng/m 3 mg/m Emissions to Sewer Suspended solids Oils and greases Iron compounds ph mg/l mg/l mg/l no units to Emissions to Air Units Process Limit Sections Mill NOx SOx mg/m 3 mg/m Emissions to Air Units Process Limit Rod and Bar Mill NOx SOx mg/m 3 mg/m N/R Emissions to Water Suspended solids Oils and greases ph Cl Fe Cr Ni Zn mg/l mg/l no units mg/l mg/l mg/l mg/l mg/l to Note the process averages indicated are derived from either the annual report or the quarterly report averages made to the EA as required in the permits to operate. N/R No longer reportable post 29. Further and more detailed technical information on the reports made to the EA is available on the EA Website as part of the Pollution Inventory which is publicly available by looking at What s in my Backyard on the EA Website 13
16 211 Environmental objectives and targets 21 As part of CELSA s Environmental Management System, CELSA has identified all of its potentially significant environmental aspects, whilst considering its legal requirements. Objectives and Targets are set on an annual basis to deliver continual improvement in the management of these environmental aspects. CELSA s governance of environmental issues goes beyond compliance with regulatory requirements and the company commitment to EMAS is evidence of this strive to operate our business in an environmentally responsible manner. This is demonstrated through the setting of targets that deliver continued environmental performance. Objective and targets performance New Melt Shop (MS) Reduce incoming commercial water consumption (m 3 /tonne) by 5% in 21 compared with 29 levels. The Melt Shop achieved the 5% target. Reduce general waste disposal (tonnes) by 1% compared with 29 disposal. The MS exceeded the 1% target. Reduce hazardous waste disposal (tonnes) by 5% compared with 29 disposal. The MS exceeded the 5% target. Reduce electricity consumption by 5% (kwh) compared with 29 consumption. The MS did not meet the 5% target reduction for electricity consumption. A number of energy efficiency measures were introduced during 21 and CELSA implemented an energy management team as part of the company s annual strategic objectives and engaged with the Carbon Trust to look at methods to reduce energy consumption. The reason for not achieving the target was due to the need to meet the short-term dynamic needs of our customers. More stoppages were required to change product mixes, which meant that overall electricity consumption remained at the 29 levels, and a further electricity reduction target has been set for 211. Minimise Noise Complaints in 21 compared with 29 levels. The MS significantly reduced the number of noise complaints in 21 compared with 29 levels. Minimise Fugitive Dust Complaints in 21 compared with 29 levels. MS has managed to reduce the fugitive dust complaints in 21 compared with 29 levels. Rod & Bar Mill (RBM) Reduce lubricating oil consumption (litres) by 1% compared with 29. The RBM exceeded the 1% target. Reduce electricity consumption (kwh/ tonne) by 5% compared with 29. A number of energy efficiency measures were introduced at the RBM during 21 and CELSA implemented an energy management team as part of the company s annual strategic objectives. The reason for not achieving the target was due to the need to meet the short-term dynamic demands of our customers, more stoppages were required to change sizes. This had a considerable effect on the energy consumption and mill energy efficiency. A further electricity reduction target has been set for 211. Reduce gas consumption (kwh/tonne) by 5% compared with 29 consumption. Again as with electricity consumption, a number of energy efficiency measures were introduced during 21 and CELSA implemented an energy management team as part of the company s strategic annual objectives. The reason for not achieving the target was due to the need to meet the short-term dynamic 14
17 Environmental objectives and targets 211 demands of our customers, more stoppages were required to change sizes. This had a considerable effect on the energy consumption and energy efficiency. A further gas reduction target has been set for 211. Reduce general waste disposal (tonnes) by 5% compared with 29 disposal. The RBM exceeded the 5% target. Reduce hazardous waste disposal (tonnes) by 5% compared with 29 disposal. The RBM exceeded the 5% target. Sections Mill (SM) Reduce incoming commercial water consumption (m 3 /month) by 6% compared with 29 consumption. The SM exceeded the 6% target. Reduce Usage of Hydraulic Oil (closed systems oil) (litres/month) by 8% compared with 29 consumption. The SM exceeded the 8% target. Reduce Effluent Discharge (m 3 / month) by 14% compared with 29 consumption. The SM exceeded the 14% target. Logistics Increase delivery of scrap by rail by 5% (gco2/tonne of product handled). The logistics department achieved the 5% target. Increase delivery of finished product by rail by 5% (CO2/tonne of product handled). CELSA did not achieve this target to increase delivery of finished product by rail. The reason for not achieving the target was due to the need to meet the short-term dynamic demands of our customer requirements. Increase efficiency and effectiveness of internal product movement (tonnes/ diesel used). The logistics department achieved the 5% target. 211 Objectives and targets Reduce effluent discharge (m 3 / month) by 5% New Melt Shop Reduce general waste (tonnes) by 5% Reduce water consumption (m 3 / tonne) by 5% Reduce total energy (KWh/tonne) by 3% Minimise noise complaints Minimise fugitive emission complaints Minimise CO emissions Rod & Bar Mill Reduce lubricating oil consumption (litres) by 5% Reduce general waste disposal (tonnes) by 5% Reduce hazardous waste disposal (tonnes) by 5% Reduce electricity consumption (KWh/tonne) by 3% Reduce gas consumption (KWh/tonne) by 3% Sections Mill Reduce commercial water consumption (litres) by 5% Reduce domestic water consumption (litres) by 6% Reduce usage of hydraulic oil (closed systems oil) (litres/month) by 8% Reduce general waste disposal (tonnes) by 5% Reduce hazardous waste disposal (tonnes) by 5% Reduce electricity consumption (kwh/ tonne) by 5% Reduce gas consumption (kwh/tonne) by 5% Logistics Increase delivery of scrap by Rail by 5% Increase delivery of finished product by Rail 5% Note the logistics targets are currently under review due to current market conditions. Note where a % reduction is stated this will be measured against the 21 performance. The 212 Objectives and Targets will be set at the next annual management review meeting which is scheduled for October 211. Image opposite: Pit side area of Melt Shop. 15
18 211 Environmental performance indicators Raw materials efficiency CELSA s manufacturing operation is effectively a metal recycling process. The principal feedstock is steel scrap which is consumed in the process to make new steel, but there is a need to provide certain additives to achieve the right quality of new steel. The process is about 95% efficient with the only wastes being furnace flue dust, slag and millscale, each of which are materials that have other beneficial uses. The raw materials data for the plant is summarised in the following graphs. 1. Materials efficiency Scrap Raw materials Production Tonnes 1,4, 1,2, 1,, 8, 6, 4, 2, Melt Shop production Tonnes 1,4, 1,2, 1,, 8, 6, 4, 2, Scrap bay. 16
19 Environmental performance indicators 211 Energy efficiency The use of energy is one of the greatest environmental impacts. Energy efficiency is therefore fundamental to the business strategy and consumption of electricity and natural gas is continuously monitored and measured. Approximately 18% of electricity supplied to the plant comes from renewable sources. 1. Rod & Bar Mill products energy usage Rod & Bar Mill Melt Shop 3. Melt Shop energy consumption Electricity Natural gas 5. Sections Mill energy consumption Electricity Natural gas KWh/tonne 1,4 1,2 1, Mw/h 7, 6, 5, 4, 3, 2, 1, Mw/h 16, 14, 12, 1, 8, 6, 4, 2, Sections Mill products energy usage Sections Mill Melt Shop 4. Rod & Bar Mill energy consumption Electricity Natural gas KWh/tonne 1,4 1,2 1, Mw/h 4, 35, 3, 25, 2, 15, 1, 5,
20 211 Melt Shop case study MS aims to achieve 6% energy consumption saving in 211 thanks to ongoing support from Carbon Trust The Melt Shop is well on the way to achieving a 6% improvement in energy consumption. This means a reduction in CO2 emissions by over 18, tonnes this year alone. In February 21, the MS team called upon the Carbon Trust Wales to help provide a strategic focus to their energy savings plans and assist in delivering energy savings. The Carbon Trust carried out a Carbon Management 18 Melt Shop electric arc furnace Energy Efficiency survey to identify which energy efficiency projects would deliver the best return on investment, as well as highlighting areas of the business needing specialist support. Working with a Carbon Trust consultant experienced in the Ferrous Sector, the team at CELSA MS has improved its appreciation of the data available from its energy metering & monitoring system. Combining data analysis with site process knowledge has refocused targeting and analysis to identify further areas for reducing kwh/t energy consumption. The approach highlighted areas where the EAF process and services could be used even more efficiently, which is central to the metal recycling process. Manageable plans have now been put in place to roll out a programme of change over the coming years. In the last year, metering and monitoring has led to a saving of over 47GWh s and over 22,7 tonnes of CO2. Bill Barnes, CELSA s Melt Shop Manager comments: We have implemented a series of low or no cost measures to improve our energy efficiency. For example, we reduced the number of lamps in the scrap bay and installed high output multitube fittings with light level and sensor controls in the metal stores area. The payback period for changes like these is less than a year and has yielded 19 tonnes in CO2 reductions. We are currently putting plans in place to install Variable Speed Drives at various points throughout our production process to yield even higher CO2 savings. You can t manage what you can t measure and thanks to the specialist advice and support from the Carbon Trust, together with our ongoing continuous improvement programme, the Melt Shop is on track to achieve significant advances in energy efficiency. Dave Moore, Account Manager at Carbon Trust Wales, adds: The Melt Shop at CELSA in Cardiff is a great example of a company who are dedicated to achieving carbon reduction savings. Being able to assist in identifying savings from a complex melting operation underlines the importance of involving a sector specialist Carbon Trust consultant. We are continuing to work with Bill and the Team on a number of areas for improvement to ensure the continued success of their programme.