Metals mining and production

We all use metals in our everyday lives. But have you ever stopped to think where those metals come from? We'd like to show you how metals are made, and to explain the actions our industry takes to protect its people and the environment.

MINING

PRODUCTION

PROTECTING PEOPLE & OUR ENVIRONMENT

It all starts in the ground

The life of our metals begins with raw materials such as:

Raw materials can contain several metals at once. When searching for copper, for example, mining firms find as many as 19 other important metals.

Metals such as gold, silver, platinum already exist in their elemental form. For others, the metal ores must first be separated from other materials. Some metal ores, such as zinc, or aluminium, are already treated at this stage, to change their chemical state before further refinement.

Responsible sourcing

'Conflict Minerals' are resources whose sales revenues may finance military and guerilla operations that contribute to human rights abuses. A primary concern of European metals producers is to ensure that so-called 'Conflict Minerals' do not end up in their supply chain.

For that reason, we work closely with the European legislators in their development of legislation to ensure supply chain transparency for minerals such as gold, tantalum, tin and tungsten.

This builds on voluntary industry schemes to guarantee conflict-free sourcing of minerals:

These schemes have achieved real results. For example, 99% of cassiterite imports from Central African countries are now controlled through the Tin Supply Chain Initiative.

European metals producers also endorse the OECD's due diligence guidelines.

Sustainability in mining

The extraction of minerals demands high standards of sustainability, so we can:

Adding value in Europe

Primary and secondary raw materials are processed in European facilities, where they are eventually turned into the finished metals that will be essential to various sustainable and innovative products.

Europe's metals industry is responsible for over a fifth of global metals production, this equates to

47m tonnes annual production

Additionally, Europe's metals industry directly employs

500,000 people
(3m indirectly)

But how do we get from raw material to metal?

Making metal

Metal must first be separated from its ore. Different metals require different processes, depending on their chemical composition.

Whatever the process, the aim is to refine the extracted raw metals into a purer form.

Refined metals are produced from a combination of mined and recycled sources, and are cast in different forms, depending on their use (i.e. ingots, cathodes, pellets).

In fact, over 52% of pure base metals and alloys now come from recycled sources.

What happens next

Once manufactured, refined metals are then:

SOLD

Directly to end-users

COMBINED

with other metals in alloys, to meet the performance requirements of their intended application

• The brass used in musical instruments is an alloy of copper and zinc.
• The stainless steel in your cutlery contains an alloy of steel, nickel, chromium and other metals.
• Aircraft turbines are made of 'nickel super-alloys' made up over 14 different metals to withstand 800°C

PROCESSED

into "semi-finished" products, such as

Semi-finished products are then transformed into the final product, whether beverage can, car frame, wiring or roofing.

A commitment to sustainability

Europe's metals industry is commited to reduce global greenhouse gas emissions, not only through our own carbon footprint, but also through the products we manufacture.

Climate change - a global challenge

Europe's non-ferrous metals industry is supportive of an ambitious global agreement to limit CO2 emissions.

The industry also supports the Emissions Trading System as the EU's main climate policy instrument, provided that it enables the European industry to remain competitive and to attract investments.

Direct CO2 emissions have been significantly reduced across the production processes of all non-ferrous metals.

REDUCED EMISSIONS IN EUROPE'S ALUMINIUM INDUSTRY SINCE 1990

53% CO2

90% Perfluorocarbon (PFCs)

This is facilitated by best-practice EU guidelines for each sector¹, and continued innovation. For example, the metals industry is an active member of the EU's SPIRE innovation platform.

Energy efficiency - a competitiveness driver

Metals production also uses a large amount of energy. For example, energy costs constitute up to 40% of total costs for aluminium production, and 36% for nickel production.²

To meet this challenge, Europe's metals industry has continued investment into lowering energy consumption through technology development and upgrading of installations. We're now amongst the most efficient in the world.

REDUCTION IN ENERGY INTENSITY

60%

SINCE 1990

48%

1999-2011

These improvements drive our competitiveness, but scientific limits are now being reached. Chemical laws state that a minimum amount of electricity will always be required for metals production.³

For example, zinc production has almost reached its maximum scientific efficiency.

PERCENTAGE OF MAXIMUM SCIENTIFIC EFFICIENCY

93-99% efficiency

Further reductions will require significant investment and innovation to deploy breakthrough technologies

Part of the solution

Metals production required energy, but metals also provide the building blocks for a low-carbon economy, helping to mitigate global warming through their various applications.

NON-FERROUS METALS ARE ESSENTIAL TO:

We will continue to encourage policy makers to support a reasoned balance between the energy needed to manufacture the building blocks of a low-carbon economy, and our common goals for reduced energy demand and carbon emissions.

Protecting the environment

Non-ferrous metals are all around us. Your own body as well as several other organisms in the environment actually need certain metals such as zinc, copper and magnesium to function healthily and effectively.

Environmental protection remains a priority, and our industry has made significant progress over the last four decades to minimise the residual risks from metals production and use.

Emissions and the environment

European metals producers fully comply with strict EU legislation on emissions to air and water, helping to minimise environmental impacts.

Through technological advances, regulatory pressure and industry commitment, emissions of different metals have decreased considerably over the last four decades.

AIR EMISSIONS

Air emissions from European copper manufacturing have dropped significantly (97% in sulphur dioxide), due to air pollution control and continuous investments into environmental protection.

All metal producers require environmental permits regulated under the Industrial Emissions Directive, which are based on best-available techniques.

WATER EMISSIONS

Emissions of metals to water have also decreased.

Take the German Rhine as an example. From 1973 to 1993, zinc concentrations dropped by over 97%.

Since then, levels of zinc have stayed consistently at background levels; meaning they pose no risk to water quality.

Protecting people

We also have a responsibility to ensure the safety of our workers. Great care is taken to reduce any risk of exposure to harmful substances, and to ensure long-term well-being.

Examples of best practice

Developing science

Metals science is complex, but our industry has top-notch expertise. We already have a great understanding of how the main metals interact with the environment and health.

We continue to work with authorities and academia to close remaining data gaps.

WHAT HAVE WE ACHIEVED?

• [1] EU "Best-Available Techniques" Reference Document (BREF)
• [2] Ecofys report on the competitiveness of the EU nonferrous metals industry
• [3] Comparison of LCI data from 2011 and 2000
• [4] Source: http://www.ila-lead.org/news/ila-news/2015-04-22/launch-of-voluntary-target-to-reduce-exposure-to-lead-will-give-added-protection-for-industry-workers
• [5] Source: http://www.european-aluminium.eu/wp-content/uploads/2011/09/EAA-sustainability-leaflet_optimal_site_January2014.pdf