francis vanbellen – plant manager · (dm) 1800. 1850. 1900. 1950. 2000. 1985. 1989. ......
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October 2010
The Hoboken recycling plantThe Hoboken recycling plantFrancis Vanbellen Francis Vanbellen ––
Plant managerPlant manager
Capital Markets Event on Recycling Capital Markets Event on Recycling ––
1818--19 Nov 201019 Nov 2010
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Agenda
Plant history
Core competences
Flowsheet
Site visit
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October 2010
Plant history
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Hoboken plant based on more than 100 years of history
1853 Asturienne des Mines
1805 Vieille-Montagne
1928
1908 Soc. Gén. Métallurgique de Hoboken
1887
1919 Société
Générale de Minerais
1959 Mechim
1906 Union Minière du Haut-Katanga
1981
1901 ACEC
1919 SIBEKA
1873 Degussa
(DM)
1800 1850 1900 1950 2000
1985
1989
1985
Union Minière
1990
1970
Usine de Désargentation
Compagnie des Métaux d’Overpelt
1981
1989
2003DMC² PMG
2010
1919
2001
2007 Nyrstar
2005 Cumerio
2005 Traxys
MHO
UM
1989
(Degussa)
1994 Delphi AC
UM
1908 Soc. Gén. Métallurgique de Hoboken
1887Usine de Désargentation 1919
2001
MHO 1989
(Degussa)
2007
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Recent history
Transformation process started in late nineties
Continued process improvements and innovations since
Lead and Precious metals refiner Precious metals Recycler
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Smelter1997
New plant
2007-2009 Spent industrial
catalysts
Sulphuric acid plant2005
Double absorption
Leaching &
electrowining
2003
New plant
PM refining1995-2001 Make-over
2008
New concentration
plant
2008
Rh
capacity increase
Lead blast furnace1995-2000 Plant make-over
2007
Glas
cleaning
installation
Lead Refinery1999-2005 Plant make-over
2008
Gas burners
Special Metals Refinery2006-2008 Make-over
Major flowsheet investments
Sampling & assaying2011-…
Make-over
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October 2010
Core competences
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Foster Flexibility Ensure ReliabilityMaster Complexity
Core competences
NiPbSb
Sn
As
BiIn
Cu Ru
TeRh
Ir
AgPt
Au SePdEmployees
Operations
Materials
Risk
management
Sampling & assaying
Knowledge management
Market
intelligence
Integrity
Environmental management
Pyrometallurgy
Hydrometallurgy
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Employees
Operations
Materials
Flexible and robust operations which can cope with high variability of supply
Wide variety
of physical aspects and metal content: treatment of more than 200 different raw materials with different physical aspects (dry, wet, dusty, with plastic, ceramic…)
Competence management –
Intensive training and development of competencies in combination with appraisal, stimulates personnel to grow
Foster Flexibility
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Master complexity
The Hoboken flow sheet•
Unique, integrated combination of innovative pyro-
and hydrometallurgical operations
Expertise in metallurgy•
Our experienced staff is the driver behind innovation (a lot of in house R&D competences)
•
Our long-standing in-house experience is an innovation driver
NiPbSb
Sn
As
BiIn
Cu Ru
TeRh
Ir
AgPt
Au SePd
Pyrometallurgy
Hydrometallurgy
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Risk
management
Sampling & assaying
Knowledge management
Recognized world-class service
Structured information gathering process
Systematic approach to enhance process efficiency
Hedging and metal accounting, stock take
Market
intelligence
Integrity Ethical business and fraud prevention
Environmental management
Management systems:
First Belgian company with one integrated certificate for ISO 9001, ISO 14001 and OHSAS 18001
Ensure reliability
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Business Excellence
Our Business Excellence system is driven by the European Foundation of Quality Management (EFQM) model.
The EFQM approach is formalized in one integrated management system
certified against international standards:•
ISO9001 certified for all our processes
•
ISO14001 environmental
care system
•
OHSAS18001 safe and healthy
production environment UPMR obtained a 5* EFQM
Award (October 2007) and an EEA-finalist award (September 2009).
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October 2010
Flowsheet
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Flowsheet
Slags
Raw Materials
PM residue
Precious Metals Operations
Pb-bullion
In/Te residue
Ag, Au, Pt, Pd, Rh, Ir, Ru In, Se, TeNi
SO2
Cu Pb, Bi, Sb, Sn, As
Se
residue
Pb
slags
Cu
matte
Ni
speiss
H2
SO4
Ag
residue
Base Metals Operations
Cu bullion
PM
residue
Sulphuric acid plant Smelter
Special Metals refinery
Leaching
&electrowinning Lead refinery
Precious metals refinery
Blast furnace
Sampling
Nickel refinery
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Sampling & AssayingThe wide variety & complexity of incoming materials mean that sampling & assaying are key success factors in determining our customer’s financial yield.
UPMR allocates more than 15% of its operating budget to these services.
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Sampling
Unique state-of-the-art facilities
Dedicated to process all raw materials
Key drivers•
Maximizing automations
•
Adequate capacities in growing segments
(e-scrap, auto catalysts…)
•
Shortening the lead times
•
Respecting environmental, health & safety standards
Employing 120 people
Secured area
± 8000 lots & 350,000 t/year
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Assaying
Recognized leadership in the precious metals industry
Up-to-date analytical equipment, supported by:•
Robust quality assurance system•
Laboratory information & management system
Key drivers•
Customer orientation•
Respect for short lead times•
Continuous investment in analytical research & method improvement
Employing 100 people
55,000 samples/year
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Recycling & RefiningPb, Cu & Ni drive our unique recycling process. By using the specific properties of these collector metals, precious & other secondary metals are recovered with the greatest efficiency.
Our in-house developed Precious Metals Refinery is one of the world’s largest & most efficient refining facilities.
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Precious metals operations Smelter
Unique Isa smelt, submerged lance combustion technology, injecting oxygen enriched air & fuel in a molten bath
Separating precious metals in a copper bullion from mostly all other metals concentrated in a lead slag
Operating at 1,000 t/day
Highly flexible technology for PM recycling:•
Variability of physical aspect (lumps, fines, wet, dry, shredded material...)
•
Variability of feed mix (e.g. volume e-scrap vs. total volume)
•
Ratio PM / PGMs
& impurities in the feed mix
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Precious metals operations Leaching & electrowinning
Leach copper to collect precious metals in a residue for further refining in the Precious Metals Refinery
Increase PM-content in residue from intake
(Cu-granules) by a factor of 10
Cu electro winning process, producing 99.99% pure Cu-cathodes
Highly flexible technology•
ratio copper / other metals
•
PM & PGM content
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Precious metals operations Precious metals refinery
Combination of classical methods & unique in-house developed processes
Unique flexibility on ratio of gold, platinum, palladium & secondary PGMs
vs. silver, varying substantially according to raw material feed
High purity metal production•
Ag & Au:
4N & 5N
•
Pt, Pd, Rh:
3N5, catalytic grade
•
Ir
& Ru:
concentrates
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October 2010
Site visit
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Forward-looking statements
This presentation contains forward-looking information that involves risks and uncertainties, including statements about Umicore’s plans, objectives, expectations and intentions.
Readers are cautioned that forward-looking statements include known and unknown risks and are subject to significant business, economic and competitive uncertainties and contingencies, many of which are beyond the control of Umicore.
Should one or more of these risks, uncertainties or contingencies materialize, or should any underlying assumptions prove incorrect, actual results could vary materially from those anticipated, expected, estimated or projected.
As a result, neither Umicore nor any other person assumes any responsibility for the accuracy of these forward-looking statements.
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Francis Vanbellen Plant Manager Precious Metals Refining
Francis Vanbellen
holds a Master of Science degree in Chemical Engineering from the Catholic University of Leuven, as well as an MBA from the Vlerick
Management School. Francis joined Umicore in 1981 as part of a team to start up Umicore's first rhodium refining plant, before assuming other precious/special metals refining management responsibilities. During the 1990s Francis headed a range of departments ranging from business excellence & development to supply management and refining. In 2001, Francis assumed his current position as plant manager of Umicore Precious Metals Refining site in Hoboken, Belgium.