BEFESA

Befesa is the current European leader in aluminum waste and salt slag recycling. In addition, it is the only recycling company that carries out both sides of the aluminum waste recycling process.

Befesa’s current growth strategy in this area contemplates organic growth in the aluminum recycling business in Central Europe, as well as international expansion in the salt slag business, thus promoting the company from its current status as European leader to a position of worldwide dominance.

The main competitive edges underpinning Befesa’s goal of continued sustainable growth include an in-depth knowledge of the processes and technologies involved in aluminum waste recycling, a broad range of products derived from secondary aluminum and excellent commercial relations with customers and suppliers of raw materials.

Aluminum Waste Recycling

The aluminum waste recycling business unit recovers aluminum contained in various types of waste and scrap metal. Befesa carries out this activity by collecting and transporting waste and aluminum scrap metal, carrying out its integral recovery and producing and marketing secondary aluminum alloys. The main use of recycled aluminum waste is the production of alloys and their sale to the automotive industry for the manufacture of components, as well as to the construction industry. It is worth noting that this line of business is particularly effective at reducing CO2 emissions as compared with the primary sector. Befesa carries out these activities at three plants – Vizcaya, Valladolid and Barcelona (Spain).

2009 was dominated by a deep global recession and therefore witnessed a sharp downturn in both sales and prices, which plummeted to all-time lows. Despite this situation, Befesa remained a market leader and a key player not only in Spain – where its leadership is unquestionable – but also in Europe. June saw the successful completion and integration of the merger between the three secondary alloy production companies, Aluminio Catalán, S.L., Befesa Aluminio Bilbao, S.L. and Befesa Aluminio Valladolid, S.L., allowing us to streamline structural costs and improve the company’s administrative management. All the actions undertaken during the year were intended to increase the productivity of our various plants, reduce energy costs and improve the service provided to our customers.

Thus, in 2009 Befesa Aluminio recycled around 89,100 t of various types of aluminum waste, leading to 68,300 t of alloy production and sales and avoiding the equivalent of 683,400 t of direct CO₂ emissions.

Salt Slag Recycling

Befesa’s aluminum waste recycling system encompasses the recovery and integral valorization of all the waste generated in the aluminum industry, including both the primary and the secondary industries, as well as the goods produced with aluminum at the end of its life cycle. It is precisely the salt slag recycling business line that brings this process round full circle and gives it its meaning.

As is also the case with the manufacture of parts and other products, oxides and other impurities are incorporated along the aluminum production value chain. The valorization of these is more costly, both because of the technical difficulties involved in the industrial process and because of the lower financial value of the products which can be recovered. Befesa has developed proprietary technology to increase the sustainability of an industry that deals with a metal with a particularly important role in reducing greenhouse gases in the transportation sector. It is worth remembering that one of the defining properties of this metal is its lightness in comparison with the alternatives.

Salt slag valorization plants are also designed to recover other types of waste from the aluminum industry, such as gas filtering dust from smelting furnaces and the dust obtained from milling and grinding aluminum sludge.

In 2009, Befesa acquired three salt recovery plants in Germany, thus becoming Europe’s main salt slag management company. In addition, its technological knowledge will enable it to expand towards other geographical markets, such as the United States, the Persian Gulf and others.

Befesa is thus contributing to sustainable development through five plants specifically designed to treat this type of waste. The plants are located in Valladolid (Spain), Whitchurch (United Kingdom) and Lünen, Hannover and Töging (Germany) and have a combined capacity of 630,000 t. This is in addition to the management of smaller amounts of other by-products of the primary and secondary aluminum industries. A total of 238,400 t of waste was treated in 2009. This is down on than the previous year, due to a slump in business within the aluminum industry. All this waste is fully converted into raw materials that can be used by the industry (aluminum, melting salts and aluminum oxide). Our salt slag recycling activity has eliminated the need to mine 267,100 t of non-renewable raw materials (mineral oxides and salts) and to dump 224,200 t of hazardous waste.

Our strategic goals and business processes are in line with the commitments assumed by the aluminum industry: To eliminate, in the mid-term, the dumping of solid waste directly and indirectly generated by the industry. Befesa is working to include innovative treatment technologies to valorize other types of waste, thereby helping the industry to move forward in a sustainable manner. A prime and practical example of this policy is the commissioning of a gas filtration dust treatment demonstration plant in Valladolid, based on one of the company’s own projects. Also in 2009, a new process designed and patented by Befesa started running in the United Kingdom. The process aims to recover all the waste from used electrolytic cells, more commonly known as spent potlining (SPL), a hazardous waste generated by the primary aluminum industry. Each ton of aluminum produced generates around 24 kg of waste. Until now, it was only partially reused in some cases, with the remainder being dumped.

Sales of Machinery and Technology

The machinery and technology sales division provides technical support to the aluminum waste recycling plants. It is also engaged in the design, construction, assembly and start-up of installations for the aluminum and zinc industries. It boasts an extensive portfolio of more than 100 installations in 40 countries. Its main products are automated lines used for the production of 5-25 kg aluminum ingots, casting wheels, rotary ovens and sludge cooling and treatment facilities.

The most important projects carried out during this period include the design and construction of two 22 kg ingot casting lines for the company Emal (United Arab Emirates); the design and manufacture of three molding lines for Qatalum (Qatar); the design and manufacture of four molding lines with trailer-loader for Vedanta (India); and the design and supply of the last sludge cooler for the Almahdi plant (Iran). In spite of the difficulties arising from the widespread drop in investment, this business unit has completed all its projects and its portfolio levels are sufficient to practically guarantee work for the next twelve months.