Aluminium Of Greece - Corporate profile 2015

Page 1

ALUMINIUM OF GREECE

Member of MYTILINEOS GROUP


ALUMINIUM OF GREECE


CONTENTS

The Company

4-5

Delphi-Distomon

6-7

Milestones

8-9

Products

10-11

Infrastructures / Facilities

12-13

Production Chart

14-15

Human Resources

16

Corporate Social Responsibility

17-21


For more than half a century now, ALUMINIUM OF GREECE is one of the leading players in the Greek heavy industries sector

THE COMPANY For more than half a century now, ALUMINIUM OF GREECE (AoG) is one of the leading players in the Greek heavy industries sector. The Company was established in 1960 by Pechiney, the French metallurgy giant of that time, in order to exploit the rich bauxite deposits of the Sterea Ellada Region for producing alumina and aluminium. The value of this investment, which proved a key strategic investment that drove economic growth and the development of know-how in Greece, multiplied over the years. In 2005, ALUMINIUM OF GREECE became a member of the MYTILINEOS Group and has since evolved into one of Europe’s leading vertically integrated alumina and aluminium production and trading plants. Under a significant investment plan currently in progress, the annual production capacity reaches 820,000 tons of alumina and 185,000 tons of aluminium, establishing the Company as the sector’s largest vertically integrated producer in Europe.

Τhe dynamics of ALUMINIUM OF GREECE has been the cornerstone of the development of the Greek aluminium manufacturing industry, which today is employing directly and indirectly more than 30,000 persons representing 5.5% of the country’s exports.


Located in Agios Nikolaos, Viotia, on the northern coast of the Corinthian Gulf, the industrial complex of ALUMINIUM OF GREECE occupies an area of 75 hectares and employs 1,050 people directly and more than 400 indirectly, all of them residents in the wider region. From its establishment to this day, the Company has been a catalyst for local growth and is proud to support – and be supported by – generations of employees who are the driving force of an industry that is developing pioneering knowhow at the global level. With equal resolve, AoG is also working to improve its social and environmental footprint, guided by the values of Corporate Social Responsibility and aiming to produce long-term benefits for society. Adhering to globally accepted environmental management standards and carrying out significant “green” investments, AoG is committed to minimising the unavoidable impact of its activity on the environment.

ALUMINIUM OF GREECE has evolved into one of Europe’s leading vertically integrated alumina and aluminium production and trading plants.

5


630.000 tons of bauxite

in the Amfissa region

DELPHI-DISTOMON A subsidiary of ALUMINIUM OF GREECE, DELPHIDISTOMON S.A. is the second largest bauxite producer in Greece and in Europe, with an annual production of 630,000 tons. The company’s sites, which supply bauxite to ALUMINIUM OF GREECE S.A., are located in the Amfissa region, while the Company’s Technical Direction, responsible for supervising production and research, is based in the Prefecture of Fokida. DELPHI-DISTOMON is the result of the merger of “Delphi Bauxites S.A.” with “Greek Distomon Bauxites S.A.”. The company today employees 217 people (82 directly and 135 indirectly), who in their majority come from the local communities. Their health and safety are a key priority for DELPHI-DISTOMON, which boasts one of the mining industry’s lowest accident severity/frequency rates. The company attaches equal significance to its commitment to the environment, implementing a strict environmental policy and investing in “green” initiatives, most notably the rehabilitation of the areas affected by its mining activity. More specifically, the company’s Occupational Health & Safety Management System and Environmental Management System are certified in accordance with the OHSAS 18001 and ISO 14001 standards, respectively.

The company today employees 217 people, who in their majority come from the local communities.


The second largest bauxite producer in Greece and in Europe.

7


1966 Plant opens and production is launched.

1960 “Aluminium of Greece Industrial and Commercial S.A.” is established. The Company’s principal shareholders are the PECHINEY Group, COMPADEC S.A., the Organisation for Industrial Development, and Stavros Niarchos.

1975 Establishment of DELPHIDISTOMON S.A.

1970

HISTORY

The plant’s facilities are expanded and production is doubled.

1973 1963 Construction of the Company’s industrial facilities in Agios Nikolaos, Viotia, begins.

The foundation stone was laid on 7/4/1963.

The Company is listed on the Athens Stock Exchange

1976 Installation of gas processing centres for removing the fluorine contained in the electrolysis gas emissions.


2007 2003 The Pechiney Group is acquired by the ALCAN Group.

1981&2000

“Aluminium of Greece Industrial and Commercial S.A.” is merged by absorption with MYTILINEOS Holdings S.A., and the trading of the company’s share on the Athens Stock Exchange ceases.

Investments are carried out to increase alumina and aluminium production.

2006 ALUMINIUM OF GREECE launches operation of the first Filter Press for the Recovery of Bauxite Residues.

2009 Operation of the second Filter Press for the Recovery of Bauxite Residues.

2005 1986 -1990 Investments are carried out to automate the electrolysis process.

MYTILINEOS Holdings S.A. acquires AoG majority stake from ALCAN.

2011 - 2016 Implementation of investments and operating cost reduction programmes (“MELLON” & “Excellence”), which bolstered AoG’s global competitiveness.

2011 Operation of the third and fourth Filter Press, whose operation allows the Company to achieve its goal of disposing all Bauxite Residues on land.

9


PRODUCTS For more than 50 years, ALUMINIUM OF GREECE embodies the impressive evolution of the metallurgical sector in Greece, possessing a know-how in industrial and commercial practices that is on a par with those of the world’s top metallurgical industries. The quality of its products and the provision of technical support and customer service are areas of continuous development. The Company’s Quality Management System has been certified in accordance with the ISO 9001:2008 International Standard. Furthermore, its chemical laboratory has been accredited by the Hellenic Accreditation System S.A. (ESYD) in accordance with the requirements of the ISO 17025:2005 International Standard, for the chemical analysis of bauxites, of alumina and of aluminium and its alloys.

Bauxite Bauxite, which is mined by DELPHI-DISTOMON, is the basic raw material for the production of alumina and aluminium. It is a mineral deposit rock formed by a mixture of metal oxides, named after the French city of Baux, where the ore’s deposits were first found. In Greece, the most important known bauxite deposits are estimated at around 100 million

ALUMINIUM OF GREECE embodies the impressive evolution of the metallurgical sector in Greece, possessing a know-how in industrial and commercial practices that is on a par with those of the world’s top metallurgical industries


125.000 tons in billets

60.000 tons in slabs

tons and are located in the Mt Helikon - Mt Parnassus - Mt Gkiona zone. Greek bauxites are of diasporic type and are composed of 1 molecule of crystalline water per 1 molecule of alumina (aluminium oxide).

Alumina Alumina is the industrial product derived from bauxite ore and is used to produce primary-cast aluminium as well as other non-metallurgical products (abrasives and insulating materials, refractory materials, detergents, pharmaceuticals and substances used in the treatment of water). Alumina, which ALUMINIUM OF GREECE extracts from bauxite using the Bayer method, may be hydrated or calcined (dehydrated), depending on the degree to which it has been processed. Calcined alumina, also known as metallurgical grade alumina, is obtained by baking hydrated alumina in order to remove the quantities of water contained in it. The annual production capacity reaches 820.000 tons of alumina.

Aluminium ALUMINIUM OF GREECE produces primary-cast aluminium through the electrolysis of calcined (anhydrous) alumina. In order to process primary-cast aluminium and deliver the end products (mainly billets and slabs), the Company’s production plant comprises the following: • The Anodes Line, which produces assembled anodes and ensures their supply to the electrolysis potlines, with an annual output capacity of 90,000 tons of baked anodes. • The Electrolysis Potlines, with an annual production capacity of 185,000 tons of liquid aluminium. • The Casthouse, where the liquid metal is alloyed and formed in billets and slabs (with production at 125,000 and 60,000 tons, respectively). • The Production Support Line, which ensures the reconstruction of the protective coating of the electrolytic cells (pots) and of the liquid metal transport ladles. 11


INFRASTRUCTURES - FACILITIES The industrial complex of ALUMINIUM OF GREECE one of Europe’s most modern vertically integrated production plants and the largest of its kind in SE Europe. The complex, located in the coastal area of Agios Nikolaos, in the Region of Sterea Ellada, is strategically positioned at the centre of the mountainous region defined by Mt Helikon, Mt Parnassus and Mt Gkiona – Greece’s major bauxite deposits zone. Infrastructures also include the nearby port, which allows direct access to sea transport and offers flexibility. Occupying a total area of 75 hectares, the Company’s industrial complex comprises the following (in production flow sequence): • The bauxite delivery and collection areas

• The anti-pollution facilities (gas treatment centres)

• The alumina production plant

• The areas for storage of fuel and raw materials

• The aluminium production plant

• The central and local maintenance workshops

• The Combined Heat and Power (CHP) Plant

• The support activities network (Environment, Quality, Safety, Chemical Laboratory, IT, Medical Station, Personnel Management etc.)

• The port facilities

In the last ten years, the total energy, industrial and environmental investments carried out in the industrial complex of ALUMINIUM OF GREECE were the largest ever to be undertaken by a private company in Greece.

The Port ALUMINIUM OF GREECE operates a privately-owned port, with a dock whose berthing capacity can accommodate vessels up to 45,000 tons. The port facilities include two electric port cranes moving on tracks, the calcined alumina ship-loader, the liquid cargo receiving facilities and the necessary storage and warehousing spaces. They also include the necessary means and equipment used in preventing and/or fighting sea pollution incidents, such as radio communication means, booms, absorbent materials etc.

Combined Heat and Power (CHP) Plant In operation since 2008, the 334 MW High-Efficiency Combined Heat and Power (CHP) Plant or Cogeneration plant, located within the ALUMINIUM OF GREECE industrial complex, is an innovative investment, not only by Greek standards but also by those applicable in the wider region of SE Europe. It operates using natural gas and produces steam, which is used in the alumina production process, as well as electricity, which is injected into the national grid.At the same time, its operation drastically reduces the use of heavy fuel oil in the alumina and aluminium plant and, consequently, optimises the whole plant’s environmental performance. 12


In the last ten years, the total energy, industrial and environmental investments carried out in the industrial complex of ALUMINIUM OF GREECE were the largest ever to be undertaken by a private company in Greece


Alumina Production Chart

ΛΕΠΤΟΜΕΡΕΙΑ ΛΕΚΑΝΗΣ ΛΕΠΤΟΜΕΡΕΙΑ ΛΕΚΑΝΗΣ

ΔΙΑΠΥΡΩΣΗ ΑΛΟΥΜΙΝΑ ΗΛΕΚΤΡΟΛΥΣΗ

Hλεκτρική Ενέργεια

ΗΛΕΚΤΡΙΚΗ ΕΝΕΡΓΕΙΑΕΛΕΚΤΡΙΚΗ ΕΝΕΡΓΕΙΑ

Άνοδος (+)

ΑΛΟΥΜΙΝΑ ΗΛΕΚΤΡΟΛΥΣΗ

Hλεκτρική Ενέργεια μύζηση μετάλλου Άνοδος (+)

Κάθοδος (-)

Πρέσσα ανόδων

Πρέσσα ανόδων Ανάμειξη

μύ με

ΠΙΣΣΑ

ΚΩΚ

ΠΙΣΣΑ

ΚΩΚ

Κάθοδος (-)

αερίων

ΔΙΑΠΥΡΩΣΗ

προς επεξεργασία

ΧΗΜΙΚΗ ΕΠΕΞΕΡΓΑΣΙΑ

αερίων

ΒΩΞΙΤΗΣ ΘΡΑΥΣΗ

προς επεξεργασία

ΒΩΞΙΤΗΣ

Ανάμειξη

Πουκαμίσωμα

Συναρμολόγηση

Φούρνος ανόδων

Αποθήκευση

Πουκαμίσωμα

Συναρμολόγηση

Αποθήκευση

Φούρνοςανόδων Τομή αίθουσας ηλεκτρόλυσης Τομή αίθουσας ηλεκτρόλυσης

ΑΝΟΔΟΙ

ΑΝΟΔΟΙ

ΗΛΕΚΤΡΟΛΥΣΗ

ΗΛΕΚΤΡΟΛΥ


ύζηση ετάλλου

ΛΥΣΗ

Κέντρο επεξεργασίας αερίων

Κέντρο επεξεργασίας αερίων

ΤΕΛΙΚΟ ΠΡΟΪΟΝ

Φούρνος χυτηρίου

Φούρνος χυτηρίου

Μηχανή χύτευσης Μεταφορά υγρού μετάλλου

ΤΕΛΙΚΟ ΠΡΟΪΟΝ

Κολώνες

Κολώνες

Πλάκες

Πλάκες

ΜηχανήΧελώνες χύτευσης

Χελώνες

Μεταφορά υγρού μετάλλου

ΧΥΤΗΡΙΟ

ΧΥΤΗΡΙΟ

ΛΙΜΑΝΙ

ΛΙΜΑΝΙ

Aluminium Production Chart


HUMAN RESOURCES For ALUMINIUM OF GREECE its human resources are its most valuable asset and its strongest competitive advantage, on which it draws to face the challenges of today’s globalised, technologically advanced and demanding business environment.

These very same values continue to serve today as the guiding principles of the practices followed and the attitudes adopted by the Company and by MYTILINEOS Group in its entirety.

The Company takes care to maximise the value of this capital, by establishing a work environment that respects individuality, recognises contribution and supports continuous development.

Training and Development

For ALUMINIUM OF GREECE, the progress of its employees is deeply rooted in its “corporate DNA”. Already since 1960, the Company’s philosophy was based on training, equal opportunities, human rights, meritocracy and – above all – caring for the health and safety of its employees. At the same time, the Company is actively involved in actions against unemployment, by taking intiatives aimed at increasing youth employment.

The training and development of its Human Resources is crucial for ALUMINIUM OF GREECE, which relies on the know-how and talent of its people and invests continuously in their development. In a constantly evolving sector that requires a high-level of expertise, the skills of its people are a key competitive advantage for the Company. For ALUMINIUM OF GREECE, the evolution of its employees is a concern of strategic significance, addressed through the implementation of a formally established and comprehensive Training and Professional Development Framework that strengthens the employees’ alignment with the corporate goals. The Company’s training policy is planned on the basis of existing needs and corporate targets and focuses primarily on health and safety at the workplace, the protection of the environment and Continuous Progress. The same policy is also followed by DELPHI-DISTOMON, where – due to the specific nature of its operations – greater emphasis is placed on training in occupational health and safety.


“ For ALUMINIUM OF GREECE, Corporate Social Responsibility,

both as conceptual framework and a range of tangible actions, is a precondition for its sustained growth and dynamic

CORPORATE SOCIAL RESPONSIBILITY For ALUMINIUM OF GREECE, Corporate Social Responsibility, both as conceptual framework and a range of tangible actions, is a precondition for its sustained growth and dynamic. The Company’s commitment to ensuring the prosperity of its people, the development of society and the protection of the environment governs all aspects of its business strategy. As a responsible corporate citizen, the Company invests in innovative actions, which it carries out in three key areas: Health and Safety at the Workplace, which also includes Occupational Hazards Prevention; Environment; and Support of Local Communities.

Health and Safety at the Workplace For ALUMINIUM OF GREECE and DELPHI-DISTOMON, Health and Safety at the workplace are long-standing core priorities. The effort to achieve the ultimate target of “ZERO ACCIDENTS AND ZERO OCCUPATIONAL DISEASES” is a constantly evolving process, in which both the Company’s Management and its employees are actively engaged, working towards a common goal. The two companies, which implement an OHSAS 18001-certified Occupational Health and Safety Management System, have a standing commitment to the continuous improvement of health and safety conditions at the work place, so as to rank among the world’s top performers in this area. This commitment is achieved through a number of actions and undertakings that include, among others, the following: • Strict compliance with the provisions of the laws, the applicable standards and the internal procedures and guidelines. • Continuous identification and assessment of hazards and adoption of measures to address them effectively, with a strong focus on prevention. • Open and transparent communication between the Management and the respective employees’ Committees on all matters concerning Occupational Health & Safety. • Regular measurement and assessment of the levels of exposure of employees to harmful factors, in tandem with systematic efforts to reduce these exposure levels. • Regular monitoring of the health of employees and organisation of employee training programmes on Health & Safety. ALUMINIUM OF GREECE has repeatedly received distinctions and awards for its excellent performance record in the domain of Safety, from the European Aluminium Association (currently, European Aluminium) and the International Aluminium Institute. 17


Environment The environmental policy of ALUMINIUM OF GREECE is not limited to compensating for the unavoidable impacts of its business activity on the environment. The Company is committed to investing in environment-related actions and infrastructures, as well as in the environmental education and awareness of its people, in order to minimise its environmental footprint on the Greek landscape. With an Environmental Management System that has been certified in accordance with the ISO 14001 International Standard, ALUMINIUM OF GREECE and DELPHI-DISTOMON comply with the applicable laws and have their environmental performance subject to annual evaluations. Their priorities are to implement up-to-date environmental protection policies and to achieve continuous improvements in performance. In line with this policy, the two companies focus on the following four key areas:

Energy consumption The rational management of energy, the reduction of energy consumption and the utilisation of renewable energy sources are key targets for ALUMINIUM OF GREECE. To this end, the Company conducts checks and carries out modernisation works in the aluminium production section, which is its most energy-intensive production activity, is supplied with energy from high-pressure steam produced by the Combined Heat and Power (CHP) Plant and, of course, carries out activities to raise the awareness of energy-saving practices among its personnel.

Pollution management and prevention The prevention of all hazards of permanent or accidental pollution and the development, testing and implementation of procedures for emergency response in extraordinary circumstances is a core commitment of ALUMINIUM OF GREECE. To this end, the Company carries out a wide range of activities, the most important of which are the following: • Management of infrastructures and adoption of best available techniques. • Constant – online – monitoring of air quality parameters, in full compliance with the approved environmental terms. • Strict control of production processes and prevention of potential leakages. • Readiness and completeness of the pollution-fighting means available to address a potential sea pollution incident. • Operation of the Combined Heat and Power (CHP) Plant and extension of the use of Natural Gas to all virtually all company installations, thus minimising the use of fuel oil.


Water consumption The rational management of groundwater is a core target for ALUMINIUM OF GREECE, as it is the region’s major consumer of water. For this reason, its plant, as well as the settlements around it, are supplied with water obtained exclusively from wells drilled and managed by the Company. Similarly, DELPHI-DISTOMON aims to minimise water consumption by reusing the water collected from stagnating waters or obtained from natural separation in site workshops.

Waste management Managing solid waste is perhaps the greatest challenge for ALUMINIUM OF GREECE. To this end, significant investments, whose total value reached â‚Ź15 million, were carried out and successfully completed (installation of four Filter Presses, configuration of areas, pilot installations etc.). As a result, since early 2012 disposal of all bauxite residues takes place on land, in accordance with relevant studies and in compliance with approved environmental terms, in a custom-configured area owned by ALUMINIUM OF GREECE. At the same time, and in collaboration with many educational institutions and specialised companies, the Company participates in research programmes focusing on the full utilisation of bauxite residues.

19


“Aspra Spitia” settlement In 1963, the establishment of the industrial plant of ALUMINIUM OF GREECE away from the populated areas of the Prefecture of Viotia, led the Company to create a nearby, model working-class community to accommodate the families of its employees. Thus, the “Aspra Spitia” (literally, “White Houses”) settlement was created at the picturesque Antikyra Cove – a settlement built to the European standards of that era by renowned Greek urban planner Constantinos Doxiadis. The infrastructures planned for this innovative community ensured its self-sufficiency and provided its inhabitants with an uncommon level of quality of life. From an architectural point of view, Aspra Spitia were an exemplary application of Doxiadis’ own man-centred approach to redefining the concept of the ancient Greek polis (city), adopting a radical and critical view of modern urban and architectural design, proposing a concept that could answer the pressing challenges of the future. Later on, two expansions of the settlement, supervised by architects M. Fotiadis, Ch. Lembessis and P. Massouridis, developed further the form of this community. Today, “Aspra Spitia” is a modern small town with a population of around 3,000 people, whose infrastructures keep being enhanced. Schools, services, shops, open squares and cultural and sport venues give the town its character of an open, outward place, rich in cultural and sport activities.


Society From its establishment to this day, the history of ALUMINIUM OF GREECE has been interwoven with the economic growth of the local community in this particular area of the Sterea Ellada Region. The Company’s “traditional” commitment to hiring mainly residents in the Prefecture of Viotia and in the neighbouring Prefectures is only one aspect of its contribution. At the same time, the Company’s priorities were – and still are – its development in parallel with that of the local communities, its collaboration with the Local Government, its evaluation of local needs and its initiatives to fulfil them. Today, ALUMINIUM OF GREECE is actively present , supporting the development of infrastructures and aiding actions that promote the social, cultural and sporting life of the wider area. It assists the initiatives of volunteer organisations, charities, cultural societies and sports clubs, schools and educational institutions and other public benefit organisations.

21


ALUMINIUM OF GREECE



ALUMINIUM OF GREECE

HEADQUARTERS 8, Artemidos Str., 15125, Marousi Athens, Greece Tel.: +30 210 36 93 000 Fax: +30 210 36 93 115 Εmail: info@alhellas.gr PLANT Agios Νikolaos, 320 03 Viotia Tel.: +30 22670 42 502 Fax: +30 22670 49 109 Εmail: info@alhellas.gr

REM DESIGN

www.alhellas.com