At AWAC's Kwinana alumina refinery in Western Australia, CO2, a major contributor to greenhouse gas emissions, is being used to reduce the alkalinity of bauxite residue. This carbonation process takes two waste products, CO2 and bauxite residue, to create a potentially useful resource. Refineries produce large amounts of residue, that is principally mud, sand and water. The residue is quite alkaline due to the chemical process used to extract alumina from the bauxite, and it requires careful management both in the short and longer term.
Alcoa Research and Development has developed the carbonation technology that passes CO2 through the bauxite residue to neutralise the alkalinity. As a result, environmental risks associated with long-term storage are reduced, and it provides an opportunity for the treated bauxite residue to be used in the future.
The CO2 that would normally find its way into the atmosphere is being mixed into the bauxite residue. Waste CO2 is also piped from a nearby (non-AWAC) ammonia plant for use in the carbonation process. At full capacity the process will utilise 70,000 tonnes of CO2 a year, the equivalent of taking 12,000 cars off the road.
Similar plants are planned for our other refineries. For example deployment across our operations in Australia alone could save 300,000 tonnes of CO2 each year. As the carbon capture project has such wide ranging community benefits, we are making the technology available to others under suitable agreements. This is significant as commercial considerations usually mean we don't make our new technologies available to industry competitors.
For more information refer to the Alcoa of Australia Sustainability Report
At the beginning of the 2007 the second gas-fired cogeneration power plant was commissioned at the Pinjarra alumina refinery in Western Australia. The refinery is using the waste heat from a natural gas power generation process to supplement energy needs. This partnership reduces AWAC's use of its boilers and will eventually result in the shutdown of some older systems. The cogeneration power plants have so far resulted in an overall reduction of Pinjarra's greenhouse emissions by approximately 270,000 tonnes per year. These plants, built in partnership with Alinta Limited, provide energy for the refinery and power to the Western Australia electricity grid.
This initiative when completed and coupled with other energy efficiency improvements resulting from an upgrade project at the Pinjarra refinery will reduce the refineries' greenhouse intensity by eight per cent.
In 2007 Alcoa made an $89 million commitment to sustainability at the Point Henry Smelter in Australia. The carbon bake upgrade was the biggest investment in Alcoa's Victorian operations for over 15 years and marks a milestone for the ongoing sustainability of the Point Henry operations.
The project involved extending the length of the furnace, removing 1000 truckloads of used refractory bricks, repairing the 'tub' which lines the furnace and laying new refractory bricks to form 384 individual baking pits that can each hold 18 anodes. In addition, the fume treatment centre, called the carbon bake scrubber, was also upgraded and overall the upgrade will help maintain production levels and significantly improve environmental performance.
Coal mined at AWAC's Anglesea Power Station and Coal Mine has a high quality heat value when compared to other brown coals used to produce electricity in Victoria, it does contains a higher level of sulphur (around 3%).
Coal, when combusted, creates sulphur dioxide (SO2) and AWAC's Anglesea Power Station has been working with the Environmental Protection Authority (EPA) of Victoria and members of the local community to understand and improve the management of SO2 emissions for several years.
The reason for this ongoing work is to improve the overall management of SO2 emissions from the power station and ensure compliance with State Environment Protection Policy (SEPP) and EPA guidelines.
Alcoa have thoroughly reviewed over 25 options for the improved management of SO2 emissions.
The project is a high priority environmental initiative for the power station at present. Evaluating individual long-term options for improved SO2 management requires careful balancing of environmental, social and economic implications for both the Anglesea community and the Anglesea and Point Henry operations.
In 2008, a reinvigorated consultation process encouraged interested community members to participate in the project and provide feedback on the options available.
A significant part of the Sulphur Dioxide Management Project, is the implementation of an Early Warning Modelling tool which analysed approaching or potential weather conditions and determined the likelihood of a SO2 exceedance of licence limits at ground level.
The tool has enhanced the effectiveness of how power station operators currently manage SO2 emissions through load management systems at Anglesea.
Station operators reduce power generation or load (ie. burn less coal) when our monitoring stations report that SO2 levels have reached a certain threshold.
The early warning modelling tool provides a more proactive system whereby station operators receive daily alerts of approaching weather conditions that are likely to lead to elevated concentrations of the emissions, allowing them to take action well in advance.
The system will continue to be refined by comparing the alerts with the actual results seen on the day.
The program has been highly successful with SO2 remaining below licence limits in 2008.
Alcoa was the first mining company in the world to achieve the goal of returning 100 per cent of plant species richness in AWAC's rehabilitated mining areas in Western Australia.
This year our custodianship and rehabilitation of our first bauxite mine - Jarrahdale in Western Australia, was recognised when the rehabilitated land was returned to the Western Australian State Government. The government issued a certificate of acceptance acknowledging rehabilitation to be complete and the land to be self-sustaining.
Alcoa's skills at restoring mined land to a self-sustaining state were further recognized with the Western Australian State Government's prestigious 2007 Golden Gecko Award for Environmental Excellence.
During the implementation phase of the bauxite mine located at Juruti in Para state Brazil, Alcoa's environmental team has taken action to protect the indigenous flora and fauna. Already species such as sloths, porcupines, angelin rajado bird and pau-rosa tree have been saved.
These actions take place during the vegetal suppression. All workers perform with respect to nature. In addition to biologists, environmental engineers, technicians and other specialized professionals, inhabitants of the region helped save animals and plant species, since they are familiar with the biodiversity in the region. Before salvaging, everyone receives training on how to handle the animals, specially reptiles, amphibians and mammals - these species are more vulnerable.
"We have achieved significant success since we have found species listed in the red list for extinction, such as, the sloth, the porcupine, and the anteater, all animals difficult to find" explains Charles Ferreira, Environmental Superintendent for Alcoa in Juruti.
When the vegetal suppression team spots an animal in the work area, an alarm is activated and the deforestation activities are fully interrupted, and the salvaging team goes into action. At no time does the salvaging team perform simultaneously with the vegetal suppression team.
The Jamalco operations of AWAC introduced a new and exciting method of transporting bauxite when it started mining on the South Manchester plateau in 2007. The new Rope Conveyor System, (RopeCon), was commissioned in the second half of the year. The system was designed by Ausrian based company, Dopplemayr, for moving materials in mountainous terrain and is said to be the longest conveyor of this type in the world. This innovative material transport system combines the benefits of proven ropeway technology with those of conventional conveyor belts and offers cost-efficient operation and maintenance with environmental sustainability.
RopeCon has a small footprint minimizing space requirements and saving 1,200 truck journeys a day along with the associated emissions of CO2 and fine dust, and also generates approximately 1,200kw of braking (green) energy per hour which is fed back into the power network.
For more information refer to the sustainability report
AWAC's West Australian mining operations have successfully reduced total water use by 22 per cent since 2000 while also increasing waste water recycling and storm water capture.
In 2007 the McCoy Crusher Facility at the Huntly bauxite mine was awarded the Water Recycling Award by the Western Australian Department of Water and the Water Corporation.
The McCoy facility was specifically designed to maximise water harvesting and recycling. Storm water runoff and treated wastewater are collected in a purpose built reservoir and used for haul road dust suppression. This leading edge design was created from a range of industry best practice engineering solutions and successful innovations.
Alcoa's operations in the Barwon Water region of Victoria, reducing their domestic water consumption by 60 per cent since 1990.
A tough new target has been set for a further 70 per cent reduction by 2010 and we're working with Barwon Water, Greening Australia and the Geelong Manufacturing Council on implementing a new water strategy to achieve it.
In addition to reducing its domestic water us, Point Henry is an important water source. The smelter manages its own EPA licensed sewage treatment system that discharges treated water into wetland areas on AWAC-owned land. The water is treated to ensure discharge is safe for the wetlands, thus forming a major input to the wetlands and helping to sustain the wetland environment.
Biodiesel has been trialed to help reduce the greenhouse gas emissions of our mining equipment. At the Willowdale bauxite mine in Western Australia and the Anglesea coal mine in Victoria, biodiesel, a renewable energy source, has been blended with diesel with the hope the alternative fuel will lower greenhouse gas emissions, as well as reduce reliance on fossil fuels.
Biodiesel is a non-fossil fuel produced from renewable resources including animal fats (tallow) and vegetable oils (canola, soy, sunflower, coconut or palm oils). It is usually blended with conventional petroleum diesel, rather than used as pure biodiesel. It is also non-toxic and biodegradable.
The Willowdale and Anglesea trials used a total of 3.4 million litres of biodiesel blend, used in all of or operating equipment including trucks, front end loaders, excavators, graders, scrapers and bulldozers.
The trial has shown preliminary signs of success and a biodiesel supplier needs to be secured for longer term research and development.
In Brazil, the substitution of fossil fuels by alternative sources of clean energy is highlighted. The use of biodiesel in vehicles at Alumar and the incentive for suppliers to fuel their trucks with biodiesel used in the transportation of bauxite also comprise some of the initiatives in this direction. "We are further analyzing the use of biomass in our furnaces", explained Mauricio Born, Manager for Health and Safety, Environment and Sustainability for Alcoa Latin America.
The Jamalco operations of AWAC introduced a new and exciting method of transporting bauxite when it started mining on the South Manchester plateau in 2007. The new Rope Conveyor System, (RopeCon), was commissioned in the second half of the year. The system was designed by Austrian based company, Dopplemayr, for moving materials in mountainous terrain and is said to be the longest conveyor of this type in the world. This innovative material transport system combines the benefits of proven ropeway technology with those of conventional conveyor belts and offers cost-efficient operation and maintenance with environmental sustainability.
RopeCon has a small footprint minimizing space requirements and saving 1,200 truck journeys a day along with the associated emissions of CO2 and fine dust, and also generates approximately 1,200kw of braking (green) energy per hour which is fed back into the power network.
For more information refer the sustainability report
In 2007 the Wagerup alumina refinery demonstrated great success through their Safety Culture Change program. Introduced at the end of 2006, the program has seen Wagerup become a benchmark for safety, with a 40 per cent reduction in the all injury rate.
The key to the program's success is an emphasis on individual accountability for safety.
The key elements of Wagerup's Safety Culture Change are:
Feedback from employees shows more than 70 per cent believe the program is making a real difference.
As the program has evolved, there has been specific focus on:
The professionals who work at the Alumar Refinery expansion project, in Sao Luis Brazil, have just surpassed the mark of 8 million man-hours worked without lost time accidents. This is the result of a continuous accident prevention work carried out by Alcoa in line with its global practices.
Before being performed, each task undergoes careful planning, in such a way that the work follows the applicable safety norms. Suggestions from employees in the field are extremely important in this process, due to the great amount of practical experience. "Many times the EHS team do not have the same vision that we do concerning certain tasks, then we make our suggestions. After debating, we find a way to optimize the work, but always having safety as a priority," - Edson Gomes, in charge of assembly at the Alumar expansion project and employee of Usiminas, another participant in the project.
Training is part of the internal culture. The accident prevention policies deal with all risks with the same degree of importance, and not a single possibility of incidence is overlooked, regardless how common it appears to be - from those that represent life-threatening hazard to the possibility of spraining an ankle or cuts to a finger. This continuous and structure process to identify, assess and eliminate or control risks result in a natural consequence: the constant proximity to the zero accident rate.
For more information refer to the sustainability report
The development of the bauxite mine and associated infrastructure at Juruti Brazil is an example of the co-operative spirit and community focus that is central to Alcoa's thinking and social commitment.
Juruti city is undergoing an intense transformation process brought about by the beginning of the work in the mine, involving 2,000 employees, most of whom are inhabitants of Juruti.
These changes followed an intense and detailed process involving dialog with representatives of the community, the region and the state. The purpose of this work is ambitious: turn Juruti into the best sustainable mining project in the world.
Located in the western portion of the state of Para, on the border with the state of Amazonas, Juruti hs 37,000 inhabitants. Income generation in the region is based on the production and marketing of manioc flour, in a subsistence activity for the local communities.
Juruti does no longer rely exclusively on manioc flour. By May 2007, the implementation phase of the bauxite extraction mine yielded to suppliers form the state R$145.3 million. Of this total, approximately R$17 million went to companies established in the city of Juruti, and R$40 million went to suppliers from the western portion of the state. In 2006 alone, Juruti City Hall collected R$1.5 million in service taxes levied upon Alcoa operations.
Education, health, safety, infrastructure, social assistance, culture and environment. To carry out improvement in these areas of the municipality, Alcoa, communities, governments, businesses, NGOs and partner institutions joined forces and created the Positive Agenda. The document gathers voluntary commitments assumed by Alcoa, in a partnership with the Juruti City Hall, partner institutions and the community, involving actions forecast at R$50 million.
In order to debate theses issues and develop a joint proposal for the regional development, the company maintained an open and transparent dialog with the local society, including government and community leaders. In a partnership with the competent authorities, a public administration model is being developed for strategic sectors of the local economy, including mining companies.
In March 2007, during a work meeting with city officials, six priority actions were defined for the Positive Agenda, in the areas of education, heath and infrastructure. These areas require immediate actions to assure improvement in the quality of life of the population of Juruti.
For further information on this process of collaboration and sustainability, please refer to the Alcoa Latin America Sustainability Report 2006/2007
AWAC's San Ciprián operations in Spain have developed and implemented a community program affecting all stakeholders
The focus and work of management, engineers, supervisors and most importantly, its shop floor workers, has created strong relations with a number of important parts of the community. It promotes the good reputation of the plant, and also adds value to the company as a plant located in a community that defends it is a better and richer plant!
In the last 12 months, San Ciprián completed 14 actions, had 1,061 Alcoa volunteers, more than 80% of the workforce, invested 70,445 hours in service and had 10,578 individual participant
Community stakeholders were consulted to determine what their needs were, and according to those needs we engaged our people.
Some of the most important needs that were found included such things as:
In response to these stakeholder needs, the following activities were held:
More than 55 people are participating in a scholarship program. This will train them and give them working experience, and perhaps in the future they can join the Alcoa family.