Kwnina

kwinana
ENVIRONMENTAL IMPROVEMENT PLAN 2006-07
ALCOA WORLD ALUMINA AUSTRALIA For more information on Alcoas Environmental Improvement Plans or any aspect of our operations near you please contact:
West Australian Operations

Kwinana Alumina Renery Linda Garner Ph: 08 9410 3171 linda.garner@alcoa.com.au Pinjarra Alumina Renery Stephanie Felstead Ph: 08 9531 6162 stephanie.felstead@alcoa.com.au Wagerup Alumina Renery Rosalie Byrd Ph: 08 9733 8768 rosalie.byrd@alcoa.com.au WA Mining Group Robyn South Ph: 08 9530 2812 robyn.south@alcoa.com.au
Victorian Operations:
Point Henry Aluminium Smelter and Rolling Mill Brendan Foran Ph: 03 5245 1314 brendan.foran@alcoa.com.au Anglesea Power Station Anthea Daley Ph: 03 5263 4249 anthea.daley@alcoa.com.au Portland Aluminium Smelter Anna Sullivan Ph: 03 5521 5463 anna.sullivan@alcoa.com.au
NSW Operations
Yennora Rolling Mill Helen Campbell Ph: 03 9225 5089 helen.campbell@alcoa.com.au
You can view the complete range of Alcoas Environmental Improvement Plans on our website: www.alcoa.com/australia/en/info_page/EIP.asp
Contents
The Kwinana renery is located on the shores of Cockburn Sound and is part of Western Australias premier industrial estate the Kwinana Industrial Area.
Alcoa World Alumina Australia Kwinana Renery external verication overview of operations how aluminium is made aluminumpart of the solution history of improvement targets and actions air quality management noise management water management and conservation visual amenity and land management waste management community involvement environmental regulation and management national pollutant inventory glossary of abbreviations and terms we welcome your feedback
| | | | |
2 3 4 6 8
| 10 | 12 | 16 | 20 | 22 | 24 | 26 | 28 | 30 | 32 | 35 | 37
Alcoa World Alumina Australia Kwinana Renery environmental areas/kwinana
esse molestie consequat, vel illum dolore eu feugiat The Kwinana renery has been in operation since nulla and is at essential et accumsan three-renery 1963facilisis an vero eros part of Alcoaset iusto odio dignissim qui blandit most advanced systems in the system among the praesent luptatum zzril delenit. world.
Alcoa World Alumina Australia environmental Kwinana areas Renery

The environmental targets, aims and actions in this EIP have been developed with direct input from Alcoa employees, community members and neighbours, local and state government representatives and environmental regulators, Alcoa Global Rening Vice President Operations Raphael Costa.
Environmental Improvement Plan 2006-07

Alcoas Kwinana Renery Environmental Improvement Plan (EIP) is part of Kwinanas operational plan for the next two years (2006 and 2007). The environmental targets, aims and actions in this EIP have been developed with direct input from Alcoa employees, community members and neighbours, local and state government representatives and environmental regulators. It is our public commitment to continuously improve Kwinanas environmental performance, reduce environmental impacts and develop more sustainable operating practices. This EIP sets clear targets for improvement and outlines the actions and initiatives which Alcoa will implement to achieve them. The Kwinana renery EIP will be reviewed with the community and regulators to assess our progress and provide input to future goals and actions. External involvement and review is integral to this EIP. Alcoa is working hard to improve the effectiveness of community involvement in our business by engaging a wider range of stakeholders and building upon well-established community reference groups.
By seeking input and utilising the creativity of our employees, neighbours and regulators we are able to build on our past environmental management and challenge our performance for the future. The EIP process helps improve our capacity for sharing information, increasing community understanding of our operations, incorporating community sustainability considerations into our decision-making and strengthening our links with local communities. We value this engagement as a fundamental component of managing our operations and growth projects into the future. We extend our thanks to everyone involved in producing this EIP. It is a further demonstration of our willingness and ability to work in partnership with community and government stakeholders on matters of mutual interest. Special thanks go to the community members of the EIP Working Group for their signicant contribution of personal time and energy to the process. This process is a leading example of community engagement within the Alcoa system and we believe, in industry more broadly.
Raphael Costa Vice President Operations Alcoa Global Rening
Arnaud Soirat Manager Kwinana Renery
external verication
An EIP is voluntarily prepared by companies wishing to set targets for environmental improvement that go beyond those specied in licence conditions. As the environmental regulator for Western Australia , the Department of Environment (DoE) will reference this EIP in the Kwinana renerys licence assessment report so it is clearly recognised that Alcoa has committed to a program beyond compliance. Importantly this EIP is an agreement between Alcoa, the surrounding community and the DoE and represents a serious commitment by all parties to abide by the spirit and intent of the agreement. A DoE representative was on the working group which developed this EIP and will be involved in monitoring of the progress of the actions identied. The DoE encourages the EIP process of community involvement, implementation of agreed targets and reporting on progress.
Community Endorsement
As members of the Environmental Improvement Plan Working Group and the community consultative process we acknowledge our participation in the development of this plan and will continue to monitor the progress achieved by Alcoas Kwinana renery throughout 2006-07.
Glen Bersan Kwinana Councillor
Rod Pattinson Kwinana Councillor
Hugh DeHaer Hope Valley Community
Julie Baker Cockburn Councillor
Lance McGlinn Hope Valley Community

Paul Rosair Director Regional Operations Department of Environment The Department of Industry and Resources (DoIR) assists in the responsible development of Western Australias resources for the benet of all Western Australians. A key aspect of this is to promote best environmental management practices with companies involved in the minerals and petroleum industry. It achieves this by educating and regulating industry under its jurisdiction, such as Alcoa. With this role in mind, DoIR encourages and supports the voluntary development and implementation of Kwinana renerys EIP.
Emma Jones DoE Representative
Les Egerton DoE Representative
Chris Oughton Kwinana Community
Janet Moore Wattleup Community
Mark Hector Hope Valley Community
Nola Waters Naval Base Village
Stan Elms Hope Valley Community
Lorraine Valli Hope Valley Community
Ron Kimber Beeliar Community
Jim Limerick Director General Department of Industry and Resources
Peter McKenzie Kwinana Environmental Health Services Manager
Nick Jones Kwinana Environmental Health Ofcer
Garry Taylor Employee Representative
John Hardy Cockburn Principal Environmental Health Ofcer
overview of operations
overview of operations
Since 1963 Alcoa has built a world-class integrated aluminium business in Australia. It is active in all major aspects of the aluminium industry technology, mining, rening, smelting, fabricating and recycling.
MELBOURNE
PERTH
Principal operations within Western Australia
Huntly Mine Willowdale Mine Kwinana Refinery/Port Pinjarra Refinery Wagerup Refinery Bunbury Port Dampier Bunbury Pipeline
Principal operations within Victoria
(20% OWNERSHIP)
Portland Aluminium Smelter (55% OWNERSHIP) Anglesea Power Station Point Henry Smelter/Rolling Mill Melbourne Alcoa Wheel Products Oakleigh Alcoa Fastening Systems
SYDNEY
Principal operations within New South Wales
Yennora Rolling Mill
Alcoas headquarters are in Perth, Western Australia. It produces aluminium from two smelters in Victoria, and alumina at three reneries in WA. The company operates a brown coal mine and power station in Victoria to supply power to the Point Henry Smelter and mines bauxite in WA to supply its reneries.
Kwinana Refinery Overview

The Kwinana renery was ofcially opened in July 1963 and began production three months later. The rst shipment of alumina left the Kwinana port aboard the Lake Sorrel on 22 February 1964, bound for Alcoas Point Henry Smelter at Geelong, in Victoria. In March the same year, the rst export shipment was despatched to Japan. As world demand for Alcoas alumina has grown, two additional reneries have been established in Western Australia at Pinjarra in 1972, and at Wagerup in 1983. Today, this three-renery system is among the most advanced in the world, with annual production of 7.8 million tonnes of alumina. The Kwinana renery is situated 20kms south of Perth in the Kwinana Industrial Area Western Australias premier heavy industrial estate. In addition to producing alumina to be smelted into aluminium, the Kwinana renery today produces a variety of specialty aluminas which have a wide range of industrial and manufacturing applications all around the world. These include applications as diverse as water purication, refractory materials, pharmaceuticals, articial marble, paper sizing, ceramics, abrasives, petroleum processing, plastic and re retardant in carpets. To meet the exacting quality standards demanded by specialty alumina buyers around the world, Kwinana maintains certication to Quality Standards AS3902 (Australian), ISO9002 (International) and ISO14001 (International environmental accreditation) the rst alumina renery in the world to be so accredited.
Alcoa has been a part of the Western Australian community for more than 40 years. Each year Alcoa contributes more than $1 billion to the economy of local communities and around 80 cents from every export dollar stays in Australia.
Alcoa has a workforce of about 7,500 in Australia. In WA, Alcoa operates alumina reneries at Kwinana, Pinjarra and Wagerup and two port facilities at Kwinana and Bunbury. Bauxite is supplied to these reneries from mines at Huntly and Willowdale in the Darling Range. In Victoria, the principal locations of operations are Geelong and Portland. Alcoa owns the Point Henry Smelter and is the operator of the Portland Aluminium Smelter, in which it has a 55 per cent interest. Alcoas primary focus as an alumina and aluminium producer is complemented by Alcoa Australia Rolled Products (Alcoa ARP) manufacturing and marketing of rolled products. Alcoa ARPs headquarters are at Point Henry in Victoria and it produces rolled products at Point Henry and Yennora in New South Wales. Alcoa ARP is the only manufacturer of aluminium rolled products in Australia.
Aluminiumpart of everyday life

Aluminium is a popular product because it is lightweight and strong, it reects heat and light, conducts heat and electricity very well, and its non-toxic. Aluminium is endlessly recyclable making it a metal energy bank for the future as recycling saves 95 per cent of the energy it would take to make new metal. Aluminium can be used for food and drink packaging, wheels, aeroplane and vehicle parts, outdoor furniture, recreational equipment like scooters, bikes, water and outdoor sporting any equipment that needs to be strong, but light.
Alcoas Kwinana renery is located on Cockburn Sound, a valuable recreation, shing and industrial port for Western Australia.
how aluminium is made
Alcoas Kwinana renery produces a variety of specialty aluminas used around the world.
how aluminium is made

from bauxite to versatile metal
It all starts with dirt a type of dirt known as bauxite. To look at it its colour and texture looks little more than ordinary gravel. However, its careful extraction from mines in the Darling Range of Western Australia start a process which since the beginning of the 20th century has revolutionised the transport, building and other high technology industries.
6
By mixing bauxite with caustic soda, and then pressure heating, Alcoa is able to extract alumina in a ne white powder form. Alumina is shipped to aluminium smelters in Victoria and exported around the world. The alumina is then smelted at very high temperatures and an electric current passed through it to form aluminium one of the worlds most versatile metals.
DARLING RANGE BAUXITE 7 TONNES BAUXITE
ENERGY CAUSTIC SODA LIME 2 TONNES ALUMINA (Al2O3) ALUMINA REFINERY BAYER PROCESS
EXPORT ALUMINA
Since the beginning of the 20th century, aluminium has revolutionised the transport, building and other high technology industries.
CHEMICAL FEED STOCK
ENERGY COKE, PITCH ALUMINIUM FLUORIDE ALUMINIUM SMELTER HALL-HEROULT PROCESS 1 TONNE ALUMINIUM (MOLTEN Al) EXPORT INGOT
ALLOY ELEMENTS
ROLLING MILL 1 TONNE CAN SHEET
EXPORT CAN SHEET
From bauxite to versatile metal.
Bauxite to aluminium

From mining bauxite to exporting rened alumina around the world, this diagram shows the process for alumina rening in Western Australia.
aluminiumpart of the solution
The sums are compelling. Using aluminium to cut a vehicles weight by 10 per cent can boost its fuel economy by around eight per cent.
aluminum part of the solution

Alcoa approaches sustainability from a local and global perspective. Locally, we are working in partnerships with communities, government and suppliers to strengthen the sustainability of the regions where we operate. Globally, we are leading the aluminium industry with greenhouse reduction projects and contributing to global sustainability through the benets aluminium delivers by reducing greenhouse emissions from the transport industry.
In Australia, we use a sustainability framework based on our global sustainability model. The use of this framework in the Pinjarra Renery Efciency Upgrade and planning for the proposed Wagerup expansion is delivering positive outcomes including increased community engagement and better business decisions, environmental improvements, cost reductions and increased local procurement. In the transport industry, it is estimated that by 2017, the increased use of aluminium will have the potential to save enough fuel to offset all the greenhouse gases produced by the aluminium industry globally.
It is estimated that by 2017 the increased use of aluminium in the transport industry will have the potential to save enough fuel to offset all the greenhouse gases produced by the aluminium industry globally.
Alcoa is the largest recycler of aluminium cans in the southern hemisphere, we recycle about 55,000 tonnes each year.
Recycling aluminium also contributes to global sustainability by reducing energy consumption, greenhouse gas emissions and the use of resources. Producing aluminium from recycled aluminium uses only ve per cent of the energy that would be required to produce the same amount from bauxite. Alcoa has set a global sustainability goal to make 50 per cent of Alcoas products from recycled aluminium by 2020, excluding ingot that is sold directly to others. Alcoa ARP is the largest recycler of aluminium cans in the southern hemisphere, with its remelting facility at Yennora in New South Wales, recycling about 55,000 tonnes of aluminium each year.
Aluminiumpart of the solution

Aluminium makes a valuable contribution to global sustainability through its recyclability and capacity to reduce greenhouse gas emissions from the transport sector. In all areas of transport, aluminium is reducing fuel consumption and greenhouse gas emissions by reducing vehicle weight. Each kilogram of aluminium used to replace heavier materials in a motor vehicle can save 20 kilograms of carbon dioxide emissions over the life of the vehicle.
Our model for sustainability is based on a robust foundation of strong corporate governance, and integrates environmental excellence, social responsibility and economic contribution. We do this through partnership with our stakeholders and using our Alcoa Business Systems.
history of improvement
history of improvement
1981
Alcoa underwrites the Dampier to Perth gas pipeline and the Kwinana and Pinjarra reneries switch their powerhouses to clean and efcient natural gas, rather than diesel fuel thus reducing sulphur dioxide and greenhouse gas emissions in the area. The move also means natural gas is available to the Perth metropolitan area.
10
1974
Water recovery program begins at residue disposal areas A B and C to reuse alkaline liquid from within the residue area.
1989
19831999
Super-thickener introduced at the A program to identify residue area to reduce and re-seal the leaks in the alkalinity of residue the clay liners of A B C materials and reduce the and F residue areas. space required to store it.
1993
A waste minimisation strategy is implemented at Kwinana renery.
1963
Kwinana renery is commissioned.
1977
A recovery bore network is installed at the A B C residue disposal area to monitor, recover and reuse alkaline liquid which has reached groundwater.
1982
Alcoa transforms a former clay mine into the Wellard Wetlands, a self-sustaining wetland providing a haven for migratory and native birds.
1984
A new method of constructing bauxite residue disposal areas is developed. This improved construction includes a synthetic and clay composite liner with a base drainage system which ensures new residue areas do not leak. Dry stacking of bauxite residue begins, and reduces the storage area required. This method uses the sand portion of residue to build embankments.
1990
United Nations include Alcoa on the Global 500 roll of honour for two decades of progress in environmental rehabilitation of its bauxite mining areas in WA. Conversion of residue mud lake storage to drystacking begins.
1992
Kwinana renery begins a bore sampling service to neighbours on a two year cycle.
1994
Continuous opacity meters are installed on the calciners to monitor and manage alumina dust. Alcoa Kwinanas Community Consultative Network (CCN) is formed. The CCN provided a valuable community perspective for Kwinanas operations for 10 years.
2001
A near shore survey shows the marine waters, sediments and marine species adjacent to the renery are as healthy as non-industrial sites in Cockburn Sound. The three bin recycling system is introduced to Kwinana renery. Independent air quality monitoring for volatile organic compounds at the renery shows levels are well below the strict standards set for the protection of employee health.
2005
11
1998
Kwinana renery hosts the Environment Health and Safety Expo to celebrate its 35th year of operations.
2003
Alcoa participates in Kwinana Industrial Area (KIA) Synergies projects to reduce industrial waste.
Review of the current emissions inventory at Kwinana is completed and the scope of work dened to complete a comprehensive inventory by 2007.
1997
Kwinana renery becomes the rst alumina renery in the world to achieve environmental certication to the ISO14001 Environmental Management System (EMS).
2000
Kwinana renery returns half of its original residue disposal area to the State Government for a world class motor sports complex. This is regarded as the rst bauxite residue disposal area in the world to be rehabilitated and returned for community use. A successful trial of residue carbonation is implemented. This reduces residue alkalinity and acts as a greenhouse gas sink for CO2.
2002
Alcoa voluntarily de-commissions the liquor burner and announces an emission reduction project.
2004
Alcoa involves community in environmental approval application for installation of emission reduction equipment for the liquor burner at Kwinana.
targets and actions
targets and actions
The following table summarises the targets and actions for 2006-07 undertaken by Alcoa and reviewed by the Environmental Improvement Plan Working Group. Further details on the initiatives committed to in each of these environmental performance areas are outlined in the sections following this table. Reports developed through action items will be reviewed with the EIP Working Group.
Issue
Particulates
Target
Reduce the particulate emissions from calcination and shipping areas
Action
Investigate fugitive emission sources from calcination and shipping areas Implement specic projects to reduce fugitive emissions from calcination building and shipping areas Install a PM10 monitor at the renery boundary Work via KIC to support a PM2.5 monitoring program at appropriate locations in the region as part of the Perth background air quality study being conducted by the Department of Environment Complete the Run Off Water Storage (ROWS) pond project to provide a clean source of sprinkler water in 2006 Upgrade the sprinkler system in Area F to reduce the distance between sprinklers to the current Alcoa standard in 2006 Commence the use of carbonated mud onto all drying areas (including Area F) as soon as practical (expected mid-2006) Involve community representatives in inspection and reporting of progress on implementing dust control Develop an easy to use feedback mechanism to encourage community to report dust issues Complete an Alcoa residue dust-related health risk assessment by 2007 Complete a feasibility study on replacement of existing less-efcient boilers with a gas turbine and waste heat boiler Commission the emissions reduction equipment on the liquor burner Use LNG gas as the primary fuel source for power and steam generation, with backup only from ultra-low sulphur diesel to minimise SOx
Air Quality Management refer page 16
Identify the ambient levels of ne particulates adjacent to the renery and residue areas
Continue to improve dust control methods and applications at the residue area
Provide the community with an understanding of the dust related health risks associated with the residue area
13
Gas Emissions, Greenhouse Gases, Odour
Options for the reduction in greenhouse gas emissions are identied Reduce VOC emissions from liquor burner by 98 per cent and odour by 95 per cent Minimise the use of diesel, and use only ultra low sulphur diesel
Noise Management refer page 20 Noise Communicate and respond to community concerns about noise following mutually agreed processes Ensure new equipment is installed with consideration to reduce noise emissions Maintain links with the Kwinana noise reference group through KIC membership to ensure noise emissions from Alcoa are managed appropriately Continue to proactively consider environmental noise emissions and cumulative noise in design for signicant capital projects to maintain compliance
targets and actions
Issue
Groundwater
Target
Reduce the potential for impacts from renery groundwater outside Alcoa property Reduce the existing contamination under the renery and adjacent property
Action
Complete a review of groundwater monitoring program including monitoring for trace elements Review options to install a renery perimeter underground barrier to effectively contain groundwater to Alcoa property Increase groundwater recovery capacity at the renery Monitor quality of existing sealed areas within the renery to maintain integrity Develop and progress research plans for the early closure of Area F in 2010 and rehabilitation over the following years Install additional recovery capacity at Area F Examine feasibility for further deliquoring of Area A B C Install additional recovery capacity at Areas A B and C Develop a ve year containment strategy Implement a risk reduction program for high risk areas over the rst 2 years Upgrade the secondary containment facilities at the renery to residue area pipeline pumping stations by end 2006 Review the options for the use of secondary or tertiary treated water for use in the renery process Develop a water use strategy focusing on water source alternatives and water reuse and efciency Support and assist the KIC and appropriate government departments in a review of the movement of the saltwater wedge in the region
Water Management and Conservation refer page 22
Reduce the plumes in the area around Area F to minimise impact on groundwater Increase contaminated groundwater recovery capacity at residue areas ABC
Containment
Reduce the risk of groundwater contamination from existing containment facilities including existing renery to residue area pipeline containment facilities
Water Use
Identify alternative industrial water uses and supplies to minimise high quality (potable and groundwater) water use by Alcoa
14
Visual Amenity and Land Management refer page 24 Residue Rehabilitation Residue rehabilitation to focus on visual amenity and dust control as a priority, and be self sustaining in the long term Use native vegetation complexes including conifers as part of the residue rehabilitation program to ensure self-sustaining ecosystems are developed Continue to support wetland research and local community use Review existing rehabilitation and develop and implement an annual rehabilitation rework plan to upgrade areas of the existing rehabilitation that do not meet current standards Develop the residue rehabilitation research plan to focus on identifying mixes of self sustaining native species
Wetlands
Include wetland research in the strategic land management program Work with local government and community interest groups to promote appropriate uses of the wetlands
Issue
Waste Reduction
Target
Continue with waste minimisation activities to identify waste to landll reduction opportunities
Action
Complete assessment of recyclable canteen food waste packaging for implementation Continue to work with suppliers to further identify packaging waste reduction and recyclable supplies initiatives Undertake an assessment of the effectiveness of the glove recycling program and implement identied improvements Implement the natural bio-removal process for oxalate destruction subject to environmental approvals Work with research groups to develop markets for alternative uses for red sand Work with research groups to develop a project for separation and alternative use of recovered lime
Waste Management refer page 26
Oxalate Management
Implement a strategy for long term oxalate management Support projects to identify and research residue reuse opportunities with involvement with external bodies
Residue Reuse
15
air quality management
The Kwinana renerys powerhouse is a source of nitrogen oxide.

Alcoas Kwinana renery commits to the following air quality targets as part of this EIP: Reduce particulate emissions from calcination & shipping. Identify ambient levels of particulates near renery and residue. Continue to improve dust control methods at residue. Provide an understanding of dust health risks associated with residue. Identify options for reducing greenhouse gas. Reduce liquor burner VOC emissions by 98 per cent and odour by 95 per cent. Minimise the use of diesel, and use ultra low sulphur diesel.
The management of air quality from Alcoas Kwinana renery receives close scrutiny from the community and government agencies, as an individual facility, and as a renery operating in close proximity to other industries in the Kwinana Industrial Area.
16
Alcoa has conducted extensive investigations over many years into emissions produced from alumina rening and our knowledge of the range and concentration of chemical compounds present in our process is unequalled in world research. The primary air emissions from the renery include nitrogen oxide (NOx), carbon monoxide (CO), particulates in the form of alumina dust, volatile organic compounds (VOCs), residue dust, and trace levels of metals. of diesel, and use only ultra-low sulphur diesel for outages and monthly test burns. Alcoa will also: Complete a feasibility study on replacement of existing less-efcient boilers with a gas turbine and waste heat boiler; Install a new ambient air monitor at the renery boundary to monitor PM10 levels; and Undertake two improvement activities to reduce alumina dust emissions. In addition, Alcoa will be completing an emissions inventory for the Kwinana Renery, which was a condition of the approval to upgrade the liquor burner. Opportunities in the future could include installation of economisers on two of Kwinanas less-efcient powerhouse boilers as overhaul scheduling permits. This would reduce both NOx and greenhouse gas emissions.
Nitrogen Oxide (NOx), Sulphur Dioxide (SO2), Carbon Monoxide (CO) and Particulates
Emissions of NOx, SO2 and CO come from the use of fossil fuels such as natural gas. The sources for these emissions are primarily the renerys powerhouse and calciners, with minor contributions from other stacks, mobile equipment and vehicles. Particulates can be released from the calciners and the ship loader in the form of alumina dust.
The Kwinana renery has worked to reduce its emissions per tonne of alumina for over 15 years through a number of improvement projects and will continue to work towards decreasing these emissions.
Kwinana has worked to reduce its emissions per tonne of alumina for more than 15 years through a number of improvement projects and will continue to work towards decreasing these emissions. Alcoa will minimise the use
Volatile Organic Compounds (VOCs)

VOC emissions from alumina reneries are caused by the breakdown of organic material contained in the bauxite, additives to the rening process and in by-products of fuel combustion processes. During alumina rening, these organics are degraded and produce a range of substances, some of which are emitted to atmosphere. These VOC emissions are the cause of the characteristic odour associated with alumina reneries.
17
Map: Indicates location of dust monitoring sites marked by pink squares.
The key project to ensure that Kwinanas VOC emissions remain at existing low levels is the installation of emission reduction equipment on the liquor burner. This equipment will result in: 98 per cent reduction in volatile organic compounds from the liquor burner; 95 per cent reduction in odour emissions from the liquor burner operation, which represents about 20 per cent of the renery emissions.
Alcoa has four dust monitoring stations measuring total dust (TSP) and is seeking approval for the location of a fth around the Hope Valley RDA. These are located in the community to measure ambient dust concentrations from the residue disposal area. The dust management systems in place at the residue area are varied and consist of a range of both proactive and reactive strategies. During winter each year a dust control plan for the coming year is prepared. Alcoa receives local, three-day weather forecasts on a daily basis, which include a Dust Risk Rating which takes into account rain, wind speed and wind direction. This forecast allows Alcoa to prepare for conditions that could cause dust and deal with dust prone areas well before strong winds arrive. For example, by operating sprinklers well ahead of forecast winds. Specic dust controls employed by Alcoa to minimise dust generation include: Using heavy mobile equipment to turn over the mud in the residue area; Using sprinklers and water carts; Applying wood mulch; Applying bitumen emulsion to exposed banks; Applying aggregate to large areas not required in the short term; Managing roads through application of emulsied waste oil as a dust suppressant; and Planting grasses or other vegetation where possible. The initiatives to be undertaken as part of this EIP to reduce residue dust are: Complete the Run off Water Storage (ROWS) pond to provide a clean source of sprinkler water; Upgrade the sprinkler system in RDA F to the current Alcoa standard; Lay carbonated mud onto RDA F as soon as practical; Involve community representatives in dust control; and Develop and implement an easy to use community feedback process for dust management.
Residue Dust
The main source of dust at Kwinana is from the Residue Disposal Areas (RDAs) in Hope Valley, particularly during the months October to April. If dry residue surfaces are not correctly managed, wind speeds over 23 km/h can pick up and transport ne dust particles.
Alcoa has four dust monitoring stations measuring total dust and is seeking approval for the location of a fth around the Hope Valley residue area.
Dust generated from the RDAs mostly consists of clay particles and sodium carbonate crystals. While this alkaline material at sufcient concentrations, could be an irritant to the eyes and respiratory tract, monitoring and modelling of dust to date indicates it is extremely unlikely this material could be at levels sufcient to cause these effects in neighbouring communities. Dust emissions from the renery and RDAs are monitored daily. This data is used to gauge the effectiveness of dust control measures. As well as the drying beds, the surrounding infrastructure such as roads, embankments and drains can also be a source of airborne dust. The Environmental Protection (Kwinana) (Atmospheric Wastes) Policy 1992 has established a dust standard of 90 micrograms/m3 and a limit of 260 micrograms/m3 for the area around and including the residue disposal area. Alcoa seeks to maintain dust control measures to keep actual dust emissions from the residue disposal area well below the standard of 90 micrograms/m3. Alcoa is required to report any dust level above this standard to the DoE.
18
Sprinklers
The improved sprinkler conguration will be incorporated into the design of any newly constructed residue areas. The red shaded areas show coverage by three sprinklers, the green shaded areas show coverage by two sprinklers and the yellow areas show coverage by one sprinkler.
The new carbonation plant has the potential to reduce CO2 emissions and the potential to reduce residue dust at Kwinana.
19
Further Studies
As part of Kwinanas EIP, a health risk assessment, related to residue dust will be completed by 2007. This project will include the following research to be carried out at Alcoas WA Operations. Kwinana will have one monitor included in this study which will provide the following: A comprehensive evaluation of dust emissions from the residue storage areas at the reneries in Western Australia; Quantication of the chemical makeup of the dust emissions; and Quantication of the particle size distribution of the dust.
Research and Development

In 2000 the Kwinana renery successfully implemented a carbonation trial at the RDA. This unique project mixes carbon dioxide (CO2), a greenhouse gas, with bauxite residue. The trial demonstrated that by mixing CO2 with the residue, we are able to reduce the alkalinity of the material, reduce residue drying time, and provide a sink for what is usually a waste gas to atmosphere, thus reducing greenhouse gas emissions. Other ow on benets include: Reducing the potential for groundwater impact; Reducing the overall size of the RDAs; Reducing the risk of dust lifting from carbonated residue; and Creating more opportunities for residue reuse. A full scale carbonation plant is in the process of being built at Kwinanas RDA. In the interim CO2 is being used to treat the residue in the newest RDA, Area L. Currently Alcoa is using waste CO2 from other industries for use in the carbonation process. However, Alcoa is developing and testing innovative technology to enable CO2 extraction and concentration from our own renery sources. This would allow for the process to be used at all Alcoa reneries and reduce our CO2 emissions.
The carbonation trial at Kwinana demonstrated that by mixing CO2 with residue, we can reduce the alkalinity of the material, thereby reducing residue drying time, and provide a sink for what is usually a waste gas to atmosphere, thus reducing greenhouse gas emissions.
A report on the study which runs over summer 2005-2006 is expected to be nalised by mid-2006.
noise management
A noise reduction program at the Kwinana renery has reduced tonal noise at several sources and the overall noise level from the plant by 2 dB(A).
noise management
Alcoas Kwinana renery commits to the following noise management targets as part of this EIP: Communicate and respond to community concerns about noise following mutually agreed processes. Ensure new equipment is installed with consideration to reduce noise emissions.
20
The Kwinana renery is part of the Kwinana Industrial Area and as a result noise management in the region is a complex issue because of the number of industries operating in close proximity.
Through Alcoas membership of the Kwinana Industries Council (KIC) we are involved with the Kwinana Noise Reference Group which manages the cumulative effects of noise in the region. We have participated in two cumulative noise surveys undertaken by KIC.
A $400,000 program to reduce noise was implemented at the Kwinana renery throughout 2004. The program successfully reduced tonal noise from several sources and Alcoas overall noise level by two decibels [dB(A)].
After the rst study in 1999, Alcoa reviewed its internal noise data and modelling work to measure changes over time.
Field monitoring showed Alcoas overall compliance with the Environmental Protection (Noise) Regulations 1997. However, predictive modelling, supported by monitoring, suggested the tonal noise originating from the renery may not have been in compliance with the regulations and were likely to exceed the allowable noise limits under rare meteorological conditions. Following this analysis a $400,000 program to reduce noise was implemented at the Kwinana renery throughout 2004. The program successfully reduced tonal noise from several sources and Alcoas overall noise level by two decibels [dB(A)]. The latest KIC noise study undertaken in 2004 showed when updated assigned levels are applied, Alcoa is in compliance with the Regulations.
21
EIP Working Group members indicated noise from the renery and residue area was not a priority for the community and the low number of noise complaints from the community supports this. Working Group members strongly urged Alcoa to minimise noise in the design of new equipment, and continue working with the community to satisfy any concerns about noise that were raised. As a result the following actions were included in the EIP with regard to Alcoa Kwinanas noise management: Proactively consider environmental noise emissions and cumulative noise in the design of signicant projects to maintain compliance; and Continue to maintain links with the Kwinana Noise Reference Group through the Kwinana Industries Council (KIC) to ensure noise from Alcoa is appropriately managed.
water management and conservation
Alcoas Kwinana renery is located on Cockburn Sound therefore our rening process does not discharge process water either as cooling water or as efuent.
water management and conservation

Alcoas Kwinana renery commits to the following water management and conservation targets as part of this EIP: Reduce the potential for impacts from renery groundwater outside the Alcoa property. Reduce the existing contamination under the renery and adjacent property. Reduce the plumes in the area around Area F to minimise impact on groundwater. Increase contaminated groundwater recovery capacity at residue areas A B and C. Reduce the risk of groundwater contamination from existing containment facilities including existing renery to residue area pipeline containment facilities. Identify alternative industrial water uses and supplies to minimise high quality water use.
As part of our environmental stewardship, Alcoa is focused on developing better ways to ensure a sustainable future. We are committed to using fewer resources, protecting resources for which we are responsible, reducing our emissions and wastes and reusing and recycling materials. We are actively working to conserve water.
22
Water supplies for the Kwinana renery are obtained by water recycling, rainfall harvesting, groundwater extraction (under licence) and scheme water purchased from the WA Water Corporation. Kwinana renery operates a closed water circuit. Rainwater runoff from the renery operational areas and the residue areas is captured and reused. The renery process does not discharge process water either as cooling water or as efuent. Process water losses are through steam, evaporation and water leaching from residue. During winter, clean stormwater from carparks and roof tops may run off to Cockburn Sound. A signicant amount of process water is gathered through rainfall catchment from the renery and residue facilities. Approximately half of the bore water for the renery is drawn from groundwater recovery bores, the other half is fresh groundwater drawn from production bores. Alcoa purchases potable water from the Water Corporation, however strategies are in place to keep high quality water use to a minimum. Future alternatives to reduce potable water usage include the use of lower grade water and alternative water sources such as waste water reuse. Kwinana renery has committed to reduce high quality water usage by: Reviewing options for the use of secondary and tertiary treated water for use in the renery process; and Developing a water use strategy that focuses on water source alternatives and reuse efciency. As the Kwinana renery is located on the coast of Cockburn Sound, discussions with EIP Working Group members highlighted a concern regarding a saltwater wedge moving eastward from the ocean into the groundwater reserve. Alcoa has agreed to raise with the Kwinana Industries Council and appropriate State Government departments the communitys request for a review of the movement of the saltwater wedge in this region.
Groundwater Protection
In 1963 Alcoa began operating the Kwinana renerys original Residue Disposal Areas (RDAs) A B and C in Naval Base. These earliest RDAs were constructed to engineering standards of the day with each RDA lined with a clay seal. In the early 1970s it was determined the clay seals were not satisfactory. Alkaline seepage was found under the original RDAs and under the rst section of the current RDA in Hope Valley Area F. Alcoa recognises proactive management of groundwater is an important feature of our environmental management program and is required to deal with this serious environmental issue for the renery. Groundwater recovery, management and protection features prominently in Kwinanas operating licence and in all our operating practices.
In 1974 Alcoa began actively removing the alkaline liquid from within the RDAs before seepage reached the water table. A detection and repair program for leaks in the oldest RDAs was carried out between 1983 and 1999. Since 1977 Alcoa has maintained an extensive network of groundwater recovery bores to monitor changes and recover contaminated groundwater both at the residue areas and the renery. Recovered groundwater is piped to the renery for reuse. When it was determined there was some leakage in the clay liners, immediate improvements to the design of RDAs were made with the inclusion of a synthetic liner. Now all RDAs are constructed with a synthetic and clay composite liner and underdrainage system.
Spills Containment
Spill reduction and containment is vital to prevent groundwater contamination. All spills are treated seriously and fully investigated. Detailed action and remediation plans to rehabilitate a spill area are completed, as are plans to prevent a recurrence of the event.
Independent Audit
In 2004 the Department of Environment commissioned an independent audit following a series of spills at the Kwinana renery. The independent audit found Alcoas response was comprehensive and appropriate and acknowledged Alcoa moved swiftly to clean up affected areas, fully investigated all incidents and implemented corrective actions. Importantly the audit found there was no single cause to the spills. Rather a range of factors contributed to the incidents including a major power failure, human error and equipment malfunction. The audit also conrmed the actions undertaken at Kwinana along with future commitments addressed the causes of the spills. The audit report did include some additional recommendations that Alcoa has accepted and begun implementing. Extensive improvement projects were completed or are underway with a total of almost $14 million spent to upgrade equipment and containment in areas where the spills occurred.
The independent audit found Alcoas response was comprehensive and appropriate and acknowledged Alcoa moved swiftly to clean up affected areas, fully investigated all incidents and implemented corrective actions.
A comprehensive report detailing the results of the groundwater monitoring program and the amount of reclaimed contaminated groundwater from the recovery bore system is provided to the Department of Environment on an annual basis as part of our licence requirements. While the plume remains under the A B C residue disposal areas, monitoring shows it has reduced signicantly over the years. The commitments in this EIP provide additional direction to reduce existing and possible future groundwater contamination at the renery and the residue areas by: Completing a review of the groundwater monitoring program including monitoring trace elements; Reviewing options to install a perimeter, underground barrier to contain groundwater within Alcoas boundary; Increasing the renery groundwater recovery capacity; Monitoring quality of sealed areas to maintain integrity; Developing and progressing research plans for the early closure of Area F in 2010, and rehabilitation over the following years; Installing additional recovery capacity at RDAs A B C and F; and Reviewing options to resume deliquoring RDAs A B C. While it is not feasible to start removing alkaline material from Area F until 2010, the EIP Working Group members have requested their recommendation to begin deliquoring Area F as soon as possible be noted in this EIP.
Extensive improvement projects were completed or underway with a total of almost $14 million spent to upgrade equipment and containment in areas where spills occurred.
23
Further Initiatives
To reduce the risk of groundwater contamination from spills or containment facilities, including the pipeline from the renery to the Hope Valley RDA, Kwinana will: Develop and implement containment strategy that focuses on risk reduction over the next ve years with the Department of Environment; Implement a risk reduction program for high risk areas over the next two years; and Upgrade the secondary containment facilities at the renery to residue area pipeline pumping stations by the end of 2006.
Alcoas RDAs are constructed with a synthetic and clay composite liner and an underdrainage system to protect groundwater.
visual amenity and land management
Sustainable rehabilitation of the residue area embankments has included the recreation of fauna habitat.
visual amenity and land management

Alcoas Kwinana renery commits to the following visual amenity and land management targets as part of this EIP: Residue rehabilitation to focus on visual amenity and dust control as a priority, and be self sustaining in the long term. Use native vegetation complexes including conifers as part of the residue rehabilitation program to ensure self-sustaining ecosystems are developed. Continue to support wetland research and local community use.
Alcoas Kwinana renery established a Long Term Residue Management Strategy (LTRMS) Stakeholder Reference Group in 2004. The efforts of this group overlap to some extent with the efforts and input of the participants in the EIP process.
24
This Stakeholder Reference Group reviewed Alcoas LTRMS in 2004 and the EIP items in this section are based on the agreements made during that process. Some of the more signicant changes and improvements for the RDA are beyond the timeframe of this EIP, but are captured in the LTRMS and Kwinanas Land Use Management Plan (LUMP) which details the visual improvements to be made to both the renery and the residue areas.
Alcoas Wellard Wetland is a created wetland in which low value farmland used for clay mining has been rehabilitated to a 40 hectare wetland site providing habitat to more than 84 species of birds.
Through the EIP process sustainable rehabilitation of the residue area embankments was identied as the most important opportunity to improve the residue area. In addition, community members requested the long term use of the area (after rehabilitation) be determined if possible to ensure the rehabilitation process is consistent with its nal application. Dust is also an important visual amenity issue, and has been addressed in the air quality section of this document.
The Wellard Wetlands provide a unique environment where birds and the community can interact.
25
Improvements to the visual amenity of the residue area will be managed by: Reviewing the existing rehabilitation to develop and implement an annual rehabilitation rework plan to upgrade areas of existing rehabilitation to meet current standards; and Developing the residue rehabilitation research plan to focus on identifying mixes of self sustaining native species. targeting both local populations and international tourists. Alcoa is one of the partners in this project after sponsoring a very successful season of local tours in 2004. Alcoas Wellard Wetland on Mundijong Road in Baldivis, is a created wetland in which low value farmland used for clay mining has been rehabilitated to a 40 hectare wetland site. It provides habitat to more than 84 species of birds in a facility that enables the passive interaction of the community with this valuable wetland habitat. This EIP document commits Alcoa to: Include wetland research in the strategic land management program; and Work with local government and community interest groups to promote appropriate uses of these wetlands. Alcoa also owns the southern portion of Mt Brown, which is part of the Beeliar Regional Park. This area is managed in partnership with CALM which has responsibility for the northern section. Triennial monitoring of ora and fauna in the area around the renery is completed to help with the ongoing management of our land holdings. The ongoing landscaping plan for the renery includes maintaining a green belt between public roads and the renery, while native-species planting protects the foreshore dunes to the west of the renery. This has helped reduce the erosion of the beach to the west of the renery.
Native-species planting is protecting the foreshore dunes to the west of the renery and helping to reduce the erosion of the beach.
Wetland Management
The Spectacles, a natural wetland on Anketell Road in Mandogalup, is jointly managed by Alcoa with the Western Australian Department of Conservation and Land Management (CALM). It is a unique paperbark wetland, part of the Beeliar Regional Park, with a rich cultural history and highly valued in the local township. A series of aboriginal cultural displays were commissioned by CALM and Alcoa in 2001, and were installed around the northern part of the perimeter trail of The Spectacles. The Town of Kwinana, CALM and the Medina Aboriginal Cultural Community are developing a series of cultural tours
waste management
Alcoas glove recycling program has diverted 81,000 pairs of gloves from landll.
waste management
Alcoas Kwinana renery commits to the following waste management targets as part of this EIP: Continue with waste minimisation activities to identify waste to landll reduction opportunities. Implement a strategy for long-term oxalate management. Support projects to identify and research residue reuse opportunities with involvement from external bodies.
26
Alcoa recognises the Western Australian Government position of zero waste to landll by 2020 and the broader communitys efforts in reducing waste. Since 1993 Alcoa challenged employees to reduce their waste through reuse and recycling. Our goal to reduce non-process waste to landll by 50 per cent by 2007 based on 2000 levels has been a signicant driver for waste minimisation at the renery.
The Kwinana waste minimisation program was signicantly expanded in 1997 through an alliance with Cleanaway Waste Management. A simple waste separation program was introduced to encourage all employees to separate recyclables, non-recyclables and food waste. were being sent to landll each year across Western Australia. The glove reuse and recycling program diverted 81,000 pairs of gloves from landll in the rst six months. Each year the group reviews waste reduction projects for Kwinana and those being targeted as part of this EIP are: Complete assessment of recyclable canteen packaging; Work with suppliers to identify reductions in packing waste, and source recyclable supplies; and Continued work on expanding and improving the glove recycling program. Alcoa requires all companies contracted to handle our waste to undergo an audit at least every three years to ensure they meet the waste management standards and requirements of Alcoa and the State Government. Contracts are not renewed unless standards are met. In 2004 the Western Australian Department of Environments Controlled Waste Branch audited the renerys controlled waste management program. There were no outstanding issues with regard to our management of controlled wastes.
Alcoa requires all companies contracted to handle our waste to undergo an audit at least every three years to ensure they meet the waste management standards and requirements of Alcoa and the State Government. Contracts are not renewed unless standards are met.
Food waste is now sent to Alcoas worm farm at Pinjarra to be used for composting and landscaping around the renery. The worm farm started operation in 1995 and in 2004 processed almost 115,000 kg of waste from all three reneries, the two mine sites and head ofce at Booragoon. The Three-Bin System was introduced to all crib rooms, lunch rooms and kitchens across the renery. Mini-skip recycling bins have been placed in all areas of the renery and residue operations to make recycling of both small and large items easy. Each year members of the Waste Minimisation Team review the list of wastes sent to landll and investigate the recycling or reuse opportunities. For example, a glove recycling and reuse project was introduced as 350,000 pairs of gloves
Alcoas glove recycling and reuse project diverted 81,000 pairs of gloves from landll in its rst six months.
Process Wastes Synergies With Other Industries

Alcoas Kwinana renery is increasing the opportunities to reuse a large-volume solid waste. We are using waste carbon dioxide (CO2) to neutralise the alkalinity of our residue so there are more options for its future reuse. Three of these potential products are red sand, Red Lime and Alkaloam. Red sand is similar to crushed bauxite. Initial testing indicates this sand could be used as a general ll material, a construction backll or as a material suitable for road base construction. Red Lime is alkaline and therefore has great potential as an acid neutraliser. Red Lime could be more effective than most pH control products because of the ne particle size and the sodium carbonate that remains with the product.
Alcoas Alumina Technology and Development Group (TDG) along with many other industry researchers have investigated the use of natural biological processes to manage waste. A successful trial using naturally occurring bacteria to process sodium oxalate has encouraged Alcoa to propose the development of a full scale project at the Kwinana RDA. The process is natural and sustainable, and similar to composting. It is compact, has low energy requirements and removes oxalate without the use of a kiln while allowing the recovery of alkaline material. The EIP Working Group members have supported this biological process for oxalate removal, which is possible as a result of carbonation. During this EIP period and with DoE approval Kwinana will: Implement the natural bio-removal process for oxalate destruction subject to environmental approvals.
The process is natural and sustainable, and similar to composting. It is compact, has low energy requirements and removes oxalate without the use of a kiln while allowing the recovery of alkaline material.
Alkaloam is the ne-grained residue often referred to as red mud. A great deal of work has been done to show the benets of adding this material to sandy soils, which are common in coastal regions of WA. Alkaloam has properties that can raise acidic soil pH levels while retaining phosphorous and reducing overall fertiliser use. The environmental outcome is the protection of sensitive waterways from nutrient loading. Alcoa and the Department of Agriculture have investigated the possible use of Alkaloam as a soil amendment in the Peel-Harvey Catchment to reduce the impact of nutrient runoff to the Peel-Harvey Estuary. Results demonstrate phosphorous losses can be reduced by as much as 90 per cent with pasture productivity increasing by about 25 per cent. The Department of Agriculture is continuing to monitoring sites, under Environmental Protection Authority guidelines, within the Peel-Harvey Catchment which have been amended with Alkaloam. The results from these trials continue to show improved pasture productivity and reduced nutrient runoff. Alcoa and the Department of Agriculture believe Alkaloam has the potential to provide signicant environmental benet by reducing nutrient loss in agricultural regions. EIP Working Group members were supportive of Alcoa actively developing markets and uses for bauxite residue. Their strong guidance was to work towards changing pessimistic community views of residue reuse and nd or develop uses for this resource. The EIP members believed the ow on benets for the community and Alcoa would be signicant. Some of the positives include: reduced storage area and construction costs, reduced risk of contaminants to groundwater, less dust, and reduction in the long term management costs of the RDAs. The items Kwinana has committed to undertake in the timeframe of this EIP are: To work with research groups to develop markets and alternative uses for red sand; and To work with research groups to develop a project for separation and alternative use of recovered lime.
Further Initiatives
One persons waste is anothers treasure. Alcoa through its membership of the KIC is contributing to research into how Kwinana industries can achieve waste synergies. Through Curtin Universitys Cooperative Research Centre for Sustainable Resource Processing (CSRP) and the Australian Research Council (ARC) the inputs and outputs of the Kwinana Industrial Area are being analysed to identify opportunities for waste synergy. Examples of synergies already in use at Alcoa are the use of waste CO2 to reduce the alkalinity of our residue and the use of waste water from occulent manufacturing as a benecial water source.
27
A natural and sustainable process for removing oxalate is being trialled at the Kwinana renery.
alcoas community consultation process
Community involvement in the EIP process is a fundamental component of managing the Kwinana renery.
community involvement
The Kwinana renery established a Community Consultative Network (CCN) in December 1994 as a way to reach the community and better understand their areas of concern and interest. The CCN was a group of community representatives who met informally with Alcoa each month.
28
This engagement is a fundamental component of managing our operations and signicant changes. It makes us more responsive to community views and creates new opportunities to work in partnership with communities on local issues. For 10 years the CCN provided Alcoas Kwinana renery with vital community feedback and input on a range of issues and activities of mutual interest in a number of areas. Over the last ve years, membership of the CCN had been open to the local community in a voluntary capacity, and during 2003 and 2004 attendance increased signicantly. Members and regular attendees of the Kwinana CCN included City of Cockburn and Town of Kwinana councillors and ofcers, the Kwinana Progress Association, Kwinana Watch Dog Group, Conservation of Rockingham Kwinana Environment (CORKE), the Wandi Progress Association, close neighbours from Wattleup and Mandogalup, and people from as far away as Safety Bay.
It was the Kwinana Community Consultative Network who nominated and agreed on the community membership of the two EIP Working Groups involved in providing guidance for the development of this EIP.
In 2004 the DoE introduced a new initiative for WA industry to voluntarily adopt Environmental Improvement Plans. In making the decision to implement an EIP at Kwinana, Alcoa chose to follow our Victorian Operations EIP process. It was the Kwinana CCN who nominated and agreed on the community membership of the two EIP Working Groups involved in providing guidance for the development of this EIP.
Stakeholder Reference Groups are project specic and contribute over a specic timeframe and scope this provides for greater indepth involvement from the community.
29
By using this EIP process Alcoas Victorian Operations had improved their capacity to: Share information with their communities; Increase community understanding of their operations; Incorporate community sustainability considerations into decision-making; and Strengthen their links with local communities. It is hoped these successes will be replicated through Alcoas Western Australian Operations EIP process. The terms of reference for SRGs differed to that of the CCN, as the SRGs were looking at project specic information over a limited timeframe and scope. This form of community engagement followed the framework used for the Pinjarra Renery Efciency Upgrade described as benchmark by EPA chairman Dr Wally Cox. The Kwinana SRG drew members from the community (CCN), local government (both ofcers and councillors), relevant government departments and Alcoa. Group membership was set between 1012 members and the group engaged an independent facilitator. The two projects utilising SRG processes in 2004 were: The Emissions Reduction project for the liquor burner; and The review of the Long Term Residue Management Strategy (LTRMS) Both groups will continue to meet into 2006 until their terms of reference are met, at which time the groups will disband. It is anticipated that as other projects or specic issues arise the SRG process will be utilised again.
Stakeholder Reference Groups (SRG)

In addition to the CCN and the EIP Working Groups, we have built on our successful consultation processes by developing a new stakeholder engagement approach to deepen community involvement particularly for long term planning and other signicant projects. During 2004 Stakeholder Reference Groups (SRG) were introduced at Kwinana for projects requiring a more intense level of community involvement than the CCN process could provide.
environmental regulation and management
Independent consultants undertake audits of Alcoas operating locations to ensure compliance with licences and certications.
environmental regulation and management

Alcoas Western Australian Operations are subject to environmental regulation under the Environmental Protection Act 1986 and are licensed by the Department of Environment (DoE). We are committed to meeting the terms of our environmental licence and other environmental approval conditions.
30
Our commitment to the Environmental Improvement Plan 2006-07 is voluntary. It both complements and exceeds the requirements of our environmental protection licence. There are a series of checks and balances in place to ensure Alcoa meets the limits and requirements of our environmental licence. These include monitoring and reporting, auditing and inspection of operations and procedures and a process of continuous improvement. Alcoa follows the international environmental management system framework (ISO14001) to ensure we meet the requirements of our environmental licence and the commitments made in this EIP.
Environmental Protection Licence

The current Kwinana Renery Environmental Licence was issued by the Department of Environment for the period 3 September 2005 to 2 September 2006. The licence establishes the conditions for control of emissions from the renery.
Alcoas operating locations are audited every six months so there is external verication of commitments made by Alcoa through ISO14001.
The primary topics covered within the licence include: Calibration of monitoring equipment; Reporting requirements for incidents, complaints and licence conditions; Waste acceptance and management; Emissions management for calciners, powerhouse and residue areas; Air quality limits and targets; Monitoring requirements for the Environmental Protection Policy for Kwinana; Groundwater monitoring and control requirements; Liquid chemical storage controls and risk reduction; and Storage of oxalate.
Environmental Management System (EMS)

Alcoas corporate environmental management systems have been certied to ISO14001:2004 by the British Standards Institute (BSI) and each location in WA is certied to the ISO14001:2004 standard through SAI Global. ISO14001 requires each location to identify activities with the potential to signicantly affect the environment, dene the controls in place to manage those risks and develop action plans for improvement. Auditing is a systematic method to review the effectiveness of operational controls to ensure unacceptable risks to the environment are effectively managed, and to identify corrective actions and opportunities for improvement. An audit involves analysis, testing and conrmation of procedures and practices.
31
Our Western Australian Operations are externally audited every six months by SAI Global so there is external verication of commitments made by Alcoa through ISO14001 certication. In addition external re-certication to ISO14001 is required every three years and takes account continued positive environmental performance, compliance with the standard, all associated legislation and regulations and a continual improvement process.
CONTINUAL IMPROVEMENT Environmental Policy EHS Values EHS Policy EHS Principles Planning Planning for improvement processes Environmental aspects Legal and other requirements Objectives and targets Implementation and Operation Structure and responsibility Training, awareness and competence Communications EMS documentation and control Operational control Emergency preparedness and response capability
External re-certication to ISO14001 is required every three years and takes into account continued positive environmental performance, compliance with the standard, all associated legislation and regulations, and a continual improvement process.
In addition to external auditing and assessment Alcoa has an independent, Internal Audit Department (IAD) which is responsible for providing nancial, information technology, maintenance, environmental, and health and safety audits in all Alcoa locations globally. Each site is subject to an internal audit every three to ve years by a team of environmental specialists from other Alcoa locations through the IAD.
Management Review Review the EMS and compliance audit results Ensure the EMS continues to be suitable, adequate and effective. Review progress and results Document the reviews
Checking and Corrective Action Monitoring, measurement and reporting Non-conformance corrective and preventative action Records EMS and compliance audits
The fundamentals of ISO14001 are based on the basic plan, implement, check and review cycle.
national pollutant inventory
Monitoring, reporting, auditing and inspections ensure a process of continuous improvement at Alcoas operating locations. The data provided to the National Pollutant Inventory is collated through these processes.

The National Environment Protection Council (NEPC) launched the National Pollutant Inventory (NPI) early in 2000. It is intended to enable our communities to make better-informed decisions and to become more active participants in environmental management by providing data on the amounts of emissions to the environment in which we live and work.
32
The NPI is published as a database on the Australian Governments Department of the Environment and Heritage website www.deh.gov.au This database contains information about emissions from sources similar to our own operations, and the EPA estimates of emissions from smaller business activities such as petrol stations, dry cleaners, fast food outlets, and other sources including transport, home heating and cigarette smoking. The aim is to satisfy community demands for this information and to assist governments and industry with environmental planning and management. Emissions to air, land and water are included. Alcoas Kwinana renery reports to the NPI annually and gures from 2002, 2003 and 2004 reporting periods are available on the NPI website www.npi.gov.au The website is updated each January. To help people understand what NPI data means, the Department of the Environment and Heritage has provided some contextual information. The aluminium industry has added further information, which can be found on the Australian Aluminium Council website: www.aluminium.org.au
There is also an industry contact for comments about the NPI or for any further questions about the data shown: aac@aluminium.org.au Other environmental links of interest are listed below: Department of the Environment and Heritage www.deh.gov.au Australian Greenhouse Ofce www.greenhouse.gov.au Minerals Council of Australia www.minerals.org.au Western Australian Department of Environment www.environment.wa.gov.au Western Australian Environmental Protection Authority www.environment.wa.gov.au Centre for Excellence in Cleaner Production www.cleanerproduction.curtin.edu.au Greening Australia www.greeningaustralia.org.au
Out of a total of 90 reportable compounds on the NPI list, Alcoas reneries in WA were required to report for 26.
33
Alcoa World Alumina Australia Western Australian Operations 2004 NPI Data
Alcoa continues to improve monitoring and measurement technologies to accurately report substances to the National Pollutant Inventory (NPI). We are committed to sharing data and information on emissions performance with the Australian community. During 2003-2004, Alcoa focused on our comprehensive emissions inventories, particularly for alumina rening in WA. Out of a total of 90 reportable compounds on the NPI list, Alcoas reneries in WA were required to report for 26, bauxite mining reported on 18 and our operations in Victoria/New South Wales reported on 26 compounds on the NPI list. In Western Australia, emission reduction projects at the Wagerup renery contributed to a decrease in formaldehyde and VOCs emissions, while improvements in the efciency of powerstation burners at Pinjarra reduced carbon monoxide emissions. Renery emissions of several other compounds increased because we used diesel for power generation during a gas shortage in order to divert the gas to the state power utility. This resulted in increased emissions of arsenic and selenium. The bauxite mining operations increased emissions of a number of compounds because an increase in the mining rate and construction of the new McCoy crushing plant increased dust production. In addition, carbon monoxide emissions were increased by more machinery activity and diesel consumption. In Victoria, a targeted uoride reduction program at the Point Henry smelter, including changes in operating practices and installation of state-of-the-art monitoring equipment, delivered a signicant reduction in uoride compound emissions. Metal compounds at the smelters were reported for the second year, with some variations in estimated emission levels compared to the previous report. Such changes can be expected because there is a lower level of accuracy when very low concentrations of a compound are detected in conjunction with very large volumes of air, as is found in parts of the smelters. A variety of substances reported by Alcoa Australia Rolled Products varied substantially from previous years. At Yennora, monitoring is undertaken once a year, resulting in variations from test period to test period. As part of our commitment to continuous improvement, testing will be increased to gain a more accurate representation of emissions. Similarly, the majority of signicant changes, both increases and decreases, in emissions at Point Henry rolling mill resulted from changes in data collection and analysis methods.
National Pollutant Inventory data for Alcoas operations in Australia for 2003-04.
Units acetaldehyde acetone ammonia arsenic and compounds beryllium & compounds cadmium and compounds carbon monoxide chlorine chromium (iii) compounds chromium (vi) compounds cobalt and compounds copper and compounds uoride compounds formaldehyde hydrochloric acid lead and compounds magnesium oxide fume manganese and compounds mercury and compounds methanol kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg kg
Bauxite Mining
Alumina Rening 53,000 190,000 71,000
Aluminium Smelting
Anglesea Power
Alcoa Australia Rolled Products
200 2.8 3.2 410,000
470 2.9 150 2,400,000
113
21 18
3.1 3.1 0.71 1,258,000 240
29 63,000,000
6.8 74,000
2,000 4 13 210 4,000
1,100 1
300
180 0.011
20.4 15.2
130 4,400 52,000
306 250,000
47 1,100
11.9 1,100
190,000 260 120 355 590 1,600 0.61 1,600 1,000 2.7 26
3,660 3.1 486 77.2 0.11 170.7
34
methyl ethyl ketone nickel and compounds nickel carbonyl oxides of nitrogen particulate matter (PM10) phosphoric acid polychlorinated dioxins & furans polycyclic aromatic hydrocarbons selenium and compounds sulphur dioxide sulphuric acid toluene total volatile organic compounds xylene zinc and compounds
29,000 36 110 1,900 140
160 19.3
980,000 2,100,000
4,300,000 1,400,000
320,000 213,000
3,800,000 340,000
128,000 18,800 5.5
0.00108 820 180 25,000 180,000
0.00003 38,000
0.00097 0.94
0.0000150073 79
10,600,000
41,000,000
27,700
10,000 77,000 420,000 56,000 26,000
1,200 120,000 320
220
760
Glossary of abbreviations and terms

Ambient CALM CCN CO CO2 The surrounding environment. Department of Conservation and Land Management. The state government agency responsible for protection of forested areas and rare or endangered ora and fauna. Community Consultative Network. Community based consultation committee. Carbon monoxide (a typical product of combustion as well as a greenhouse gas) Carbon dioxide (a greenhouse gas). Occurs naturally in the environment and is a product of complete combustion (burning) of carbon containing materials such as natural gas. Levels normally present in the atmosphere are unlikely to cause ill effect. People can be exposed to CO2 by smoking, using malfunctioning equipment such as gas water heaters, fuel red heaters, replaces and woodstoves, gas stoves, gas dryers, charcoal grills, and using poorly vented automobiles. Extraction of free liquid from within existing residue disposal areas by drains or pumping systems. Department of Environment (Western Australia). The state government agency responsible for regulation of industry from an environmental protection perspective. Parts of the DoE regulate industrial discharges (licensing). Technical professionals in the DoE (e.g air quality specialists) also advise the EPA in the assessment of projects. Department of Industry and Resources, (Western Australia). Environment, Health and Safety. Environmental Improvement Plan. Environmental Management System. A system of policies, planning processes and procedures put in place by the company to aid the management of the environmental aspects of its operations. Environmental Protection Authority (Western Australia). Independent ve-person board established to assess the environmental impact of signicant proposals to ensure unacceptable environmental impacts do not occur. Gases that contribute to global warming such as carbon dioxide. These gases trap the radiant heat of the sun, allowing less of the radiation to be reected back into space. High-volume. Usually used in relation to Hi-Vol dust samplers, which quickly draw large volumes of air through a lter paper so the amount of dust carried in the air can be measured. Health Risk Assessment; also called Quantitative Health Risk Assessment (QHRA). A risk assessment process (and report) that compares the amount of individual and combined chemical emissions against internationally accepted health criteria. This examines the risk of exposure at 1-hour and lifetime scales. This includes an assessment of life-time risk of contracting cancer from the emissions. Will be a specialist study undertaken by a suitably qualied consultant. International Standard for environmental management systems (EMS) and a framework for the overall management of environmental issues at an operation. All Alcoas Western Australian Operations have been ISO14001 accredited. Kwinana Industries Council. Representative body for the industries located in the Kwinana Industrial Area (KIA). Liquid Natural Gas. Long Term Residue Management Strategy. This is the 2530 year plan prepared by Alcoa to show where and how the Residue Drying Areas (RDAs) will be located in the future. National Environmental Protection Council. Sets some national environmental standards and guidelines, such as air quality NEPMs. National Environmental Protection Measure. A national guideline prepared by the NEPC. NEPMs exist for some air quality parameters. Oxides of nitrogen including nitrogen oxide and nitrogen dioxide. Most people are exposed outdoors to low levels of oxides of nitrogen from a variety of combustion processes. These include: tobacco smoke, car and power plants, and some welding operations. People living near industries that produce oxides of nitrogen, or near major transport routes may also be exposed to higher levels in the surrounding air. Nitrogen dioxide. National Pollutant Inventory. A public document (web-based) that lists the estimated amount of various pollutants released by industry and other sources on an annual basis. Polycyclic Aromatic Hydrocarbons. Group of over 100 chemicals. PAHs are formed by the incomplete combustion of coal, oil, petrol, wood, tobacco, charbroiled meats, garbage, or other organic materials. There are a wide range of sources that produce particulates or dust and exposure will occur even in pristine environments. Exposure may be higher in urban and industrial areas due to an increase in the number of sources, however high levels may also occur in natural environments. Examples include lawn mowing, wood stoves, res, cigarette smoke, and wind generated dust though this tends to be coarser. Fine secondary aerosols generated as part of smog and some forms of winter-time haze will register as PM10 and PM2.5.
Deliquoring DoE
DoIR EHS EIP EMS EPA
Greenhouse gases Hi-Vol, HRA
35
ISO14001
KIC LNG LTRMS NEPC NEPM NOx
NO2 NPI PAH Particulates
Glossary of terms and abbreviations
Groundwater Plume PM10 PM2.5 RDA RPLG
Localised area of groundwater that has been affected by Alcoas operations, which is indicated by pH and/or alkalinity above background levels. Particulate matter with an aerodynamic particle diameter of less than 10 microns. This is a measure of part of the total dust emissions from Alcoa operations and/or other sources, includes the PM2.5 component. Particulate matter with an aerodynamic particle diameter of less than 2.5 microns. This is a measure of part of the total dust emissions and does not include all of the PM10 component. Residue Drying Area. These are often termed mud lakes and are the large areas where the bauxite residue (red mud) is deposited, dried and stacked. Residue Planning Liaison Group, which consists of representatives from the DoIR, DoE, Department of Planning and Infrastructure, Peel Development Commission, local government and Alcoa. The RPLG and the Minister for Environment assess the LTRMS. Sulphur Dioxide is predominantly emitted by the combustion of fossil fuels containing sulphur or sulphur compounds by large industries such as power stations, wood pulping, petroleum production and metal smelting. Natural sources of SO2 can be volcanic eruptions and the decay of vegetation. In high concentrations SO2 has a pungent odour and irritates the human respiratory system resulting in coughing and a heavy chest. Stakeholder Reference Group. A stakeholder-Alcoa-government consultation group. SRGs are working on the Pinjarra Efciency Upgrade implementation and Kwinana liquor burner assessment. Both cases have roles very similar to the working groups for the Wagerup Unit 3 proposal. Total Suspended Particulates, a measure of mass of total airborne dust. Includes suspended particles of aerodynamic diameter 50 microns and smaller, therefore includes PM10 and PM2.5. Particles greater than 10 and less than 50 microns are of most interest from a dust nuisance perspective. Volatile organic compounds, being those organic compounds that have high volatility, or evaporate readily under normal atmospheric conditions. Includes such chemical compounds as Formaldehyde, aromatic compounds and other aldehydes and ketones. These compounds are usually considered to be responsible for the odours emitted by parts of Alcoas reneries, such as the wet cement smell people notice. VOCs are released from a wide range of industrial processes. The major point sources of VOCs in Australian cities are petrol rening and fuel storage, and manufacturing industry. Petrol stations are signicant emitters of VOCs. VOCs can also be released from common household items such as painted surfaces, carpets, varnishes, cleaning products, disinfectants and cosmetics. Working groups have been formed as the key community consultation forum to advise Alcoa on aspects of its operations. They have been established for the areas of: emissions and health; noise and transport; residue and water; social and economic and land management.
SO2
SRG
TSP
VOCs
Working Group
36
Units of Measurement
A$ dB dB (A) C ha km kL mm m m2 m3 m/s MJ MW ML ML/yr MLpa Mt Mtpa ppm ppb g g/m3 m t tph tpa vol/vol % Australian dollars decibels decibels (A-weighted) degrees Celsius hectares kilometres kilolitres millimetres metres (length) square metres (area) cubic metres (volume) metres per second mega joules mega watts megalitres megalitres per year megalitres per annum megatonnes megatonnes per annum parts per million parts per billion micrograms (one-millionth of a gram) micrograms per cubic metre microns (or micrometers, one-millionth of a metre) tonnes tonnes per hour tonnes per annum volume/volume (usually concentration measure such as % or ppm) per cent
we welcome your feedback

Kwinana Refinery Environmental Improvement Plan Feedback
We regard community engagement and external input as a most important part of our EIP. In order to allow us to further improve on the content and development of our EIP, we would greatly value your thoughts and feedback. Please take the time to consider the following points and feel free to add any additional comments as you feel necessary. Were you satised with the information contained in the EIP?
1 = not satised
2 = somewhat satised
3 = satised
4 = exceeded expectations What information did you nd useful?
What information would like to see included in future?
Was the EIP easy to read/follow?

1 = it was difcult to read/follow
2 = some areas were easy to read/follow
3 = most areas were easy to read/follow
4 = it was easy to read and follow Please explain why you thought this.
37
What would make the EIP easier to read/follow in the future?
we welcome your feedback
Did the EIP give you a better understanding of environmental initiatives at Kwinana renery?
1 = no it did not improve my understanding
2 = it detailed environmental initiatives, but I did not learn anything new
3 = it improved my understanding of environmental initiatives
4 = I feel condent to discuss the quality of environmental initiatives at Alcoas operations Please explain why you thought this.
What would you like to see included in future?
Would you consider being involved in the Alcoas community engagement processes in the the future? Yes
No
Are you happy for Alcoa to contact you regarding your comments or specic query? Yes
No
Would you like to receive regular information from Alcoa? Yes

No
38
Name: Phone: Address: Email: Further comments:
Please fax back your comments to: Community Relations Ofcer Alcoa World Alumina Australia Kwinana Renery Fax: (08) 9410 3164 or post to: PO Box 161 Kwinana WA 6966
39
environmental areas/kwinana
40

Kwnina

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Kwnina

Încărcat de

Drepturi de autor:

Formate disponibile

kwinana

ENVIRONMENTAL IMPROVEMENT PLAN 2006-07

West Australian Operations

Alcoa World Alumina Australia Kwinana Renery environmental areas/kwinana

Alcoa World Alumina Australia environmental Kwinana areas Renery

Environmental Improvement Plan 2006-07

Raphael Costa Vice President Operations Alcoa Global Rening

Arnaud Soirat Manager Kwinana Renery

Environmental Improvement Plan 2006-07

Glen Bersan Kwinana Councillor

Rod Pattinson Kwinana Councillor

Hugh DeHaer Hope Valley Community

Julie Baker Cockburn Councillor

Lance McGlinn Hope Valley Community

Emma Jones DoE Representative

Les Egerton DoE Representative

Chris Oughton Kwinana Community

Janet Moore Wattleup Community

Mark Hector Hope Valley Community

Nola Waters Naval Base Village

Stan Elms Hope Valley Community

Lorraine Valli Hope Valley Community

Ron Kimber Beeliar Community

Jim Limerick Director General Department of Industry and Resources

Peter McKenzie Kwinana Environmental Health Services Manager

Nick Jones Kwinana Environmental Health Ofcer

Garry Taylor Employee Representative

John Hardy Cockburn Principal Environmental Health Ofcer

Principal operations within Western Australia

Principal operations within Victoria

Principal operations within New South Wales

Yennora Rolling Mill

Environmental Improvement Plan 2006-07

Kwinana Refinery Overview

Aluminiumpart of everyday life

how aluminium is made

how aluminium is made

DARLING RANGE BAUXITE 7 TONNES BAUXITE

CHEMICAL FEED STOCK

ROLLING MILL 1 TONNE CAN SHEET

EXPORT CAN SHEET

From bauxite to versatile metal.

Environmental Improvement Plan 2006-07

aluminiumpart of the solution

aluminum part of the solution

Aluminiumpart of the solution

Environmental Improvement Plan 2006-07

Environmental Improvement Plan 2006-07

targets and actions

targets and actions

Environmental Improvement Plan 2006-07

Air Quality Management refer page 16

Gas Emissions, Greenhouse Gases, Odour

targets and actions

Water Management and Conservation refer page 22

Environmental Improvement Plan 2006-07

Waste Management refer page 26

air quality management

The Kwinana renerys powerhouse is a source of nitrogen oxide.

air quality management

Volatile Organic Compounds (VOCs)

Environmental Improvement Plan 2006-07

Map: Indicates location of dust monitoring sites marked by pink squares.

air quality management