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Written by Enviroadmin
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Monday, 24 May 2010 22:51 |
Wild Coast conservation gets R46m UN injection
By Guy Rogers Environment & Tourism Editor - The Herald
CONSERVATION and ecotourism on the Wild Coast have received a huge boost in the form of a R46-million donation from the UN Development Programme.
Project co-ordinator Xolani Funda said the money would be channelled through the World Bank‘s global environmental facility to the Eastern Cape Parks Board in a five-year project, and the board would use the funds to improve the management capacity of all the conservation agencies in the area.
Besides the Eastern Cape Parks Board, the other conservation agencies in the area include the water affairs and forestry department and the marine and coastal management directorate of the national environment department. Then there are eight local municipalities from the Kei River in the south to the Mtamvuna River in the north, on the border of KwaZulu Natal: Mnquma, Mbhashe, King Sabata Dalindyebo, Nyandeni, Port St Johns, Ingquza and Mbizana.
Strengthening the conservation units in each of these municipalities would be an important focus, Funda said. One of the anticipated outcomes was that conservation would feature more strongly in the integrated development plans established by these local government bodies.
Another possible focus was the issue of protected areas within communal land, and the board‘s flagship Mkambati Nature Reserve would be receiving considerable attention, he said.
The launch of the new project follows on the completion in 2005 of several studies commissioned by the government and undertaken by the Wild Coast Conservation and Sustainable Development Project, overseen by the Wilderness Foundation.
Funda said that while he was aware of other land-use development proposals considered in the studies, like the Wild Coast N2 and dune mining, his team would be focusing on conservation and would not be getting involved in the options debate.
Wilderness Foundation director Andrew Muir said he believed the launch of the project would be a key step in strengthening the case for ecotourism as the appropriate development option on the Wild Coast.
“It will put another layer in place which will support this approach.
“There is a fantastic opportunity here to create islands of excellence around Mkambati and the other provincial reserves (Hluleleka, Dwesa/Cwebe and Silaka) on the Wild Coast and to link them in a conservation corridor,” Muir said.
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Written by Enviroadmin
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Monday, 24 May 2010 22:51 |
Materials, Substances, Wastes and Gases
What are the main emissions that come from the aluminium smelting process at Hillside?
Hillside Aluminium uses the Hall-Héroult process and Pechiney Technology (AP-30 electrolytic pots) to produce aluminium from alumina by electrolysis. The major emissions which are contained, treated and monitored are:-
Solid Particulates
These include carbon, alumina (aluminium oxide), fluorides and condensed hydrocarbons.
Carbon Dioxide and Carbon Monoxide
These gases are generated during the electrolysis process as the carbon in the anode reacts with oxygen in the molten electrolytic liquid.
Gaseous Fluorides
These have evaporated from the molten electrolytic liquid.
Sulphur Dioxide
Sulphur dioxide is generated during the anode oxidation (as above) and during the baking of the anodes before they are used in the pots.
What is sulphur dioxide?
Sulphur dioxide (SO2) is a colourless, acrid gas formed by the burning of sulphur or sulphur-containing substances such as coal, coke and oil. It readily combines with water to form a mild, acidic solution, which may result in so-called, acid-rain. Hillside Aluminium releases SO2 as a result of the sulphur contained in the petroleum coke that is used in the reduction process. Sulphur dioxide is a natural substance which is also released in vast quantities during volcanic eruptions. Sulphur is an important micro nutrient for plants but as soon as its concentrations reach beyond tolerance levels, it becomes toxic and dangerous to most living things. Sulphur dioxide can aggravate the state of health of those people with existing health conditions such as asthma, bronchitis, emphysema and other respiratory complaints.
What is dross?
Dross (essentially oxidised aluminium) is the name given to the "skimmings" on the surface of molten aluminium which is removed because it contains impurities which can affect the final quality of the aluminium metal after smelting. Dross is further treated to remove the aluminium content.
What is alumina?
Alumina is the name given to the raw material, aluminium oxide, which is used in the smelting process to produce aluminium.
What is bath?
Bath, also described at other stages as electrolite, is the name given to the electrolitic medium (molten cryolite, alumina and aluminium fluoride which create the conditions to produce molten aluminium) within the pot. The substance is constantly changing as alumina and aluminium fluoride is added to the pot and aluminium is being produced.
What is petroleum coke?
Petroleum coke is the main carbon source for the anode blocks. It is imported from overseas and is made from oil derivatives which are regarded as a waste product by oil refineries.
What is pitch (or its correct name "coal tar pitch")?
Pitch is a heavy, sticky, tar-like substance also made from the remnants of oil after refining. It is used to bind together the carbon in the anode blocks, prior to baking.
What is an anode?
An anode is the name given to a positive electrode in a reduction cell. The anode used in the aluminium industry provides the positive electrical contact as well as the carbon for the reduction process. This process uses electrical energy to break the aluminium and oxygen bonds, which results in liquid aluminium. The anode assembly consists of a T bar with a baked carbon block attached which conducts current through the "pot" to smelt the aluminium.
What is a cathode?
A cathode is the negative electrode at the base of the pot, that provides the negative contact in the reduction cell. The electrical current passes through the electrolyte in the cell, creating heat which keeps the electrolytic medium in a molten state. The energy from the electrical current breaks the aluminium oxide's chemical oxygen bonding which is part of the process of separating (or smelting) the aluminium metal.
What is a reduction cell or "pot"?
A reduction cell or "pot" is a steel container within which the electrolysis process of producing molten aluminium occurs. Reduction cells or pots are arranged in long buildings called "potrooms". Each pot or cell consists of a steel shell which is lined with carbon blocks and refractory bricks. The carbon blocks form the cathode. Suspended above the pot are carbon blocks which act as anodes and complete the electrical circuit allowing energy to flow through the cell and cause the action which results in the production of molten aluminium.
What is cryolite?
Cryolite, which is the main component of the bath, representing 80% of it's composition. The substance is a compound of aluminium fluoride and sodium fluoride.
What is carbon? (in the context of aluminium smelting)
Carbon is used in the anode to facilitate the electrolysis process. The carbon consists of petroleum coke and coal tar pitch which is mixed together and baked into a solid block in an anode baking furnace. The carbon in the anode blocks “wears out” (i.e., is consumed in the electrolysis process and released as carbon dioxide (CO2) gas over time) and approximately every 27 days, the anode blocks must be removed and replaced. The used blocks are taken for reprocessing and the remaining carbon is recycled onto new blocks.
Process
Operations
How do you produce aluminium?
Hillside Aluminium uses the Hall-Héroult process to produce aluminium from alumina by electrolysis. A large steel container called a "pot" is lined with refractory bricks and carbon blocks (which serve as the cathode or negative electrode). Suspended above the cathode are anodes (positive electrodes). Electric current is passed through the anodes to the cathode. The current heats up the materials between the anode and cathode creating a molten liquid with a surface "crust" which acts as a crude "lid". The molten liquid (at about 960ºC) consists of molten aluminium, cryolite, aluminium fluoride and alumina. Alumina, and aluminium fluoride are periodically added and molten aluminium is frequently poured off. Gases (and some particulates) such as hydrogen fluoride, carbon dioxide, carbon monoxide, sulphur dioxide and condensed hydrocarbons are released. Most of these are captured above the pots and taken to a Gas Treatment Centre which removes the majority of fluorides and particulates before releasing the remaining gases to the atmosphere.
What is the difference between smelting and melting?
The words are used widely and often incorrectly. In the context of the Hillside operation, smelting describes the reduction of alumina to pure aluminium metal and melting describes the next stage of changing the aluminium, in the form of ingots, to products or intermediate products (e.g. rolls of aluminium foil, round aluminium blanks for stamping into pans, etc.).
Where does the sulphur dioxide originate from in the process?
Petroleum coke and coal tar pitch both contain sulphur which coverts to sulphur dioxide during the smelting process. Sulphur dioxide emissions are influenced by the sulphur content of petroleum coke and coal tar pitch. Limitations in this respect are the availability of low sulphur supplies and the price thereof. Currently, sulphur content is a maximum of 0.6 % in pitch and 3.5% in petroleum coke.
Electricity
How much electricity do you consume?
At present, Hillside Aluminium consumes more electrical power (850MegaVolt Ampere (MVA)) than that of the cities of Port Elizabeth and East London combined. It has been calculated that if the expansion goes ahead, the consumption will rise to approximately 1,100 MVA. (Both the Durban and Cape Town Greater Metropolitan areas consume over 1,500 MVA each.)
Will the expansion require additional Eskom power lines?
No. The existing power lines are operating below their maximum capacities and the expansion's additional electricity requirements can be comfortably met without the need for additional, or upgrading of, power lines.
Have you considered the environmental impact of the generation of the electricity that you consume?
Not directly. This was originally considered by Eskom when carrying out the EIA for the power lines that they built to supply the original plant. Eskom also carried out EIA's on the means of generation of their electricity.
Transport
Will more conveyor belts be needed to get the raw materials to the plant?
No. The existing conveyor belts have the spare capacity to bring in the extra requirements. The belts will just operate for longer periods of time than they do presently.
Will there be more trucks transporting molten aluminium between Hillside and Bayside?
Yes. Currently, about 20,000 tons per annum are moved from Hillside to Bayside and the expansion will result in an increase to 100,000 tons per annum. At present, there are about five trucks per twenty four hour period moving between Hillside and Bayside. The expansion will result in an increase in traffic to one truck per hour, twenty four hours per day.
Will there be an increase in the number of trucks taking aluminium ingots from Hillside?
Yes, there will be an increase from 44 to 63 trucks leaving Hillside every twenty four hours, if the expansion is approved.
Will the extra trucks cause traffic congestion?
It is unlikely as the trucks are few in number and spaced apart. Consideration will be given to avoiding travel at rush hour peaks in the morning and afternoon. In any event, this will be looked at in more detail during a traffic study to be conducted as a part of the feasibility study.
How will the impact of the additional traffic be considered?
During the EIA and the Feasibility Study, a specialised traffic study will be undertaken if necessary to evaluate the impacts of the additional traffic on the roads and the environment.
Wastes
What are the main wastes produced by the plant?
Wastes (excluding gaseous emissions) include spent potlinings, domestic waste, process waste water, site stormwater runoff, miscellanoeus industrial waste (wood, metals, etc) and laboratory wastes.
What are spent potlinings?
The steel shell of the pot is lined with refractory bricks (to insulate the heat and prevent damage to the steel shell) and carbon blocks (which form the cathode) which together is called the potlining. During the lifetime of the pot, the continuous flows of molten bath or cryolite cause some ingredients and by-products to diffuse ("soak in") into the refractory bricks and the carbon. Eventually, this can cause the materials to double their weight and begin to distort in the pot which then needs to be replaced. These materials, known as spent potlinings, must be disposed of.
How often are spent potlinings generated and in what quantities?
A potlining has a life span of about 5 years, after which the spent potlinings are broken out, the steel shell relined and the pot returned to the potline. Under normal operating conditions, Hillside will rotationally replace 12 pots per month. These weigh approximately 80 tons each which equates to 11,520 tons of spent potlinings per annum. As Hillside is approaching its first major period of replacement since commissioning, about 2000 tons per month will be replaced until January 2003. Thereafter, this will drop down to 1000 tons per month when the rotational cycle continues.
Can the spent potlinings pollute the environment?
The effluent from spent potlinings can pollute the environment due to the cyanide and fluoride content. In addition, hydrogen and methane gases (both of which are potentially explosive) can be emitted. For this reason, the waste must be stored in dry, watertight and well ventilated buildings. Mixing spent potlining with water is prohibited by law.
Can the spent potlinings be used for anything useful?
To render the cyanide content harmless, the spent potlinings must be subjected to temperatures in excess of 550°C. The kilns and furnaces used by the cement industry are perfectly suited for this. Refractory spent potlinings are recycled by the cement industry through being added to raw materials used to manufacture cement and the carbonaceous spent potlinings (the cathode material) are mixed with the coal used to fire the kilns in the Lime industry.
Do spent potlinings pose a threat to health?
Spent potlinings are stored in a custom built, 12800 cubic metre, watertight building which is ventilated. As long as the materials remains dry, there is no threat. Spent potlining dust can be harmful unless personnel working with the materials wear appropriate personal protective equipment (respirators, safety glasses, gloves and overalls) and use barrier creams where necessary.
Do you have temporary and permanent disposal options for spent potlinings?
Spent potlinings are currently stored in a custom built building designed for that purpose. Hillside is about to enter into a long term contract with a cement manufacturers for the recycling of the spent potlinings. Tests are under way with the steel and brick industries for them to also recycle the material in their processes.
What safeguards exist to prevent pollution resulting from their disposal?
There is a third party monitoring programme under way to ensure that emissions remain within acceptable limits. However, from a legal point of view, Hillside will continue to have a co-responsibility with the cement manufacturer for the safe management and ultimate disposal of the material.
Health and Environment
Health
How does sulphur dioxide affect human health?
There is very little evidence to suggest that sulphur dioxide directly affects non-smoking healthy humans, unless it is in abnormally high concentrations. In lower concentrations, it has the ability to aggravate existing respiratory conditions such as asthma, emphysema, bronchitis, and sinusitis. In extreme conditions, it can cause extreme respiratory distress and result in heart failure. The acidic nature of the gas has an irritant effect at lower concentrations which can cause infections of the respiratory tract and general discomfort, mainly of the nose and throat.
How do fluorides and hydrogen fluoride affect human health?
Fluorides are found everywhere throughout the environment but at very low levels that are not believed to be harmful and may even be beneficial. With current control levels at Hillside, levels of hydrogen fluoride are unlikely to significantly affect human health beyond the boundaries of the site. There are four Gas Treatment Centres which remove fluorides from the air evacuated above the pots. Within the plant where hydrogen fluoride concentrations are orders of magnitude higher than the surrounding area, employees work within strict procedures and controls to minimise unnecessary exposure, use appropriate personal protective equipment and are subject to regular health checks.
Do fluorides and hydrogen fluoride cause cancer?
Fluorides and hydrogen fluoride have not been classified for carcinogen effects. Studies in people have not shown fluorides to be carcinogenic whereas results from studies in animals and insects have been inconclusive. Research is continuing.
How do particulates affect human health?
Particulates have a strong irritant effect and long term exposure to particulates, especially when they are very small, can result in lug infections and lung disease. Efficient control of particulates at source through filtration and "scrubbing", has a drastic effect on reducing impacts.
What controls exist for safe levels of fluorides in the workplace and how do your emission levels compare with international health standards for fluorides?
Hillside Aluminium has a strict Occupational Health programme which includes provision for correct and appropriate personal protective equipment, on-going training and reinforcement, workplace monitoring and access to a fully equipped clinic on site with a doctor in regular attendance. Workplace standards compare favourably with international practice. International benchmarking checks of operations, standards and performance indicate that Hillside is performing reasonably well (most of the international operations are worse than Hillside and a few that are performing better) but can still aspire to beat the performance of the top international operations.
Do the processes at Hillside affect worker health?
Hillside has a number of processes which can potentially affect worker health if not managed professionally. Dust and gaseous emissions have the potential to be dangerous to workers. However, Hillside has an effective occupational health and safety programme which ensures that worker exposure to harmful substances is minimised through proper procedures and appropriate personal protective equipment.
Are any of the substances that you use carcinogenic?
Yes, the coal tar pitch volatiles are known carcinogens. Workers involved with the pitch use work procedures and personal protective equipment designed to reduce risk of exposures to the pitch which could result in health problems. A medical surveillance programme is also in place to specifically monitor the health status of workers dealing with pitch. There are no volatiles that could escape the boundaries of the site and therefore there is no carcinogenic risk from coal tar volatiles to the community outside the site.
Does working in the smelter cause asthma?
There is some evidence that uncontrolled exposure to the potroom atmosphere can induce asthma in certain individuals. The exact nature of the sensitivity, or cause thereof, within individuals has not yet been clearly identified. This phenomenon is being closely monitored and research is on-going. Any individuals found susceptible are withdrawn from the exposure areas until the condition disappears.
Do the fluoride emissions from the plant cause asthma?
Nobody outside of the boundaries of Hillside can get occupational asthma. It is also highly unlikely that anyone would get asthma as a result of hydrogen fluoride exposure from the plant. Tests have determined that atmospheric concentration generally drop significantly beyond the boundaries of the Hillside site to levels where they are too low to have any significant impact upon humans. The role of industry in the rising incidence of asthma in urban populations is under debate and study but at this time no specific cause has been established.
Can asthma or other illnesses be caused from sulphur dioxide emissions from the plant?
Under certain climatic conditions e.g. winter inversions at certain times of the year, some individuals with respiratory sensitivities might find that increased SO2 levels aggravate their conditions. The Richards Bay Clean Association is measuring and modelling SO2 emissions and climatic conditions to ultimately provide guidelines to industries in the area on the management of SO2 emissions under problematic climatic conditions.
What is a Health Risk Assessment?
A Health Risk Assessment is a study which evaluates the risk to human health of exposure to certain activities and substances where those exposures will be in varying quantities and concentrations, over varying lengths of time. An important factor in the study is consideration of the toxicity of the substances, the degree and type of exposure and the need for such exposure. The goal of the study is to assess the desirability of exposure and whether or not it is possible to “plan” exposures to minimise short, medium and long term risks to health. Health Risk Assessments can have different levels of detail. A Preliminary Health Risk Assessment is the broadest analysis and could be described as a screening method. This assessment looks only at existing research literature data and does not include original site-based research data. A Detailed Generic Health Risk Assessment makes use of detailed background information and uses data relating to the Maximum Exposed Individual. A Site Specific Detailed Health Risk Assessment is basically the same but it instead makes use of Actual Population Data. This is the highest level of study and involves original research and investigation that looks at site specific and people specific data.
Environment
What is Hillside Aluminium's contribution to the pollution in Richards Bay?
It is difficult to be define precisely the contribution of various companies and industries to overall air pollution. The measure used to define different companies' financial contributions to the air pollution monitoring and measurement carried out by the Richards Bay Clean Air Association is to look at the percentage contribution to SO2 emissions. SO2 emissions are further used as a pollution indicator in the monitoring programmes. Based on measured and calculated data, Hillside contributes approximately 41% of SO2 emissions in the area.
What is acid rain?
Acid rain or 'acid deposition' occurs when sulphur dioxide released into the atmosphere from industries, towns and cities is transported by prevailing winds and combines with water vapour or dust particles to form droplets or dust particles and fall back to earth. The droplets or particles fall in either a wet or dry form. The wet form falls as acidic rain, snow, fog or cloud vapour and the dry form as acidic particles. Rain is normally slightly acidic (around pH 5.0 - 5.6) because it contains carbonic acid from chemical reactions in the atmosphere. However, industrial activity can push the acidity up to pH 3 (same pH as vinegar) and even up as high as 2.3 (same pH as lemon juice) which can be about 1,000 higher than normal rainfall. Excessive acidic rain can cause environmental damage to plants and soil.
What legal limits have been set to protect human health from fluorides?
Air Quality:
Permit conditions stipulate that the ambient fluoride levels must not exceed 26 micrograms per cubic metre as a 24 hour average in areas of permanent residency.
Water Effluent
Hillside's present water discharge permit allows water from the impoundment dam to be released into the Manzamnyama natural water course at fluoride concentration levels below 20 milligrams per litre. Water concentrations above 20milligrams per litre are discharged to the Mhlatuze Water Board pipeline.
Will the fluorides going into the Manzamnyama Canal affect fluoride levels in groundwater?
At the present time, there is no clear evidence to suggest that the fluorides entering the Manzamnyama Canal are affecting fluoride levels in groundwater.
Drinking Water
In South Africa, maximum levels of fluoride in drinking water is set at 1 milligram per litre with a maximum allowable level of 1.5 milligrams per litre and a crisis level of 3 milligrams per litre. The US Environmental Protection Agency (EPA) has set a maximum of 4 milligrams of fluoride per litre of drinking water. The EPA has recommended that the US States individually limit fluoride in drinking water to 2 milligrams per litre. (Not all States have implemented that recommendation.)
Air
How do you monitor atmospheric fluoride levels?
On site atmospheric fluoride levels are monitored regularly. A project has recently been completed to sample fluoride levels in the Richards Bay area. The final stage of this project is to integrate the data into the Richards Bay Clean Air Association's monitoring programme and validate the Association's modelling programme for fluoride emissions. If successful, this would mean that the RBCAA could monitor and predict fluoride emissions in the same way that it does with SO2. Results from this initiative are expected later this year.
How do you monitor atmospheric sulphur levels?
Hillside Aluminium is a member of the Richards Bay Clean Air Association, an association of companies and interested and affected parties, which has established a long term, sulphur dioxide monitoring programme using an independent specialist group. The companies in the Association are all companies that contribute to sulphur dioxide emissions and the independent monitoring programme forms a part of the companies' permit conditions and they contribute to the costs of the monitoring. Independent results are published regularly and issued to the various stakeholders.
What is the Richards Bay Clean Air Association?
The townspeople and representatives of the Richards Bay industries saw the need for air quality management in the region and formed the Air Quality Steering Committee. From this committee, was evolved a Section 21 (not for gain) associated company, The Richards Bay Clean Air Association (RBCCA). The company decided that a comprehensive, real time monitoring network should be established to understand the dynamics of air quality in the area. In addition, it was decided that a mathematical model should be incorporated in the system to predict concentrations of chemicals and gases throughout the region to allow the RBCCA to follow the path of chemicals and gases from their source to affected parties and the environment. As it is not possible to monitor all gases and chemicals, sulphur dioxide has been chosen as an indicator pollutant. Five sulphur dioxide monitoring stations, seven meteorological stations and a base station have been established to collect data which is then analysed through the mathematical (computer) model. When pollution complaints are received, information from the model can be used to identify weather conditions at that point, and the contribution to overall pollution concentrations at that position. The information collected and modelled is being used to manage air quality in the region through influencing emission controls from various industries under varying weather conditions. As the data store increases, it will become possible to plan industrial and residential development against the capacity of the regional environment to handle additional pollution loading.
What is the difference between ground level and atmospheric sulphur dioxide concentrations?
Sulphur dioxide is released from stacks and disperses through the influence of wind and weather patterns. As it disperses it begins to dilute and fall earthwards. Once it reaches ground level, it can influence communities from a health and nuisance point of view. Ground level sulphur dioxide measurements are crucial in assessing the impact of sulphur dioxide on humans and the environment. Atmospheric concentrations are less usable because they are not yet necessarily directly affecting human health and may be dispersed and diluted by favourable weather conditions before they fall to earth.
What is ambient air?
Ambient air is the term used to describe background air quality.
Will the expansion result in acid rain in Richards Bay?
Although an increase is expected in the SO2 emissions from the plant, these will still be within the existing permit limits. At this stage, it is not clear how the emissions will affect the incidence of acid rain but this will be one of the areas to be checked by the EIA.
What happens when fluorides and hydrogen fluoride enter the environment?
Fluorides released to the air from volcanoes and industry are carried by wind and rain to nearby water, soil and food sources. Fluorides erode from rocks into soil and water, and leach from phosphorous fertilisers into food and water supplies. Some plants take up and store fluorides in their leaves and stems. Fluorides are found naturally in the environment and do not normally pose a threat to human health or ecological functioning. It has been shown that low levels of fluorides can have a beneficial effect, for example strengthening teeth in children. Certain plant species derive benefit from fluoride and have the ability to take in and store fluorides. Excessive quantities of fluorides have adverse health effects (they can blacken and stain teeth, cause a brittleness in bones and result in the onset of osteoperosis). Permit levels and human exposure limits have been set to specifically prevent the occurrence of fluoride levels that could pose a threat to human health and the natural environment.
Natural Environment
How do fluorides affect the natural environment?
Fluorides occur naturally in the environment and an average for natural background levels is 0.05 micrograms per cubic metre. Studies have shown that sensitive plants begin to show the first signs of damage (such as slight discolouration of leaves) at around 0.4 micrograms per cubic metre. Locally, the most sensitive plants include pines, blue gum trees, strelitzia, caster oils, apricot trees, plum trees, gladiolus, azaleas and iris. Normal plants will only begin to shows signs of damage at levels above 1 microgram per cubic metre. Fluorides can work their way through food chains (atmosphere - plants - grass eating animals) and this concentrates the fluorides. In extreme cases, grass eating animals show signs of high fluoride levels in the form of dental staining, an increase in bone volume, a weakening of bones, fractures of the ribs and problems in moving around. Bees are also sensitive to fluorides because they depend upon plants for their food. Excessive fluoride levels will show in bees through a decreased activity rate and an increase in their mortality rate.
What limits have been set on gaseous Fluorides?
A limit of 1.0 micrograms per cubic metre has been set for residential areas.
Have you studied the effects of fluorides on the natural environment of Richards Bay?
Baseline studies were undertaken as a part of the original Hillside EIA. The effects of fluorides on the vegetation formed a part of the studies on the natural environment. It was indicated that the emission levels from Hillside were below the levels likely to cause injury to plants. The EIA will re-visit this factor and check the cumulative effects of the expansion.
How will the expansion affect the natural environment?
One of the objectives of the feasibility study and the EIA is to check the expansion plans for potential impacts and where necessary, recommend actions or programmes to prevent or reduce negative impacts. There will be impacts on the environment but every effort will be made to reduce the negative environmental impacts and introduce mitigating measures to minimise environmental impacts as far as possible. The first step is to identify the actual and potential impacts and then plans and proposals can be developed to eliminate or mitigate those impacts.
Policy and Legal
How can you consider expanding, or even undertaking a Feasibility Study, a) when the results of the SEA show that individual expansion opportunities are limited and b) the SEA process has not yet been completed?
a)The feasibility study will explore the economic and environmental possibilities and consider both opportunities and limitations.
b)The SEA is a policy process which looks at macro-implications. The feasibility study and associated EIA will link closely to the SEA process and both feed in, and feed from, the on-going SEA outputs.
Why can the third potline not be built separately from the existing plant, i.e. further away from residential and business areas?
One of the key motivating factors for expanding the operations is the close proximity of existing infrastructure and services. If the potline is moved away from the site, additional facilities will have to be built which will affect the economic viability of the expansion.
Will you expand the plant any further after this expansion, if it is approved?
Decisions relating to "expansion versus new greenfield site" are heavily dependant upon market conditions, economic feasibility, cost structures and policy issues such as health, safety and environment. Current estimates seem to indicate that 650,000 tons is the optimal production for the infrastructure on site. However, it is difficult to predict futures changes and circumstances and give a definitive answer. In theory, there is space on the site to add a further half a potline. It is prudent to ensure that the space available is left in a manner that would permit that expansion in the future, if economic, health, safety and environmental feasibility suggests that it is viable.
What is the link between Hillside and Bayside?
Both companies are owned by Billiton. They are, however, independent companies. Hillside sells molten aluminium to Bayside for processing into value added products. At present, this totals 20,000 tons per annum but the expansion will cause this amount to rise to 100,000 tons per annum.
Who pays the R2.5 billion for the expansion? What is their environmental standing and performance?
The funds required for the expansion comes from Billiton, the owners of Hillside. Billiton is a multi-national company that has a clearly defined Safety, Health and Environmental policy and programme which conforms to the best global business and ethical standards. Billiton has supported Hillside's drive for accreditation in terms of ISO 9002 (Quality Management Systems) and ISO 14001 (Environmental Management Systems). Both systems require commitments from suppliers to conform to the standards in place. Billiton also has an independent International Environmental Advisory Committee which makes regular reports to the Billiton Board on international environmental performance within the Billiton Group.
What legal controls and limits have been set on SO 2 from the plant?
Hillside Aluminium's permit in terms of the Air Pollution Prevention Act of 1965 states that total SO2 emissions will not exceed 13,500 tons per annum or 37 tons per day.
How will this be affected by the expansion?
Negotiations will be held with the authorities to request an amendment of the permit to include the proposed extended activity. The current plan is, however, not to increase total SO2 emissions beyond the levels in the current permit.
What legal controls and limits have been set for fluoride from the plant?
Hillside Aluminium's permit in terms of the Air Pollution Prevention Act of 1965 states that total fluoride (solid and gaseous) emissions will not exceed 41.7 tons per month or 500 tons per annum.
Will you be looking to increase your permitted levels of emissions?
The target of the feasibility study and EIA is to try and not exceed existing permit levels, and with additional technological opportunities, even reduce emissions, in line with the company's on-going commitment to continuous improvement in terms of health, safety, environment and quality.
Why expand in Richards Bay when Maputo seems to be able to accommodate expansion better?
There is always a choice of options between developing new “greenfield” operations (with the attendant start up costs) and the expansion to existing operations. Both options have benefits and disadvantages. The function of feasibility studies and EIAs is to clarify decision-making on these kinds of options. However, if the expansion occurs at Mozal, then South Africa will lose the benefits of “downstream” manufacturing expansions (expansions which result from new developments). For example, after Hillside was originally built, it triggered the recent R2.5 billion Hulett Aluminium expansion in Pietermaritzburg, the R500 million AWI plant in Port Elizabeth and the new Tiger Wheels plant in Babelegi. Furthermore, if Hillside cannot optimise its ultimate site production capacity, this could have a negative medium and long term effect on Hillside's ability to stay internationally competitive in terms of production costs.
Will both Mozal and Hillside expand or is it a “one-or-the-other” option?
Pre-feasibility studies indicate that both operations are economically viable. The Mozal EIA has been approved, and if the EIA for the Hillside expansion is approved, both projects may go ahead. However, the decision on the go-ahead on the two projects will be taken by Billiton, based upon wider global business factors such as the balancing of the Billiton business portfolio with other areas of business activity, country risk (e.g. Mozambique and its economic, political and environmental stability), and the availability of other international economic options for aluminium production.
What is the tie-in with Mozal?
The main link is that both companies are owned by Billiton. Although there are technical and training links between the two (Hillside is providing training and some technical support), both companies are operated as independent business concerns.
Miscellaneous
Hillside was designed for 466,000 tpa, currently it produces 500,000 tpa. This is over the capacity it was designed for. "Sweating" will push this up by a further 20,000 tons more than originally designed for. How does, and will, this affect:
1)Environmental management and performance
2)The increase in health, safety and environmental risks
3)Operational efficiencies
1)Environmental Management and Performance
Hillside recently achieved certification for ISO 14001 and 9002, the international environmental management systems and quality standards. This means that Hillside has a clearly defined and documented environmental management system in place which guides environmental management methods, procedures, systems and approaches. It also includes clearly defined measurements and monitoring systems and a management structure for analysing and reacting to environmental performance. Capacity will not affect environmental management as such but it will change the parameters and targets that are used to measure and monitor environmental performance.
2)Increase in health, safety and environmental risks
Part of the function of the economic and environmental feasibility studies is to identify and quantify the extent and manageability of the changing health, safety and environmental risks. If the studies show that any of the risk factors (health, safety, environmental and economic) are excessive or unmanageable, then this will cause a rethink of the proposal to go ahead with the expansion. One can only make a decision of this nature once the studies have been competed and all the information analysed. 3)Operational Efficiencies
This forms a part of the feasibility studies and answers to this question will only emerge once the studies have been completed.
How will the expansion affect the harbour facilities?
The expansion will result in increased shipments of raw materials and exported aluminium.
What public consultation process will you follow?
The EIA regulations stipulate a minimum requirement for public consultation and the Hillside Expansion feasibility study will include extensive public consultation at a number of stages of the EIA's process. A full and detailed explanation of the proposed public consultation process can be found elsewhere on the website. News updates on the progress of the Scoping Report, EIA and other matters relating to the authorisation process will also be posted regularly on the website.
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