Final Technology Review Report -...

EIA FOR THE PROPOSED COEGA ALUMINIUM SMELTER WITHIN THE COEGA INDUSTRIAL

DEVELOPMENT ZONE, PORT ELIZABETH, SOUTH AFRICA

Final Technology Review Report

CSIR REPORT NUMBER: ENV-S-C 2005-033

JULY 2005

EIA FOR THE PROPOSED COEGA ALUMINIUM SMELTER WITHIN THE COEGA INDUSTRIAL DEVELOPMENT ZONE, PORT ELIZABETH,

SOUTH AFRICA

Final Technology Review Report

PREPARED BY: CSIR Environmentek P.O. Box 320 Stellenbosch 7599 South Africa www.csir.co.za CONTACT PERSON: Paul Lochner Tel: +27-21-888 2486 Fax: +27-21-888 2693 Email: [email protected] PREPARED WITH INPUTS FROM: Paul Lochner, Mark Zunckel, Greg Scott, Atham Raghunandan, Marieta Oosthuizen, Philip de Souza, Stephen Luger, Bernie Oberholzer, Quinton Lawson, Sanjeev Raghubir, Johan van der Walt and Sandy Wren

PREPARED FOR: Alcan Centr’Alp BP7 38341 Voreppe Cedex France CONTACT PERSON: Denys Poission (General Operations Manager – Coega Aluminium Smelter)

CSIR REPORT NUMBER: ENV-S-C 2005-033 CSIR PROJECT REFERENCE: JG143

DATE: JULY 2005

EIA FOR THE PROPOSED COEGA ALUMINIUM SMELTER WITHIN THE COEGA INDUSTRIAL DEVELOPMENT ZONE, PORT ELIZABETH, SA

FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page i

Contents

Chapter 1 Introduction

Chapter 2 Updated Description of the Proposed Project

Chapter 3 Approach to the Technology Review

Chapter 4 Materials Handling and Waste Management

Chapter 5 Air Quality and Human Health

Chapter 6 Water Consumption, Wastewater Generation and Integrated Water Management

Chapter 7 Water Discharges to the Marine Environment

Chapter 8 Traffic and Transportation

Chapter 9 Visual Impacts

Chapter 10 Socio-Economic Impacts

Chapter 11 Conclusions and Recommendations

Chapter 12 Comments and Response Trail

Chapter 13 References and Personal Communications A Letters from authorities relating to the Technology

Review B Letters, invitations and adverts issued as part of the

public consultation process for the Technology ReviewDatabase of interested and affected parties

C Database of interested and affected parties

Appendices

D Record of comments received during the public review period for the Draft Technology Review Report (including meeting notes and individual submissions)

COPYRIGHT RESERVED When used as a reference, this report should be cited as:

CSIR, 2005. EIA for the proposed Coega Aluminium Smelter within the Coega Industrial Zone, Port Elizabeth, South Africa: Final Technology Review Report. CSIR Report No. ENV-S-C 2005-033. Stellenbosch.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page ii

Definitions

Alternatives A possible course of action, in place of another, that would meet the same purpose and need (of proposal). Alternatives can refer to any of the following but are note limited hereto: alternative sites for development, alternative site layouts, alternative designs, alternative processes and materials. In Integrated Environmental Management the so-called “no go” alternative refers to the option of not allowing the development and may also require investigation in certain circumstances.

Alumina Alumina is the name given to the raw material, aluminium oxide (Al2O3), which is used in the smelting process to produce aluminium. It is a white powdery oxide produced through refining of bauxite.

Aluminium Aluminium (in metallic form) is a relatively lightweight metal which is highly corrosion resistant, an excellent thermal conductor, non-magnetic, non-toxic and highly workable. End uses of aluminium include building and construction materials, electrical products, packaging and containers, cooking utensils, the aeronautical, automotive industries and leisure goods industries. Aluminium is produced by a smelting process which separates the aluminium from alumina (aluminium oxide) through electrolytic reduction.

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. The anode block is consumed during the smelting process.

Baking furnace The anodes produced at the paste plant are baked at about 1100°C in an oil-fired furnace for several weeks in order to give them mechanical and conductivity properties.

Bath This is the name given to the electrolytic medium within the pot through which the electric current is passed in the aluminium smelting process. Bath is made up of cryolite, alumina and aluminium fluoride.

Bauxite Aluminium ore which is refined to produce alumina.

Best practicable environmental

option

The option that provides the most benefit or causes the least damage to the environment as a whole, at a cost acceptable to society, in the long term as well as in the short-term. In terms of the Aluminium Pechiney proposal, the identification of the BPEO is differentiated from impact mitigation and benefit enhancement measures in that the identified option involves a decision regarding fundamental design alternatives for the project.

Butt crushing plant At the butt crushing plant the spent anodes which are recovered from the potline are crushed in order for them to be used for the production of new anodes.

Casthouse Liquid aluminium which is extracted from the potline is transported to the casthouse where it is cast into aluminium ingots.

Cathode A cathode is the name given to the negative electrode in a reduction cell. The cathode used in the aluminium industry provides the negative electrical contact as well as serving as the lining of the pot in which the smelting process takes place.

Cementation C Cementation is the process in which chemical precipitates (in the form of new crystals) form in the pores of a sediment or rock, binding the grains together.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page iii

Climate change A change in climate which is attributed directly or indirectly to human activity that alters the composition of the global atmosphere and which is in additionto natural climatic variability observed over comparable time periods.

Cryolite A mineral (sodium aluminium fluoride) which the main component of bath in the aluminium smelting process.

Dross The skimmings on the surface of the molten aluminium which are removed because they contain impurities which could affect the quality of the aluminium metal produced in the smelter.

Dry scrubbing The process whereby potential gaseous pollutants such as fluoride are attracted onto a solid substance and thereby removed from the air. An alternative approach is “wet scrubbing” but this has the disadvantage of producing additional liquid waste and may lead to corrosion.

Electrolysis When electricity is passed through a liquid solution of an ion or an electrolyte, a chemical reaction called electrolysis occurs. The energy from the electric current breaks chemical bonds. In the aluminium smelting process this enables the separation of aluminium from alumina (aluminium oxide).

Environment The biophysical, social, economic, cultural, political and historical context within which people live and within which development takes place.

Environmental impact

A change resulting from the effect of an activity on the environment, whether desirable or undesirable. Impacts may be the direct consequence of an organisation’s activities or may be indirectly caused by them.

Environmental impact assessment

An Environmental Impact Assessment (EIA) refers to the process of identifying, predicting and assessing the potential positive and negative social, economic and biophysical impacts of any proposed project, plan, programme or policy which requires authorisation of permission by law and which may significantly affect the environment. The EIA includes an evaluation of alternatives, as well as recommendations for appropriate mitigation measures for minimising or avoiding negative impacts, measures for enhancing the positive aspects of the proposal, and environmental management and monitoring measures.

Environmental issue A concern felt by one or more parties about some existing, potential or perceived environmental impact.

Fatal flaw A fatal flaw is an environmental constraint that is considered so important that development should not proceed at all, or requires significant changes to be environmentally feasible.

Fume treatment centre

The fume treatment centre (FTC) extracts and recycles fluoride, poly-aromatic hydrocarbon containing tar and dust from emissions created by the anode baking process.

Fugitive emissions Emissions not caught by a capture system which are often due to equipment leaks, evaporative processes, and windblown disturbances.

Gas treatment centre

The gas treatment centres have the primary role of recycling the fluoride and dust captured from the pots.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page iv

Greenhouse gases Greenhouse gases are those gases, both natural and resulting from human activities, which absorb and re-emit infrared radiation from the earth’s surface. They contribute to a warming of the earth’s atmosphere by acting as a blanket over the earth’s surface. Greenhouse gases included under the Kyoto Protocol are carbon dioxide (CO2), methane (CH4), hydrofluorocarbons (HFCs), Nitrous oxide (N2O), perfluorocarbons (PFCs) and sulphur hexafluoride (SF6). These gases have different global warming potentials, which is a measure of the relative effect of a gas in warming the atmosphere over a given time period (100 years in terms of the Kyoto protocol)., compared against a value of one for CO2. For purposes of comparability greenhouse gas emissions are therefore often expressed in terms of equivalent volumes of CO2.

Industrial Development Zone

An Industrial Development Zone is an area identified for industrial development. The aim is to attract domestic and foreign investment into industrial and commercial parks by providing serviced industrial sites with purpose-built infrastructure.

Ingot Bars of aluminium metal which are produced as the final product of the primary aluminium smelting process.

Interested and affected parties

Individuals or groups concerned with or affected by an activity and its consequences. These include the authorities, local communities, investors, work force, consumers, environmental interest groups and the general public.

Key issue An issue raised during the Scoping process that has not received an adequate response and which requires further investigation before it can be resolved.

Liquid pitch Pitch is a heavy, sticky, tar-like by-product derived from the coking of coal. It is used as a binding agent for the petroleum coke in the anode blocks, prior to baking.

Listed activities Development actions that are likely to result in significant environmental impacts as identified by the Minister of Environmental Affairs and Tourism in terms of Section 21 of the Environment Conservation Act.

Megawatt A measure of power, equal to 1 000 kilowatts or 1 million Watts. This is the unit used to quantify the electricity required by a given system.

Necrosis Death of tissue

Negative impact A change that reduces the quality of the environment (for example, by reducing species diversity and the reproductive capacity of the ecosystem, by damaging health, or by causing nuisance).

Paste plant At the paste plant crushed petroleum coke and spent anode butts (the remainder of the anode which was not consumed in the potline) are mixed with liquid pitch to form an anode paste which is compacted into anode blocks prior to baking.

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 by-product by oil refineries.

Pitch fume treatment centre

The pitch fume treatment centre (PFTC) treats PAH containing tar and dust emissions from the paste plant.

Positive impact A change which improves the quality of life of affected people or the quality of the environment.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page v

Pot The pot is the steel shell within which the aluminium smelting process takes place. Otherwise referred to as electrolytic reduction cells.

Potline Pots are electrically connected and arranged in long buildings called potrooms. Two potrooms constitute a potline.

Potlinings Potlinings consist of the refractory bricks that are used to insulate the steel shell of the pot (to contain the heat and prevent damage to the steel shell) and the carbon blocks that form the cathode.

Reduction Reduction is an electrochemical process that involves the transfer of electrons from one atom to another. Reduction forms part of the electrolysis process.

Relevant authority The environmental authority on national, provincial or local level entrusted in terms of the Constitution and in terms of the designation of powers in Notice No. R. 1184 of 5 September 1997 with the responsibility for granting approval to a proposal or allocating resources.

Rodding shop Newly manufactured anodes are attached to an electrical conducting stem in the rodding shop before being transported to the potline.

Scoping This refers to the process of determining the spatial and temporal boundaries (the extent) for the EIA and key issues to be addressed in an environmentall assessment.

Smelting Aluminium smelting refers to the separation of aluminium from aluminium oxide.

Spent Potlinings The potlinings which have reached the end of their useful life and which need to be replaced and disposed of.

Abbreviations

A2O3 Alumina (Aluminium Oxide)

AP Aluminium Pechiney

APCO Air Pollution Control Officer

BAT Best available techniques

BEE Black economic empowerment

BPEO Best practicable environmental option

CO2 Carbon dioxide

CDC Coega Development Corporation

CSIR Council for Scientific and Industrial Research

DBSA Development Bank of Southern Africa

DEAT Department of Environmental Affairs and Tourism (National)

DEAE&T Department of Economic Affairs Environment & Tourism (Eastern Cape)

DTI Department of Trade and Industry

DWAF Department of Water Affairs and Forestry

EIA Environmental Impact Assessment

EIR Environmental Impact Report

EMP Environmental Management Plan


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page vi

EMS Environmental Management System

FTC Fume Treatment Centre

GCM General Construction Manager

GTC Gas Treatment Centre

HFO Heavy fuel oil

I&AP Interested and Affected Party

IEM Integrated Environmental Management

IDC Industrial Development Corporation

IDZ Industrial Development Zone

ISO 14001 International Standards Organisation’s Environmental Management System

MHI Major hazardous installation

NMMM Nelson Mandela Metropolitan Municipality

NPA National Ports Authority

OHSA Occupational Health and Safety Act (No 85 of 1993)

PAH Poly-aromatic hydrocarbon

PM10 Particulate matter < 10 microns

ROD Record of Decision

SABS South African Bureau of Standards

SANPARKS South African National Parks

SEA Strategic Environmental Assessment

SMME Small, Medium and Micro Enterprises

SO2 Sulphur dioxide

SPL Spent potlining

TSP Total suspended particulates

US EPA United States Environment Protection Agency

WESSA Wildlife and Environment Society of Southern Africa

WHO World Health Organisation Units used

kg/tAl Kilogram per metric tonne of aluminium produced kV Kilovolt

MW Megawatt

t/year Metric tonnes per year

µg/m3 Microgram per cubic meter


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page vii

Summary

Background In 2002, an Environmental Impact Assessment (EIA) was carried out for the construction and operation of an aluminium smelter within the Coega Industrial Development Zone near Port Elizabeth. The smelter was proposed by Aluminium Pechiney (AP) and would operate using new generation AP50 smelting technology. The EIA process led to the provincial Department of Economic Affairs, Environment and Tourism (DEAE&T) granting AP authorisation for the development of the aluminium smelter, subject to the conditions specified in a Record of Decision (ROD) that was issued in December 2002. In December 2003, Alcan Inc. acquired Pechiney. This resulted in a review by Alcan of Pechiney’s existing and proposed projects, including the Coega Aluminium Smelter. Alcan has since made a decision to proceed with a detailed feasibility study for the proposed Coega Aluminium Smelter project, but using AP35 technology rather than AP50 technology. The AP35 smelting technology is similar to that used at the Hillside aluminium smelter at Richards Bay and the Mozal aluminium smelter at Maputo, and differs from the AP50 technology in that the smelter would operate at approximately 350 000 amperes rather than at 500 000 amperes of electricity. Alcan is considering constructing the smelter in the Coega Industrial Development Zone using two AP35 potlines rather than the initially proposed single AP50 potline. The output of the AP35 smelter (between 660 000 and 720 000 tonnes per annum) would exceed that of the proposed AP50 smelter (approximately 485 000 tonnes per annum). The decision by Alcan to change to AP35 smelting technology requires that a Technology Review be undertaken, that will supplement the EIA conducted in 2002.

Objectives of the Technology Review The Technology Review focuses on aspects of the EIA conducted in 2002 that may change as a result of the change to AP35 technology and associated design refinements. The main objectives of the Technology Review are to:

Identify where the change in the proposed project (from an AP50 to an AP35 smelter and associated design changes and updates) leads to a change in the predicted impact assessment ratings in the Final Environmental Impact Report (EIR) prepared by CSIR in November 2002.

Re-assess the predicted impacts, as well as the associated management actions to reduce negative impacts (i.e. mitigation) or enhance benefits.

Review the ROD issued in December 2002 and identify where the changes in assessment or mitigation identified in this Technology Review might have implications for the conditions of the ROD. This is intended to assist DEAE&T in amending the current ROD.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page viii

Overview of the proposed project The aluminium smelter is proposed to be established in an area demarcated for metallurgical industries within the Coega IDZ, which is located within the Nelson Mandela Metropolitan Municipality (NMMM), approximately 15km north-east of Port Elizabeth. The site for the proposed AP35 smelter is the same as that proposed for the AP50 smelter in 2002. The AP30 series technology is an advanced and successful aluminium smelting technology and is being employed in many aluminium smelters around the World. The AP30 series smelting technology in its base case for the Coega project, operates at 350 000 amperes of electricity, using a physically smaller pot and will produce approximately 660 000 metric tonnes of aluminium metal per year from two potlines (2x336 pots). The “upside” case results mainly from optimisation of the process parameters, initially in the design phase and then in the operational phase. Currently under evaluation and validation, consideration is being given to operate the pots at a higher amperage level, up to 370 000 amperes. The number of pots in each of the two potlines could also be increased. Both the base case and the “upside” case are included in this Technology Review. A comparison of the key features of the AP50 and AP35 proposals is provided below: Aspect AP50 AP35 Base Case AP35 “Upside” case Infrastructure Number of potlines 1 2 2 Number of potrooms

2 (in parallel) 4 (in parallel) 4 (in parallel)

Total site area

135 ha Approx 120 ha (could increase by up to 10%)

Approx. 120 ha (could increase by up to 10%)

Length of potline 1200m Approx. 1070m Approx. 1120m Number of pots (electrolysis cells)

1 x 336 2 x 336 2 x 352

Port Infrastructure Use of 2 berths at the Port of Ngqura interim product storage area

Use of 2 berths at the Port of Ngqura interim product storage area

Use of 2 berths at the Port of Ngqura interim product storage area

Raw material conveyor (Port to Plant)

1 (belt conveyor) 1 (pipe conveyor) 1 (pipe conveyor)

Number of alumina silos on site

2 3 3

Type of alumina silos on site

Dome (40m height) Cylindrical (50m height) Cylindrical (50m height)


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page ix

Inputs Alumina consumption

Approx. 931 000 t/year

Approx. 1 250 000 t/year Approx. 1 382 000 t/year

Petroleum coke consumption


Appr 240 000 t/year Appr 265 000 t/year

Liquid pitch consumption


Approx. 52 000 t/year Approx. 57 500 t/year

Aluminium fluoride consumption

Approx. 8 800 t/year Approx. 11 700 t/year Approx. 13 000 t/year

Heavy Fuel Oil consumption


Approx. 38 500 t/year Approx. 42 600 t/year

Average Electricity demand

Approx. 860 MW Approx. 1082 MW Approx. 1180 MW

Water usage Approx. 500 000m3/year

940 000 + 84 000 m3/year. Industrial water + drinking water

Approx. 1 036 800 + 87 000 m3/year. Industrial water + drinking water

Total investment $2094 million 2200 million US$ (approx.)

2200 million US$ (approx.)

Outputs Aluminium production capacity


Approx. 660 000 t/year (round figure)

Approx. 720 000 t/year (round figure)

Direct jobs created Construction 4000 average, 6500 peak. Operation 750 with 200-300 sub-contractors

Construction of two potlines in sequence 4000 average, 6500 peak. Operation 1050 with 200-300 sub-contractors

Construction of two potlines in sequence 4000 average, 6500 peak. Operation 1080 with 200-300 sub-contractors

Process wastewater

Approx. 300 000 m3/year

Approx. 470 000 m3/year. Evaporation loss estimated at 50%.

Approx. 518 400 m3/year. Evaporation loss estimated at 50%.

Storm water Varies according to rainfall

Varies according to rainfall

Varies according to rainfall

Air emissions Sulphur dioxide (SO2), hydrogen fluoride (HF), particulate fluoride (Fp) total suspended particulates (TSP), polycyclic aromatic hydrocarbons (PAH), perfluorocarbons (PFCs), carbon dioxide (CO2), greenhouse gases (GHG), nitrogen oxides (NOx)

Estimated project schedule Construction of the first potline is anticipated to commence in early 2007 and last for a maximum period of 28 months. The construction of the second potline and its associated supporting infrastructures could start 12 months after the first potline is completed, and continue for 21 months. Overall, the construction of the two potlines sequentially, from beginning of the construction of the first potline, to operation at full capacity, is expected to be between 60 to 70 months. The life of the project is expected to be 30 to 40 years.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page x

Approach to the Technology Review Clause 8.1.4 of the Record of Decision issued in December 2002 states: “Any changes in the project that could have significant environmental impacts and that would differ from that which were authorised by DEAE&T to be submitted to DEAE&T for approval prior to such changes being effected.” Based on discussion between Alcan, DEAE&T and other authorities, it was established that the proposed changes fall within the scope of clause 8.1.4. Consequently, Alcan is not expected to go through another full EIA process and obtain a new Record of Decision, given that a comprehensive Environmental Impact Report and ROD have already been prepared for the AP50 smelter on the same site. Alcan must prepare an updated assessment, and submit this for approval. The overall approach to the Technology Review is therefore to identify the changes in technology and design from the AP50 to the AP35 proposal, determine where these might alter the predicted significance of the environmental impacts, and review the mitigation measures accordingly. This analysis is presented to DEAE&T in the form of a Technology Review Report. The Draft Technology Review Report was provided to DEAE&T, other authorities and the public for their comment and input. Thereafter, a Final Technology Review Report was prepared and submitted to DEAE&T. Depending on the findings of the Technology Review, DEAE&T may issue an amended ROD for the AP35 smelter, based on the current ROD. This Technology Review Report also incorporates relevant findings from additional studies undertaken since completing the Final Environmental Impact Report in November 2002. In particular, the outcomes from the “Review of wastewater treatment options with special emphasis on stormwater and process wastewater” prepared by CSIR in 2003 (de Souza et al, 2003) are included in Chapter 6 on water management.

Public review process A public review process is being conducted by independent facilitators (Public Process Consultants) as part of the technology review. It should be borne in mind that in-depth public consultation was conducted for the original EIA in 2002, in which a comprehensive scope of issues was identified. These issues are generally as applicable to an AP35 smelter as to an AP50 smelter. The public review process includes the following:

Distribution of letters to interested and affected parties (I&APs) on the existing Coega IDZ database (approximately 1400 people) at various stages of the Technology Review process.

Placing adverts regarding the process in two local newspapers. Placing of information on the CSIR’s website for the smelter EIA

(http://smelter.csir.co.za), as well as in public places (eg libraries). Providing a 30 day public review period from 3 June to 4 July 2005 for comments on the

draft Technology Review report. Hold two focus group meetings to discuss the technology and design changes. These

meetings are intended to include the following stakeholders: SANParks, Sundays River Valley Community Forum, Alliance Structures and WESSA.

Holding one public meeting at the PE City Hall to which the broad public will be invited. Preparation of a Comments Response Report, following the review period.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xi

Updated impact assessment for the proposed smelter Materials handling and waste management The impacts due to materials handling and waste management for both the base case and “upside” case of the AP35 smelter are assessed to be insignificant or of low significance. This is supported by the high level of confidence for each impact assessed. Whilst the AP35 smelter will generate more waste than the AP50 smelter, a great percentage will be recycled or re-used thus reducing the impact on landfill space. The AP35 upside case scenario will generate approximately 9% more waste than the AP35 base case scenario. The related impact of disposing of an additional 9% waste to the local waste disposal sites will not impose significant pressures onto the site’s disposal capacity. Air quality (including human health) The increase in production capacity increases the total atmospheric emissions from the proposed smelter by approximately 36% (base case) and 48% (upside case), i.e. identical to the increase in production. Based on the results of the revised modelling and quantitative assessments undertaken during the technology review no changes in the significance assessment ratings, as specified in the Final EIR, were made. The most important findings with regard to air quality and human health are listed below:

Sulphur dioxide - modelled SO2 annual average and 24-hour maximum concentrations do not exceed international guidelines or standards. The modelled 1-hour maximum concentration exceeds the proposed South African standard concentration. The exceedence is mostly limited to the smelter site with relatively few off-site exceedences.

There are no acute or chronic health effects expected in any healthy or sensitive individual exposed to the predicted SO2 concentrations, even under an absolute worst-case scenario.

Hydrogen fluoride - there are no adverse health effects, either acute (such as irritation) or chronic (skeletal fluorosis), expected in any individual, including sensitive individuals.

Particulate fluoride - it is unlikely for any individual to develop skeletal fluorosis from exposure to fluoride particulates emitted by the smelter.

Fluoride deposition - although fluoride deposition rates are low, negative impacts in ecological receptors could occur in the IDZ, or further afield. The receptors may include surface waters and vegetation.

Greenhouse gas emissions - the smelter emissions are relatively small, but those associated with electricity use are large, although this has not been assessed in this study.

Surface water and liquid waste This assessment incorporated additional information from the water treatment and re-use study conducted in 2003 and from the recent planning and development of stormwater infrastructure within the IDZ. This resulted in the types of impacts specified in the 2002 impact assessment table being revised. The revised water management options and associated impact are listed below:


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xii

Process wastewater and stormwater discharge to port via CDC stormwater system

On-site treatment of process wastewater and stormwater with disposal of sludge at a hazardous waste site

On-site treatment of process wastewater and stormwater treatment with discharge of concentrated brine to port via CDC stormwater system

On-site treatment of process wastewater and stormwater with operation as a Zero Liquid Effluent Discharge facility

Off-site treatment of process wastewater and stormwater (e.g. Coega IDZ facility). While the above options would provide certain benefits (e.g. reduced water consumption due to treatment and re-use) they would also result in some negative impacts (e.g. disposal of sludge). These negative impacts are assessed to be of low significance (with or without mitigation). The re-assessment of water-related impacts found that there are no significant differences in predicted impacts between the AP50 and AP35 smelter proposals (for both the base case and upside case). Consequently, there are no changes in the impact assessment ratings for the AP35 proposal, except for the following:

The negative impact of increased water use during operation increased from low to medium (without mitigation) due to the significant increase in process water use for the AP35 proposal. With effective mitigation, this can be reduced to a low impact.

Discharges to the marine environment In the 2002 marine specialist study, the concentrations of constituents in stormwater and process water used were based on actual monitoring results from AP-series smelters worldwide and consolidated into a single set of predicted stormwater concentrations for the operations phase of the Coega smelter. The updated specialist studies undertaken for the Techology Review have shown that these stormwater concentrations are considered reasonable estimates for the AP35 smelter. The modelling and assessment of impacts on the marine environment presented in the Final EIR (CSIR, 2002b) therefore remains unchanged. The marine specialist study shows that a 200m mixing zone in the port provides sufficient dilutions for the controlled release of “first flush” stormwater from the smelter site to meet the Marine Water Quality Objectives, when measured at the edge of the mixing zone. The rate of release needs to be relatively low, in order to achieve the necessary mixing. The waste water treatment and re-use study (de Souza et al., 2003) led to a new potential impact being identified that needs to be considered in this chapter, i.e. the discharge of brine to the marine environment. The brine would essentially be of the same quality as seawater, and is therefore predicted to result in an impact of low significance. However, the specific quality and quantity of the brine is not known at this stage, and can only be determined when more detailed designs have been completed for the wastewater treatment and re-use option.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xiii

Traffic and transportation The increase in transport requirements due to the change to the proposed AP35 smelter only causes marginal increases in the traffic and transport-related impacts. The significance ratings of the impacts, however, remain unchanged. Visual

The nature of the predicted visual impacts will remain similar to those in the Final EIR, namely:

Potential visual intrusion of the proposed smelter, conveyor belt and port facilities on the natural and amenity value of the existing coastal / rural landscape.

Potential increase of lighting at night, including navigation lights on the tall stacks, which may be visible to surrounding areas, shipping, and the islands in the bay.

The significance and rating of the visual impacts is unchanged from those in the Final EIR. The cumulative effects and magnitude of the visual impacts also remain unchanged. Notwithstanding the unchanged visual impact ratings, the change in the design of the plant requires that the previous mitigation measures, as well as three additional recommendations, be addressed. Socio-economics The assessment ratings remain unchanged from the 2002 assessment. The main benefits are listed below:

The positive impact of employment creation at a local scale during operations, remains of high significance. No change in mitigation is required.

The number of local people who would directly benefit from employment during operation of the smelter remains small. Therefore, the significance of the positive impact remains low in the absence of measures to enhance the positive aspects, and still increases to medium when enhanced.

The positive impact of training and skills development during operation of the smelter remains of medium significance, both with and without the implementation of additional benefit enhancement measures.

The NMMM is reported to have spare public transport capacity (van der Walt, 2002). The utilisation of spare public transport capacity during operations results in a positive impact, but this remains of low significance due to the small amount of additional transport required.

No additional negative or positive socio-economic impacts have been identified, which may occur due to the changes in technology. The duration of the positive impact of employment creation during the construction phase is extended due to the sequential construction of the two potlines.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xiv

Updated management actions The management actions (i.e. actions to mitigate negative impacts or enhance positive impacts) contained in the Final EIR (CSIR, 2002) generally remain unchanged. In some cases, these actions have already been implemented (eg. undertaking the investigation into the potential for water treatment and re-use). The Technology Review has identified the following additional management actions:

Specialist study Additional management actions

Materials handling and waste management

None

Air quality (including human health)

None

Surface water and liquid waste Conduct further investigations into the advantages and disadvantages of the various management options identified in the Technology Review for contaminated stormwater and process wastewater.

Discharges to the marine environment

Water treatment and re-use option - Investigate potential impacts of brine disposal to the marine environment, when the necessary information is available on the quantity and quality of brine.

Traffic and transportation None Visual The visual specialists recommended the following:

1. The proposed AP35 plant could be re-sited to the north-west corner of the site. This would result in the plant being located further back on the plateau, and would increase the distance from certain viewpoints, including those along the N2, by 300m in some cases. The overall effect would be to marginally reduce the visibility of the plant from the surrounding area. The practicality of this re-siting would have to be determined.

2. The previously proposed dome silos should preferably be used instead of the currently proposed cylindrical silos which are some 10m higher than the dome design and which would be more pronounced against the skyline. The dome silos have a more subtle profile.

3. The previous intention of using a pale grey colour for all building cladding should be adhered to. Use of a reflective cladding should be avoided.

Socio-economics None


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xv

Implications for the Record of Decision The implications for the Record of Decision (ROD) that were identified through the updated specialist studies are summarised below:

ROD clause Discussion and recommendations

Materials handling and waste management 8.3.3 – Specifies that all materials handling areas on the site to be under cover or enclosed and no external stockpiles of raw materials or by-products to be allowed on site.

As discussed in Section 4.2, heavy loads (e.g. anodes, metal ladles and bath ladles) will be transported on the open smelter roads and not in covered passageways. Spillages of these materials are not expected to have significant impacts as the spillages can be quickly cleaned up and the materials in these forms are relatively innocuous. Recommendation: Clause 8.3.3 of the ROD should be amended to reflect this design change, noting that this change does not increase the significance of potential negative impacts associated with transport of heavy loads.

8.4.10 - Specifies that clarity be obtained on the recycling, re-use or disposal of spent pot linings (SPL) and dross before the smelter is commissioned.

Two cement kilns in South Africa are currently conducting environmental impacts assessments on the use of waste streams as alternative fuel sources (Bohlweki Environmental, 2004). SPLs could potentially be considered as an alternative fuel option. Recommendation: No change is required to the ROD. Alcan could initiate contact with these and/or other cement kiln operators.

Air quality (including human health) 8.5 – Specifies conditions relating to emissions to the atmosphere

Based on discussions with national DEAT, it has been confirmed that the air permit can be issued based on the draft air permit that was prepared for the proposed smelter in 2003, taking into account the technology changes presented in this report. Recommendation: Project proponent to submit a request to DEAT to issue an updated scheduled process air permit, following the amendment of the ROD.

Clause 8.5.6 - States that the sulphur content in petroleum coke used at the smelter may not exceed 3% w/w

Since completing the Final EIR in 2002, the global availability of petroleum coke with low sulphur content has reduced dramatically. Recommendation: This clause should be changed to require that the smelter use petroleum coke with “the lowest possible sulphur content commercially available” and not state a maximum % w/w.

Clause 8.5.21 – Proposes minimum emission standards for the smelter

Recommendation: This clause should be removed from the ROD since this incorrectly quotes ambient air quality concentrations as the proposed minimum emission standards for the proposed smelter. This clause should be replaced with a statement that requires the proponent to comply with the World Bank emissions standards for aluminium smelters.

Surface water and liquid waste

8.6.3 - Regarding substitution of contaminated stormwater and process wastewater.

Recommendation: Should be reworded to allow the option to be considered practically feasible.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xvi

ROD clause Discussion and recommendations 8.6.6.6 - Relating to total stormwater containment; and Clause 8.6.8 - Relating to design for 1:100 year stormwater run-off.

Recommendation: Should be modified to only require containment of contaminated stormwater, and not total stormwater.

Clause 8.6.21 - Specifies water quality monitoring requirements

If a water treatment and re-use plant is implemented, the need for monitoring potential impacts of water discharges is reduced. Recommendation: Could be modified, and monitoring requirements possibly reduced, if treatment and re-use of liquid wastes is implemented. Recommendation: Change the ROD to allow wastewaters with higher concentrations of problematic parameters to be discharged to the municipal sewer system via an appropriate pipeline (if discharge to the sewer is acceptable by NMMM and is predicted to have a low negative impact). Recommendation: Change the ROD to allow wastewaters with higher concentrations of problematic parameters to be combined with other stormwater from the Coega IDZ and discharged to the port via the CDC stormwater system. Comparison of modelling results for the combined stormwater with previously developed CSIR stormwater release limits indicates a low negative impact. Recommendation: Change the ROD to state that in the unlikely event that monitoring shows an unacceptable environmental impact, implementation of an on-site wastewater treatment facility must be fast tracked. Wastewaters could be treated on-site for re-use purposes:

With disposal of sludge to an appropriate hazardous waste site and discharge of brine to the port via a dedicated pipeline (with special authorisation from DWAF and if the discharge to the port is proven to have an acceptable level of environmental impact) OR

With operation of a Zero Industrial Effluent Discharge facility with disposal of sludge as a solid to an appropriate hazardous waste site and brine discharged to evaporation ponds or via brine concentration and disposal.

Clause 8.6 - Specifies conditions pertaining to water use and liquid waste. Note: The recommendations provided alongside are based on two key findings from the Technology Review: (i) that stormwater quality limits

in clause 8.6.15 are set as 95% ile limits, but were derived largely from averages from actual monitoring at smelters; and

(ii) that a wider range of potential wastewater management options exist than currently provided by the ROD.

Recommendation: Change the ROD to allow wastewaters to be transported and treated off-site for re-use purposes (e.g. at a central facility in the Coega IDZ).

Discharges to the marine environment 8.6.15 - Specifies water quality requirements (95%ile limits) for stormwater leaving the CAS site

Recommendation: Stormwater quality limits could be set for the total stormwater discharge into the port. The lead authorities responsible for managing the port and IDZ (i.e. NPA and CDC respectively) could then determine the necessary limits for individual operations within the port and IDZ, in order to achieve the water quality requirements at the discharge point.


FINAL TECHNOLOGY REVIEW REPORT – JULY 2005 page xvii

ROD clause Discussion and recommendations Recommendation: The table with specifications for stormwater

quality (clause 8.6.15) could be amended to state that these limits apply at the point of discharge into the port, and not at the edge of the smelter site.

Traffic and transportation 8.9 – Conditions pertaining to traffic and transportation

No changes to the ROD are proposed.

Visual 8.11 – Conditions pertaining to visual aspects

The following is proposed by the visual specialists: The siting of the smelter within the property, and the choice of cylindrical silos over the dome design would have marginal significance, when seen in terms of the larger view catchment area. These mitigations would therefore be 'desirable', but not 'essential'. The use of a reflective cladding for the structures would probably increase the visibility of the proposed plant for receptors from all viewpoints, near and distant. The use of more muted colours (as prescribed in Chapter 9), is therefore seen as an 'essential' mitigation, without which the significance of the predicted visual impact of the structures on the visual/scenic quality would revert to 'high'.

Socio-economics

Section 8.12 – Conditions pertaining to social aspects

No changes to the ROD are proposed.

Public review The Draft Technology Review Report was provided to DEAE&T and other authorities for their comment and input; and released for a 30 day public review period from 3 June to 4 July 2005. During this period, a public meeting was held in Port Elizabeth, as well as several focus group meetings. Thereafter, comments from stakeholders were incorporated into the Final Technology Review Report, dated July 2005. A Comments and Response Trail was also prepared and is presented in Chapter 12 of this report.

Request for an amendment to the Record of Decision The Final Technology Review Report has been submitted to the lead environmental authority (DEAE&T) with a request for an amendment to be issued on the existing Record of Decision (ROD). Depending on the findings of the Final Technology Review Report, DEAE&T may issue an amended ROD for the proposed AP35 smelter at Coega, based on the current ROD.

Date post:	02-Jun-2020
Category:	Documents
Upload:	others
View:	6 times
Download:	0 times

Final Technology Review Report -...

Documents