Project to implement a processing plant for spent potlining in Jonquière
Comprehensive Study Report (document prepared by Tecsult Inc.)
JANUARY 2006 Project to implement a processing plant for spent potlining in Jonquière i Comprehensive Study Report
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1 SUMMARY...... 1-1 1.1 Background...... 1-1 1.2 The Issue ...... 1-1 1.3 Project Description...... 1-2 1.3.1 Construction...... 1-2 1.3.2 Operating Activities ...... 1-2 1.3.2.1 Pot Lining Processing ...... 1-2 1.3.2.2 Recovering the Condensate ...... 1-3 1.3.2.3 Vapour Production ...... 1-3 1.3.2.4 Cooling Tower...... 1-3 1.3.3 Supply and Transportation...... 1-4 1.3.4 Storage Site ...... 1-4 1.4 Alternatives and Implementation Methods...... 1-4 1.5 Public Consultation ...... 1-5 1.5.1 By the Proponent ...... 1-5 1.5.2 Quebec’s Environment Quality Act ...... 1-5 1.5.3 Canadian Environmental Assessment Act...... 1-5 1.6 Description of the Receiving Environment ...... 1-6 1.6.1 Physical Environment ...... 1-6 1.6.1.1 Hydrography ...... 1-6 1.6.1.2 Industrial Waste Disposal Sites...... 1-6 1.6.1.3 Atmospheric Environment...... 1-6 1.6.1.4 Noise Environment...... 1-7 1.6.1.5 Flora and Fauna...... 1-7 1.7 Human Environment ...... 1-8 1.8 Impacts and Mitigation Measures ...... 1-8 1.8.1 Soil, Surface Water and Groundwater: Operations...... 1-8 1.8.2 Atmospheric Environment...... 1-9 1.8.2.1 Construction Period ...... 1-9 1.8.2.2 Operating Period...... 1-9 1.8.2.3 Cumulative Impacts ...... 1-9 1.8.3 Greenhouse Effect ...... 1-10 1.8.4 Hydrology and Water Quality ...... 1-10 1.8.4.1 Water Resources ...... 1-10 1.8.4.2 Impacts of Liquid Discharges...... 1-11 1.8.5 Waste Management Site...... 1-11 1.8.6 Ambient Noise Environment ...... 1-11 1.8.7 Biological Environment ...... 1-12 1.8.8 Human Environment ...... 1-12 1.8.8.1 Traffic ...... 1-12 1.8.8.2 Aesthetics and Landscape...... 1-12 1.8.8.3 Psychosocial Impact ...... 1-12 1.8.8.4 Health...... 1-12 1.8.9 Security ...... 1-13 1.8.9.1 Security Measures ...... 1-13 1.8.9.2 Emergency Response Plan ...... 1-14
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1.8.10 Economic Spinoffs ...... 1-14 1.9 Monitoring and Follow-Up Program ...... 1-18 2 INTRODUCTION...... 2-1 3 PROJECT DESCRIPTION...... 3-1 3.1 Description of the Processing Plant’s Technical Features ...... 3-1 3.1.1 Development and Construction Activities...... 3-1 3.1.1.1 Construction Work ...... 3-1 3.1.1.2 Raw Water Supply for the Plant...... 3-2 3.1.1.3 Leachates ...... 3-2 3.1.1.4 Natural Gas Supply...... 3-3 3.1.1.5 Electrical Supply ...... 3-3 3.1.1.6 Vapour Supply ...... 3-3 3.1.1.7 Schedule ...... 3-3 3.1.2 Operational Activities at the Plant ...... 3-3 3.1.2.1 Processing Capacity ...... 3-8 3.1.2.2 Storage of Raw Materials...... 3-8 3.1.2.3 Crushing...... 3-9 3.1.2.4 Water and Caustic Leaching...... 3-10 3.1.2.5 Cyanide Destruction...... 3-11 3.1.2.6 Evaporation, Crystallization and Causticization ...... 3-11 3.1.2.7 Recovering the Condensate ...... 3-12 3.1.2.8 Vapour Production ...... 3-12 3.1.2.9 Cooling Tower...... 3-12 3.2 Description of Waste and Hazards...... 3-12 3.2.1 Mass Balance ...... 3-12 3.2.2 Air Emissions ...... 3-16 3.2.2.1 Description ...... 3-16 3.2.2.2 Respecting Discharge Standards...... 3-19 3.2.3 Liquid Discharges ...... 3-20 3.2.4 Solid Discharges ...... 3-24 3.2.4.1 Iron Oxides...... 3-24 3.2.4.2 Descaling Residues ...... 3-25 3.2.4.3 Carbon and Inert Materials...... 3-25 3.3 Supplies, Transportation and Traffic ...... 3-25 3.3.1 Supply of Spent Pot Lining...... 3-25 3.3.2 Transportation Requirements...... 3-26 3.3.2.1 Supply Sources of Spent Pot Lining...... 3-26 3.3.2.2 Waste Disposal ...... 3-32 3.3.3 Distribution of Travel on Transportation Networks...... 3-33 3.4 Carbon and Inert Material Storage Site...... 3-39 3.4.1 Background...... 3-39 3.4.2 Site Description...... 3-39 3.4.3 Description of Development...... 3-39 3.4.4 Construction Phases...... 3-49 3.4.5 Waste Storage ...... 3-49 3.4.6 Covers...... 3-50 3.4.7 Managing Leachates...... 3-51
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3.4.8 Waste Recovery...... 3-52 3.5 Decommissioning and Rehabilitating the Site...... 3-52 4 ALTERNATIVES AND IMPLEMENTATION METHODS...... 4-1 4.1 Project rationale ...... 4-1 4.2 Background...... 4-1 4.2.1 Spent Pot Lining as a Hazardous Material...... 4-1 4.2.2 Current State of Spent Pot Lining Management in Quebec...... 4-1 4.3 Management Options...... 4-2 4.3.1 Reduction at the Source ...... 4-2 4.3.2 Reuse...... 4-3 4.3.3 Recycling ...... 4-3 4.3.4 Upgrading ...... 4-3 4.3.5 Disposal ...... 4-3 4.4 Technological Choices...... 4-3 4.4.1 Technologies Being Contemplated ...... 4-3 4.4.1.1 Pyrometallurgical Processes...... 4-4 4.4.1.2 Hydrometallurgical Processes...... 4-5 4.4.1.3 Technology Comparison ...... 4-5 4.5 Preferred Technology...... 4-6 4.5.1 Economic and Technical Issues ...... 4-6 4.5.1.1 Pilot Tests ...... 4-7 4.5.1.2 Advantages of the LCLL Process...... 4-8 4.5.1.3 Economic Feasibility ...... 4-8 4.5.2 Environmental and Socio-political Issues...... 4-9 5 SCOPE OF THE STUDY ...... 5-1 5.1 Scope of the Project...... 5-1 5.2 Factors to be Considered...... 5-1 5.3 Scope of the Factors to be Considered...... 5-2 5.3.1 Any Change to the Project Attributable to the Environment...... 5-3 5.3.2 Accidents or Malfunctions ...... 5-3 5.3.3 Cumulative Environmental Effects ...... 5-3 5.3.4 Renewable Resources...... 5-3 5.3.5 Spatial and Temporal Boundaries...... 5-4 5.3.6 Proposed Design of the Follow-up Program ...... 5-4 6 PUBLIC CONSULTATION...... 6-1 6.1 Introduction ...... 6-1 6.2 Alcan Consultations ...... 6-1 6.2.1 Scope of the1997 Consultations ...... 6-1 6.2.2 Community Concerns Based on Analysis of the Questions...... 6-2 6.2.3 Public Participation Approach and Communication Activities (2000- 2001)...... 6-6 6.3 Government Consultations...... 6-7 7 DESCRIPTION OF THE RECEIVING ENVIRONMENT ...... 7-1 7.1 Site Pre-selection and Selection ...... 7-1 7.2 Delineation of the Study Area ...... 7-2 7.3 Biophysical Environment Components ...... 7-2
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7.3.1 Physical Environment Components ...... 7-2 7.3.1.1 Land Topography...... 7-2 7.3.1.2 Regional Geology ...... 7-2 7.3.1.3 Seismicity...... 7-3 7.3.1.4 Surface Materials ...... 7-3 7.3.1.5 Hydrography ...... 7-4 7.3.1.6 Hydrogeology...... 7-4 7.3.1.7 Groundwater Quality ...... 7-5 7.3.1.8 Industrial Waste Removal Locations...... 7-5 7.3.2 Atmosphere...... 7-5 7.3.3 Regional Climate...... 7-10 7.3.3.1 Choice of Weather Station ...... 7-10 7.3.3.2 Winds ...... 7-10 7.3.3.3 Temperature ...... 7-10 7.3.3.4 Precipitation ...... 7-11 7.3.4 Surrounding Noise Environment ...... 7-20 7.3.4.1 Location of the Measurement Points...... 7-20 7.3.4.2 Nature of the Measurements ...... 7-20 7.3.4.3 Measuring Instrumentation ...... 7-20 7.3.4.4 Weather Conditions ...... 7-23 7.3.4.5 Noise Environment During the Day...... 7-23 7.3.4.6 Noise Environment During the Night...... 7-24 7.3.5 Flora and Fauna...... 7-29 7.3.5.1 Vegetation...... 7-29 7.3.5.2 Wetlands ...... 7-29 7.3.5.3 Wildlife ...... 7-29 7.3.5.4 Endangered Species...... 7-32 7.4 Human Environment Components...... 7-32 7.4.1 Regional Setting...... 7-32 7.4.2 Socio-economic Profile ...... 7-35 7.4.3 Characterization of the Study Area ...... 7-35 7.4.3.1 Use by Non-Aboriginal People...... 7-35 7.4.3.2 Use by Aboriginal People...... 7-36 7.4.4 Infrastructure and Equipment...... 7-41 7.4.4.1 Rail Network...... 7-41 7.4.4.2 Road Network ...... 7-41 7.4.4.3 Water, Sewer, Electrical and Gas Systems ...... 7-42 7.5 Archaeological Potential...... 7-43 7.5.1 Geographic and Geomorphic Context...... 7-43 7.5.2 History of the Area ...... 7-43 7.5.3 Aboriginal Way of Life ...... 7-44 7.5.4 Archaeological Potential of the Plant Site ...... 7-44 7.5.4.1 Prehistoric Period...... 7-44 7.5.4.2 Historical Period...... 7-44 7.5.4.3 Conclusion ...... 7-44 8 IMPACT AND MITIGATION MEASURE ANALYSIS...... 8-1 8.1 Impacts on the Natural Environment...... 8-1
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8.1.1 Components of the Physical Environment ...... 8-1 8.1.1.1 Soil, Surface Water and Groundwater: Possibility of an Accidental Spill at the Site...... 8-1 8.1.1.2 Soil, Surface Water and Groundwater: Possibility of an Accidental Spill During the Transportation of Materials...... 8-2 8.1.1.3 Soil, Surface Water and Groundwater: Operating Activities ...... 8-2 8.1.2 Atmospheric Environment...... 8-3 8.1.2.1 Construction Period ...... 8-3 8.1.2.2 Operating Period...... 8-3 8.1.2.3 Method ...... 8-3 8.1.2.4 Results – Total Concentrations of Suspended Particulates...... 8-5 8.1.2.5 Results - Concentrations of Fine Particulates...... 8-13 8.1.2.6 Results – Ammonia Concentrations...... 8-15 8.1.2.7 Results - SO2 Concentrations ...... 8-18 8.1.2.8 Results - Concentrations of Carbon Monoxide (CO)...... 8-26 8.1.2.9 Results – Concentrations of Nitrogen Dioxide (NO2) ...... 8-29 8.1.3 Greenhouse Gas...... 8-32 8.1.4 Hydrology and Water Quality ...... 8-32 8.1.4.1 Use of Water Resources...... 8-32 8.1.4.2 Impacts Related to Liquid Discharges...... 8-33 8.1.5 Waste Management Site...... 8-34 8.1.6 Ambient Noise...... 8-34 8.1.6.1 Projection Calculation Method ...... 8-34 8.1.6.2 Characterization of Impact Sources...... 8-36 8.1.7 Impact Analysis on Ambient Noise...... 8-37 8.1.7.1 Impacts Linked to the Stationary Sources Used for the Operation of the Plant...... 8-37 8.1.7.2 Impacts of Noise of Transportation and Shipping of Raw Materials ...... 8-41 8.1.7.3 Noise Impacts Linked to the Storage Site and to Transportation Activities Inside the Property ...... 8-41 8.1.8 Wetlands ...... 8-45 8.1.9 Biological Environment ...... 8-45 8.1.9.1 Vegetation...... 8-45 8.1.9.2 Fish, terrestrial and avian fauna and wildlife habitats ...... 8-45 8.1.9.3 Endangered species ...... 8-45 8.2 Human Environment ...... 8-45 8.2.1 Transportation and Traffic...... 8-45 8.2.1.1 Impact of Resulting Traffic on General Traffic...... 8-45 8.2.1.2 Road Safety ...... 8-46 8.2.2 Aesthetics and Landscape...... 8-46 8.2.2.1 Pot Lining Processing Plant ...... 8-46 8.2.2.2 Carbon and Inert Temporary Storage Site...... 8-46 8.2.3 Psychosocial Impact ...... 8-49 8.3 Health...... 8-49 8.3.1 Direct Effects...... 8-49 8.3.2 Incidences from Cumulative Effects...... 8-50 8.4 Safety...... 8-50 8.4.1 Identification of Danger ...... 8-51
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8.4.2 Identification of Sensitive Elements ...... 8-52 8.4.3 Review of Passed Accidents...... 8-52 8.4.4 Standardized Scenario...... 8-53 8.4.4.1 Definition of a Standardized Scenario...... 8-53 8.4.4.2 Assessment of the Consequences of a Standardized Scenario ...... 8-53 8.4.5 Other Scenarios ...... 8-58 8.4.5.1 Crushed Pot Lining Silo ...... 8-61 8.4.5.2 Leaching Gas...... 8-61 8.4.5.3 Pot Lining Container ...... 8-62 8.4.5.4 Defect of the Acid Supply System...... 8-62 8.4.6 Discussion on External Dangers...... 8-63 8.4.6.1 Natural Phenomenons ...... 8-63 8.4.6.2 Industrial Activities ...... 8-63 8.4.7 Conclusion ...... 8-64 8.5 Safety Measures ...... 8-64 8.5.1 General Design Parameters...... 8-64 8.5.2 Access Restriction to the Site ...... 8-64 8.5.3 Receiving and Handling Spent Pot Lining...... 8-64 8.5.4 Leaching ...... 8-65 8.5.5 Safety Installations...... 8-65 8.5.6 Emergency Shutdown...... 8-66 8.5.7 Fire-Control Systems ...... 8-66 8.5.8 Preliminary Risk Management Program ...... 8-67 8.5.8.1 Staff Protection ...... 8-67 8.5.8.2 Health and Safety Management Program...... 8-67 8.5.8.3 External Services Interventions (Contractors)...... 8-68 8.5.8.4 Critical Review Program...... 8-68 8.5.8.5 Preventive and Predictive Maintenance Program...... 8-68 8.5.8.6 Health and Safety Auditing Program...... 8-68 8.5.9 List of Regulations and Codes ...... 8-69 8.6 Emergency Response Plan...... 8-70 8.7 Economic Spinoffs ...... 8-71 8.7.1 Economic Impacts Resulting from Construction Activities ...... 8-71 8.7.1.1 Impacts for the Province of Quebec...... 8-71 8.7.1.2 Impacts for the Saguenay - Lac-Saint-Jean Region ...... 8-72 8.7.2 Annual Impacts resulting from Operating Activities...... 8-73 8.7.2.1 Impacts for the Province of Quebec...... 8-73 8.7.2.2 Impacts for Saguenay - Lac-Saint-Jean...... 8-73 8.7.3 Economic Impact Maximisation Strategy ...... 8-74 8.8 Heritage, Cultural, Historic, Archaeological, Paleontological Resources ...... 8-74 8.9 Land and Resource Use by Aboriginals and Land Claims...... 8-74 8.10 Renewable resources ...... 8-74 8.10.1 Use of the space ...... 8-74 8.10.2 Upgrading of materials...... 8-74 9 SIGNIFICANCE OF IMPACTS...... 9-1 9.1 Impact Identification and Assessment Method...... 9-1 9.2 Impact Summary...... 9-3
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10 MONITORING AND FOLLOW-UP SYSTEM ...... 10-1 10.1 Work Monitoring...... 10-1 10.1.1 Processing Plant ...... 10-1 10.1.2 Carbon and Inert Storage Cell ...... 10-1 10.1.2.1 Qualification of Stakeholders ...... 10-1 10.1.2.2 Quality of Other Materials Used...... 10-1 10.2 Discharge Monitoring ...... 10-1 10.2.1 Air Emissions ...... 10-2 10.2.2 Liquid Discharges ...... 10-2 10.2.3 Solid Discharges ...... 10-3 10.3 Environmental Follow-up...... 10-3 10.3.1 Noise Environment...... 10-3 10.3.2 Atmospheric Environment...... 10-4 10.3.3 Inert and Carbon Storage Cell ...... 10-4 10.3.4 Result Dissemination ...... 10-4 10.3.4.1 Follow-up Committee ...... 10-4
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LIST OF APPENDICES
Appendix A Jonquière Complex Drawing Appendix B General Plan Appendix C Material Safety Data Sheets Appendix D Letter from the MENV – Ambient Air Criteria Appendix E Data and Results from Atmospheric Emission Modellings Appendix E-1 Topographic Table Appendix E-2 Building-related Data Appendix E 3 Emission-related Data Appendix E-4 Results - Particulates Appendix E-5 Results – NH3 Appendix E-6 Wind Rose Appendix F Drawings of Atmospheric Emission Sources - Plan View and Elevation Drawing
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LIST OF FIGURES
Figure 3.1.1 Schematic Diagram of the SPL Processing Plant...... 3-4 Figure 3.1.2 Services Diagram ...... 3-6 Figure 3.2.1 Mass Balance ...... 3-14 Figure 3.2.2 Location of Outfall Sewers at the Jonquière Complex...... 3-22 Figure 3.3.1 Spent Pot Lining Supply Sources ...... 3-28 Figure 3.3.2 Carrier Modes for Spent Pot Lining...... 3-30 Figure 3.3.3 Distribution of Travel on the Road Network ...... 3-35 Figure 3.3.4 Container Used to Transport Spent Pot Lining ...... 3-37 Figure 3.4.1 Storage Site – Location Plan ...... 3-40 Figure 3.4.2 Storage Site – Layout Overview ...... 3-42 Figure 3.4.3 Top View of the Storage Cell ...... 3-44 Figure 3.4.4 Cross-Sectional View of the Storage Cell...... 3-46 Figure 3.4.5 Detail Drawing - Profile of the Foot of the Waste Heap ...... 3-51 Figure 7.3.1 Location of the Parc Berthier Air Quality Measurement Station in Jonquière ...... 7-7 Figure 7.3.2 Wind Direction Frequencies (1996-2000) ...... 7-12 Figure 7.3.3 Wind Speed Variation According to the Direction the Wind is Coming from (1996-2000) ...... 7-14 Figure 7.3.4 Average Monthly Temperatures (1996-2000)...... 7-16 Figure 7.3.5 Average Monthly Precipitation (1961-1990)...... 7-18 Figure 7.3.6 Location of Noise Environment Measurement Points...... 7-21 Figure 7.3.7 Temporal Noise Trends at 2310 Hébert Street...... 7-27 Figure 7.4.1 Regional Site and Location of Aluminium Plants ...... 7-33 Figure 7.4.2 Land Use and Allocation...... 7-37 Figure 7.4.3 Land Use in the Chemin de la Réserve Sector...... 7-39 Figure 8.1.1 Annual Average Particulate Concentrations (µg/m3) – Year 2000...... 8-7 Figure 8.1.2 Trend for Average Total Particulate and PM 10 Particulates Concentrations (Annual Averages) at the Parc Berthier Station in Jonquière ...... 8-11 Figure 8.1.3 Estimated Trend for the 98th Percentile of Fine Particulates (PM 2.5) at the Parc Berthier Station in Jonquière ...... 8-16 3 Figure 8.1.4 Annual Average Concentrations of NH3 (µg/m ) –1996...... 8-19 3 Figure 8.1.5 Hourly Maximum Concentrations of NH3 (µg/m ) –1998...... 8-21 3 Figure 8.1.6 Annual Maximum Concentrations of SO2 (µg/m ) – 2000...... 8-24 Figure 8.1.7 Annual Average Concentrations of CO (µg/m3) – 2000 ...... 8-27 3 Figure 8.1.8 Annual Average Concentrations of NO2 (µg/m ) – 2000...... 8-30 Figure 8.1.9 Leq24h Isophon Map ...... 8-39 Figure 8.2.1 Temporary Storage Site for Inert Wastes – Impact on the Landscape...... 8-47 Figure 8.4.1 Standardized Scenario– Toxic Gas Release ...... 8-55 Figure 8.4.2 Standardized Scenario – Explosion...... 8-59
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LIST OF TABLES
Table 1.6.1 Concentration of Pollutants in the Ambient Air Measured at the Parc Berthier Station (02016) Between 1996 and 2003...... 1-7 Table 1.8.1 Modeled Concentrations of Pollutants in the Ambient Air (Maximum Point of Impact)...... 1-10 Table 1.8.2 Impacts and Mitigation Measures Summary...... 1-15 Table 3.1.1 Raw Materials – Annual Quantities...... 3-8 Table 3.2.1 Typical Composition of Spent Pot Lining ...... 3-13 Table 3.2.2 Sources of Air Emissions – Conditions and Emission Rates...... 3-16 Table 3.2.3 Particulate Discharges into the Air – Respecting Standards ...... 3-19 Table 3.2.4 Liquid Discharges ...... 3-20 Table 3.2.5 Typical Analysis – Boiler Water Flushes...... 3-21 Table 3.2.6 Planned Composition – Flushes from the Cooling Water System ...... 3-24 Table 3.2.7 Colloidal Iron Oxide Waste – Approximate Composition ...... 3-24 Table 3.2.8 Solid Waste – Estimated Annual Quantities ...... 3-25 Table 3.3.1 Transportation Requirements Generated by the Spent Pot Lining Supply Sources...... 3-32 Table 3.3.2 Transportation Requirements Generated by Solid Waste Disposal...... 3-33 Table 3.3.3 Number of Trucks Circulating on a Normal Day and a Peak Day...... 3-34 Table 4.44.1 Comparing Hydrometallurgic and Pyrometallurgic Processes...... 4-5 Table 5.3.1 Factors to be Considered ...... 5-2 Table 7.3.1 Features of the Air Quality Measurement Station in Jonquière ...... 7-6 Table 7.3.2 Concentration of Ambient Airborne Particulates Measured at the Parc Berthier Station (02016)...... 7-6 Table 7.3.3 Concentration of Ambient Airborne Particulates Smaller Than 10 µm (PM 10) Measured at the Parc Berthier Station (02016)...... 7-9 Table 7.3.4 Concentration of Sulphur Dioxide Measured in Ambient Air at the Parc Berthier Station (02016)...... 7-9 Table 7.3.5 Weather Conditions During the Main Measurement Periods...... 7-23 Table 7.3.6 Results of Noise Measurements Taken During the Day (dBA)...... 7-23 Table 7.3.7 Results of Noise Measurements Taken at Night (dBA) ...... 7-25 Table 7.3.8 Species of Mammals Likely to be Found in Urban, Peri-urban and Agricultural Areas ...... 7-31 Table 7.3.9 Birds Likely to be Found in Urban and Peri-urban Areas in the Saguenay-Lac-Saint-Jean Region...... 7-31 Table 7.4.1 Jobs Within Companies by Area of Activity in Saguenay ...... 7-35 Table 8.1.1 Total Modelled Maximum Particulate Concentrations...... 8-6 Table 8.1.2 Comparison of Maximum Modelled Particulate Concentrations at the Parc Berthier Station with Measured Results from 1996 to 2000 ...... 8-10 Table 8.1.3 Modelled Concentrations of Particulates Smaller than 2,5 µm (PM 2,5) ... 8-13 Table 8.1.4 Modelled Concentration of Particulates Smaller than 2.5 µm (PM 2.5) at the Parc Berthier Station...... 8-14 Table 8.1.5 Modelled Maximum Concentrations of Ammonia ...... 8-15 Table 8.1.6 Modelled Maximum Concentrations of SO2 ...... 8-23 Table 8.1.7 Modelled Maximum Concentrations of CO ...... 8-26 Table 8.1.8 Modelled Maximum Concentrations of NO2 ...... 8-29 Table 8.1.9 Source Noise Levels Considered for the Simulations...... 8-36
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Table 8.1.10 Levels of Noise Anticipated During the Day and Resulting Increases at the Measurement Points Considered (dBA) ...... 8-38 Table 8.1.11 Level of Noise Anticipated at Night and Resulting Increases at the Measurement Points Considered (dBA) ...... 8-41 Table 8.1.12 Noise Levels (Leq1h) Resulting from the Development of the Storage Site and the Transportation of Materials (dBA)...... 8-43 Table 8.1.13 Noise Levels (Leq1h) Resulting from the Operation of the Storage Site and Transportation (dBA)...... 8-44 Table 8.3.1 Effect Rate of Certain Pathologies (per 100,000 Inhabitants)...... 8-49 Table 8.4.1 Results – Toxic Gas Release...... 8-54 Table 8.4.2 Results – Explosion in the Silo...... 8-58 Table 8.7.1 Plant Construction – Main Expenditure Items (in Millions of Dollars) ...... 8-71 Table 8.7.2 Regional Economic Impacts Related to the Plant Construction (in Millions of Dollars)...... 8-73 Table 9.1.1 Environmental Resistance Estimation Matrix...... 9-2 Table 9.1.2 Impact Significance Estimation Matrix ...... 9-3 Table 9.2.1 Impacts and Mitigation Measures Summary...... 9-4 Table 10.2.1 Monitoring Program – Air Emissions...... 10-2 Table 10.2.2 Monitoring Program – Liquid Discharges...... 10-3
Project to Implement a Processing Plant for Spent Pot Lining in Jonquière 1-1 Comprehensive Study Report
1 SUMMARY
This section outlines the main elements from each part of the environmental impact assessment for the project to implement a processing plant for spent pot lining in Jonquière.
1.1 Background
Alcan Primary Metal Group (Alcan or the proponent) submitted a funding request to Technology Partnerships Canada (a division of Industry Canada) for its "project to implement a processing plant for spent pot lining" (the project), at its Jonquière complex in Saguenay, in the Saguenay- Lac-Saint-Jean region and the Le Fjord-du-Saguenay RCM, near the Alcan aluminium smelters.
The proposed project consists of constructing and operating a full-scale pilot plant for the processing of spent pot lining (SPL) with an approximate capacity of 80,000 tons/year. The plant will use a chemical process developed by Alcan, called "Low Concentration Caustic Leaching and Liming" (LCLL), that enables the company to process SPL in order to convert it into a non- hazardous waste and to recycle and upgrade some products derived from this treatment.
The project is subject to the federal environmental assessment process under the Canadian Environmental Assessment Act.
This document details the comprehensive environmental impact assessment of the proponent’s project, as required by the Canadian Environmental Assessment Act. This document was developed from the environmental impact assessment conducted in 2001 as per the requirements of Quebec’s Ministère de l’environnement. This assessment is intended to address all the various points enumerated in the project’s Environmental Assessment Scoping Document.
1.2 The Issue
Pot lining is the interior coating of the electrolytic cells used to produce aluminium. This lining is composed of insulating and refractory bricks and carbon blocks. Throughout the electrolytic process, this lining absorbs a certain amount of the electrolyte’s components. The lining must be replaced every three to eight years. The internal pot lining (spent pot lining or SPL) is therefore removed and stored in a site designed specifically for this purpose.
According to Quebec’s Regulation respecting hazardous materials (Q-2, r.15.2), spent pot lining is considered a hazardous material because it is leachable, and because it can, in certain conditions, generate a flammable and toxic gas. In fact, SPL contains leachable fluorides and cyanides, and the presence of various chemical products gives it properties that are reactive to water. The pot lining is also corrosive because of the presence of sodium compounds, which also raises the pH of any leachate.
Despite efforts made by aluminium smelters to reduce the amount of SPL being generated, some 55,000 tons are generated in Quebec each year. Nearly one-half of this tonnage comes from Alcan’s aluminium smelters.
Alcan has been safely storing SPL in Jonquière since 1980. During the October 2001 to November 2003 period, Alcan shipped the SPL generated from its ongoing operations by train to the United States. On October 31, 2003, Quebec’s ministère de l’Environnement issued an authorization amendment to Alcan concerning its storage activities. The amendment extended
Project to Implement a Processing Plant for Spent Pot Lining in Jonquière 1-2 Comprehensive Study Report
the storage time of roughly 517,000 tons of pot lining to November 31, 2008 and allowed the company to increase the inventory of pot lining in storage.
1.3 Project Description
1.3.1 Construction
The site selected for the construction of a SPL processing plant is located inside the Jonquière complex in the area currently occupied by Building 311, which was previously used for the storage of bauxite (Lot 13279 of the City of Arvida valuation roll). Consequently, it is located in an area managed by the Vaudreuil plant, which is a large producer of various chemical products, such as diverse aluminas and fluorine-based products. The main steps involved in the construction of the pot lining processing plant are as follows:
· Demolition of Building 311 in the Jonquière complex; · Soil characterization at the selected site; · Installation of landfill infrastructures and building foundation piles; · Construction of foundations; · Erection of steel structures for the buildings; · Installation of processing equipment.
The SPL processing plant will be comprised of the following buildings: