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2009 Success snowballs for Environmental Education Project Since 2002, the Alcoa Foundation has been supporting the Environmental Education and Citizenship (EEC) project in Québec and elsewhere in Canada. The project has now spread beyond the Canadian border, to be exported to Chile and Israel. The person in charge of the program is Claude Poudrier, an expert in EEC. more
Défi, on recycle, learning through example Since 2008, small and medium-sized businesses in the Nicolet-Yamaska and Bécancour regional county municipalities have benefited from a free coaching service by taking part in the Défi, on recyle (Recycling Challenge) program. more
Smelter Turns Around Contentious Management/Employee Relationship By rebuilding its leadership team, changing its leaders’ management style, and boosting communication with employees, Alcoa’s Aluminerie de Becancour (ABI) smelter in Quebec, Canada, addressed a contentious management/employee relationship and today is in the top echelon of Alcoa plants in regards to employee engagement and satisfaction. more
Aluminum Innovates at Home Alcoa Canada launched a design competition on April 16 under the theme, Aluminum Innovates at Home. The goal was to foster the ecologically responsible use of aluminum while showcasing the ingenuity and creativity of Quebec’s industrial designers. more
No less than 116 risks of fall avoided at Electrolysis In 2006, a budget of $1.8 million was approved to modify the eight service machines at Electrolysis (MSE) at the Deschambault Smelter to help prevent the risk of falls which, due to the proximity of molten metal, could be fatal. more
Aluminum Innovates at Home Alcoa Canada launched a design competition on April 16 under the theme, Aluminum Innovates at Home. The goal was to foster the ecologically responsible use of aluminum while showcasing the ingenuity and creativity of Quebec’s industrial designers. more
2008 Better protection at the Bécancour Rod Plant In a spirit of continuous improvement, occupational health and safety (OH&S) requirements have evolved over the years in the aluminium sector. The Bécancour Rod Plant, which celebrated its 15th anniversary in 2007, has done the same. In this same spirit, it recently modified some of its machines to better protect employees. more
Controlling beryllium: it’s in the bag! The residues from the electrolytic bath are crushed and bagged so they can be reused. Although an excellent example of reuse, this process does involve some health risks. more
Ensuring that safety instructions are carefully followed You have worked with your team to identify the major safety risks, you have found the appropriate corrective measures, you put everything in place to ensure they are quickly applied and you, of course, expect that these essential safety instructions will be followed. Congratulations! But what if they aren’t? Or if they are, but only some of the time? What then? more
Improving the control and management of assisted ventilation breathing apparatus maintenance through outsourcing Workers in several sectors of the Baie-Comeau Smelter have to protect themselves from dust, gases and other potentially dangerous substances by wearing an assisted ventilation breathing apparatus, commonly known as a Racal. These devices must be carefully maintained to ensure they are working properly and providing optimal protection. more
Leader in qualifying protective clothing and equipment Although Alcoa’s priority is to eliminate the risk of accidents and their resulting injuries at the source, protective clothing and equipment always have a role to play in dealing with the unexpected. As a result, protective clothing and equipment at Alcoa Canada Primary Products must comply with a number of rigorous standards to ensure the safety and well-being of employees at all times. more
Phasing out pressurized containers Molten metal and pressurized containers (tanks, cans and others) are just not a good mix. Any pressurized container submerged into an environment as hot as molten metal would become a bomb. However, since a number of products essential to our operations are found in this form, eliminating pressurized containers is easier said than done. more
A birthday, that’s something to celebrate with the community! In 2006, when it marked its 20th year in operation with a big splash, the Bécancour Smelter (ABI) started the ball rolling on a series of events to celebrate the anniversaries of the founding of Alcoa Canada Primary Metals plants. In 2007, together with our employees, families, friends and neighbors, we celebrated the 50th anniversary of the Baie-Comeau Smelter as well as the 15th anniversary of the Deschambault Smelter and the Bécancour Rod Plant. more
ACTION at Baie-Comeau schools At the Baie-Comeau Smelter, volunteering is not only contagious but induces an uncontrollable desire to do it over and over again. more
Building bridges between the generations During the meeting of employees who participated in Worldwide Month of Service activities in 2007, our talented volunteers commented that seniors rarely benefit from ACTION programs. This stems from the fact that the residences where they live are owned by private concerns and are not eligible for Alcoa Foundation grants. more
Inspiration, a renewable resource The Bécancour Smelter (ABI) has always maintained as one of its priorities to reduce the amount of waste it sends to landfill. In 2007, it met Alcoa’s ambitious corporate target – to reduce landfilled waste by 50% in 2007 compared to the base year of 2000. This achievement speaks volume about its commitment, as does its certification under the program ICI ON RECYLCE! (Here we recycle) of RECYC-QUÉBEC. more
Promoting equal opportunity The Women’s Network of Alcoa Canada Primary Metals is one of the local chapters of this international initiative launched by Alcoa to contribute to the development and advancement of women leaders within the organization. In Quebec, the network is made up of close to 40 women from every facility, where they assume roles of varying responsibility. more
Sustainability Advisory Committee Helps Alcoa Meet Expectations of Canadian Society In Quebec, Canada, a sustainability committee is advising Alcoa’s Primary Metals Canada operations on how best to integrate sustainability to meet the expectations of society. more
Deschambault gets Triple Crown for corporate auditing All of Alcoa’s major facilities must regularly undergo a corporate audit. In 2007, the Deschambault Smelter was the first Alcoa Canada Primary Metals plant to receive a score of “excellent” in all of the audit’s three components, garnering it a Triple Crown trophy. more
Sustainability advisory committee helps Alcoa meet expectations of Canadian society In Quebec, Canada, a sustainability committee is advising Alcoa’s Primary Metals Canada operations on how best to integrate sustainability to meet the expectations of society. more
Alcoa Center of Excellence sparks international exchange From its base in Québec, the Center of Excellence ensures that the expertise and know-how of the employees of the Baie-Comeau, Bécancour and Deschambault smelters are shared with their colleagues around the world. more
Alcoa supports mentorship for North Shore entrepreneurs In partnership with the Centre local de développement de Manicouagan, Alcoa Canada Primary Metals has helped create a mentoring service to assist young companies in the region to reach the crucial five-year mark. more
Céddi-Al 2007: aluminum the order of the day The Baie-Comeau Smelter joined the Ministry of Economic Development, Innovation and Export Trade, the City of Baie-Comeau, the Manicouagan Chambre of Commerce, the Centre de développement de Manicouagan, the Service d’actions entrepreneuriales Manicouagan and Entrepac to present the first Québec edition of the Conférence sur l’énergie et le développement durable dans l’industrie de l’aluminium (Céddi-Al). more
The secret to the successful start-up of Fjarðaál and Møsjoen: Deschambault How do you supply world-class green anodes and baked anodes to Norway and Iceland when regular production barely meets internal demand? You have to plan, ensure flawless execution, and have an outstanding team not only in the paste plant and the baking furnace, but all throughout the smelter. more
Two students at the Alcoa Technical Center (ATC) ATC: an outstanding R&D experience By Sébastien Bolduc Master’s Student Université du Québec à Chicoutimi
Summer at the ATC By Jayson Tessier Doctoral Student, Laval University more
A noteworthy performance in GHG emission reduction In 2002, Alcoa Canada Primary Metals was the first corporation to sign a voluntary greenhouse gas (GHG) emissions reduction agreement with the Government of Quebec. This five-year agreement fixed specific reduction targets and required compensation to be paid if the targets were not reached. more
Alcoa takes active part in the PRRI The Programme de Réduction des Rejets Industriels (PRRI) (Industrial Waste Reduction Program) of Quebec’s Ministère du Développement durable, de l’Environnement et des Parcs aims to gradually reduce industrial waste. This strategy targets some 250-300 companies in the industrial sector whose discharge of contaminants can have a potentially significant impact on the surrounding area. more
Extending pot life to reduce waste A series of initiatives at the Deschambault Smelter resulted in the development of a new technology to extend the life cycle of pots. This innovation, which has also been adopted in Australia, Iceland and the United States, received a 2008 Alcoa Impact Award for North America. more
Fluorides: landmark results at the Deschambault Smelter Despite increasing production, the Deschambault Smelter achieved its lowest fluoride emissions ever in 2007: 0.26 kg F/t Al compared to an annual average of 0.32 kg F/t Al over the last few years. Emissions are measured in two locations, at the scrubbers and at the roof vents, and measures have been specifically adopted in both places to achieve this strong performance. more
Optimizing every kWh, the way into Hydro-Quebec’s Écolectrique network Electricity is more than just a raw material needed to manufacture aluminium. It is also a precious resource. Since every kWh saved can be used to produce a bit more aluminium, it is in our best interest to be extremely vigilant. more
Recycling and reuse of waste – two major priorities For many years, all four plants of Alcoa Canada Primary Metals have been certified under ICI ON RECYCLE! (Here we recycle!). This program, operated by the government corporation of RECYC-QUÉBEC, recognizes corporations, businesses and institutions that achieve certain reduction, reuse, recovery and recycling objectives for containers, packaging, materials or products, and that promote reuse with a view to resource conservation. more
The ABS approach to better environmental compliance New, stricter regulations will be going into effect in 2010 for polycyclic aromatic hydrocarbons (PAH) emissions – contaminants produced during the combustion of organic matter. In anticipation of these harsher requirements and to ensure compliance, the Baie-Comeau Smelter applied ABS (Alcoa Business Systems) tools such as visual management and the standardization of work methods to reduce emissions at its Söderberg potrooms. more
The Deschambault Smelter’s facilities at the Port of Trois-Rivières The main raw materials used by the Deschambault Smelter – alumina, coke and petroleum – arrive by ship at the Port of Trois-Rivières. Storage capacity is 75,000 metric tons for alumina and 20,000 metric tons for coke and petroleum. more
Employees take charge of equipment maintenance Employee commitment is one of the fundamental principles of ABS (Alcoa Business System), the management approach adopted by all Alcoa facilities. And the team from Alcoa Canada Primary Metals takes this principle very seriously, as you will see from this case study. more
Impact Awards 2008: Quebec rakes in the honours! Of the 220 project presented at this year’s Impact Awards, an Alcoa jury – which included Pascal Cléry, General Manager of the Bécancour Smelter – narrowed the list down to 12 finalists (two per category). more
Training at the Bécancour Rod Plant: An example of our commitment to Iceland Here at the Bécancour Rod Plant, we had the opportunity to train eight of our colleagues from Iceland on how to operate the Properzi rod machine. more
The Alcoa Team Builds with its People in Québec! Its employees devoted over 800 hours to volunteer services. In the framework of the Alcoa Worldwide Month of Service, roughly 200 employees from the various Alcoa Canada facilities decided to join forces and to serve their community as volunteers by actively participating in the improvement of the installations of different non-profit organizations. more
2007 Centraide: Alcoa practically doubles its donation Every year, Centraide, an umbrella charitable organization, runs one of the most important fund-raising campaigns in Quebec, and redistributes the money it raises to hundreds of non-profit organizations that help people in need. more
Giving Dreams Flight Thank to volunteers from Alcoa Baie-Comeau, cadets of Escadron 654 Baie-Comeau are flying high. more
Customers: a priority at Baie-Comeau In 2006, the Customer Relations team at Baie-Comeau set its sites on improving customer service at the aluminum smelter and foundry. more
Reliability: a question of joint custody! What should be done to ensure that the machinery in an aluminum smelter is carefully operated and meticulously maintained to increase its operating time and useful life? more
STAS-Alcoa: partners in innovation With technological advances becoming more complex and far-reaching, companies do not always have the financial resources or the expertise needed to go it alone in the area of research and development. more
A new life for by-products The Bécancour smelter has always thought that the waste it generates can be reused. This belief has been held since plant start-up, as was apparent from its early purchase of a building to store process wastes until a new use or recycling solutions could be found. more
Better water management In 2006, the Baie-Comeau aluminum smelter acquired a new flow meter that enabled it to precisely measure its water consumption. Previously, the plant had relied on estimates made by its water supplier, but had noted discrepancies between these estimates and its own calculations. more
Daily management of scrubbers in the Electrolysis sector The Air Environment team at the Deschambault aluminum smelter has developed a highly effective tool for optimally managing fluoride emissions at the scrubbers in the Electrolysis sector. more
Energy efficiency: always part of the program In its Policy on Energy Efficiency, Alcoa Canada Primary Metals declares its commitment to optimizing energy use in its facilities and promoting conservation among its employees and partners. more
Innovation for capital expenditures All of the major capital expenditures at Alcoa are subject to a rigorous evaluation process that takes into account their impact on the environment and health and safety. This so-called PESHER, for Project Environment, Safety and Health Review, is based on compliance with U.S. regulations, where the program was originally developed. more
Learning about energy while having fun In a Canadian city economically centered on energy-intensive industries, 475 local children learned about energy and energy consumption through a fun and interactive Alcoa-sponsored program called Kilojoue. more
Optimization and reuse in the Electrolysis sector As part of a project to optimize the electrolysis process, the Deschambault aluminum smelter removed almost 300 metric tons of carbon dust from its pots. Carbon dust, which is considered a hazardous waste, is formed when small quantities of carbon fall into the electrolysis bath when anodes are being replaced. more
Reducing greenhouse gases: a winning proposition for the Bécancour aluminum smelter Thanks to persistent teamwork, the Bécancour aluminum smelter (ABI) has made remarkable progress in reducing greenhouse gases. For several years, the plant has applied itself to the task of reducing emissions of perfluorocarbons (PFCs), which are potent greenhouse gases. more
Replacing pot hoods in the Electrolysis sector A curved electrolytic pot hood has two marked advantages relative to a flat one. First, it is more solid, and thus less likely to be damaged in the potline. Secondly – and this is environmentally significant – it is more air tight and accordingly reduces fluoride emissions. more
System update to meet new requirements New and stricter environmental requirements for wastewater have been in place at the Bécancour Rod Plant since June 2006. The requirements apply to suspended particles, chlorides, oxidants and aluminum. New requirements for measurement tools and frequency were also implemented. more
Testing hybrid pitch at the Söderberg pots To meet future government environmental standards, the Baie-Comeau aluminum smelter is working on reducing its polycyclic aromatic hydrocarbon (PAH) emissions, which are produced during the combustion of briquettes in the anodes of the Söderberg pots. more
Better ventilation improves health and safety Good ventilation in a plant is a question of balance between the air that goes out and the air that comes in from the outside. This stability contributes not only to the well-being of employees but also to the more efficient management of some aspects of production. A number of projects were carried out recently to correct the situation in some sectors of the Bécancour Rod Plant. more
Daily management: at the heart of Baie-Comeau’s efficiency At the Baie-Comeau smelter, quality management is a daily affair. The strong presence of managers in various sectors of the plant is one indication. more
Ergonomic improvements to bridge cranes From the moment that the operation of bridge cranes was identified as one of the ten highest ergonomic risks to occupational health and safety (OHS) at the Baie-Comeau aluminum smelter, a multidisciplinary team set to work. The team was made up of ergonomics and health and safety leaders, representatives of the labour union and from engineering services, and four crane operators. The team quickly applied its collective pool of expertise to developing a prototype of a more user-friendly workstation. more
Managers get involved with workplace health and safety Thanks to the program of daily health and safety visits (HSV) by managers, office workers at the Bécancour aluminum smelter play an important role in the plant's workplace health and safety. more
Protecting employees from beryllium The Baie-Comeau and Bécancour aluminum smelters have implemented special measures to protect all employees from the dangers of beryllium exposure. This element, contained in alumina, accumulates and concentrates in the electrolytic bath of pots during aluminum production. The bath residues are eventually ground up for reuse. It is at this stage that beryllium becomes a health and safety issue, because inhaling this dust may lead to berylliosis, a serious lung disease. more
Protection against falls: a priority at Deschambault The people responsible for health and safety at the Deschambault Smelter focus on continuous improvement of practices to ensure the well-being of all workers. Preventing falls is one of the key issues they are looking at in several areas of the plant. more
Reduced noise exposure at Deschambault An aluminum smelter can be a noisy work environment and measures must be taken to protect employees from the negative effects of exposure to too many decibels. more
Safety: a priority at the homogenization furnace in the Bécancour aluminum smelter Since becoming operational, the new homogenization furnace at the Bécancour smelter has been equipped with a number of safety devices to protect workers. The plant's multidisciplinary team charged with carrying out the risk analysis before the furnace was built established a fundamental rule: zero access to the danger zone. more
2007 ABS Conference: hats off to innovation The second edition of the ABS Conference has illustrated, once again, the ingenuity of the people at Alcoa Canada when they tackle the issue of quality. more
Alcoa Canada Primary Metals: open to the world The activities of the Alcoa Canada Primary Metals team extend well beyond the borders of Québec and even Canada. Thanks to projects in Iceland, Norway and elsewhere in the world, our experts share their best practices on a global scale. more
Much appreciated training in the electrolysis sector To ensure the updating of technical skills in the electrolysis sector at the Deschambault aluminum smelter, two operators and a group of technicians have developed a four-module training program with the help of a consultant in education. more
The Alcoa Women's Network: for better leadership Some 30 women who work for Alcoa in various regions of Quebec, and who are at various stages of their careers, meet each year to deal with a current issue of particular concern to them. more
