aluminium for future generations sustainability update 2005

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ALUMINIUM FOR FUTURE GENERATIONS The Aluminium for Future Generations initiative is a programme of continuous improvement on the part of the global aluminium industry, overseen by the International Aluminium Institute (IAI). It comprises voluntary objectives, currently thirteen in number but increasing year by year, related to all key phases of aluminium’s life cycle. The industry’s performance towards meeting these objectives is measured annually against twenty two performance indicators. This update reports on year 2005 performance recorded in the annual survey of sustainability data collected from IAI member companies, collectively responsible for over 70% of global primary aluminium production and around 20% of recycled metal production. For further information on IAI members, please visit the World Aluminium website. This year survey data was collected from: • 75 smelters representing almost 18 million tonnes of primary aluminium production, a 21% increase on 2004 coverage and equivalent to 55% of total global aluminium production; • 24 refineries representing over 36 million tonnes of smelter grade alumina, a 41% increase on 2004 coverage and equivalent to around 60% of total global alumina production; • 11 mines representing over 81 million tonnes of bauxite, a 13% increase on 2004 coverage and equivalent to around 50% of total global bauxite production. 2005 Sustainability Performance Voluntary Objective 1 An 80% reduction in Perfluorocarbon (PFC) greenhouse gas emissions per tonne of aluminium produced for the industry as a whole by 2010 versus 1990 levels. Tonnes CO 2 equivalent per tonne aluminium produced 5 4 3 2 1 0 4.4 1990 1992 1.0 1994 1996 1998 2000 2002 2004 2006 0.9 2008 2010 PFC emissions from the global aluminium industry have been reduced by 76% per tonne of aluminium produced between 1990 and 2005. Total PFC emissions have been reduced by over 60% between 1990 and 2005, even though total primary production has increased from 20 to over 30 million tonnes per annum in the same period. PFCs are potent greenhouse gases with long atmospheric lifetimes, formed in the aluminium smelting process during brief upset conditions known as ‘anode effects’. The improvement in PFC emissions performance over the last fifteen years is in part due to a heightened awareness at all levels within companies and the availability of facility benchmarking data and sharing of best practices to reduce the frequency of anode effects. Current global PFC emissions performance is equivalent to a reduction of over 3 tonnes of CO 2 per tonne of aluminium produced since 1990. Voluntary Objective 2 A minimum of a 33% reduction in fluoride emissions by IAI member companies per tonne of aluminium produced by 2010 versus 1990. Data collected from facilities representing 83% of IAI member company production indicate a reduction in total fluoride emissions (gaseous and particulate) of over 50% per tonne of aluminium produced between 1990 and 2005. Voluntary Objective 3 A 10% reduction in average smelting energy usage by IAI member companies per tonne of aluminium produced by 2010 versus 1990. Megawatt hours per tonne aluminium produced 16.2 16.0 15.8 15.6 15.4 15.2 15.0 14.8 14.6 14.4 16.1 1990 1992 15.3 1994 1996 1998 2000 2002 2004 2006 2008 14.5 2010 The average electrical energy required to smelt one tonne of aluminium from alumina has been cut by 5% between 1990 and 2005, mainly through investment in modern, more efficient technologies. New smelters generally utilise best available technologies, no matter where in the world they are located and the IAI is helping producers to share knowledge and best practice to improve energy efficiency. 1
Voluntary Objective 4 A 50% reduction in the lost time accident rate and recordable accident rate by 2010 versus 2000 by IAI member companies, with a review in 2006. Safety performance data is collected in a separate survey which has a wider reporting base than the IAI membership. The survey was initiated in 1997, with a coverage of 107 million working hours. By 2002 the number of working hours surveyed had risen to 315 million and by 2005 to 411 million. The survey now covers 98 aluminium smelters, 34 alumina refineries and 15 bauxite mines. Per million hours worked 30 25 20 15 10 5 0 1997 1998 1999 2000 2001 2002 2003 2004 2005 Lost Time Accident Rate Recordable Accident Rate The recordable accident rate at reporting plants has been cut by 75% over the period 2000-2005. The lost time accident rate has been reduced by 64% over the same period. A focus on improving accident rates has also seen the number of days lost per accident (the severity rate) decrease by 60% from 1997 to 2005. Lost Time Accident Rate (Injuries per million hours worked) 8 7 6 5 4 3 2 1 0 2004 2005 1998 1999 2000 2001 2002 2003 1997 0 50 100 150 200 Severity Rate (Days lost per million hours worked) The improvement in the industry’s accident rates is being driven by factors including increased top management attention and commitment on safety, more systematic accident follow up and increased involvement of the workforce, as well as mechanization and automation as a means to improving technical conditions. While continuing to improve on these rates, the industry is now focusing on reducing the severity of accidents and on preventing fatalities by compiling guidelines based on best practice from the worldwide industry. Most serious accidents involve mobile equipment and cranes and other lifting devices. In 2004, 35% of all fatal accidents were traffic-related while in 2005 this figure was 25%. The IAI has developed a set of safety guidelines for mobile equipment based on the shared procedures and experiences of a number of aluminium companies in managing the risks involved in mobile equipment and pedestrian segregation. These guidelines have been made available to the aluminium industry (member and non-member companies) and other industries. Further guidelines on cranes and lifting devices are also being developed. Future Priority areas include: • The concentration of management actions on the operation of mobile equipment, cranes and lifting devices; • Improving rules, procedures and work standards; • Improving equipment design and engineering; • Improving training in the use of equipment; • Addressing behaviour based safety. • Drafting an IAI Safety Audit Protocol to be used in connection with a generic occupational health and safety audit of member companies. Voluntary Objective 5 Implementation of Management Systems for Environment (including ISO 14000 or equivalent certification) and for Health and Safety in 95% of IAI member companies’ plants by 2010. 92% of plants surveyed have such management systems in place, with 82% having ISO 14000, compared to around 60% in 2004, and 20% having OHSAS 18000, compared to around 10% in 2004. Voluntary Objective 6 Implementation of an Employee Exposure Assessment and Medical Surveillance Programme in 95% of IAI member companies’ plants by 2010. Employee exposure assessment and medical surveillance programmes are in place at 89% of IAI member company plants. A detailed industry-wide definition of criteria required to meet this objective was included with the survey questionnaire this year and so the data from 2005 can be considered more robust than those from 2004, which gave a figure of 92%. 2
Page 4 and 5: Voluntary Objective 7 The industry
Page 6: The energy needed for primary alumi

aluminium for future generations sustainability update 2005

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