Presentation prepared for ARABAL

1. Presentation prepared for ARABAL    A Solution for Aluminium Smelter Spent Potlining Based on the Principles of Industrial Ecology: A Case Study Qatar November, 2012

2. Introduction • Changing environmental regulatory conditions mean an alternative to landfilling SPL is required • There is potential value in SPL for industries such as cement and clay brick manufacture • Realisation of the potential value in SPL has proved difficult due to: • hazards in SPL • variable properties of SPL • regulatory and community perceptions regarding SPL • Industrial ecology provides a framework for: • objective and rational stakeholder engagement • a comprehensive solution for SPL

3. Industrial Ecology • Industrial ecology uses the natural environment as a model for industrial environmental problems • In natural ecosystems, waste of one species is food for other species • Concepts of industrial ecology set the tone for constructive engagement of disparate stakeholders • Key is to reconceptualise waste as products • Industrial ecology enables synthesis of: • environmental imperatives • technological innovation • business economics

4. Regulatory Perspective • General trend away from disposal and towards recovery • 2008 EU requirements for a substance to be regarded as byproducts rather than waste • further use is certain • the substance can be used directly without further processing • the substance is produced as an integral part of the production process • further use is lawful • Australian regulatory input for this case study: • avoid residual material • sensitivity to community reaction • reluctant to approve export under Basel Convention

5. Nature of SPL • Hazards: • explosive gases • cyanide • leachable fluoride • Solutions for SPL have proven difficult: • inherent hazards • highly variable properties • complex chemistry Ship damaged by SPL gas explosion Shipping container damaged by SPL gas explosion Raw SPL

6. Value in SPL for Other Industries • Cement and clay brick industries • environmental pressure to reduce CO2 emissions • economic pressure to reduce energy costs • Fluxes & mineralisers • fluxes lower process temperatures • mineralisers accelerate reaction rates • Valuable constituents in SPL • carbon – thermal energy • sodium as a flux • fluorine as a mineraliser • alumina and silica as raw materials

7. Strategy for SPL Solution • Objectives • 100% beneficial re-use of SPL with no residual material • Low cost of SPL processing • Lower energy use & CO2 emission for cement & clay brick • Positive impact on environment • Strategy • gain support of regulatory agencies • develop chemical process to eliminate explosive gas & cyanide hazards • develop markets for mineral products • products not classified as hazardous waste • establish integrity of overall system

8. SPL Processing • REQUIREMENTS OF PROCESS • Ability to handle highly variable SPL • Chemical process to eliminate hazards • Maximise inherent value in resultant products

9. An Industrial Ecosystem for SPL Aluminium Industry Cement Industry Enabling Platform Cement Plant A Smelter A SPL Process Technology Technology to use products Cement Plant B Regulatory Approvals Smelter B Cement Plant C Manufactured products for energy saving and CO2 reduction Clay Brick Plant A Smelter C Clay Brick Plant B Product Marketing and Logistics Body of Knowledge Smelter D Clay Brick Plant C Clay Brick Industry Regulatory Stakeholders Community Stakeholders

10. In Summary …… • Changing environmental regulatory conditions mean an alternative to landfilling SPL is required • There is potential economic and environmental value in SPL materials • Applying the principles of industrial ecology provided the basis for constructive engagement • By removing the hazards in SPL, products derived from SPL are not classified as hazardous waste • Comprehensive and low risk solution for SPL • Proven over ten years with 90,000 tonnes of SPL