hsec report 2003

8/3/2019 HSEC Report 2003

1/20


2/20

TITLECONTENTS

Our MDs Report . . . . . . . . . . . .1

Our Vision and Values . . . . . . .2

Our HSEC Policy . . . . . . . . . . . . .5

Our Operation . . . . . . . . . . . . . .6The ProcessOwnershipEmploymentEconomic Contribution

Our Health Performance . . . . .72003 PerformanceImprovement Targets for 2004

Our Safety Performance . . . . .82003 PerformanceImprovement Targets for 2004

Our Environmental Performance102003 PerformanceReportable IncidentsCommunity MonitoringGreenhouseEnvironmental EvaluationDust

- Calciners- Boilerhouse- Other Fugitive Dust Sources

AlkaliOdour

NoiseWaterWaste ManagementLand RevegetationAwardsImprovement Targets for 2004

Our Community . . . . . . . . . . . .142003 ActivitiesQAL Community ForumCommunity Involvement

- Committees- Open Days

Community Assistance- Sponsorships and Donations

- QAL Community HouseEducation- ALP Education Program- Tours

Vocational Development- Work Experience- Vacation Employment- Apprentices- Second-chance Employment- Engineering Co-operative Program- Graduate Program

Employment DiversityImprovement Targets for 2004

Glossary . . . . . . . . . . . . . . . . . .17

Your Feedback (attached)


3/20

1

Our MDs report

Welcome to Queensland Alumina Limiteds (QAL) 2003 Health, Safety,Environment and Communities report our first ever.

Our choice to produce this annual report is based on providing all of ourstakeholders, and in particular our neighbours, with an accurate andaccountable measure of our health, safety, environment and communityperformance, and our commitment to future improvements.

Although 2003 was a year of considerable environmental improvement, safetymilestones and consolidation of community relations, we also recognise the roomfor improvement and this will be our focus for 2004 and beyond.

I am particularly pleased to note recordable serious injuries for 2003 were closeto the lowest on record. Two world-class safety milestones were a highlight. Thesite achieved 500 000 serious injury free work hours, and in the last six monthsof 2003 recordable injuries were comparable to benchmark industry safetyperformance. The challenge for 2004 is to further reduce recordable injuriesand continue safety initiatives that contribute toward our goal of zero incidents.

Hand in hand with safety, environmental impact is our biggest concern.According to survey data and feedback from our Community Forum it is alsowhat concerns our community the most. Significant environmental improvementswere made during the year and it is expected that this will continue as more ofthe $233 million five-year capital environmental improvement projects come online. There is however still a way to go, and I thank the community, andespecially our Community Forum, for their understanding and support whilstthese projects are implemented.

Environmental highlights during 2003 included:

Commissioning of the $175 million Calciner Project to reduce alumina dustemissions by 92 per cent. Design issues prevented the Calciners fromrunning at 100 per cent throughput at the end of 2003. This was adisappointment and one that will be rectified in 2004.

Commissioning of a purpose built, cost neutral on-site waste transferfacility. The facility has resulted in an 85 per cent reduction in waste goingto landfill which is a significant win for the environment and sets astandard for other industries.

Commissioning of a thermal oxidiser odour destruction unit. Olfactometrytests in 2004 should confirm the unit reduced odour from the Digestionsection of the plant by 40 per cent.

Since commissioning of the treated effluent pipeline to recycle and reuseGladstone citys wastewater, QAL has maintained its lowest fresh waterusage ever.

Transparency, integrity, communication and assistance remained the staplefoundations of QALs community relations program. The QAL Community Forumcontinued to be a constructive and invaluable medium for feedback and socialaccountability. Feedback is a continual reminder for us that our standards are setby our communitys expectations, not minimum legal requirements. Anothercorporate and community issues survey will be carried out in 2004 measuringour performance as a corporate citizen, highlighting areas that require morefocus and allowing us to work toward meeting community expectations.

As this is our first report I encourage you to complete the enclosed feedbackform assisting us to tailor future reports to best suit your needs.

Thank you for taking an interest in our operations. I hope you enjoy the read.

Kind regards

Johann van ZylManaging Director


4/20

2

QAL Vision and Values

QAL Vision

QAL will be recognised asthe best producer ofalumina in the world

The best to work for

The best corporatecitizen

The supplier of choice

The best to own

The best to supply

Our basic strengths willbe the initiative, innovationand teamwork of ourworkforce, together withour ability to anticipateand effectively respondto change, and ourcommitment to continuous

improvement across allfacets of our businessactivity.

Safety

Everyone gives safety top priority

Everyone knows the safety rules

No-one accepts unsafe practices orconditions

We stop a job if it is unsafe

Everyone keeps their workplacetidy and safe

Teamwork

We treat each other with fairness,dignity and respect

We are involved in decisions thataffect us

We speak openly and frankly

We listen to each other

We change for the good of theteam

We develop and use our skills

We keep each other informed

Performance

We strive to be the best

We agree what is required of usand that it is realistic

We work hard

We act on good ideas

Everyone knows how they areperforming

We recognise good performance

We learn from our mistakes

Customers

We know who our customers are

We ask our customers what theywant

We work with our customers to getthe best result

We continually improve the qualityof our output

We deliver

Integrity

Our behaviour is consistent withour values

We are ethical, open, honest andfair

We honour the trust others place inus

We have the courage to face up tothe issues and responsibilities thatconfront us

We let others know before they getinto strife

Environment and Community

Everyone knows how their workaffects the environment

We do not take short cuts whichimpact the environment

We find better ways to look afterthe environment

We talk with our community and

respond to their views

We are involved with communityaffairs and support communityprojects

QAL Values


5/20

3


6/20

4


7/20

5

Our HSEC Policy

Policy

Ensure HSEC principles are an essential part of QALs management anddecision-making process. QALs objective is to demonstrate leadershipthrough performance that contributes to maximisation of value.

Create an atmosphere that motivates and supports all employees in theirefforts to achieve a zero injury / incident working environment.

Minimise emissions, giving priority to those that may present the highest riskto health and the environment.

Audit the operation and business processes at regular intervals to assessHSEC performance and compliance.

Prepare, test and maintain emergency procedures. Eliminate substandard behaviour and conditions (hazards) in the workplace. Address HSEC implications of development, operations, maintenance and

closure.

Continually evaluate and improve our business practices, processes andservices to reduce risk.

Engage in open and transparent communication with stakeholders to achievegreater HSEC understanding to ensure the long-term sustainability of QAL asa business in Gladstone.

Consider and establish appropriate HSEC requirements when selectingbusiness partners and contractors.

Participate in voluntary and community programs such as the GreenhouseChallenge Program and Alumina Learning Partnership with local schools.

Comply, as a minimum, with legal requirements and adopted internationalstandards aiming to perform beyond regulatory requirements.

Report on performance to our workforce, our owners, and the greater

community.

MD Personal Commitments

I will ensure there are effective systems and processes in place to give effectto this Policy,

I will hold leaders accountable for annual action plans to deliver HSECimprovements,

I will authorise the allocation of resources, including appropriate training,sufficient for those plans to be implemented,

Legal compliance is the absolute minimum performance standard expected,best practice is encouraged,

Compliance with this Policy is a condition of employment for employees andcontractors,

Individual HSEC performance will be assessed each year, I expect the following guiding principles to be applied at all times to all tasks,

by people in our business: Safer. Cleaner. Better.

Johann van ZylManaging DirectorJanuary 2003

QAL is committed to managing ourworkplace in a safe manner, free

from incidents, injuries andillnesses. We will ensure thatenvironmental impacts directly orindirectly related to QAL areminimised. We acknowledge theimportance of effectivecommunication both internally andto our stakeholders.

Excellence in managing Health,Safety, Environment andCommunities (HSEC) is essential toour long-term success and is aprimary responsibility for all QALemployees and contractors.


8/20

QAL commenced in March 1967with a production rate of 600,000tonnes of alumina. Today QAL isthe worlds largest aluminarefinery, producing some 3.75million tonnes of the worlds bestsmelter grade alumina. Estimatedreplacement value of QAL isapproximately US$4 billion.

The refinery covers 80 hectares ofa 400-hectare site on the south-eastoutskirts of the city of Gladstone.Adjacent to the plant is a wharf

and storage facility on South TreesIsland, which is connected to themainland by a causeway bridge.

The Process

QALs bauxite supplies are mined atWeipa in far north Queensland. Thebauxite is loaded onto speciallydesigned, and QAL chartered, coal-fired ships that transport the bauxitearound Cape York and 2000

kilometres down to Gladstone.

Alumina is produced at QAL throughthe continuous four stage BayerProcess involving:

1.Digestion Dissolving bauxitesalumina content

Bauxite is finely ground in mills, thenmixed with a recycled caustic sodasolution and steam in digester vesselsoperating at high temperature. Thisdissolves the alumina content of the

bauxite and the solution is thencooled in a series of flash tanks.

2.Clarification Settling outundissolved impurities

The impurities, which remainundissolved, are allowed to settle asa fine mud in thickening tanks. Afterseveral washing stages to recovercaustic soda, this residue is pumpedto storage dams. The solution ofalumina in caustic soda is further

clarified by filtration.

3.Precipitation Forming aluminacrystals

The next step involves the recovery ofalumina crystals from the causticsolution. In open-top tanks, thesolution is stirred by mechanicalagitation and seeded with previouslyprecipitated alumina to assist crystalformation.

4.Calcination High-temperaturedrying of alumina

The precipitated material (calledhydrate) is washed and calcined attemperatures exceeding 1000degrees Celsius. This forms the drywhite anhydrous aluminium oxidepowder, alumina, which is cooledand conveyed to storage.

Ownership

At the beginning of 2003 QALproduced alumina on behalf of aconsortium of four aluminiumcompanies. During 2003 Alcanobtained Pechineys interests and QAL

now produces alumina on behalf ofthree Owners. As of December 2003the shareholdings in QAL were:

Alcan 41.4% Comalco 38.6% Kaiser 20.0%

Owners are supplied with alumina inproportion to their equity. A tollingcharge per tonne of alumina is appliedto recover the costs of processing,including operating, maintenance, raw

materials, energy and administration.The following graph illustrates wherealumina was shipped during 2003.

QAL Alumina Shipments 2003

Employment

In 2003, QAL operated with an

average workforce of 995 employees,and some 300 plus contractors whovaried with workload.

At the end of 2003, 72 employees(excluding contractors) were female,representing 7.2 per cent of the totalworkforce. Of that 7.2 per cent, 74 percent worked in administration, training,purchasing, accounting and humanresources, 18 per cent in laboratoriesand research and development and 8per cent in operations.

The average workforce turnover rate in2003 was 6.7 per cent, up from 5.1per cent in 2002.

Economic Contribution

QAL contributed approximately $200million directly to the local economy inwages, salaries and maintenance andcapital work carried out by localcontracting companies during 2003.Local goods and services were usedwhere possible.

6

Our Operation


9/20

QALs goal is zero occupationalhealth illnesses. To achieve this

goal, a comprehensive program oftesting and ongoing monitoring hasbeen established to track potentialcauses and implementimprovements. A team of healthprofessionals are employed tomonitor workplace conditions,provide medical services andhealth assessments, assist withrehabilitation programs and deliverpreventative programs promotinggood health practices.

2003 Performance

Primary Target Result

Zero recordable illnesses 0

In 2003, there were no new cases ofoccupational illnesses or diseasesrecorded. QALs OccupationalHygienist undertook comprehensivemonitoring to reduce or eliminate

exposure to noise, heat stress,hazardous substances and airbornedusts.

QAL has a voluntary health monitoringservice for all employees. In 2003, 54per cent of employees aged 40+ (thetarget group for 2003) participated inthe health monitoring program.

Other health related programs carriedout in 2003 included:

Stringent pre-employmentscreening procedures

Regular monitoring for best-fitrespirators for those working inasbestos removal areas

Influenza vaccination program toreduce susceptibility

Comprehensive work grouptraining and awareness packageson the signs, symptoms andtreatment of heat stress

Implementation of random drugand alcohol testing on site

Improvement Targetsfor 2004

Health program improvement targetsfor 2004 include:

Delivery of a health monitoringprogram

Reduction of plant noise

Implementation of a lifestylemanagement program

7

Our Health Performance


10/20

Safety is QALs highest priority andthere is a range of systems andmanagement tools in place toidentify and reduce or eliminaterisks, report and investigateincidents and monitor and improveindividual safety behaviour inorder to achieve a zero incidentworking environment.

QAL is responsible for the safety ofevery person on site and henceplant safety statistics are acombination of QAL employees

and contractor personnel.

2003 Performance


Total Case Incident Rate


11/20

Contractors were of particular focus in2003. Additional safety programsincluded:

Involving major contractors inbehavioural safety programs

Promoting the Mentoring system

Continuing to refine the ContractorSafety Management System

Reviewing contractor training andinduction requirements

There were two safety initiatives ofparticular note in 2003. One was aseries of tenderheart posters and

stickers developed and displayedaround site to encourage employees toconsider the potentially dramaticpersonal losses by not working safely(eg loss to the family, lifestyle, incomeetc). The second was theimplementation of a Job Safe Analysis(JSA) procedure ensuring a thoroughrisk analysis is carried out prior to atask being undertaken.


Safety requires constant vigilance.2004 will see continuation of safetyprograms that worked well in 2003plus a mix of improvement targets thatinclude:

Entrenching the JSA process in theplant safety program

Further engaging the contractworkforce in the QSafe process

Surveying the workforce to identify

further improvement initiatives Delivery of QSafe planned

activities

Continuation of the personal safetyawareness program

Reducing strain and sprain andlaceration incidents

Conducting a gap analysis againstAS4801 safety managementsystem with a view to certifyingQALs safety systems to thisstandard in 2005

The target TCIR for 2004 will be


12/20

QAL is committed to reducing theenvironmental impact of itsoperations. Significantimprovements were made duringthe year and it is expected that thiswill continue as moreenvironmental projects areimplemented. A total of $233million is being spent onenvironmental improvementprojects over a five year period. Inthe last two years over 80 per centof total capital expenditure wasdedicated to environmental

improvements.

Operations at QAL are conductedunder an Integrated EnvironmentalManagement System, which is asystem of checks and balancesensuring compliance with QALsenvironmental authority to operate.QAL has been accredited to theinternational standard ISO 14001since 1998 and has maintainedcertification since that date.

2003 Performance


No Reportable Incidents 4

Reportable Incidents

During 2003, QAL reported fourincidents to the EnvironmentalProtection Agency (EPA):

In February, QAL breached its five-minute emission licence for dustemissions from the boiler housestacks while burning wet coal

following excessive rain.

In February, a power interruptionexternal to QAL resulted in a shutdown of the Calcination plant. Thisin turn meant that the kilns had toundergo a statutory purge ofcombustible gases. This resulted ina breach of the five-minuteemission licence for dust emissionsfrom the Calcination stacks.

In May, a process upset in the

Digestion section caused multipleboiler trips. This resulted in abreach of the five-minute emissionlicence for dust emissions from theboiler stacks.

In July, another power interruptionexternal to QAL resulted inshutdown of the boilers. This in turnmeant that the boilers had toundergo a statutory purge ofcombustible gases. This resulted ina breach of the five-minute

emission licence for dust emissionsfrom the boiler stacks.

Environmental incident reports weresubmitted to the EPA for each incident.

Community Monitoring

QAL has a comprehensive complainthandling system, which includesthorough investigation followed by thedevelopment of mitigation measureswhere possible, and ongoing review ofthe effectiveness of those measures.

A total of 339 community complaintswere received during 2003, relating todust, alkali, odour and noise. Thedistribution is shown in the followinggraph.

Distribution of Community

Complaints 2003

Greenhouse

Total greenhouse gas emissions in2003 were 4 257 000 CO2 equivalenttonnes, an increase of 145 000 tonnesor 3.5 per cent on emissions in 2002.This increase was a result of a 4.4 percent increase in alumina production(180 000 CO2 equivalent tonnes)offset by savings from energy reductionprojects (14 000 CO2 equivalenttonnes) in the process and improvedprocess efficiencies (21 000 CO2equivalent tonnes). On a tonne CO2per tonne of production basis,emissions in 2003 were 13.1 per centbelow 1990 levels.

10

Our Environmental Performance

New Calcination Plant


13/20

QAL Greenhouse Gas Emissions,in Tonnes of CO2 per tonne of

alumina 1990 - 2003

QALs forecast, for the next two yearswith actions, are 4 170 000 CO2equivalent tonnes for the reportingyear 2004 and 4 181 000 CO2equivalent tonnes for the reportingyear 2005.

EnvironmentalEvaluation

In April 2002, the EPA issued a Noticeunder the Environmental Protection Actrequesting QAL commission anenvironmental investigation intoemissions from its alumina refiningoperations.

In response to this request, QALcommissioned investigations byprofessionally recognised air pollutionexperts Pacific Air and Environment(PAE). This report was submitted to theEPA for consideration in February2003.

The investigation found that the impacton air quality in Gladstone due to therefinerys activities is significantly lowerthan Australian and internationallyrecognised standards under normaloperating conditions. Furthermore, italso confirmed that when the plant isoperating normally there is a portion ofthe local community who are annoyedby the plant odour.

In addition, a health assessment studybased on worst-case exposurescenarios, carried out by anindependent expert (Toxicos Pty Ltd),found that all health hazard indicesdue to QALs emissions were withinacceptable health guidelines.

Although emissions are withinguidelines under normal operatingconditions, they are still a concern forthe community as illustrated bycommunity complaints, and therefore aconcern to QAL.

Negotiations with the EPA in 2003 ledto Environmental ManagementPrograms (EMP) being entered into for

dust and alkali emissions.

Dust

Calciners

In 2003, three new $175 million state-of-the-art gas suspension calciner units,designed to replace the existing ninerotary kilns, were commissioned. Muchto the disappointment of allstakeholders the units were onlyproducing at 80 per cent throughput atthe end of 2003 due to design issues.This meant that two of the existing ninerotary kilns were still in operation atthat time. Design changes to bring theunits up to full production capacity willbe implemented in 2004.

However, the new Calcination plant isworld-class and has already resulted indramatic improvements inenvironmental performance, exceedingdesign expectations. Data demonstratesthe reduction of fugitive alumina dustemissions will be more than theanticipated 92 per cent, closer to 95per cent.

In addition to the dramatic reduction of

alumina dust emissions, natural gasusage has reduced with a consequentreduction in greenhouse gas emissions.Commonwealth Government fundingthrough the Australian GreenhouseOffice supports this project.

11


14/20

The final stage of the CalcinationProject started with decommissioningone of the nine rotary kilns from the oldcalcining section. The remaining eightwill be decommissioned in 2004.

Boilerhouse

A three-year EMP was submitted to andaccepted by the EPA to significantlyreduce fly ash emissions from the sevencoal fired boilers. The EMP reiteratesQALs commitment to install baghousetechnology representing the bestenvironmental management practiceavailable.

The first installation of a baghouse wascarried out on boiler six during amaintenance turnaround in June 2003.Environmental performance from thisinstallation has exceeded designexpectations reducing from 80milligrams per normal cubic metre(mg/Nm3) to 10 mg/Nm3. A secondboiler will be fitted with a baghouse in2004 and the remaining boilersthereafter.

Other Fugitive Dust Sources

A three-year EMP was submitted to andaccepted by the EPA to reduce fugitivedust emissions from coal and aluminahandling systems. Projects are beingimplemented to reduce emissions fromcoal unloading and stockpiling andfrom alumina belt transfer stations.

Alkali

A three-year EMP was submitted to the

EPA in December 2003 to addressfugitive alkali emissions. The objectivesof the EMP are to control as much aspossible, alkali emissions from theplant.

Earlier in the year QAL beganresearching how to set up a reliablemeasurement technique for determiningalkali emissions outside of QALboundaries. The research segment ofthe EMP is due to be complete by April

2004. Implementation of projects toreduce emissions will commence in2004.

Odour

Odour from the plant is generated fromthe Digestion section where decayedorganic matter in the bauxite is brokendown in the refining process. Asignificant proportion of the odourreduction program was installed in2003 with the commissioning of a $3.5

million Thermal Oxidiser. The only oneof its type in Australia, the Oxidiseressentially burns non-condensablegases coming from the heater deck inDigestion (a major source of plantodour) at a high temperature,eliminating the odour. It is estimatedthat testing in 2004 will show theproject has successfully reduced odourfrom the Digestion section by 40 percent.

Noise

QAL is committed to reducing peaknoise events from the plant. One of atotal of three high pressure steam linesbetween the Boilerhouse and Digestionwas fitted with a silenced relief valveduring 2003. The valves eliminatenoisy events when previously boilerpressure relief valves lifted followingprocess upsets. The remaining twoDigestion units will be fitted in January2004.

Water

Water is essential to refinery

operations. Since commissioning of thetreated effluent pipeline to recycle andreuse Gladstone citys wastewater inNovember 2002, QAL has maintainedits lowest fresh water usage ever. Thefollowing graphs illustrate treatedeffluent water usage sincecommissioning and fresh water usageover time.

Recycled Treated Effluent fromGladstone City Treatment Plant,

in megalitres

QAL Water Usage fromAwoonga Dam,

in megalitres

12

Our Environmental Performance

Thermal Oxidisor for reducing plant odour


15/20

Waste Management

June 2003 saw the official opening ofthe on-site waste management facilityoperated by Transpacific, by EPADirector General, James Purtill.

QAL is the first major industry inAustralia to invest in a purpose builtdedicated waste management facility.The cost-neutral facility allows QAL tosegregate waste, recyclingapproximately 85 per cent of materialsmainly metal, cardboard and wood.This has significantly reduced wastegoing to landfill.

In a sideline benefit, glove recyclinghas also proved very successful. Out of30 000 pairs of gloves recoveredduring 2003, 25 000 were recycledthrough an off-site facility and will bereused in the plant in 2004.

Land Revegetation

Throughout the year, QAL continuedwith long-term land revegetation on theplants ash ponds, a portion of number

one red mud dam and the buffer zonebetween QAL and the Barney Pointcommunity.

Long-term revegetation work onnumber one red mud dam has beenextremely successful with wellestablished trees and a large supply ofgrass for native animals.

Three major planting and mulchingsessions over 2003 by the QAL TreePlanting Committee resulted in 1500new trees in the buffer zone betweenQAL and Barney Point. The Committeeis aiming to plant 2000 trees in 2004.

Awards

At the 2003 Gladstone RegionEnvironment and Sustainability Awards,QAL won the Waste ManagementAward for the Treated Effluent PipelineProject and was also the MayorsEnvironmental Champion for being abusiness or industry which made thecontribution most worthy of recognitionand acknowledgement.

In addition, QAL was highly commendedby the Australian Institute of Engineers(Queensland) for the Treated EffluentPipeline Project. The $8 million project,jointly managed with Gladstone CityCouncil, was fully commissioned on timeand within budget.


2004 will be a year of furtherenvironmental improvement throughconsolidation of current projects andinitiatives that include:

Determining environmentaleffectiveness of the newCalcination plant for odour

Conducting a risk assessment of theenvironmental Aspects and ImpactsRegister

Determining the effectiveness of theheater vent odour destructionproject

Development of an alkalideposition measurement technique

Development of a project list forreducing alkali emissions

Tracking of developments ingreenhouse gas abatementmeasures through the AustralianAluminium Council

The target for 2004 is no reportableincidents.

13

EPA Director General opening the on-site

waste management facility


16/20

As the oldest and largest corporatecitizen in Gladstone, QAL forms anintegral part of the regions socialand economic fabric. QAL has along established record ofdeveloping communityinfrastructure and supportingdevelopment. Continuation ofmutually beneficial relationshipswith the community is essential tocorporate standing and long-termsustainability the operationcannot grow or prosper without thesupport of its community.

Support of the community isfounded on solid two-waycommunication, participation andfinancial assistance toorganisations, events and causeswith particular focus on localinitiatives relating to environment,education and communitydevelopment.

2003 Activities

QAL Community ForumThe QAL Community Forum,established in 2001, is a valuable andconstructive asset within the communityrelations program. The group is madeup of QAL employees and volunteercommunity representatives who havean interest in the impact QAL has onthe local community.

During 2003, QAL held six CommunityForums with an average of twenty

participants at each meeting.The QAL Community Forum operatesunder the following principles:

To continuously reduce the impacton the community whilemaintaining the operation of theplant

To work together and achieveresults to the satisfaction of thebroader community

To achieve a mutual understanding

of technical environmental mattersthrough education and sharing ofinformation via an agreed andshared database

Forum input, activities and outcomes forthe year were numerous coveringmainly environmental improvementprojects (see EnvironmentalPerformance section), however otherhighlights included:

Establishing an annual meeting

between the QAL Board ofDirectors and Forumrepresentatives

Involving the community inmonitoring environmental impactsoutside the QAL boundary

Introduction of regular updates onenvironmental improvementprojects, community relationsactivities and complaints

The Forum continues to be a

constructive medium for provision ofinformation relating to mutual areas of

interest. Meetings will continue to beheld approximately every secondmonth during 2004, beginningFebruary.

The minutes of all Forum meetings, aswell as progress reports are publishedon the website atwww.qal.com.au/community/

Community Involvement

Committees

QAL is a member of numerousstakeholder groups ensuring industryrepresentation, sustainability ofoperations and input into decision-

making in the local area. Membershipincludes, but is not limited to,Gladstone Area Industry Network (andassociated subcommittees), Port CurtisCatchment Working Group, Port CurtisIntegrated Monitoring SteeringCommittee, Gladstone RegionSustainability Group, Landcare / Landfor Wildlife and Gladstone City CouncilEnvironmental Group.

Open Days

As part of the Companys commitmentto open and transparentcommunications and the promotion ofenvironmental improvement projects,QAL participated in several communityopen days during 2003 includingGladstone Ecofest and Port Open Day.In addition to the Community Forumand 1800 181 110 CommunityRelations Hotline, open days providefurther opportunity for communitymembers to discuss operations,community programs andenvironmental improvement projects.

14

Our Community

QAL Community Forum members inspectingvegetation on the red mud dam


17/20

Community Assistance

Sponsorships and Donations

As every year, QAL provided bothfinancial and in-kind support tocommunity groups and organisations.During 2003, 80 groups receivedassistance including Gladstone HarbourFestival, Ecofest, Roseberry YouthServices, Queensland Training Awards,Martin Hansen Art Awards and theGladstone Eisteddfod. QALssponsorship and donations programprovides support in the areas ofenvironment, community development,youth, art, music and culture, healthand welfare and sport and recreation.QAL also awarded school bursaries,tertiary academic prizes and universityscholarships. In addition to financialsupport, in-kind redundant equipmentsuch as computer equipment, conveyorbelt and lighting was donated to localcommunity groups.

QAL Community House

In August 2003, the QAL Community

House was opened as headquarters forthe QAL Retirees Club, and a freemeeting place for not-for-profitcommunity groups. The House iscomplete with boardroom table andchairs, TV and video, white board,kitchen and bathroom facilities suitable for groups of up to ten.

In the second half of the year, QALCommunity House was utilised byretiree, environmental, fundraising,respite health and sporting groups.

Education

ALP Education Program

QALs Alumina Learning Partnership(ALP) continued in 2003 with one of itsmost successful years yet. A total of1592 students from 24 schools withinthe Gladstone region were schooledthrough the science and environmentmodules. The ALP proved its communityworth taking out the Ecofest GladstoneArea Environment and SustainabilityAward for Educating our Communityfor 2003. The program continues to bean asset to the local schools as well asto the Company as an education toolenhancing community knowledge ofoperations and environmentalimprovement projects.

Tours

For many years QAL has routinelyoffered free tours of the refinery forschools, community and seniors groups.During 2003, approximately 1160people not directly involved in QALbusiness visited the refinery,

representing a 32 per cent increaseover 2002. Over ninety per cent of the2003 visitors were made up ofcommunity groups, school groups anduniversity students. As with previousyears, the QAL Retirees Club provideda guide for the free once-a-week touristtours.

VocationalDevelopment

Work Experience

During 2003, QAL ran a school basedwork experience program to introducehigh school students to industry. Fiftystudents from five local schools werehosted for one week each, providingthem with an invaluable insight intopossible future careers. The programwill run again in 2004.

Vacation Employment

QAL offered a paid employmentprogram for tertiary students on theirsummer vacation. The annual programoffers a unique opportunity for tertiaryuniversity students willing to give uptheir three months of holiday forpractical work experience. Vacationstudents are usually in their penultimateyear and are employed to carry outspecific project work for a 10-weekperiod. QAL employed 11 vacationstudents over the 2003/04 summer inthe areas of mechanical, chemical andprocessing engineering,communications, psychology andoccupational health and safety.

15


18/20

Apprentices

January 2003 saw a significant

increase in QAL apprenticeships. QALwelcomed 22 new apprentices to site,the first intake of a four-year programto increase indentures to 100, makingQAL the largest employer ofapprentices in Queensland. Of QALsnew apprentices one was training inrefrigeration, 10 electrical/instrumentand 11 fitting and turning.

Second-chance Employment

QAL worked in conjunction withYouthtrek to provide supervisedemployment for youths at risk. Theprogram gives local youths a second-chance by providing employmentopportunity, support, direction andguidance. The success of the program,thanks to the excellent support andsupervision from key employees andthe willingness from Youthtrek clients,has ensured its implementation foranother year at QAL.

Engineering Co-operative

Program

QAL has a long-standing relationshipwith Central Queensland University(CQU) and the Engineering co-opprogram demonstrates one of the manypositive outcomes from this mutuallybeneficial relationship. Since 1996QAL has hosted second and third yearEngineering Co-operative students. Aspart of the CQU Co-op degree studentsmust undertake two six-month blocks ofpractical project training. In 2003 QALhosted one student as part of this

program.Graduate Program

In 2003 QAL employed two graduateEngineers in the Research andDevelopment section and one Chemistin the Control Laboratory as part of thecompanys formalised two-yearGraduate Program. The highly soughtafter program offers selectedgraduates an opportunity to gainextensive experience and knowledgewithin their field in a short space of

time. The program develops them into avaluable commodity and prepares themfor future industry positions. Graduatesare put on a tour of duty working inall sections for the first year and thenconcentrate on specialised project workfor their second year.

Employment Diversity

In 2003, QAL established an internal

Equal Employment OpportunityWorking Group (EEOWG) to assist inthe development of equal employmentopportunity initiatives for minoritygroups across site. Terms of reference,a communication plan and work scopeswere developed in 2003 for action in2004. Particular focus for 2004 will bethe EEO framework, internal appealsprocedures and family friendlyinitiatives.


In addition to the regular CommunityRelations program as outlined in thissection, focus areas and improvementtargets for 2004 include:

Development of an interactivewebsite

Additional modules for the AluminaLearning Partnership program

Introduction of a quarterlycommunity newsletter

Reduction of community complaints

Publishing a Health SafetyEnvironment and Communitiesreport

Commissioning of a Corporate andCommunities Issues Survey

16

Our Community


19/20

Alkali is any class of substance whichhas a pH higher than seven. In the QALcontext, alkali emissions can refer tofugitive lime dust, alumina dust oraerosol generated from plant processliquor.

Alumina is aluminium oxide. It isextracted from bauxite in the BayerProcess and is subsequently theprincipal raw material in theelectrochemical process by whichaluminium is produced.

AS4801 is the Australian Standard foran occupational health and safety

management system.Aspects and Impacts Register is aregister of the organisations actual orpotential risk of causing environmentalimpact. The register determines thepriority for implementing environmentalcontrols.

Baghouse is a device that is used totrap fine dust particles from an airstream, similar in principle to a vacuumcleaner.

Bauxite is mainly hydrated aluminiumoxides and is the principal ore fromwhich alumina is made.

CO2 Equivalent Tonnes refers to carbondioxide equivalent. The differentgreenhouse gases have different globalwarming potencies. Therefore, tocompare the relative effect of thedifferent gases they are compared tothe effect of an equivalent amount ofcarbon dioxide. For example, onetonne of N2O is equivalent to 210

tonnes of CO2, expressed as 210 CO2equivalent tonnes.

Community Complaint is an issue raisedby a member of the community relatingto the operation, whether resolved ornot.

Environmental Management Program(EMP) is an agreed environmentalimprovement program between anorganisation and the EnvironmentalProtection Agency.

Environmental Protection Agency (EPA)is Queenslands governing body forenvironmental matters.

Fly Ash is residual dust as a result ofthe combustion of coal.

Greenhouse Challenge Program is anAustralian Greenhouse Office initiativefor companies to voluntarily report andabate greenhouse gas emissions.

HSEC is the abbreviation for Health,Safety, Environment and Communities.

Integrated Environmental ManagementSystem is an environmental

management system.ISO 14001 is an international standardfor environmental managementsystems.

Lost Time Injury (LTI) is recorded whenan incident results in a person losingone whole shift due to an injury.

Lost Time Injury Frequency Rate (LTIR)is the number of LTI's per 200 000work hours.

Medical Treatment Case is an injury orillness requiring treatment by a medicaldoctor.

Restricted Work Case (RWC) isrecorded when an incident results in anemployee returning to work, but whocannot perform the full duties of thepermanently assigned job due to theinjury.

Serious Injuries include medicaltreatment cases, restricted work casesor lost time injuries.

Total Case Incident Rate (TCIR) is thetotal number of lost time cases, medicaltreatment cases and restricted workcases per 200 000 work hours.

Treated Effluent is secondary treatedwater from the Gladstone City CouncilSewage Treatment Plant.

Glossary

17


20/20

Queensland Alumina LimitedParsons Point

Gladstone Queensland 4680Australia

Tel +61 7 4976 2211Fax +61 7 4976 2300

[email protected]

hsec report 2003

Documents