Example of a green sense to the economy

Dear all,

there is always a lot a reluctance to implement strict environmental rules in economic activities, especially the ones involving manufacturing of products requiring chemical reactions.

Here is example where very strict environmental conduct led to massive economic savings. As an engineer, I was involved with all of them; so you could considere this article as a testimony.

In Quebec, at the beginning of the nineties, new environmental laws forced to change aluminum smelters. Several reports did point two areas where the companies were polluting the air and waters of nearby cities such as Joncquiere (Alcan) or Baie-Comeau (Reynolds). In the transformation process to change aluminum ore into aluminum metal, we have to apply electrolysis which requires a catalyst. This last one is a chemical powder based on highly poisonous mixtures with Bore and the like. The problem was that the whole process released large quantities of gaz which proved later to be the cause of skin and lung cancer and this was verified in Joncquiere.

In an other fashion, the ingots are produced on vertical machines in those large foundries. They usually consume large amount of water to cool off and lubricate the liquid aluminum coming out of the tilting ovens. This water is mixed with some amount of oil, usually vegetable like Castor oil in such quantities that it also raised issues about polluting the underground water wells around the cities.

Hence, the government took his responsibility like they ought to in any similar situation and voted laws requesting companies to adopt new methods to either clean the environment or to change their process into better ones.

This led to joint research projects between Universities and Companies well funded by the governments. Doing so, they designed new recycling schemes which saved large amounts of money.

Firstly, they realized that the gas released by aluminum electrolysis was as good a catalyst as the original powder. Then, they just designed efficient recovery and return systems which allowed them to reduce their boric powder consumption by 90 %. They would only have to buy powders to complement the amount lost in the process. Needless to say that cancer levels dramatically diminished in the whereabouts of the smelters improving their community image accordingly.

Therefore, Alcan decided to replace the old poluting Joncquiere factory with an ambitious plan to build three major new smelters in the Saguenay and Lac St-Jean area.

Secondly, they commenced designing water recycling and treatment centers which I did personally instrument, automate and control when I worked at SNC for the two aforementioned companies. They instantly corrected one major problem. They were consuming large amount of water coming from the numerous Quebec's lakes. However, the lake water temperature, saline content and acid levels were plagued by large variations which could pose a threat to a ingot production quality.

There are a few lessons that we can learn form these stories.

1- With a capital investment wisely spent on “not so obvious” projects, companies could save dramatically and also improve their relationships with the community.

2- My experience with a lot of companies is that, being only profit driven, they will not often develop new processes by themselves if someone does not come with the methods showing good results beforehand. This can only be done by Universities funded by public money. I would even advocate that the academic people salaries to be directly paid by government and to considere them as civil servants.

3- Companies do not usually accept to invest in major improvements where large capital investments are required unless forced by law and also its effective application.

4- Indeed, it is quite possible to have green companies which are profitable and do not destroy our planet.