For over forty-five years, a small plant in southeast Edmonton has been playing a big role in the global aluminum industry.

The Rio Tinto Alcan facility is responsible for turning a waste byproduct from oil refineries into a key ingredient for the production of one of the most widely used, lightest, non-corrosive and infinitely recyclable metals.

“We are proud to operate the only petroleum coke calcining plant in Alberta and one of just a handful in Canada,” says Luc Côté, Plant Manager – Strathcona Works. “We buy high quality green petroleum coke (GPC) from our partners and turn it into anode grade calcined coke for use in the aluminum smelting process.”

Every year, 245,000 MT of GPC makes its way to the plant via rail from Alberta, Saskatchewan, Washington and California. The wet black product is then loaded into a rotary kiln and the calcining process begins.

As the temperature in the kiln rises to more than 1300°C, moisture and volatile combustion matter are removed. The calcined coke is then cooled and prepared for transport.

“Our recovery rate is roughly 74 percent,” says Côté. “Once processed, the product is transported to aluminum smelters in Quebec and Washington.”

Last year, 20 employees and half as many contractors onsite produced enough calcined coke to fill 2600 rail cars.

“We’re running a tight ship’’ he says. “Daily ‘lean meetings’ provide an opportunity for everyone to discuss issues that have transpired over the last 24 hours and anything that is upcoming. It’s about value adding and eliminating waste where possible.”

Rio Tinto Alcan has had tremendous success in this area.

In 2003, the company invested $16 million dollars into replacing older gas treatment infrastructure with more efficient and effective technology.

“The installation of a new pyro scrubber and a new wet scrubber meant that we were able to reduce our fugitive dust emissions by 50 percent,” explains Côté. “Since then we’re injecting 2-3 million dollars a year to further enhance our performance.”

Rio Tinto Alcan continues to incorporate responsible resource use into production processes and internal practices.

“All water used on site is recycled and grey water is fed back into our production system where it cools the calcined coke,” says Côté. The site is also self-contained which means that there is no effluents to the river. As a matter of fact, the facility just upgraded all of its run-off water management system, adding a berm system, expanding its North storm pond and expanding a large new pond East of the facility.

“For a small plant, we have accomplished a lot in a year,” adds Côté. “We are cognizant of our activities and always looking for ways to improve.”

As a member of the Strathcona Industrial Association (SIA), Rio Tinto Alcan is committed to environmental performance, safety and community wellbeing.

The company has played an active role in SIA governance since its inception and continues to represent SIA.

Together, SIA members are ensuring heavy industry operators not only lead with responsible and sustainable policies and practices, but also that they act as environmental stewards at every step of the way. SIA is greening our capital region.

For over forty-five years, a small plant in southeast Edmonton has been playing a big role in the global aluminum industry.

The Rio Tinto Alcan facility is responsible for turning a waste byproduct from oil refineries into a key ingredient for the production of one of the most widely used, lightest, non-corrosive and infinitely recyclable metals.

“We are proud to operate the only petroleum coke calcining plant in Alberta and one of just a handful in Canada,” says Luc Côté, Plant Manager – Strathcona Works. “We buy high quality green petroleum coke (GPC) from our partners and turn it into anode grade calcined coke for use in the aluminum smelting process.”

Every year, 245,000 MT of GPC makes its way to the plant via rail from Alberta, Saskatchewan, Washington and California. The wet black product is then loaded into a rotary kiln and the calcining process begins.

As the temperature in the kiln rises to more than 1300°C, moisture and volatile combustion matter are removed. The calcined coke is then cooled and prepared for transport.

“Our recovery rate is roughly 74 percent,” says Côté. “Once processed, the product is transported to aluminum smelters in Quebec and Washington.”

Last year, 20 employees and half as many contractors onsite produced enough calcined coke to fill 2600 rail cars.