December 2012Capability brochure

AluminiumUnique and versatile: a modern metal

Capability brochureAluminium

December 2012

Capability brochureAluminium

December 2012

Our Aluminium businessBuilding on more than a century of experience and expertise, Rio Tinto Alcan is a global leader in the aluminium industry. We are one of the world’s largest producers of high quality bauxite, alumina and aluminium worldwide and our AP™ smelting technology is the industry benchmark.

Our leadership is reinforced by our:• access to the largest and best quality bauxite

reserves in the industry;• benchmark smelting technology; and• enviable hydropower position, which delivers

significant competitive advantages in today’s carbon constrained world.

Rio Tinto Alcan is the aluminium product group of Rio Tinto, a leading international mining company involved in each stage of metal and mineral production. The Group is listed on the London Stock Exchange and Australian Securities Exchange under the symbol RIO. Rio Tinto’s major products are aluminium, copper, diamonds, coal, iron ore, uranium, gold and industrial minerals.

Left Rio Tinto Alcan Mining Operation, Weipa, Australia.

Below Aluminium bicycle chain.

Cover End use of aluminium in architecture - Le Pont du Moulin bridge structure, Quebec, Canada.

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Capability brochureAluminium

December 2012

Delivering value since 1902Over 100 years of operation translates into broad experience and a deep understanding of our industry. We have spent decades innovating and continue to do so, perfecting our mining and smelting processes and how to best look after the environments in which we work.

We are committed to advancing the economic, environmental and social sustainability of our operating communities around the globe, while creating value for Rio Tinto.

Bauxite is the main sourceof aluminium.

From bauxite to aluminium

Below Daily safety dialogue with employees at the Jaguaquara, Amargosa Project, Brazil.

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Capability brochureAluminium

December 2012

Aluminium: a modern metalWhile metals such as copper, lead and tin have been used for thousands of years, aluminium is a comparatively young metal. Its commercial use dates back only about 150 years, yet more aluminium is produced than any other non-ferrous metal.

Today, a world without aluminium is difficult to imagine. This unique and versatile metal is used in a broad range of applications for transportation, packaging, electrical materials, medicine, construction and other sectors.

An alloy wheel made from molybdenum, aluminium and steel.

Aluminium is used for glasses frames.

An example of the end use of aluminium in the medical industry.

The use of one kilogram of aluminium to replace heavier materials in a car or light truck can save a net 20 kilogram of CO2 over the life of the vehicle.

Aluminium is light, strong, flexible, non corrosive and infinitely recyclable. When compared to most other metals, less energy is required to transport products made from aluminium.

While providing a superior barrier to stored food, aluminium indirectly saves energy and water by reducing waste. Recycling aluminium uses only five per cent of the energy needed to produce primary metal, reducing total greenhouse gas emissions.

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Capability brochureAluminium

December 2012

We also sell smelter anodes, cathodes and aluminium fluoride. We provide leading technology solutions for aluminium smelting and technical services for processing our aluminium products.

How aluminium is madeBauxite, the natural ore used to make aluminium, is the most abundant mineral in the earth’s crust. Mined bauxite is refined into alumina, which is then smelted into aluminium. Approximately four tonnes of bauxite are required to produce two tonnes of alumina, which in turn makes one tonne of aluminium metal.

Smelting occurs in large carbon lined steel furnaces called reduction cells. A continuous electric current flows from the anode (carbon blocks), through the alumina/cryolite mixture to the carbon cathode cell lining. The alumina reacts with the anode to form aluminium.

Our productsWe are a worldwide supplier of bauxite, smelter grade alumina and hydrate for domestic and export markets. Our aluminium products include rolling slab, extrusion billet, foundry (ingot and T-bar), rod and EC grade ingot, high-purity ingot (up to P0101), busbars and metal matrix composites, remelt ingot and molten metal.

The molten aluminium sinks to the bottom of the cell. It is then siphoned out of the cell and transported to a holding furnace to be cast into various products.

Primary metal can be rolled, extruded or cast as pure aluminium or aluminium alloys. Alloys are formed by combining pure aluminium with magnesium, silicon, manganese or other elements to produce properties such as extra strength or additional corrosion resistance.

We produce primary aluminium at some of the lowest cost, most technologically advanced smelters in the industry.

Above Aluminium exhaust pipe.

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Capability brochureAluminium

December 2012

We generate value by sharing best practices and supply chain benefits across our facilities. Our demonstrated commitment to excellence in health, safety and environmental performance also contributes to our success.

Our operations are divided into two operating units: Bauxite and Alumina and Primary Metal.

Bauxite and AluminaOur wholly owned and joint venture bauxite mines are located in Australia, Brazil, and Guinea. Rio Tinto Alcan is one of the leading and the largest bauxite producers in the industry and benefits from access to the largest and best quality reserves.

Our operationsRio Tinto Alcan’s high quality bauxite, alumina and aluminium businesses have broad global reach. Everywhere we operate, our passion for excellence drives our success.

Above Bauxite at Alumina plant, Gladstone, Queensland, Australia.

Our wholly owned and joint venture alumina refineries are located in Australia, Brazil and Canada. Completed expansion at our Yarwun refinery in Australia will more than double its alumina production and will solidify our position as a leading supplier of aluminium in the industry.

Primary metalRio Tinto Alcan has the world’s largest share of first quartile aluminium production capacity. Our largest concentration of smelting assets is located in Canada (eight smelters), along with smelters in France, Cameroon, Iceland, Norway and the Middle East. Rio Tinto Alcan also provides technology sales and service, engineering services, smelting equipment sales and smelting consumables production for the global aluminium industry.

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Capability brochureAluminium

September 2012Capability brochure

Below XXXXX

97%Rio Tinto Alcan’s energy portfolio is

the cleanest in the industry, mainly from self-generated hydro-power facilities

carbon free

Energy A secure, long life and competitively priced supply of electricity is vital to maintaining a competitive edge in the aluminium industry. Rio Tinto Alcan owns 11 power stations with an annual capacity of over 4,100 megawatts. This meets 36 per cent of our electricity needs, a proportion well above the industry average. Our long term power purchase contracts account for a further 30 per cent of our electricity supply.

Above Aerial view of the Shipshaw hydropower plant, Québec, Canada.

Below Aluminium T-Ingots.

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Capability brochureAluminium

December 2012

We optimise our use of resources, manage materials responsibly, and build active partnerships with our communities and other stakeholders based on mutual respect and sustainable benefit across generations.

Health, safety and environmental excellenceExcellence in managing HSE responsibilities is essential to our long-term success. We are committed to protecting the environment, preventing pollution and safeguarding the health, safety and welfare of those who work at or visit our sites. We respect local laws, customs and cultures. Our ultimate goal is zero harm by choice. Our vision is supported by our core values of accountability, respect, teamwork and integrity.

Climate change Rio Tinto Alcan has a strong commitment to climate change, which includes both short-term operational improvements and long-term adaptation strategies. Helping address climate change is one of the ways we seek to reinforce our industry leadership and strengthen our competitive advantage. Joining forces with our employees, customers and other key stakeholders, we promote greater energy efficiency, along with the increased use of aluminium applications, as a means to reduce greenhouse gas emissions.

Below Employee – Energy Distribution, Québec, Canada.

Stepping forward

We also continue to invest in advancing our AP Technology™ solutions, widely recognised as being the industry benchmark. Indeed, AP60 is the most advanced AP electrolysis technology within Rio Tinto Alcan and will become an aluminium industry benchmark due to its operating costs, energy consumption, and environmental performance.

For customers around the world, we demonstrate how using our AP Technology™ solutions brings excellent results for reliability, energy efficiency, sustainability and productivity while being the cleanest smelting technology with the lowest emission levels.

At Rio Tinto Alcan, we care about people and the world in which we live. Rio Tinto Alcan is committed to building enduring relationships with our neighbour that demonstrate mutual respect, active partnership and long-term commitment in countries where we operate. This is why sustainable development is at the heart of all we do and its principles guide our actions and decisions.

Total GHG intensity at Rio Tinto Alcan was reduced by 49 per cent in 2011 from 2008 baseline performance, which is attributable to portfolio changes and operational improvement.

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Capability brochureAluminium

December 2012

Rio Tinto Alcan installations†

Head office 1Canada Montreal, Quebec

Regional office 2Australia Brisbane

SydneyBrazil São Paulo

Canada Burns Lake, British ColumbiaQuebec City, QuebecSaguenay–Lac-Saint-Jean, QuebecVancouver, British ColumbiaVanderhoof, British Columbia

China BeijingHong Kong

France GennevilliersParisVoreppe

Guinea Conakry

Japan Tokyo

Singapore Singapore

Switzerland Neuhausen

United States Cleveland, OhioFullerton, CaliforniaNeshanic Station, New Jersey

Smelter 3Cameroon Edéa (Alucam – 46.7%)

Canada Bécancour, Quebec (ABI – 25.1%)Kitimat, British ColumbiaAlma, Saguenay–Lac-Saint-Jean, QuebecArvida, Saguenay–Lac-Saint-Jean, Quebec Grande-Baie, Saguenay–Lac-Saint-Jean, Quebec Laterrière, Saguenay–Lac-Saint-Jean, Quebec Sept-Îles, Quebec (Alouette – 40%)Shawinigan, Quebec

France DunkerqueSaint-Jean-de-Maurienne

Iceland Reykjavik (ISAL)

Norway Husnes (Søral – 50%)

Oman Sohar (Sohar Aluminium – 20%)

United Kingdom

Lochaber

Alumina refinery 4Australia Gladstone (Queensland Alumina – 80%)

Gladstone (Yarwun)Brazil São Luís (Alumar – 10%)

Canada Saguenay–Lac-Saint-Jean, Quebec (Vaudreuil)

Mine 5Australia Weipa

Brazil Porto Trombetas(Mineração Rio do Norte – 12%)

Guinea Kamsar-Sangaredi(Compagnie des Bauxites de Guinée – 22.95%)

Power facility 6Australia Gladstone (Yarwun co-generation facility)

Canada Kemano, British ColumbiaSaguenay–Lac-Saint-Jean, Quebec(Chute-à-Caron)Saguenay–Lac-Saint-Jean, Quebec(Chute-à-la-Savane)Saguenay–Lac-Saint-Jean, Quebec(Chute-des-Passes)Saguenay–Lac-Saint-Jean, Quebec(Chute-du-Diable)Saguenay–Lac-Saint-Jean, Quebec(Isle-Maligne)Saguenay–Lac-Saint-Jean, Quebec(Shipshaw)

4 52

5 82

10

2 10

3

2

2

9

2 9

9

9

9

9

4 5 6 7 8 92

3 8

4 6 7 8 91 32

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3

3

6

3 6

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8

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Capability brochureAluminium

December 2012

Ancillary business* 9Australia Dandenong (RTA Alesa)

Eagle Farm (ECL)Bahrain Manama (ECL)

Canada Montreal, Quebec (RTA Alesa)Quebec City, Quebec (ECL)Saguenay–Lac-Saint-Jean, Quebec (ECL)Sept-Îles, Quebec (ECL)

China Shanghai (ECL)

France Gardanne (RTA Alesa)Lannemezan (Carbone Savoie)Notre-Dame-de-Briançon (Carbone Savoie)Ronchin (ECL)Vénissieux (Carbone Savoie)

India Bhubaneswar (ECL)

Mozambique Matola (ECL)

Netherlands Ritthem (ECL)

South Africa Richards Bay (ECL)

Switzerland Zurich (RTA Alesa)

United ArabEmirates

Dubai (ECL)

Pacific Aluminium and other sites1 10Australia Bell Bay, Boyne, Gladstone power station,

Tomago and Gove (Alumina refinery and Mine)New Zealand Tiwai Point

(New Zealand Aluminium Smelters – 79.4%)United States Sebree, Kentucky

United Kingdom

Lynemouth

† Locations on the map are indicative. Operations and projects are wholly owned unless otherwise shown.

* RTA Alesa, ECL and Carbone Savoie are subsidiaries of Rio Tinto Alcan.1 In October 2011, Rio Tinto announced the intention to divest or close a

number of smelter assets. These are now managed and reported upon separately by the Rio Tinto Group.

Norway Nr Kristiansand (Vigelands)United Kingdom

KinlochlevenLochaber (Highlands power station)

Research and development centre 7Australia Brisbane (Pacific Technology Centre)

Canada Saguenay–Lac-Saint-Jean, Quebec(Arvida Research and Development Centre)

France Saint-Jean-de-Maurienne(Laboratoire de Recherche en Fabrication)

Production support facility 8Australia Gove

Cameroon Douala (Alubassa)Edéa (Socatral)

Canada Beauharnois, QuebecSaguenay–Lac-Saint-Jean, Quebec (Dubuc)Saguenay–Lac-Saint-Jean, Quebec(Énergie Électrique, Centrale de conduitedu réseau)Saguenay–Lac-Saint-Jean, Quebec(Port Alfred)Saguenay–Lac-Saint-Jean, Quebec(Roberval-Saguenay)Saguenay–Lac-Saint-Jean, Quebec(Spent potlining plant)Strathcona, Alberta

France Castelsarrasin

Guinea Kamsar-Sangaredi(Compagnie des Bauxites de Guinée)

Netherlands Rotterdam

Sweden Helsingborg

United Kingdom

Anglesey(Anglesey Aluminium Metals Limited – 51%)

4 52

5 82

10

2 10

3

2

2

9

2 9

9

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4 5 6 7 8 92

3 8

4 6 7 8 91 32

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3 6

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2 93 7

8 92

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0019 V1 ENG ALUMINIUM DECEMBER 2012 PDF

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T +61 (0)3 9283 3333

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T +44 (0)20 7781 2000

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