Greater Sudbury Greater Sudbury Emergency Response Emergency Response

CommitteeCommitteeXstrata Nickel/NorFalco PresentationXstrata Nickel/NorFalco Presentation

Sudbury, OntarioSudbury, OntarioNovember 23, 2007November 23, 2007

. . . more than H2 SO4

AgendaAgenda

Agenda (30 Agenda (30 –– 40 minutes)40 minutes)Sulfuric Acid Sulfuric Acid –– Properties & First AidProperties & First AidTransportation EquipmentTransportation EquipmentTransportation Emergency Response Transportation Emergency Response ––Xstrata/NorFalco Xstrata/NorFalco Site Emergency Response Site Emergency Response –– Xstrata NickelXstrata Nickel

Xstrata/NorFalcoXstrata/NorFalcoNorth AmericaNorth America’’s Largest marketer of s Largest marketer of sulfuric acid sulfuric acid Parent company Xstrata Parent company Xstrata

2006 purchase of combined Noranda 2006 purchase of combined Noranda and Falconbridgeand Falconbridge

5 Xstrata production facilities in 5 Xstrata production facilities in North AmericaNorth America

2.3 million tons per year production 2.3 million tons per year production and sales in North Americaand sales in North AmericaXstrata global acid production over 5 Xstrata global acid production over 5 Million tons per yearMillion tons per year

Fully integrated network of trains, Fully integrated network of trains, trucks, terminals, shipstrucks, terminals, shipsOffices in Cleveland and Offices in Cleveland and Mississauga Mississauga Commitment to Responsible Care & Commitment to Responsible Care & Product StewardshipProduct StewardshipDelivering More than HDelivering More than H22SOSO44

Responsible Care :Responsible Care :

Poor industry reputation required actionPoor industry reputation required action

CCPA & ACC initiative CCPA & ACC initiative -- now 50+ countriesnow 50+ countries

NorFalco is a member company NorFalco is a member company

6 Codes of Practice 6 Codes of Practice ““from Cradle to Gravefrom Cradle to Grave””

Product Stewardship a key focus Product Stewardship a key focus

Sulfuric Acid

Chemical Properties Chemical Properties &&

First Aid ProceduresFirst Aid Procedures

Sulfuric AcidSulfuric Acid

““Sulphuric Acid, with more than 51% acidSulphuric Acid, with more than 51% acid””

Corrosive Label 1830 Placard

WHMIS symbols

GUIDE 137 SUBSTANCES –

WATER-REACTIVE - CORROSIVE

ERG2004SULFURIC ACID , 8, UN1830, PGII, RQERAP# 2-0074 and 24 Hour Number:

1-877-337-2243ERG 137

Sample Bill of Lading entry

Sulfuric AcidSulfuric Acid

Sulphuric Acid, with more than 51% acidSulphuric Acid, with more than 51% acid

NFPA Symbol for H2 SO4

NorFalco WHMIS Label

0

3 2W

ACID

Chemical & Physical Properties

Sulfuric AcidSulfuric AcidStrong, inorganic acidStrong, inorganic acidVery corrosive to skin and eyesVery corrosive to skin and eyesReacts violently with water ( or different concentrations of Reacts violently with water ( or different concentrations of acid ! )acid ! )Visually can look like waterVisually can look like waterCan react with metals to produce hydrogenCan react with metals to produce hydrogenCan be corrosive to metals and many plasticsCan be corrosive to metals and many plasticsFreezing and corrosive properties vary widely depending on Freezing and corrosive properties vary widely depending on concentrationconcentration

Chemical & Physical PropertiesChemical & Physical Properties

Properties 93%(66° Be′) 98% Strength, % H2SO4 93.2 Min 98 Min Freezing Point, °F -31 29

Freezing Point, °C -35 -2 Boiling Point, °F 535 621

Boiling Point, °C 279 327

Specific Gravity, 60°F(15.6°C)

1.835 1.844

Density, lbs/gal, 60°F (15.6°C)

15.3 15.4

Viscosity, cP, 68°F (20°C) 22 25

Specific Heat, cal/g •°C 0.38 0.35 Appearance Clear to slightly turbid oily

liquid Clear to slightly turbid

oily liquid Odor None None

Personal Protective Equipment

Hard hatHard hat

Goggles (chemical)Goggles (chemical)

Face shield Face shield ––

In addition to In addition to gogglesgoggles

Acid resistant gloves, Acid resistant gloves, gauntlet lengthgauntlet length

Acid resistant splash suit Acid resistant splash suit --

not rainwearnot rainwear

Acid resistant boots, steel Acid resistant boots, steel toed recommendedtoed recommended

For a For a ““line breakline break””, an acid resistant hood is , an acid resistant hood is required (replaces goggles and face shield )required (replaces goggles and face shield )Respiration Protection Respiration Protection --

not generally not generally required under normal handling operations.required under normal handling operations.

Why wear both chemical goggles and a face shield??

NorFalco LLC Sulfuric Acid Safety SeminarNorFalco LLC Sulfuric Acid Safety Seminar First Aid For Sulfuric Acid Burns

Skin or Eye ContactSkin or Eye ContactImmediatelyImmediately wash under a safety shower or eyewash for a wash under a safety shower or eyewash for a ““minimumminimum””of 15 minutes while removing contaminated clothing. of 15 minutes while removing contaminated clothing. (Nothing should (Nothing should replace time spent under a safety shower, this is why tepid watereplace time spent under a safety shower, this is why tepid water is so r is so important) important) Hold eyelids open if necessary.Hold eyelids open if necessary.

Call for medical help.Call for medical help.

Apply ice water compresses to affected body area. Apply ice water compresses to affected body area. (Greatly decreases (Greatly decreases chance of scarring and keeps burn cool)chance of scarring and keeps burn cool)

Continue ice water compresses while injured is transported to a Continue ice water compresses while injured is transported to a medical medical facility & while waiting in the medical facility.facility & while waiting in the medical facility.

Do not apply creams or ointments in lieu of ice water compressesDo not apply creams or ointments in lieu of ice water compresses, unless , unless directed by a physiciandirected by a physician

Transportation EquipmentTransportation Equipment

Typical Sulfuric Acid TrailerTypical Sulfuric Acid TrailerTC 312 or DOT 412TC 312 or DOT 412

••Bottom discharge design Bottom discharge design c/wc/w

internal internal hydraulic valvehydraulic valve••Safety Relief Valve (to prevent over Safety Relief Valve (to prevent over pressurizing)pressurizing)••““Spill boxSpill box””

around top manaround top man--wayway••Acid compatible hose located on trailerAcid compatible hose located on trailer••Fittings to be stainless steel suitable for Fittings to be stainless steel suitable for acid serviceacid service

Typical Typical SulfuricSulfuric

Acid Tank CarAcid Tank Car

DOT 111 A 100 W2DOT 111 A 100 W2••Empty: 55 000 to 60 000 lbs.Empty: 55 000 to 60 000 lbs.

••Loaded: 263,000 lbsLoaded: 263,000 lbs

••All openings (fittings) located at All openings (fittings) located at top centre of all Sulfuric Acid top centre of all Sulfuric Acid tank cars. (Bottom washouts are tank cars. (Bottom washouts are being eliminated).being eliminated).

TANK CARTANK CAR Historical Historical Fittings arrangementFittings arrangement

RUPTURE DISCRUPTURE DISC ASSEMBLYASSEMBLY

11’’’’ PRESSURE PRESSURE VALVEVALVE

FILL HOLE NOZZLE FILL HOLE NOZZLE AND COVERAND COVER

ACID OUTLET CAP ACID OUTLET CAP AND CONNECTIONAND CONNECTION

TANK CARTANK CAR Historical Fittings ArrangementHistorical Fittings Arrangement

TANK CARTANK CAR Historical Fittings ArrangementHistorical Fittings Arrangement

NorFalco“LOW PROFILE” FITTINGS ARRANGEMENT for SULFURIC ACID TANK CARS

Relocated Air Valve (c/w 1- 5/8” hex plug) - Only extraOnly extra--

strong strong welded fittings or welded fittings or flanged fittings are flanged fittings are accepted.accepted.

Lower Eduction Pipe (c/w 1- 5/8” Hex Nut Cap, Gasket and ACME cap threads) - 44””

max. above the fill hole cover.max. above the fill hole cover.Lower 165 psi Rupture Disc Assembly - 11””

max. above the fill hole max. above the fill hole cover.cover.

Prominent Fill Nozzle & Cover (c/w 1- 5/8” hex nuts) - Fill hole nozzle Fill hole nozzle and cover will act as and cover will act as the fittings the fittings protective device.protective device.

Protective Side GuardsMan-way cover & all fittings made of 316 Stainless Steel with Viton B® gaskets

Security TrendsSecurity Trends

Tank car seals

&

Supply chain security

TANK CAR SHIPPINGTANK CAR SHIPPING

Before a tank car is released by Xstrata Nickel:Before a tank car is released by Xstrata Nickel:WalkWalk--By inspection(stenciling, decals, exterior By inspection(stenciling, decals, exterior coating, tank, jacket and insulation, running gear, coating, tank, jacket and insulation, running gear, placards etc.)placards etc.)Tank car interior inspection.Tank car interior inspection.Gaskets and top fittings inspection.Gaskets and top fittings inspection.After loading, 40 psi air leak test After loading, 40 psi air leak test on every tank car . on every tank car .

TRANSPORTATION TRANSPORTATION INCIDENT INCIDENT

REPORTING AND REPORTING AND EMERGENCY EMERGENCY

RESPONSERESPONSE

What is an What is an ““IncidentIncident””

All injuries exposures to acidAll injuries exposures to acidAll accidents causing equipment damage All accidents causing equipment damage ALL railway derailments (with or without damage)ALL railway derailments (with or without damage)All acid releases All acid releases All NonAll Non--Accidental acid Releases ( Accidental acid Releases ( NARNAR’’ss))All incidents involving residue trucks or tank carsAll incidents involving residue trucks or tank carsRegulatory citations Regulatory citations Acid incidents at customer facilities Acid incidents at customer facilities

2007 Incidents (Sept YTD)2007 Incidents (Sept YTD)

40 incidents, 22 in US and 18 in Canada40 incidents, 22 in US and 18 in Canada27 rail , 14 in US and 13 in Canada27 rail , 14 in US and 13 in Canada10 truck, 6 in US and 4 In Canada10 truck, 6 in US and 4 In Canada1 marine incident at South Port1 marine incident at South Port2 customer incidents (tank overflows)2 customer incidents (tank overflows)

2007 ER Response2007 ER Response

9 ER responses by NorFalco/Xstrata and 7 by 9 ER responses by NorFalco/Xstrata and 7 by ER ContractorER Contractor5 CEZ5 CEZ

1 Alcan,Garneau1 Alcan,Garneau--2 CATL Rollover2 CATL Rollover--1 CSX 1 CSX Huntington and 1 CN SanmaurHuntington and 1 CN Sanmaur

1 Kidd 1 Kidd ONR ONR EnglehartEnglehart

2 Sudbury2 SudburyONR ONR EnglehartEnglehart, ONR North Bay, ONR North Bay

Xstrata/NorfalcoXstrata/Norfalco

Incident ResponseIncident Response

What do we have in place?What do we have in place?Emergency Response Plan and ProceduresEmergency Response Plan and ProceduresEmergency Response Teams (Internal/External)Emergency Response Teams (Internal/External)Emergency Response EquipmentEmergency Response EquipmentTrainingTraining

Designed to meet Responsible Care and Regulatory Designed to meet Responsible Care and Regulatory requirementsrequirements

TRANSPORT CANADA TRANSPORT CANADA --

ER PLANER PLAN

SulfuricSulfuric Acid Acid –– Column 7 of Schedule I ERAP Column 7 of Schedule I ERAP index index -- chemical shipped above Quantity chemical shipped above Quantity indicated requires emergency plan indicated requires emergency plan filed/approved with Transport Canadafiled/approved with Transport CanadaFrench and English ER manual were reviewedFrench and English ER manual were reviewedFinal English Manual published in June 2007Final English Manual published in June 2007Sudbury ER Team has been audited by Sudbury ER Team has been audited by Transport CanadaTransport Canada--No major findingsNo major findingsPlan/Manual is updated by NorFalco ER Team Plan/Manual is updated by NorFalco ER Team coordinator.coordinator.

INCIDENT REPORTINGINCIDENT REPORTING

Report incidents Report incidents immediately :immediately :

In call Xstrata/NorFalco 24 Hour reporting In call Xstrata/NorFalco 24 Hour reporting line : line :

877877--377377--2243 or 2243 or 877877--ERPERP--ACIDACID

EMERGENCY RESPONSEEMERGENCY RESPONSE

Control Center is in Valleyfield, QC, Canada Control Center is in Valleyfield, QC, Canada (one of five manufacturing facilities).(one of five manufacturing facilities).1010 ER Members on call all year long.ER Members on call all year long.This number willThis number will put you in touch with a put you in touch with a Technical Advisor within 5 minutes.Technical Advisor within 5 minutes.Immediate assistance will be given.Immediate assistance will be given.If ER Team Members are required on site:If ER Team Members are required on site:

The closest team to the incident site will be dispatched.The closest team to the incident site will be dispatched.Or a contractor will be sent.Or a contractor will be sent.In USA, In USA, SPSISPSI has an agreement with NorFalco.has an agreement with NorFalco.

Xstrata/NorFalcoXstrata/NorFalco Emergency Response NetworkEmergency Response Network

40 Trained 40 Trained Xstrata/NorFalcoXstrata/NorFalco respondersresponders

Call Centre -

Valley field

Timmins Rouyn-Noranda

OverviewOverview

Flexible Flexible ER plan ER plan to address incidents with varying to address incidents with varying degrees of severity. degrees of severity.

1.1.

Emergency Response Team onEmergency Response Team on--scene (will scene (will consist of Xstrata plant ER team)consist of Xstrata plant ER team)

2.2.

Plant Management Team at the plant.Plant Management Team at the plant.

3.3.

NorFalco Incident Management TeamNorFalco Incident Management Team

4.4.

NorFalco and Xstrata Crisis Management NorFalco and Xstrata Crisis Management TeamTeam

NorFalco ER Call Flow ChartNorFalco ER Call Flow ChartIncident Occurs and is reported to NorFalco 24-hr line (at CEZinc)

CEZinc ER Coordinator activates a plant ER Team response if needed. Consults with Plant Home Coordinator to determine seriousness of incident.

Incident designated Low Severity

Incident designated a Medium or High

Severity Level

CEZinc or designated Plant Home Coord and ER Team issue fact report within 24-hrs and work to complete ER response as needed

Plant ER team responds to incident site as needed

Valleyfield or designated Plant Home Coordinator contacts NorFalco Incident Co-

ordinator

NorFalco Incident Co-

ordinator activates NorFalco Incident Management Plan Priority Actions as needed, alerting NorFalco and initiating integrated response

NorFalco President & Incident Coordinator lead integrated response with ER Team, Plant, Corporate resources and NorFalco management to mitigate incident

NorFalco Tech group ensure follow-up investigation corrective actions and learnings are developed and tracked to completion

Specific Procedures developed by NorFalcoand Xstrata

Potential Accident Assessment Potential Accident Assessment ERAP 2ERAP 2--00740074

Various Potential Accidents are outlined in Various Potential Accidents are outlined in ERAPERAP filed with Transport Canada.filed with Transport Canada.Includes responsibilities of Xstrata, NorFalco, Includes responsibilities of Xstrata, NorFalco, regulatory, and municipal agenciesregulatory, and municipal agenciesFederal, provincial or municipal agencies may be Federal, provincial or municipal agencies may be involved and asked to provide infrastructure involved and asked to provide infrastructure support (evacuation, equipment, support (evacuation, equipment, communication, etc).communication, etc).

ERAP 2ERAP 2--0074 0074 --

continuedcontinued

Xstrata/NorFalco are on the scene to provide Xstrata/NorFalco are on the scene to provide Sulfuric Acid technical advice, and will manage Sulfuric Acid technical advice, and will manage activities related to Sulfuric Acid.activities related to Sulfuric Acid.Incident Command typically will fall to local Incident Command typically will fall to local municipal, provincial or federal response municipal, provincial or federal response personnel.personnel.Environment Canada or Transport Canada may Environment Canada or Transport Canada may be on scene, depending on severity of incident. be on scene, depending on severity of incident.

EMERGENCY RESPONSE EMERGENCY RESPONSE -- EQUIPMENTEQUIPMENT

Level B(splash suit with SCBA)Level B(splash suit with SCBA)

Trucks and trailers with transfer equipment Trucks and trailers with transfer equipment (pumps, hoses, tank car and tank truck spare (pumps, hoses, tank car and tank truck spare parts, tools, lighting etc.)parts, tools, lighting etc.)

EMERGENCY RESPONSE EMERGENCY RESPONSE –– TRAININGTRAINING

Noranda and Falconbridge ER Teams Training Requirements:

HAZARDOUS MATERIALS TECHNICIAN – PRIVATE SECTOR SPECIALISTEMPLOYEE A

STANDARD TRAINING REFRESHERS :

ANNUAL :

Estimated duration(hours)

- Review of ER manual procedures 8

- Tank car acid transfer by air pressure 4

Tank car acid transfer by pump 4

Tank car eduction pipe gaskets replacement 2

• Tank truck acid transfers(for sites shippingtank truck)

4

Explosive gas measurements 2

Incident simulation(including communicationverification)

4

Air Breathing Apparatus( 2 x 2 hours exercices) 4

TOTAL : 28 to 32

EVERY THREE YEARS

Estimated duration(hours)

- TDG training 8

- Sulfuric acid basic chemistry 8

Basic media training 8

Tank car damage assessment 4

TOTAL : 28

TRAINING TRAINING STANDARDSSTANDARDSOSHA 1910.120 and OSHA 1910.120 and NFPA 472NFPA 472

Xstrata/NorFalco ER Training Xstrata/NorFalco ER Training –– Sudbury May 2006Sudbury May 2006

Joint training with other Xstrata/NorFALCO teams

Xstrata/NorFalco ER Training Xstrata/NorFalco ER Training –– BelleduneBelledune

September 2006September 2006

14 Participants Kidd Met (5), Sudbury (5), Brunswick Smelter (2) CEZinc (1) and HORNE (1)Also CN Personnel participated in the Training

Xstrata Nickel Site Emergency Xstrata Nickel Site Emergency PlanningPlanning

EMERGENCY RESPONSEEMERGENCY RESPONSESULFURIC ACID SPILLSULFURIC ACID SPILL

Dilution the solutionDilution the solution??

For a spill of 1 gallon of strong sulfuric acid, 1 For a spill of 1 gallon of strong sulfuric acid, 1 000 000 gallons of water would be required to bring 000 000 gallons of water would be required to bring the pH level to 6.0the pH level to 6.0

EMERGENCY RESPONSEEMERGENCY RESPONSESULFURIC ACID SPILLSULFURIC ACID SPILL

Any significant spill should be recovered and or Any significant spill should be recovered and or neutralized.neutralized.

EMERGENCY RESPONSEEMERGENCY RESPONSERECOMMENDATION:RECOMMENDATION:

The use of a calcium(Ca) based neutralizing agent such as The use of a calcium(Ca) based neutralizing agent such as hydrated lime(first choice) or limestone, is preferred hydrated lime(first choice) or limestone, is preferred compared to sodium(Na) based neutralizing agent such as compared to sodium(Na) based neutralizing agent such as caustic soda, sodium carbonate(soda ash) or sodium caustic soda, sodium carbonate(soda ash) or sodium bicarbonate(cow brand). bicarbonate(cow brand). The salt produced by the reaction of calcium base material The salt produced by the reaction of calcium base material with acid is gypsum, which is not soluble in water, thus not with acid is gypsum, which is not soluble in water, thus not creating any harm to the environment. While with sodium creating any harm to the environment. While with sodium base products, the salt produced by the reaction is soluble base products, the salt produced by the reaction is soluble in water, which can affect animal and plant life by in water, which can affect animal and plant life by ‘‘saltingsalting’’certain areas of lakes and rivers.certain areas of lakes and rivers.

EMERGENCY RESPONSEEMERGENCY RESPONSERECOMMENDATIONS (RECOMMENDATIONS (…… continuedcontinued))The use of course limestone is not very efficient. The use of course limestone is not very efficient. Finely crushed limestone is more effective. Finely crushed limestone is more effective. Limestone has a low solubility in water, and thus Limestone has a low solubility in water, and thus will not will not ““overdoseoverdose”” the treatment area.the treatment area.

EMERGENCY RESPONSEEMERGENCY RESPONSE

NaOHNaOH= = Caustic SodaNH3= NH3= Aqua Ammonia (fertilizer)Na2CO3= Na2CO3= Soda AshCaCO3= CaCO3= Calcium Carbonate (Antacid, limestone is a source)Ca(OH)2= Ca(OH)2= Hydrated LimeNaHCO3= NaHCO3= Sodium Bicarbonate (Baking Soda, not on table)

Questions?Questions?

EnglehartEnglehart Acid DeAcid De--RailmentRailment March 30, 2007March 30, 200714 Cars of 93% 14 Cars of 93% SulphuricSulphuric

Acid,Acid,

7 Box Cars of Copper Anodes Derailed7 Box Cars of Copper Anodes Derailed3 Acid Cars Re3 Acid Cars Re--railed, 11 Acid Cars railed, 11 Acid Cars

TransferredTransferred

3 tank carsre-railed from

this areaNot shown on

this map

Porta

tank forthe safety shower

water until we had the safety shower set up

3 tank cars that were re-railed and pulled away

Potable water brought infrom the railway station

for the safety shower

Safety officer appointeddaily over looking the transfers

Leaking car Attaching the cable as per Hulcher

instructions

Note – Tank Car has new, low profile fittings arrangements, which ensured no release to environment

Safety Shower

(2)-260 US Gallon Totes 20 liters

per minute (5 gallons)Shower time of 1.7 hours

Honda water pump capable of

600 litres per minute

Tank Truck Roll Tank Truck Roll OverOver AprilApril

16, 200716, 2007

Where:Where:Highway 138, Cornwall, OntarioHighway 138, Cornwall, Ontario

Type:Type:RollRoll--over with leaking by 3 inch over with leaking by 3 inch flangflang on man holeon man hole

Action plan:Action plan:Fire department install & operate the showerFire department install & operate the showerWe ask to obtain a welder on siteWe ask to obtain a welder on siteUsing transfer by pump Using transfer by pump (around 1 hour 15 minutes)(around 1 hour 15 minutes)

IssueIssueA lot of Wind A lot of Wind –– Dangerous on topDangerous on top

PicturesPictures

PicturesPictures

PicturesPictures

LaTuqueLaTuque, Qu, Quéébecbec July, 2007July, 2007

SummarySummaryLocation: 80km Location: 80km northnorth of of LaTuqueLaTuqueSix Six tankcarstankcars derailedderailed and and hadhad to to bebe transferredtransferredTwelveTwelve hourhour drive drive fromfrom the Horne to the Horne to LaTuqueLaTuqueThreeThree hourshours by rail to by rail to getget to the site to the site fromfrom LaTuqueLaTuqueFortyForty minutes by minutes by helipcopterhelipcopterOne km One km fromfrom a a sideside road but a road but a threethree hourhour drive in a drive in a veryvery rough rough gravelgravel road road fromfrom LaTuqueLaTuque

SummarySummaryAll All equipmentequipment broughtbrought in by railin by railNo water No water nearnear by, 20 gallon by, 20 gallon bottlebottle hadhad to to bebe usedusedand portable and portable eyeeye washwash for emergency for emergency HelipcopterHelipcopter requiredrequired atat all times all times duringduring transfertransfer but but workwork limitedlimited to to dayday lightlightLEL LEL levellevel up to 17%, up to 17%, hadhad to drill a second to drill a second holehole to to purge purge withwith compressedcompressed airairPoorPoor conditions: no conditions: no foodfood, no place to , no place to restrest, etc.. , etc..

Note the zigzag derailment – Double shelf couplers

Multiple pumps used to offload carsEach pump can unload a tank car in 2 hours

Note pumps are equipped with isolation valves for transferring from tank car to tank truck

Receiving Sulfuric Acid from Damaged tank cars

General InfoGeneral Info

Some environmental strategies for major releaseSome environmental strategies for major release

EMERGENCY RESPONSEEMERGENCY RESPONSE Helicopter DropHelicopter Drop

EMERGENCY RESPONSEEMERGENCY RESPONSE Treatment SiteTreatment Site

EMERGENCY RESPONSEEMERGENCY RESPONSE Treatment Treatment

EMERGENCY RESPONSEEMERGENCY RESPONSE Lake TreatmentLake Treatment

EMERGENCY RESPONSEEMERGENCY RESPONSE Injection BargeInjection Barge

EMERGENCY RESPONSEEMERGENCY RESPONSE Injection BargeInjection Barge

HandoutsHandouts Sulfuric Acid HandbookSulfuric Acid Handbook