( Reaffirmed 1999 )

IS:12185

- 1987

Indian Standard
CODE OF PRACTICE FOR CONTROL OF AIR POLLUTION IN INTEGRATED ALUMINIUM INDUSTRIES
Air Quality
Chairman DR B. B. SUNDARE~AN Members _DR H. KOTRANDARAMAN ( Alternate to Dr B. B. Sundaresan ) National Environmental Engineering Research DR A. L. AQARWAL Institute ( CSIR ), Nagpur SHRI P. K. YENNAWAR ( Alternate ) Indian Oil Corporation Ltd, Faridabad DR J. S. AHLUWALIA SHRI V. S. MORE ( Alternate ) Dharmsi Morarji~chemical Co Ltd, Bombay SHRI N. G. ASHAR DR M. S. VAIDYA ( Alkrnats ) Central Mechanical Engineering Research Institute, DR B. B. BANSAL Durgapur SHRI B. BEADWRY ( Alternate ) Calcutta Metropolitan Deve!opment Authority, SHRI A. K. BASU Calcutta SHRI RANJIT KUMAR SENGUPTA ( Alternate) Directorate General Factory Advice Service & SRRI S. CHA~I~ABARTY Labour Institutes, Bombay DR PHULEXAI~ ( Alternate ) National Organic Chemicals Industries Ltd, Bombay SRRI P. CHATTERJIE SHRI K. D. A&IRE ( Alternate ) Central Board for the Prevention and Control of DR NILAY CH~\UDHURI Water Pollution, New Delhi MEMBER-SECRETARY ( Alternate ) Jawaharlal Nehru University, New Delhi SHRI J. M. DAVE Society for Clean Environment, Bombay DR P. J. DEORAS DR S. B. CHAPREI~AR ( Alternate ) Indian Chemical Manufacturers Association, Calcutta SHRI hf. V. DESAI SRRI B. SARAN ( Alternate ) Projects & Development India Ltd, Sindri DR V. S. GUPTA SHRIHATI M. CHANDRA ( Alternate ) ( Continuedon Page 2 ) @ Copyright 1988 BUREAU OF INDIAN STANDARDS This publication is protected under the Indian Copyright Act ( XIV of 1957 ) and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act.

Sectional

Committee,

CDC

53

Representing University of Madras, Madras

IS : 12185- 1987
( Continuedffompap 1 ) Members SBRI A. LAHIRI SHRI A. MITILA ( Al&mate ) DR.N.K. MERROTNA Hindustan R.qreseniing Lever Ltd, Bombay Research Centre ( CSIR ),

SHRI M. M. LAL ( Alternate I ) SHRI J. L. KAW ( Alternate II ) SHRI A. K. M~SSER Cement Manufacturers Association, New Delhi SHICI P. A. MITBA Union Carbide of India Ltd, Bombay SHRI Y. G. P~ra~xan ( Alternate ) SHRI A. K. MOOXHERJEIZ Flakt India Ltd, Calcutta Sam M. CHAUDH~Y ( Alternate ) DR P. N. MUKHERJEE Central Fuel Research Institute ( CSIR ), Dhanbad DR R. U. ROY ( Alternate ) DR V. PAC~~AIYAPAN Fertilizer Association of India, NewDelhi DR S. NANU ( Alternate ) SHRI G. K. PANDEY Department of Environment Government of India, New Delhi National Institute of Occupational Health ( ICMR ), DR T. S. PATEL Ahmadabad SHRI S. K. Pt\TIL Maharashtra Pollution Control Board, Bombay SARI D. R. RASAL ( Alternate ) SHRI C. R. M.\DRAVA RAO Steel Authority of India Ltd, Ranchi SRRI I. JAYAILAMAN ( Alternate ) Directorate General of Technical Development, SHRI A. N. Rae New Delhi SHRI P. 1~. RAX~~~IIAX~I~AN Ministry of Defence ( D%I ) DR B. V. RXWANI ( Alternate ) Central Electricity Authority, New Delhi SHRI CH V. RAX~~X~~MUI~T~Y SRRI R. K. SHAIW~ ( Alternate ) Municipal Corporation of Greater Bombay, Bombay DR S. G. RETARXAR SHRI DRIREN~RA J. VYAS ( Alternate ) Coal India Ltd, Calcutta SHRI S. B.~%ILKAR Gujarat Pollution Control Board, Gandhinagar SHRI B. F.S%LrrJa DR U. I. BHATT ( Alternate) Bhabha Atomic Research Centre, Bombay DR V. V. SHIRVAII~X~ DR R. K. K~POOR ( Alternate ) Central Mining Research Station ( CSIR ), Dhairbad DR J. K. SINHA YHRI A. K. BOSE ( Alternate ) Director General, BIS ( Ex-o&o Member ) SHRI SATTSR CH.~N~~R, Director ( Chem ) Secretary SHRI S. ARAVAMUDHAN Joint Director ( Chem ), BIS

Industrial Toxicology Lucknow

( Conrinlred on page 17 )

IS:12185

-1987

Indian Standard
CODE OF PRACTICE FOR CONTROL AIR POLLUTION IN INTEGRATED ALUMINIUM INDUSTRIES OF

0. FOREWORD
0.1 This Standards Sectional Council. Indian Standard was adopted on 30 July 1387, after the draft Committee had been approved by the Bureau of Indian finalized by the Air Quality by the Chemical Division

0.2 In the recent years, great concern has been universally expressed regarding environmental pollution arising as a side effect of industrial and other human activities. It has now been recognized generally that these pollutants ultimately discharged in the working environment pose health hazards, producing chronic effects on living organisms including human beings. 0.3 An integrated aluminium complex consists mainly of the alumina plant, where bauxite is converted to alumina, the smelter or the reduction plant, where alumina is converted to primary aluminium and the fabrication plant where primary aluminium is converted to various fabricated and semi-fabricated end-products. Auxiliary installations like captive power plant, bauxite mines, foundry, etc, are also existing. Each of these units, to a different degree, is a source of air pollution. Figure 1 gives the main sources of air pollution in an integrated aluminium complex. 0.4 This standard is formulated to help the industry to identify source and also to take suitable action for pollution abatement. 0.4.1 The recommended dust and mist collectors for abatement pollution in an integrated aluminium plant is given in Fig. 2. 3 the

of

BAUXITE

STEAM COAL

F;vLAcE

C.

P. COKE

ANTg$C I

ITE

HARi%Tt H SOFT PITCH I

fZZ
CAPTIVE POWER

I
1

BOILER

HOUS&fJUSl

.
I

_A

PITCH

FUMES

RODDING

ROOM

ANODES

f-

r
_.I
4
f

CARBON DUCTION

PLANT

PLANT

c
I
PRIMARY I METAL

c 1

ADDITIVE DUST

AREA

FOUNDRY
NOx,CO, AND CO2 SO2

ALUMINA

PLANT

FABRICATION

FIG. 1

SOURCESOF AIR POLLUTION IN AN INTEGRATED ALUMINIUM FACTORY

IS : 12185 - 1987 1. SCOPE 1.1 This standard prescribes a code for controlling air pollution various processes/sections of an integrated aluminium complex. code covers the following:
a) Air pollutants, control; b) Location their sources and techniques of air from The

pollution

and lay-out; survey; and

c) Air pollution d) Emission 2. AIR

factors.

POLLUTANTS, OF AIR YOLLUTION Materials

THEIR SOURCES CONTROL

AND

TECHNIQUES

2.1 Raw

2.1.1 Brief Description of the Process - In an integrated aluminium industry, a large quantity of raw materials like bauxite, steam, coal, calcined petroleum coke, pitch, furnace oil, etc, are handled. Dust is produced while unloading the wagons, subsequent crushing, conveying transferring to storage points and reclaiming. Separate by belt conveyors, handling systems are provided generally for different raw materials.
2.1.2 Generation of Air Pollutants A lot of particularly in the dry season, during the handling wagon tippler, conveyors, transfer points, crushers, discharge points. dust is produced, of raw materials in etc, right up to the

2.1.3 Measures to Control Air Pollution - The concentration of dust in the air should be maintained within the prescribed limits. For this purpose, suitable dust collectors of dry or wet type and also either of the pressure or the vacuum type depending on the conditions shall be provided. Dry type dust collectors like bag filters and cyclones shall be Dust suppression by water spray used depending on the application. can also be done at locations like wagon tippler during the dry season. 2.1.4 Generation of dust can also be minimized by small modification in~the process of raw materials handling. These include reduction in number of transfer points, hooding of dust generating equipment, etc. In an aluminium industry normally raw material unloading, crushing, transfer and conveying operations need to be checked and proper hoods and ducting leading to common dust collection system in various sections have to be provided.

IS : 12185 - 1987 2.2 Slurry Mixing Area

2.2.1 Brief Description of the Process - In the slurry mixing area, the crushed bauxite is ground in ball mills or rod mills with process liquor ( sodium aluminate solution ), the slurry consistency varies from 3 to 50 percent depending on the process adopted. This is subsequently charged to the digesters at a measured rate. 2.2.2 Generation %c Air Pollutunts - In the slurry mixing area, normally a small quantity of caustic vapour gets entangled with the fumes generated during transfer of the bauxite slurry. 2.2.3 Measures to Control Air Pollution - The fumes generated at the out and do not contain any toxic ball mill discharge are vented contaminants. However, a small hood with a chimney leading to the top of the building may be adequate. 2.3 Digestion -Piant

2.3.1 Brief Description of the Process - In the digestion area, the bauxite slurry is digested in digesters under different conditions like low pressure or high pressure digestion, the condition depending on the quality of the bauxite used. During the process of digestion of the bauxite slurry, additional quantities of steam and spent liquor are added into the digesters. Alumina from the bauxite is extracted and the insolubles remain in the form of red mud. Subsequently, pressure and temperature of the slurry is brought down gradually in flash tanks. The flashed Slurry from the last steam so liberated is used for pre-heating of liquor. flash tank is pumped to the clarification area for further processing. The condensate generated in the heaters is sent back to boiler area for converting to steam again. 2.3.2 Generation of Air Pollutants - Normally there is no emission of air pollutants from the digestion area. The steam and other vapours escaping out of the relief tanks and heater vents have to be screened by proper entrainment separators to avoid caustic vapours lvhich may arise during process upsets. 2.4 Clarification and Filtration Area

2.4.1 Brief Description of the Process - The digested slurry from the digestion area is pumped to the clarification area for removing the red mud ( impurities ) from the pregnant liquor or green liquor ( saturated sodium aluminate liquor ). Slurry enters conventional thickeners where flocculants are also added. The settled red mud is pumped through a series of counter current washers to recover entrained caustic soda. After the last stage of washing, the mud is either filtered or directly pumped to red mud ponds. The clear overflow of sodium aluminate from the thickeners is then filtered in pressure filters to remove the finer 7

IS:12185

- 1987 next section which is to the washer system and filtration

particles of impurities and then pumped to the precipitation section. The filtered cake is pumped for subsequent disposal to red mud lake.

2.4.2 Generation of Air Pollutants - In the clarification area also, no toxic air pollutants are generated. 2.5 Precipitation Area

sodium aluminate 2.5.1 Brief Description of the Process - The saturated solution is fed into batch type or continuous type of precipitators. Alumina hydrate seed is then added to the precipitators and the mixture is agitated either with compressed air or mechanically for over 25 to 30 hours. 2.5.1.1 In the case of continuous precipitation, the liquor moves from one precipitator to-the subsequent one continuously and a time of Selection of the precipitation approximately 60 to 70 hours is given. system depends on the product quality requirement. 2.5.1.2 During this process, alumina hydrate precipitates from the saturated sodium aluminate solution. Hydrate so precipitated is classified either in thickners or by filtration. Out of the classified hydrate, the coarser fraction is calcined to give product alumina. The finer fractions are used for seeding. 2.5.2 Generation oj Air Pollutants is only the fine particles of caustic of precipitators. The effect of this area only. Of course, when there be carried by high velocity wind to The main air pollutant in this area fumes coming out of the open type vapour is felt mostly in the working is excessive vapour coming out, it can nearby areas in the plant.

2.5.3 Measures to Control Air Pollution - The formation of excessive mist or vapour with the air cornin,? out of the precipitators is to be avoided by controlling the quantities of air or by providing proper By exercising proper control on the operating parameters like covers. quantity of air, type of agitation and temperature of the liquor, the emission of the vapour can be more or less reduced to minimum. The workers working in the area should be advised to use face and hand creams. 2.6 Calcination Area

2.6.1 Brief Description of the Operating Process - In the calcination area, the precipitated product hydrate is filtered, washed free of caustic soda and other impurities and fed into rotary kilns or calciners. The rotary kilns are fired by furnace oil ( This is true for all the existing aluminium industria in India ). The calcination of alumina hydrate to alumina takes place at a temperature of around 1 100C. The calcinated alumina

IS:12185-1987 In case is stored in silos or transferred to the smelter area. plants, where the smelter is located far away from the alumina transportation is done by rail, road or ships. 2.6.2 Generation of Air Pollutants of some facility,

2.6.2.1 Dusting is produced during the calcination of alumina hydrate to alumina. Dust emission is present in the main exhaust chimney of I.D. fan and also in the exhaust points of the bag filter house fans. point 2.6.2.2 Dusting is produced at each and every transfer/collection of the calcined alumina along with the conveyors.

2.6.2.3 Gaseous pollutants are generated during the burning of furnace oil in the rotary kilns and these escape through the I.D. fan The gaseous pollutants may chimney together with particulate matter. contain hydrogen sulphide, sulphur dioxide, carbon dioxide, carbon monoxide and particulate matter. 2.6.3 Measures to Control Air Pollution be taken to control airpollution: a) Control gases, b) Control of emission of gaseous The following dust particles measures with the should stack

of alumina pollutants dust at

in the stack gases, and transfer and conveying points of

c) Control of alumina calcined alumina.

2.6.3.1 Alumina dust can be controlled cyclones and a good electrostatic precipitator. system at this point can practically eliminate through the stack gases.

by providjng proper Efficient dust collecting any alumina going out

2.6.3.2 The pollutants in the stack gases can be controlled only by exercising proper control on the combusted parameters of furnace oil. The stack height should be properly designed for dispersion and dilution of the gases after discharging to atmosphere. 2.6.3.3 Local exhaust ventilation hoods should be provided at each The transfer point land above other points where dusting is produced. exhaust air should be led to a central dust collection system which are normally bag filters. 2.7 Evaporation Area

2.7.1 Brief Description of the Operating Process - In the evaporation area, the spent liquor coming out of the precipitation area is eva.porated for the purpose of maintaining water material balance in the process circuit. 9

IS I 12185--

1987

The concentration of caustic soda is increased during this process and the evaporated liquor then circulated to the digester through spent liquor heaters for dissolving more alumina. 2.7.2 Generation of Air generated in this particular 2.8 Additive Area Pollutants area. There are no air pollutants

2.8.1 Brief Description of the Operating Process - During the process~of manufacture of alumina, certain important additives are used, which are generally prepared in the additive area and a few are listed below: a) Slake lime in the form of lime slurry is added at various stages The purpose of this of the alumina manufacturing process. addition is to control the causticity of the process liquor and also in some cases to eliminate phosphate and to reduce organic contaminant levels in the process. b) Synthetic or natural flocculants are added for enhancing characteristics of red mud and hydrate. for precoating c) Filter aids are prepared aluminate solution is filtered for removing 2.8.2 Generation of Air Pollutants area are as follows: The air filters where impurities. generated setting sodium in this

pollutants

a) Huge amount of dust is generated during handling of quick lime. The lime is usually received by trucks or wagons and Lime is crushed before it is slaked in lime unload into hoppers. The entire lime handling operation is a dust generating slakers operation. b) Some amount of dust materials like flocculants, ants like starch is used. is also generated during handling of particularly, where the natural floccul-

2.8.3 Measures to Control Air Pollution - Dust generated during handling, of lime should be preferably absorbed in a wet scrubbing unit using water and the collected dust together with water should be re-circulated to the lime slaker. Proper hooding with natural exhaust will be adequate for taking care of the dust during handling of flocculants. 2.9 ~Reduction 2.9.1 Plant

Carbon Plant Area

2.9.2 Brief Description of the Operating Process - The carbon plant area In the cells used is ncu-mally located in the reduction plant or smelter. the anode is for pot electroytic reduction of aluminia to aluminium,

IS : 12185 - 1987
made of carbon and cathode is also a lining of carbon. During the process, the anode carbon gets consumed continuously and this has to be replenished. The carbon plant manufactures and supplies the anode in the form of prebake blocks or anode paste depending on the type of smelter operation. The anode is prepared by mixing powdered calcined petroleum coke with medium soft pitch. In case of prebake anode plant, the green anodes in the form of anode blocks are baked in baking furnace fired by furnace oil at a temperature around 1 150C. The baked anodes are then fixed with anode stubs and copper rods for subsequent replenishment in the potroom. In the other type, namely, the Soderberg type cells, the anode paste is directly charged to the pots. 2.9.3 Generation of Air Pollutants - A lot of carbon dust is produced during handling, conveying and crushing operations of calcined petroPitch fumes are also generated during-the melting of pitch. leum coke. In the baking furnace, the exhaust fans which continuously exhaust the furnace throw out stack gases containing carbon monoxide, carbon dioxide and sulphur dioxide. 2.9.4 Measures to Control Air Pollution - The best method of collecting the dust in the CP coke handling and crushing area is to provide proper hoods with ducting leading to a bag filter type dust collection arrangement. Properly designed bag filters for this application have been found to be very effectivein controlling the dust level in the working~area and in the environment. 2.9.4.1 Pitch fumes can proper hoods and stacks. also be controlled by scrubbing, providing

2.9.4.2 In the baking furnace, an efficient control on the combustion .of furnace oil will take care of the composition of the stack gases. The chimney which exhaust gases from the baking furnace should also be high enough to disperse gases over a wide area thereby ensuring proper dilution. 2.10

Potroom

2.10.1 Brief Description of the Operation Process - The potroom is the main plant area of an integrated aluminium complex. The potroom consists of facilities like pot cells, electrical bus bars, cranes, etc, for carrying out reduction operation. The pot cell is lined with a layer of carbon which forms the cathode. Anode carbon blocks are suspended from the top frame. Heavy DC current varying from 55 000 to 100 000 amperes depending on the design of the plant, is passed through the cell. The cell is filled with a bath of cryolite, sodium aluminium fluoride and Alumina gets dissolved in the molten cryolite and aluminium fluoride. due to the passage of the high current, it gets electrolyzed to aluminium The oxygen combines with the carbon anode and escapes and oxygen.
I1

IS:12185-1987
into the atmosphere as carbon dioxide. The molten aluminium collects at the cathode and is intermittently tapped out into a crucible using cast iron syphon. The molten aluminium thus tapped is transferred to the pig casting area or to the remelt casting shop of fabrication. 2.10.2 Generation of Air Pollutants In an integrated aluminium industry, the smelter happens to be the area producing maximum amount of air pollutants. The smelter operation is carried out at a temperature ~of about 960 to 970C. The bath contains fluorine combined with dust particulates. During various operations in the potroom, a lot of dust particulate and also gaseous contaminants are produced. The gaseous carbon-dioxide, gaseous fluorine, gaseous contaminants are mainly hydrofluoric acid, some volatile fluorides of silica, iron and suspended particles of alumina, aluminium fluoride, cryolite and carbon. 2.10.3 Measures to Control Air Pollution - The control of air pollution from aluminium smelter has been studied on an international basis. Basically there are two methods of air pollution control. One is a wet scrubbing method and the other is dry scrubbing method. The wet scrubbing method for the potroom gases being an old method and having, its own problems like corrosion, cumbersome operation, etc. The dry scrubbing system is by and large being universally accepted by many modern aluminium industries using prebaked pots. Dry scrubbing system system is used in is not applicable to Solderberg pots; only wet scrubbing these pots. In the dry scrubbing system, the pots are properly hooded and the gases collected through the ducting of central scrubbing unit where alumina is used for scrubbing. The alumina adsorbs more than 98 percent of the gaseous flourine contaminants of the gases. These gases then are passed through an efficient bag filter system where the particulate matters is also removed and recycled to the process. The gases coming out of the bag filter which are free from gaseous and particulate contaminants, are discharged into the atmosphere through high stacks. Provision of a dry scrubbing system for older type of plants is lengthy and necessary time factors may be allowed for and costly proposition, implementation of the schemes. So the scrubber selection will depend upon the types of pots used, namely, prebaked or Solderberg. At all points where alumina, aluminium fluorides and cryolite are handled inside the reduction plant, proper care should be taken to avoid dusting by controlling the operations, provision of telescopic chutes, hooding, wherever necessary, etc.

12

IS : 12185 - 1987 2.11 Fabrication Plant and large, line: rods, the

2.11.1 Brief Description of the Operating Process - By following processes are involved in aluminium fabrication a) Remelting b) Productionof c) Production d) Hot rolling e) Cold f) Production g) Production and casting electrical of extruded of aluminium aluminium of aluminium of aluminium operations, conductor sections, slabs into sheets, sheets, paste and powder, foils. and grade properzi

rollingiof

2.11.2 Generation of Air Pollutants The only section where air pollutants are generated in the fabrication plant is the remelting section. Furnace oil is generally burned in the melting furnaces and gases coming out of the stacks of these furnaces contain pollutants like SOz, COB, CO, chlorides, and NOx. The contaminants can be controlled to some extent by proper combustion of the oil. The stack should be high Recuperators enough to ensure proper dispersion of the stack gases. or heat conserving methods should be adcpted to reduce the temperature of the exhaust gases to the minimum possible. 2.12 Boiler Plant for Process Steam

2.12.1 Brief Description of the Operating Process - A boiler plant with suitable capacity is required for supplying process steam to the alumina plant, carbon plant and some other auxiliaries of aluminium industry, The process steam is supplied to processes like digestion, evaporation, cleaning, additives preparation, furnace oil heating, etc. 2.12.2 Generation of Air Pollutants - Depending on the type of boilers and the quality of coal, good amount of fly ash, dust and stack gases containing sulphur dioxide and nitrogen oxide are generated in the The coal handling also generates coal dust at unloading, boiler area. transfer and conveying points. 2.12.3 Measures to Control Air Pollution - Boiler should by provided with multi-cyclones and electrostatic precipitators, if found necessary, so as to maintain the particulate matters in the stack gases within acceptable limits. It has been found that normally electrostatic precipitator for such appiications is not very efficient due to the low sulphur content in the Indian coal. An efficient cyclone separator or a multicyclone properly designed should serve the purpose. 13

IS:12185 -1987 2.12.4Bag filter shall be provided for collecting the dust ~emanating from the coal handling area, hoods and proper ducting shall be provided at dusting and they should be led to the central dust collection bag house.
2.13

CaptivePower

Plants

2.13.1Captive power plants generate and supply electric power to the aluminium industry. Presently there is only one such unit in the country. The existing one is a thermal power plant.
2.13.2 Generation of Air Pollutants As already mentioned under boilers for process steam, the thermal power stations also generate air pollutants due to sulphur dioxide, particulate contaminants and nitrogen The emission limits may vary from unit to unit depending on oxides. the capacity of the plant, ambient air quality level, wind speed directions, chimney height and topography. 2.13.3 Measures to Control Air Pollution - Generally, it is poesible to minimize air pollution caused by thermal power stations and boilers by adopting multi-flue stacks ( for new units only ) proper design of stacks, and by providing cyclone separators and/or electrostatic precipitators. Bag house is also efficient dust collecting equipment. 2.14 Foundry

2.14.1 Brief Description of Operating Process - Foundry unit is provided as an auxiliary unit in or around an integrated aluminiuul industry. The purposes of the foundry are generally for making indigenous spare parts for various equipments deployed in the plant. 2.14.2 General Air Pollutants - The main atmospheric pollutants are produced during the melting of cast iron scrap. The gases coming out of the melting furnace contain oxides of nitrogen, sulphur and carbon monoxide. 2.14.3 Measures to Control Air Pollution - Generally the foundries are intermittent operating plants and do not cause any serious air pollution. However, the chimneys of the furnace should be properly designed and should be high enough to ensure effective dispersion and dilution. 3. LOCATION AND LAYOUT complex or acceptable

3.1 While deciding the location for new aluminium expansion of the existing operations, environmentally approach has to be ensured. This task will include: a) Selection c) cleaning of best site for smelters available equipments be installed 14 particularly; b) the best technology for the industry together

be adopted;

with the whole plant;

IS : 12185 - I987 d) cleaning equipments to have monitor to comply with specifications; levels before start up of

e) it is advisable the plant;

air pollution

f) the plant should be so located direction carries the gases away and greenbelts; and g) alternately, residential area clearner side of the plant. 3.2 Stacks

that the from the be

predominant wind residential localities located towards

should

the

3.2.1 All stacks should be designed such that emission of particulate matter from the stacks should be within the prescribed limits. Proper dispersion at reasonable heights shall also be ensured. 4. Air Pollution Survey

4.1 It is advisable to conduct air pollution survey of the locality around Pollution control unit of the plant new plants or proposed expansion. existing background should be designed to take care of the already pollution level. 4.2 All integrated aluminium industries should have independent pollution monitoring facilities. A systematic record of the emissions in working area and also in the ambient air within a diameter of 5 km should be maintained by the pollution monitoring and control group. A fully equipped analytical laboratory and trained personnel is an asset to the industry. 5. EMlSSION FACTORS for primary aluminium with process are as given factor in

5.1 The emission factors Table 1 and 5.1.1.

5.1.1 Sulphur oxides may be estimated, of C, by the following calculations: a) Anode rg;ace b) Prebake where baking furnace, fuel combustion ( reduction

an emission

rating

uncontrolled SO2 emissions ( excluding emissions ) : 20 ( C) ( S ) ( l-0.01 K) SO2 emissions: kg/t

) cell, uncontrolled 0.2 ( C ) ( S ) ( X)

C = anode consumption [ weight of anode paste ( coke + pitch ) before baking ] during electrolysis, kg anode consumed/kg alum.ina produced. S -I- percent K = percent cells. sulphurin of total anode SO2 15 before baking. by prebake ( reduction ) emitted

IS : 12185- f987
TABLE 1 EMISSION FACTORS PRODUCTION TOTAL PARTICULATE+ kg/t 1.5 c-------_-.-Not 0.375 0.375 0.03 47.0 2.5 445 9.8 0.9 8.9 0.9 cyclones FOR PRIMARY PROCESS ALUMINIUM

(Cluuss 5.1 ) OPERATION GASEOUS FLUORIDE kg/t 0.45 available---_-0.1 01 001 120 0.6 114 114 065 15 1.7 PARTICULATE FLUORIDE kg/t r.05 ---_+ 005 0.05 002 10.0 0.5 9.5 2.1 0.85 2.0 0.2

Anode Raking Uncontrolled Fugitive Spray tower Electrostatic precipitator ( ESP ) Dry alumina scrubber Prcblzks Ccl1 Uncontrolled Fugitive Emission to collector Multiple Dry alumina scrubber Spray tower Coated bag filter dry scrubber Vertical Soderbcrg Stud Cell Uncontrolled Fugitive Emission to collector Spray tower Venturi Multiple scrubber cyclones 39.0 6.0 33.0 8.25 1.3 16.5 0.65 16.5 2.45 l&O5 0.15 0.7 1405 0.75
11.0

5.5 0.85 465 115 0.8 -235 0.75 6.0 0.6 5.4 135 12 0.7 0.7 0.75

Dry alumina scrubber Horizontal Sodcrberg Stud Cell Uncontrolled Fugitive Emission to corlector Spray tower Floating bed scrubber Scrubber Wet ESP Dry alumina scrubber *Includes particulate fluoride. plus wet ESP

49.0 5.0 440 11.0 9.7 O-9 0.9 0.9

11 99 3.75 0.3 0.3 0.8 075

16

IS:12185 ( Continuedfrom
page 2 )

-1987

Codes of Practice
Convcncr SHRI N. G. ASHAR Members

for Control of Air Pollution CDC 53 : 4

Subcommittee,

Co Ltd, Bombay

SHRI L. K. JAIN ( Alternate to Shri N. G. Ashar ) DR A. L. AG~RWAL

SHRI S. CHAKRABARTY
SHRI P. CHATTERJEE

SHRI G. K. PANDEY ( Alternale) DR PHELEKAR ( Alternate )

Engineering National Environmental Institute ( CSIR ), Nagpur Directorate General Factory Advice Labour Institutes, Bombay National Organic Chemical

Research Services and

SHRI P. R. GRARE KHAN SHRI M. K. PRABHU ( Alternate DR V. S. GUPTA SHRI S. B. SINHA ( Alternate ) SHRI D. B. IRANI

SHRI K. D. AMRE ( Alternate )

Industries Ltd, Thane

Indian Petrochemicals Corporation Ltd, Vadodara ) Proiects & Development India Ltd, Sindri

National Council for Cement and Building Materials, New Delhi SHRI R. GANAPATHY ( Alternate ) Chemical Manufacturers Association, Indian SHRI J. P. KAP~R Calcutta Da N. C. MEHTA ( Altrrnale) Industrial Toxicology Research Centre, Lucknow SHRI M. M. LAL Flakt India Ltd, Calcutta SHRI S. K. M.URA SHRI B. MAJUMDAR (Alternate) Fertilizer Association of India, New Delhi DR V. PACHAIYAPPAN DR S. NAND ( Alternate ) Bharat Heavy Electricals Ltd, Hyderabad SHRI T. C. PARTHASARATHY SHRI P. R. KRISHNA MURTHY ( Alternate ) Batliboi & Co Ltd, Bombay SHRI R. RAMANAN SRRI J. N. MEHROTRA ( Alternate ) Central Board for the Prevention and Control of DR K. R. RANQANATHAN Water Pollution, New Delhi DR B. SENGUPTA ( Alternate ) Central Mining Research Station ( CSIR ), Dhanbad DR B. SINGH DR J. K. SINHA ( Alternate ) Central Electricity Authority, New Delhi SHRI S.A. SUBRAMANIAN Indian Oil Corporation Ltd, New Delhi SARI S. V~NKATARA~~~AN SHRI M. KANNAN ( Allernate ) Voltas Limited, Bombay SHRI R. VIKUPAKSAIA~C Municipal Corporation of Greater Bombay, Bombay SH~I DHIRENURA J. VYAS SHRI S. G. RETAREKAR ( Alternate )

17

INTERNA-TIONAL
Base

SYSTEM

OF UNITS

( SI UNITS

Units
QUANTITY
UNTT

SYMBOL In kg S

Length
MWS

metre kilogram second ampere kelvin candela mole

Time Electric current Thermodynamic temperature Luminous intensity Amount of substance Supplementary
QUANTITY

A K cd mol

Units UNIT radian steradian SYaaBOL rad sr

Plane angle Solid angle Derived Units QUANTITY Force Energy Power Flux Flux density Frequency Electric conductance Electromotive force Pressure, stress

UNIT newton joule watt weber tesla hertz siemens volt Pascal

SYMBOL N 1

DEFINIWON

N = 1 kg.m/s J = 1 N.m

J
W Wb T Hz S V Pa

1 W=lJ/s 1 Wb = 1 V.s 1 1 T = 1 Wb/ms 1 Hz = 1 c/s (3-s) S = 1 A;V

1 v = 1 W/A I Pa = I N/m