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ANNEXU.K. BAT CONCLUSIONS FOR THE NON-FERROUS METALS INDUSTRIES

1.3.BAT CONCLUSIONS FOR ALUMINIUM PRODUCTION INCLUDING ALUMINA AND ANODE PRODUCTIONU.K.

1.3.1. Alumina production U.K.

1.3.1.1. Energy U.K.
BAT 55.In order to use energy efficiently during the production of alumina from bauxite, BAT is to use one or a combination of the techniques given below.U.K.
TechniqueDescriptionApplicability
aPlate heat exchangersPlate heat exchangers allow a higher heat recovery from the liquor flowing to the precipitation area in comparison with other techniques such as flash cooling plantsApplicable if the energy from the cooling fluid can be reused in the process and if the condensate balance and the liquor conditions allow it
bCirculating fluidised bed calcinersCirculating fluidised bed calciners have a much higher energy efficiency than rotary kilns, since the heat recovery from the alumina and the flue-gas is greaterOnly applicable to smelter-grade aluminas. Not applicable to speciality/non-smelter-grade aluminas, as these require a higher level of calcination that can currently only be achieved with a rotary kiln
cSingle stream digestion designThe slurry is heated up in one circuit without using live steam and therefore without dilution of the slurry (in contrast to the double-stream digestion design)Only applicable to new plants
dSelection of the bauxiteBauxite with a higher moisture content carries more water into the process, which increases the energy need for evaporation. In addition, bauxites with a high monohydrate content (boehmite and/or diaspore) require a higher pressure and temperature in the digestion process, leading to higher energy consumptionApplicable within the constraints related to the specific design of the plant, since some plants are specifically designed for a certain quality of bauxite, which limits the use of alternative bauxite sources
1.3.1.2. Air emissions U.K.
BAT 56.In order to reduce dust and metal emissions from alumina calcination, BAT is to use a bag filter or an ESP.U.K.
1.3.1.3. Waste U.K.
BAT 57.In order to reduce the quantities of waste sent for disposal and to improve the disposal of bauxite residues from alumina production, BAT is to use one or both of the techniques given below.U.K.
Technique
aReduce the volume of bauxite residues by compacting in order to minimise the moisture content, e.g. using vacuum or high-pressure filters to form a semi-dry cake
bReduce/minimise the alkalinity remaining in the bauxite residues in order to allow disposal of the residues in a landfill

1.3.2. Anode production U.K.

1.3.2.1. Air emissions U.K.
1.3.2.1.1. Dust, PAH and fluoride emissions from the paste plant U.K.
BAT 58.In order to reduce dust emissions to air from a paste plant (removing coke dust from operations such as coke storage and grinding), BAT is to use a bag filter.U.K.

BAT-associated emission levels: See Table 7.

BAT 59.In order to reduce dust and PAH emissions to air from a paste plant (hot pitch storage, paste mixing, cooling and forming), BAT is to use one or a combination of the techniques given below.U.K.
a

Descriptions of the techniques are given in Section 1.10.

Techniquea
aDry scrubber using coke as the adsorbent agent, with or without precooling, followed by a bag filter
bRegenerative thermal oxidiser
cCatalytic thermal oxidiser

BAT-associated emission levels: See Table 7.

Table 7

BAT-associated emission levels for dust and BaP (as an indicator of PAH) emissions to air from a paste plant

a

As a daily average or as an average over the sampling period.

b

As an average over the sampling period.

ParameterProcessBAT-AEL (mg/Nm3)
Dust
  • Hot pitch storage, paste mixing, cooling and forming

  • Removing coke dust from operations such as coke storage and grinding

2-5a
BaPHot pitch storage, paste mixing, cooling and forming0,001-0,01b

The associated monitoring is in BAT 10.

1.3.2.1.2. Dust, sulphur dioxide, PAH and fluoride emissions from the baking plant U.K.
BAT 60.In order to reduce dust, sulphur dioxide, PAH and fluoride emissions to air from a baking plant in an anode production plant integrated with a primary aluminium smelter, BAT is to use one or a combination of the techniques given below.U.K.
a

Descriptions of the techniques are given in Section 1.10.

TechniqueaApplicability
aUse of raw materials and fuels containing a low amount of sulphurGenerally applicable for reducing SO2 emissions
bDry scrubber using alumina as the adsorbent agent followed by a bag filterGenerally applicable for reducing dust, PAH and fluoride emissions
cWet scrubber

Applicability for reducing dust, SO2, PAH and fluoride emissions may be limited in the following cases:

  • very high off-gas flow rates (due to the significant amounts of waste and waste water generated)

  • in arid areas (due to the large volume of water necessary and the need for waste water treatment)

dRegenerative thermal oxidiser in combination with a dust abatement systemGenerally applicable for reducing dust and PAH emissions.

BAT-associated emission levels: See Table 8.

Table 8

BAT-associated emission levels for dust, BaP (as an indicator of PAH) and fluoride emissions to air from a baking plant in an anode production plant integrated with a primary aluminium smelter

a

As a daily average or as an average over the sampling period.

b

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)
Dust2-5a
BaP0,001-0,01b
HF0,3-0,5a
Total fluorides≤ 0,8b

The associated monitoring is in BAT 10.

BAT 61.In order to reduce dust, PAH and fluoride emissions to air from a baking plant in a stand-alone anode production plant, BAT is to use a pre-filtration unit and a regenerative thermal oxidiser followed by a dry scrubber (e.g. lime bed).U.K.

BAT-associated emission levels: See Table 9.

Table 9

BAT-associated emission levels for dust, BaP (as an indicator of PAH) and fluoride emissions to air from a baking plant in a stand-alone anode production plant

a

As a daily average.

b

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)
Dust2-5a
BaP0,001-0,01b
HF≤ 3a

The associated monitoring is in BAT 10.

1.3.2.2. Waste water generation U.K.
BAT 62.In order to prevent the generation of waste water from anode baking, BAT is to use a closed water cycle.U.K.
Applicability U.K.

Generally applicable to new plants and major upgrades. The applicability may be limited due to water quality and/or product quality requirements.

1.3.2.3. Waste U.K.
BAT 63.In order to reduce the quantities of waste sent for disposal, BAT is to recycle carbon dust from the coke filter as a scrubbing medium.U.K.
Applicability U.K.

There may be restrictions on applicability depending on the ash content of the carbon dust.

1.3.3. Primary aluminium production U.K.

1.3.3.1. Air emissions U.K.
BAT 64.In order to prevent or collect diffuse emissions from electrolytic cells in primary aluminium production using the Søderberg technology, BAT is to use a combination of the techniques given below.U.K.
Technique
aUse of paste with a pitch content between 25 % and 28 % (dry paste)
bUpgrade the manifold design to allow closed point feeding operations and improved off-gas collection efficiency
cAlumina point feeding
dIncreased anode height combined with the treatment in BAT 67
eAnode top hooding when high current density anodes are used, connected to the treatment in BAT 67
Description U.K.

BAT 64(c): Point feeding of alumina avoids the regular crust-breaking (such as during manual side feed or bar broken feed), and thus reduces the associated fluoride and dust emissions.

BAT 64(d): An increased anode height helps to achieve lower temperatures in the anode top, resulting in lower emissions to air.

BAT-associated emission levels: See Table 12.

BAT 65.In order to prevent or collect diffuse emissions from electrolytic cells in primary aluminium production using prebaked anodes, BAT is to use a combination of the techniques given below.U.K.
Technique
aAutomatic multiple point feeding of alumina
bComplete hood coverage of the cell and adequate off-gas extraction rates (to lead the off-gas to the treatment in BAT 67) taking into account fluoride generation from bath and carbon anode consumption
cBoosted suction system connected to the abatement techniques listed in BAT 67
dMinimisation of the time for changing anodes and other activities that require cell hoods to be removed
eEfficient process control system avoiding process deviations that might otherwise lead to increased cell evolution and emissions
fUse of a programmed system for cell operations and maintenance
gUse of established efficient cleaning methods in the rodding plant to recover fluorides and carbon
hStorage of removed anodes in a compartment near the cell, connected to the treatment in BAT 67, or storage of the butts in confined boxes
Applicability U.K.

BAT 65.c and h are not applicable to existing plants

BAT-associated emission levels: See Table 12.

1.3.3.1.1. Channelled dust and fluoride emissions U.K.
BAT 66.In order to reduce dust emissions from the storage, handling and transport of raw materials, BAT is to use a bag filter.U.K.

BAT-associated emission levels: See Table 10.

Table 10

BAT-associated emission levels for dust from the storage, handling and transport of raw materials

a

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)a
Dust≤ 5-10

The associated monitoring is in BAT 10.

BAT 67.In order to reduce dust, metal and fluoride emissions to air from electrolytic cells, BAT is to use one of the techniques given below.U.K.
a

Descriptions of the techniques are given in Section 1.10

TechniqueaApplicability
aDry scrubber using alumina as the adsorbent agent followed by a bag filterGenerally applicable
bDry scrubber using alumina as the adsorbent agent followed by a bag filter and a wet scrubber

Applicability may be limited in the following cases:

  • very high off-gas flow rates (due to the significant amounts of waste and waste water generated)

  • in arid areas (due to the large volume of water necessary and the need for waste water treatment)

BAT-associated emission levels: See Table 11 and Table 12.

Table 11

BAT-associated emission levels for dust and fluoride emissions to air from electrolytic cells

a

As a daily average or as an average over the sampling period.

b

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)
Dust2-5a
HF≤ 1,0a
Total fluorides≤ 1,5b

The associated monitoring is in BAT 10.

1.3.3.1.2. Total emissions of dust and fluorides U.K.

BAT-associated emission levels for the total emissions of dust and fluoride to air from the electrolysis house (collected from the electrolytic cells and roof vents): See Table 12.

Table 12

BAT-associated emission levels for the total emissions of dust and fluoride to air from the electrolysis house (collected from the electrolytic cells and roof vents)

a

As mass of pollutant emitted during a year from the electrolysis house divided by the mass of liquid aluminium produced in the same year.

b

These BAT-AELs are not applicable to plants that due to their configuration cannot measure roof emissions.

ParameterBATBAT-AELs for existing plants (kg/t Al)a bBAT-AELs for new plants (kg/t Al)a
DustCombination of BAT 64, BAT 65 and BAT 67≤ 1,2≤ 0,6
Total fluorides≤ 0,6≤ 0,35

The associated monitoring is in BAT 10.

BAT 68.In order to prevent or reduce dust and metal emissions to air from melting and molten metal treatment and casting in primary aluminium production, BAT is to use one or both of the techniques given below.U.K.
a

Description of the technique is given in Section 1.10.

Technique
aUse of liquid metal from electrolysis and uncontaminated aluminium material, i.e. solid material free of substances such as paint, plastic or oil (e.g. the top and the bottom part of the billets that are cut for quality reasons)
bBag filtera

BAT-associated emission levels: See Table 13.

Table 13

BAT-associated emission levels for dust emissions to air from melting and molten metal treatment and casting in primary aluminium production

a

As an average of the samples obtained over a year.

b

The lower end of the range is associated with the use of a bag filter.

ParameterBAT-AEL (mg/Nm3)a b
Dust2-25

The associated monitoring is in BAT 10.

1.3.3.1.3. Sulphur dioxide emissions U.K.
BAT 69.In order to reduce emissions to air from electrolytic cells, BAT is to use one or both of the techniques given below.U.K.
a

Description of the technique is given in Section 1.10.

TechniqueApplicability
aUse of low-sulphur anodesGenerally applicable
bWet scrubbera

Applicability may be limited in the following cases:

  • very high off-gas flow rates (due to the significant amounts of waste and waste water generated)

  • in arid areas (due to the large volume of water necessary and the need for waste water treatment)

Description U.K.

BAT 69(a): Anodes containing less than 1,5 % sulphur as a yearly average can be produced by an appropriate combination of the raw materials used. A minimum sulphur content of 0,9 % as a yearly average is required for the viability of the electrolysis process.

BAT-associated emission levels: See Table 14.

Table 14

BAT-associated emission levels for SO2 emissions to air from electrolytic cells

a

As mass of pollutant emitted during a year divided by the mass of liquid aluminium produced in the same year.

b

The lower end of the range is associated with the use of a wet scrubber. The higher end of the range is associated with the use of low-sulphur anodes.

ParameterBAT-AEL (kg/t Al)a b
SO2≤ 2,5-15

The associated monitoring is in BAT 10.

1.3.3.1.4. Perfluorocarbon emissions U.K.
BAT 70.In order to reduce perfluorocarbon emissions to air from primary aluminium production, BAT is to use all of the techniques given below.U.K.
TechniqueApplicability
aAutomatic multiple point feeding of aluminaGenerally applicable
bComputer control of the electrolysis process based on active cell databases and monitoring of cell operating parametersGenerally applicable
cAutomatic anode effect suppressionNot applicable to Søderberg cells because the anode design (one piece only) does not allow the bath flow associated with this technique
Description U.K.

BAT 70(c): The anode effect takes place when the alumina content of the electrolyte falls below 1-2 %. During anode effects, instead of decomposing alumina, the cryolite bath is decomposed into metal and fluoride ions, the latter forming gaseous perfluorocarbons, which react with the carbon anode.

1.3.3.1.5. PAH and CO emissions U.K.
BAT 71.In order to reduce CO and PAH emissions to air from primary aluminium production using the Søderberg technology, BAT is to combust the CO and the PAH in the cell exhaust gas.U.K.
1.3.3.2. Waste water generation U.K.
BAT 72.In order to prevent the generation of waste water, BAT is to reuse or recycle cooling water and treated waste water, including rainwater, within the process.U.K.
Applicability U.K.

Generally applicable to new plants and major upgrades. The applicability may be limited due to water quality and/or product quality requirements. The amount of cooling water, treated waste water and rainwater that is reused or recycled cannot be higher than the amount of water needed for the process.

1.3.3.3. Waste U.K.
BAT 73.In order to reduce the disposal of spent pot lining, BAT is to organise operations on site so as to facilitate its external recycling, such as in cement manufacturing in the salt slag recovery process, as a carburiser in the steel or ferro-alloy industry or as a secondary raw material (e.g. rock wool), depending on the end consumer’s requirements.U.K.

1.3.4. Secondary aluminium production U.K.

1.3.4.1. Secondary materials U.K.
BAT 74.In order to increase the raw materials’ yield, BAT is to separate non-metallic constituents and metals other than aluminium by using one or a combination of the techniques given below depending on the constituents of the treated materials.U.K.
Technique
aMagnetic separation of ferrous metals
bEddy current separation (using moving electromagnetic fields) of aluminium from the other constituents
cRelative density separation (using a fluid with a different density) of different metals and non-metallic constituents
1.3.4.2. Energy U.K.
BAT 75.In order to use energy efficiently, BAT is to use one or a combination of the techniques given below.U.K.
TechniqueApplicability
aPreheating of the furnace charge with the exhaust gasOnly applicable for non-rotating furnaces
bRecirculation of the gases with unburnt hydrocarbons back into the burner systemOnly applicable for reverberatory furnaces and dryers
cSupply the liquid metal for direct mouldingApplicability is limited by the time needed for the transportation (maximum 4-5 hours)
1.3.4.3. Air emissions U.K.
BAT 76.In order to prevent or reduce emissions to air, BAT is to remove oil and organic compounds from the swarf before the smelting stage using centrifugation and/or drying(1).U.K.
Applicability U.K.

Centrifugation is only applicable to highly oil-contaminated swarf, when it is applied before the drying. The removal of oil and organic compounds may not be needed if the furnace and the abatement system are designed to handle the organic material.

1.3.4.3.1. Diffuse emissions U.K.
BAT 77.In order to prevent or reduce diffuse emissions from the pretreatment of scraps, BAT is to use one or both of the techniques given below.U.K.
Technique
aClosed or pneumatic conveyor, with an air extraction system
bEnclosures or hoods for the charging and for the discharge points, with an air extraction system
BAT 78.In order to prevent or reduce diffuse emissions from the charging and discharging/tapping of melting furnaces, BAT is to use one or a combination of the techniques given below.U.K.
a

Description of the technique is given in Section 1.10.

TechniqueApplicability
aPlacing a hood on top of the furnace door and at the taphole with off-gas extraction connected to a filtration systemGenerally applicable
bFume collection enclosure that covers both the charging and tapping zonesOnly applicable for stationary drum furnaces
cSealed furnace dooraGenerally applicable
dSealed charging carriageOnly applicable for non-rotating furnaces
eBoosted suction system that can be modified according to the process neededaGenerally applicable
Description U.K.

BAT 78(a) and (b): Consist of applying a covering with extraction to collect and handle the off-gases from the process.

BAT 78(d): The skip seals against the open furnace door during the discharge of scrap and maintains furnace sealing during this stage.

BAT 79.In order to reduce emissions from skimmings/dross treatment, BAT is to use one or a combination of the techniques given below.U.K.
Technique
aCooling of skimmings/dross, as soon as they are skimmed from the furnace, in sealed containers under inert gas
bPrevention of wetting of the skimmings/dross
cCompaction of skimmings/dross with an air extraction and dust abatement system
1.3.4.3.2. Channelled dust emissions U.K.
BAT 80.In order to reduce dust and metal emissions from the swarf drying and the removal of oil and organic compounds from the swarf, from the crushing, milling and dry separation of non-metallic constituents and metals other than aluminium, and from the storage, handling and transport in secondary aluminium production, BAT is to use a bag filter.U.K.

BAT-associated emission levels: See Table 15.

Table 15

BAT-associated emission levels for dust emissions to air from the swarf drying and the removal of oil and organic compounds from the swarf, from the crushing, milling and dry separation of non-metallic constituents and metals other than aluminium, and from the storage, handling and transport in secondary aluminium production

a

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)a
Dust≤ 5

The associated monitoring is in BAT 10.

BAT 81.In order to reduce dust and metal emissions to air from furnace processes such as charging, melting, tapping and molten metal treatment in secondary aluminium production, BAT is to use a bag filter.U.K.

BAT-associated emission levels: See Table 16.

Table 16

BAT-associated emission levels for dust emissions to air from furnace processes such as charging, melting, tapping and molten metal treatment in secondary aluminium production

a

As a daily average or as an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)a
Dust2-5

The associated monitoring is in BAT 10.

BAT 82.In order to reduce dust and metal emissions to air from remelting in secondary aluminium production, BAT is to use one or a combination of the techniques given below.U.K.
Technique
aUse of uncontaminated aluminium material i.e. solid material free of substances such as paint, plastic or oil (e.g. billets)
bOptimise combustion conditions to reduce the emissions of dust
cBag filter

BAT-associated emission levels: See Table 17.

Table 17

BAT-associated emission levels for dust from remelting in secondary aluminium production

a

As an average over the sampling period.

b

For furnaces designed to use and using only uncontaminated raw material, for which dust emissions are below 1 kg/h, the upper end of the range is 25 mg/Nm3 as an average of the samples obtained over a year.

ParameterBAT-AEL (mg/Nm3)a b
Dust2-5

The associated monitoring is in BAT 10.

1.3.4.3.3. Organic compound emissions U.K.
BAT 83.In order to reduce emissions to air of organic compounds and PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g. swarf) and from the melting furnace, BAT is to use a bag filter in combination with at least one of the techniques given below.U.K.
a

Descriptions of the techniques are given in Section 1.10.

Techniquea
aSelect and feed the raw materials according to the furnace and the abatement techniques used
bInternal burner system for melting furnaces
cAfterburner
dRapid quenching
eActivated carbon injection

BAT-associated emission levels: See Table 18.

Table 18

BAT-associated emission levels for emissions to air of TVOC and PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g. swarf) and from the melting furnace

a

As a daily average or as an average over the sampling period.

b

As an average over a sampling period of at least six hours.

ParameterUnitBAT-AEL
TVOCmg/Nm3≤ 10-30a
PCDD/Fng I-TEQ/Nm3≤ 0,1b

The associated monitoring is in BAT 10.

1.3.4.3.4. Acid emissions U.K.
BAT 84.In order to reduce emissions to air of HCl, Cl2 and HF from the thermal treatment of contaminated secondary raw materials (e.g. swarf), the melting furnace, and remelting and molten metal treatment, BAT is to use one or a combination of the techniques given below.U.K.
a

Description of the techniques are given in Section 1.10.

Technique
aSelect and feed the raw materials according to the furnace and the abatement techniques useda
bCa(OH)2 or sodium bicarbonate injection in combination with a bag filtera
cControl of the refining process, adapting the quantity of refining gas used to remove the contaminants present into the molten metals
dUse of dilute chlorine with inert gas in the refining process
Description U.K.

BAT 84(d): Using chlorine diluted with inert gas instead of only pure chlorine, to reduce the emission of chlorine. Refining can also be performed using only the inert gas.

BAT-associated emission levels: See Table 19.

Table 19

BAT-associated emission levels for HCl, Cl2 and HF emissions to air from the thermal treatment of contaminated secondary raw materials (e.g. swarf), the melting furnace, and remelting and molten metal treatment

a

As a daily average or as an average over the sampling period. For refining carried out with chemicals containing chlorine, the BAT-AEL refers to the average concentration during chlorination.

b

As an average over the sampling period. For refining carried out with chemicals containing chlorine, the BAT-AEL refers to the average concentration during chlorination.

c

Only applicable to emissions from refining processes carried out with chemicals containing chlorine.

d

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)
HCl≤ 5-10a
Cl2≤ 1b c
HF≤ 1d

The associated monitoring is in BAT 10.

1.3.4.4. Waste U.K.
BAT 85.In order to reduce the quantities of waste sent for disposal from secondary aluminium production, BAT is to organise operations on site so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below.U.K.
Technique
aReuse collected dust in the process in the case of a melting furnace using salt cover or in the salt slag recovery process
bFull recycling of the salt slag
cApply skimmings/dross treatment to recover aluminium in the case of furnaces that do not use salt cover
BAT 86.In order to reduce the quantities of salt slag produced from secondary aluminium production, BAT is to use one or a combination of the techniques given below.U.K.
TechniqueApplicability
aIncrease the quality of raw material used through the separation of the non-metallic constituents and metals other than aluminium for scraps where aluminium is mixed with other constituentsGenerally applicable
bRemove oil and organic constituents from contaminated swarf before meltingGenerally applicable
cMetal pumping or stirringNot applicable for rotary furnaces
dTilting rotary furnaceThere may be restrictions on the use of this furnace due to the size of the feed materials

1.3.5. Salt slag recycling process U.K.

1.3.5.1. Diffuse emissions U.K.
BAT 87.In order to prevent or reduce diffuse emissions from the salt slag recycling process, BAT is to use one or both of the techniques given below.U.K.
Technique
aEnclose equipment with gas extraction connected to a filtration system
bHood with gas extraction connected to a filtration system
1.3.5.2. Channelled dust emissions U.K.
BAT 88.In order to reduce dust and metal emissions to air from crushing and dry milling associated with the salt slag recovery process, BAT is to use a bag filter.U.K.

BAT-associated emission levels: See Table 20.

Table 20

BAT-associated emission levels for dust emissions to air from crushing and dry milling associated with the salt slag recovery process

a

As a daily average or as an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)a
Dust2-5

The associated monitoring is in BAT 10.

1.3.5.3. Gaseous compounds U.K.
BAT 89.In order to reduce gaseous emissions to air from wet milling and leaching from the salt slag recovery process, BAT is to use one or a combination of the techniques given below.U.K.
a

Descriptions of the techniques are given in Section 1.10.

Techniquea
aActivated carbon injection
bAfterburner
cWet scrubber with H2SO4 solution

BAT-associated emission levels: See Table 21.

Table 21

BAT-associated emission levels for gaseous emissions to air from wet milling and leaching from the salt slag recovery process

a

As an average over the sampling period.

ParameterBAT-AEL (mg/Nm3)a
NH3≤ 10
PH3≤ 0,5
H2S≤ 2

The associated monitoring is in BAT 10.

(1)

Description of the techniques are given in Section 1.10.