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Technique | Description | Applicability | |
---|---|---|---|
a | Plate heat exchangers | Plate heat exchangers allow a higher heat recovery from the liquor flowing to the precipitation area in comparison with other techniques such as flash cooling plants | Applicable if the energy from the cooling fluid can be reused in the process and if the condensate balance and the liquor conditions allow it |
b | Circulating fluidised bed calciners | Circulating fluidised bed calciners have a much higher energy efficiency than rotary kilns, since the heat recovery from the alumina and the flue-gas is greater | Only 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 |
c | Single stream digestion design | The 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 |
d | Selection of the bauxite | Bauxite 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 consumption | Applicable 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 |
Technique | |
---|---|
a | Reduce 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 |
b | Reduce/minimise the alkalinity remaining in the bauxite residues in order to allow disposal of the residues in a landfill |
BAT-associated emission levels: See Table 7.
a Descriptions of the techniques are given in Section 1.10. | |
Techniquea | |
---|---|
a | Dry scrubber using coke as the adsorbent agent, with or without precooling, followed by a bag filter |
b | Regenerative thermal oxidiser |
c | Catalytic thermal oxidiser |
BAT-associated emission levels: See 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. | ||
Parameter | Process | BAT-AEL (mg/Nm3) |
---|---|---|
Dust |
| 2-5a |
BaP | Hot pitch storage, paste mixing, cooling and forming | 0,001-0,01b |
The associated monitoring is in BAT 10.
a Descriptions of the techniques are given in Section 1.10. | ||
Techniquea | Applicability | |
---|---|---|
a | Use of raw materials and fuels containing a low amount of sulphur | Generally applicable for reducing SO2 emissions |
b | Dry scrubber using alumina as the adsorbent agent followed by a bag filter | Generally applicable for reducing dust, PAH and fluoride emissions |
c | Wet scrubber | Applicability for reducing dust, SO2, PAH and fluoride emissions may be limited in the following cases:
|
d | Regenerative thermal oxidiser in combination with a dust abatement system | Generally applicable for reducing dust and PAH emissions. |
BAT-associated emission levels: See 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
The associated monitoring is in BAT 10.
BAT-associated emission levels: See 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
The associated monitoring is in BAT 10.
Generally applicable to new plants and major upgrades. The applicability may be limited due to water quality and/or product quality requirements.
There may be restrictions on applicability depending on the ash content of the carbon dust.
Technique | |
---|---|
a | Use of paste with a pitch content between 25 % and 28 % (dry paste) |
b | Upgrade the manifold design to allow closed point feeding operations and improved off-gas collection efficiency |
c | Alumina point feeding |
d | Increased anode height combined with the treatment in BAT 67 |
e | Anode top hooding when high current density anodes are used, connected to the treatment in BAT 67 |
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.
Technique | |
---|---|
a | Automatic multiple point feeding of alumina |
b | Complete 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 |
c | Boosted suction system connected to the abatement techniques listed in BAT 67 |
d | Minimisation of the time for changing anodes and other activities that require cell hoods to be removed |
e | Efficient process control system avoiding process deviations that might otherwise lead to increased cell evolution and emissions |
f | Use of a programmed system for cell operations and maintenance |
g | Use of established efficient cleaning methods in the rodding plant to recover fluorides and carbon |
h | Storage of removed anodes in a compartment near the cell, connected to the treatment in BAT 67, or storage of the butts in confined boxes |
BAT 65.c and h are not applicable to existing plants
BAT-associated emission levels: See Table 12.
BAT-associated emission levels: See 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. | |
Parameter | BAT-AEL (mg/Nm3)a |
---|---|
Dust | ≤ 5-10 |
The associated monitoring is in BAT 10.
a Descriptions of the techniques are given in Section 1.10 | ||
Techniquea | Applicability | |
---|---|---|
a | Dry scrubber using alumina as the adsorbent agent followed by a bag filter | Generally applicable |
b | Dry scrubber using alumina as the adsorbent agent followed by a bag filter and a wet scrubber | Applicability may be limited in the following cases:
|
BAT-associated emission levels: See Table 11 and Table 12.
BAT-associated emission levels for dust and fluoride emissions to air from electrolytic cells
The associated monitoring is in BAT 10.
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.
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. | |||
Parameter | BAT | BAT-AELs for existing plants (kg/t Al)a b | BAT-AELs for new plants (kg/t Al)a |
---|---|---|---|
Dust | Combination 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.
a Description of the technique is given in Section 1.10. | |
Technique | |
---|---|
a | Use 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) |
b | Bag filtera |
BAT-associated emission levels: See Table 13.
BAT-associated emission levels for dust emissions to air from melting and molten metal treatment and casting in primary aluminium production
The associated monitoring is in BAT 10.
a Description of the technique is given in Section 1.10. | ||
Technique | Applicability | |
---|---|---|
a | Use of low-sulphur anodes | Generally applicable |
b | Wet scrubbera | Applicability may be limited in the following cases:
|
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.
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. | |
Parameter | BAT-AEL (kg/t Al)a b |
---|---|
SO2 | ≤ 2,5-15 |
The associated monitoring is in BAT 10.
Technique | Applicability | |
---|---|---|
a | Automatic multiple point feeding of alumina | Generally applicable |
b | Computer control of the electrolysis process based on active cell databases and monitoring of cell operating parameters | Generally applicable |
c | Automatic anode effect suppression | Not applicable to Søderberg cells because the anode design (one piece only) does not allow the bath flow associated with this technique |
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.
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.
Technique | |
---|---|
a | Magnetic separation of ferrous metals |
b | Eddy current separation (using moving electromagnetic fields) of aluminium from the other constituents |
c | Relative density separation (using a fluid with a different density) of different metals and non-metallic constituents |
Technique | Applicability | |
---|---|---|
a | Preheating of the furnace charge with the exhaust gas | Only applicable for non-rotating furnaces |
b | Recirculation of the gases with unburnt hydrocarbons back into the burner system | Only applicable for reverberatory furnaces and dryers |
c | Supply the liquid metal for direct moulding | Applicability is limited by the time needed for the transportation (maximum 4-5 hours) |
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.
Technique | |
---|---|
a | Closed or pneumatic conveyor, with an air extraction system |
b | Enclosures or hoods for the charging and for the discharge points, with an air extraction system |
a Description of the technique is given in Section 1.10. | ||
Technique | Applicability | |
---|---|---|
a | Placing a hood on top of the furnace door and at the taphole with off-gas extraction connected to a filtration system | Generally applicable |
b | Fume collection enclosure that covers both the charging and tapping zones | Only applicable for stationary drum furnaces |
c | Sealed furnace doora | Generally applicable |
d | Sealed charging carriage | Only applicable for non-rotating furnaces |
e | Boosted suction system that can be modified according to the process neededa | Generally applicable |
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.
Technique | |
---|---|
a | Cooling of skimmings/dross, as soon as they are skimmed from the furnace, in sealed containers under inert gas |
b | Prevention of wetting of the skimmings/dross |
c | Compaction of skimmings/dross with an air extraction and dust abatement system |
BAT-associated emission levels: See 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. | |
Parameter | BAT-AEL (mg/Nm3)a |
---|---|
Dust | ≤ 5 |
The associated monitoring is in BAT 10.
BAT-associated emission levels: See 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. | |
Parameter | BAT-AEL (mg/Nm3)a |
---|---|
Dust | 2-5 |
The associated monitoring is in BAT 10.
Technique | |
---|---|
a | Use of uncontaminated aluminium material i.e. solid material free of substances such as paint, plastic or oil (e.g. billets) |
b | Optimise combustion conditions to reduce the emissions of dust |
c | Bag filter |
BAT-associated emission levels: See Table 17.
BAT-associated emission levels for dust from remelting in secondary aluminium production
The associated monitoring is in BAT 10.
a Descriptions of the techniques are given in Section 1.10. | |
Techniquea | |
---|---|
a | Select and feed the raw materials according to the furnace and the abatement techniques used |
b | Internal burner system for melting furnaces |
c | Afterburner |
d | Rapid quenching |
e | Activated carbon injection |
BAT-associated emission levels: See 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
The associated monitoring is in BAT 10.
a Description of the techniques are given in Section 1.10. | |
Technique | |
---|---|
a | Select and feed the raw materials according to the furnace and the abatement techniques useda |
b | Ca(OH)2 or sodium bicarbonate injection in combination with a bag filtera |
c | Control of the refining process, adapting the quantity of refining gas used to remove the contaminants present into the molten metals |
d | Use of dilute chlorine with inert gas in the refining process |
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.
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. | |
Parameter | BAT-AEL (mg/Nm3) |
---|---|
HCl | ≤ 5-10a |
Cl2 | ≤ 1b c |
HF | ≤ 1d |
The associated monitoring is in BAT 10.
Technique | |
---|---|
a | Reuse collected dust in the process in the case of a melting furnace using salt cover or in the salt slag recovery process |
b | Full recycling of the salt slag |
c | Apply skimmings/dross treatment to recover aluminium in the case of furnaces that do not use salt cover |
Technique | Applicability | |
---|---|---|
a | Increase 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 constituents | Generally applicable |
b | Remove oil and organic constituents from contaminated swarf before melting | Generally applicable |
c | Metal pumping or stirring | Not applicable for rotary furnaces |
d | Tilting rotary furnace | There may be restrictions on the use of this furnace due to the size of the feed materials |
Technique | |
---|---|
a | Enclose equipment with gas extraction connected to a filtration system |
b | Hood with gas extraction connected to a filtration system |
BAT-associated emission levels: See 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. | |
Parameter | BAT-AEL (mg/Nm3)a |
---|---|
Dust | 2-5 |
The associated monitoring is in BAT 10.
a Descriptions of the techniques are given in Section 1.10. | |
Techniquea | |
---|---|
a | Activated carbon injection |
b | Afterburner |
c | Wet scrubber with H2SO4 solution |
BAT-associated emission levels: See 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. | |
Parameter | BAT-AEL (mg/Nm3)a |
---|---|
NH3 | ≤ 10 |
PH3 | ≤ 0,5 |
H2S | ≤ 2 |
The associated monitoring is in BAT 10.
Description of the techniques are given in Section 1.10.