COMPOSITION OF THE PROJECT

Transcription

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2 COMPOSITION OF THE PROJECT of the construction of primary aluminium smelter in Pavlodar region Volume 1.General Explanatory Note Volume 2. General Layout And Transport Book 1. Book 2. Drawings Volume 3. Process Concepts Volume 4. Production Control, Enterprise Management, Arrangement of Labor Conditions and Labor Protection For Workers And Employees Volume 5. Civil And Architectural Engineering Book 1. Book 2. Drawings Volume 6. Engineering Equipment, Networks, Systems Book 1. Book 2. Drawings Volume 7. Arrangements For the Enterprise Construction Volume 8. al Impact Assessment (EIA) Book 1. Air Book 2. Water Resources, Soils, Production Waste, Physical Impact, Land Resources Book 3. Flora, Fauna, Social And Economic, Assessment Of Ecological Risk Volume 9. Engineering Measures, Related To the Civil Defense, Measures To Prevent Emergency Situations Volume 10. Estimate Documentation Volume 11. Efficiency Of the Investments, Technical-And-Economic Indices Volume 12. Specification On Main Equipment Types Volume 13. Requirements To the Design Documentation To Be Developed For the Enterprise Construction 2

3 TABLE OF CONTENTS 1. Description of climatic conditions of location area of Pavlodar Aluminium Smelter Description of current state of air invironment in location area of enterprise Sources and scales of design pollution Brief description of facility planned Processes and equipment conditioning emissions of hazardous substances into atmosphere Dust-gas-treatment equipment used in aluminium smelter Description of sources of hazardous substances emissions into atmosphere Possible volley and emergency emissions Methodology of impact assessment of design facility on air basin state Results of dispersion calculations Implementation of low-waste technologies and mesures on reduction of emissions into atmosphere Offers on maximum permissible emissions of Pavlodar Aluminium Smelter Definition of buffer zone size of enterprise Assesment of pollution consequences and measures for reduction of negative impact Organization of monitoring and control of atmosphere emissions in enterprise Measures on emissions adjustment in period of unfavorable meteorological conditions Conclusions APPENDICES

4 1. Description of climatic conditions of location area of Pavlodar Aluminium Smelter The Pavlodar Aluminium Smelter site is located to the south-east of the Pavlodar residential zone: 13.5 km away from its boundary and 10 km away from the operating alumina refinery and from the heat power plant of the JSC Aluminium of Kazakhstan. There are no settlements and other industrial enterprises in immediate proximity to the site of the smelter constructed. The arrangement layout of the accommodation area of the smelter designed is shown in Figure 1. The distance to the nearest settlements is as follows: Zhetekshi settlement 12 km, Kenzhekol settlement 10 km, Shakat settlement 13.5 km, Krasnoarmeika settlement 15.5 km. The locality in the accommodation area of the future smelter represents a plain with the slight height difference - not less than 50 km per 1 km. The climate in the accommodation area of the enterprise belongs the abruptcontinental one, with severe winters with snowstorms and with dry and hot summers. Abrupt changes in the air temperature when passing from the cold season to the warm season and substantial fluctuations in temperature within a year belong to the local climate character. The cold season duration is 6.5 months. As it follows from Table 1 the average annual air temperature makes +2.3 С according to long-term observations information. The average maximum ambient air temperature of the hottest month of the year is equal to С. The average temperature of the coldest month, January, is 22.6 С. The absolute maximum of ambient air temperature makes +40 С, and the absolute minimum is 47 С. 4

5 Figure 1. Arrangement layout of location of Pavlodar Aluminium Smelter 5

6 Table 1. Average monthly annual and average annual air temperatures according to data of observations in Pavlodar weather station, С Month Year I II III IV V VI VII VIII IX X XI XII The area belongs to the underprovided area as of the atmospheric precipitation level. The precipitation amount makes within a year on average about 260 mm, the maximum of them (about 40 %) falls at the summer months with high temperatures. The average annual absolute humidity makes in this period 6.0 to 6.5 mb. In summer it reaches 12 to 14 mb, and in winter it decreases down to 2 3 mb. The relative humidity varies from 75 to 88 % (December March) down to 50 to 60 % (May August). The territory character is lack of substantial fluctuations in the precipitation fall regime (Table 2). The rainy weather periods change into the long-term dry periods, within these periods the territory soil is dried up. The evaporation exceeds the amount of precipitates fallen in this period 4 to 5 times. The climate aridity becomes apparent in the low air humidity. The relative air humidity decreases in individual summer months down to 20 %. The moderate air humidity in the summer period promotes the intensive fluid evaporation from the dusting surfaces (specifically from waste accumulators). The territory climate features noted predetermine the frequent occurrence of the drought that becomes apparent at high wind speeds as dry hot winds. Table 2. Average monthly precipitation amount in Pavlodar region, mm Precipitation fall-out per months, mm I II III IV V VI VII VIII IX X XI XII

7 The steady snow cover is formed in the middle of November. The main snow amount falls in the first half of the winter; the duration of the steady snow cover standing is about 130 to 140 days. The average perennial height of the snow cover varies 3 to 22 cm, and the great space nonuniformity is typical for it. Its thickness in the elevated areas is practically equal to zero, its thickness reaches in hollows and in leeward hillsides 1.0 to1.5 m. The soil frost zone is 1.2 to 2.0 m. Ice loadings are not typical for this area. The normal weight of the snow cover is 100 kg/m 2 per the II nd geographic area. The wind activity of the area is typical for all seasons; however, it is more active in spring and in winter. Blowing dusts and hot winds are to be observed in the summer months. The heavy storms probability is up to 4 days a month. The average perennial periodicity of the main wind directions as per the Kazhydromet data is given in Table 3. Table 3. Periodicity of wind directions and calms within a year, % Main wind directions Calm N NE E SE S SW W NW In Tables 4 and 5 the average annual wind speed per directions and their periodicity per graduations are shown. Table 4. Average wind speed per directions, m/s N NE E SE S SW W NW Baffling wind Table 5. Average annual periodicity of wind speeds per graduations, % Wind speed graduations, m/s

8 The available inversion layers in the lower atmosphere layers are typical for the region. In the cold season the deep and thick ground inversions predominate. Fogs are often to be observed in winter. In spring and in summer in the nighttime the great frequency of ground inversions (65 to 80%) takes place. In the daytime in the transient seasons the probability of inversions is reduced, in the summer season it comes practically to naught. The climatic features make its contribution to the formation of the emission dispersal and atmosphere pollution conditions, as well as to the region climate fluctuation. In the cold season the role of high pollution sources decreases, and the contribution of low ones increases. On the contrary, in summer, in the absence of an impending layer in the lower part of the atmosphere, the high emission sources play a leading part in the atmosphere pollution in the presence of the dangerous wind speeds. 2. Description of current state of air environment in location area of enterprise The atmospheric air pollution level assessment in the area of the Pavlodar Aluminium Smelter location was executed by means of comparison of the observational data in the stations of the Pavlodar hydrometeorology center of the Russian Public Enterprise Kazhydromet, as well as of the results of the underplume observations carried out by a number of organizations (JSC Kazakhstan Aluminium, Pavlodar Regional al Control Administration, Pavlodar Municipal Sanitary-Epidemiologic Station), with the hygienic regulations of the contaminants content in the populated areas atmospheric air. The atmospheric air pollution monitoring in Pavlodar is to be implemented in two stationary stations of Kazhydromet: No. 1 (12/1, Moscow str.) and No. 2 8

9 (26, Aimanov str.). It is to be mentioned that to obtain more objective evidence concerning the atmospheric air pollution it is necessary to establish the station No. 3 of Kazhydromet in the location area of the JSC Kazakhstan Aluminium and of the JSC Pavlodar Aluminium Smelter designed. Results of observations for these stations within 1998 to 2002 are indicated in Tables The observation procedure and the analysis of atmospheric air samples selected in the course of works are to be realized in Kazhydromet according to Atmosphere pollution control manual. 9

10 Table 6. Characteristic of air pollution according to observational data in stationary stations for 1998 Impurity Maximum permissible concentration (MPC) MPCms MPCad Total number of obser vations Q aver. * / qp** Repeatability *** of concentrations in toto per town g, % > 10 MPC > MPC Average monthly concentration in toto per town, Q aver. Dust / Sulfur dioxide / Carbon oxide / Nitrogen dioxide / Note: * q aver. average concentration within a year; ** qp peak concentration within a year; *** Repeatability of concentrations in toto per town g, % calculated according to maximal from single MPC. 10

11 Table 7. Characteristic of air pollution according to observational data in stationary stations for 1999 Repeatability Total *** of concentrations in toto number of stations 1, stations 2, Stationary Stationary Quarter per town g, % observations > MPC Q aver. * / qp** Q aver. * / qp** > 10 MPC Dust, MPC ms = 0.5 mg/m 3, MPCad= 0.15 mg/m 3 Average monthly concentration in toto per town, Q aver. I / / II / / III / / IV / / Sulfur dioxide, MPC ms = 0.5 mg/m 3, MPCad = 0.05 mg/m 3 I / / II / / III / / IV / / Carbon oxide, MPC ms = 5 mg/m 3, MPCad = 3 mg/m 3 I / 9 1 / II / 3 1 / III / 17 1 / IV / 4 1 / Nitrogen dioxide, MPC ms = mg/m 3, MPCad = 0.04 mg/m 3 I / / II / / III / / IV / / Note: * q aver. average concentration within a year; ** qp peak concentration within a year; *** Repeatability of concentrations in toto per town g, % calculated according to maximal from single MPC. 11

12 Table 8. Characteristic of air pollution according to observational data in stationary stations for 2000 Repeatability Total Permissible Permissible *** of concentrations in toto number of minimum minimum Quarter (PM) 1, (PM) 2, per town g, % observations >MPC Q aver. * / qp** Q aver. * / qp** > 10 MPC Dust, MPC ms = 0.5 mg/m 3, MPCad = 0.15 mg/m 3 Average monthly concentration in toto per town, Q aver. I / / II / / III / / IV / / Sulfur dioxide, MPC ms = 0.5 mg/m 3, MPCad = 0.05 mg/m 3 I / / II / / III / / IV / / Carbon oxide, MPC ms = 5 mg/m 3, MPCad = 3 mg/m 3 I / 4 1 / II / 14 1 / III / 2 1 / IV / 2 1 / Nitrogen dioxide, MPC ms = mg/m 3, MPCad = 0.04 mg/m 3 I / / II / / III / / IV / / Note: * q aver. average concentration within a year; ** qp peak concentration within a year; *** Repeatability of concentrations in toto per town g, % calculated according to maximal from single MPC. 12

13 Table 9. Characteristic of air pollution according to observational data in stationary stations for 2001 Name of impurity Dust MPC ms = 0.5 mg/m 3, MPC ad = 0.15 mg/m 3 Sulfur dioxide MPC ms = 0.5 mg/m 3, MPC ad = 0.05 mg/m 3 Carbon oxide MPC ms = 5 mg/m 3, MPC ad = 3 mg/m 3 Nitrogen di- Total number of observations Number exceedings Peak concentration mg/m 3 / MPC ratio Average concentration, mg/m 3 Repeatability of exceedings, % / / / / oxide MPC ms = mg/m 3, MPC ad = 0.04 mg/m 3 13

14 Table 10. Characteristic of air pollution according to observational data in stationary stations for 2002 Name of impurity Dust MPC ms = 0.5 mg/m 3, MPC ad = 0.15 mg/m 3 Sulfur dioxide MPC ms = 0.5 mg/m 3, MPC ad = 0.05 mg/m 3 Carbon oxide MPC ms = 5 mg/m 3, MPC ad = 3 mg/m 3 Nitrogen di- Total number of observations Number exceedings Peak concentration mg/m 3 / MPC ratio Average concentration, mg/m 3 Repeatability of exceedings, % / / / / oxide MPC ms = mg/m 3, MPC ad = 0.04 mg/m 3 14

15 The data shown in Tables 6-10 indicate that the atmospheric air quality in Pavlodar meet requirements of the hygiene and sanitary regulations on the content of substances shown in tables. In 2003 the average monthly concentrations of all impurities to be determined in atmospheric air of Pavlodar were within the norm: the maximal single concentrations of contaminants varied within a year as follows: of dust 0.2 to 1.8, of sulfur dioxide 0.03 to 0.5, of carbon oxide 0.4 to 2.0 of MPC, of nitrogen dioxide 0.5 to 2.7, of hydrogen sulfide 0.25 to 0.9 of MPC, of phenol 0.5 to 4.8, of chlorine 0.1 to 0.4 and of hydrogen chloride 0.5 to 1.9. The maximum atmosphere pollution level was observed in May 2.19, the minimum level was in November As is well known, the maximum concentration level of any contaminant in the populated areas air is characterized by the so-called background concentration, which is accepted as a statistically valid maximal single concentration of the impurity (average within 20 min), its value is exceeded in 5 % of cases of observations. The background concentrations are to be calculated by Kazhydromet and are used by enterprises and organizations to reduce the pollutants emission by means of setting standards of the maximum permissible emissions - (MPE). The background concentration values (characterizing the statistically valid maximum atmosphere pollution level) presented by Kazhydromet for and for 2004 are shown in Table

16 Table 11. Background concentrations of pollutants in Pavlodar Concentration, mg/m 3 Average Impurity value, calm north east south west mg/m 3 Background concentrations for Station No. 1 dust sulfur dioxide nitrogen dioxide carbon oxide Station No. 2 dust sulfur dioxide nitrogen dioxide carbon oxide Background concentrations for 2004 Station No. 1 dust sulfur dioxide nitrogen dioxide carbon oxide The background concentrations of dust, sulfur dioxide and carbon oxide shown in Table 11 are within the values of the hygiene and sanitary regulations, and on nitrogen dioxide some exceeding of them was observed at individual wind directions up to 1.07 ms. Thus the Kazhydromet data shown above concerning the atmospheric air pollution by sulfur dioxide, nitrogen dioxide, carbon oxide (carbonic oxide), dust, as well as by phenol and hydrogen chloride allow drawing a conclusion of the favorable atmosphere state directly in the zone of the Pavlodar apartment block. In view of the circumstance that Kazhydromet did not carry out any observations of the atmospheric air pollution by solid and gaseous fluorides, ben- 16

17 zapilene that are present in emissions of aluminium smelters, it seems to be necessary to consider within this work the data concerning the atmospheric air state in the area investigated, which were obtained by laboratories of the JSC Kazakhstan Aluminium, Pavlodar Regional al Control Administration and Pavlodar Municipal Sanitary-Epidemiologic Station. The JSC Kazakhstan Aluminium whose enterprises, PAZ and the Heat Power Plant, are situated in the southern industrial zone 2-3 km away from residential areas carries out on regular basis underplume observations of pollution of the atmosphere in the enterprise directly adjacent zone with a radius up to 5 km. Besides the JSC Kazakhstan Aluminium investigated within August - October 1999 according to the methodical guideline on carrying out of underplume observations and under the method direction of the Pavlodar center Kazhydromet the atmospheric air quality within the buffer zone of the of PAZ and of the Heat Power Plant, at its border and in the populated areas. The atmospheric air sampling and its analysis were performed according to procedures used by Kazhydromet. The observations were carried out in the solar day at the northeast, east and southeast wind directions so that in the checkpoints subject to the enterprises location a contribution to the atmosphere pollution of their emission sources is to be detected. The results of underplume measurements are shown in Table 12. Table 12. Results of underplume observations of atmospheric air pollution in JSC Kazakhstan Aluminium adjacent zone Date Wind direction, deg. Wind speed, m/s Concentration, mg/m 3 /unit According to data of measurements 17

18 Date Concentration, mg/m 3 /unit Wind direction, Wind speed, According to data of measurements deg. m/s Aluminium oxide in terms of aluminium, (MPCad= 0.01mg/m 3 in terms of aluminium) Zelenstroy settlement / / / 0.4 Average / 0.33 Eastern microdistrict / / 0.5 Average / 0.5 Dachny microdistrict / / 0.2 Average / 0.1 Within buffer zone at a distance of 1 km west from PAZ / / / / / / 0.3 Average / 0.5 Nitrogen dioxide, MPCms = mg/m 3 Zelenstroy settlement / / / 0.46 Average / 0.34 Eastern microdistrict /

19 Date Concentration, mg/m 3 /unit Wind direction, Wind speed, According to data of measurements deg. m/s / 0.35 Average / 0.53 Dachny microdistrict / / 0.35 Average / 0.29 Within buffer zone at a distance of 1 km west from PAZ / / / / / / 0.34 Average / 0.25 Sulfur dioxide, MPCms = 0.5 mg/m 3 Zelenstroy settlement / / / 0 Average 0.06 / Eastern microdistrict / / 0.12 Average 0.06 / 0.12 Dachny microdistrict / / 0.04 Average 0.02 / 0.04 Within buffer zone at a distance of 1 km west from PAZ / / 0 19

20 Date Concentration, mg/m 3 /unit Wind direction, Wind speed, According to data of measurements deg. m/s / / / / 0 Average 0.08 / 0.16 Dust, MPC ms = 0,5 mg/m 3 Zelenstroy settlement / / / 1.76 Average 0.51 / 1.02 Eastern microdistrict / / 1.04 Average 0.57 / 1.14 Dachny microdistrict / / 2.40 Average 0.78 / 1.56 Within buffer zone at a distance of 1 km west from PAZ / / / / / / 0.70 Average 0.45 / 0.90 The available data allow to draw a conclusion that in the period of observations the emission sources PAZ and the Heat Power Plant, enterprises of the 20

21 JSC Kazakhstan Aluminium, generated subject to the natural atmosphere dustiness the dust concentrations (inclusive of all solid substances, including aluminium oxide) exceeding the maximum permissible concentration up to 1.7 MPC ms. On the remaining pollutants (on nitrogen and sulfur dioxides, aluminium oxide) the concentration exceeding was not observed both at the buffer zone borders and in the residential areas. In Table 13 the results of investigations of the atmospheric air quality in the buffer zone and on the JSC Kazakhstan Aluminium territory by the labor protection laboratory (LPL) of the enterprise are shown within In Tables the results of measurements of the pollutants content in atmosphere within the JSC Kazakhstan Aluminium buffer zone by the laboratory of the Pavlodar Regional al Control Administration are presented within To interpret correctly the data shown in these tables it is to be kept in mind that the buffer zone for PAZ has been approved at a distance of 3000 m. 21

22 Table 13. Results of investigation of atmospheric air in buffer zone and on JSC Kazakhstan Aluminium territory by labor protection laboratory of enterprise (average annual values within ) Sampling point Defined Concentration, Number of analyses mg/m 3 MPC, mg/m 3 above min. max. aver. total MPC ingredient % of analyses above MPC From leeward side from sintering furnace stacks of heat power plant at a distance of: а) 500 m enterprise territory dust 2.0 below assumed purity (bap) alkali 0.2 bap SO2 3.3 bap NOx 1.7 bap б) 2000 m dust 0.5 bap alkali 0.01 bap SO2 0.5 bap NOx bap в) 3000 m dust 0.5 bap alkali 0.01 bap SO2 0.5 bap NOx bap From windward dust 0.5 bap side alkali 0.01 bap checkpoint SO2 0.5 bap

23 Sampling point Defined Concentration, Number of analyses mg/m 3 MPC, mg/m 3 above min. max. aver. total MPC ingredient % of analyses above MPC NOx bap Point 2. Zelenstroy settlement (residential zone behind greenhouses) 1997 dust 0.5 bap alkali 0.01 bap SO2 0.5 bap NOx bap From leeward side from sintering furnace stacks of heat power plant at a distance of: а) 500 m PAZ territory б) 500 m heat power plant territory dust 2.0 bap alkali 0.2 bap SO2 3.3 bap bap bap NOx 1.7 bap dust 2.0 bap alkali 0.2 bap SO2 3.3 bap bap bap NOx 1.7 bap в) 2000 m buffer zone dust 0.5 bap alkali 0.01 bap SO2 0.5 bap NOx bap

24 Sampling point Defined Concentration, Number of analyses mg/m 3 MPC, mg/m 3 above min. max. aver. total MPC ingredient % of analyses above MPC г) 3000 m buffer zone dust 0.5 bap alkali 0.01 bap SO2 0.5 bap bap bap NOx bap From windward side checkpoint dust alkali 0.01 bap SO2 0.5 bap bap bap NOx bap Point 2. Zelenstroy settlement (residential zone behind greenhouses) dust alkali 0.01 bap SO2 0.5 bap bap bap NOx bap From leeward dust side from sintering furnace stacks of heat power plant at a distance of: а) 500 m alkali 0.2 bap SO2 3.3 bap bap bap territory of enterprise NOx 1.7 bap б) 500 m heat power plant territory dust 2.0 bap alkali 0.2 bap SO2 3.3 bap bap bap NOx 1.7 bap

25 Sampling point 2. Point m towards town 3. Point 2. Zelenstroy settlement (residential zone behind greenhouses) 4. Point 3. Eastern boundary of buffer zone 1999 Concentration, % of Number of analyses Defined mg/m 3 analyses MPC, ingredient min. max. aver. total above mg/m 3 above MPC MPC dust 0.5 bap alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap NOx bap dust 0.5 bap alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap NOx bap alkali 0.01 bap dust 2.0 bap From leeward side from sintering furnace stacks of heat power plant at a distance of: а) 500 m enterprise territory alkali 0.2 bap SO2 3.3 bap bap bap NOx 1.7 bap bap

26 Sampling point б) 500 m heat power plant territory 2. Point m towards town 3. Point 2. Zelenstroy settlement (residential zone behind greenhouses) 4. Point 3. Eastern boundary of buffer zone From leeward side from sintering furnace stacks of heat power plant at a distance of: а) 500 m enterprise territory Concentration, % of Number of analyses Defined mg/m 3 analyses MPC, ingredient min. max. aver. total above mg/m 3 above MPC MPC dust 2.0 bap bap alkali 0.2 bap SO2 3.3 bap bap bap NOx 1.7 bap dust 0.5 bap alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap NOx bap dust alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap Nox bap alkali 0.01 bap dust alkali 0.2 bap SO2 3.3 bap NOx 1.7 bap

27 Sampling point б) 500 m heat power plant territory 2. Point m towards town 3. Point 2. Zelenstroy settlement (residential zone behind greenhouses) 4. Point 3. Eastern boundary of buffer zone Concentration, % of Number of analyses Defined mg/m 3 analyses MPC, ingredient min. max. aver. total above mg/m 3 above MPC MPC dust alkali 0.2 bap SO2 3.3 bap NOx 1.7 bap dust 0.5 bap alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap NOx bap dust 0.5 bap alkali 0.01 bap al.oxide 0.04 bap SO2 0.5 bap bap bap NOx bap alkali 0.01 bap

28 Table 14. Data of measurements by laboratory of Pavlodar Regional al Control Administration within (at a distance of 1000 m under plume of PAZ) Concentration, Number of analyses % of analyses above Defined ingredient mg/m 3 above MPC, mg/m 3 min. max. total MPC MPC 1997 dust SO NO HCI hydrogen sulfide formaldehyde ammonia dust SO NO HCI hydrogen sulfide formaldehyde ammonia alkali dust SO NO HCI hydrogen sulfide formaldehyde ammonia alkali

29 dust SO NO HCI formaldehyde alkali

30 Table 15. Results of analyses of atmospheric air in buffer zone of JSC Kazakhstan Aluminium (PAZ) (on plume) within MPC, I II III IV V VI VII VIII IX X XI XII mg/m 3 nitrogen dioxide carbon oxide formaldehyde sulfur dioxide dust alkali 0.01* nitrogen dioxides carbon oxide formaldehyde sulfur dioxide dust alkali 0.01*

31 2002 MPC, I II III IV V VI VII VIII IX X XI XII mg/m 3 nitrogen dioxides carbon oxide formaldehyde sulfur dioxides dust alkali 0.01* nitrogen dioxides carbon oxide 5.0 formaldehyde sulfur dioxide hydrogen sulphide dust alkali 0.01* 31

32 Table 16. Average annual data of atmospheric air state within 2001 in buffer zone of JSC Kazakhstan Aluminium Defined index Wind direction min. max. Number of samples/ % of deviations MPC. Average value mg/m 3 mg/m 3 number of exceedings mg/m 3 sulfur dioxides SW / nitrogen dioxides SW / formaldehyde SW / dust SW / alkali SW / * 0.0 hydrogen sulphide SW / sulfur dioxides W / nitrogen dioxides W / formaldehyde W / carbon oxide W / ammonia W / dust W / sulfur dioxides E / nitrogen dioxides E / formaldehyde E /

33 Defined index Wind direction min. max. Number of samples/ % of deviations MPC. Average value mg/m 3 mg/m 3 number of exceedings mg/m 3 alkali E / * 0.0 dust E / sulfur dioxides S / nitrogen dioxides S / formaldehyde S / alkali S / * 0.0 hydrogen sulphide S / dust S / sulfur dioxides SE / nitrogen dioxides SE / formaldehyde SE / alkali SE / * 0.0 hydrogen sulphide SE / dust SE / sulfur dioxides NE /

34 Defined index Wind direction min. max. Number of samples/ % of deviations MPC. Average value mg/m 3 mg/m 3 number of exceedings mg/m 3 nitrogen dioxides NE / formaldehyde NE / alkali NE / * 0.0 hydrogen sulphide NE / dust NE / sulfur dioxides NW / nitrogen dioxides NW / formaldehyde NW / alkali NW / * 0.0 hydrogen sulphide NW / dust NW / sulfur dioxides SE / nitrogen dioxides SE / formaldehyde SE / alkali SE / * 0.0 hydrogen sulphide SE /

35 Defined index Wind direction min. max. Number of samples/ % of deviations MPC. Average value mg/m 3 mg/m 3 number of exceedings mg/m 3 dust SE / sulfur dioxides NE / nitrogen dioxides NE / formaldehyde NE / alkali NE / * 0.0 hydrogen sulphide NE / dust NE / sulfur dioxides NW / nitrogen dioxides NW / formaldehyde NW / alkali NW / * 0.0 hydrogen sulphide NW / dust NW / Note: * RSIL (relatively safe impact level). 35

36 According to the data given in Table 16 the exceedings on alkali 3.2 times were observed in 1996 at a distance of 2000 m from the emission sources of the enterprise within the enterprise buffer zone, the exceeding of MPC on dust 2.6 times was in the Zelieny (Green) settlement. In 1997 the exceedings on dust 1.2 times were stated, on alkali 1.4 times at a distance of 2000 m from the emission sources of the enterprise. In the settlement Zelieny (Green) the exceedings on dust 1.4 times were observed. In 1999 the exceedings on dust 1.5 times were stated, on alkali 1.2 times, on aluminium dioxide 1.7 times at a distance of 1000 m from the emission sources of the enterprise. In the Zelieny (Green) settlement the exceeding on dust 5.5 times were observed, on alkali and on aluminium dioxide 1.5 times. In 2000 the exceedings on dust 1.18 times were stated at a distance of 1000 m from the emission sources of the enterprise. In the Zelieny (Green) settlement the exceeding on alkali 1.3 times was observed. The information shown in Tables characterizes the air pollution level within the buffer zone. The trend of the air concentration reduction on dust and hydrogen chloride is observed at the expense of the application of the air protection measures in the enterprise. In Table 17 the data of the underplume investigations of the atmospheric air pollution level in the JSC Kazakhstan Aluminium buffer zone are shown that were executed by the laboratory of the Pavlodar Municipal Sanitary- Epidemiologic Station in

37 Table 17. Data of underplume investigations of atmospheric air pollution level in buffer zone of JSC Kazakhstan Aluminium executed by Pavlodar Municipal Sanitary-Epidemiologic Station Result of investigations Sampling point PAZ, 1 km PAZ, 2 km Meteorological factors Atmospheric pressure, mm merc. col. Temperature, С , , + 17 Relative humid ity, % Wind direction speed m/s Name of defined substance 74 СЗ 9-14 sulfur dioxide sulfur dioxide aluminium oxide aluminium oxide alkali alkali dust dust 74 СЗ 9-14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust maximal single concentration, mg/m 3 /unit 0.08 / / / / / / / / / / / / / / / / / / 2.1 MPC, mg/m

38 Result of investigations Sampling point PAZ, 3 km Meteorological factors Atmospheric pressure, mm merc. col. Temperature, С , + 17 Relative humid ity, % Wind direction speed m/s Name of defined substance 74 СЗ 9-14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust maximal single concentration, mg/m 3 /unit 0.08 / / / / / - - / / / / / 6.2 MPC, mg/m PAZ, 1 km З 9-14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust PAZ, 2 km dust З 9-14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust / / / / / / / / / / / / / / / / / / / /

39 Result of investigations Sampling point PAZ, 3 km Meteorological factors Atmospheric pressure, mm merc. col. Temperature, С Relative humid ity, % Wind direction speed m/s Name of defined substance З 9-14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust maximal single concentration, mg/m 3 /unit 0.72 / / / / / / / / / / 0.40 MPC, mg/m PAZ, 1 km С 9 14 sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust 0.04 / / / - - / / / / / / /

40 Result of investigations Sampling point PAZ, 2 km PAZ, 3 km Meteorological factors Atmospheric pressure, mm merc. col. Temperature, С Relative humid ity, % Wind direction speed m/s С С 9 14 Name of defined substance sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust sulfur dioxide sulfur dioxide nitrogen dioxide nitrogen dioxide aluminium oxide aluminium oxide alkali alkali dust dust maximal single concentration, mg/m 3 /unit 0.09 / / / / / / / - - / / / / / / - - / / / / / / / 0.2 MPC, mg/m It is to be mentioned that according to the data of the long-term observations by the laboratory of the Pavlodar Regional al Control Administration, LPL of the JSC Kazakhstan Aluminium and by the laboratory of the regional center Kazhydromet such high alkali and sulfur dioxide concentration, as it was detected by one-time measurements of the Municipal Sanitary- Epidemiologic Station, was not observed. It is also necessary to mention that when executing measurements in the same day the Sanitary-Epidemiologic 40

41 Station obtained the data concerning the concentrations of aluminium oxide, sulfur dioxide, alkali which differed from each other in an order. Thus the data comparison of different laboratories concerning the atmospheric air state within the residential zone and at the border of the JSC Kazakhstan Aluminium buffer zone allows to speak about the enterprise influence on the atmosphere pollution. The periodic exceeding of the maximum permissible concentrations occurs: on dust in 30 % of cases, on alkali in 13.6 % of cases (according to the data of the laboratory of the Regional al Control Administration), on dust in 12.4 % of cases, on alkali in 4.2 % of cases (according to the LPL data). In July August 2001 the LPL of the JSC Kazakhstan Aluminium executed instrumental measurements in the area of the intended aluminium smelter construction and in the residential area to determine the concentration of hydrogen fluoride and of solid fluorides in the atmospheric air. As checkpoints the points were selected as follows: eastern border of Dachny microdistrict; eastern border of Metallurgist gardening; Stationary stations -1 of Kazhydromet ; Zelieny (Green) settlement; 1000 m to the west of stacks of the PAZ sintering shop. The analysis of atmospheric air samples was performed with use of the procedures of determination of the hydrogen fluoride content in the atmospheric air accepted in Kazhydromet with sampling onto the film chemisorbent and of the solid fluorides content with sampling onto the solid sorbent. The procedures are intended for determination of the hydrogen fluoride and fluorides concentrations in the atmospheric air in the range of mg/m 3. The data of the measurements results indicated that the content of hydrogen fluoride and solid fluorides in the atmospheric air in checkpoints were below the detection limit of techniques, i.e. less than mg/m 3. 41

42 To assess the atmosphere pollution level by solid and gaseous fluorides, as well as by benzapilene the laboratory of the Pavlodar Regional al Control Administration executed in August-September 2001 instrumental measurements in the area of the intended aluminium smelter construction and in the residential area. The measurement results indicated that the content of the above pollutants in the atmospheric air in checkpoints makes as follows: Point 1- in stationary stations -1 of Kazhydromet : on hydrogen fluoride mg/m 3 ( from MPC ms ), on benzapilene mg/m 3 ( from MPC ad );. Point 2 at the eastern border of Dachny microdistrict: on hydrogen fluoride mg/m 3 (0.1 from MPC ms ), on benzapilene mg/m 3 ( from MPC ad ); Point 3 - at the eastern border of Metallurgist gardening: on hydrogen fluoride mg/m 3 ( from MPC ms ), on benzapilene mg/m 3 ( from MPC ad ). Within measurements carried out by the laboratory of the Pavlodar Regional al Control Administration the solid fluorides were not detected. As can be seen from the above data the concentrations of hydrogen fluoride and benzapilene in the residential area atmospheric air meet the quality standards stated for these substances. 3. Sources and scales of design pollution 3.1 Brief description of facility planned 42

43 The design production capacity of the Pavlodar Aluminium Smelter is 250 thousand tons of primary aluminium per year with baked anode production of 136 thousand tons per year. The main feedstock for the designed facility is alumina, in amount of 482 thousand tons per year. The feedstock for the baked anode production is calcined petroleum coke, in volume of 96 thousand tons per year, coal tar pitch in amount of 24 thousand tons per year. The aluminium production in the smelter will be based on the use of 320 ka prebake pots equipped by the automated feed and process control systems. In the composition of the enterprise designed are provided: Reduction Shop, Carbon Plant, Power and Utilities, Utility Supply Facilities, Repair-auxiliary Purpose Facilities, Warehousing Facilities, Transportation Management Facilities. The Reduction Shop will consist of two potrooms connected to each other through passageways. Besides Gas Treatment Facilities, Alumina Feed Bins, Automated Process Control System of the reduction facility, Casthouse, Alumina and Fluorides Storage Silos will be part of the shop. To the Carbon Plant facilities will belong as follows: Receiving Unit and Liquid Pitch Storage with Gas Treatment Facilities; Coke Receiving Unit with Coke Silo Storage and Conveyor Gallery; Green Anode Plant; Anode Baking Plant with Conveyor Galleries; Green Anode Storage; Anode Rodding Shop with Baked and Rodded Anode Storages. To the Power and Utilities the facilities will belong as follows: Main Step-down Substation; Central Step-down Substation; Rectifier Substation; Compressor Station; Transformer and Oil Facilities; Electric Boiler Houses. To the Auxiliaries facilitates the facilities will belong as follows: Pot Relining Shop, Material Storages Block, Fuel Oil Storage, Auxiliaries of Reduction Facility and of Carbon Plant, Central Smelter Laboratory, Water Recycling Facilities of Shops, Garage with Light Oil and Lubricant Storage, Diesel Loco- 43

44 motive Handling Plant, Fire Department, Smelter Administration Building, Amenities, Gate Houses, etc. 3.2 Processes and equipment conditioning emissions of hazardous substances into atmosphere The industrial aluminium production is based on the electroreduction of aluminium oxide in the cryolite-alumina melt and is to be performed in pots that belong to the main facility of the Reduction Shop. The scheme of the pot structure is as follows: a shallow shaft-cavity (cathode assembly) is to be lined by refractory and insulating materials, on which the bottom made of carbon blocks is to be. The pot is to be filled with bath, in which baked carbon anodes are dropped. In the operating pot liquid aluminium serves as the cathode being constantly on the bottom. To the anode and to the bottom (cathode) the current-carrying bars are intaken. The melt forms a frozen bath crust at the air border. Alumina, fluorides (cryolite, aluminium fluoride) and baked anodes serve as a feedstock for aluminium production. The process of the aluminium reduction is accompanied by emission of the fluorides in the form of gas (hydrogen fluoride), dust (salts of fluorohydrogen acid), coke dust, alumina-containing dust, carbon oxide, sulfur dioxide, nitrogen oxides into the air environment. The prebake anode production process is connected with multistage cokes crushing, considerable traffic lines extension, frequent transfer of materials from one belt onto another one, a great deal of different chutes and feeders, repeated lifting of charge onto upper working levels what defines main sources of the carbon dust release. The use of a great deal of coal tar pitch containing in its composition 60 to 65 % of volatile tarry matters inclusive 1.0 to 1.5 % of carcinogen benzapilene also contributes to emission of pollutants into atmospheric air. 44

45 During executing of the analytical works in the Central Smelter Laboratory (CSL) the matters will be emitted into atmosphere as follows: charge dust, sludge, abrasive material, sinter dust, colophony fumes and different acids, carbon and nitrogen oxides, sulfur dioxide, ammonia, hydrocarbons, benzol, toluol. 3.3 Dust-gas-treatment equipment used in aluminium smelter It is provided in the aluminium smelter project to outfit the process equipment, which operation is connected with emission of pollutants into atmosphere, with high-performance Gas Treatment Centers (GTC). In the Reduction Shop the equipment is to be outfitted with GTC as follows: pots, fresh and secondary alumina bins, fluorides receiving silos. In the Carbon Plant the equipment is to be outfitted with GTC as follows: blending machine, vibropress plant, pitch batcher, coal tar pitch receiving unit and storage, anode baking furnace, crushing and screening plants, coke receiving unit, coke silo storage. In the Pot Relining Shop the equipment is to be outfitted with GTC as follows: Area for Ramming Bottom Blocks with Paste, Lining Removal Area. It is planned to direct the pot off-gases containing solid and gaseous fluorides, dust, sulfur dioxide via ducts to reactors with the suspended alumina bed, to which fresh alumina adsorbing fluorides will be fed simultaneously. Then gas and alumina as a high-speed flow will be transported to the bag filter. Dust and secondary alumina collected in the filter will be deposited in the bin and father will enter an airslide being in each bag filter bin. Air will be supplied into the airslide by means of fans. Secondary alumina will be directed from the airslides to the bin, from which it is to be fed to the secondary alumina silos by means of a chamber pump. It is intended to treat off-gases from the discharging facility and from the pitch storage by the electrostatic method on electrostatic precipitators. 45

46 It is proposed to treat off-gases from the coke storage, the crushing and screening units containing the coke dust in the bag filters. It is intended to treat off-gases from anode baking furnaces by the dry sorption method in modules reactor bag filter. It is provided to cool gases before feeding into the reactor. Alumina, on which surface hydrogen fluoride and tarry matters are adsorbed in the reactor, will be used as adsorbent in the module. Alumina and coke dust will be collected in the bag filter. The adsorbent with products collected are to be returned to the pot. In Table 14 the indices of operation of the gas treatment and dust collecting centers in the above shops are given. Table 18. Indices of operation of gas treatment and dust collecting centers Shop and name of release source No. of emission source Name and type of dustgas-collecting equipment Reduction Shop Pots 0001 reactor bag 0004 filter Fresh alumina 0009 bag filter bin 0016 Secondary alumina 0017 bag filter bin 0020 Alumina discharging 0021 bag filter facility Efficiency factor of Code Name of pollutant to dust-gascollecting of pollutant be treated equipment, % hydrogen fluoride fluorides, poorly soluble alumina dust alumina dust fluorides, poorly soluble alumina dust alumina dust

47 No. of Shop and name emission of release source source Fluoride storage Carbon Plant Name and type of dustgas-collecting equipment bag filter Efficiency factor of Code Name of pollutant to dust-gascollecting of pollutant be treated equipment, % fluorides, poorly soluble Blending ma Reactor- chine, vibropress adsorber; plant, pitch bag filter coal tar pitch fumes batcher coke dust Anode baking furnaces 0026 reactor bag filter nitrogen dioxide hydrogen fluoride coal tar pitch fumes Anode treatment 0027 filter line coke dust Coal tar pitch receiving 0028 electrostatic coal tar pitch fumes unit precipitator Coal tar pitch 0029 electrostatic coal tar pitch fumes storage precipitator Coke receiving unit 0030 bag filter coke dust Coke silo storage 0031 bag filter coke dust Pot Relining Shop Area for Ramming Bottom Blocks with bag filter Paste inorganic dust

48 Efficiency No. of Name and factor of Code Shop and name emissiogas-collecting be treated collecting type of dust- Name of pollutant to dust-gas- of pollutant of release source source equipment equipment, % Lining Removal Area 0036 bag filter fluorides, poorly soluble inorganic dust Anode Rodding Shop Bath butt treatment 0046 bag filter fluorides, poorly solu- line ble Stub treatment machine 0047 bag filter fluorides, poorly soluble Trumlling drum 0048 bag filter fluorides, poorly soluble Anode Butts 0049, bag filter Processing Facil inorganic dust ity Bath Processing 0051, bag filter fluorides, poorly solu- Facility 0052 ble Description of sources of hazardous substances emission into atmosphere In the Reduction Shop the equipment belongs to sources of the hazardous substances emission as follows: pots, fresh alumina receiving bins, fresh alumina silo, day silos, silos of alumina and fluorides receiving storage. 48

49 During the reduction process substances will be emitted into atmosphere as follows: inorganic dust, alumina dust, sulfur dioxide, carbon oxide, hydrogen fluoride, poorly soluble inorganic fluorides, tetrafluormethane. Stacks and aeration lanterns are emission sources. In the Carbon Plant the equipment belongs to sources of the hazardous substances emission as follows: Coke Receiving Unit (charging funnels, feeders, conveyors, elevators), Coke Silo Storages (silos, feeders, conveyors, elevators, drum drier), Discharging Facility and Liquid Pitch Storage (coal tar pitch storage tanks), Green Anode Plant (crusher, screen, conveyors, elevators, grinding plant with pneumatic separation, blending machine, vibropress plant, pitch batcher), Anode Baking Plant (anode baking furnaces, burned addition anode treatment line), Anode Rodding Shop (induction cast iron melting furnaces, bath butt treatment plant, stub treatment machine, tumbling drum, butt and breakage crushers, screen, bath processing facility). Calcined petroleum coke is accepted as the main carbon feedstock for anode production. The baked anode production process will be accompanied with release of pollutants as follows: coke dust, inorganic dust, carbon dust, sulfur dioxide, nitrogen dioxide and oxide, hydrogen fluoride, tarry matters in pitch fumes including benzapilene m stacks are emission sources. Casthouse holding furnaces are sources of release potassium and sodium chlorides, silicium dioxide, nitrogen oxide and dioxide, well and poorly soluble inorganic fluorides, hydrochloride, aluminium oxide, carbon oxide, fuel oil ash. 25 m stacks are emission sources. Auxiliaries facilities, Pot Relining Shop facilities, Central Smelter Laboratory are sources of emission into atmosphere of hazardous substances as follows: inorganic dust, charge, sludge, abrasive dust, sinter, hydrocarbons, welding aerosol (including manganese oxide), colophony and acids fumes, nitrogen and carbon oxides, sulfur dioxide, ammonia m stacks are emission sources. 49

50 To the disorganized enterprise emission sources the facilities will belong as follows: rail transportation (diesel locomotives), motor vehicles and freight transportation. During their work the substances will be emitted into atmospheric air as follows: nitrogen and sulfur dioxides, carbon and plumbum oxides, hydrocarbons, soot. Parameters of pollutants emission sources (height and diameter of the stack orifice), parameters of the air-gas mixture in the emission sources output (speed, volumetric rate, temperature), name of pollutants and emission number (of maximal single emission in g/s and total emission in t/y), position data of the sources location in the plan-map of the area are shown in Table 19. The list of pollutants emitted into atmosphere with the indication of maximal single, average daily MPC and RSIL and of their emission values in g/s and t/y are shown in Table

51 Table 19 (s. file "табл.19eng.xls" 15 pages to be printed out on A3 format sheets) 51

52 Table 20. List of pollutants Code Name of substance Maximum Permissible Concentration Emission of substance Type Ref. value Used in calc. g/sec. t/y 0101 Aluminium oxide MPC a/s* Potassium chloride MPC m/s Manganese and its compounds MPC m/s Sodium chloride MPC m/s Plumbum and its compounds MPC m/s Nitrogen (IV) oxide (Nitrogen dioxide) MPC m/s Nitric acid MPC m/s Ammonia MPC m/s Nitrogen (II) oxide (Nitrogen oxide) MPC m/s Hydrogen chloride MPC m/s Sulfuric acid MPC m/s Silicium dioxide amorphous RSIL Ozone MPC m/s Carbon black (Soot) MPC m/s Sulfur dioxide MPC m/s Carbon oxide MPC m/s Fluorides gaseous MPC m/s Fluorides well soluble MPC m/s Fluorides poorly soluble MPC m/s Hydrocarbons saturated С12-С19 RSIL Benzol MPC m/s Toluol MPC m/s

53 Code Name of substance Maximum Permissible Concentration Emission of substance Type Ref. value Used in calc. g/sec. t/y 0725 Coal tar pitch fumes, content of benzopilene 0,1 to 0,15% RSIL Tetrafluormethane RSIL Petroleum benzine MPC m/s Colophony, glycerine ether RSIL Suspended matters MPC m/s Oil ash of power plants MPC a/s* Coke dust MPC m/s Dust inorganic: 70-20% of MPC m/s SiO Dust inorganic: up to 20% of SiO2 MPC m/s Corundum white RSIL Group of summ. dust (101, 2902, 2904, 2907, MPC m/s , 2909, 2930) 6006 Group of summ. (4) Group Group of summ. (2) Group Group of summ. (2) Group Group of summ. (2) Group Group of summ. (5) Group Group of summ. (2) Group Group of summ. (3) Group

54 Code Name of substance 6046 Group of summ. (2) Group of summ. (3) Maximum Permissible Concentration Emission of substance Type Ref. Used in g/sec. t/y value calc. Group Group Possible volley and emergency emissions Reduction facility To the facility the equipment belong as follows: units for aluminium production by means of reduction method (pots); lifting-transport equipment to serve pots (erection cranes and pot tending cranes); floor mobile vehicles (feedstock distribution machine, dust handling machines, tractors and fork-lift trucks); internal and external raw material transportation (dense phase system pipelines at low velocities of transportation). The experience of running of analogous operational facilities indicates the maximum probability of the fluid aluminium leakage from the pot cavity through cathode collector bar openings in the cathode shell onto the busbar and then onto the ground level of the potroom. The analysis of the cases occurred indicates that it was caused by the deviation from the design requirements or by the improper execution of pot lining works or detection of the latent defect in the lining material during the pot operation. At that the emergency flowing out of pot metal is restricted by the ground level and is localized by the working area boundaries beneath the pot at the potroom ground level. 69

55 The selection and the removal of the cooled metal spillage is to be executed by workers having special leave for work at the potroom ground level demanding the special observance of the electrical safety requirements. Breaking of the pot duct pipes continuity during the servicing operations performance and the erection works execution can be considered as an emergency situation. In this case the hazardous substances released from the pots in the form of dust and gas will penetrate into the potroom working area and then through the lantern into atmosphere bypassing the gas-suction system. In Table 21 the description of possible emergency situations in the potrooms is given. The emergency situations duration (subject to their elimination) makes approximately 6 hours a year. The volley emissions per potrooms are lacking. Foundry The emergency situations in the Cast House can be connected with the fluid metal spillage from the ladle or from the trough. At that hazardous emission into atmosphere will not occur. The single fluid metal spillages can make 50 to 100 kg per 1 time (within 5 minutes) 1 time a month. At that 0.1 % of aluminium of the aluminium mass spilled can be emitted into the shop atmosphere. In Table 22 the description of possible emergency situations in the foundry is given. The volley emissions in the foundry are lacking. Baked Anode Facility During the baked anode production the most process operations are connected with processing of solid nonexplosive substances, therefore the emergency situations occurring while breakdown in process and in case of the equipment failure do not affect the atmospheric air. 70

56 In case of the gas treatment system shutdown the process equipment stops automatically. The hazardous from the point of view of the atmospheric air impact situations can occur only during the emergencies connected with processing of liquid substances of melt coal tar pitch. During the pipelines breaking the stop time of the pumping-over process is to be measured in minutes. Taking into consideration the fact that the maximum pitch pump capacity makes 30 m 3 /hr the spilled pitch quantity will be in this case relatively little. The maximum danger can occur in case of the emergency seal failure of the liquid pitch tank. The tank capacity makes 400 m 3. The tank is situated in the area with 1.3 m diking height. In case of the complete tank unloading (in case of the emergency seal failure of the tank) pitch will flood total free area within diking that makes 540 m 3. In tanks pitch is to be stored at 160 to 180 С. At this temperature volatiles consisting of the compound mixture of different hydrocarbons will be emitted. At temperature below 150 С the volatiles emission stops. Within the upper pitch surface cooling down to 150 С the volatiles emission will make ~50 kg from the 540 m 2 surface according to the calculation. When contacting the soil and cooling down to the temperature below 85 С pitch becomes hard. To reduce the volatiles volley emission in case of such emergency the pitch surface water refluxing can be used. It is possible to avoid ladle or trough metal spillages observing safety standards and following undeviatingly. In case of the trough metal spillage the metal supply from the holding furnace stops (the holding furnace taphole is to be closed), and beneath the spillage place a 0.1 to 0.2 m 3 metallic mould is to be installed. The spillages can be usually in the troughs junction; according to safety engineering manual the spillage mould has always to be in these places. In Table 23 the description of possible emergency situations in the Carbon Plant is presented. 71

57 There is no historical data on similar emergencies in operational aluminium smelters as there were no cases of the pitch tanks seal failure there according to available information. Volley emissions are missing in the Carbon Plant. 72

58 Table 21. Description of possible emergency situations in potrooms Name of products Facility, shop, block, building Cause of emergency and probability Name of pollutants Quantity of substances emitted into atmosphere in case of emergency kg/hr kg/y Area of polluted territory (m 2 ) Consequences of emergency Measures on elimination of emergency consequences Alumin- Potrooms fluid melt aluminium Melt aluminium, Pollution of ium- and bath leakage bath potroom green- from pot cavity F gas m 2 atmosphere Removal of fro- ware through cathode col- F solid zen metal and lector bar openings SO bath in cathode shell СО Breaking of pot duct F gas m 2 Pollution of Repair of duct pipes continuity F solid potroom pipe SO atmosphere dust СО

59 Table 22. Description of possible emergency situations in foundry Name of products T-pigs 22,5 kg small pigs Ladle splashings when pouring into holding furnace Facility, shop, block, Measures on elimination of emergency consequences building Casthouse Cause of emergency and probability Trough aluminium spillage (0.5%) Name of pollutants Fluid aluminium in volume of 10 to 50 kg Quantity of substances emitted into atmosphere in case of emergency Aluminium oxide in amount of 1% of spilled metal kg/year Area of polluted territory Consequences of emergency up to 2 m 2 none Removal of frozen metal and bath -«- -«- -«- -«- -«- -«- -«- -«- Hitting of metal stream past holding furnace pocket (1%) Fluid aluminium in volume of up to 100 kg Aluminium oxide in amount of 1% of spilled metal 1.2 kg/year up to 5 m 2 -«- -«- 74

60 Table 23. Description of possible emergency situations in Carbon Plant Facility, shop, building Cause of emergency and probability of its arising Name of pollutants, emitted in case of emergency Quantity of substances emitted in case of emergency (tons) into atmosphere Onto territory Area of polluted territory (m 2 ) Measures on elimination of emergency consequences Carbon Plant. Tank seal fail- Liquid coal tar pitch Volatile fumes Liquid pitch 540 m 2 water refluxing of melt pitch Liquid pitch ure. at 160 С. of coal tar 520 t per surface for its freezing. storage Volatile fumes of pitch about 540 m 2. coal tar pitch. 50 kg. 75

61 3.6 Methodology of impact assessment of design facility on air basin state At present the determination of the surface concentrations of hazardous substances, which will be generated when operating the future facility, belongs to the main method of the air environment impact prediction in case of realization of the economical activity planned. The standard method of calculation of the hazardous substances in the atmospheric air when arranging and designing the enterprises is stated in Procedure of calculation in atmospheric air of concentrations of hazardous substances containing in enterprises emissions РНД According to the procedure the calculations are to be executed subject to the background pollution of the atmospheric air of the enterprise surrounding territory. For new enterprises under construction the sum of design and background (generated as a result of emissions of other enterprises and of transport) concentrations of each pollutant must not exceed the maximum permissible concentration stated for it in air of the populated areas. The reference concerning the background pollutant concentrations in Pavlodar is submitted by Kazhydromet (letter No. 9/ of ). 3.7 Results of dispersion calculations The calculations of the atmosphere emission dispersion were executed with use of the PC program UPRZA Ecologist, version 3, developed the Integral company on the basis of РНД The calculations have been carried out for the summer period characterized by the most adverse conditions for the pollutant emission dispersion in atmosphere. Meteorological characteristics and factors accepted in the calcula- 76

62 tions that determine the conditions of the pollutants dispersion in atmosphere of the Pavlodar aluminium smelter location area are shown in Table 20. The size of the design rectangle is accepted subject to coverage of Pavlodar town, its adjacent dacha areas, as well as Kenzhekol, Zhetekshi, Krasnoarmaika, Shakat settlements in the calculations of the intended construction site. The size of the design rectangle is equal to х m with the computational grid step of 1000 m. The dispersion calculations are executed concerning all pollutants subject to full-power operation of the smelter process and dust-gas-treatment equipment. Table 24. Meteorological characteristics and factors accepted determining conditions of pollutants dispersion in atmosphere Nos. Characteristic Designation, dimensionality Value 1. Factor of temperature atmosphere stratification А Factor of relief h Average maximum temperature of atmospheric air of t s, С 27.8 hottest month 4. Average maximum temperature of atmospheric air of T w, С coldest month 5. Average annual wind rose % N % 9 NE % 9 E % 8 77

63 Nos. Characteristic Designation, dimensionality Value SE % 11 S % 18 SW % 15 W % 20 NW % 10 Calm % 9 6. Wind speed not exceeding repeatability of 5% U*, m/s 9.0 Since in the smelter emissions the substances will be having harmful action summation, the dispersion calculations have been made not only for individual substances but also for groups of their summation: summation group of dust - aluminium oxide + Oil ash of power plants + coke dust + dust inorganic +Corundum white + suspended matters; summation group fuel oil ash + sulfur dioxide + nitrogen dioxide + nitrogen oxide (N6006); summation group sulfur dioxide + nitrogen dioxide (N6009); summation group plumbum and its compounds + sulfur dioxide (N6034); summation group sulfur dioxide + gaseous fluorides (N6039); summation group sulfuric acid + sulfur dioxide + nitrogen dioxide + nitrogen oxide + ammonia (N6040); summation group sulfuric acid + sulfur dioxide (N6041); summation group carbon oxide +inorganic dust: 70-20% of SiO 2 (N6046); summation group gaseous fluorides + well-soluble fluorides + poorly soluble fluorides (N6302). 78

64 Parameters of pollutants emission sources (height and diameter of the stack orifice), parameters of the air-gas mixture in the emission sources output (speed, volumetric rate, temperature), name of pollutants and emission number (of maximal single emission in g/s), position data of the sources location in the map of the area accepted in calculations are shown in Table 19. The layout chart of the emission sources with marked numbers is shown in Figure 2. The sources are specified as follows: - organized single sources as point ones; - lanterns as line ones. In the calculation all emission sources are taken into account subject to fullpower operation of the smelter process and dust-gas-treatment equipment of the Pavlodar Aluminium Smelter. In the first stage the calculation of the calculation expediency has been carried out per substances and per summation groups. The execution of the concrete substance calculation was considered as inexpedient if the sum of maximum concentrations in parts on all sources was less than

65 Fig. 2. Layout chart of the emission sources 80

66 In Table 25 the list of substances, which calculation is inexpedient, is presented. Table 25. List of substances which calculation is inexpedient Code Name Sum Cm/MPC 0152 Sodium chloride Nitric acid Ammonia Nitrogen (II) oxide (Nitrogen oxide) Sulfuric acid Silicium dioxide amorphous Ozone Carbon black (Soot) Benzol Toluol Tetrafluormethane 7.8E Petroleum benzine Colophony Oil ash of power plants Corundum black The results of maximum concentrations for all other substances and summation groups are shown in Appendix 1, the isolines of the design concentrations of substances and summation groups are given in Figures

67 Fig. 3. Aluminium oxide (0101) 82

68 Fig. 4. Manganese and its compounds (0143) 83

69 Fig. 5. Plumbum and its compounds (0184) 84

70 Fig. 6. Nitrogen dioxide (0301) 85

71 Fig. 7. Sulfur dioxide (0330) 86

72 Fig. 8. Carbon oxide (0337) 87

73 Fig. 9. Fluorides gaseous (0342) 88

74 Fig. 10. Fluoride well soluble (0343) 89

75 Fig. 11. Fluoride poorly soluble (0344) 90

76 Fig. 12. Hydrocarbons saturated (0401) 91

77 Fig. 13. Coal tar pitch fumes (0725) 92

78 Fig. 14. Suspended matters (2902) 93

79 Fig. 15. Dust coke (2907) 94

80 Fig. 16. Dust inorganic 70-20% SiO 2 (2908) 95

81 Fig. 17. Dust inorganic up to 20% SiO 2 (2909) 96

82 Fig. 18. Group of summ. dust (101, 2902, 2904, 2907, 2908, 2909, 2930) 97

83 Fig. 19. Group of summ (301, 304, 330, 2904) 98

84 Fig. 20. Group of summ (301, 330) 99

85 Fig. 21. Group of summ (184, 330) 100

86 Fig. 22. Group of summ (330, 342) 101

87 Fig. 23. Group of summ. (301, 303, 304, 322, 330) 102

88 Fig. 24. Group of summ (322, 330) 103

89 Fig. 25. Group of summ (337, 2908) 104

90 Fig. 26. Group of summ (342, 343, 344) 105

91 It is evident from the table and the figures that the maximum concentrations of the following pollutants are lower than 0.05 : potassium chloride (0126), hydrogen chloride (0316), summation group These substances will not influence on the atmospheric air pollution. The affected zone, i.e. a territory, on which the pollutant value can make more than 0.05, but less than 1, the substances form as follows: aluminium oxide (0101), well soluble fluorides (0343), poorly soluble fluorides (0344), manganese and its compounds (0143), sulfur dioxide (0330), carbon oxide (0337), saturated hydrocarbons (0401), suspended matters (2902), oil ash (2904), coke dust (2907), inorganic dust 70-20% of SiO 2 (2908), inorganic dust up to 20% of SiO 2 (2909), summation groups 6041, The polluted zone, i.e. a zone, in which the concentration exceeds 1, the sources generate that emit gaseous fluorides (0342), coal tar pitch fumes (0725), nitrogen dioxide (0301), plumbum and its compounds, summation group of dust, summation groups 6006, 6009, 6034, 6039, 6040, The dimensions of the enterprise affected zone defined on each hazardous substance or substances combination with the summing deleterious effect will make for the emission sources of the Pavlodar Aluminium Smelter as follows: aluminium oxide -9 km plumbum and its compounds -4 km nitrogen (IV) oxide (nitrogen dioxide) -5 km sulfur dioxide -9 km carbon oxide -5 km gaseous fluorides -10 km poorly soluble fluorides -12 km coal tar pitch fumes -21 km summation group of dust.-10 km summation group oil ash + sulfur dioxide + nitrogen dioxide + nitrogen oxide (N6006) -11 km 106

92 summation group sulfur dioxide + nitrogen dioxide (N6009) -11 km summation group plumbum and its compounds + sulfur dioxide (N6034) -12 km summation group sulfur dioxide + gaseous fluorides (N6039) -14 km summation group sulfuric acid + sulfur dioxide + nitrogen dioxide + nitrogen oxide + ammonia (N6040) -11 km summation group sulfuric acid + sulfur dioxide (N6041) -9 km summation group carbon oxide + inorganic dust: 70-20% of SiO2 (N6046) -5 km summation group gaseous fluorides + well soluble fluorides + poorly soluble fluorides (N6302) -12 km In Table 22 the maximum concentration values are shown (S.) that can occur in zones of the apartment block of the smelter adjacent territory. The indicated information allows to draw a conclusion concerning the minimum influence of the Pavlodar Aluminium Smelter emissions on the atmospheric air pollution in the residential zone of Pavlodar town and the smelter adjacent settlements: the background pollutant concentration values in the atmosphere of Pavlodar and settlements will not change. The maximum surface concentrations will be generated in site or in immediate proximity to it what is shown obviously on the dispersion maps, on which the maximum concentration points are marked in red. 107

93 Table 26. Results of calculation of maximum concentrations ( part) generated by emission sources of PAS in residential zone subject to background Krasnoarmaika Name of substance Pavlodar Dachas Kenzhekol Zhetekshi Shakat Aluminium oxide Manganese and its compounds Plumbum and its compounds Nitrogen (IV) oxide (Nitrogen dioxide) Hydrogen chloride Sulfur dioxide Carbon oxide Gaseous fluorides Well soluble fluorides Poorly soluble fluorides Hydrocarbons saturated С12-С Coal tar pitch fumes Suspended matters Coke dust Inorganic dust: 70-20% of SiO Inorganic dust: up to 20% of SiO Summ. group of dust Summ. group (4) Summ. group (2)

94 Name of substance Pavlodar Dachas Kenzhekol Zhetekshi Shakat Krasnoarmaika Summ. group (2) Summ. group (2) Summ. group (5) Summ. group (2) Summ. group (3) Summ. group (2) Summ. group (3) To the sources of the Pavlodar Aluminium Smelter contributing most of all to the surface concentrations the facilities belong as follows: on aluminium oxide and summation group of dust Nos. 5, 6, 7, 8 (aeration lanterns of the Reduction Shop); on sulfur dioxide - Nos (gas treatment facility stacks); on carbon oxide, hydrogen fluoride, on poorly soluble fluorides, on summation groups 6039 и Nos (aeration lanterns of the Reduction Shop); on coal tar pitch fumes - Nos. 0026, 0028, 0029 (anode baking furnaces and pitch discharge and storage facility); on summation groups 6006, 6009, Nos. 96, 97 (transport) on manganese dioxide - Nos (welders); on plumbum oxide, hydrocarbons, nitrogen dioxide No (anode baking furnaces); 109

95 4. Implementation of low-waste technologies and mesures on reduction of emissions into atmosphere The aluminium production in the Pavlodar Aluminium Smelter is to be organized on the basis of the foreign companies advanced technology, specifically on the technology of Pechiney (France) of the world leader in the aluminium industry. It is planned to organize the facility based on application of 320 ka prebake pots equipped by automated feed system, high-efficient hoods providing for the pot gas suction level up to 98.5 % and process control system. Between potrooms the dry gas treatment facility will be located. The process control is automated completely; each pot is to be equipped with a microprocessor to control main parameters (pot voltage, anode effect frequency and voltage, bath temperature, alumina content) and to perform main operations for the pot servicing. The aluminium production is characterized by large off-gas quantity, available various pollutants such as hydrogen fluoride, sulfur dioxide, fine dust containing alumina and fluorides. Scopes of the total pollutant emissions depend on reduction process, pots design, hoods efficiency, gas treatment methods, quality of the raw material used, plant designs, level of technical fitting-out and servicing. When using Soderberg pots, which are also applied in the aluminium production, the emission of the polycyclic aromatics (PA) occurs; a number of their components have carcinogenic properties, as the Soderberg paste coking takes place directly in potrooms at high temperature (690 to 950 С). Change to the baked anode technology decreases these emissions substantially. Such technology modification in combination with more perfect gas treatment methods allows decreasing gas emission of tarry matters and fluorine down to the level close to MPC. 110

96 The dry sorption gas treatment, which is intended to be applied in the smelter designed, is based on adsorption and return to the reduction process of hydrogen fluoride by alumina being feedstock for aluminium production. Alumina produced under commercial conditions contains aluminium oxides (α - Al2О3, β - Al2О3, γ - Al2О3,) with different activity with respect to hydrogen fluoride (α - Al2О3 is characterized by the minimum activity, and γ - Al2О3 by the maximum one). The content in alumina of the minimum activity aluminium oxides does not exceed 40% as a rule what conditions on the sufficient sorption activity of alumina with respect to hydrogen fluoride. According to the data of numerous investigations the sorptive capacity, i.e. the quantity of hydrogen fluoride, absorbable without decrease of the purification efficiency, makes 12 to 25 mg/g or 1.2 to 2.5 % of alumina weight what allows using of alumina in the closed cycle (up to 10 hours) without decrease of purification efficiency of the reduction process off-gases. To obtain necessary sorption the contact between fluorine molecules and alumina particles is to be realized in two sequential stages. The first stage takes place in the reactor where gas and alumina are agitated; in the second stage gas passes through an alumina bed sprayed on the bag filters. By means of adjusting fresh alumina feeding or alumina recycling the reactor efficiency is changed. The final gas treatment takes place on the bag filters and depends on the alumina bed thickness. The gas treatment is included in the processing chain of aluminium production and is used not only for the off-gases treatment but also for supply of the feedstock for the reduction process (the fresh and secondary alumina ratio is adjusted depending on process needs necessity of first-class alumina production). Advantage of the dry sorption gas treatment, in comparison with the wet treatment, is absence of: polluted wastewater to be neutralized, drip carryover, corrosion and erosion of equipment. 111

97 The collection efficiency of fluorides and dust makes more than 99 %. For comparison, the efficiency of the wet treatment equipment is 95% on hydrogen fluoride, and 80% - on solid fluorides. The expected maximum specific pollutants emission from the main (Reduction Shop and Carbon Plant) emission sources of the Pavlodar Aluminium Smelter will make in kg/t as follows: fluorides (total), in terms of fluorine 1.02; sulfur dioxide 12.5; carbon oxide 51.2; summation group of dust 2.256; nitrogen oxides (total) 0.47; coal tar pitch fumes 0.033; including benzapilene For comparison the pollutants content is shown after the dry pot gases treatment in analogous facilities guaranteed by the leading foreign companies (Table 27). The data indicated in Table 27 shows that the pollutants content in pot gases after treatment for the Pavlopdar Aluminium Smelter is analogous to the indices of the leading foreign companies. 112

98 Table 27. Guarantee pollutants content after dry pot gases treatment Company Name of substance Micropooldair Aluminium PAS Prosi- Kaiser Project Flect Guarantee content in gases after treatment, mg/nm3 Fluorides gaseous Fluorides solid Fluorides general Tarry matters data n/a 2.0 Benzapilene 0.02 data n/a data n/a data n/a 0.02 Dust Offers on maximum permissible emissions of Pavlodar Aluminium Smelter According to "Instruction on carrying out of environment impact assessment of economical activity and other activity when preparing preplanned documentation, predesign and design packages (Almaty, 2004) the offers concerning the maximum permissible emission (MPE) of hazardous substances are given in this work. In connection with the fact that the sources of the pollutants emission will not generate surface concentrations exceeding MPC for the populated areas (subject to background concentrations), the design emission values are to be stated in the design stage as maximum permissible (MPE). In Table 28 the standards of the pollutant emission into atmosphere are shown for complete development on each source and each impurity. In Table 29 the standards for the smelter as a whole are shown. 113

99 Table 28. Standards of pollutants emission for existent state and term of MPE achievement Facility, shop, section Standards of pollutants emission Number of source g/s t/g 0101 Aluminium oxide (in terms of aluminium) Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Casthouse

100 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Potassium Chloride Casthouse Total for enterprise Manganese and its compounds (in terms of manganese (IV) oxide) Pot Relining Shop Pot Relining Shop Pot Relining Shop Pot Relining Shop Repair Shop Repair Shop Repair Shop Repair Shop Repair Shop Repair Shop Total for enterprise Sodium chloride Casthouse Total for enterprise Plumbum and its inorganic compounds (in terms of plumbum) Transport Total for enterprise

101 Standards of pollutants Number emission Facility, shop, section of source g/s t/g 0301 Nitrogen dioxide Carbon Plant Casthouse Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Transport Transport Transport Total for enterprise Nitric acid (based on molecule of HNO3) Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory

102 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Total for enterprise Ammonia Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Nitrogen oxide Carbon Plant Casthouse Total for enterprise Hydrochloric acid Casthouse Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory

103 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Sulfuric acid based on molecule of H2SO4 Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory

104 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Silicium dioxide amorphous Casthouse Total for enterprise Ozone Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Soot Transport Total for enterprise Sulfur dioxide Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Carbon Plant

105 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Casthouse Central Smelter Laboratory Central Smelter Laboratory Transport Total for enterprise Carbon oxide Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Casthouse Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Transport

106 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Transport Total for enterprise Hydrogen fluoride Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Carbon Plant Casthouse Total for enterprise Fluorides inorganic: well soluble Casthouse Total for enterprise Fluorides inorganic: poorly soluble Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop

107 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Casthouse Pot Relining Shop Anode Rodding Shop Anode Rodding Shop Anode Rodding Shop Anode Rodding Shop Anode Rodding Shop Anode Rodding Shop Anode Rodding Shop Total for enterprise Hydrocarbons saturated С12-С19 Pot Relining Shop Transport Transport Total for enterprise Benzol Central Smelter Laboratory

108 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Total for enterprise Methyl benzol Central Smelter Laboratory Total for enterprise Coal tar pitch fumes with benzapilene content 0.1 to 0.15% Carbon Plant Carbon Plant Carbon Plant Carbon Plant Total for enterprise Tetrafluormethane Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Reduction Shop Total for enterprise Benzine (petroleum, low-sulfur in terms of carbon) Central Smelter Laboratory Central Smelter Laboratory Total for enterprise

109 Standards of pollutants Number emission Facility, shop, section of source g/s t/g 2844 Colophony glycerine ether Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Suspended matters Pot Relining Shop Pot Relining Shop Pot Relining Shop Pot Relining Shop Anode Rodding Shop Anode Rodding Shop Repair Shop Repair Shop Repair Shop Repair Shop Repair Shop Repair Shop Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Coke dust Carbon Plant Carbon Plant Carbon Plant Carbon Plant

110 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Total for enterprise Oil ash Carbon Plant Casthouse Total for enterprise Dust inorganic: 70-20% of silicium dioxide Pot Relining Shop Pot Relining Shop Pot Relining Shop Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Central Smelter Laboratory Total for enterprise Dust inorganic: lower than 20% of silicium dioxide Carbon Plant Pot Relining Shop Pot Relining Shop Pot Relining Shop Central Smelter Laboratory Total for enterprise Abrasive dust Central Smelter Laboratory Central Smelter Laboratory

111 Standards of pollutants Number emission Facility, shop, section of source g/s t/g Central Smelter Laboratory Total for enterprise TOTAL Table 29. Standards of pollutants emission for smelter as a whole Standards of pollutants emission Facility, shop, section g/s t/g 0101 Aluminium oxide (in terms of aluminium) Total for enterprise Potassium chloride Total for enterprise Manganese and its compounds (in terms of manganese (IV) oxide) Total for enterprise Sodium chloride Total for enterprise Plumbum and its inorganic compounds (in terms of plumbum) Total for enterprise

112 Standards of pollutants emission Facility, shop, section g/s t/g 0301 Nitrogen dioxide Total for enterprise Nitric acid (based on molecule HNO3) Total for enterprise Ammonia Total for enterprise Nitrogen oxide Total for enterprise Hydrochloric acid Total for enterprise Sulfuric acid based on molecule H2SO4 Total for enterprise Silicium dioxide amorphous Total for enterprise Ozone Total for enterprise Soot Total for enterprise Sulfur dioxide 127

113 Standards of pollutants emission Facility, shop, section g/s t/g Total for enterprise Carbon oxide Total for enterprise Hydrogen fluoride Total for enterprise Fluorides inorganic: well soluble Total for enterprise Fluorides inorganic: poorly soluble Total for enterprise Hydrocarbons saturated С12-С19 Total for enterprise Benzol Total for enterprise Methyl benzol Total for enterprise Coal tar pitch fumes with benzapilene content 0.1 to 0.15% Total for enterprise 0965 Tetrafluormethane Total for enterprise

114 Standards of pollutants emission Facility, shop, section g/s t/g 2704 Benzine (petroleum, low-sulfur in terms of carbon) Total for enterprise Colophony glycerine ether Total for enterprise Suspended matters Total for enterprise 2904 Oil ash Total for enterprise Coke dust Total for enterprise Dust inorganic: 70-20% of silicium dioxide Total for enterprise Dust inorganic: lower than 20% of silicium dioxide Total for enterprise Dust abrasive Total for enterprise TOTAL

115 6. Definition of buffer zone size of enterprise According to СанПиН 2.2.1/ the minimum buffer zone size for aluminium smelters by means of the melt aluminium salts (alumina) reduction method is fixed approximately 1000 m. The definition of the buffer zone size is to be performed based on results of the emission dispersion calculation according to requirements of the normative document РНД concerning the control of dimensions of a normative buffer zone. The buffer zone is a part of the polluted zone within the bounds of the industrial enterprise and of the residential area of the settlement, within which the atmosphere surface layer is polluted with hazardous substances containing in production emissions in concentrations exceeding permissible norms. The buffer zone restricts the territory of the increased (above permissible level) influence of those smelter impact types, which, after reaching their maximum on the smelter site territory, decrease monotonically according to moving away from it (as it appears from the results of dispersion calculation of the pollutants in the atmosphere). Among these are: the atmospheric air pollution with low organized and disorganized emission sources. The buffer zone has a sector configuration towards the apartment block. It means that to the proper buffer zone the area section between the enterprise boundary and the boundary of the settlement residential area (part of the polluted zone) belongs, the rest of the territory is a polluted zone. The pollutants dispersion calculation, subject to the full-power aluminium smelter operation and background pollutions, indicates that the enterprise emission sources will not generate hazardous substances concentrations exceeding their MPC in the residential zone, because Pavlodar town, Zhetekshi, Kenzhekol, Shakat, Krasnoarmaika settlements are situated at a considerable distance from the intended construction area. The minimum distance 130

116 from the Pavlodar Aluminium Smelter site to the apartment block makes 10 km. As appears from the dispersion calculation results the maximum pollution area will be generated by emissions of coal tar pitch fumes (0725) and of fluorine summation groups (6302). The radius of the pollution zone from coal tar pitch fumes will make m from the enterprise boundaries, from dust summation emissions m, from fluorine summation emissions m. In Table 30 the results of definition of the rated buffer zone size of the aluminium smelter are shown subject to the average annual wind rose correction according to РНД Table 30. Results of definition of rated buffer zone size of aluminium smelter subject to average annual wind rose correction Name of index Wind direction meteorological N NE E SE S SW W NW Р0 average annual repeatability of wind directions at circular wind rose, % Р average annual repeatability of wind directions of rhumb considered, % Value of ratio Р/Р L0 rated size of area section in Dust summation group this direction where hazardous substances concentration exceeds Fluorine summation group (6302) MPC subject to background concentration, m Coal tar pitch fumes (0725) Maximum value L l rated size of buffer zone, m

117 The boundaries of rated buffer zone of the Pavlodar Aluminium Smelter are represented in the map-plan of the smelter location area (Figure 27). The buffer zone radius makes m from the enterprise boundaries. Besides the pollutants emission into atmosphere the Pavlodar Aluminium Smelter has no other physical influences (noise, electromagnetic fields) conditioning the buffer zone dimensions upon the environment. The buffer zone dimensions indicated are to be set in coordination with the Chief state sanitary inspector of the Republic of Kazakhstan. 132

118 Figure 27. Map-plan of smelter location with boundaries of rated buffer zone 133