EHS Env Guidelines

PCFC ENVIRONMENTAL GUIDELINES (EGs) TABLE OF CONTENTS EG No. 1.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Description

Air Environment Guidelines 1.1: Air Environment General Guidelines 1.2: Chimneys and Dispersion Modeling 1.3: General Industry Air Emissions Guidelines 1.4: Source Emission Criteria- Air Pollutants Large Boilers and Furnaces 2.1: General Guidelines 2.2: Technical Guidelines for Steam Boiler Installation Chemical Fertilizer Works Ammonia Works Sulphuric Acid Works Lead Works Mineral Works Iron and Steel Works-Foundries Secondary Aluminum Works Chemical Incineration Works Cement Works Di-isocyanates Works Petroleum Works – Refineries Chlorine and Hydrochloric Acid Works Iron and Steel Works Montreal Protocol for Ozone Depleting Substances Control of Substances Hazardous to Health and a Danger 17.1: Handling and Processing 17.2: Storage 17.3: Guidance Note 17.4: General Guidelines for Dangerous/ Hazardous Materials Handling and Storage

21.

17.5: PCFC Requirements for Handling, Export of Radioactive Substances Water Environment Guidelines 18.1: Water Environment General Guidelines 18.2: Treated Wastewater Disposal in Harbour/Gulf (Open sea) 18.3: Elements to be taken into Account in the Issue of the Authorization for Discharge of Treated Waste in to Harbour/Open Sea 18.4: Wastewater Criteria at Point of Discharge to Marine Environment/Harbour: Standards for Discharge of Waste to Harbour 18.5: Wastewater Pre-Treatment Criteria for Industrial Effluent to Dubai Municipality Sewers Environmental Management Tools (EMT) Guidelines for Conducting Environmental Impact Assessment (EIA) Study in PCFC/Pre-qualified Consultants list for EIA/RA Studies. Best Available Techniques (BAT) and Best Practicable Environmental Option (BPEO)

22. 23 24. 25. 26. 27.

Guidance for Linear Soakaways Installation Guidance for Groundwater Monitoring Wells Installation Energy Efficiency EHS Standards References DUCAMZ Environmental Guidelines. Guidelines for Cleanliness

18.

19. 20.

PCFC-EGs-Table of Contents

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28.

General Environmental Guidelines for Manufacturing/Assembly/Service Industries.

29. 30. 31. 32. 33. 34. 35. 36.

EHS Performance Audits Guidelines for Conducting Waste Audits in PCFC. Environmental Guidelines for Gold and Diamond Facilities in DMCC Energy, Water Conservation and Management Guidelines Glass Recycling Environmental Reporting Cleaner Production, Waste Minimization and RRR Options Waste Management in PCFC

PCFC-EGs-Table of Contents

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ENVIRONMENTAL GUIDELINE No.1 AIR ENVIRONMENT GUIDELINES

1.1

AIR ENVIRONMENT GENERAL GUIDELINES: There are some general guidelines/features which are common to most works. Such guidelines are outlined below. a. As part of proper supervision, the owner shall make tests and inspections of the process at frequent intervals as required by the Authority. b. The results of all tests shall be recorded for inspection by the Authority representatives. c.

Adequate facilities for sampling shall be provided on chimneys and ducts.

d. The reference test method for particulate emissions is by the procedure of British Standard 3405:1983 or similar relevant standard. e. All limit values including EGs are expressed as being at the gas reference conditions of 30oC and a pressure of 1 bar, without correction for water vapour content. f.

Emissions shall be monitored continuously wherever practicable.

g. Roads and operating areas shall be hard surfaced and kept clean. h. A good standard of housekeeping is essential. i.

Staff at all levels shall receive proper control training and instructions in their duties, with special emphasis on start-up, shut-down and abnormal conditions.

j.

Chimney heights shall be determined by the Authority taking into account all the relevant information on throughput, type of material, quality of emission, fuel type and rate of usage, local circumstances, etc.

k. Dry emissions shall normally be vented to air with an efflux velocity of 10 to 15 m/sec at full load. l.

When waste gases are wet, or have been in contact with liquids, the maximum chimney velocity shall be 9m/s to prevent the emission of liquid droplets physically stripped from the wet inside chimney surfaces by high velocity gases.

m. The minimum height of any chimney shall not be less than 3m above the ridge of any tallest building to which it is attached or adjacent. n. There shall be suitable means for dealing with spillages, as agreed with the Authority. o. The construction of any boiler, heater, oven etc shall comply with PCFC requirements (see relevant EG) p. For any spray painting operation, a proper painting booth should be constructed with a proper extraction/filtration system to the Authority’s satisfaction. q. Proper extraction/filtration system to be provided for the air borne emissions from the proposed machinery. The detailed drawings to be submitted to PCFC for approval.

PCFC-EG#1

1.2

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CHIMNEYS AND DISPERSION MODELING When the best practicable control means for prevention of emission of noxious or offensive substances have been used, the second part is to render harmless and inoffensive such substances as may be discharged. This is achieved by dispersion from suitably tall chimneys, taking into account the composition, volume rate of emission and temperature of the waste gases. The final decisions on the heights and diameters of chimneys shall be taken by the Authority. For purposes of deciding on chimney heights of industry in the Free Zone, industry is divided into two parts: (a) where chimneys are needed to disperse the products of combustion of fuel, and (b) where chimneys are needed to disperse airborne emissions from process operations. In the case of (a), for relatively small plants where the heat output is below 30 MW, the publication on “Chimney Heights” issued by the UK government and obtainable from HMSO is used for determining heights of chimneys. It is a well - tried document over many years and allows multiple sources to be sited in industrial areas without exceeding permitted ground level concentrations. On a case-bycase basis air dispersion modeling would be required from the clients.

1.3

GENERAL INDUSTRY AIR EMISSIONS GUIDELINES a.

Particulate matter

Emission

(i)

Inert dust in ducts and chimneys from combustion sources.

250 mg/m3

(ii)

Fugitive dust - there shall be no significant visible emission except from combustion sources.

(iii)

There are many dusts and fumes which can have a harmful or nuisance effect on humans, animals, vegetation and materials of construction and for which special limits of emission are required. The following list is not exclusive and substances not on the list will be considered on their merits.

Limit

Iron oxide fume from oxygen refining *Petroleum - solids from catalytic crackers *Petroleum - furnace carbon black Phosphorus (as P2 O5) Tar fumes Vinyl Chloride

75 mg/m3 100 mg/m3 5 mg/m3 5 mg/m3 20 mg/m3 10 mg/m3

*Note: Desired range of Sulphur Recovery Units (SRUs) efficiency 98- 99.9% All volumes are referred to standard conditions of 30oC and 1 bar; electricity works burning fossil fuels are also referred to a standard of 12 percent carbon dioxide in the waste gases. (iv)

Routine methods of assessment may be used by agreement with the Authority, and continuous monitoring instruments shall be fitted wherever practicable.

(v)

Emissions in normal operation shall be free from visible smoke and in any case shall not exceed 250 mg/m3.

(vi)

Sand is prohibited for use as blasting media. Use of any abrasive blasting media containing more than 1% free silica shall not be used in abrasive blasting operations in PCFC.

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(vii)

All abrasive blasters operating in PCFC shall use a recyclable non-metallurgical abrasive material.

b.

Gaseous Emissions

Emission

Amines - total amine - trimethylamine Asphalt fumes

5 p.p.m v/v 1 p.p.m v/v 5 mg/m3

Limits

The waste gases from industrial processes are often a mixture of acid gases and whilst it is not practicable to measure each component separately, it is convenient to measure the total acidity and to express it as sulphur trioxide (see below table) as a basis for comparison.

1.4

SOURCE EMISSION CRITERIA - AIR POLLUTANTS SUBSTANCE Visible Emissions Carbon Monoxide Nitrogen Oxides

(Expressed as nitrogen dioxide)

Sulphur Dioxide

Sulphur Trioxide Including Sulphuric Acid Mist (Expressed as sulphur trioxide) Total Suspended Particles

SYMBOL

CO NOx

Material producing industries SO2

SO3 TSP

Ammonia and Ammonium Compounds (expressed as ammonia) Benzene Iron Lead and its compounds (expressed as lead) Antimony and its Compounds (Expressed as antimony) Arsenic and its Compounds (expressed as arsenic) Cadmium and its compounds (expressed as cadmium) Mercury and its compounds (expressed as mercury) Nickel and its compounds (expressed as nickel)

SOURCES Combustion sources Other sources All sources Combustion sources

NH3 C6H6 Fe Pb Sb

Other sources Combustion sources Material producing industries Other sources Material producing industries Other sources Combustion sources Cement Industries Other sources Material producing industries Other sources All sources Iron & Steel foundries All sources

EMISSION LIMITS (mg/Nm3) 250 none 500 Gas fuel-350 Liquid fuel-500 1500 200 500 2000 1000 150 50 250 50 150 50 10 5 100 5 5

As

Material producing industries Other sources All sources

Cd

All sources

1

Hg

All sources

0.5

Ni

All sources

1

1 1

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Copper and its compounds (expressed as copper) Hydrogen Sulphide Chloride

Cu

All sources

H2S Cl

Hydrogen Chloride

HCI

Hydrogen Fluoride Silicon Fluoride Fluoride and its Compounds Including HF & SiF4 (expressed fluoride) Formaldehyde

HF SiF4 F

All sources Chlorine Works Other sources Chlorine Works Other sources All sources All sources Aluminum smelters Other sources

5 200 10 200 20 2 10 20 50

Material producing industries Other sources Anode production Waste incineration All sources

20

Carbon Total Volatile Organic Compounds (expressed as total organic carbon -TOC) Dioxins and Furans

CH20 C VOC

All sources

5

2 250 50 20

1 ng TEQ/m3

Notes: 1. The concentration of any substance specified in the first column emitted from any source specified in the third column shall not at any point before admixture with air, smoke or other gases, exceed the limits specified in the fourth column. 2. “mg” means milligram; 3. “ng” means nanogram. 4. “Nm3” means normal cubic meter, being that amount of gas which when dry, occupies a cubic meter at a temperature of 25 degree Centigrade and at an absolute pressure of 760 millimeters of mercury (1 atm); 5. The limit of “Visible Emission” does not apply to emission of water vapour and a reasonable period for cold start up, shutdown or emergency operation. 6. The measurement for “Total Suspended Particles (TSP)’’ emitted from combustion sources should be @12% reference CO2. 7. The total concentration of the heavy metals (Pb, Cd, Ni, Hg, Cu, As & Sb) must not exceed 5 mg/Nm3. 8. VOC limit is for unburned hydrocarbons (uncontrolled). 9. The emission limits for all the substances exclude “Dioxins and Furans” conducted as a daily average value. 10. TEQ means “Total Equivalent Quantity.” Dioxins and Furans”. Average values shall be measured over a sample period of a minimum of 6 hours and a maximum of 8 hours. The emission limit value refers to the total concentration of dioxins and furans calculated using the concept of toxic equivalence (Refer to PCFC-ER, 3rd Edition for more details).

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

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ENVIRONMENTAL GUIDELINE No.2 LARGE BOILERS AND FURNACES

2.1 (i)

A.

GENERAL GUIDELINES These notes apply to works in which solid, liquid or gaseous fuel is burned, having a heat input equal to or greater than 30 megawatts (100 million BTU/h). A guide for boiler installation (available from EHS Dept. separately) should be used as a reference.

Sampling, Measurement Of Emissions And Monitoring

(i)

Emissions of sulphur dioxide, nitrogen oxides and particulate matter, including smoke, from each boiler or furnace shall be monitored continuously and shall be displayed on a meter visible to operating staff. Sampling ports and ladder/flanges facilities to be made available for monitoring.

(ii)

The accepted form of particulate emission monitoring is by optical density measurements for the fine particles and by a gravimetric method for coarse particles.

(iii)

Zero and calibration checks on monitoring instruments shall be carried out by the company. The reference test method for particulates is by the procedure of British Standard 3405:1983.

(iv)

All limit values in these notes are expressed as being at the reference conditions of 30oC and 1 bar and a standard of 12 percent CO2 in the waste combustion gases.

B.

Emission Limits And Controls

(i)

For oil-fired plant, sulphur dioxide removal equipment shall be installed with a removal efficiency of not less than 99.9 per cent.

(ii)

The design of the combustion system on oil-fired plant shall aim to limit the emission of nitric oxides to the air to a concentration not exceeding 500 mg/m3 in normal operation for oil-fired.

(iii)

The concentration of particulate matter in emissions to air shall not exceed 500mg/m3 as a 2-hour average.

(iv)

Emissions in normal operation, shall be free from visible smoke and in any case shall not exceed 250 mg/ m3.

(v)

For non-combustion plant, the concentration of particulate matter in emissions to air from the handling, crushing or screening of solid materials used in or produced by the combustion process shall not exceed 250 g/m3.

C.

Operational Controls

(i)

Means for preventing the emission of acid soot from oil-firing shall be operated continuously and the temperature of the gases in the chimney shall normally be maintained at not less than 150oC.

(ii)

Chimneys, flues and the duct work leading to the chimney shall be insulated to prevent liquid condensation on internal surfaces.

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D.

Chimneys

(i)

Chimney heights shall be assessed on the basis of estimated ground-level concentrations of the residual gases and taking account of local circumstances and recognized air quality standards or criteria.

(ii)

The efflux velocity of the emitted hot, dry gases shall not be less than 15 m/s at maximum continuous rating for boilers or furnaces from 30 to 700 MW thermal rating, and not less than 18/m/s for combustion plant rated above 700 MW.

(iii)

For non-combustion processes, chimneys shall normally be designed for an efflux velocity of not less than 15 m/s, but where a wet method of arrestment has been used, the velocity in the chimney shall not exceed 9 m/s to avoid droplet entrainment from the chimney surface.

2.2

TECHNICAL GUIDELINES FOR STEAM BOILER INSTALLATION Prior to any steam boiler installation in the Free Zone, the following Health, Safety and Environment Guidelines are to be fulfilled:

(i) (ii) (iii)

(iv)

Details of the steam boiler including capacity, fuel type (with sulphur content < 1%), fuel rate, fuel sulphur content etc. have to be provided. Boiler room height and any adjacent building height to be provided. Boiler chimney height calculation will be provided by PCFC to the client. The fuel tank should be bunded with impervious bund wall including the bund floor. The same should be designed to confine fuel of 110% fuel tank capacity and the underground bund area to be lined with proper PVC lining. Details of the bund wall volume calculation and design should be provided. Proper drainage facility should be provided for the boiler condensate and blow down to PCFC satisfaction, away from the domestic drainage of the facility. A detailed drawing in this regard should be provided. a. b.

Conditions mentioned under the title ‘Large Boilers and Furnaces’ should be fulfilled and acknowledged. Proper sampling point to be provided on the chimney for emission quality checks.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

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ENVIRONMENTAL GUIDELINE No.3 CHEMICAL FERTILIZER WORKS

1

INTRODUCTION These notes apply to processes for the manufacture of superphosphate, phosphoric acid, ammonium nitrate and ammonium phosphate, the granulation of compound fertilizer and the production of complete fertilizer mixtures by melt granulation or prilling.

2

SAMPLING, MEASUREMENT OF EMISSIONS AND MONITORING The tests normally carried out are for total acidity and hydrogen chloride, ammonia, hydrogen sulphide, fluoride and particulates, depending on what is being processed at the time of sampling.

3

EMISSION LIMITS AND CONTROLS

A

Phosphate Rock Processing i.

All emissions to the air shall be substantially free from persistent mist or fume, and free from droplets.

ii.

The concentration of particulate matter in emissions to the air from phosphate rock grinding shall not exceed 250 mg/m3

B

C

D

Superphosphate and Phosphoric Acid Plant i.

The total acidity of all process gases emitted to the air shall not exceed 150 mg/m3, expressed as sulphur trioxide.

ii.

The hydrogen sulphide concentration in all process gases shall not exceed 5 p.p.m v/v.

iii.

Waste or recovered acids likely to cause the emission of odorous substances shall not be used without prior evaluation and agreement of the Authority. Granulation and Prilling Plant

i.

The concentration of particulate matter shall not exceed 150 mg/m3.

ii.

The concentration of hydrogen chloride shall not exceed 200 mg/m3.

iii.

The concentration of ammonia (free) shall not exceed 50 mg/m3 to meet 2 ppm ambient criterion

iv.

The concentration of fluorides (as HF) shall not exceed 2 mg/m3.

v.

VOCs should be removed/incinerated 99.9% to ensure maximum emission of 20 mg/ m3.

Ammonium Nitrate i.

The concentration of free ammonia from prilling plants shall not exceed 10 p.p.m v/v.

ii.

The concentration of free ammonia from neutralisers and evaporator shall not exceed 50 p.p.m. v/v.

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E

F

G

H

iii.

The concentration of particulate matter from evaporators, prilling towers and melt granulation plants shall not exceed 150 mg/m3.

iv.

The concentration of particulate matter from coolers and dryers, and from other contained emissions shall not exceed 150 mg/m3.

Ammonium Phosphate i.

The concentration of free ammonia shall not exceed 10 p.p.m v/v.

ii.

The concentration of fluoride shall not exceed 20 mg/m3 expressed as hydrogen fluoride.

iii.

The concentration of particulate matter from all contained sources shall not exceed 150 mg/m3.

Operational Controls i.

Emissions from rock grinding, evolution of acid gases from dissolving plant and emissions from granule preparation vessels, dryers and coolers, shall be contained and ducted to a suitable treatment plant acceptable to the Authority to meet the limit values above.

ii.

Inlet and outlet gas temperatures on granulation plants shall be continuously monitored to prevent decomposition of the materials. Where ammonium nitrate is used, provision shall be made for quenching any exothermic decomposition occurring in the dryer. Measures shall also be taken to prevent the possibility of unburnt fuel entering the dryer.

iii.

It is preferable that ammonium nitrate neutralisers should be fully enclosed with no direct vent to air, but if this is not practicable then suitable treatment equipment shall be installed to meet the limit values in above paragraphs. Total condensation evaporators are preferred to emission treatment plant.

Material Handling and Storage i.

Stocks of dusty material shall be stored under cover to prevent wind-whipping. Loading to and from stockpiles shall be carried out so as to minimize airborne dust.

ii.

Storage silos for dusty material shall be vented to air through suitable equipment to prevent dust emissions.

iii.

All handling, transport and processing of dusty materials shall be carried out in a manner which gives rise to no significant visible emission.

iv.

The storage and handling of liquids shall be carried out in such a manner as to prevent the emission of noxious or offensive substances to the satisfaction of the Authority.

Chimneys i.

The minimum height for process gases shall be 37m. Discharge heights for other emissions shall be agreed with the Authority and shall not be less than 3m. above roof ridge level of nearest tallest building. Emissions should take place from the minimum number of chimneys and it is good practice to combine clean, warm, dry emission with wet emissions where practicable.

ii.

To reduce the risk of mist formation, emissions containing ammonia should not be mixed with other emissions, and outlets should be spaced as far as practicable from outlets discharging acidic gases.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

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ENVIRONMENTAL GUIDELINE No.4 AMMONIA WORKS

1

INTRODUCTION These notes apply to all new ammonia production plants and works in which ammonia is stored and handled in anhydrous form in fixed tanks with an aggregate capacity exceeding 100 tons.

2

EMISSION LIMITS AND CONTROLS

(i)

A single emission limit for ammonia is not readily applicable to this class of works. Design criteria for the discharge from individual plant exits shall be discussed with the Authority and where practicable should aim for a concentration of free ammonia (point source limit 50 mg/m3) shall be so that ambient criterion of 2 ppm (fenceline) is met at all times.

(ii)

All emissions shall be free from droplets and persistent mist.

(iii)

The emission of combustion products from reformer or other furnaces shall be maintained free from visible smoke or fumes during normal operation.

3

OPERATIONAL CONTROLS

(i)

Reformer production gas (‘make gas’) during start-up or shut-down procedures shall be vented to a suitable flare, or when not combustible, discharged at an agreed height.

(ii)

Carbon dioxide discharged to atmosphere from CO2 absorber - stripper units shall at all times pass through an efficient droplet and spray eliminator system. This shall apply also to emergency venting systems, and extra care shall be taken when absorbents of high toxicity are used.

(iii)

All gas purged from the synthesis loop during normal operation shall be burned in a suitable furnace or flare.

(iv)

Gaseous ammonia from pressure relief systems shall when practicable be vented to a flare or discharged at an agreed height.

(v)

Storage facilities for ammonia liquor shall be vented to a suitable absorber.

(vi)

Means shall be provided for minimizing escapes of ammonia from loading or unloading facilities.

(vii)

Storage for light liquid hydrocarbon feedstocks shall be fitted either with double-sealed floating roofs, or with a vapour recovery system, or equivalent means for minimizing vapour loss.

4

CHIMNEYS

(i)

Chimney heights (min.37m) for ammonia works shall be agreed with the Authority on the basis of the expected maximum rate of emission of ammonia or any other significant pollutant, taking into account emergency situations.

(ii)

To reduce the possibility of mist formation, chimneys for emissions containing ammonia should be spaced as far as practicable from chimneys discharging acid gases.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

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ENVIRONMEMNTAL GUIDELINE No.5 SULPHURIC ACID WORKS

1

INTRODUCTION These notes apply to the manufacture of sulphuric acid by the double-contact process and to the production of sulphur trioxide for use in chemical processes.

2

SAMPLING, MEASUREMENT OF EMISSION AND MONITORING

(i)

As part of proper supervision, the owner shall make tests and inspections of the process. Tests shall normally be taken not less than once per day from each exit and adequate facilities shall be provided on chimneys and ducts.

(ii)

Continuous monitors for emission of sulphur dioxide shall be installed, with sufficient range to cover start-up conditions.

(iii)

The Reich test or an agreed alternative shall be used to determine the sulphur dioxide (SO2) content of the strong gas fed to the first catalytic converter. Allowance shall be made for the use of quench or additional air.

3

EMISSION LIMITS AND CONTROLS

(i)

During normal operation the proportion of sulphur dioxide emitted to air shall not exceed 2000 mg/m3. SO3, including Sulphuric Acid mist, shall not exceed 150 mg/m3.

(ii)

The waste gases shall be substantially free from persistent mist.

4

OPERATIONAL CONTROLS

(i)

An efficient mist eliminator shall be provided after the final absorber.

(ii)

Means for rapid warning of absorber acid feed failure shall be installed.

(iii)

Means for indicating the sulphur feed rate and the air flow rate to the sulphur burner shall be installed.

(iv)

Means for the early detection of leaks on acid coolers shall be provided.

(v)

When sulphuric acid is being transferred or loaded into tanks, non-splash techniques and bottom loading shall be practised.

(vi)

Adequate preheating facilities shall be provided to enable at least two catalyst stages to “strike” as soon as sulphur dioxide is fed to the system.

(vii)

Absorber acid strength and temperature shall be adjusted to optimum before the start-up.

(viii)

By careful preparation and control, the duration of abnormal emissions on start-up shall be minimized.

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5

MATERIALS HANDLING AND STORAGE

(i)

The receipt, handling and storage of powdered raw materials shall be carried out in such a manner as to minimise the emission of dust to the point where there is no significant visible emission. Covered storage shall be provided.

(ii)

Gaseous sulphur trioxide shall be kept in a closed system and escapes to air shall be prevented.

(iii)

If oleum is produced, storage and tanker-loading facilities shall be fitted with means to prevent the emission of fumes.

6

CHIMNEYS

(i)

Chimneys are an insurance policy against plant breakdown and are determined on the basis of the expected maximum rate of sulphur dioxide emission.

(ii)

The minimum height for a sulphuric acid plant shall be as follows:

(iii) (iv)

Plant Rated Capacity

Height

Up to 400 tonnes/day 600 “ 800 “ 1000 “

60 meters 75 “ 85 “ 95 “

The height may need to be increased to allow for special local circumstances. The linear velocity of waste gases in the chimney shall not exceed 9m/s.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

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ENVIRONMENTAL GUIDELINE No.6 LEAD WORKS 1

INTRODUCTION These notes apply to: a.

works in which compounds of lead are produced by the application of heat: i. ii. iii

b.

lead is extracted or recovered from any material containing lead or its compounds; or lead is refined; or lead is applied as a surface coating to other metals by spraying; or

works in which compounds of lead are manufactured, extracted, recovered or used in processes which give rise to dust or fume.

2

SAMPLING AND MEASUREMENT OF EMISSIONS AND MONITORING

(i)

As part of proper supervision, the owner shall make inspections of the process and tests of the chimney emissions at least once per week for each exit. Where effective continuous monitors are fitted, less frequent manual tests shall be carried out, with the agreement of the Authority, to check the performance of the monitors. The results of all tests shall be recorded for examination by the Authority.

(ii)

Fugitive emissions shall be assessed visibly by the company’s control staff on a daily basis.

3

EMISSION LIMITS AND CONTROLS

(i)

The permitted limit for the mass rate of emission of lead is based on the aggregate volume of emission from all lead processes on the site, including emissions from secondary collection systems.

(ii)

Each emission to air shall not exceed 5 mg/m3 of lead.

(iii)

Where lead-containing fumes or dusts are collected by secondary extraction, installed to prevent fumes entering the working atmosphere, they shall be passed through filters before discharging to air and the concentration of lead in each emission shall not exceed 5 mg/m3.

(iv)

The concentration of total particulates in emissions to air shall not exceed 150 mg/m3.

4

MATERIALS HANDLING AND STORAGE

(i)

Dusty materials shall be delivered to the works in a manner which prevents their escaping into the external environment, e.g. wetted, in closed containers, or sheeted wagons. The same applies to the transport of dusty materials within the works.

(ii)

a. Dusty materials shall be stored and handled under cover where practicable, preferably wetted. For outside storage of dusty materials, enclosed bays shall be provided with walls sufficiently high to prevent wind whipping, and water sprays shall be installed where applicable. b. Where materials contain compounds which could emit noxious or offensive substances (such as arsine or stibine) when in contact with water, they shall be stored under dry conditions in clearly marked bays or containers.

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(iii)

The handling and transfer of collected fine dusts from dry arrestment plant shall be carried out by methods which do not give rise to dust emission. a.

Preferred practices include: i) ii) iii) iv)

b. (iv)

recycling within the process by means of a directly connected closed handling system. conversion into a non-dusty form by feeding into a continuous fusion furnace. discharging directly from the arrestment plant into bags or drums in an enclosed filling booth extracted to a filter. direct filling into containers which can be charged unopened into furnaces.

Another option is the wet pelletising of dust, but this requires careful control to produce a stable pellet which will not break down again.

The transfer of dusty materials to storage and the recovery of materials from storage shall be carried out by methods which minimize dust emissions. Preferred practices for materials reclamation and transport within the works include: a.

transport of materials from stockpiles to process by fully enclosed mechanical conveying systems, with enclosed transfer points, and not by vehicles.

b.

chutes or conveyors discharging onto stockpiles shall be equipped with fixed water sprays.

c.

conveyor discharge points shall be arranged to minimize the height of fall onto the stockpile or hopper.

d.

for reclamation from stockpiles, an overhead grab crane is preferred to front end loaders.

e.

all conveyors external to buildings shall be enclosed.

(v)

Storage silos for fine materials shall be enclosed and vented to air through filters.

5

OPERATIONAL CONTROLS All sources of lead fume and dust emissions from the process, such as charging points, slag and metal pouring points, shall be closely hooded and adequately draughted to filters. Preferred practices include: a. the provision of lock chambers, where furnaces are top charged. b. the use of covered launders and ladles for slag and metal tapping, together with close hooding of the tapping points. c. the hooding of facilities for removing hot drosses from refining or melting furnaces, extended to include the dross receptacles. d. effective local extraction, or almost complete enclosure, of rotary furnaces to contain combustion gases and fume escape from charging and tapping operations.

6

GENERAL OPERATIONS

(i)

The highest standards of housekeeping shall be achieved throughout the works.

(ii)

Roadways and other areas where there is regular movement of vehicles shall be hard-surfaced and kept clean, preferably by a machine which combines sweeping, vacuum suction and wetting.

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(iii)

Measures shall be taken to control dust arising from works traffic, preferably as follows: a. preclude the access of private vehicles to the works area. b. restrict works operating vehicles to designated functions and do not allow such vehicles onto public roads. c.

use one-way systems for delivery or collection vehicles entering or leaving works.

d. a single exit route for vehicles to the site. (iv)

Adequate vehicle washing facilities shall be provided and used to prevent transport of dust outside the works. Particular attention shall be given to the cleaning of vehicle wheels.

7

CHIMNEYS

(i)

Chimney heights for lead works shall be determined by the Authority after discussions with works management. As a first assessment the formula He = 2 x M1/2 shall be used, where He is the effective chimney height in meters, and M is the total site lead emission in g/hr calculated at the emission limits specified in above paragraphs. The chimney heights so obtained may need to be adjusted to allow for thermal buoyancy and local circumstances such as topography, nearby buildings and other nearby emissions.

(ii)

The minimum chimney height for lead works shall normally be 30m, but in the case of small scale processes, or works with dual arrestment systems the minimum chimney height shall be 3m above the ridge of the attached or adjacent building.

(iii)

In order to obtain maximum advantage from thermal buoyancy, it is recommended that hot emissions take place from the practicable minimum number of chimneys.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#6

Page 3 of 3

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.7 MINERAL WORKS

1

INTRODUCTION

(i)

These notes apply to works in which min erals, metallurgical slags, or pulverised fuel ash are subjected to any size reduction, grading or heating by processes giving rise to dust or fume, including the subsequent handling of the products of such process. The crushing, screening, drying and coating of materials for use as roadstone, etc. fall within this definition, whether fixed or mobile.

(ii)

The concentration of particulates in emissions to air shall not exceed 150 mg/m3.

(iii)

Emissions shall be maintained free from visible smoke during the normal operations and substantially free from persistent mist or fume (excluding steam).

(iv)

The emissions from any chimney or final outlet shall be free from droplets.

(v)

Fugitive emissions shall be substantially free from visible emissions of dust.

2

GENERAL OPERATIONS

A

Arrestment Plant High efficiency scrubbing or bag filters, or their equivalent, are appropriate methods of arrestment capable of meeting the emissions limits.

B

Materials processing, handling and storage. In general and where practicable a policy of dust containment is preferred. In some cases suppression techniques, where properly designed, used and maintained, can be an effective alternative and may be the preferred method for some operations.

C

Crushers Crushing plant shall be fitted, where necessary, with an efficient means for the control of dust emission, including the tipping of raw materials into the hopper and the separation of oversize. It may be necessary to require such dusty operations to be carried out in an enclosed structure ventilated to a filter, or to have an equally effective alternative system.

D

E

Conveyors i.

All exposed belt-type conveyors carrying dusty materials shall be enclosed to such an extent as to prevent the generation of airborne dust, e.g.wind-whipping.

ii.

Transfer points shall be enclosed and fitted with flexible seals on inlet and exit. Where dry materials are being handled, transfer points shall be ducted to arrestment plant.

iii.

Conveyors shall be fitted with an effective means of cleaning the returning belt.

Surge piles and storage i.

PCFC-EG#7

Open surge piles following primary and secondary crushing and screening shall be kept to a minimum and the height of free fall of stone similarly minimized, incorporating dust suppression treatment.

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Revised:23/04/03

F

3

ii.

Loading to and from stockpile shall be carried out by methods which minimize dust emission and the stockpile should be wetted before being disturbed.

iii.

Storage silos for fine materials shall be enclosed and vented to air through filters.

Transport/loading i.

Tankers carrying dusty non-waste material shall discharge only into vessels fitted with an effective dust collecting system.

ii.

Road transport of dusty materials shall be carried out in closed tankers or sheeted vehicles.

iii.

Loading of road vehicles or ships shall be carried out in a manner to minimize airborne dust.

iv.

Waste dust shall be transported, disposed of or stored in a manner which prevents the emission of dust.

CHIMNEYS Chimney heights for roadstone plants shall be determined by the Authority after consideration of all the relevant information on throughput, type of material, type and rate of fuel usage, etc.

4

GENERAL A high standard of housekeeping shall be maintained and all roadways and working areas in regular use shall be hard surfaced and kept clean.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#7

Page 2 of 2

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.8 IRON AND STEEL WORKS - FOUNDRIES 1

INTRODUCTION These notes apply to works where iron or steel are melted, refined and cast, and they cover the associated processes. Melting is usually carried out in cupolas, electric arc furnaces, induction furnaces, and similar small furnaces.

2

SAMPLING, MEASUREMENT OF EMISSIONS AND MONITORING

(i)

As part of proper supervision, the owner shall make tests and inspections of the process. The frequency of testing shall normally be not less than once per year, but more frequent tests may be necessary in special circumstances. The results of all tests and inspections shall be recorded and made available to the Authority’s representatives.

(ii)

Visual inspections shall be made of fugitive emissions which cannot be measured.

3

EMISSION LIMITS AND CONTROLS

A

Cupola Furnaces During normal operation and blow-down all the cupola gases shall be contained and burnt before discharge to air through a suitable dust arrestor. The final discharge to air shall be virtually invisible as judged by the naked eye and shall contain not more than 150 mg/m3 of total particulate matter.

B

C

Electric Arc Furnaces i.

Primary collection and arrestment are required on all new furnaces and the final emission to air shall contain not more than 150 mg/m3 of particulate matter.

ii.

For large furnaces over 20 tonnes capacity, secondary collection shall be used to remove all fume from tapping, refining, charging, etc. and the emission from the arrestment plant shall contain not more than 150 mg/m3 of particulate matter.

iii.

Where associated processes give rise to particulate emissions, collection and arrestment are normally required and the concentration of particulate emissions to atmosphere shall not exceed 150 mg/m3.

iv.

The emission from any chimney or other final outlet shall be free from liquid droplets.

Induction Furnaces i.

Induction Furnaces normally melt relatively clean scrap and discharge waste gases into the factory atmosphere and thence to air through roof ventilators. The final discharge shall not exceed 150 mg/ m3.

ii.

When dirty and greasy scrap is being melted, it shall either be pre-cleaned, or the furnace shall be hooded and the waste gases must pass through suitable treatment plant to give an emission which is virtually invisible as judged with the naked eye.

PCFC-EG#8

D

General

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Revised:23/04/03

i.

Scrap metal usually contains small quantities of non-ferrous metals such as lead and zinc and where this is so the limits for emissions of the non-ferrous metals industries apply, e.g. lead to be less than 0.005 g/m3 and Iron 0.1g/m3. Total heavy metals concentration not to exceed 5 mg/ m3.

ii.

There are many processes associated with foundry work which give rise to particulate emissions and these shall be treated suitably to render them harmless and inoffensive. Where shot blasting is carried out the process shall be extracted to a filter to give an invisible emission.

iii.

Fugitive dust emissions shall have no significant visible emission as judged by the naked eye.

4

OPERATIONAL CONTROLS

(i)

In general, finely divided materials associated with or arising from the process, shall be controlled in such a manner as to minimize emissions to atmosphere.

(ii)

Stocks of fine materials (e.g. fluxes, additives, etc) shall normally be delivered and stored under cover to prevent wind-whipping. Loading to and from stock shall be carried out so as to minimize airborne dust.

(iii)

Storage silos for fine materials shall be enclosed and vented to air through a filter.

(iv)

Slag shall be handled and disposed of in a manner which minimizes dust generation.

5

CHIMNEYS

(i)

Waste cupola gases shall be vented to air from chimney heights based on the table below, but shall be not less than 6 metres above the cupola structure or adjacent buildings. Cupola Capacity, TPH 7 or below 10 15 20 25

(ii)

Chimney Height, m. 21 23 26 28 30

The heights of chimneys for emissions shall be decided by the Authority after discussions with works managements, taking into account local circumstances and nearby buildings. The minimum height shall not be less than 3m above any tallest building to which it is attached or adjacent.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#8

Page 2 of 2

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.9 SECONDARY ALUMINIUM WORKS

1

INTRODUCTION

(i)

These notes apply to works in which: a. b. c. d.

Aluminum swarf is degreased by the application of heat; or Aluminum or aluminum alloys are recovered from aluminum or aluminum scrap fabricated metal, swarf, skimmings, drosses or other residues by melting; or aluminum is recovered from slag; or molten aluminum or aluminum alloys are treated by any process involving the evolution of chlorine or its compounds;

The materials used in above processes or the products are treated or handled by methods which cause noxious or offensive substances to be evolved. (ii)

The notes are intended to provide a basis for consultation between works management and the Authority with flexibility to meet special needs and circumstances.

2

SAMPLING AND MEASUREMENT OF EMISSIONS

(i)

As part of proper supervision, the owner shall make tests and inspections of the process. The results of tests and inspections shall be recorded and made available for examination by the Authority representatives. The frequency of testing shall be determined by the Authority after discussions with the works management.

(ii)

Tests shall be carried out periodically for emissions of chlorine and hydrogen chloride, where applicable.

3

EMISSION LIMITS AND CONTROLS

(i)

The concentration of particulate matter in emissions to air from furnaces using salt as a flux shall not exceed 150 mg/m3. Emissions shall also be substantially free from persistent mist or fume.

(ii)

The concentration of particulates in emissions to air from swarf degreasing furnaces shall not exceed 150 mg/m3.

(iii)

The concentration of particulates in emissions to air from operations in which dross is treated mechanically for the recovery of metal residues shall not exceed 150 mg/m3. HF/Si F4 not to exceed 20 mg/m3.

(iv)

Concentration of chlorine in emissions to air shall be as low as practicable, and in no case shall exceed 10 mg/m3.

(v)

Concentrations of hydrogen chloride in emissions to air shall be as low as practicable, and in no case shall exceed 20 mg/m3.

(vi)

During normal operation, including charging, emissions shall be maintained substantially free from visible smoke and in any case not more than 150 mg/ m3.

(vii)

Where a wet method of gas cleaning is used, the emission from any chimney or final outlet shall be free from liquid droplets.

PCFC-EG#9

Page 1 of 2

Revised:23/04/03

4

OPERATIONAL CONTROLS

A

Treatment of Oily swarf and contaminated scrap

B

i.

Aluminum swarf contaminated with oil-based materials shall not normally be fed to a processing furnace, but shall be treated substantially to remove the oil so as to meet the smoke limit in above paragraph. Alternatively, additional equipment, such as an afterburner, may be installed, effectively to consume smoke emissions from the charging of contaminated swarf.

ii.

Charging of contaminated scrap, other than swarf, to furnaces shall be controlled so as to minimize emissions to air.

Arrestment plant Because of the corrosive nature of the emissions from most secondary aluminum operations, particular emphasis shall be paid to the selection of suitable materials of construction for ducting, arrestment plant and chimneys.

C

Use of chlorine The storage, handling and use of chlorine shall be carried out with particular care to prevent emissions to atmosphere, preferably to the supplier’s recommendations, and to the satisfaction of the Authority. Safer alternates are recommended for use.

D

Use of fluoride fluxes Procedures for the use of fluoride-containing fluxes shall be agreed with the Authority and additional monitoring may be needed to ensure control of gaseous and particulate fluoride emissions. Each case will be judged on its merits.

E

Dross handling and recovery i.

Drosses from the processing furnaces shall be handled and stored in such a manner as to prevent particulate emissions to atmosphere. Drosses shall be cooled in covered containers or tipped for cooling purposes in an enclosed building, with adequate extraction to arrestment plant if necessary in the opinion of the Authority.

ii.

Dross recovery operations shall be fully enclosed and extracted to suitable arrestment plant, and the remaining dross residues shall be discharged in a manner which produces no significant visible dust.

iii.

Where drosses and other materials contain compounds which emit noxious or offensive gases on the application of heat or contact with water, e.g. arsine or stibine, they shall be stored under dry conditions in clearly marked bays or containers. Procedures for processing such materials shall be agreed with the Authority.

5

CHIMNEYS

(i)

Chimney heights for secondary aluminium plants shall be determined by the Authority after discussions with works management.

(ii)

The minimum chimney height for any rotary furnace using salt flux shall normally be 37m and for other furnaces shall be 3m above the roof ridge of the building to which it is attached or close by tallest building. The height may need to be increased to allow for local circumstances such as topography, nearby buildings and existing emissions.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai. PCFC-EG#9

Page 2 of 2

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.10 CHEMICAL INCINERATION WORKS

1

INTRODUCTION

(i)

These notes apply to: Works for the destruction by burning of: a. Waste produced from chemical manufacturing processes; or b.

Chemical wastes containing combined bromine, cadmium, chlorine, fluorine, iodine, lead, mercury, nitrogen, phosphorus, sulphur or zinc; or

c.

Waste produced in the manufacture of plastics.

(ii)

In the context of these notes “works” includes the storage and handling of such wastes at the incineration works prior to incineration, and to the handling of any residues or ashes by methods whereby any noxious or offensive substance may be evolved. Incineration, however, is not considered as safe disposal means of waste gases.

2

SAMPLING AND MEASUREMENT OF EMISSIONS On incinerators burning a wide variety of wastes, a continuous monitoring and recording instrument shall be installed on the chimney to measure the emission of particulate matter by optical methods.

3

EMISSION LIMITS

(i)

All limit values for emission concentrations are expressed as being at the reference conditions of 30oC and a pressure of 1 bar, without correction for water vapour content.

(ii)

Emissions shall be maintained free from visible smoke or carbon and in any case not 50 mg/m3, during normal operation.

(iii)

Emissions shall be substantially free from persistent mist or fume, as judged by the naked eye.

(iv)

Emissions shall be free from droplet fallout.

(v)

The concentration of black carbon or particulate matter in emissions to air shall not exceed 50 mg/m3.

(vi)

With the exception of Iron, Potassium, Sodium and Calcium, the concentration of any individual metal, or metal compound calculated as metal, shall not exceed 5 mg/m3. The term ‘metal’ shall be taken to include such elements as Arsenic, Antimony, Selenium, etc. which are also called semimetals or metalloids. The following limits will also apply: Phosphorus compounds, calculated as P Total acidity, calculated as sulphur trioxide Hydrogen chloride Hydrogen fluoride

PCFC-EG#10

Page 1 of 5

5 mg/m3 150 mg/m3 20 mg/m3 2 mg/m3

Revised:23/04/03

(vii)

In addition to the above limits it may be necessary to set limits on other emissions, depending on what is being incinerated. Each case will be considered on its merits. In order to meet the strict emission limits, it may be necessary to restrict the rate of incineration of certain feedstocks.

4

OPERATIONAL CONTROLS There is a wide variety of types and sizes of incinerators and an equally diverse chemical and physical nature of wastes handled, so it is not possible to lay down requirements which are universally applicable. Each case will be considered on its merits, taking into account the general principles in the following paragraphs.

A

Receipt and handling of materials i.

Materials for incineration should normally be tested to determine the appropriate method of storing and means of transfer to the incinerator, and required operating conditions for the incinerator and flue gas treatment plant.

ii.

Where materials differing widely in composition are received there should be a comprehensive and well documented system for testing or analysing and for controlling movement of the material through storage and transfer to the incinerator to ensure that it is processed in the correct manner.

iii.

All materials for incineration should be handled and stored in suitable equipment and in such a manner as to minimize atmospheric emissions and odours by such practices as closed circuit connections for vapour displacements from liquid transfers, the use of self sealing hose couplings, venting of tanks to vapour control systems, and minimum opening of containers. Account should be taken of any reactions which may take place on mixing of wastes or during storage. Special facilities will be required for handling strongly smelling substances such as mercaptans, amines and acrylates.

iv.

There should be appropriate facilities for transferring waste to the incinerator with the minimum emissions of vapour or odour and for controlling the rate of transfer. The requirement shall be considered in relation to the feed systems(s) of the particular incinerator and may include: a. b. c. d.

B

Pipeline systems for bulk liquids or sludges; Drum handling facilities for liquids, sludges or solids; Systems for handling packaged solids; Conveyor or screw feed systems for solids or sludges.

v.

Suitable facilities shall be provided to contain and deal with any spillage of materials destined for incineration, arising from operations on the site.

vi.

All containers which have been emptied should be disposed of by methods which minimize emissions to atmosphere.

Design and operation of the incinerator i.

The class of materials to be incinerated, operating conditions of the incinerator and maximum rate of incineration should be agreed between the works management and the Authority.

ii.

When wastes containing polychlorinated biphenyls (PCBs) are to be incinerated a trial burn must be carried out to demonstrate that the equipment is capable of achieving a Destruction Efficiency Removal (DRE) of not less than 99.9999%.

iii.

Where solids are to be incinerated the feed system and primary combustion chambers must be so designed and operated that charging does not cause an unacceptable rise in chamber pressure, drop in temperature, or oxygen starvation except where starved air incineration is designed for and therefore subject to above paragraph and adequate instrumentation must be installed to ensure this requirement is met.

PCFC-EG#10

Page 2 of 5

Revised:23/04/03

C

iv.

All liquids and sludges being handled in pumped systems should be injected into the combustion chambers through burner assemblies that are designed to achieve complete combustion.

v.

Incinerators will normally be equipped with a separate afterburner/secondary chamber facility. An afterburner must be provided in all cases where starved air combustion in the primary chamber is practiced. Systems where complete combustion can be achieved at all times in the primary chamber with effective control of temperature, residence time and excess oxygen may be allowed to operate without a separate afterburning facility.

vi.

The minimum residence time for any chemical incineration process shall be 0.5 seconds.

vii.

The afterburner chamber shall be designed to produce a high level of turbulence with a minimum of 3% excess oxygen over that required for complete combustion. Afterburners on incinerators used for the destruction of wastes which could contain chlorinated organic compounds, including phenols, dioxins or related chemical compounds, shall be operated at not less than 1100oC with a residence time of 2 seconds. If the primary combustion chamber outlet is also maintained at a minimum of 1100oC with not less than 3% oxygen content then the 2 second residence time may refer to the whole system. Less stringent afterburning conditions may be agreed for specific limited ranges of waste material but after burner temperatures of less than 800oC will not normally be permitted.

viii.

The suitability of an incinerator for a particular waste and the maximum rate of incineration will depend on such factors as the chemical and physical nature of the waste, achievable temperatures in the combustion chambers, performance of afterburners and flue gas cleaning plant, the chemical nature of gaseous or particulate matter in the flue gas and the height of the chimney.

ix.

Where liquid wastes are to be burnt suitable facilities for sampling the liquid(s) in the feed tank, and in the feed line to the burners will be required.

x.

Where no scrubber is fitted wastes containing more than 0.1% by weight of halogen should not be burned. Alternatively wastes containing more than 0.1% by weight of chlorine may be incinerated providing that the concentration of hydrogen chloride in the undiluted combustion gases shall not exceed the limit value of paragraph 9 and that the hydrochloric acid gas concentration be continuously monitored.

xi.

There shall be an adequate supply of clean support fuel for lighting the incinerator, for bringing the combustion chamber and afterburner up to the required temperatures, and for maintaining these conditions during operation. Clean liquid support fuel shall only be stored in dedicated tanks and its specification agreed.

xii.

The incinerator and associated control systems shall be designed so that the plant can be shut down safely, without any significant increase in emission, in the event of a failure of the electricity supply. Requirements may include the provision of stand-by power supplies to enable the plant to continue operating or be shut down safely.

xiii.

Removal from the incinerator of ash, burned-out drums or containers should be effected in a manner which minimises the emission of smoke, dust or odour. Where facilities for quenching ash or burned-out containers need to be provided the operation should be ventilated to an appropriate point on the incinerator. Removal of ash or drums shall only be effected when incineration is complete.

Flue gas treatment i.

The design and method of operation of any flue gas treatment equipment will be specified and agreed according to the type and quantity of materials to be incinerated. Incinerators handling a wide range of chemical wastes will normally require flue gas treatment systems to deal with both gaseous and particulate matter.

PCFC-EG#10

Page 3 of 5

Revised:23/04/03

D

5

ii.

Where wet arrestment is used the plant shall be designed and operated to achieve a substantially invisible plume for not less than 95% of operating hours.

iii.

Where wet scrubbing plant is to be used the liquid supply should be free from contaminants which could give rise to the emission of noxious or offensive substances. Liquid circulation should be monitored by suitable instruments, such as pH meters and flow meters, to give continuous indication of operating conditions, and interlocks between these and waste feed may be required. Incineration shall not commence until it has been ascertained that the absorption capacity of the liquid is sufficient adequately to scrub all the combustion gases expected to arise during the proposed period of incineration.

iv.

Where high energy wet scrubbers are used there shall be continuous recording of the differential pressure across the scrubbing section.

v.

Wet arrestment systems should be provided with effective droplet elimination to prevent carryover of liquid droplets into the exhaust gas stream.

vi.

Where dry collection systems are used, the particulate matter collected should be handled in a manner which prevents emission of dust.

Monitoring and automatic control systems i.

The primary combustion chamber and afterburner chamber shall be fitted with temperature recorders and alarms. Oxygen and carbon monoxide monitors shall also be fitted where practicable to indicate that satisfactory combustion conditions are being attained.

ii.

The control systems of the incinerators shall be fitted with interlocks to prevent the introduction of waste, when combustion conditions are such that adequate thermal destruction would not be achieved.

iii.

Instrumentation shall be fitted, where practicable, to measure and record the concentration of total dust in the exhaust gases. The use of data logging equipment will be considered.

iv.

When organochlorine compounds are being burned samples of the exhaust gases shall be taken continuously and analyzed to an agreed schedule for agreed “marker” compounds which demonstrate the effectiveness of destruction. At least quarterly samples shall be analyzed for the presence of dioxins and dibenzofurans.

CHIMNEYS

(i)

Chimney heights for chemical incineration works shall be determined by the Authority after discussions with the works management. The first assessment will be based on the maximum mass emission rate of the most significant pollutants, such as sulphur dioxide or others above in paragraphs calculated at the limiting values as appropriate.

(ii)

The chimney height so obtained may need to be increased to allow for local circumstances such as topography, nearby buildings and existing emissions.

(iii)

The minimum chimney height for any chemical incineration works shall normally be 40m, but this may be modified by the Authority depending on the scale of the operation and the type of material being burnt.

(iv)

Chimneys or vents shall normally be designed for an efflux velocity of not less than 15m/sec at full load operation. Caps or cowls will not be permitted. Care should be taken to avoid generating positive pressure zones within the chimney unless the wall is impervious or suitably lined.

(v)

All new chimneys shall be designed and insulated to minimize the cooling of waste gases and condensation on internal surfaces. This is particularly important for acidic gases.

PCFC-EG#10

Page 4 of 5

Revised:23/04/03

6

GENERAL OPERATIONS

(i)

All roads, storages and operating areas shall be hard surfaced with facilities for washing spillages and contamination into sumps for recovery or treatment to render them harmless and inoffensive.

(ii)

A high standard of housekeeping shall be maintained with particular attention being given to chemical waste storage areas. This shall include regular inspection of drums awaiting treatment, adequate facilities for dealing with suspect drums or containers, satisfactory means of decontamination of containers not being themselves incinerated, methods of preventing spillages entering the environment.

(iii)

There should be provision of suitable cleaning substances and/or inert adsorbents to deal with spillages.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#10

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Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.11 CEMENT WORKS

1

INTRODUCTION These notes apply to works in which: a. b. c.

cement clinker is produced; or cement clinker is handled and ground; or ground cement is packed, or loaded into vehicles in bulk.

The definition above includes the handling, storing and processing of raw materials used in cement works. 2

SAMPLING, MEASUREMENT OF EMISSIONS AND MONITORING

(i)

As part of proper supervision, the owner shall make tests and inspections of the process to ensure that the equipment is achieving the required results. The results of tests and inspections shall be recorded for examination by the Authority’s representatives.

(ii)

Emissions of particulate matter from kilns and clinker coolers, and any other outlet considered by the Authority to be significant, shall be continuously monitored, preferably by optical density measurement.

(iii)

Check tests shall be carried out at least once every six months on chimney emissions monitored continuously, to ensure that the calibration has not changed.

3

EMISSION LIMITS AND CONTROLS

(i)

The concentration of particulate matter in emissions to the air from kiln waste gases shall not exceed 50 mg/m3, in normal operation.

(ii)

The concentration of particulate matter in emissions to air from all other contained sources shall not exceed 50 mg/m3, in normal operation.

(iii)

The concentration of hydrogen sulphide in kiln exhaust gases shall normally be absent and in any case shall not exceed 5 ppm (v/v).

(iv)

The oxygen content of the kiln waste gases shall be controlled so as not to fall below 1.5% oxygen.

(v)

The kiln waste gases shall be maintained free from visible smoke and in any case not more than 50 mg/ m3.

(vi)

Fugitive dust from miscellaneous operations shall be substantially free from visible emissions as judged with the naked eye.

4

MISCELLANEOUS CEMENT WORKS OPERATIONS

(i)

Roads and operating areas shall not be of interlock bricks but be hard surfaced and kept clean, and a high standard of housekeeping shall be maintained throughout the works.

PCFC-EG#11 (ii)

Page 1 of 2

Revised:23/04/03

Operations such as clinker cooling, grinding, handling and storage, and cement packing, bulk loading and storage, shall be fitted with filters to prevent emissions of dust. Bulk storage silos shall be vented to air through bag filters.

(iii)

Special attention shall be paid to methods of handling if and when clinker has to be stored temporarily in the open in an emergency, in order to minimize dust emissions.

(iv)

Miscellaneous non-cement operations such as rock and gypsum crushing, screening, storage, recovery and handling, which may give rise to appreciable emissions of dust shall be fitted with efficient means of dust extraction and arrestment, or dust suppression.

(v)

Conveyors above ground shall be enclosed or fitted with wind-boards to prevent wind-whipping, and where dusty materials are being conveyed shall be enclosed and fitted with dust extraction and filtration equipment at changeover points.

(vi)

Collected dust shall be disposed of in a manner which is harmless and inoffensive.

(vii)

Vehicle speeds in the works should be limited to 16 km./h and downward pointing exhausts should be discouraged.

(viii)

An adequate supply of essential spares should be held and duplicate equipment should be installed whenever practicable and necessary to maintain continuity of operations whilst minimizing emissions to air.

5

CHIMNEYS

(i)

The minimum height of a new chimney for kiln waste gases shall be 60m and not less than the heights shown below, as extrapolated for intermediate throughputs. Clinker Throughput TPH 30 60 90 120 240

Dry Process (m) 60 73 85 94 126

(ii)

The chimney height so obtained might need to be further adjusted to take care of exceptional local circumstances.

(iii)

Chimneys should be adequately insulated to avoid condensation on inner surfaces which may lead to the emission of agglomerates.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#11

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Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.12 DI-ISOCYANATES WORKS

1

INTRODUCTION

(i)

Di-isocyanates works are defined as “works in which di-isocyanates (DIC) are made, or partly polymerised, or used in the manufacture of expanded or rigid plastics”. DIC works are preferably, not recommended for PCFC.

(ii)

The air pollution control regulations require that the Owner of a works shall use the best practicable means (a) to prevent the emission of noxious or offensive substances, either directly or indirectly; and (b) to render harmless and inoffensive such substances as are necessarily discharged. Smoke, grit, dust, vapour, aerosol and gases are included in the list of noxious or offensive substances.

(iii)

In di-isocyanates works there is often a wide range of operations where di-isocyanates in admixture with other substances are used, for example, in two-pack and non-drip paint, for making expanded plastics for bed mattresses, pillows, cushions, etc., for direct spraying onto construction work as a means of protection and insulation, for making rigid articles including panels for construction work, etc. The most commonly used di-isocyanates are TDI = toluene di-isocyanate (2.4 and 2.6 isomers), and MDI = 4.4’ - diphenyl methane di-isocyanate.

(iv)

The characteristic hazard associated with TDI is not just the primary chest irritation following exposure to high vapour concentration, where “high” relates to the Maximum Exposure Limit (MEL) of 0.02 mg/m3 as - NCO (isocyanate) in air, but the liability to sensitisation. It is well established that a proportion of people working with TDI can become sensitised to it and thereafter be unable to tolerate exposure to unmeasurably low concentrations. The symptoms exhibited are similar to acute asthma. Medical opinion is that sensitisation can be caused either by brief exposure to vapour concentrations above the MEL, or by repeated exposure to sub-MEL Concentrations. Industrial sensitisation seems to affect only a small proportion of workers. Within the factories, careful medical screening and supervision, and high standards of hygiene control by ventilation are needed. With this medical picture, a wide margin of safety for the general public is essential. The problems of MDI and the remaining di-isocyanates in industrial use, excepting :TDI, arise from dust or droplet mists and no significant public health hazards are normally encountered.

2 (i)

SAMPLING, ASSESSMENT OF EMISSIONS AND MONITORING The reference test method for TDI and MDI shall be based on the Marcali method, for testing occupational atmospheres, but modified to take account of the higher concentrations and different circumstances when sampling chimney emissions. An introduction to this method is given below. Other methods may be agreed with the Control Authority for control purposes if shown to give results comparable with the reference method.

3

INTRODCUTION TO METHOD OF TEST FOR ISOCYANATES

(i)

In 1983, a new MEL control limit was introduced which applies to all substances containing the free isocyanate group, - NCO. The control limit as -NCO is 0.02 mg/m3 for an 8-hour time weighted average and 0.07 mg/m3 for a 10-minute time weighted average. The analytical methods to assess potential exposure by these two standards differ. To date, only one method has been developed that is capable of measuring the concentration of all isocyanate-containing species in the atmosphere to meet the new control limit. This method employs high performance liquid chromatography (HPLC) with dual electrochemical (EC) and ultraviolet (UV) detection, which is very sophisticated instrumentation outside the scope of most isocyanates users.

PCFC-EG#12

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Revised:23/04/03

Also, there are distinct advantages in having the capability of on-site measurement, such as is afforded by the Marcali method in use previously for specific isocyanates. Accordingly, it is proposed to use the modified Marcali method for measuring the concentrations of specific isocyanates in ducts or chimneys discharging process gases to air. If the resulting concentrations at ground-level are to be measured, it is recommended that HPLC be used, as giving a more sensitive and precise assessment of the potential hazard, if any.

4

EMISSION LIMITS

(i)

The aim shall be to achieve a concentration of total di-isocyanate in discharges to air not exceeding 0.1 ppm (equivalent to 0.70 mg/m3 for TDI and 1.0 mg/m3 for MDI). The important aspect is to have a good suction at all points of the processing equipment, before discharge to air at a suitable height, and after treatment if necessary.

5

CONTROL OF EMISSIONS

(i)

All di-isocyanate processes shall be operated so as efficiently to contain all emissions from the process and to minimize losses of di-isocyanate to air.

(ii)

The containment and extraction arrangements for each process emission shall be agreed with the Authority.

(iii)

The spraying of articles in the works shall take place under cover in well-ventilated booths and droplets shall be eliminated before discharge to air.

(iv)

Droplets and aerosols from the “blowing-out” of injection heads by compressed air or by solvents shall be contained and ventilated to the main extraction system.

(v)

Block foam is allowed to mature for 24 hours after production, during which time TDI is released in small amounts as vapour. The foam should be matured either in the open air, or in a well-ventilated storage space under cover.

(vi)

In the case of large plants, it may be necessary to install waste gas, alkali scrubbers, depending upon the mass rate of release of total di-isocyanates from the site. “Large” is expressed in terms of the volume of discharge V from all di-isocyanate sources (cubic meters per hour) and the concentration T of total di-isocyanates in the emissions, expressed as cyanate (-NCO)(in units of milligrams per cubic meter), and is defined as works in which the product VT exceeds 50,000.

6

HEIGHTS OF DISCHARGE

(i)

Vent heights for the residual di-isocyanates emissions shall be assessed as follows:A basic height is calculated from the formula

H where H

= =

V T

= =

(0.0086 VT)1/2 chimney height in metres,

volume of emission, cubic meters per hour, concentration of total di-isocyanates, expressed as cyanate, - NCO, milligrams per cubic meter. The product VT is summed over all di-isocyanate emissions from the works.

PCFC-EG#12

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Revised:23/04/03

(i)

The value of T used in the determination above shall be based upon the highest expected emission for all the process formulations in general use, or anticipated to be in general use.

(ii)

The height so obtained shall then be adjusted to allow for the height of neighbouring buildings and for any special local circumstances, and subjected where appropriate to the minimum height requirement.

(iii)

The minimum discharge height for all small works shall normally be 5 meters above the roof ridge level, and for all other works shall normally be 15 meters, or 8 meters above roof ridge level, whichever is the higher. In this context “small” means works in which the emission volume (V) is less than 8,500 m3/h and the concentration of total di-isocyanate does not exceed 0.1 mg/m3.

(iv)

Vent efflux velocities shall not be less than 10 m/s except in the case of vents following a wet scrubbing system, when final efflux velocities shall not exceed 9 m/s. The emission from any such scrubbing system shall be free from droplets at all times.

(v)

When a new plant is being designed, it is important that emissions take place from the minimum number of chimneys or vents. Unless there are sound technical reasons to support it, a multiplicity of discharges shall be avoided.

7

STORAGE AND HANDLING OF DI-ISOCYANATES

(i)

Where the bulk import of di-isocyanates is concerned, storage of di-isocyanates should wherever practicable be in fixed tanks fitted with closed circuit, inter-vessel vents covering all tankers, storages and intermediate process vessels. The system should only be allowed to breathe through silica gel traps or be vented to the main process vent stack. The storage room should be air conditioned to maintain a temperature not exceeding 20oC.

(ii)

Where storage and handling of di-isocyanates is in drums, a. Drums shall be stored in an air-conditioned room where the temperature does not exceed 20oC. b. Drums shall be inspected by a responsible person before storage or movement of drums to ensure lid tightness and absence of leaks. c.

Drums shall be discharged by submerged pump to fixed intermediate tanks vented through silica gel traps. Portable containers shall not be used except for special purposes and by agreement with the Control Authority.

d. Other noxious or offensive substances used in the process, e.g. methylene chloride, shall be treated with e. the same care and attention as the di-isocyanates f.

Empty drums shall be decontaminated by an agreed process, or otherwise checked for lid tightness by a responsible person. Drums shall be disposed of in a manner, which is harmless and inoffensive.

g. Adequate arrangements to deal with di-isocyanate spillage shall be agreed with the h. authorised representative of the Authority. 8

GENERAL

(i)

Best practicable means applies not only to the control of emissions, but also to efficient maintenance, proper use of equipment and the installation of duplicate equipment, where necessary, to maintain continuity of production and avoid stoppages which lead to emissions to air. Operators must be properly trained, instructed and supervised to minimize emissions.

PCFC-EG#12

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Revised:23/04/03

(ii)

Some ancillary processes such as cutting, abrading and disintegration of expanded plastics produce finely divided particulate matter and these processes must be extracted by fans to suitable filters.

(iii)

A high standard of housekeeping shall be maintained throughout the works.

(iv)

Malfunctioning or breakdowns leading to abnormal emissions shall be dealt with promptly; in serious cases the plant shall be shut down for repairs. The Authority shall be informed when abnormal emissions occur.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#12

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Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.13 PETROLEUM WORKS - REFINERIES

1

INTRODUCTION

(i)

The petroleum industry covers a very wide range of operations from simple primary separations to complex petrochemical products. This note covers only refining separation processes, which can again be simple primary distillations or complex secondary treatments such as catalytic cracking, hydrogenation, allkylation units and vaccum distillation, etc. These notes apply to works in which a.

Crude or stabilized crude petroleum or associated gas, or condensate is i. handled or stored; or ii. refined; or

b.

any product of such refining is subjected to further refining or to conversion; or

c.

natural gas is refined or odorised; or

d.

used lubricating oil is prepared for re-use by any thermal process.

(ii)

These notes are intended to provide a basis for consultation between works managements and the Authority so that the latter can take into account the types of plant and their capacities when deciding on requirements, leaving flexibility to make allowances for special local circumstances.

(iii)

PCFC has published a Health and Safety Manual dealing with requirements for the protection of employees and neighbours from risks of injury, health, fire, and electricity hazards, and this should be studied in conjunction with these notes.

(iv)

The health, safety and environmental problems of the petroleum industry are many and varied and long experience has brought solutions for the design, construction, operation and standardization of refineries to make them acceptable. Such requirements and standards are embodied in national and international agreements with organizations such as the American National Fire Protection Association (NEPA), the American Petroleum Institute (API) and Stichting CONCAWE of Western Europe. All new refineries are required to design and plan their equipment to those standards.

2

EMISSION LIMITS AND CONTROLS

(i)

The emission of combustion products from furnaces shall be maintained free from visible smoke or fumes and in any case shall not be more than 150 mg/m3 during normal operation.

(ii)

Carbon monixide from a catalytic cracker shall be burnt in an efficient appliance.

(iii)

Particulate matter from catalytic crackers shall not exceed an emission concentration of 150 mg/m3

(iv)

The aim shall be completely to destroy hydrogen sulphide, but an emission concentration of 5 p.p.m. v/v can be tolerated for a short time. SO2/NOx shall not exceed 500 mg/m3.

PCFC-EG#13

3

OPERATIONAL CONTROLS

Page 1 of 4

Revised:23/04/03

A

Liquid Effluents All crude oil refineries produce substantial quantities of aqueous effluents which have been in contact with sulphur-containing hydrocarbon streams and are contaminated with hydrocarbons, hydrogen sulphide and mercaptans. These sour water effluents must be freed from foul-smelling substances, normally by steam stripping in a distillation column, or equivalent. The liquid effluent, perhaps containing water-soluble organic compounds and phenols from catalytic cracking, is then passed to the liquid effluent treatment process, such as oil/water separator, biological treatment and aeration to produce an aqueous stream fit to discharge. Oil/water separators on oil refineries should be covered to reduce evaporation and prevent the free emission of oily vapours from the surface. The standards for discharge of liquid effluents are discussed in detail in the water environment section.

B

C

Catalytic Crackers And HF Alkylation Units a.

Most modern oil refineries now use catalytic crackers and HF alkylation units to meet demands for low-lead and lead-free petrol and great care has to be taken in the design of these massive units to prevent hazards and nuisance from solids and gases.

b.

Carbon Monoxide from cracking plants must be burnt before discharge.

c.

Particulate matter separators can be designed to reduce dust emissions to below 150 mg/m3 by inertial separation, otherwise more energy consuming units such as electrical precipitators may have to be used.

Desulphurisation Gas and liquid streams can contain hydrogen sulphide and mercaptans which are absorbed in ethanolamines, the latter then being regenerated by removing the hydrogen sulphide gas in concentrated form. Sulphur recovery is effected in Claus kiln units by partial combustion to form sulphur dioxide and hydrogen sulphide which react to deposit sulphur. At least 98-99.9% percent efficiency must be achieved and the final emission has to be combusted to emit a small amount of sulphur dioxide for discharge at a suitable height. There are times when a Claus kiln has to be out of commission for routine testing or maintenance and at least two kilns have to be used to take care of this situation. Ideally, three Claus units should be used, with any two capable of handling the total flow. The final design will depend largely on the scale of operations, which should be odor free.

4

FLARING

(i)

On all oil refineries, flares are used to burn flammable gases under controlled or breakdown conditions. All plants handling gases and volatile petroleum fractions are connected to the flare system through pressure relief valves or remotely controlled depressurizing valves, so that in the event of a shut down or process disturbance, the flammable gases can be vented to the flare and there burned safely. The system has to be carefully designed with a knockout pot to remove liquid droplets, followed by a water seal of given pressure and a tall flare stack. Waste gases would be burnt in efficient and adequately tall flaring stack by virtue of complete combustion, preferably during night time, using steam assistance. Otherwise prior agreement/approval of Authority is required. Odorous emissions to be avoided.

PCFC-EG#13

(ii)

Page 2 of 4

Revised:23/04/03

One of the difficulties with elevated flares is that of achieving good mixing of the massive amounts of the flared gases with air to produce clean and smokeless combustion. This is achieved by injecting steam into the gas at the tip to cause turbulence and aid combustion by reacting with carbon and

hydrocarbons in the high temperature flame zone. Such treatment with steam is essential and whilst perfection has not yet been achieved, there are several good designs on the market. (iii)

When simple hydro-skimming operations are employed in the distillation process, ground-level flares can be used to give better combustion control and smokeless operation, and are less conspicuous, but they are more costly to maintain and a high level flare is still needed for a major emergency discharge. With catalytic crackers and HF alkylation units in use, large quantities of sulphur containing gases and traces of hydrogen fluoride would have to be discharged at high level.

5

LIQUID STORAGE

(i)

Crude oils vary enormously in their physical and chemical properties. Some are “sweet” and some are “sour”, but all have characteristic odours which can be a nuisance unless proper storing and handling facilities are used. Crude oils must be received and stored either in double-seal, floating roof tanks, or in fixed roof tanks with vapour extraction to a scrubbing system.

(ii)

The crude oil tanks must be designed to permit the settling and extraction of water. Such water has to be stripped of volatile matter for destruction, with the water passing to a well-designed oil/water separation system to the satisfaction of the Authority.

(iii)

There are times when tanks have to be emptied for maintenance, or change of product, and floating roofs have to be supported on legs or pedestals, leaving a vapour space between the roof and the tank bottom. In order to minimize vapour emissions when the tanks are refilled, the legs or pedestals should be as short as is practicable.

(iv)

The storage of volatile organic compounds with vapour pressures above 570mm mercury should be accompanied by a vapour recovery system. Below that vapour pressure, pressure/vacuum (P/V) ventilation valves should be fitted to storage tanks. In some cases it is practicable to install a floating, light metal sheet on the surface of the liquid to reduce evaporation.

(v)

All storage tanks must be adequately bunded to contain their contents in the event of a catastrophic leakage. They must also be fitted with foam and water connections in case of fire. The bunded area shall be sufficient to contain 110 percent of the volume of the largest tank within the bund. The floor shall consist of a good quality, impervious concrete with 2mm HDPE liner and Peak detection system is required.

(vi)

The storage tanks for volatile organic compounds should ideally be of floating roofs with nitrogen blanketing. The vapors, upon filling, be recovered and routed to flare or recycled.

6

CHIMNEYS

(i)

The quality of oil processed on refineries can vary from time to time as sources change, and also petroleum refineries tend to use their own arisings of high-sulphur residues, as well as petroleum gas, to heat their own furnaces. It is good practice to have these residues burnt on oil refineries with waste gases dispersed from tall chimneys and with supervision by well-trained and knowledgeable staff, rather than to allow them to be burnt in numerous works elsewhere. In general, the policy for dispersion of waste products of combustion is to treat a refinery as a point source and to base the chimney heights of the major emitters on the total emission of the significant pollutants. These are usually oxides of sulphur or nitrogen. Small sources can be treated appropriately. The temperatures of waste gases from petroleum works tend to be significantly higher than from combustion processes in some other industries, such as power stations or industrial boilers, and so the plume rise due to momentum and buoyancy can be high and has to be taken into account. PCFC-EG#13

(ii)

Page 3 of 4

Revised:23/04/03

There is a dispersion advantage in combining emissions into as few chimneys as is practicable, and in some cases a single common chimney has been built. Much will depend upon the complexity of operations as to how far a works can go along this route. Final chimney heights can only be decided after discussions between managements and the Authority.

7

GENERAL ODOR PREVENTION

(i)

An enormous potential exists for potential odorous and offensive gaseous and liquid emissions from petroleum works and the utmost care has to be taken in the design, operation, control and training for such works to be acceptable neighbours. The modern industry is aware of these problems and has a high reputation for its efforts to prevent nuisance. In a new refinery, the very latest is expected from high technology control and instrumentation, usually with its own environment division to ensure compliance with regulations and to be the company’s own critic.

(ii)

It is not possible in a note of this kind to cover all aspects of health, safety and the environment for a petroleum works and only the vigilance of the management, cooperation with the Authority and continuing inspection can ensure an acceptable process.

(iii)

All sources where such odorous air emissions/offensive vapour emissions can be expected, such as hot wells, vacuum installations, etc., have to be connected to extraction and treatment plant.

(iv)

The products from a petroleum works have to be marketed in small or large containers or in bulk and great care has to be taken to minimize offensive and hazardous emissions from such sources. This is especially true when loading tankers with bulk supplies of volatile organic liquids such as petrol. Vapour return lines and bottom loading are good practices which should be adopted in well designed systems. Means must be used to deal with spillages.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#13

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Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.14 CHLORINE AND HYDROCHLORIC ACID WORKS

1

INTRODUCTION

(i)

These two classes of works are taken together because chlorine is often generated as an intermediate in the manufacture of hydrochloric acid. The classic mercury cell electrolysis produces both chlorine and hydrogen and these are then mixed and burnt to form hydrochloric acid gas. Hydrochloric acid gas can also be formed from the use of chlorides in chemical processes, especially when a chloride and an acid react together. In all cases the hydrochloric acid gas is absorbed in water to form liquid hydrochloric acid with an acid strength of 33-35 per cent. Air pollution problems can also arise when chlorine or hydrochloric acid are used in other processes.

(ii)

Chlorine works are defined as “works in which chlorine is made or used in any manufacturing process”.

(iii)

Hydrochloric acid works are defined as “works where hydrogen chloride gas is evolved either during the preparation of liquid hydrochloric acid, or for use in any manufacturing process, or as the result of the use of chlorides in a chemical process”.

2

SAMPLING AND MEASUREMENT OF EMISSIONS

(i)

The frequency and time of sampling shall be determined by the Authority after discussion with works management. For chlorine works this shall not be less than once per week and the method of testing for chlorine shall be agreed between the works management and the Authority.

(ii)

For hydrochloric acid works the frequency of sampling and testing shall normally not be less than once per day, the testing being by absorption in aqueous solution and analysis for chloride ion.

3

EMISSION LIMITS AND CONTROLS

(i)

In all cases where chlorine is made or used the concentration of chlorine shall not exceed 10 ppm (v/v).

(ii)

In mercury cell plants, the concentration of mercury in strong hydrogen shall not exceed 0.5 mg/m3 and in weak hydrogen (i.e. air extracted from the process vents and containing hydrogen at less than the lower explosion limit) shall not exceed 2mg/m3.

(iii)

The concentration of hydrochloric acid or chlorine gas in all emissions to the air shall not exceed 20 mg/m3.

(iv)

Emissions to the air from all sources shall be substantially free from persistent mist or fume, and free from droplets.

(v)

The concentration of particulates in emissions to air shall not exceed 150 mg/m3.

PCFC-EG#14

4

OPERATIONAL CONTROLS

Page 1 of 2

Revised:23/04/03

(i)

Storage and handling facilities, including those for loading or unloading, shall be provided with venting and purging arrangements to suitable absorbers capable of dealing with the expected maximum rate of venting or purging, as agreed between the management and the Authority.

(ii)

Where hydrogen chloride gas is being generated for use in a further process, a standby absorber, capable of absorbing the maximum rate and quantity of hydrogen chloride expected to be evolved during breakdown conditions, shall be installed.

(iii)

All chlorine production facilities shall be designed to achieve quick and effective shut down. Emergency absorption systems shall be provided to take all chlorine produced during the shut down, with an adequate margin of safety. Power to implement shut down and emergency absorption shall be available at all times, independent of the electricity supply for chlorine production.

(iv)

On diaphragm cells and ancillaries, all sources of emission of gas and fume to the atmosphere shall be fully contained and treated by appropriate means agreed with the Authority.

(v)

On Downs cells and ancillaries, all sources of emission to the atmosphere shall be contained to the maximum practicable extent, and shall be treated by means agreed with the Authority.

5

CHIMNEYS

(i)

Chimney heights shall be determined after discussion between works management and the Authority, who use for the first assessment the maximum mass rate of emission of hydrochloric acid gas, or chlorine and any other significant components in the waste gas stream.

(ii)

The chimney height so obtained may need to be increased to allow for local circumstances such as topography, nearby buildings or existing emissions. In no case shall it be less than three meters above the roof ridge height of any adjacent buildings.

(iii)

Chimneys or vents shall be designed to minimize the cooling of waste gases and so prevent condensation on internal surfaces.

6

GENERAL OPERATIONS

(i)

Best practicable means applies not only to the control of emissions, but also to efficient maintenance, proper use of equipment, and adequate supervision of the process. Planned maintenance should be used to the maximum extent, an adequate supply of essential spares should be held and duplicate equipment should be installed whenever practicable and necessary to allow continuity of operations whilst minimising emissions to air.

(ii)

Malfunctioning, breakdowns or leakages leading to abnormal emissions shall be dealt with promptly; in serious cases the process shall be shut down as soon as practicable for repair. The Authority should be informed of any such incidents.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#14

Page 2 of 2

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.15 IRON AND STEEL WORKS 1

INTRODUCTION

(i)

The iron and steel industry covers an enormous range from small, simple processes such as foundries, metal working and finishing, to very large integrated iron and steel works where many major ancillary processes are operated, such as ore beneficiation, coke ovens, gas producers, tar and hydrocarbon distilleries, lime plants, by-product recovery, fabrication, tempering, hardening, etc. etc. In the advanced industry, modern processes have replaced many of the traditional iron and steel processes such as clamp calcination, cupolas, open hearth furnaces, etc. although they are still used elsewhere. Instead, sinter plants, electric furnaces of various kinds, direct ore reduction and Basic Oxygen Steel furnaces are now being used. The steel industry was revolutionized in the early 1950s by the availability of tonnage oxygen for refining iron and making steel, thus reducing the time of batch turn-round from about 12 hours to 30 minutes with its fierce rate of reaction. At the same time it introduced a new problem with the intense brown fumes of iron oxide which were liberated and had to be prevented because of the nuisance they created. The first oxygen-steel making process was developed in Austria and was known as the L-D Process, which quickly gave way to variations. This note will deal with the types of modern furnaces and processes which may be expected in the Jebel Ali Free Zone, such as electric arc furnaces, electric induction furnaces, basic oxygen steel plants, blast furnaces, direct reduction furnaces (sponge iron) and ore preparation.

(ii)

Iron and steel works are defined as “Works” in which :a.

Iron ores or iron ores and other materials for the production of iron are handled, stored or prepared; or

b.

Iron ores for the production of iron are calcined, sintered or pelletised; or

c.

Iron or Ferro-alloys are produced in a blast furnace or by direct reduction; or

d.

Iron or steel is melted in electric furnaces; or

e.

Steel is produced, melted or refined; or

f.

Air or oxygen or air enriched with oxygen is used for the refining of iron or for the production, shaping or finishing of steel; or

g.

Ferro-alloys are made by methods giving rise to dust or fume; or

h.

Iron or Ferro-alloys produced in any process described in sub-paragraphs (c), (d) or (g) of this paragraph are desulphurised by methods giving rise to dust or fume”.

(iii)

In the context of these notes “works” includes not only all the processes on the lessee’s site, but also the unloading and loading of materials on ships PCFC harbours and their conveyance to and from the processing site.

2

RAW MATERIALS HANDLING AND PREPARATION

(i)

The solid raw materials normally handled in iron and steel works are iron ore, coke and lime or limestone, together with smaller amounts of additives to adjust final composition of the product, or the liquidity of the slag. It is unlikely that coke ovens and lime kilns will be used in Jebel Ali steel works, but that coke and lime will be imported ready for use. Similarly, it is unlikely that low quality iron ore will be beneficiated on site, and that any pretreatment will have been done elsewhere to produce a high quality ore.

PCFC-EG#15

Page 1 of 4

Revised:23/04/03

(ii)

Solid raw materials arriving by ship in bulk will be discharged by grab onto conveyors or road trucks and be delivered to the storage areas on site. All these handling operations, including material recovery, have to be conducted without any significant visible sign of dust emission. Conveyors shall be fully enclosed to prevent windwhipping and shall be fitted with effective means for keeping the underside of the return belt clean. Transfer points shall be enclosed and be fitted with dust collection and arrestment units.

(iii)

Consideration should be given to the effect of wind-whipping of raw materials from stockpiles and blending beds, where dust suppression may be needed.

(iv)

Minor mix components shall normally be delivered and stored under cover.

(v)

When the ore has to be prepared by sintering or polarization, the plant shall be enclosed and all points where dust is likely to be emitted shall be equipped with dust collection and arrestment plant.

(vi)

Loading to and from blending beds and other stockpiles shall be carried out in a manner to prevent airborne dust.

(vii)

Storage bunkers for sinter return fines shall be enclosed and vented to air through suitable dust arrestment plant.

(viii)

The disposal of collected fines shall be carried out in a manner which prevents the generation of airborne dust, including suppression techniques.

(ix)

The concentration of particulate matter in emissions to atmosphere from arrestment plant shall not exceed 150 mg/m3.

(x)

The heights of chimneys shall be determined after discussions between managements and the Authority and shall be based on the maximum mass rate of emission of pollutants concerned, taking account of local circumstances.

3

BLAST FURNACES OPERATIONAL CONTROLS

(i)

Blast furnaces are large vertical furnaces for extracting iron from its ores by reduction of the iron oxide with coke at high temperatures. A large, modern, blast furnace will contain thousands of tons of the burden at any one time and the raw materials have to bear this enormous weight without disintegrating into fines. That is why the ore has to be sintered to form hard lumps and hard coke lumps have to be used, together with lump limestone to form a molten slag. The coke serves two purposes, to provide heat and to take part in the chemical reaction of reducing iron oxide to iron. Pre-heated air enters near the bottom of the furnace and the hot waste gases containing carbon monoxide leave at the top. These dirty gases are used to pre-heat the combustion air in two sets of regenerators, called “ Cowper stoves”, used alternately. Periodically the iron and slag are tapped from the blast furnace, which once started, operates continuously for about seven years.

(ii)

Blast furnaces operate under pressure and there are two safety valves at the top known as “bleeders” which open and emit dirty gas when the pressure is too high. High pressure usually results from uncontrolled “slips” of the hot burden and these can be prevented by regular, controlled slips by manipulating the air blast so as not to open the “bleeders”.

4

CONTROL OF EMISSIONS

(i)

During normal operation, all blast furnace gas which is not used as fuel, but is bled to atmosphere shall be burnt and shall pass through a gas cleaning system to reduce the particulate matter to below 150 mg/m3.

PCFC-EG#15

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Revised:23/04/03

(ii)

The emissions from chimneys serving combustion processes shall be maintained free from visible smoke and in any case not more than 150 mg/ m3.

(iii)

Collection and arrestment of fume arising from furnace tapping, iron and slag runners and transfer of iron and slag to ladles or other receivers is required. The concentration of particulate matter in emissions to atmosphere from arrestment systems shall not exceed 150 mg/m3.

(iv)

Where associated processes (eg. desulphurisation, iron or slag processing, raw materials handling) give rise to particulate emissions, collection and arrestment are required to a standard of not more than 150 mg/m3.

(v)

Water used for slag quenching or for slag or iron granulation shall be free from suspended or dissolved substances, such as ammonium compounds, which give rise to odorous or harmful emissions. Slag quenching can give rise to odorous emissions of hydrogen sulphide, which are difficult to prevent.

5

DIRECT REDUCTION

(i)

A modern development is the direct reduction of iron ore by gas in rotary or vertical furnaces to give an impure iron known as sponge iron because of its characteristic physical shape. The sponge iron has then to be further purified or converted into steel, usually with scrap iron, in electric furnaces.

(ii)

The iron ore feed is in the form of pellets and the prevention of dust and gas emissions is similar to that of the blast furnace. All dust producing points have to be collected and arrestment plant fitted to give a dust emission of not more than 150 mg/m3.

6

ELECTRIC ARC FURNACES

(i)

Electric arc furnaces have already been dealt with in an earlier note, but they refer essentially to the small units normally used in foundries. This note deals with larger electric are furnaces above 20 tons capacity which range up to 100-200 tons and normally use tonnage oxygen for melting and refining.

(ii)

Primary collection and arrestment are required on all furnaces, Secondary collection and arrestment are also required on any individual furnace exceeding 20 tons capacity. The concentration of particulate matter in emissions from arrestment systems shall not exceed 150 mg/m3 from combined arrestment systems. It is sometimes the practice to use the secondary collection air to reduce the primary gas temperature by mixing the two streams to the point where it is acceptable to the fume arrestment plant, eg. bag filters, electrical precipitators or venturi-scrubbers.

(iii)

Limits for emissions of non-ferrous metals or compounds, e.g. lead, zinc, may need to be applied in particular circumstances by the Authority.

(iv)

During normal operations and with the furnace roof in position, the primary extraction system shall be capable of collecting all the emissions generated, including the oxygen blow period, and of minimizing emissions of carbon monoxide by burning in the offtake duct.

(v)

The aim of secondary collection systems shall be the total collection of adventitious emissions throughout the complete operating cycle of charging, melting, refining, slagging and tapping.

(vi)

When two or more furnaces are served by a single secondary collection and arrestment system their operations shall be so co-ordinated as to avoid exceeding the designed collection capability of the secondary system.

PCFC-EG#15

7

BASIC OXYGEN STEEL PLANTS

Page 3 of 4

Revised:19/04/03

(i)

Basic Oxygen Steel plants (BOS) are essentially vertical furnaces receiving hot iron, or hot iron and scrap, onto the surface of which tonnage oxygen is blown from a retractable lance. A violent reaction takes place producing large amounts of iron oxide fume and carbon monoxide, and generating exit gas temperatures of 2,000 oC. The waste gas may then be treated in one of two ways. Either it is burnt at the mouth of the vessel and the hot gases have to be cooled by heat exchange or water sprays before passing through arrestment plant. Or the vessel is close hooded to prevent ingress of air and the burning of carbon monoxide, and the smaller volume of gas is cooled and passed through arrestment plant. The clean gas is then burned usefully or flared. The turn-round time for a batch by this process is about 30 minutes.

(ii)

The concentration of particulate matter in emissions to atmosphere from arrestment plant serving all processes carried out in, or associated with, BOS plants shall not exceed 150 mg/m3.

(iii)

Limits for emissions of non-ferrous metals or compounds may need to be applied in particular circumstances e.g. lead, zinc.

(iv)

Oxygen lacing shall be carried out in a manner which minimizes “boil-overs”.

(v)

Slag shall be disposed of in a manner which prevents the generation of airborne dust.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#15

Page 4 of 4

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.16 MONTREAL PROTOCOL FOR OZONE DEPLETING SUBSTANCES

1

INTRODUCTION The ozone layer is found in the stratosphere between about 30 km above the earth. The ozone layer protects us from the harmful effects of ultraviolet (UV) radiation from the sun. Thinning of the ozone layer increases the amount of UV reaching the earth which can increase skin cancers, suppress the body’s immune system making people more vulnerable to disease, can cause cataracts and other eye disorders, damage marine life and reduce crop yields. Thinning of the ozone layer was first reported in 1975. It was identified that certain chemicals notably Chlorofluorocarbons (CFC’s), Halons, Carbon Tetrachloride and Trichloroethane which are highly stable and eventually reach the stratosphere and are broken down by UV radiation, releasing free chlorine or bromine which catalyses the destruction of ozone. Scientists predict that the ozone layer will recover if we cease emissions of the chemicals which are causing the damage, although it will be a slow process. Efforts to control and phase out ozone depleting substances was led by the United Nations. The 1987 Montreal Protocol on the Control of Substances that Deplete the Ozone Layer requires the signatory governments to regulate consumption and production. UAE is a signatory to the Montreal Protocol. The protocol divides countries into two classes based on their level of use of controlled substances. Developed countries were required to cease all production and importation of controlled substances on 1 January 1996. Developing countries (Article 5 countries) have a 10 year grace period to meet the phase out targets. This grace period is a time to plan to meet the phase out targets in an orderly economical way. Alternatives already exist and these will become increasingly cheaper, while the cost of controlled substances will rise as supplies are harder to obtain. In order to prepare industry in the Jebel Ali Free Zone for the phase out program and minimize economic impacts, EPSS of Dubai Municipality has enforced a policy to implement the objectives of above mentioned agreements. It shall apply to occupiers of all premises at which the ozone depleting substances (ODSs) listed in Section 1 are imported, stored, traded and used.

2

CONTROLLED SUBSTANCES Section 1 The following substances shall be the controlled substances for the purpose of this policy. Product Trade Name

Description

CFC-11 CFC-12 CFC-113 CFC-114 CFC-115 R-500 R-502 Halon 1211 Halon 1301 Halon 2402 CCl4 CH3CCl3 CH3Br HBFC

Trichlorofluoromethane Dichlodifluoromethane Trichlorotrifluoromethane Dichlorotetrafluoromethane Chloropentafluoromethane Dichlorodifluoro/difluoromethane Chlorodifluoro/Chloropentafluoromethane Bromochlorodifluoromethane Bromotrifluoromethane Dibromotetrafluoromethane Carbon Tetrachloride Methyl Chloroform Methyl Bromide Hydrobromofluorocarbons

PCFC-EG#16 3

GENERAL REQUIREMENTS

Page 1 of 3

Revised:23/04/03

(i)

The importation of the controlled substances listed in Section 1 have been banned since 01 January 1996.

(ii)

The importation of any appliances such as freezers, refrigerators, air conditioners already filled with controlled substances listed in Section 1 have been banned since January 01, 1996.

(iii)

The utilization of ozone depleting substances shall be controlled in accordance with this policy in the following controlled activities. o o o o

Refrigeration and air conditioning, Foam manufacturing, Fire protection; and Degreasing and dry cleaning.

(iv)

The venting of controlled substances shall not be permitted. Recovery, recycling and reuse shall be practiced at all stages in the refrigeration and air conditioning industries and fire protection systems.

4

IMPLEMENTATION

(i)

PCFC in coordination with EPSS/DM shall actively promote the goal of controlling ozone depleting substances and encourage a cooperative approach with industry, the workforce and the community to achieve the timely phase out of ODSs.

(ii)

PCFC in coordination with EPSS shall implement this Policy as appropriate through the exercise of their statutory powers.

(iii)

The importers, traders and users of controlled substances shall be required to comply with this policy and adopt recovery, recycling and reuse practices.

5

AUDIT & MANAGEMENT CONTROL

(i)

PCFC shall promote ODSs control by encouraging the use of audits and the development of management plans. JAFZA shall work with industry and other interested parties to develop management plant.

(ii)

PCFC shall require occupiers of industrial premises or similar activities which utilize ODSs to prepare a sound management and strategic action plant for CFC phase out.

(iii)

EPSS in coordination with PCFC shall prepare an annual inventory of ODSs which are traded and used in the Emirate of Dubai.

(iv)

PCFC in coordination with EPSS shall restrict the entry of controlled substances through ports.

6

GUIDELINES FOR CONTROLLED ACTIVITIES

A

Refrigeration and Air Conditioning i.

The CFC’s 11,12,113,114 and 115 are not allowed to be used in any new equipment for refrigeration and air conditioning since January 01, 1996.

ii.

All existing air conditioning and refrigeration equipment utilizing controlled substances listed in Section 1 shall be

o o o

Maintained leak free, Supplied with gases from existing supplies or recycled sources; and Converted to use approved gases.

PCFC-EG#16

iii.

Page 2 of 3

Revised:23/04/03

The venting of controlled refrigerants during equipment maintenance shall not be permitted.

B

C

D

E

iv.

Recovery, recycle and reuse of refrigerants shall be practiced during repair and maintenance.

v.

Alternative refrigerants including but not limited to R134a, R125, R143a, R22, etc. which have low ozone depletion potential are already available in the market and are being used.

vi.

After the adoption of this policy, all newly built centralized air conditioning and refrigeration system shall use alternative refrigerants with zero ozone depletion potential.

Fire Protection Systems i.

Halons 1211, 1301, and 2402 are not used in any new fire protection system since January 01, 1996. Alternative fire suppressant substances already available in the market shall be used in newly built fire protection systems.

ii.

Existing halon systems shall be maintained in accordance with the requirements below.

iii.

The venting of halons during repair and maintenance of existing fire protection system shall not be allowed. Existing large premises shall install equipment to recover, recycle and reuse halon.

iv.

All halon filled cartidges or cylinders for fire extinguishers shall be periodically serviced only to qualified premises with halon recovery equipment.

v.

Companies with Halon systems shall have these regularly maintained to minimize leakage.

Foam Production i.

No controlled substances is being used as blowing agents in foams manufactured in Free Zone or imported into Free Zone after 1 January 1996.

ii.

Alternative substances which are already available in the market with low ozone depletion potential shall be used in the manufacture of foam and insulation materials.

Cleaning/Degreasing i.

All products containing CFC-113 and III - Trichloroethane (also known as methylchloroform) which are ozone depleting substances are not used since January 01, 1996.

ii.

Alternative substances which have low ozone depleting potential including but not limited to trichloroethylene, perchloroethylene and methylene chloride shall be used in dry cleaning and vapour degreasing activities.

iii.

Companies should examine whether there is a need to clean items at all and whether waterbased caustic systems can be used before considering vapour and solvent degreasing systems.

Aerosol sprays i.

Aerosols which contain ozone depleting substances, with the exception of approved items for medical use, are not be allowed to be traded in Free Zone since January 1, 1996.

ii.

Aerosol manufacturers shall not be allowed to use propellants with high ozone depletion potential.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai. PCFC-EG#16

Page 3 of 3

Revised:23 /04/03

ENVIRONMENTAL GUIDELINE No.17 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH AND A DANGER These notes form a Best Practicable Means Code of Practice for the handling and processing of substances which are Dangerous and Hazardous to Health. It is divided into five parts as detailed below. 17.1

HANDLING AND PROCESSING a)

A substance hazardous to health means any substance which is: i.

a substance which is included in the U.N. classification of dangerous goods and for which the general indication of risk is specified as very toxic, toxic, harmful, corrosive or irritant;

ii

A substance for which a maximum exposure limit is specified in the following Table 17A.

iii a micro-organism which creates a hazard to the health of any person; iv. v

b)

dust of any kind, when present at a substantial concentration in air; a substance not mentioned above, which creates a hazard to the health of any person which is comparable with the hazards created by substances mentioned above.

Employers have a duty to protect their employees and any other person, whether at work or not, who may be affected by the hazardous and dangerous work carried on by the employer. Contractors, sub-contractors and self-employed persons all have the duties of employers and where an employee of the above works at another employer’s premises, both employers have duties of protection, and so there must be collaboration. Visiting members of emergency services, e.g. fire fighters, must be made aware of any substance on the premises which poses a danger or a risk to their health.

c)

Prohibitions

i.

Some substances are so hazardous to health that their use or importation are prohibited, whilst other substances are a health hazard when used in certain process, which are prohibited.

ii.

The importation into PCFC of the following substances is prohibited, and their use in any manufacturing process is also prohibited, namely: 2-naphthylamine, benzidine, 4-nitrodiphenyl, 4-aminodiphenyl, their salts and any substance containing any of those compounds in a total concentration exceeding 0.1 per cent. Matches made with white phosphorus are prohibited.

iii

Sand or other substances containing free silica shall not be used as an abrasive in any blasting apparatus for cleaning, smoothing roughening or removing part of the surface of any article by the use as an abrasive of a jet of sand by the blast of compressed air or steam or by a wheel.

iv

The Authority may grant exemptions to these prohibitions, but only where it can be satisfied that the health of persons will not be prejudiced as a consequence.

PCFC-EG#17

Page 1 of 17

Revised:23/04/03

TABLE - 17A LIST OF SUBSTANCES ASSIGNED MAXIMUM EXPOSURE LIMITS

Reference periods Long-term Short-term maximum maximum exposure limit exposure limit (8-hour TWA (10-minute reference reference period) period)

________________________ Substance

Formula

Acrylonitrle Ammonia Arsenic & compounds except arsine and lead arsenate as As Buta 1.3-diene 2-Butoxyethanol Cadmium & cadmium compounds except cadmium oxide fume and cadmium sulphide pigments (as Cd) Cadmium oxide fume (as Cd) Cadmium sulphide pigments (respirable dust as Cd) Carbon disulphide CH2Cl2 2.2’ Dichloro-4.4’ methylene dianiline (MbOCA) 2-Ethoxyethanol 2-Ethoxvethvi acetate Ethylene dibromide Ethylene oxide Formaldehyde Hydrogen cyanide Isocyanates. all (as NCO) Man-made mineral fibre 1-Methoxypropan-2 ol 2-Methoxyethanol 2-Methoxyethyl acetate Polychlorinated biphenys (PCB’s) Rubber process dust Rubber fume Styrene 1.1.1. Trichloroethane Trichloroethylene Vinyl chloride+ Vinylidene chloride Wood dust (hard wood)

ppm

mg/m3

ppm

mg/m3

CH2 = CHCN NH3 As

2 25

4 18 -

0.2

0.5

CH2 = CHCH=CH2 C4H9OCH2CH2OH

10 25

120

-

-

Cd

-

0.05

-

-

CdO

-

0.05

-

0.05

CdS CS2 100

10 -

0.04 30

-

-Dichloromethane

10 10 1 1 1 -

0.005 37 54 8 2 1.2 0.02 5 100 16 24 0.5 8 0.75 420 1900 535 5 5

2 10 360 250 450 150 20 -

2.5 10 0.07 1.0 1050 2450 802 -

350

-

CH2 (C6H3CINH2)2 C2H2OCH2CH2OH C2H5CCH2CH2OOCCH3 BrCH2CH2Br CH2CH2O HCHO HCN CH3OCH2CHOHCH3 CH3OCH2CH2OH CH2COOCH2CH2OCH3 C12 H10-nCln C6H5CH=CH2 CH3CCl3 CCl2=CHCl CH2=CHCl CH2=CCl2

5 5 100 350 100 7 -

.

Limit relates to cyclohexane soluble material

+

Vinyl chloride is also subject to an overriding annual maximum exposure limit of 3 ppm

-

-

Notes: a “substantial” concentration of dust should be taken as the values shown in the current Health, Safety and Environment Guidance Note EH/40 “Occupational Exposure Limits”, or, where such values are not shown lower, as a concentration of 10 mg/m3, 8-hour time weighted average of total inhalable dust, or 5 mg/m3 of respirable dust.

PCFC-EG#17

d)

Page 2 of 17

Control of Exposure to substances hazardous to health

Revised:23/04/03

i.

PCFC Environmental Rules and Requirements (3rd Edition), the Health and Safety Manual, and UAE Ministerial Decision No. 32 of 1982 entitled “The Determination of Preventive Methods and Measures for the Protection of Labour from Risks of Works”, lay down the responsibilities of employers for protecting employees and the environment. These include the assessment of risks, measurements of pollution, training, information to employees, health measures and records, provision of protective clothing and other service facilities, etc. All these requirements must be implemented. The employer must also ensure that control measures and protective devices are inspected and maintained at suitable intervals and that they are being used properly by employees.

ii.

An employer shall not carry on any work which is liable to expose any employees to any substance hazardous to health unless he has made a suitable and sufficient assessment of the risks created by that work to the health of those employees and of the steps that need to be taken. Employees or their representatives at the place of work should be informed of the results of the assessment.

iii.

Every employer shall ensure that the exposure of his employees to substances hazardous to health is either prevented, or is adequately controlled. The prevention or adequate control shall be secured normally by measures other than the provision of personal protective equipment. However, where such practicable measures are not adequate to give sufficient control of exposure, the employer shall provide, in addition, suitable personal protective equipment. In the case of any substance appearing in Table 1-A, it shall only be treated as adequate if the exposure is reduced below the maximum exposure limit, for which the employer shall undertake a monitoring programme.

iv.

Every employer who provides any control measures, personal protective equipment or other facility shall take all reasonable steps to ensure that it is properly used or applied. Every employee shall make full and proper use of any control measure or personal protective equipment or facility.

v.

Every employer who provides any control measures, shall ensure that it is maintained in an efficient state, in efficient working order and in good repair, by carrying out examinations and tests and by keeping a record.

vi.

The employer shall ensure that the exposure of employees to substances hazardous to health is monitored in accordance with a suitable procedure agreed with the Authority, and shall keep a record.

vii.

Where it is appropriate for the protection of the health of his employees who are, or are liable to be, exposed to a substance hazardous to health, the employer shall ensure that such employees are under suitable health surveillance and that a medical record is maintained.

viii.

An employer who undertakes work which may expose any of his employees to substances hazardous to health shall provide that employee with such information, instruction and training as is suitable and sufficient for him to know the risks to health created by such exposure and the precautions which should be taken.

ix.

Occupational cancer is a special case of the general provisions mentioned above and it may arise from various causes not yet properly defined as a casual link between a particular chemical and cancer in humans. The principles of occupational health are no different for carcinogenic substances than for those involving other health hazards. However, there are specific substances and processes with which a cancer hazard is associated and prevention of exposure must be the first objective in view of the serious and often irreversible nature of the disease. It is particularly important that exposure should be controlled to as low a level as is reasonably practicable, bearing in mind the high risk of death. The following is a list of substances and processes which have been assigned the risk that they “may cause cancer”.

PCFC-EG#17

-

Page 3 of 17

Aflatoxins

Revised:23/04/03

-

Arsenic and its inorganic compounds Benzo (α) pyrene Beryllium and beryllium compounds Insoluble chromium (VI) compounds Mustard gas (B.B’Dichlorodiethyl sulphide) Inorganic nickel compounds arising during the refining of nickel Ortho-toluidine Coal soots, coal tar, pitch and coal tar fumes Non-solvent refined mineral oils and contaminated used mineral oils Auramine manufacture Leather dust in boot and shoe manufacture, arising during preparation and finishing Hard wood dusts Isopropyl alcohol manufacture (strong acid process) Rubber industry (processes giving rise to dust and fume) Magenta manufacture 3,3’ Dimethoxy benzidine (Dianisidine) and its salts 1-Naphthylamine and its salts 4-Nitrobiphenyl Orthotolidine and its salts Vinyl Chloride monomer (VCM)

For list of substances assigned maximum limits see Table 17-A.

17.2

STORAGE

(i)

Introduction: This part of the note on Best Practicable Means describes the methods to be practised by the lessees in the Jebel Ali Free Zone for the storage of substances hazardous to health and a danger.

(ii)

Marking And Labelling: Each receptacle containing dangerous goods shall be marked with the correct technical name and identified with a distinctive label or stencil of the label so as to make clear the dangerous character. Each receptacle shall be labelled according to the classification of dangerous goods as per U.N. regulation (Refer to Appendix-I).

(iii)

Documentation: In all documents relating to dangerous goods the correct technical name of the goods shall be used and the correct description given in accordance with the U.N. goods classification.

(iv)

U.N. Classifications : In addition to the four-digit U.N. number, a substance must be assigned to a class depending on that substance’s characteristics and the type of hazard involved during its transportation/handling and storage. The U.N. has devised a classification system which forms the basis for the hazard classes of all the main transport codes. Where necessary these classes further sub-divide into divisions to allow more specific classification.

PCFC-EG#17

Page 4 of 17

Class 1

:

Explosives

Class 1

:

is divided into 5 classes as follows:

Revised:23/04/03

Class 1.1

:

Class 1.2

Substances and articles which have a mass explosion hazard. :

Substances and articles which have a projection hazard but not a mass explosion hazard.

Class 1.3

:

Substances and articles which have a fire hazard and either a minor blast hazard or a minor projection hazard or both, but not a mass explosion hazard.

Class 1.4

:

Substances and articles which present no significant hazard.

Class 1.5

:

Very insensitive substances which have a mass explosion hazard.

Class 2

:

Gases

Compressed, liquefied or dissolved under pressure. Class 2 is sub-divided as follows:Class 2.1

:

Flammable gases

Class 2.2

:

Non-flammable gases

Class 2.3

:

Poisonous gases

Class 3

:

Flammable Liquids

Class 3 is sub-divided as follows:Class 3.1

:

Low flash point group of liquids having a flash point of -18oC (0oF), closed cup test.

Class 3.2 :

Intermediate flash point group of liquids having a flash point of -18oC (0oF) up to, but not including 23oC (73oF), closed cup test.

Class 3.3 :

High flash point group of liquids having a flash point of 23oC (73oC) up to and including, 61oC (141oF), closed cup test.

Class 4

:

Flammable Solids

Class 4 is sub-divided as follows:Class 4.1

:

Flammable solids. Solids possessing the common property of being easily ignited by external sources such as sparks or flame, and of being readily combustible.

Class 4.2

:

Substances liable to spontaneous combustion. The substances in this class are either solids or liquids possessing the common property of being liable spontaneously to heat and to ignite.

Class 4.3

:

Substances emitting flammable gases when wet. The substances in this class are either solids or liquids possessing the common property, when in contact with water, of evolving flammable gas. In some cases these gases are liable to spontaneous ignition.

PCFC-EG#17

Class 5

Page 5 of 17

:

Oxidizing Substances (Agents) And Organic Peroxides

Class 5 is subdivided as follows:-

Revised:23/04/03

Class 5.1

:

Oxidizing substances (agents) : These are substances which although in themselves not necessarily combustible, may either by yielding oxygen or by similar processes, increase the risk and intensity of fire in other materials with which they come into contact.

Class 5.2 :

Organic peroxides : Most substances in this class are combustible. They may act as oxidizing substances and are liable to explosive decomposition. In either liquid or solid from they may react dangerously with other substances. Most will burn rapidly and are sensitive to impact or friction.

:

Class 6

Poisonous (Toxic) And Infectious Substances

Class 6 is subdivided as follows:

(v)

(vi)

Class 6.1 :

Poisonous (toxic) substances : The substances in this class are liable to cause death or serious injury to human health if swallowed, inhaled or by skin contact.

Class 6.2 :

Infectious substances : These are substances containing disease - producing organisms.

Class 7

:

Radioactive Substances

Class 8

:

Corrosives

Class 9

:

Miscellaneous Dangerous Substances

Packing

:

The packing of dangerous goods shall be :

i. ii

: :

iii

:

well made and in good condition; of such a character that any interior surface with which the contents may come in contact is not dangerously affected by the substance being conveyed; and capable of withstanding the ordinary risks of handling.

Material Safety Data Sheets It is the responsibility of the lessees storing dangerous goods to obtain the appropriate Material Safety Data Sheets and display them.

(vii)

Storage Of Chemical And Dangerous Goods A variety of statutory regulations exists for the storage of chemicals and dangerous goods. It may however be advisable to restrict the accessibility of certain chemicals and dangerous goods to those whose job it is specially to handle them, particularly if careless handling can have serious consequences. The precautions to be taken for different dangerous goods classes depending on their hazardous nature, could be keeping the dangerous good for example: -

separate from other goods classes keeping it cool keeping in the dark keeping it dry keeping it in fireproof place keeping it under inert gas keeping it in ventilation along the floor keeping it under inhibitors

PCFC-EG#17 A

Page 6 of 17

Revised:23/04/03

Segregation: Dangerous goods shall be segregated in the storage according to their danger classifications and requirements specified in Appendix II attached. to this issue. Dangerous goods stored in aboveground tanks shall not share common bund areas unless the materials are of the same dangerous goods class.

-

Dangerous goods storage areas shall where practicable be external to the work place. Where dangerous goods are stored within industrial premises there shall be a minimum of 3 meter separation to any production facilities for non-flammable materials and 10 meters between flammable materials and any source of ignition.

-

Dangerous goods shall be separated from areas frequented by the public in accordance with the following requirements. CLASS

MINIMUM SEPARATION (METRES)

1. 2.1 2.2 2.3 3.1 4.1/4.2/4.3 5.1/5.2 6.1/6.2/6.3 8 B.

Flammable materials: -

Flammable liquids shall be stored under cover in a well ventilated area.

-

Flammable liquid storate areas shall be clearly marked in several languages understandable to the workers in particular premises and shall have warning signs against any flame sources e.g. smoking, welding, etc.

-

All electrical equipment located or used within 10 meters of flammable liquid storage areas shall be of explosive proof nature. -

C.

50 5 5 15 10 5 5 5 5

Any drum stores, or above ground tanks holding in excess of 5000 liters of flammable liquids, shall be equipped with fire fighting services as approved by the Fire Dept.

Spillages: All dangerous goods shall be stored on impervious surfaces capable of containing spills. Some means of limiting the effects of leakage are: 1. 2. 3. 4. 5.

D.

Facilities for collecting spilled liquid Sand or suitable absorbing material for containment or absorption. Provision to seal leaking drums. Provision to rinse away spilled substance Ventilation

Cylinders: Cylinders of compressed gas or flammable gases shall be stored upright in secure racks and out of direct sunlight or heat source.

E.

Bulk storage of dangerous goods: All bulk above-ground storage tanks shall be located in impervious bund areas where the volume of the storage bund is not less than 110% of the largest storage tank contained within the bund.

PCFC-EG#17

F.

Page 7 of 17

Revised:23/04/03

Underground storage tanks: -

All new underground storage tanks, including petroleum storage, shall be equipped with the means of inspection for leakage or shall be of a double walled design to prevent leakage.

G.

All existing underground storage tanks shall maintain adequate inventory checks to identify any leaking tanks and shall undertake tank tests if so directed by an EHS inspector.

Housekeeping and site management: -

Dangerous goods shall be stored in a safe manner with sufficient space for the safe movement of forklift vehicles or personnel.

-

Lessees storing dangerous goods shall maintain stocks of materials and equipment for the clean up of any spills.

-

Lessees storing dangerous goods shall ensure that its staff are aware of the hazardous nature of the goods, provided with personal protective equipment as required and trained in the procedures for handling spills.

PCFC-EG#17

Page 8 of 17

Revised:23/04/03

APPENDIX - I DANGEROUS GOODS CLASS LABELS AS PER UN REGULATIONS Form and Colouring of Class Labels and Subsidiary Risk Labels

Class or Subsidiary Risk Category

Class Label (Note 1)

(Note 2)

Subsidiary Risk Label Colouring of Label

Black lettering, symbol, numberals (if any) and lines ona background of the colour Orange. 2.1 Black or white lettering, symbol, numeral (if any) and lines on a background of the colour Red

2.2 Black or white lettering, symbol, numeral (if any) and lines on a background of the colour Green

2.2 and Subsidiary Risk 5.1

N.A

Black lettering, symbol, numeral and lines on a background of the colour Yellow

(Only for use on cylinders and Unit Loads of NITROUS OXIDE COMPRESSED and OXYGEN, COMPRESSED)

2.3 Black lettering, symbol numeral (if any) and lines on a white background.

(Cont’d)

PCFC-EG#17

Page 9 of 17

Revised: 23/04/03

APPENDIX - I Class or Subsidiary Risk Category

Class Label (Note 1)

Subsidiary Risk Label (Note 2)

Colouring of Label

3.1 and 3.2 Black or white lettering, symbol, numeral (if any) and lines on a background of the colour Red

4.1 Black lettering, symbol, numeral(if any) and lines on white back- ground with vertical stripes of the colour Red

4.2 Upper background white, Lower background of the colour Red specified in Table 3.4. Black lettering, symbol, numeral (if any) and lines 4.3 Black or white lettering, symbol, numeral (if any) and ines on a background of the colour Blue

5.1 Black lettering, symbol, numeral (if any) and lines on a background of the colour Yellow.

5.2 N.A.

Black littering, symbol, numeral and lines on a background of the colour Yellow.

(Cont’d)

PCFC-EG#17

Page 10 of 17

Revised:23/04/03

APPENDIX I Class or Subsidiary Risk Category

Class Label (Note 1)

Subsidiary Risk Label (Note 2)

Colour of Label

6.1 (a) Black lettering, symbol, numeral (if any) and lines on a white back- ground.

6.1 (b) Black lettering, symbol, numeral (if any) and lines on a white back- ground.

6.2 N.A.

Black lettering, symbol, numeral and lines on a white background

N.A.

Upper background of the colour yellow specified in Table 3.4 Lower background white. Black lettering, symbol, numeral and lines. Roman numerals in the colour Red.

7.

(Category II)

8. Upper background white. Black symbol and lines. Lower background back. White lettering and numeral (if any).

PCFC-EG#17

Page 11 of 17

Revised:23/04/03

APPENDIX - II DANGEROUS GOODS SEGREGATION REQUIREMENT

NA SP FS PR areas.

CLASS

1.1

2.1

2.2

2.3

3.1

4.1

4.2

4.3

5.1

5.2

6.1

8

1.1

NA

PR

PR

PR

PR

PR

PR

PR

PR

PR

PR

PR

2.1

PR

NA

NA

PR

FS

FS

PR

FS

PR

PR

FS

FS

2.2

PR

NA

NA

PR

SP

SP

FS

FS

SP

FS

SP

SP

2.3

PR

PR

PR

NA

PR

PR

PR

PR

PR

PR

PR

PR

3.1

PR

FS

SP

PR

NA

FS

FS

FS

PR

PR

FS

SP

4.1

PR

FS

SP

PR

FS

NA

FS

FS

PR

PR

FS

SP

4.2

PR

PR

FS

PR

FS

FS

NA

FS

PR

PR

FS

SP

4.3

PR

FS

SP

PR

FS

FS

FS

NA

PR

PR

FS

FS

5.1

PR

PR

SP

PR

PR

PR

PR

PR

NA

FS

FS

FS

5.2

PR

PR

FS

PR

PR

PR

PR

PR

FS

NA

PR

FS

6.1

PR

FS

SP

PR

FS

FS

FS

FS

FS

PR

NA

SP

8

PR

FS

SP

PR

SP

SP

SP

FS

FS

FS

SP

NA

-

PCFC-EG#17

Not applicable may be stored in the same room. Separate by at least 3 meters Separated by fire proof walls or a min. of 5 m Prohibited, must not be stored in the same room or space. Min. 10 m separation between storage

Page 12 of 17

Revised:23/04/03

17.3

GUIDANCE NOTE

A.

Liquefied Gas Storage Bulk storage of liquefied gases can be a serious safety hazard unless correctly designed, erected and maintained. Cost and safety are the two important factors. Storage for liquefied gases can be: a) b) c)

fully-refrigerated, where the liquid is stored at its bubble point at near-atmospheric pressure; or full pressure, where the liquid is stored at ambient temperature; or semi-refrigerated, an intermediate approach where the liquid is stored below ambient temperature but at a vapour pressure above atmospheric.

Following Table 17B lists the gases which are commonly stored in liquid form B.

Fully-refrigerated Storage Single-containment tanks are not suitable for fully refrigerated storage. It is normal practice to surround the primary liquid containment with a secondary shell, separated from it by a gap of up to six metres. The outer shell is capable of holding liquid but it is not designed to contain vapour released by product leaking from the inner shell. It is know as the double containment tank. If the outer shell is designed to hold vapour as well as liquid, the result is a full containment tank. In this case the gap between the two shells is one to two meters. The material of the inner tank depends on the product to be stored and the design code applicable. For the outer shell one of three materials is generally used : steel prestressed concrete, or reinforced concrete with an earthen embankment. A modern technique is to line a structural shell of prestressed concrete with a thin gas - and liquid-tight membrane of 304 stainless steel, or a lowexpansion nickel alloy such as Invar, supported on load-bearing insulation. The maximum capacity of fully-refrigerated tanks is normally up to 100,000m3, although some upto 150,000m3, have been constructed.

C.

Full pressure and Semi-refrigerated Storage Full pressure storage tanks are either cylinders or spheres. The modern tendency is to use cylinders for reasons of safety, spheres being more vulnerable to mechanical damage and they also suffer from cracking if the stress-relieving is imperfect. Full-pressure tanks are made from carbon steel or highimpact carbon steel, with insulation only provided to protect against fire and solar heating. The pressure vessel design code specifies the design pressure. Semi-refrigerated storage uses cylinders or spheres, depending on the required capacity. The tanks are insulated and the product temperature is maintained by re-liquefying the vapour which boils off. Carbon steel, normally killed, is the usual material of construction. For spheres, the mazimum plate thickness which can be welded is normally 50-60 mm and this, with the design pressure, the grade of steel, and the design code, fixes the maximum capacity, usually within the range 1,000-5000m3, depending on the type of gas. For cylindrical tanks the usual maximum capacity is about 600m3,but much bigger tanks have been built for special purposes.

PCFC-EG#17

Page 13 of 17

Revised:23/04/03

TABLE - 17B PRODUCTS COMMONLY STORED AS LIQUEFIED GASES.

GAS

BOILING LIQUID POINT AT DENSITY AT 1 BAR ABS BOILING ( oC) POINT (KG/M3)

VAPOUR PRESSURE AT 30 oC (BAR BAS)

CRITICAL TEMP. (oC)

Can be stored without refrigeration Ethylene oxide n-butane Butadiene (1, 3) Butylene (oC) Isobutane Ammonia Propane Propylene

11 0 -4 -6 -12 -33 -42 -48

883 602 650 626 595 682 582 614

2.7 3.6 4.1 4.3 5.0 14.6 13.0 15.7

195 152 152 146 135 133 97 92

-89 -104 -162 -183 -196

546 568 424 1140 808

-

32 9 -82 -119 -147

Require refrigeration Ethane Ethylene Methane (LNG) Oxygen Nitrogen

PCFC-EG#17

Page 14 of 17

Revised:23/04/03

D.

Tanks to suit the Product Nitrogen, oxygen and LPG are best stored at their boiling points at near-atmospheric pressure. Thus, fully-refrigerated storage is appropriate. For ethane and ethylene, their critical temperatures (32oC and 9oC respectively) exclude fullpressure storage at ambient temperature. For small capacities, semi-refrigerated storage in spheres of low-carbon steel is usual. For large capacities, fully refrigerated tanks are used. Propane, propylene, butane, butylene and ammonia can only be stored in full pressure tanks up to a certain capacity because of the limitation of plate thickness. Larger capacities commonly use semirefrigerated storage in insulated spheres and the largest capacities use fully refrigerated storage. Certain products need special attention during storage. Butadiene, for instance, must be stored at low temperatures to retard the formation of dimmers, even in the presence of an inhibitor. It is also important to keep an oxygen-free atmosphere to prevent the formation of explosive peroxides, and to circulate the liquid to prevent stratification and hence polymerization. Ethylene oxide is so unstable that it cannot be stored at ambient temperatures and is commonly maintained at about 5oC. The vapour space should be inerted with nitrogen or methane.

E.

Insulation A refrigerated tank is insulated to limit the leakage of heat into the tank and thus reducing to an acceptable level the rate at which product boils off. Insulation for single containment LPG tanks is often polyurethane foam applied to the outside of the shell and roof and rain-proofed. Doublecompartment tanks used for low temperatures, and single-containment tanks of the double-wall type, typically use a loose-fill insulation such as expanded perlite in the gap between inner and outer shells. Polyurethane or glass foam insulate the roof. For full containment tanks the insulation is typically sprayed polyurethane foam specially designed for cryogenic service. All flat-bottomed cylindrical tanks require insulation to limit heat transfer through the base.

F.

Pressure Relief All tanks must be protected by safety valves from overpressure. For tanks at atmospheric pressure the safety valves should generally be of the pilot-operated type and the discharge should point upwards to terminate at least 3 meters above the top of the tank. Some safety valves discharge to a closed system to catch liquid and in that case there must be no liquid traps in the discharge line nor must the back-pressure be excessive. To avoid excessive pressure, there should be a safety valve relieving to atmosphere and set at a slightly higher pressure than that to the closed system. It is also more important to avoid collapsing the tank under an internal vacuum, and pressure/vacuum valves are usually fitted.

G.

Fire Protection Various codes and regulations define the separation distances between storage tanks, and between groups of tanks and other facilities. Proper spacing can avoid disasters and is very important. Bunds are necessary to contain spills and should be low enough to give easy access in an emergency and to facilitate ventilation. The ground within a bund should slope away from the storage area to the remotest point practical. The Engineering Equipment and Materials Users Association (EEMUA, London) has published new recommendations for the design and construction of liquefied gas storage. It includes the latest requirements for refrigerated storage, giving special attention to environmental concerns and to the safety of surrounding areas.

PCFC-EG#17

Page 15 of 17

Revised:23/04/03

17.4

GENERAL GUIDELINES FOR DANGEROUS/HAZARDOUS MATERIALS HANDLING AND STORAGE

(i)

Areas for storage of hazardous material in any form (tanks, drums, solids, stockpiles, etc.) shall have a containment system for collecting and holding spills and leaks. The entire area shall be impervious to the waste or its waterborne constituents.

(ii)

Storage sites shall be designed such that storm water runoff from the rest of the site is diverted around storage areas. The runoff from the dike-enclosed storage areas shall be held for monitoring and treatment (if required) prior to discharge. The runoff water from storage areas shall meet the point source discharge criteria (see relevant Table in if it is to be discharged to the harbour and be treated on site if the above criteria cannot be met.

(iii)

The storage area shall be operated in such a manner that the spreading of hazardous material within or outside the area is eliminated or minimized.

(iv)

Tanks shall be equipped with an alarm or warning device which will sound an audible warning or other suitable device in the event the liquid level is exceeded.

(v)

A container holding hazardous material shall always be closed during storage except when it is necessary to remove or add material.

(vi)

Provision shall be made, if necessary, to prevent dust from hampering site operations and from causing health or safety hazards or nuisances.

(vii)

Containment curbs shall be maintained around loading and unloading areas, with controlled discharge as noted above.

(viii)

Containers and storage tanks shall be designed and made of suitable materials permanently to contain the hazardous materials. Storage facilities shall be inspected regularly for leakage.

(ix)

Incompatible materials shall not be placed in common containment areas or the same containers.

(x)

Storage facilities for volatile substances shall be covered, and venting systems shall be designed to prevent violation of air pollutant source emission criteria.

(xi)

Surface impoundments used to store hazardous materials shall be hard surfaced and underlined with impervious line and shall be designed with leakage monitoring and collection systems. Lining systems shall be liquid tight, shall be compatible with the structure material and the substance stored in the structure, and shall generally comply with the criteria for construction and operation of surface impoundments shall be to Authority’s satisfaction. Surface impoundments shall not be used to store volatiles, ignitable or reactive materials.

(xii)

Where groundwater pollution potential exists, monitoring of the aquifers is required. (see relevant Table for monitoring parameters)

(xiii)

Contingency plans shall be established to deal with emergencies arising from the accidental discharge of hazardous materials. Adequate fire-fighting, safety, and spill control equipment shall be readily available. Personnel shall be trained to handle emergency procedures. In the case of bulk storage of corrosive chemicals, adequate supplies of neutralizing agents shall be kept on hand. The contingency plan should also be developed so as to provide for coordination with the Authority and other government agencies.

(xiv)

The volume of the bund areas for the bulk storage tanks shall be 110% of the volume of the largest tank within the bunded area.

(xv)

The flooring of the bunded areas for chemical/hazardous material tanks shall be of good concrete and impervious material to prevent contamination of underground water from the seepage. Chemical Storage tanks basement should be of concrete and HDPE liner (2mm). Storage tanks for normal chemicals (i.e. with single liner) should have proper leak detection system while cathodic protection is preferred. For toxic chemical storage double liner with proper leak detection system is mandatory.

PCFC-EG#17

Page 16 of 17

Revised:23/04/03

17.5

PCFC REQUIREMENTS FOR HANDLING, IMPORT AND EXPORT OF RADIOACTIVE SUBSTANCES

(i)

Form S1 (available from H & S Section of EHS-FZ Dept.) to be duly filled and signed by company’s authorized person along with “Civil Defence” approval should be submitted to EHS-FZ Dept/PCFC.

(ii)

H & S Inspectorate will then check all submitted papers for approval.

(iii)

H & S Inspector to go and personally check the following: • • •

Radiation warning sign boards are placed on the vehicle. Driver of transporting vehicle should have TLD wrist/chest badge. To check the radiation level outside the box, stand atleast 1 meter distance from the box and record it on Form S1.

(iv)

Enter all details in the Radioactive Transportation Permits Register and write down the permit number on the form, sign and release it.

(v)

Copies of form S1 and all relevant papers shall be filled in respective company and radioactive materials file.

PROCEDURE FOR RE-EXPORTING & DISPOSAL OF SPENT SOURCE (i)

Form S2 (available from H & S Section of EHS-FZ Dept.) to be duly filled and signed by company’s authorized/competent person along with “Civil Defence” approval for re-exporting to other countries or for disposal of spent source back to the original supplier, should be submitted to H & S Section of EHS-FZ Dept/PCFC.

(ii)

H & S Inspector to check all the submitted papers and “Civil Defence” approval.

(iii)

Same procedure as for importing.

(iv)

Same procedure as for importing.

(v)

Follow up with the company for submission of proof of disposal/air way bill for the same. (It should be submitted within 30 days).

(vi)

Copies of form S2 and all relevant papers shall be filled in the respective company and radioactive materials file.

NOTE: All companies shall forward a monthly tracking report (available from H & S Section of EHS-FZ Dept./PCFC) by 5th of every month. References PCFC has based its requirements for the handling and storage of dangerous materials on the Gulf and United Arab Emirates standards and requirements. The following documents should be consulted. a)

Gulf Standard No. 62/1987 (U.A.E. Standard No. 69/1988). Industrial Safety and Health Regulations Hazardous Materials - Flammable and Combustible liquids. Part 1: Tanks, Piping and Accessories.

b)

Gulf Standard No. 63/1987 (U.A.E. Standard No. 70/1988). As above Part 2: Container and Portable Tank Storage.

c)

Gulf Standard No. 55/1987 (U.A.E Standard No. 62/1988). As above. Requirements.

d)

Gases. Part 1: General

PCFC Health and Safety Manual.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai. PCFC-EG#17

Page 17 of 17

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.18 WATER ENVIRONMENT GUIDELINES

18.1

WATER ENVIRONMENT GENERAL GUIDELINES

(i)

All the A.C drains to be discharged into a properly designed soakpit.

(ii)

Septic tank details shall comply with PCFC standard guidelines (See relevant EG)

(iii)

A linear soakaway (see relevant EG) to be adopted for all areas in the Free Zone without PCFC sewerage facilities.

(iv)

The area above the linear soakaway to be utilised for plantation purposes only and it should not be compacted to maintain the permeability of the soil as well as to prevent the soakaway from any damage. The number of branches and dimensions of the linear soakaway shall be checked by Health, Safety and Environment Section prior to backfilling.

(v)

Proper treatment plants to be constructed for the industrial waste effluent to meet PCFC harbour standards.

(vi)

Periodic sampling and analysis of final waste effluent should be carried out for those companies discharging to the harbour/open sea. Any sampling/analysis of wastewater effluent should be carried out by a third party laboratory.

(vii)

The drain from the compressor to be connected to a proper holding tank of suitable capacity for testing/further assessment and the same to be shown in the drainage layout drawing.

(viii)

A 2 mm mesh to be provided for all the wash basins in the restaurant.

(ix)

A proper Wade Actimatic grease trap should be installed for restaurants/canteens

(x)

Groundwater Monitoring Wells should be installed as per PCFC guideline (see relevant EG).

(xi)

Surface impoundments and storage tanks of trade waste (non-volatile) shall be designed to prevent the potential leakage. Use of impermeable (2mm HDPE) liner is mandatory.

18.2

TREATED WASTEWATER DISPOSAL IN HARBOUR/GULF (OPEN SEA) PCFC discourages disposal of treated wastewater in to the marine environment as a matter of policy. However, if an industrial liquid waste can be treated so as to meet the criteria for marine disposal then on a case-by-case basis the effluent may be assessed /evaluated by EHS FZ Dept for disposal to the harbour or open sea. Otherwise, industrial liquid effluents, hazardous or non-hazardous, have to be sent to the Dubai Municipality’s disposal systems, with or without pretreatment as decided by the Municipality. Samples, analyses and rates of production have to be submitted to the Municipality and forms have to be completed for decision as to where the effluents may be taken for disposal, either to the sewerage system or to the Jebel Ali waste site, if accepted. Relevant criteria which have to be met for disposal to the Municipality sewage treatment plant. The Municipality will issue certificates to companies and the Authority must issue gate passes to carriers to enable them to leave the Free Zone with their loads and be acceptable at the disposal sites. Industries should ensure that at least two days storage capacity of waste water is available on site, as contingency plan in the event that the wastewater cannot be removed as planned.

PCFC-EG#18

Page 1 of 6

Revised:23/04/03

18.3

ELEMENTS TO BE TAKEN INTO ACCOUNT IN THE ISSUE OF THE AUTHORIZATION FOR DISCHARGES OF TREATED WASTE INTO HARBOUR/OPEN SEA With a view to the issue of an authorization for the discharges of treated waste containing chemical substances, particular account will be taken, as the case may be, of the following factors:

A.

CHARACTERISTICS AND COMPOSITION OF THE DISCHARGES i ii iii iv v vi vii

B.

CHARACTERISTICS HARMFULNESS i ii iii iv v vi

C.

OF

DISCHARGE

CONSTITUENTS

WITH

RESPECT

TO

THEIR

Persistence (physical, chemical, biological) in the marine environment. Toxicity and other harmful effects. Accumulation in biological materials or sediments. Biochemical transformation producing harmful compounds. Adverse effects on the oxygen content and balance. Susceptibility to physical, chemical and biochemical changes and interaction in the aquatic environment with other sea-water constituents which may produce harmful biological or other effects on any of the users listed in section E below.

CHARACTERISTICS OF DISCHARGE SITE AND RECEIVING ENVIRONMENT i ii iii iv v vi

D.

Type and size of point or diffuse source (e.g. industrial process). Type of discharges (e.g. origin, average composion). State of waste (e.g. solid, liquid, sludge, slurry). Total amount (volume discharged, e.g. per year). Discharge pattern (continuous, intermittent, seasonally variable, etc.). Concentrations with respect to relevant constituents of substances as appropriate. Physical, chemical and biochemical properties of the waste discharges.

Hydrographic meteorological, geological and topographical characteristics of the coastal area. Location and type of the discharge (outfall, canal outlet, etc.) and its relation to other areas (such as amenity areas, spawning, nursery, and fishing areas, shellfish grounds) and other discharges. Initial dilution achieved at the point of discharge into the receiving environment. Dispersion characteristics such as effects of currents, tides and wind on horizontal transport and vertical mixing. Receiving water characteristics with respect to physical, chemical, biological and ecological conditions in the discharge area. Capacity of the receiving marine environment to receive waste discharges without undesirable effects.

AVAILABILITY OF WASTE TECHNOLOGIES

The methods of waste reduction and discharge for industrial effluents as well as domestic sewage should be selected taking into account the availability and feasibility of: i ii iii iv

Alternative treatment processes; Re-use or elimination methods; On-land disposal alternatives; Appropriate low-waste technologies.

PCFC-EG#18 E

Page 2 of 6

Revised:23/04/03

POTENTIAL IMPAIRMENT OF MARINE ECOSYSTEMS AND SEA-WATER USES

i

Effects on human health through pollution impact on: a. edible marine organisms; b. bathing waters; c. aesthetics

ii

Effects on marine ecosystems, in particular living resources, endangered species and critical habitats. Effects on other legitimate uses of the sea.

iii

18.4

WASTEWATER CRITERIA AT POINT OF DISCHARGE TO MARINE ENVIRONMENT/HARBOUR: STANDARDS FOR DISCHARGE OF WASTE WATER TO HARBOUR (1)/

PARAMETERS (2)

Colour Total Suspended Solids Floating Particles pH Temperature(3) Total Dissolved Solids Turbidity

SYMBOL

UNIT

Physical Properties Colour units TSS mg/1 mg/m3 pH units T C TDS mg/1 NTU Inorganic Chemical Properties

+

MAX. ALLOWABLE STANDARD (7)

50 50 None 6-9(6) 35 (max) 1500 75

Ammonia Total as (N) Biochemical Oxygen Demand Chemical Oxygen Demand

NH4 BOD5 COD

mg/1 mg/1

2 50 100

Chlorine Residual (4)Total Cyanide

ClCN

mg/1 mg/1

1.0 0.05

mg/1 mg/1 mg/1 mg/1 mg/1 mg/1

>3 20 40 0.1 10 2

mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1

20 0.1 0.05 2 0.05 0.05 0.2 0.15

Dissolved Oxygen(5) Fluoride Nitrate Sulfide Total Kjeldahl Nitrogen as (N) Total Phosphorus, as (P) Aluminum Antimony Arsenic Barium Beryllium Cadmium Chromium, total Chromium, VI

PCFC-EG#18

DO F NO3-N S-2 TKN PO4-3 Trace Metals Al Sb As Ba Be Cd Cr Cr+6

Page 3 of 6

Cobalt

Co

Revised:23/04/03

mg/1

0.2

Copper Cyanide Fluoride Iron Lead Manganese Mercury Nickel Selenium Silver Zinc Halogenated Hydrocarbons and Pesticides Hydrocarbons Oil & Grease Phenols Solvent Total Organic Carbon

Colon Group Egg Parasites Fecal Coliform Bacteria Total Coliform Warm Parasites

Cu mg/1 CN mg/1 F mg/1 Fe mg/1 Pb mg/1 Mn mg/1 Hg mg/1 Ni mg/1 Se mg/1 Ag mg/1 Zn mg/1 Organic Chemical Properties

0.5 0.1 25 2 0.1 0.2 0.001 0.1 0.02 0.005 0.5

mg/1 mg/1 mg/1 mg/1 mg/1 mg/1

Nil 15 10 0.1 none 75

HC O&G TOC

Biological Properties TC No./100 cm2 Cells/100 ml MPN/100ml -

5000 None 1000 1000 None

Notes: 1) Any discharge to surface drainage ditches must be authorized by PCFC and shall only be permitted in exceptional circumstances. 2) For any parameters not identified, specific standards will be determined on a case-by-case basis. 3) Temperature limit is the maximum allowed for discharge. 4) Chlorine residual is after 30 minutes contact and is total residual chlorine 5) Dissolved oxygen requirement is a minimum concentration requirement 6) Inclusive range not to be exceeded. 7) With respect to Harbor Discharge Standard, FZ Cos. should concentrate on full compliance of harbour discharge Standard Any sample repeated twice excedance of allowable standard will permit imposition of appropriate sanction as per FZ rules.

PCFC-EG#18

Page 4 of 6

Revised:23/04/03

18.5 WASTEWATER PRE-TREATMENT CRITERIA FOR INDUSTRIAL EFFLUENT INTO DUBAI MUNICIPALITY SEWERS

VARIABLE Physical Temperature Total Dissolved Solids Total Suspended Solids Chemical Aluminium Ammonia, Total (as N)a,b Arsenic Barium Biological Oxygen Demand (BOD5) Boron a,b Cadmium Chemical Oxygen Demand (COD) Chloride a,b Chromium – Total Chromium – Hexavalent Cobalt Copper Cyanide compounds Detergents Emulsified Tar, Oil & Grease Fluorideb Free Chlorine Iron Lead Manganese Mercury Metals (Total)d Nickel Non Chlorinated Pesticides Oil and Grease pH c Phenols Phosphorus, Total (as P) Sodium a.b Sodium Absorption Ratio (SAR) a.b Silver Sulfates (Total) Sulfides Synthetic Detergents Tar/Oils Total Organic Carbon (TOC) Zinc e

PCFC-EG#18

NOTES

UNITS

MAXIMUM VALUE

°C mg/l mg/l

45 3000 500

mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l pH units mg/l mg/l mg/l SAR units mg/l mg/l mg/l mg/l mg/l mg/l mg/l

30 40 0.5 2.0 1000 2.0 0.3 3000 700 1.0 0.25 2.0 1.0 1.0 30 150 30 10 25 1.0 1.0 0.015 10 1.0 5 50 6-9 50 30 1000 20 1.0 500 6 100 20 1000 2.0

Page 5 of 6

Revised:23/04/03

a) Parameters which will change if wastewater, after treatment, is not used for irrigation. b) A well-drained sandy soil is assumed for irrigation water receiving areas which will not be used for forage. c) Inclusive range not to be exceeded. d) The total amount of the above metals shall not exceed 10 mg/l of effluent. e) Zinc equivalent is defined as the sum of the concentrations in milligrams per liter of the following after application of toxicity factors. Toxicity factors: Zn = X1 Cu = X2 Ni = X3 Zinc equivalent = 1x(Zn)+2x(Cu)+3x(Ni)

f)

The effluent shall not at any time include the following substances : 1- Calcium carbide. 2- Compounds which in its state or in combination produce in the sewers an inflammable or toxic vapour. 3- Chlorinated hydrocarbons or related compounds. 4- Radioactive materials. 5- Volatile petroleum products.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#18

Page 6 of 6

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.19 ENVIRONMENTAL MANAGEMENT TOOLS (EMT)

1

GENERAL In order to improve industrial environmental performance cost-effectively, new environmental concepts, policies and management systems are being developed. This section introduces some of the main Environmental Management Tools (EMT) for awareness of PCFC clients. Environmental management tools are structured with the overall aim of improving the environmental performance of industry. Thus, environmental management tools can be used by companies to monitor, better manage or improve their environmental performance. The environmental management tools discussed here cannot be rigidly classified into different groups; there are overlaps between many of them, and most are still evolving. The descriptions that follow comprise basic definitions plus supplementary information illustrating how these tools are used in practice. The tools are presented in three groups - tools for action, tools for analysis and tools for communications. These tools can be used by industry for many benefits.

2

TOOLS FOR ACTION

A

Environmental Management Systems (EMS)/ ISO 14001 An Environmental Management Systems (EMS) is that aspect of an organization’s overall management structure that addresses the immediate and long term impact of its products, services and processes on the environment. It provides order and consistency in organizational methodologies through the allocation of resources, assignment of responsibilities, and on going evaluation of practices, procedures and processes. An EMS is essential to an organization’s ability to anticipate and meet growing environmental performance expectations and to ensure ongoing compliance with national and international requirements. EMS succeed best when corporations make environmental management among their highest priorities. ISO 14000 is an evolving series of generic standards being developed by the International Organizations of Standardization (ISO) that provides business management with the structure for managing environmental impacts. The standards include a broad range of environmental disciplines, including the basic management systems, auditing, performance evaluation, labeling and life - cycle assessment. ISO has assigned responsibility for the standard development to Technical Committee (TC) 207, which is made of sub committees and their working groups. The standards are basically of two types: guidance and specification. All the standards except ISO 14001 are guidance standards. Companies register for ISO 14001- the specification standard for EMS. PCFC recently received EMS ISO 14001 Certification and encourages companies to obtain the same, which can render them following advantages * * * * * *

Improved environmental control Integrated plant wide system Ownership of environmental matters throughout the plant from the lowest level up. More cost efficient and environmentally effective plant production performance. Improved waste management; and Industrial respect and recognition.

PCFC-EG#19 JAFZA hereby requires that:

Page 1of 6

Revised:23/04/03

i

All large sources and any other premises deemed by the EHS-FZ Department to have a significant or potentially significant impact on the environment in the event of an accident, shall within two years of the approval of this requirement, establish an environmental management system and shall either present this system to an independent certifying body for assessment against the requirements.

ii Any person directed in accordance with the above requirements or in management control of a large source shall report progress on a quarterly basis until certification or approval is received for the environmental management system and, once approved or certified, they shall submit one copy of the annual management system audit to the competent department for information. iii The occupier of any premises who has an environmental management system certified by an independent body approved shall be exempt from holding any discharge permits required under these regulations provided that the requirements are written into the management system objectives and targets and provided they submit to the competent department: a. an annual report on their progress against the EMS targets b. a waste audit in accordance with the requirements of PCFC. B

Integrated Pollution Prevention and Control (IPPC) Integrated Pollution Control (IPC) is the system by which the Authority regulates the largest and most polluting industrial processes. IPC is a permitting regime, under which no one may operate a process subject to IPC without an authorization issued by the Authority. The authorization must contain conditions based, primarily, on the use of the best available techniques not entailing excessive cost (BATNEEC) for preventing or minimizing polluting emissions, having regard to the best practicable environmental option (BPEO). Reductions in emissions secured through IPC make an important contribution to a number of environmental objectives, including those of reducing greenhouse gas emissions, acidification, dioxins and the precursors of low level ozone. The Integrated Pollution Prevention and Control (IPPC) is derived in large measure from IPC itself, although there are some important differences. IPPC requires to prevent or, where that is not possible, to reduce pollution from a range of industrial and other installations, by means of an integrated permitting process based on the application of “best available techniques” (BAT). This approach takes a wide range of environmental impacts into account - emissions of pollutants to air, water and land; energy efficiency; consumption of raw materials; noise and site restoration - with the aim of achieving a high level of protection for the environment as a whole. By implementation of IPPC industries would ensure to meet PCFC environmental requirements.

C

Cleaner Production “Cleaner Production” is defined as the continuous use of industrial processes and products to increase efficiency to prevent the pollution of air, water and land, to reduce wastes at source, and to minimise risks to the human population and the environment. On the other hand industrialization has proven to be at some cost to public health and the environment. When no care is taken this is especially true. When end-of-pipe pollution controls are added to industrial systems, less immediate damage occurs. But these solutions come at increasing monetary costs to both society and industry and have not always proven to be optimal from an environmental aspect. End-of-pipe controls are also reactive and selective Cleaner production, on the other hand, is a comprehensive, preventative approach to environmental protection. It requires people to be creative and to investigate all phases of manufacturing processes and product life cycles, including product usage in offices and homes. Cleaner production, thus, encompasses such actions as energy and raw materials conservation, eliminating toxic substances (as raw materials and as product constituents), and reducing the amount of wastes and pollutants created by processes and products,

PCFC-EG#19

Page 2 of 6

Revised:23/04/03

thereby lowering the amounts emitted to air, land and water. Following requirements would apply:

i

It shall be an offence to cause the pollution of any segment of the environment or to do any act or thing likely to cause the pollution of any segment of the environment.

ii In addition to the general provision of above item the following actions shall be deemed to be pollution of the environment. a. Disposal of any solid or liquid waste to the land environment at a site not approved for that purpose by DM/PCFC. b. Abandoning any wastes or chemical substances. c. Placing any wastes or chemical substances in a place where there is a risk of them entering any segment of the environment and affecting any protected beneficial uses. d. Emitting any substance to the air environment which affects the health or well-being of human beings. e. Discharging oil to the water or land environment. f. Emitting odorous substances into the air environment which are deemed by the Authority to be offensive to human beings. g. Discharges any oil, oily waste, waste water or solid waste from any vessel to the waters of PCFC.

D

iii

Where in the opinion of the Authority, a waste discharging from any premises is causing or is likely to cause the pollution of the environment or a condition of the environment unacceptable to the community, he may issue an order to cease that discharge immediately.

iv

Where a person receives an order under above item and that person does not act to cease the discharge in accordance with the order, that person shall be guilty of an offence and the Authority may take action to disconnect services to the premises and suspend the activities at the premises.

Waste Minimization: Waste minimization means the reduction of waste to the extent feasible at the source. It is based on the belief that prevention is better than cure. JAFZ, industries should make use of Reduce, Reuse and Recycle (RRR) options. Following requirements would apply: i

The occupier of any premises which emits waste to the air environment or generates any solid or liquid wastes shall employ good control practice as a minimum requirement to control the activities at that premises.

ii The waste generator shall have a duty of care to ensure that all wastes approved for disposal are securely packaged and loaded and reach the designated disposal facilities without alteration or loss. iii Any person handling wastes at any site, where these wastes were not generated by operations under that persons control at that site, must hold a permit from the DM/PCFC specifying: a. b. c. d.

The type of waste permitted to be handled. The quantity which may be handled. How the waste must be handled, and The information which must be collected and reported.

iv Any person generating any wastes must conduct an analysis of those wastes and report on the quantity and quality of those wastes, if directed by DM/PCFC.

PCFC-EG#19

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Revised:23/04/03

v All industrial premises in the Free Zone shall conduct their activities in such a way as to minimize the quantities of waste produced to the maximum extent practically achievable based on accepted cleaner production standards for that industry.

vi The competent department may require the occupier of any premises to prepare a waste audit and waste reduction plan to implement above item. vii The Authority may refuse any application for a new industrial or trade premises where it can be demonstrated that discharges or wastes from the project exceed the industry benchmark or an alternative lost waste technology is capable of achieving comparable output and product quality, unless the proponent modifies the proposed process. E

Land Restoration/Remediation: PCFC believes that the land allocated to the clients must be used so that proper measures are taken to avoid contamination of the same. Upon permanent closure it is client’s responsibility to restore or remediate the site to the Authority’s satisfaction before closing operation. Following requirements would apply: i

Any person who has caused pollution of any segment of the environment or any person who has done any act or thing which is likely to cause the pollution of any segment of the environment may be directed by notice in writing from the Authority to clean up the segment of the environment so affected or remove any material or wastes likely to cause pollution of the environment.

ii A notice to clean up any segment of the environment may specify: a. b. c. d. e. f.

A time limit within which a clean up must be completed. Requirements for sampling and testing. Standards prescribing acceptable residual levels in the environment. The means by which any wastes are to be treated and disposed of. Any procedures for conducting the clean up. Any requirements for protecting the health and safety of workers conducting the clean up.

iii When in the opinion of the Authority, the clean up of any segment of the environment is an urgent matter to protect that segment from pollution or protect the health of any person, the competent department may conduct the clean up or direct any other person to conduct the clean up and may recover all costs from the person proven to have caused the pollution or risk of pollution to accur. iv It shall be an offence to fail to carry out a clean up of any segment of the environment if so directed by notice in writing from the Authority. v

F

A person conducting soil excavation of site or conducting any activity which causes the disturbance of any area of levels would get Authority’s approval.

Energy Conservation: The energy should be used efficiently. The Authority and clients would take this principle in to account at the early stage of interaction. Use of natural light penetration roofs, windows are encouraged.

PCFC-EG#19

Page 4 of 6

Revised:23/04/03

The consumption of raw materials and their energy efficiency is also one of the factors to be considered when determining Best Available Technology (BAT). The level of improvement in energy efficiency to be secured by installations will, as with other improvements required by the Authority, need to take into account costs and advantages, but as a minimum, it is likely that operators will be required to take up all energy efficiency measures which are cost effective on

normal commercial criteria. Alternatively, it could be argued that the balance of costs and benefits might suggest that operators should be required to go further than implementing cost effective measures. In addition, the requirement to take energy efficiency into account means that regulators will not automatically penalize measures which involve combustion on site rather than remotely (such as combined heat and power or the use of processes which are driven by fuel rather than electricity) where such processes lead to higher emissions from the installation itself.

3

TOOLS FOR ANALYSIS

A

Environmental Impact Assessment (EIA) Environmental Impact Assessment (EIA) is an activity designed to identify and predict the impact on the biogeophysical environment and on man’s health and well-being of legislative proposals, policies, programmes, projects and operational procedures, and to interpret and communicate information about the impacts. In other words “The term ‘environmental assessment’ [a synonym of EIA] describes a technique and a process by which information about the environmental effects of a project is collected, both by the developer and from other sources, and taken into account by the planning authority in forming its judgment on whether the development should go ahead. [In EIA there is an] emphasis on systematic analysis, using the best practicable techniques and the best available sources of information, and on the presentation of information in a form that provides a focus for scrutiny of the project. The assessment should address both ecological and human health considerations, as well as such other effects as habitat modification and noise pollution. i

JAFZA has prepared EIA Guidelines for conducting the study and to prepare the “EIA Report”. A separate “Environmental Guideline” is available with the Authority for reference. These guidelines apply to the assessment of new projects in the Free Zone.

ii The proponent of any new or substantially modified industrial project or major service or utility project shall submit an environmental impact report at the planning stage in accordance with the guidelines of the Authority. iii On receipt of any environmental impact report as per above item, the authority may request any additional information required to adequately assess the project. iv On the final acceptance of an environmental impact report the Authority shall issue its assessment and recommendations. B

Environmental Auditing An environmental audit is a management tool comprising a systematic documented, periodic and objective evaluation of how well environmental organization, management and equipment are performing, with the aim of helping to safeguard the environment by facilitiating management control of environmental practices; and assessing compliance with company policies, which would include meeting regulatory requirements.

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Revised:23/04/03

Stated in other terms than the definition above, auditing is a methodological examination, involving analyses, tests, and confirmations of a facility’s procedures and practices with a goal of verifying whether they comply with legal requirements and internal policies, and evaluating whether they conform with good environmental practices. In this context, auditors base their judgements of compliance on evidence gathered during the audit and documented in the auditor’s working papers. Environmental auditing thus differs from assessments or inspections, which offer an opinion based

based primarily on professional judgment. Various names are used to describe the application of audit principles to environmental programmes. Audit is the most common, although review, surveillance, survey, appraisal, evaluation, and assessment are also used. In this context following requirements would apply: i

The Authority may require the occupier of any premises to conduct an independent environmental audit, if such an audit has not been carried out in the previous 2 years, in accordance with the PCFC guidelines.

ii The PCFC shall seek pre-qualification documents from environmental consultants and experts and based on their experience shall prepare an approved list of auditors to conduct audits or certify environmental management systems in accordance with earlier sections. iii No person shall offer professional services as an auditor or assessor of environmental management systems without the approval of the PCFC. C

Life Cycle Analysis (LCA) Life Cycle Analysis (LCA) is a systematic evaluation of the needs and opportunities to reduce the environmental burden associated with energy and raw materials use and environmental releases throughout the whole life cycle of the product, process or activity. This analysis may include both quantitative and qualitative measures of improvements, such as changes in product, process and activity design; raw material use; industrial processing; consumer use, and waste management. Life Cycle Analysis is sometimes used interchangeably with life-cycle assessment. While the term life cycle assessment has been used interchangeably, analysis is now preferred, as embodying fewer assumptions about the exhaustiveness of the evaluation. The terms analysis and assessment are also sometimes given different senses; analysis applying to the quantitative life-cycle inventory, and assessment to the qualitative interpretation of inventory results.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#19

Page 6 of 6

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No. 21 BEST AVAILABLE TECHNIQUES (BAT) AND BEST PRACTICABLE ENVIRONMENTAL OPTION (BPEO)

1.

BEST AVAILABLE TECHNIQUES It should be always be borne in mind that BAT is one of a number of objectives set out in section 7 of EPA 1990, which must be achieved as part of authorization conditions. It is helpful to consider the definitions of words Best Available Techniques (BAT). BEST: It means most effective in preventing, minimizing or rendering harmless polluting releases. There may be more than one set of techniques that achieves effectiveness. AVAILABLE: It should be taken to mean procurable by the operator of the process in the process in question. It does not imply that the technique has to be in general use, but it does require general accessibility. It includes a technique which has been developed (or proven) at pilot scale, provided this allows its implementation in the relevant industrial context with the necessary business confidence. It does not imply that sources outside the UK are ‘unavailable’. Nor does it imply a competitive supply market. If there is a monopoly supplier the technique counts as being available provided that the operator can procure it. TECHNIQUES: It is defined in section 7(10) of the EPA 1990. The term embraces both the plant in which the process is carried on and how the process is operated. It should be taken to mean the components of which it is made up and the manner in which they are connected together to make the whole. It also includes matters such as numbers and qualifications of staff, working methods, training and supervision and also the design, construction, lay-out and maintenance of buildings, and will affect the concept and design of the process.

2.

BEST PRACTICABLE ENVIRONMENTAL OPTION (BPEO) If the process is likely to involve the release of substances to more than one environmental medium, then section 7 (7) of the EPA 1990 requires that the Best Practicable Environmental Option (BPEO) is employed by the operator. BPEO can be defined as the option, which minimizes pollution to the environment as a whole, at acceptable cost, in the long term as well as the short term. A BPEO assessment for IPC should include an assessment of the environmental effects of releases and the economic implications of a number of options. BPEO is described as “the outcome of a systematic consultative and decision – making procedure, which emphasises the protection and conservation of the environment across land, air and water. The BPEO procedure establishes, for a given set of objectives, the option that provides the most benefit or least damage to the environment as a whole, at acceptable cost, in the long term as well as in the short term”. The significance of the concept of BPEO is by considering its elements as given below: BEST: It is the option chosen as best and will depend on the interpretation and evaluation of the predicted impacts by whoever takes the final decision. Research and development will continue to generate new technology, which may provide improved solutions. BPEO must therefore be kept under review. PRACTICABLE: It is one of the guidance notes on Best Practical Means (BPM) which explains how HMIP interprets the term:

PCFC-EG#21

Page 1 of 3

Revised:23/04/03

“In the Clean Air Act 1956 ‘practicable’ is interpreted as ‘reasonably practicable, having regard, amongst other things, to local conditions and circumstances, to the financial implications and to the current state of technical knowledge’”. The word ‘financial implications’ can relate both to the direct

direct capital and to the revenue costs borne by the operator of the process. The aim is to achieve a reasonable balance between the costs of prevention and / or dispersion and the benefits. Complete evaluations in monetary terms are seldom possible and experience has to be used in arriving a decision. The term ‘current technical knowledge ‘refers not only to knowledge about air pollution control technology but also the effects of substances on human health, flora and fauna, construction materials, property, agriculture and amenity, etc.’ In the context of BPEO, the use of the term ‘practicable’ implies that the option must not have disproportionate financial implications. The best practicable option will not necessarily be the cheapest. ENVIRONMENTAL: It is a central element in BPEO in the evaluation of options for their environmental effects early in the decision – making process. It is more cost effective to take account of environmental considerations at an early stage than to apply remedies later. It is essential to consider local and remote, short and long term effects in all environmental media. The possibility of improving the environment should always be explored. The effects on the environment of malfunctions, accidents or emergencies must also be considered. Plans should be developed to monitor environmental effects and to deal with mishaps. OPTION: It is the procedure for selecting a BPEO which should include a diligent and imaginative search for alternative ways of achieving the desired result. It is important to look into all options and not to be hindered by preconceptions. Where it is not enough to consider the BPEO for the disposal of a waste stream without also examining the production process to see whether the waste can be avoided reduced or its nature modified (RCEP, 1988). Principles and Procedures for selecting a BPEO include: •

Industrial plant which avoids emitting any pollutant;

•

Avoiding accumulation of a pollutant in the environment;

•

Permanent rather than temporary solutions to environmental problems.

BPEO methodology is set into six (6) stages as summarized below:-

Stage 1: Define the objective; e.g. produce a product or provide a service and meet the objectives of Integrated Pollution Control (IPC) Stage 2: Generate options for achieving the objective; -

generate available techniques screen the techniques select a small number of options to achieve the object

Stage 3: Assess the options -

Environmental assessment Economic assessment

Stage 4: Summarise and present the assessment -

set out all factors used in evaluation

PCFC-EG#21

Stage 5:

Page 2 of 3

Identify BPEO

Revised: 23/04/03

-

justify choice

Stage 6: -

Review the BPEO

sensitivity testing ensure there is an audit trail

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#21

Page 3 of 3

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.23 GUIDANCE FOR GROUNDWATER MONITORING WELLS INSTALLATION

1.

GROUNDWATER MONITORING WELL INSTALLATION GUIDELINES:

(i)

Groundwater Monitoring boreholes are drilled to a depth of 3-6 m (depending on local area) beneath existing ground level using boring rig. The boreholes (see diagram on next page) can be advanced through soil deposits using a casing vertically down and by removing soil inside to form a 150 mm (6 inches) diameter hole.

(ii)

Prior to commencing each borehole a services inspection pit should be hand dug to a depth of 1.0m

(iii)

Careful attention should be paid during boring to the existence of groundwater while inserting casing.

(iv)

The well should consist of a 5.0m long section of 100mm diameter PVC well screen, having a nominal slot width of 1.0mm and surrounded by washed fine gravel.

(v)

Above the screen plain casing be used to extend the well to ground level. The gravel pack be continued up to the top of the screen section and then a seal of cement/bentonite grout be placed to within 0.75m of the ground surface followed by fine sand to 0.5m below ground level. Concrete can be then placed around the pipe from 0.5m below ground level to just above the surface.

(vi)

The installation be completed by closing the PVC with a screw on top cap to about existing ground level. The installation be then encased in concrete and fitted with a lockable steel protection cover for height of about 0.3m above ground level (see diagram on next page).

(vii)

Ensure that perforated portion of pipe is always immersed in groundwater considering groundwater level decrease during summer.

(viii)

Safety barriers/bollards should ideally be put around the well with a warning sign.

PCFC-EG#23

Page 1 of 2

Revised:19/04/03

2.

GROUNDWATER MONITORING WELL/BOREHOLE DIAGRAM

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#23

Page 2 of 2

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No. 24 ENERGY EFFICIENCY 1

INTRODUCTION This guide is to motivate PCFC clients and make them aware about energy efficiency and to reduce the consumption of the energy. It also emphasises on the importance of energy efficiency as a management issue and provides guidance on how to motivate staff and start an energy awareness and saving campaign in the areas of steam systems, compressed air systems, motors, combustion, lighting, ventilation, air conditioning, heating, refrigeration, etc. A sustainable use of energy has direct commercial benefits and adds a competitive edge. Improvements in the way PCFC clients use energy will enhance working conditions, reduce operating costs and improve productivity and profitability as well as contribute in saving our plant and environment.

2

BACKGROUND While energy is at the heart of economic development, its excessive use is the cause of environmental concern at the local, national and global levels. United Nations Environment Programme (UNEP) is actively addressing these issues through the UNEP Collaborating Center on Energy and the Environment (UCCEE). The demand for energy, mostly met with fossil fuel (particularly oil), has increased steadily during recent years. Demand is expected to continue growing. The energy systems developed so far to meet this demand are clearly unsustainable, as they lead directly or indirectly to health-damaging levels of air pollution, acidification of ecosystems, land and water contamination, loss of biodiversity, and global warming. Nevertheless, there are reasons to hope that the destructive link between energy use and environmental quality can be broken. Improvements in technology, and the willingness to experiment with new economic approaches to energy pricing, are fundamentally changing energy markets and presenting new opportunities. It is increasingly true that there are no reasons why we cannot enjoy the benefits of a high level of energy services and a better environment. Renewable energy technologies, clean and efficient use of fossil fuels, have in many ways come of age. These will give an excellent opportunity to bypass the polluting energy path. Clearly we must eventually shift to sustainable energy systems. How soon that shift occurs depends on actions taken today. If investment is directed towards clean energy technologies, we will all enjoy economy that is more secure and much cleaner. This guide addresses the broad issues of energy and ideas concerning practical actions that can be taken to PCFC more energy efficient. PCFC stands ready to contribute towards achieving this goal.

3

INDUSTRY –SPECIFIC ENERGY EFFICIENT TECHNOLOGIES Industry uses more than one-third of all the energy used. Certain industries require a large amount of energy per unit of product, and are the best candidates on which to focus energy-efficiency efforts. Efforts to develop energy-efficient technologies are focused on the most energy-intensive industries, including the glass industry, the metalcasting industry, the petroleum industry, and the steel industry.

PCFC-EG#24

Page 1 of 3

For more information refer to useful web sites like:

Revised:23/04/03

i www.energy.gov/ ii www.osti.gov/

4.

COMBINED HEAT AND POWER SYSTEMS: The onsite production of electricity should be particularly attractive to industries that can also make use of the waste heat. Such combined heat and power systems – also called cogeneration systems – achieve higher thermal efficiencies than stand-alone power plants. For more information refer to useful web sites like: i www.dpa.gov/ ii www.pnl.gov/ iii www.ost.gov/

5.

MOTORS: Motor-driven equipment accounts for nearly 60% of the electricity consumed by industries. Energyefficient motors can cut this energy use by nearly 15%. For more information refer to useful web sites like: i ii

6

www.oit.doe.gov/bestpractices/ www.oitdev.nrel.gov/

STEAM SYSTEMS Nearly 50% of all the fuel burned by the manufacturers is consumed to raise steam. A typical industrial facility can realize steam savings of 20% by improving its steam system. Simple approaches to improving energy performance include insulating steam and condensate return lines, stopping any steam leaks, and maintaining steam taps. Condensate return to the boiler is essential for energy efficiency. For more information refer to useful web sites like: i www.ciac.lln.gov/ ii www.sandia.gov/

7

COMPRESSED AIRE SYSTEMS Optimization of compressed air systems can provide energy-efficiency improvements of 20-50%. Compressors using variable-speed drives are saving energy, while simple measures like detecting and fixing air leaks remain all-important. For more information refer to useful web sites like: i www.cdiac.esd.ornl.gov/ ii www.rrede.nrel.gov/

PCFC-EG#24

8

COMBUSTION

Page 2 of 3

Revised:23/04/03

Boiler and furnaces, rely on advanced burners to operate cleanly and efficiently, Emissions of pollutants such as nitrous oxides (NOx) and sulphur Dioxide (SO2) are always of environmental concern in combustion processes. For more information refer to useful web sites like: i www.http.lle.etd.lbl.gov/ ii www.ca.sandia.gov/CRF/

9.

SENSORS AND CONTROLS All industrial systems rely on sensors and controls. Advanced sensors and control systems can allow processes to operate at their optimal conditions. For more information refer to useful web sites like: i ii

10

www.energy.gov/ www.dpa.gov/

LIGHTING Energy efficient lights/bulbs are commercially available. Let us use it and save energy! For more information refer to useful web sites like: i ii

www.eefd.lbl.gov/ www.ornl.gov/hybridlighting

Be energy smart. Let us adopt energy efficient machines/products!

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#24

Page 3 of 3

Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.25 EHS STANDARDS REFERENCE Alphabetical Subject Index S.No. 1-

Standard Subject ABATTOIRS Hygienic regulations

2-

ABRASIVE WHEEL MACHINES Safety

70

ACETYLENE Industrial Safety and health regulations Transportable containers

56 56

3-

UAE/Gulf Standard No. 713

4-

AFLATOXINS Maximum limits of mycotoxins permitted in foods

5-

AIR POLLUTION see pollutant gases

6-

AMMONIA Liquid Safety

483 59

ASBESTOS CEMENT Flat sheets Pipe fitting Pipes, for sewage

487 481 33

ASHTRYS Plastics

476

7-

8-

841

9-

BABY FOODS Based on milk, potassium, phosphors and manganese, determination 786 Breast-milk substitutes 223 Canned 355 Chemical analysis 181 Infants foods based on milk 354 Formula based on milk, pantotuenic acid, 793 determination Powdered, cereal and legume based 677 Sampling methods 180

10-

BAKER’S YEAST Test Methods

264

BAKERY PRODUCTS Biscuits Biscuits, test methods Cakes Cakes, test methods

989 990 342 341

11-

PCFC-EG#25

1012-

13-

141516-

17-

Page 1 of 11

BACKING POWDER Test methods BATTERIES Lead acid starters Lead acid starters, test methods

Revised:23/04/03

291 34 35

BEANS Beans Frozen green beans

1036 344

BEEF Fresh, chilled and frozen

997

BLANKETS Acrylic blankets, test methods

753

BOILERS Code of practice, part 4: Comprehensive procedure for performance tests Industrial Safety and health regulations Requirements part 8

thermal 374 215 1338

BUILDING AND CONSTRUCTION WORK Industrial safety and health regulations

215

BUILDINGS Building facilities, safety Fire protection, safety Heat insulation Modular coordination Sanitation, safety and health

79 208 977 406 54

19-

BURGER MEAT

948

20-

BUSES see motor vehicles Pilgrim buses, safety requirements

967

BUTANE – PROPANE MIXTURE Commercial, household

672

18-

212223-

CAKES Mixes Test, methods CAMEL Fresh, chilled and frozen meat

342 852 341 834

24-

CANE SUGAR see sugar

25-

CANNED FOODS Baby foods Chickpeas

355 838

26-

CARBONATED DRINKS Carbon dioxide content determination Phosphoric acid content determination

18 12 14

27-

CARCINOGENS Industrial safety and health regulations

211

PCFC-EG#25

Page 2 of 11

Revised:23/04/03

28293031-

CARGO HANDLING Industrial safety and health regulations

82

CEMENT Hydraulic, chemical analysis

938

CENTRIFUGAL PUMPS Performance tests CEREALS Cereals and pulses-Part2: Sampling Hidden insect infestation, sampling Samollina Storage, control of attack by pests

288 952 952 843 721

32-

CEREAL FLOUR Enriched and enriched treated wheat flour 194 Enriched and enriched treated wheat flour, test methods 193

33-

CEREAL FOOD PRODUCTS see also wheat flour, wheat grains. Corn flakes Corn flakes, test methods Macaroni, spaghetti and vermicelli Macaroni, spaghetti and vermicelli, test methods Plant baby foods, sampling methods Sampling methods (as grains)

34-

259 258 163 164 180 245

CHEESE Cheddar cheese Chemical analysis Processed, with vegetable oils White, domiati and feta cheese

336 171 182 831

CHEMICAL PLANTS Industrial safety and health regulations

65

36-

CHEWING GUM Test methods

709 708

37-

CHICKENS Chilled Frozen Chilled fish

322 986 380

CHICKPEAS Canned

838

35-

3839-

CHIPS (FOO) see fried potatoes

40-

CHLORINE Liquid, sampling Liquid, water content determination

528 534

CHLOROFLOUROCARBONS For industrial use For industrial use, degree of purity determination

110 109

CHOCOLATE

567

41-

42-

PCFC-EG#25 43-

Page 3 of 11 CIGARETTES

see

also

tobacco

and

Revised:23/04/03 tobacco 597

products. Alkaloid determination Carbon monoxide determination Sampling Smoking machine-definitions conditions 44-

44-

4546474849-

and

COFFEE Caffeine content determination Green coffee beans Green Coffee in bags, sampling Vocabulary

101 292 598 standard 103

720 442 410 850

COLD STORAGE Fruits & vegetables, physical condition in cold 434 stores 225 Oranges Pears 321 COLORANTS (FOOD) 23 Test methods 22 COMPOST Municipal solid waste

901

COMPOUND FERTILIZERS Test methods

879

COMPRESSED GAS Safety

61

COMPRESSED GAS EQUIPMENT Safety

215

50-

COOLANTS See engine coolants

51-

CORN Puffed Puffed, test methods

784 784

CORNED BEEF Canned

504

53-

CORN FLAKES Test methods

259 258

54-

CRUDE OIL Standard test for cloud point

560

CUSTARD Powder

853

CYLINDERS Dissolved acetylene, basic requirements

744

DATES Prepackaged Whole, prepacked, test method

656 781, 657

52-

555657-

PCFC-EG#25

Page 4 of 11

Revised:23/04/03

58-

59-

DETERGENTS Anionic – active matter Liquid detergents for dish washing, test methods Sampling division Synthetic powdered detergents DIAMMONIUM PHOSPHATE Fertilizer

391 256 151 694

60-

DICHLORODIFLUOROMETHANE See chlorofluorocarbons

61-

DICHLOROTETRAFLUROMETHANE See chlorofluorocarbons

62-

DRAINAGE See sewage and drainage

63-

DRIED FOODS Conditions of storage

168

EDIBLE OILS AND FATS Storage, transport and handling Vegetable, Blanded Vegetable ghee

1018 658 991

EGGS Chemical testing Chicken

445 1002

ENVIRONMENTAL CONTROL Industrial safety and health regulations

209

EXPIRATION PERIODS Food products, part 1 Food products, part 2

150 1023

64-

65-

6667-

68-

EXPLOSIVES Dusts, explosives and blasting agents, safety and 210 regulations Transportation of explosive substances 975

69-

FERTILIZERS Ammonium sulphate Diammonium phosphate Compound Compound, test methods Monoammonium phosphate Organic Organic, test methods Singly superphosphate Superphosphate, test methods Triple superphosphate FIRE EXTINGUISHERS Dry chemical powder, multipurpose Phosphate Portable, dry powder Portable, foam

70-

PCFC-EG#25

Page 5 of 11

297 694 803 879 693 555 556 339 878 745 340 637 636

Revised:23/04/03

7172-

73-

747576-

77-

787980-

81-

FIRE PROTECTION Buildings safety FISH Canned pacific salmon Chilled Handling fresh fish at sea, general specification Hygienic practice for preparation and storing Microbiological tests Physical and chemical tests Shrimps, frozen Smoked

208 524 380 514 1026 655 589 582 270

FLAMMABLE AND COMBUSTIBLE LIQUIDS Container and portable tank storage, safety Industrial and bulk plants, Safety 63 Service stations, processing plants, Refineries and chemical plants, safety 64 Tanks, piping and accessories, safety 65 62 FLAVORINGS Use in foodstuffs 707 FLAVOURED ARTIFICAL Powders 848 FRLOURESCENT LAMPS Ballast’s for high pressure mercury vapor lamps 368 Ballast’s, for high pressure mercury vapor lamps, test methods 369 FOOD ADDITIVES See also sugar (food) Food preservatives. Antioxidants 357 Coloring matter 23 Coloring matter, test methods 22 Emulsifiers, Stablizers, thickners 381 In vegetable oils and fats 19 In vegetable oils and fats, test methods 17 Sweeteners, determination of 840 FOOD FLAVORINGS 707 FOOD HYGIENE Fresh meat 815 FOOD PACKAGING Packages, General requirements 838 Plastics cups and containers for packing beverages 462 FOOD PRESERVATIVES Benzoic acid, sodium benzoate and potassium 172 benzoate Benzoic acid, sodium benzoate and potassium 173 benzoate, test methods Permitted for use in foodstuffs 356 Salts of sulphurous acid 175 Salts of sulphurous acid, test 176

PCFC-EG#25 Page 6 of 11 Revised:23/04/03 82FOOD PRODUCTS See also animal fats, baby foods, bakery products, cereal food products, cocoa, dairy products, eggs, flour, halawa, hard candy, honey, meat and meat products, processed foods, sugar, tehena vegetable fats and oils, vegetable.

83-

8485-

86-87-88--

and oils, vegetable. Expiration periods, part1 Expiration periods, part 2 150 Omycotoxins, maximum limits permitted aflatoxins 1023 841 Prepackaged foods, labeling Transportation and storage of chilled and frozen 9 foods 323 FOOD TESTING 795 Antioxidants permitted for use in food products Baker’s yeast and inactive dried yeast Black and white pepper, determination of pipeline 264 content 819 Cereals, determination of falling number Cereals and pulses, determination of mass of 1000 792 grains 791 Fruit and vegetable determination of soluble solids content 1004 Fruit and vegetable determination of sorbic acid Fruit and vegetable determination of specific 347 gravity, pectin, pentosans Meat and meat products, glucono-delta-lactone 260 content determination Meat and meat products, - I (+) – glutamic acid 108 content determination Meat and meat products – I (-) – hydroxyproline 105 content determination Vegetable fats and oils, fatty acids determination, 106 part 2 Vegetable products, chloride content 275 determination 313 Vegetables, canned, microbiological tests Vegetables, caned, physical and chemical tests 178 177 FOOD TRANSPORATION 815 FRESH VEGETABLES Onions 1030 Potatoes 1029 Sampling methods 125 Vegetables marrow 1033 FREEZERS Household electric freezers 923 Household electric freezers, test methods 924 FRIED POTATOES 286 Test methods 285 FROZEN FOODS Mutton and goat meat 996 Peas 345 Shrimps 582 Spinach 811 Strawberries 415 Temperature of frozen foods, determination 324 Transportation and storage 323

PCFC-EG#25 Revised:23/04/03

89-

Page 7 of 11

FRUIT DRINKS Flavoured artificial powder

848

90-

Fruit drink Fruits See also tomatoes. Net weight and drained weight determination Water insoluble solids contents determination Water melon

794 244 239 1035

9192939495-

96979899100101102103-

104105106107108-

PCFC-EG#25 Revised:23/04/03 109-

FRUIT NECTARS Mango nectar Mixed fruit nectars FUELS See automotive fuels, aviation, fuels, gasoline, liquid fuels GAS CONTAINERS Pressure regulations, Lpg. Pressure regulations, lpg., test methods GAS CYLINDERS See cylinders, Personnel requirements for professions GASES See hazardous materials Dissolved acetylene Dissolved acetylene, test methods Liquefied petroleum Liquefied petroleum, test methods Oxygen, medical use Oxygen, medical use, test methods Oxygen industrial Oxygen industrial, test methods GASOLINE See also automotive fuels, aviation fuels. GLASS BOTTLES GLUTEN-FREE FOODS GOAT MEAT Fresh, chilled and frozen Organs and viscera GRAIN (FOOD) See cereal, food Products, wheat grains GRAPE FRUIT JUICE GREEN BEANS HAZARDOUS Materials See also industrial safety and health regulations Bulk plants, safety Gases, hydrogen, safety Gases, LPG, safety Gases, nitrous oxide and oxygen, safety Spray finishing paints HEALTH AND SAFETY REGULATIONS See industrial safety and health regulations HONEY HYDROGEN HYGIENE Food plants and personnel Poultry abattoirs, personnel INDUSTRIAL AND BULK PLANTS

249 846

586 587 472 557 559 672 673 563 564 139 138

1021 996 835

490

64 57 60 58 66

147

21 713

Page 8 of 11

INDUSTRIAL SAFETY AND HEALTH REGULATIONS Equipment, forging machines Equipment, machinery, general requirements Equipment, materials handling Equipment, machinery, power press

71 124 214

Equipment, mills, plastic and rubber industry Petroleum industries Processing paints Refineries Service station Tanks, flammable materials Vehicle mounted work platforms Welding, cutting and brazing 110111112113114115-

116117118119120121122123124125126127-

128-

PCFC-EG#25 Revised:23/04/03

129-

JAMS JELLIES KEROSENE LABAN AND LABENH LABELING Pre-packaged foods Tobacco products LAMPS Ballast’s for high pressure mercury vapor lamps High pressure mercury vapour lamps LEAD ACID BATTERIES LIQUEFIED PETROLEUM GAES LIVESTOCK TRANSPORTATION Sheep & goat 714 LPG See liquefied petroleum gases LUBRICATING OILS Demulsification number determination Diesel oil MACARONI Test methods MAIZE OIL Edible MALT BEVERAGE Test methodos MANGO JUICE MANGOES Canned Guide to storage MARMALADES MEAT Ash determination Beef and buffalo fresh, chilled and frozen Starch content determination Total fat content Total phosphorus content determination MICROBIOLOGICAL TESTING Cheese Detection of salmonella Drinking and mineral water Genera guidance Preparation of samples Sterility test Water non-routine tests

72 75 74 65 65 65 62 80 220 640 193 816 9 246 369 829 34

131 477 163 164 114 1027 1028 249 951 847 640 993 83 89 85 107 179 287 818 810 261 590 378

Page 9 of 11

MILK Detection of salmonella Dried Liquid, microbiological tests Physical and chemical analysis Raw

994 10 571 570 174

130131-

132133134135136137138-

139140141-

142143145146147148149150151-

PCFC-EG#25 Revised:23/04/03

152-

Sampling methods Sterilized MILK PRODUCTS Cream MINERAL WATER Bottled natural Determination of arsenic Determination of barium Determination of borate Non-routine microbiological tests Sampling Unbottled drinking water MONOAMMONIUM PHOSPHATE Fertilizer MUTTON See also meat Fresh, chilled and frozen MUSTARD SEED OIL MOZZARELLA CHEESE OCCUPATIONAL SAFETY See industrial safety ORGANIC FERTILIZERS PACKAGING See also this (containers) Food Packages Plastic bottles for chemical materials and products Plastic cups for beverages Polyethylene films used for packaging nonfoodstuffs PERSONAL PROTECTIVE EQUIPMENT See industrial safety and health regulations PETROLEUM INDUSTRY See also refineries Safety POLLUTANT GASES Motor vehicles, diesel engines, exhaust gaseous pollutants determination Motor vehicles, diesel engines, limits of pollutants emitted to the atmosphere Quality assurance inspection and test RADIOACTINE MATERIALS RAW MILK REFINERIES SAFETY Fire safety, colors & signs SEMOLINA SLAUGHTERING Animal slaughtering requirements STERILIZED MILK STORAGE See also cold storage, expiration periods Cereals and pulses, control of attack by pests Chilled and frozen foods, general requirements

569 985 651 987 117 154 642 379 111 149 693 997 833 555 839 132 462 393

74 414 144 9003 174

522 843 993 985 721 323

Page 10 of 11

STORES For frozen and chilled foodstuff, definitions, 968 classification and terminology For frozen and chilled foodstuff, general requirements 969 For frozen and chilled foodstuff, labelling and marking 970

153154-

155156157-

158-

159160

SUGAR AND SUGAR PRODUCTS See also Gulucose TANKS Equipment, industrial safety Hazardous materials, industrial safety Portable hazardous materials, industrial safety TOLUENE For industrial and commercial use For industrial and commercial use, test methods UTENSILS See cooking utensils VEGETABLE See also tomatoes Alcohol insoluble solids determination Alcohol insoluble solids determination, method for fresh or quick frozen peas Alkalinity of total ash determination Apparent viscosity determination Canned microbiological tests Canned, physical and chemical tests Carrots Vegetables marrow Ware potatoes, storage Water insoluble solids content determination VEGETABLE OILS AND FATS See also oilseeds Edible, arachis oil Edible, food additives Edible, maize oil

215 62 63 891 892

299 331 243 244 299 178 177 1038 1033 310 239 1023 19 144 163

VERMICELLI WATER Bottled drinking water 1025 Drinking and mineral water, arsenic determination 177 642 Drinking and mineral water, calcium determination 641 Drinking and determination

mineral

water,

fluoride 117

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#25 Revised:23/04/03

Page 11 of 11

ENVIRONMENTAL GUIDELINE No.26 DUCAMZ ENVIRONMENTAL GUIDELINES

1

INTRODUCTION The Workshop and Maintenance areas of DUCAMZ needs to be upgraded to meet EHS guidelines in line with the standard operating practices of PCFC.

2

GENERAL GUIDELINES














3

ANTIFREEZE











4

Substitute a less toxic raw material. Switch to non-chlorinated compounds, such as citrus based solvent for parts cleaning. Always ask for and keep MSDS of any product used in the facility. Always use funnels or pumps to dispense chemicals. Keep all chemicals in sealed containers with tight fitting lids. Keep lids on all solvent containers when not in use. Seal all floor drains to prevent ground contamination. Use dirty solvents first when cleaning parts and use a filter on parts washer to extend life of solvent. Consider switching to water based cleaner instead of chlorinated spray cans of brake/ carburetor cleaner. Contact a PCFC approved contractor for recycling of used solvent Contact a PCFC approved transporter for disposal of used hazardous wastes. Consider installation of an on-site distillation unit to recycle spent solvents. Dirty floor washings should be routed with other industrial waste water (effluent) to a proper holding tank for suitable disposals.

When good antifreeze must be removed for repairs only, save it and return it to the system after repairs have been completed. Separate spent antifreeze from other wastes. Consider keeping antifreeze in two separate, closed containers: one marked waste anti freeze for those that cannot be reused, and on marked usable antifreeze only for anti freeze that can be reused. If on-site recycling is not feasible, recycle your antifreeze through an authorized recycling service or dispose as per PCFC procedures. If you recycle antifreeze on the premises, filters and other recycling products may be hazardous. You need to make a waste determination. Consider purchasing equipment to recycle antifreeze on-site. Check before putting recycled antifreeze into any vehicle. Don’t mix waste antifreeze with any other waste. Keep it separate. Don’t mix propylene glycol & ethylene glycol – it’s harder to recycle. Don’t ever dispose of antifreeze in a storm drain, septic tank, or dry well. Don’t ever pour antifreeze on the ground/sewer system.

BRAKE FLUID





Collect brake fluid in a separate, marked, closed container and identify a contractor that will recycle it. Disposals shall be done as per PCFC procedures Don’t put brake fluid into your used oil container. Don’t pour brake fluid down any drain or on the ground. Don’t spray brake cleaner around brake fluid.

PCFC-EG#26 Revised:23/04/03

Page 1 of 5

5

CARBURETOR CLEANER (COLD TANK)





Consider eliminating chlorinated carburetor cleaner and switching to a less hazardous, non – chlorinated cleaner. Keep the carburetor cleaner container closed when not in use to avoid evaporation. When carburetor cleaner is spent, contact a company to recycle it or properly dispose of it at a permitted hazardous waste disposal facility. Don’t pour carburetor cleaner down any storm drain, or into a septic system, dry well, or sewer.




Don’t put sludge from your cold tank into the skip or on the ground.





6

FLOOR CLEANING WASH WATER








7

FREON (CFC’s)




8

Freon (if imported) should be registered with the Federal Environmental Agency (FEA). Keep records of the dates and quantities of freon recovered and recycled. Don’t evaporate or vent freon to the atmosphere.

HOT TANK SOLUTION






9

Keep your floors as clean as possible at all times. Catch leaks before they spill on floor and dispose the residue in the appropriate waste container. Clean small, non-chlorinated spills immediately with absorbent material and save for reuse until absorbing ability is gone. It can then be placed in a waste container for suitable disposal. It is recommended to connect all industrial wastewater sources to a holding tank. Use absorbent pads to collect floor cleaning wash water and wring out the pads into appropriate waste container when saturated. Do not dispose into sewerage system. Use holding tanks. Receive permission from PCFC for disposal. Don’t dispose of absorbents contaminated with chlorinated solvents in a skip. These are hazardous. Don’t allow floor cleaning wastewater to flow into a storm drain (inside or outside) or sewerage system.

Consider alternative cleaning methods such as detergent-based cleaning liquids. Accumulate all sludge from hot tanks in a closed, marked, plastic container. Determine through testing if sludge is hazardous, and dispose accordingly. Don’t dispose of spent hot tank solution down any drain or on ground. Don’t dispose of hot tank sludge in a skip or on the ground.

LEAD ACID BATTERIES














Properly dispose of batteries by delivering them to: a wholesaler or retailer from whom you purchased the batteries, a permitted secondary lead smelter, a facility that recycles the batteries by extracting the lead, or a collection center that sends batteries to a smelter or recycler. Dispose/recycle batteries at least every six months with approvals form PCFC Store batteries upright in a secure, leak resistant, covered location. Check regularly for leaks, if leaking dispose as hazardous waste. Don’t store batteries outside. Don’t dispose batteries in the garbage or skip. Don’t take lead acid batteries to a unsecure landfill. Don’t burn/incinerate batteries. Don’t pour acid down the drains.

PCFC-EG#26

Page 2 of 5

Revised:23/04/03

10

PAINT WASTE











11

PRESSURIZED SPRAY CANS






12

Minimize use of shop towels by preventing spills/leaks. Use cloth towels that can be cleaned/reused. When possible, use less hazardous cleaning solvents. Keep soiled shop towels in a closed container marked separately for disposal or cleaning. Minimize disposable paper towels or rags. Don’t dispose dirty towels in your skip. Don’t saturate the towels, if you do, wring them out and reuse the liquid. Don’t dispose solvents by pouring the into containers of used shop towels.

SOLVENTS & SOLVENT TANKS








14

Consider phasing out spray cans in your shop and switch to non-aerosol. Consider using refillable canisters that use compressed air, portable parts washers or pump sprayers. Make sure spray cans are empty prior to disposal. If a spray can malfunctions, handle as hazardous waste, don’t dispose as general waste. Recycle empty metal cans.

SHOP TOWELS









13

Use paints with no heavy metals as far as possible. Use water based paints wherever feasible. Re-use thinner until capability is exhausted. Spray paint systems should be controlled to mitigate overspray. Use proper paint booths approved by PCFC. Keep lids tight on all cans of solvent or paint. Vent paint emissions only through suitable extraction/filtration systems Dispose paint residues, filters, wastewater through PCFC as per approved procedures. Don’t dispose any waste paint to ground, sewer etc. Don’t evaporate paint waste. Don’t buy/store more paint than required.

Consider using less hazardous solvents. Install a filter on the solvent sink and dispose filters as hazardous waste. Make sure a solvent is dirty before using a new solvent. Remember that sludges, filters etc. are hazardous and should be handled, disposed as such. Keep different types of solvents in separate, clearly labelled, closed containers. Don’t dispose spent solvents by pouring them on the ground/floor drains or by evaporating. Don’t mix solvents with other wastes or used oil.

SPRAY CABINET WASH WATER







Skim off oil from wash water and store separately for disposal. Contact PCFC authorities for disposal of washwater. Accumulate paint sludge in closed containers for disposal as per standard procedures. Close of all drains that lead to storm sewers, septic tanks etc. Check with PCFC authorities for disposal of any wastes from this unit. Don’t dispose paint sludge or any hazardous waste in the domestic skip.

PCFC-EG#26 Revised:23/04/03 15

SUMP SLUDGES

Page 3 of 5







16

Have sludge segregated/tested/analyzed prior to disposal. Keep all records of disposal. Don’t put hazardous sludge in the skip or ground. Don’t use a domestic tanker service for sludge disposal. Obtain relevant forms from PCFC for disposal to DM facilities.

TRANSMISSION FILTERS






17

Remove oil by draining for minimum 24 hours. Keep filters in a container marked separately for “Transmission Filters”. Try & locate a waste recycling facility for these filters. Put transmission fluid drained from filters in your “Used Oil” Container. Don’t discard any filters in the trash skip.

TRANSMISSION FLUID


Catch the Automatic Transmission fluid (ATF) in containers when removed/drained form the vehicle. Designate a proper area in the workshop to help consolidate/arrange wastes. Keep used oil in a properly marked container (Used Oil Only). Use a specially designated Mop and bucket (or sponge) to collect spills and transfer to a used ATF container. Make sure that your container for wastes is placed in a secure area and train your workers. Don’t dispose used ATF in a sewer, septic tank, drainage system. Don’t mix brake or carburetor cleaners/fluids with ATF. Dispose ATF in accordance with PCFC procedures. Use only approved transporters to collect/dispose the wastes.











18

USED OIL








Catch oil dripping from parts, transfer funnels, leaking vehicles etc. in a drip pan. Keep used oil in a properly marked container (Used Oil Only). Make sure that your container for wastes is placed in a secure area and train your workers. Use only approved transporters to collect/dispose the wastes. Know where the waste oil goes from your facility. Keep all disposal /recycling records. Don’t pour used oil on the ground, storm drains, floor drains, septic tank etc. Don’t mix incompatible wastes like brake fluid, used antifreeze, solvent cleaners etc. with used oils. Try and identify used oil recycling companies instead of disposal.




19

USED OIL FILTERS







20

Remove oil by puncturing filter and collect after draining for minimum 24 hours. Keep used drained/undrained filters in separate marked containers Keep used oil from filters in a properly marked container (Used Oil Only). Use only approved transporters to collect/dispose the wastes. Dispose filters in accordance with PCFC procedures. Don’t put filters in your waste skip.

UNDERGROUND STORAGE TANKS Get your underground storage tanks approved by the authority (PCFC). Ensure that the tanks are in compliance with leak detection requirements of PCFC Don’t remove/dispose contents of the storage tanks without PCFC approvals.

PCFC-EG#26

Page 4 of 5

Revised:23/04/03

21

TYRES






Disposal of waste tyres should be as per standard PCFC procedures. Identify retreading companies to recycle the tyres. Store the tires in accordance with PCFC requirements. Don’t accumulate large number of tyres. It is a fire hazard. Don’t illegally dispose, burn tyres.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#26 Revised:23/04/03

Page 5 of 5

ENVIRONMENTAL GUIDELINE No.27 GUIDELINES ON CLEANLINESS

1.

OBJECTIVES These guidelines specify the requirements on cleanliness in PCFC to ensure that the work places are maintained in a manner that will enhance clean environment.

2. (i)

SCOPE AND RESPONSIBILITES ( i.e from cradle – to grave) The Industries This document follows the chain by which waste is generated and disposed off in a suitable manner to keep work place in the PCFC free of objectionable waste.

(ii)

Roles of PCFC, Industry and Consumers PCFC being an authority will encourage the implementation of these guidelines to keep the environment clean and eventually protect the public from hazards that can affect their health. The Industry’s Responsibility is to provide a system by which waste is handled and disposed off in a manner that will achieve goal of environment mutation. The consumers should follow relevant instructions and apply appropriate food hygiene measure.

3.


ENVIRONMENTAL HYGIENE No person is allowed to throw, put, leave, melt or discharge any of the following materials or objects on roads/streets, lanes, alleys, pavements, open spaces, buildings, roofs, walls, stairways and any other place whether public or private: a. All kinds of garbage and waste such as refuse, sweepings, rubbish, discarded paper, stagnant water, bathing, laundry, sewerage, absorption pits, cesspools and others. b. Anything whether a chattel, animal, material or object which may obstruct traffic or pedestrians or occupy the public road or disfigure the public view or beauty in PCFC, or violates the requirements of public hygiene and environment protection and non-pollution.




Exceptions to these precedent provisions are the areas and places, which are specified by PCFC in accordance with necessary situations, conditions, specifications and permits.




All pedestrians, car drivers and passengers are prohibited from discarding paper or any type of garbage including cigarette butts and spitting in the public road or open spaces whether fenced or unfenced. The car driver shall be jointly liable with the passenger if the passenger commits the said violation.




Dumping trees and park’s residues in the road and squares whether public or private, and in the open areas whether fenced or unfenced is prohibited. The responsible parties to the sites specified for that purpose must transport it.




Spitting, Urinating or defecating in places other than those specified for that purpose are prohibited.

PCFC-EG#27

Page 1 of 4 Revised:23/04/03




Litter bins allotted by the PCFC for pedestrian’s litter in public places shall not be used for purposes other than its intended purpose. Dumping of domestic waste from camps and stores or combustible and inflammable materials is also prohibited.




Owners of restaurants, cafeterias, barbeque stalls and other places using open fire or charcoal are prohibited to dump fire residues and flaming coal ashes in litterbins, bags or boxes or in the public roads. They are also prohibited to place chairs and tables outside their business premises without the PCFC approval.




Empty bottles of carbonated waters and other drinks shall be kept in their respective boxes. Empty or filled boxes or bottles broken or otherwise shall not be left on the pavements, streets, lanes, squares or public parks.




Tire repairs and oil changing waste should not be left on pavements or roads. These should be transported at their own expense to the designated Municipality places or advise Public Health Services of EHS-DPA Dept. at 8816128.




Cars, vehicles and other means of transport should not be washed in public roads or open spaces except where permitted by the Authority.




Housekeeping both within and outside the industries/showrooms, service stations, canteens and other establishments shall be maintained as per PCFC requirements.




All wastes should be handled and collected in suitable containers for necessary disposal with the approval of the Authority. No industrial/trade wastes shall be dumped in sewers, garbage bins, roadsides, storm water drains etc.




No wastes (solid, liquid or airborne) shall be disposed/released without appropriate approvals from the Authority.




Looking is not allowed at any of the showrooms, service stations, workshops etc. other than the licensed canteens and eating establishments. These eating establishments shall conform to the requirements of PCFC.




Adequate Fire protection/detection facilities should be provided at all facilities/establishments and this equipment should be tested and certified each year from an approved third party agency.




No washing of cars or maintenance activities shall be permitted at any establishment other than the licensed service stations or car wash centres.




All authorized car wash/maintenance/service stations shall provide suitable collection/treatment/ recycling facilities for the wastewater generated from the same.




All facilities/establishments shall ensure that garbage/domestic wastes are disposed by an approved agency.




Manual Cleaning of vehicles in DUCAMZ showroom plots should not lead to any drainage of contaminated water into adjacent plots/roads/storm water drains etc. and suitable provisions should be made to mitigate such eventualities. Water Spray washing of vehicles within the showrooms establishment premises is not permitted.




For all spray painting/blasting operations, a proper painting/blasting booth should be constructed with a proper extraction/filtration system. These systems shall be designed to achieve the EHS standards for emissions as per PCFZC/DM guidelines.




All facilities generating wash/process wastewater should have valid disposal permits from PCFC and/or DM.




Wherever applicable, on-site process waste/wash water storage facility for a minimum of 7 days of generation should be installed to cater for emergencies.




No storage of hazardous chemicals or industrial waste effluent generation shall be allowed in showroom units.

PCFC-EG#27 Revised:23/04/03


Page 2 of 4

Accommodation is not permitted within any of the industrial premises in PCFC -JAFZ/DUCAMZ.




Waste oils shall be recycled/disposed only after requisite approvals from the Authority.




Vehicles shall not be parked on the roads and within roundabouts and only within the company’s premises, allowing a clear 5.5m setback distance for emergency access.




Contact a PCFC approved contractor for recycling of used solvent




Dirty floor washings should be routed with other industrial waste water (effluent) to a proper holding tank for suitable disposals.




Don’t mix waste antifreeze with any other waste. Keep it separate.




Don’t mix propylene glycol & ethylene glycol – it’s harder to recycle.




Don’t ever dispose of antifreeze in a storm drain, septic tank, or dry well.




Don’t ever pour antifreeze on the ground/sewer system.Collect brake fluid in a separate, marked, closed container and identify a contractor that will recycle it. Disposals shall be done as per PCFC procedures.




Don’t pour carburetor cleaner down any storm drain, or into a septic system, dry well, or sewer.




Keep your floors as clean as possible at all times. Catch leaks before they spill on floor and dispose the residue in the appropriate waste container.




Keep records of the dates and quantities of freon recovered and recycled.




Don’t dispose of hot tank sludge in a skip or on the ground.




Don’t dispose batteries in the garbage or skip.




Use water based paints wherever feasible.




Recycle empty metal cans.




Keep soiled shop towels in a closed container marked separately for disposal or cleaning.




Keep different types of solvents in separate, clearly labeled, closed containers.




Accumulate paint sludge in closed containers for disposal as per standard procedures.




Have sludge segregated/tested analysed prior to disposal. Keep all records of disposal.




Keep filters in a container marked separately for “Transmission Filters.”




Keep used oil in a properly marked container (Used Oil Only).




Keep used oil in a properly marked container (Used Oil Only).




Dispose filters in accordance with PCFC procedures.




Ensure that the tanks are in compliance with leak detection requirements of PCFC.




Identify retreading companies to recycle the tyres.

PCFC-EG#27

Page 3 of 4 Revised:23/04/03




All over-ground bulk fuel/chemical tanks should be bunded/dyked by a suitable concrete enclosure to prevent spills and contamination in case of tank failure/emergencies.




A proper spillage collection facility to be provided for all chemical/fuel storage and mixing/filling/processing areas.




A.C./chiller drains to be discharged into a properly designed soakpit or to the nearest floor drain.




A septic tank and linear soakaway system should be adopted for all areas that do not have a sewerage system.




No cooking is allowed in the company/showroom premises.




Any abrasive blasting shall follow PCFC/DM guidelines for Abrasive blasting.




All facilities generating wash/process wastewater should have valid disposal permits from PCFC and/or DM.




Wherever applicable, on-site process waste/wash water storage facility for a minimum of 4 days of generation to be built to cater for emergencies.




Proper extraction/filtration systems to be provided for the airborne emissions from any proposed machinery.




The drain from compressors/pump rooms/blow down etc. are considered as industrial waste and should be connected to a proper holding tank of suitable capacity for testing/further assessment.




mm mesh to be provided for all the washbasins in any restaurants. Also, a proper Wade Actimatic grease trap should be installed for the drainage from the cutting/cooking areas in the restaurants.




No storage of hazardous chemicals or industrial waste effluent generation shall be allowed in pre-built units.




Chimneys as well as ducting from any extraction/filtration systems shall be released at a minimum of 3 m. above the roof ridge of the tallest adjacent building.




A proper facility should be provided for placing/servicing of a domestic solid waste skip on the site.




The trucks/vehicles loaded with material, which might be blown by wind, are prohibited from being on the roads without tarpaulin cover. Also the leakage/spill of any loaded sand or any materials is prohibited from vehicles/trucks on being on road in PCFC/JAFZ/DUCAMZ.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#27

Page 4 of 4 Revised:23/04/03

ENVIRONMENTAL GUIDELINE No.28 GENERAL ENVIRONMENTAL GUIDELINES FOR MANUFACTURING/ASSEMBLY/SERVICE INDUSTRIES 1

INTRODUCTION PCFC applies specific environmental guidelines for specific projects on a case-by-case basis. With respect to subject types of industries the general environmental guidelines outlined here can be used, but, depending on the project, the requirements may need to be supplemented by additional requirements. Projects must comply with PCFC polices and guidelines, which emphasize pollution prevention Reuse, Recovery, Recycle (RRR) options, waste minimization, including the use of cleaner production technologies. The intent of the guidelines is to minimize resource consumption, including energy use, and to eliminate or reduce pollutants at the source. For ease of monitoring, maximum permitted emissions limits are often expressed in concentration terms- for example, milligrams per liter (mg/I) for liquid effluents and, for air emissions, milligrams per normal cubic meter (mg/Nm3), where “normal” is measured at one atmosphere and 0 Celsius. The focus, however, should continue to be on reducing the mass of pollutants emitted to the environment. Dilution of effluents and air emissions to achieve maximum permitted values is unacceptable. Occasionally, emissions limits are specified in mass of pollutants per unit of production or other process parameter. In such cases, the limits include leaks and fugitive emissions. Pollution control systems may be required in order to meet specified emissions limits. These systems must be will maintained and operated and must not be fitted with overflow or bypass devices unless such devices are required for emergencies or for safety purposes. The following sections contain requirements for air emissions, liquid effluents, hazardous wastes, and solid wastes. Sections on ambient noise and monitoring requirements are included. The final section summarizes the key steps that will contribute to minimizing the impact of the project on the environment.

2

EMISSIONS GUIDELINES Emission levels for the design and operation of each project is established through the Environmental Impact Assessment (EIA) process. The guidelines given below present emissions levels acceptable to PCFC. All of the maximum levels should be achieved at all the time that the plant or unit is operating.

A

Air Emissions Most of the air emissions from subject types of industrial facilities originate with the fuel used for heating purposes or for generating steam for process purposes. Particular emissions that may originate in the process are addressed case by case. Concentration of contaminants emitted from the stacks of significant sources including boilers, furnaces, etc., should not exceed the limits presented in Attachment-1. The plant owner is required to demonstrate full compliance with the emissions limits specified in Attachment –1. The following methods may be used to demonstrate compliance. For point sources compliance with the guidelines for particulate matter may be demonstrated by maintaining the stack emissions opacity below 20%. Opacity can be determined visually by a qualified observer, with a continuous opacity meter, or with a mobile light detection and ranging (LIDAR) system.

PCFC-EG#28 Revised:23/04/03

Page 1 of 10

The sulfur content of fuels may be used to demonstrate compliance with the sulfur dioxide (SO2) emissions guidelines. The guidelines are met by the use of liquid fuels with sulfur content of 1% or less. The client must maintain records of fuel analyses to demonstrate that the sulfur content of the fuel is at or below the specified levels. Manufacturers performance guarantees can be used to demonstrate that the emissions guidelines for nitrogen oxides (NOx) are met. The performance guarantees must be verified by conducting an initial performance test after the equipment has been commissioned. The sponsor must maintain record to demonstrate that the equipment is operated within manufacturers specifications. Alternatively, stack emissions can be monitored for specified contaminants. The monitoring must be sufficiently frequent to demonstrate continued compliance with the guidelines. To ensure that ambient air conditions are not compromised, concentration of contaminants measured immediately outside the project property boundary should not exceed the limits shown in Attachment-2. B

Liquid Effluents Process wastewater, domestic sewage and contaminated storm water and runoff must meet the maximum limits shown in Attachment-3. Pollutants of concern that are not included in Attachment–3 will be specified by the PCFC separately. Liquid effluent may be discharged to central waste water treatment system, Dubai Municipality (DM) or Harbour. The company is to confirm that the waste treatment system has the capacity and is managed adequately to treat the project’s liquid effluents. Such proper treatment is required prior to discharge to the harbor based on which PCFC approves harbour disposal.

C

Hazardous Materials And Wastes Free Zone companies shall, whenever possible, use non-hazardous instead of hazardous materials. All hazardous wastes, process residues, solvents, oils, and sludge’s must be properly disposed of to DM. The following management measures for handling hazardous wastes and materials should be implemented: i

All hazardous (ignitable, reactive, flammable, radioactive, corrosive and toxic) materials must be stored in clearly labeled containers or vessels.

ii Storage and handling of hazardous materials must be in accordance with local regulation or international standards and appropriate to their hazard characteristics. Storage and liquid impoundment areas for fuels, raw and in process materials solvents, wastes and finished products should be designed with secondary containment (e.g.,dikes and berms) to prevent spills and the contamination of soil, groundwater, etc. iii Fire prevention systems and secondary containment should be provided for storage facilities, where necessary or required by regulations, to prevent fires or the release of hazardous materials to the environment. iv Formulations containing chromates should not be used in water treatment processes. v Transformers or equipment containing polychlorinated biphenyls (PCBs)or PCB-contaminated oil should not be installed. Existing equipment containing PCBs or PCB-contaminated oil should be phased out and disposed of in a manner consistent with the relevant requirements.

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vi Several chemicals classified as ozone- depleting substances (ODSs) are scheduled for phase out under Montreal Protocol on Substances That Deplete the Ozone Layer. They include chloro-flurocarbons (CFCs); halons;1,1,1-trichloroehtane(methylchloroform); carbontetrachloride;hydrochlorofluorocarbons(HCFCs);hydrobromofluorocarbons(HBFCs); and ethyl bromide .These chemicals are currently used in a variety of applications, including domestic, commercial, and process refrigeration (CFCs and HCFCs); domestic, commercial, and motor vehicle air conditioning ( CFCs and HCFCs);manufacturing of foam products (CFCs);solvent cleaning applications (CFCs, HCFs, methyl chloroform, and carbon tetrachloride); aerosol propellants (CFCs) fire protection systems (halons and HBFCs); and crop fumigants (methyl bromide). No systems or processes are to be installed using CFCs, halons, 1,1,1trichloroehtane, carbontetrachloride, mehtlylbromide, or HBFCs. HCFCs should be considered only as interim or bridging alternatives, since they too are to be phased out. D

Solid Wastes Free Zone Companies are to implement the following practices for managing solid wastes generated in the course of operating the facility: • •

Recycle or reclaim materials where possible. If recycling or reclamation is not practical, wastes must be disposed of in an environmentally acceptable manner and in compliance with DM/PCFC regulations.

Other Environmental Requirements:

3.

AMBIENT NOISE Noise abatement measures should comply with maximum allowable noise level of 70 dBA at the fence line of plant.

4.

MONITORING AND REPORTING Free Zone Companies are required to maintain record of air emissions, effluents, and hazardous wastes sent off site, as well as significant environmental events such as spills etc that may have an impact on the environment. The information should be reviewed and evaluated to improve the effectiveness of the environmental protection plan.

A

Air Environment This section establishes reporting, testing, monitoring and analyses requirements for sources of air pollution located or proposing to locate in FZ. The purpose of these requirements is to enable the Authority to assess compliance with the ambient air quality criteria and air emission limitations specified in Attachment –1. Prior to commencing construction or modification, all sources of air pollution not specifically exempted must prepare and submit an EIA report and include a section pertaining to the air environment. Depending on the nature and size of the source, Authority may require the applicant to prepare an ambient air quality analysis and/or provide ambient air monitoring data. After start-up, large emission sources and potentially hazardous or nuisance-type sources are required to conduct source emission (performance testing) and report the results to Authority for compliance evaluation. For certain specified emission sources, continuous air emission monitoring and quarterly reporting is required on a case to case basis. At any time, after start-up, Authority may request any industrial facility to prepare an updated air emissions inventory or provide other information relating to the source in question.

PCFC-EG#28 Revised:23/04/03 B

Air Emissions Performance Testing

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i

Performance tests are required on a case-by-case basis, for any source that may be hazardous to the environment or may be an odour nuisance. The aim of performance testing is to verify a pollutant’s emission concentrations or rate at a point source and to ensure that there is no violation of the industrial source emission criteria stated in Attachment – 1 and/or ambient air quality (at fenceline) criteria as stated in Attachment –2 or any emission limit used for compliance evaluation. It should be noted that as a general industry requirement stack testing ports and work platforms should be installed at all facilities, which have a potential to release pollutant quantities or are otherwise subject to the criteria stated above.

ii Performance tests shall be done at earliest after normal operation. These tests shall be conducted by an independent consultant. The date, time and place of any performance test shall be given to Authority at least one week in advance so they may witness such tests. iii Performance tests shall consist of the determination of exhaust gas temperatures and volumetric flow rates and gas analyses for the pollutants and efficiency of abatement equipment for which the test is required. The tests shall be conducted according to the accepted international reference test methods. iv Each performance test shall consist of a minimum of three separate sampling runs conducted within a 48-hour period. Each run shall be obtained while the source is operating at normal load. The arithmetic mean of the results of the three runs shall be used for the purpose of determining compliance with applicable emission limitations. v

C

The results of the performance tests shall be submitted to Authority within one month of their completion. If Authority finds that procedures and/or methodologies used for any tests were inappropriate or defective, it may require a retest.

Water Environment This section establishes reporting, testing, monitoring and analyses requirements for sources of water pollution located or proposing to locate at the FZ. The purpose of these requirements is to enable Authority to assess compliance with harbour wastewater discharge criteria specified in Attachment – 3. At least six (6) months prior to commencing construction of any industrial or other wastewaterproducing facility, or adding to or modifying an existing facility, an Environmental Impact Assessment (EIA) report, containing a water environment details as per Authority EIA Guidelines shall be submitted by the industry or facility to Authority. After start-up, the facility owner/operator may be required to sample/analyze effluents initially and/or periodically to demonstrate compliance with the discharge criteria specified earlier. For groundwater appropriate number of boreholes will be installed for quarterly monitoring and reporting. For some effluent parameters, a continuous monitoring and monthly quality-reporting is required on a case-by-case basis.

D

Wastewater Discharge Performance Testing Performance tests are required for any facility that discharges wastewater to the FZ harbour, or Gulf (open sea). Performance tests shall be done within one-month time after normal operation. The date, time and place of any performance test shall be given to Authority at least one week in advance.

E

RRR Options, Cleaner Production and Waste Minimization: Free Zone companies should adopt reuse, recovery or recycling (RRR) options for wastewater generated. It is emphasized to minimize the generation of wastewater and adopt cleaner production practices.

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F

Noise Environment & Performance Testing In line with Authority’s requirements for premises a noise performance testing, at the boundary fence line, would be conducted within one month upon normal operation. On a case-by-case basis or annual noise level testing and reporting is required.

G

Solid/Hazardous Waste: All solid/hazardous waste generated in PCFC entities is to be disposed off as per PCFC/DM guidelines. RRR Options (see above Section) and wastes minimization must be adopted by all Free Zone companies

5.

KEY ISSUES FOR ENVIRONMENT CONTROL The key production and control practices that will assist in meeting emissions requirements can be summarized as follows: • Where feasible, choose RRR options, cleaner production, integrated pollution control, waste minimization, energy-efficient and environmentally sound processes. • Ensure that control, treatment, and monitoring facilities are properly maintained and that they are operated according to their instruction manuals.

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Attachment –1 SOURCE EMISSION CRITERIA GENERAL: STATIONARY SOURCES AIR POLLUTANTS EMISSION LIMITS FOR STATIONARY SOURCES SUBSTANCE

SYMBOL

Visible Emissions Carbon Monoxide Nitrogen Oxides (Expressed as nitrogen dioxide)

CO

SOURCES Combustion sources Other sources All sources Combustion sources

NOx Material industries

Sulphur Dioxide

Sulphur Trioxide Including Sulphuric Acid Mist (Expressed as sulphur trioxide) Total Suspended Particles

SO2

SO3 TSP

Ammonia and Ammonium Compounds (expressed as ammonia) Benzene Iron Lead and its compounds (expressed as lead) Antimony and its Compounds (Expressed as antimony)

NH3 C6H6 Fe Pb Sb

250 none 500 Gas fuel-350 Liquid fuel-500 producing 1500

Other sources Combustion sources Material producing industries Other sources Material producing industries Other sources Combustion sources Cement Industries Other sources Material producing industries Other sources All sources Iron & Steel foundries All sources

200 500 2000 1000 150 50 250 50 150 50 10 5 100 5

producing 5

As

Material industries Other sources All sources

Cd

All sources

1

Hg

All sources

0.5

Ni

All sources

1

Cu

All sources

5

H2S Cl

All sources Chlorine Works Other sources Chlorine Works Other sources All sources All sources

5 200 10 200 20 2 10

Arsenic and its Compounds (expressed as arsenic) Cadmium and its compounds (expressed as cadmium) Mercury and its compounds (expressed as mercury) Nickel and its compounds (expressed as nickel) Copper and its compounds (expressed as copper) Hydrogen Sulphide Chloride Hydrogen Chloride

HCI

Hydrogen Fluoride Silicon Fluoride

HF SiF4

PCFC-EG#28 Revised:23/04/03

EMISSION (mg/Nm3)

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1 1

LIMITS

-

Fluoride and its Compounds Including HF & SiF4 (expressed fluoride) Formaldehyde

CH20

Carbon

C

Total Volatile Compounds (expressed as total carbon -TOC) Dioxins and Furans

F

Organic VOC

Aluminum smelters Other sources

20 50

Material producing industries Other sources Anode production Waste incineration All sources

20 2 250 50 20

All sources

1 ng TEQ/m3

organic

Notes: 1. The concentration of any substance specified in the first column emitted from any source specified in the third column shall not at any point before admixture with air, smoke or other gases, exceed the limits specified in the fourth column. 2. “mg” means milligram; 3. “ng” means nanogram. 4. “Nm3” means normal cubic meter, being that amount of gas which when dry, occupies a cubic meter at a temperature of 25 degree Centigrade and at an absolute pressure of 760 millimeters of mercury (1 atm) ; 5. The limit of “Visible Emission” does not apply to emission of water vapour and a reasonable period for cold start up, shutdown or emergency operation. 6. The measurement for “Total Suspended Particles (TSP)’’ emitted from combustion sources should be @12% reference CO2. 7. The total concentration of the heavy metals (Pb, Cd, Ni, Hg, Cu, As & Sb) must not exceed 5 mg/Nm3. 8. VOC limit is for unburned hydrocarbons (uncontrolled). 9. The emission limits for all the substances exclude “Dioxins and Furans” are conducted as a daily average value. 10. TEQ means “Total Equivalent Quantity.” Dioxins and Furans” Average values shall be measured over a sample period of a minimum of 6 hours and a maximum of 8 hours. The emission limit value refers to the total concentration of dioxins and furans calculated using the concept of toxic equivalence. 11. For source standards air pollutants emission limits from incinerators refer to relevant Annexes.

PCFC-EG#28

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Revised:23/04/03

Attachment –2 AMBIENT AIR QUALITY STANDARDS (AIR POLLUTANTS LIMITS IN THE AMBIENT AIR)

SUBSTANCE

SYMBOL

MAX.ALLOWABLE LIMITS AVERAGE TIME (ug/m3)

SO2

350

1 hour

150

24 hours

CO

60 30 mg/m3

1 year 1 hour

NO2

10 mg/m3 400

8 hour 1 hour

O3

150 200

24 hours 1 hour

TSP

120 230

8 hour 24 hour

Sulphur Dioxide

Carbon Monoxide Nitrogen Dioxide Ozone Total Suspended Particles 90

1year

Particulate Matter (with 10 microns or less in PM10 diameter)

150

24 hours

Lead

1

1 year

PCFC-EG#28 Revised:23/04/03

Pb

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Attachment –3 STANDARDS FOR DISCHARGE OF WASTE WATER TO HARBOUR (1) PARAMETERS (es2)

SYMBOL

Physical Properties Colour Total Suspended Solids TSS Floating Particles pH Temperature(3) T Total Dissolved Solids TDS Turbidity Inorganic Chemical Properties Ammonia Total as (N) Biochemical Oxygen Demand Chemical Oxygen Demand Chlorine Residual (4)Total Cyanide

+

NH4 BOD5 COD ClCN

Dissolved Oxygen(5)

DO F Fluoride Nitrate NO3-N Sulfide S-2 Total Kjeldahl Nitrogen as (N) TKN Total Phosphorus, as (P) PO4-3 Trace Metals Aluminum Al Antimony Sb Arsenic As Barium Ba Beryllium Be Cadmium Cd Chromium, total Cr Chromium, VI Cr+6 Cobalt Co Copper Cu Cyanide CN Fluoride F Iron Fe Lead Pb Manganese Mn Mercury Hg Nickel Ni Selenium Se Silver Ag Zinc Zn PCFC-EG#28 Revised:23/04/03 Organic Chemical Properties Halogenated Hydrocarbons

UNIT

MAX. ALLOWABLE STANDARD (7)

Colour units mg/1 mg/m3 pH units C mg/1 NTU

50 50 None 6-9(6) 35 (max) 1500 75

mg/1 mg/1 mg/1 mg/1

2 50 100 1.0 0.05

mg/1

>3

mg/1 mg/1 mg/1 mg/1 mg/1

20 40 0.1 10 2

mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1

20 0.1 0.05 2 0.05 0.05 0.2 0.15 0.2 0.5 0.1 25 2 0.1 0.2 0.001 0.1 0.02 0.005 0.5

mg/1

Nil

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and Pesticides Hydrocarbons Oil & Grease Phenols Solvent Total Organic Carbon

HC O&G TOC

mg/1 mg/1 mg/1 mg/1 mg/1

15 10 0.1 none 75

Biological Properties Colon Group Egg Parasites Fecal Coliform Bacteria Total Coliform Warm Parasites

TC -

No./100 cm2 Cells/100 ml MPN/100ml

5000 None 1000 1000 None

Notes: 1) Any discharge to surface drainage ditches must be authorized by PCFC and shall only be permitted in exceptional circumstances. 2) For any parameters not identified, specific standards will be determined on a case-by-case basis. 3) Temperature limit is the maximum allowed for discharge. 4) Chlorine residual is after 30 minutes contact and is total residual chlorine 5) Dissolved oxygen requirement is a minimum concentration requirement 7) Inclusive range not to be exceeded. 7) With respect to Harbor Discharge Standard, FZ Cos. should concentrate on full compliance of harbour discharge Standard Any sample repeated twice excedance of allowable standard will permit imposition of appropriate sanction as per FZ rules.

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#28 Revised:23/04/03

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ENVIRONMENTAL GUIDELINE No.29 EHS PERFORMANCE AUDITS 1.

OVERVIEW Recent years have seen tremendous growth in public awareness and concern for the environment and its impact on the quality of life. The proposed auditing is a commonly used term that describes an examination of operating facility’s operation and practices. Such audit would serve as a management tool comprising a systematic, documented, periodic and objective evaluation of how well a particular activity is performing with regard to PCFC EHS aims/requirements. All FZ companies should be encouraged first to get EMS ISO 14001 and OHSAS 18001, as relevant, certifications. Because current environmental legislation, marketing requirements and community expectations reflect an increased awareness of the need to protect the environment that requires all aspects of the industrial activities to be undertaken in an environmentally responsible way. Environmental audits can help the industry to become environmentally responsible and demonstrate this responsibility to the community. Environmental audits help in assuring the accuracy and relevance of environmental monitoring. They also measure an organization’s environmental performance and can encourage continual improvement. Procedures for conducting an environmental audit vary from simple checklists (see Attachment) to complex standards or programs. These procedures use a systematic approach to record whether and operation is meeting its environmental objectives. The steps include: pre-audit planning site activities (interviews and inspections); gathering and evolution of audit evidence; development of audit findings; and recommendations, documentation and reporting of the findings and audit follow-up (action plan, etc). In their most basic application, environmental audits help companies demonstrate to regulatory authorities that they are complying with EHS legislation and regulations and the conditions contained in pollution control approval, discharge licenses/permits and leases. Identifying issues through the audit process may also lead to more efficient operations that go well beyond regulatory requirements.

2

PERFORMANCE AUDIT REQUIREMENT This type of audit begins with an overview of operating facility, determining the mass emissions to the air, water, etc. and comparing with the permitted levels. For today’s industry, regulations, financial reporting equipments, market competition and community expectations require environmental performance to be assessed and reported. The need to carry out an environmental audit will vary depending upon the type of organization and the objectives of the audit. The principal aims of an environmental audit are to identify and evaluate potential liabilities, risks and hazards. This in turn will assist in assessing the viability of operations after including the cost of reducing environmental risks and liability to acceptable levels. There is no single environmental audit procedure applicable to all situations. An audit can take different forms to achieve different objectives. The reason for undertaking and audit and the agreed outcomes are the deciding factors. For auditing purpose, the FZ industries can be graded as follows:

(i)

Grade – A: FZ Cos. having major chemical/manufacturing processes with serious potential for EHS impacts.

PCFC-EG#29 Revised:23/04/03 (ii)

Grade-B:

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FZ Cos. having medium chemical/manufacturing activities (like blending unit, chemical filling, etc) with medium potential for EHS impacts. (iii)

Grade-C: FZ Cos. having no chemical/manufacturing activities (like trading/offices, etc) with no potential for EHS impacts. The companies where EMS ISO 14001 is implemented would be required to set relevant performance objectives and targets for the management system which link back to the commitments as per policy i.e. prevention of pollution, continual improvement and compliance of performance. Thus, EMS coupled with OHSAS i.e. EHS Performance Auditing can be used as a framework to help FZ industries improve their overall performance.

3

EHS Performance Reporting: A salient requirement to the FZ companies as part of compliance evaluation/EHS Performance Audit would be to regularly submit their EHS monitoring reports to PCFC. This would cover all EHS aspects, releases to the environment, discharges and /or emissions as part of approval/permits, etc.

4

Benefits of EHS Performance Audits: The proposed audit would focus on all type of wastes. In the past, waste management has concentrated on end-of–pipe waste treatment; designing waste treatment plants and installing pollution control equipment to prevent contamination of the environment. A different philosophy has emerged in recent times, that of waste prevention and reduction. Now we ask how can we prevent the generation of this waste? How can we reduce this waste? Can we reuse or recover or recycle (RRR options) this waste? This progressive shift from inspections to proposed audits would have the following benefits: • Waste quantities are reduced; • Raw material consumption and therefore costs are reduced; • Waste treatment costs are reduced; • The pollution potential is reduced; • Working conditions are improved; • Process efficiency is improved. In order to prevent or reduce waste generation we need to examine the process to identify the origins of waste, the operational problems associated with the process and those areas where improvements can be made. An audit is the first step to achieve maximum resource optimization and improved process performance. It is common sense approach to problem identification and problem solving. A waste audit enables you to take a comprehensive look at a site or process to facilitate your understanding of material flows and to focus your attention on areas where waste reduction and therefore cost saving is possible. Undertaking a waste audit involves observing, measuring recording data and collecting and analyzing waste samples. To be effective it must be done thoroughly together with full management and industry support.

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A good waste audit: • Defines sources, quantities and type of waste being generated; • Collates information on unit operation, raw materials, products, water usage and wastes; • Highlights process inefficiencies and areas of poor management; • Helps set targets for waste reduction; • Permits the development of cost-effective waste management strategies; • Raises awareness in the workforce regarding the benefits of waste reduction; • Increases you knowledge of the processes; • Helps to improve process efficiency. At the plant level, wastes can be traced to particular processes allowing allocation of treatment changes where necessary; and at the process level the exact origins of wastes can be identified enabling waste reduction measures to be established. 5

Conclusions/Recommendations:

(i)

The proposed swift from current Inspections to Audits is feasible. The most–relevant type of audit would be EHS Performance Audit, as we would be assessing the overall performance of ongoing activities.

(ii)

Environmental auditing has become an essential management tool for any industrial operation. It is not an end in itself, but the basis on which an environmental action plan can be developed to improve environmental performance.

(iii)

It is recommended that EHS Performance Audits should be part of an ongoing EHS management and improvement program, that is, not a one-off event but a periodic reassessment of the environmental management system.

(iv)

Performance auditing is and emerging and evolving technique. It has been common in industry only since the 1980’s.

(v)

International standards for auditing environmental management systems should be used as a useful basis for developing the techniques. Audit remains the most effective tool for assessing occupational, health, safety and environmental risks and for measuring such potential impacts of and operating facility.

(vi)

The proposed audit outcome recommendations would range from minor changes in operating procedures and training, to performing a detailed waste inventory to determine the source of problems within the Free Zone companies.

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EHS Performance Audit checklist A A1

C5

Applicable Standards Have all the necessary licenses/permits etc. relating to EHS requirements been obtained? Are the licenses/permits for EHS standards being complied with? If and EIA/RA studies were conducted for the project at the design stage, are the relevant commitments/predictions, relating to emission levels, mode of operation etc. being complied with? Have any problem areas discussed in A2 and A3 been highlighted and rectified? Have the deficiencies in EIA /RA and design methodologies been officially recorded and fed back to the appropriate consultants who will be involved in future EIA/RA and design work? Design Issues Have the initial objectives been met? (e.g. plant efficiency, air emissions, noise control, etc.) If not, have the reasons for such failings been identified? Has consideration been given to whether the designs selected were appropriate in the light of B2? Have the deficiencies in the design methodology been officially recorded and fed back to the appropriate consultants who will be involved in future design work? Waste Issues Does the pollution control/abatement technology employed remove pollutants at the guaranteed efficiencies? Do the monitoring techniques employed detect down to the guaranteed levels? Has any ambient air monitoring been performed? If so, do the results compare with any predictions made in an EIA if previously conducted? Have any other deficiencies/potential improvements in the design as regards attaining the desired environmental standards been highlighted? Have the deficiencies /potential improvements form B4 been officially recorded for future reference?

D D1

Health & Safety Issues Have all Health and Safety Issue been addressed as per RA Study?

A2 A3 A4 A5 B B1 B2 B3 B4 C C1 C2 C3 C4

Yes

No

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#29 Revised:23/04/03

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ENVIRONMENTAL GUIDELINE No.30 GUIDELINES FOR CONDUCTING WASTE AUDIT IN PCFC

1

BACKGROUND A waste Audit as a procedure for surveying processes and/or equipment and identifying waste minimization options as a necessary first step to waste minimization. The results of a Waste Audit can provide management with timely and useful information for developing a viable waste Management plan that can accomplish the following goals: • Save money by reducing water treatment and disposal costs, raw material purchases, and other operating costs. • Reduce potential environment liabilities. • Protect public health and worker health and safety. • Protect the environment. • Improve corporate image. The purpose of a general waste audit is to identify all possible outputs from an industrial process to each segment of the environment and to assess the likely impact of those wastes as well as compliance to local standards and regulations. Waste Audit will be required for certain operating industries (as decided by EHS-FZ Dept –JAFZA) to ensure compliance with the provisions of PCFC Environmental Rules and Requirements 3rd Edition (2003).

2

GUIDELINES FOR WASTE AUDIT REPORTS:

A

Objectives of Waste Audit The objectives for conducting a waste audit are to: • Identify each and every gas, liquid and solid waste stream generated by the industry. • Quantify and characterize every waste stream. • Establish how and why the waste stream is generated. • Calculate the costs incurred with pretreatment, storage, handling and disposal. • Determine the liabilities associated due to the generation of those wastes, including compliance with EHS-FZ Dept/PCFC Regulations. • Identify options for effective waste management so that a waste management plan can be developed including waste minimization potential.

B

Stages of Waste Audit • • • • • • •

Selections of an Audit team. Determination of Audit Scope. Collection of preliminary Data. Identification and characterization of input materials, products and waste streams. Comprehensive plant and environmental analysis. Evaluation of data and regulatory compliance. Preparation of Waste Audit Report.

i

Selection of an Audit Team An audit team usually comprises a leader and several members. However its exact size will be determined by the time span of the audit, manpower availability and plant size.

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The audit team may consist of: • • • • • •

Consultants (to be priorily approved by EHS-FZ Dept. of PCFC) Site or Works/Production Manager/ Environmental Engineer/Office. Supervisor with hands-on Knowledge of the process. Process Engineer. Waste treatment supervisor, etc etc.

ii

Determination of Audit Scope This will usually be determined by EHS-FZ Dept. of PCFC at the time of requiring the Audit. The approved consultant would propose Audit Scope for PCFC approval. An audit may involve a single industrial process or an entire industrial facility. An audit may be limited to the outputs from the plant of facility or may involve detailed assessment of waste impacts on the environment.

iii

Collection of Preliminary Data The objective of this activity is to collect all necessary background information on the plan’s operation. The types of information that can be useful in conducting the audit are as follows: a.

Design Information
Process flow diagrams
Materials and heat balances of the processes.
Operating manuals and process descriptions.
Equipment lists.
Equipment specifications.
Plan, elevation and layout of plant.
Other.

b.

Raw material and production information
Product composition and batch sheets.
Raw materials (including water. Fuel)analysis.
Operating procedures.
Operating schedules.
Material Safety Data Sheets(MSDS).
Other.

c.

Environmental Information
Waste disposal receipts (eg. Dubai Municipality-DM) and data.
Emission inventories.
Waste analysis reports(eg. air emissions, wastewater, etc).
Correspondence with PCFC/EHS-FZ Dept. (i.e EHS Issues).
EHS permits.
Risk Assessment (RA) and Environmental Impact Assessment (EIA).
Other. (eg. Cleaner Production Alternatives, Odor Complaints from neighbors, etc).

d.

Economic Information
Waste treatment and disposal costs.
Product and raw materials costs.
Water consumption costs.
Energy consumption costs.
Operating (eg. Fuel, Raw Materials) and maintenance costs.
Other.

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iv

Identification and Characterization of Input materials, product and waste streams a.

Identify and name each and every waste stream (gas, liquid and solid), input material stream and output product stream using the flow diagrams of the facility.

b. Collect data on input material and product streams:
Hazardous components.
Material handling and storage
Production rate.
Products. c.

v

Collect data on the identified waste streams.
Nature of waste (gas, liquid, solid).
Generation rate.
Composition of the waste.
Quantity (present and future).
Degree of hazard (toxicity, flammability, etc.).
Current disposal practices for each stream.

Material Balance A material balance is an important tool to identify losses and to verify quantitative data of material input and output of the production process. The principle of mass conservation is as shown in the diagram below: Air Emissions

Mass out Total mass in

Mass out

Mass Accumulate

Product

Mass out

. Solid Waste . Wastewater

Total Mass in = Total Mass Out + Mass Accumulated

A material balance should be made individually for all components that enter and leave the process. When chemical reactions take place in a system there is and advantage of doing “elemental balances” for chemical elements in a system. Material balance can assist in determine concentrations of waste constituents where analytical teat data is limited. vi

Comprehensive plant Analysis A comprehensive plant assessment is performed to fill gaps identified during the review of the background information. This is mainly achieved through a sit inspection. The main objective of an inspection is to achieve a fuller understanding of the principal and secondary causes of waste generation and to cover the items missed in the preliminary data collection stage.

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vii Evaluation of Data and Regulatory Compliance.

a.

Waste Impacts.
Evaluate the volumes and components contained in each waste stream against the regulatory standards.
Report on company environmental practices, policies and monitoring systems.
Assess the impact of waste streams on the surrounding environment.

b.

Minimization a. Generate waste minimization options for each waste stream such as:
Changing plant operation and/or procedures by improved house keeping and educating employee about waste reduction.
Substituting non-toxic material in the production process.
Reclaiming materials to avoid creating wastes.
Adopting Reuse, Recovery and Recycling (RRR) alternatives
Modifying equipment to improve efficiency.
Altering final product to eliminate processes that recate waste.
Using clean fuel. b. Conduct preliminary technical and economic assessment of waste minimization options by considering the following factors: Technical factors:
Product quality.
Safety/occupational health.
Production constraints/flexibility.
Space requirements.
Installation time, production downtime.
Reliability.
Commercial availability.
Proven performance in a similar application.
Regulatory constraints.
Expertise/skill level required for operation and maintenance. Economic factors:
Capital cost.
Operating cost.
Potential savings.
Profitability requirement using methods like payback period, net present value (discounted cash flow) and return on investment.
Intangible or qualitative benefits such as improvement in corporate image and, reduction of risk and liability associated with the avoidance of penalties for non-compliance and cost of workers compensation.

viii Preparation of Waste Audit Report When all the information and findings are collected, they should be dated, documented and filed for future reference. The final product of a waste audit is a report that presents the results of the audit and recommendations of waste minimization options. A suggested format for the Waste Audit Report outline is given below: a.

Introduction



Give a brief description of company’s operations, dates when audit was conducted, and team members involved. Mention environmental and/or other related EHS issues (i.e air emissions, wastewater, hazardous, H & S issues, etc) that provide the basis for the audit.

PCFC-EG #30 Revised:23/04/03

b.

Scope of Audit

Page 4 of 5



c.

Results of Audit



d.

Give a brief description of target processes and equipment that are selected including the rationale for the selection. Provide a site plan showing the drainage system, wastes discharge point and interim storage onsite, air, wastes) facility layout and surrounding land uses/neighbors, etc.

Provide both qualitative and quantitative description of waste steams(eg. air, wastes) identified. Describe problems in process operation and maintenance, waste management methods and practices, storage and handling of raw materials (including water, fuel) and spill control.

Evaluation of Audit Provide technical and economic assessment of identified waste minimization options. Assess compliance with EHS-FZ Dept/PCFC regulations. Evaluate impact of the plant on the local environment with respect to air emissions, solid/liquid wastes.
Recommend changes to management policies or practices including cleaner production and RRR options as alternatives.






There are many informative websites related to the audits. Please visit www.epa.gov/Environmental, www.policyworks.gov, www.ea.gov.au websites

For more information please contact Environment, Health and Safety – Free Zone (EHS-FZ) Department on Tel# 8040275, Fax # 8817023 or P.O.Box17000, Dubai.

PCFC-EG#30 Revised:23/04/03

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ENVIRONMENTAL GUIDELINE No.31 ENVIRONMENTAL GUIDELINES FOR DUBAI METALS AND COMMODITIES CENTRE (DMCC)

1.

INTRODUCTION DMCC would apply specific environmental guidelines for its projects on a case-by-case basis. With respect to DMCC types of industries the general environmental guidelines outlined here can be used, but, depending on the project, the requirements may need to be supplemented by additional requirements. DMCC clients are required to comply with its relevant, polices and guidelines, which emphasize pollution prevention, Reuse, Recovery, Recycle (RRR) options, waste minimization, including the use of cleaner production technologies. The intent of the guidelines is to minimize resource consumption, including energy use, and to eliminate or reduce pollutants at the source. For ease of monitoring, maximum permitted emissions limits are often expressed in concentration terms- for example, milligrams per liter (mg/I) for liquid effluents and, for air emissions, milligrams per normal cubic meter (mg/Nm3), where “normal” is measured at one atmosphere and 0 Celsius. The focus, however, should continue to be on reducing the mass of pollutants emitted to the environment. Dilution of effluents and air emissions to achieve maximum permitted values is unacceptable. Occasionally, emissions limits are specified in mass of pollutants per unit of production or other process parameter. In such cases, the limits include leaks and fugitive emissions. Pollution control systems may be required in order to meet specified emissions limits. These systems must be well maintained and operated and must not be fitted with overflow or bypass devices unless such devices are required for emergencies or for safety purposes. The following sections contain requirements for air emissions, liquid effluents, hazardous wastes, and solid wastes. Sections on ambient noise and monitoring requirements are also included. The final section summarizes the key steps that will contribute to minimizing the impact of the project on the environment.

2.

EMISSIONS GUIDELINES Emission levels for the design and operation of each project is established through the Environmental Impact Assessment (EIA) process. The guidelines given below present acceptable emissions levels. All of the maximum levels should be achieved at all the time that the plant or unit is operating.

A.

Air Emissions Most of the air emissions from subject types of industrial facilities originate with the fuel used for heating purposes or for generating steam for process purposes. Particular emissions that may originate in the process are addressed case by case. Concentration of contaminants emitted from the stacks of significant sources including boilers, furnaces, etc., should not exceed the limits presented in Attachment-1. The plant owner is required to demonstrate full compliance with the emissions limits specified in Attachment –1. The following methods may be used to demonstrate compliance. For point sources compliance with the guidelines for particulate matter may be demonstrated by maintaining the stack emissions opacity below 20% or 250 mg/m3 of Particulate Matter. Opacity can be determined visually by a qualified observer, with a continuous opacity meter, or with a mobile light detection and ranging (LIDAR) system.

PCFC-EG#31

Page 1 of 13

Revised:23/04/03

The sulfur content of fuels may be used to demonstrate compliance with the sulfur dioxide (SO2) emissions guidelines. The guidelines are met by the use of liquid fuels with sulfur content of 1% or less. The client must maintain records of fuel analyses to demonstrate that the sulfur content of the fuel is at or below the specified levels.

Manufacturers performance guarantees can be used to demonstrate that the emissions guidelines for sulfur dioxide (SO2) and nitrogen oxides (NOx) are met. The performance guarantees must be verified by conducting an initial performance test after the equipment has been commissioned. The sponsor must maintain record to demonstrate that the equipment is operated within manufacturers specifications. Alternatively, stack emissions can be monitored for specified contaminants. The monitoring must be sufficiently frequent to demonstrate continued compliance with the guidelines. To ensure that ambient air conditions are not compromised, concentration of contaminants measured immediately outside the project property boundary should not exceed the limits shown in Attachment-2.

B.

Liquid Effluents Proper treatment facilities for process wastewater and domestic sewage should be provided or the same to be disposed to Dubai Municipality (DM) facility. Please refer to Attachment-3 for DM Standards applicable to pretreated wastewater disposal at their central wastewater treatment plant and re-use in irrigation.

C.

Hazardous Materials And Wastes DMCC clients shall, whenever possible, use non-hazardous instead of hazardous materials. All hazardous wastes, process residues, solvents, oils, and sludge’s must be properly disposed of to DM. The following management measures for handling hazardous wastes and materials should be implemented: i.

All hazardous (ignitable, reactive, flammable, radioactive, corrosive and toxic) materials must be stored in clearly labeled containers or vessels.

ii.

Storage and handling of hazardous materials must be in accordance with local regulation or international standards and appropriate to their hazard characteristics. Storage and liquid impoundment areas for fuels, raw and in process materials solvents, wastes and finished products should be designed with secondary containment (e.g.,dikes and berms) to prevent spills and the contamination of soil, groundwater, etc.

iii.

Fire prevention systems and secondary containment should be provided for storage facilities, where necessary or required by regulations, to prevent fires or the release of hazardous materials to the environment.

iv.

Formulations containing chromates should not be used in water treatment processes.

v.

Transformers or equipment containing polychlorinated biphenyls (PCBs) or PCB-contaminated oil should not be installed. Existing equipment containing PCBs or PCB-contaminated oil should be phased out and disposed of in a manner consistent with the relevant requirements.

PCFC-EG#31 Revised:23/04/03

Page 2 of 13

vi.

3

Several chemicals classified as ozone- depleting substances (ODSs) are scheduled for phase out under Montreal Protocol on Substances That Deplete the Ozone Layer. They include chloro-flurocarbons (CFCs); halons;1,1,1-trichloroehtane (methylchloroform) ;carbontetrachloride;hydrochlorofluoro,carbons HCFCs);hydrobromofluorocarbons (HBFCs);and methyl bromide .These chemicals are currently used in a variety of applications, including domestic, commercial, and process refrigeration (CFCs and HCFCs); domestic, commercial, and motor vehicle air conditioning ( CFCs and HCFCs);manufacturing of foam products (CFCs);solvent cleaning applications (CFCs, HCFs, methyl chloroform, and carbon tetrachloride); aerosol propellants (CFCs) fire protection systems (halons and HBFCs); and crop fumigants (methyl bromide). No systems or processes are to be installed using CFCs, halons, 1,1,1-trichloroehtane, carbontetrachloride, mehtlylbromide, or HBFCs. HCFCs should be considered only as interim or bridging alternatives, since they too are to be phased out.

SOLID WASTE DMCC companies are to implement the following practices for managing solid wastes generated in the course of operating the facility: • •

Recycle or reclaim materials where possible. If recycling or reclamation is not practical, wastes must be disposed of in an environmentally acceptable manner and in compliance with DM regulations.

4

OTHER ENVIRONMENTAL REQUIREMENTS:

A

Ambient Noise Noise abatement measures should comply with maximum allowable noise level of 70 dB at the fence line of plant.

B

Monitoring and Reporting DMCC companies are required to maintain record of air emissions, effluents, and hazardous wastes sent off site, as well as significant environmental events such as spills etc that may have an impact on the environment. The information should be reviewed and evaluated to improve the effectiveness of the environmental protection plan.

C

Air Environment This section establishes reporting, testing, monitoring and analyses requirements for sources of air pollution located or proposing to locate in DMCC. The purpose of these requirements is to assess compliance with the ambient air quality criteria and air emission limitations specified in Attachment –1. Prior to commencing construction or modification, all sources of air pollution not specifically exempted must prepare and submit an EIA report and include a section pertaining to the air environment. Depending on the nature and size of the source, Authority may require the applicant to prepare an ambient air quality analysis and/or provide ambient air monitoring data. After start-up, large emission sources and potentially hazardous or nuisance-type sources are required to conduct source emission (performance testing) and report the results to Authority for compliance evaluation. For certain specified emission sources, continuous air emission monitoring and quarterly reporting is required on a case by case basis. At any time, after start-up, request can be made for any industrial facility to prepare an updated air emissions inventory or provide other information relating to the source in question.

PCFC-EG#31

i Air Emissions Performance Testing

Page 3 of 13

Revised:23/04/03

a. Performance tests are required on a case-by-case basis, for any source that may be hazardous to the environment or may be an odor nuisance. The aim of performance testing is to verify a pollutant’s emission concentrations or rate at a point source and to ensure that there is no violation of the industrial source emission criteria stated in Attachment – 1 and/or ambient air quality (at fence-line) criteria as stated in Attachment –2 or any emission limit used for compliance evaluation. It should be noted that as a general industry requirement stack testing ports and work platforms should be installed at all facilities, which have a potential to release pollutant quantities or are otherwise subject to the criteria stated above. b. Performance tests shall be done at earliest after normal operation. These tests shall be conducted by an independent consultant. The date, time and place of any performance test shall be given to Authority at least one week in advance so they may witness such tests. c. Performance tests shall consist of the determination of exhaust gas temperatures and volumetric flow rates and gas analyses for the pollutants and efficiency of abatement equipment for which the test is required. The tests shall be conducted according to the accepted international reference test methods. d. Each performance test shall consist of a minimum of three separate sampling runs conducted within a 48- hour period. Each run shall be obtained while the source is operating at normal load. The arithmetic mean of the results of the three runs shall be used for the purpose of determining compliance with applicable emission limitations. e. The results of the performance tests shall be submitted within one month of their completion. If procedures and/or methodologies used for any tests were inappropriate or defective, a retest may be required. D

Water Environment This section establishes reporting, testing, monitoring and analyses requirements for sources of water pollution located or proposing to locate at DMCC. The purpose of these requirements is to assess compliance with the DM wastewater discharge criteria. At least six (6) months prior to commencing construction of any industrial or other wastewater-producing facility, or adding to or modifying an existing facility, an Environmental Impact Assessment (EIA) report, containing a water environment details as per Authority EIA Guidelines shall be submitted by the industry or facility to Authority. After start-up, the facility owner/operator may be required to sample/analyze effluents initially and/or periodically to demonstrate compliance with the discharge criteria specified earlier. For groundwater appropriate number of boreholes will be installed for quarterly monitoring and reporting. For some effluent parameters, a continuous monitoring and monthly quality-reporting is required on a case-by-case basis.

E

RRR Options, Cleaner Production and Waste Minimization All DMCC companies should adopt reuse, recovery or recycling (RRR) options for wastewater generated. It is emphasized to minimize the generation of wastewater and adopt cleaner production practices.

F

Noise Environment Performance Testing In line with DMCC requirements (see Attachment-4) for premises a noise performance testing, at the boundary fence line, would be conducted within one month upon normal operation. On a case-by-case basis or annual noise level testing and reporting is required.

G

Solid/Hazardous Waste All solid/hazardous waste generated in DMCC companies is to be disposed off as per DM guidelines. RRR options (see above Section 4.2.1) and wastes minimization must be adopted by all DMCC companies

PCFC-EG#31 Revised:23/04/03

5.

Key Issues for Environment Control

Page 4 of 13

The key production and control practices that will assist in meeting emissions requirements can be summarized as follows: i

Where feasible, choose RRR options, cleaner production, integrated pollution control, waste minimization, energy-efficient and environmentally sound processes. ii Ensure that control, treatment, and monitoring facilities are properly maintained and that they are operated according to their instruction manuals.

6.

Case Study: Specific Environmental requirements for Gold/Diamond Refineries and Workshops.

A.

EIA STUDY Gold and Diamond finishing is often a pollution intensive industry, with significant emissions of both metals and organic process chemicals. It is a major contributor of toxic inputs to water treatment plant, landfill and atmosphere. Due to potential serious environmental impacts a proper EIA study should be required.

B.

POLLUTION PATHWAYS Gold finishing is the application of physical, chemical or electrochemical processes to a work piece to alter its surface properties or appearance. Chemical (degreasing, cleaning, pickling, etching, coating and electrochemical (electro-plating, polishing, cleaning and anodizing) processes are the main waste producers. Both types of processes on a work piece are usually performed in baths with chemicals and other compounds, followed by rinsing operations. Process chemicals and compounds which are carried from baths to the water (drag-out) and accumulate in the rinse.

i

Rinsing operation waste and drag out pollution. Gold rinsing generates wastewater, which constitutes the metal finishing industry’s chief overall source of waste. Drag-out in rinse wastewater is responsible for the majority of process chemicals lost in metal finishing and can contain toxic compounds such as cyanides. Other potential hazards in wastewater can include: nitric, sulfuric, hydrochloric and hydrofluoric acids, cyanides and oil and grease. Failure to incorporate efficient drainage techniques and equipment while rinsing adds up to 70% more drag out waste than is otherwise necessary. Operations lacking the technological means to reuse rinse water and to recover metals and metals salts from rinse water and spent process baths can also contribute to extra water use and toxic effluent. Open – loop systems discharge more waste than do closed loop designs. Excess water consumption and drag out generation increase the volume of wastewater requiring treatment. This produces great amounts of sludge, a solid waste which can contain toxic metals. To conserve rinse water, reduce drag-out, reuse rinse water, and recover metals.

ii

Bath solution replacement The replacement of spent or contaminated baths (plating, cleaning, etc.) can yield much waste which typically is taken off line and treated or put in containers for off-site disposal. This waste contains many of the same toxic compounds found in rinse water, acids, metals, and cyanides. Facilities without methods to extend bath life augment the quantities of such compounds discharged into the waste stream.

iii Toxic air emissions: Many gold finishing operations generate air emissions, including mists, from plating baths and vapors from cleaning and degreasing processes, which use solvents. These toxic emissions can threaten the safe of the workplace and labors and surrounding area. Operations, which neither provides equipment to prevent the escape of air pollutants nor substitute less hazardous alternatives where feasible, enhance the danger to workers, their neighbors, and the environment.

PCFC-EG#31

iv Hazardous process compounds

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Revised:23/04/03

There are a number of metal finishing process compounds which present particular health and pollution problems e.g. cyanide-based solutions. For many applications of these materials substitutes exists. Failure to implement viable alternatives perpetuates the unnecessary discharge or escape of highly toxic compounds into the environment. For DMCC applicable source air emissions and ambient standards please refer to Attachments 1 & 2. v

Cyanide-Based Solution Various cyanides are used in gold electroplating baths. Plating generates significant amounts of cyanide waste, much of it in wastewater from associated rinsing operations. Discharge of this waste risks production of especially toxic hydrogen cyanide gas (HCN) from the mixture of cyanide waste with other effluent containing acids.

Cyanide in solutions is extremely dangerous. A potentially more serious problem for electroplaters is the accidental addition of an acid to a plating bath with cyanide, which can create HCN. HCN enters the human body by inhalation, ingestion, or skin absorption. C

ENVIRONMENTAL IMPACTS i

The environmental effects of the gold finishing industry are potentially severe and wide-ranging. Some toxic compounds used in metal degrade quickly; others are persistent and can impact the environment far from the point of discharge. Many metals tend to accumulate in sediment and plant and animal and human beings.

ii

Residues or spills which taint soil around industry facilities may lead to surface and ground water pollution. Disposal of wastewater containing hazardous materials can contaminate streams. Proper wastewater treatment facility is required.

iii

Corrosive acids presence in wastewater would potentially attack sewers structures proper acid resistant materials/floor used.

iv

Good housekeeping, proper ventilation/exhaust systems be installed. Baths (acids) must be provided with hoods, which should be connected to scrubbers before venting to the environment. Planned multi story building will only make it more acute.

v

Segregated industrial and domestic waste be planned.

vi

Potential sludge/waste filters should be disposed off as a Hazardous waste.

vii Acidic and cyanide bearing wastewater should ideally be segregated for treatment. All wastewater streams should be treated to meet DM acceptable limits (see Attachement-3) for disposal or reuse in irrigation.

D

ALTERNATIVES i

Technologies and processes Rinse water can be recycled in an open- loop or closed- loop system. The former allows treated effluent to be reused in rinsing, but the final rinse is fed by fresh water; effluent thus continues to be discharged. In a closedloop design, the treated effluent is returned to the rinse system. According to the U.S. EPA:” This system can significantly reduce water use and the volume of water discharged to the waste water treatment plant.” Closedloop systems also facilitate recovery processes to reclaim metals from the plating operations.

PCFC-EG#31 Revised:23/04/03

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Rinse water efficiency techniques can improve the economic viability of either system. Ways to improve rinse efficiency and conserve water include: agitation of rinse water, by air and hydraulic, mechanical, or ultrasonic methods; agitation of work pieces during rinsing; and use of spray rinsing techniques ( which require between

one- eight and one- fourth the water that dip rinses use), alone or in combination with immersion. In addition, equipment to permit the reuse of rinse water for one operation as feed for another (reactive rinsing) can reduce rinse water consumption by 50%. Established metals recovery and process bath regeneration technologies are: filtration and centrifugation; evaporation; electrolytic recovery; reverse osmosis; ion exchange; and elecro-dialysis (the most effective method will depend on a variety of factors, e.g. size of facility or type of baths or effluent) Process bath life can be extended by: filtration; electrolytic dummying; precipitation ; and various improved housekeeping measures. Air emission controls include: exhaust hoods with air filters; mist eliminators; and fume scrubbers. Process baths, which generate mists should be designed to reduce the amount of mist reaching the ventilation system ( i.e with more freeboard) In addition, there are process changes, which can eliminate the need for solvents or for cleaning altogether. These are: ultrasonic cleaning; automated aqueous cleaning; aqueous power washing: no-clean flux (low solids fluxes); no-clean soldering (inert atmosphere); and vacuum furnaces.

ii

Cyanide. According to UNEP/IEO alternatives to cyanide are non-cyanide copper plating baths available commercially. Cyanide free alkaline phosphonate copper plating technology is one possibility; pyrophosphate based solutions (which have been the most readily available replacements for cyanide plating baths) are another. Recent industry literature also describes non- cyanide sulfite gold plating and gold electroplating solutions.

PCFC-EG#31 Revised:23/04/03

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Attachment –1 SOURCE EMISSION CRITERIA GENERAL: STATIONARY SOURCES AIR POLLUTANTS EMISSION LIMITS FOR STATIONARY SOURCES

SUBSTANCE

SYMBOL

Visible Emissions Carbon Monoxide Nitrogen Oxides (Expressed as nitrogen dioxide)

CO

SOURCES

EMISSION (mg/Nm3)

Combustion sources Other sources All sources Combustion sources

NOx Material producing industries

LIMITS

250 none 500 Gas fuel-350 Liquid fuel-500 1500

Other sources Sulphur Dioxide

Sulphur Trioxide Including Sulphuric Acid Mist (Expressed as sulphur trioxide) Total Suspended Particles

SO2

SO3

TSP

Combustion sources Material producing industries Other sources Material producing industries Other sources Combustion sources Cement Industries Other sources Material producing industries Other sources

200 500 2000 1000 150 50 250 50 150 50

Ammonia and Ammonium Compounds (expressed as ammonia)

NH3

Benzene Iron Lead and its compounds (expressed as lead) Antimony and its Compounds (Expressed as antimony)

C6H6 Fe Pb Sb

Material producing industries Other sources

Arsenic and its Compounds (expressed as arsenic) Cadmium and its compounds (expressed as cadmium) Mercury and its compounds (expressed as mercury) Nickel and its compounds (expressed as nickel) Copper and its compounds (expressed as copper) Hydrogen Sulphide

As

All sources

1 1

Cd

All sources

1

Hg

All sources

0.5

Ni

All sources

1

Cu

All sources

5

H2S

All sources

5

PCFC-EG#31

All sources Iron & Steel foundries All sources

Page 8 of 13

Chloride

Cl

10 5 100 5 5

Revised:23/04/03

Chlorine Works Other sources

200 10

Hydrogen Chloride

HCI

Hydrogen Fluoride Silicon Fluoride Fluoride and its Compounds Including HF & SiF4 (expressed fluoride) Formaldehyde

HF SiF4 F-

Carbon Total Volatile Organic Compounds (expressed as total organic carbon TOC) Dioxins and Furans

CH20

Chlorine Works Other sources All sources All sources Aluminum smelters Other sources

200 20 2 10 20 50

Material producing industries Other sources

20

C VOC

Anode production Waste incineration All sources

All sources

2 250 50 20 1 (ng TEQ/m3)

Notes: 1.

The concentration of any substance specified in the first column emitted from any source specified in the third column shall not at any point before admixture with air, smoke or other gases, exceed the limits specified in the fourth column. 2. “mg” means milligram; 3. “ng” means nanogram. 4. “Nm3” means normal cubic meter, being that amount of gas which when dry, occupies a cubic meter at a temperature of 25 degree Centigrade and at an absolute pressure of 760 millimeters of mercury (1 atm) ; 5. The limit of “Visible Emission” does not apply to emission of water vapour and a reasonable period for cold start up, shutdown or emergency operation. 6. The measurement for “Total Suspended Particles (TSP)’’ emitted from combustion sources should be @12% reference CO2. 7. The total concentration of the heavy metals (Pb, Cd, Ni, Hg, Cu, As & Sb) must not exceed 5 mg/Nm3. 8. VOC limit is for unburned hydrocarbons (uncontrolled). 9. The emission limits for all the substances exclude “Dioxins and Furans” are conducted as a daily average value. 10. TEQ means “Total Equivalent Quantity.” Dioxins and Furans” Average values shall be measured over a sample period of a minimum of 6 hours and a maximum of 8 hours. The emission limit value refers to the total concentration of dioxins and furans calculated using the concept of toxic equivalence. 11. For source standards and air pollutants emission limits from incinerators refer to PCFC –ER (3rd Edition) relevant Annexes.

PCFC-EG#31 Revised:23/04/03

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Attachment –2 AMBIENT AIR QUALITY STANDARDS (AIR POLLUTANTS LIMITS IN THE AMBIENT AIR)

SUBSTANCE

SYMBOL

MAX.ALLOWABLE LIMITS (ug/m3)

AVERAGE TIME

SO2

350

1 hour

150

24 hours

CO

60 30 mg/m3

1 year 1 hour

NO2

10 mg/m3 400

8 hour 1 hour

O3

150 200

24 hours 1 hour

TSP

120 230

8 hour 24 hour

90

1year

150

24 hours

1

1 year

Sulphur Dioxide

Carbon Monoxide

Nitrogen Dioxide

Ozone

Total Suspended Particles Particulate Matter (with 10 microns or less in diameter) Lead

PCFC-EG#31

PM10

Pb

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Attachment –3 DUBAI MUNICIPALITY (DM) STANDARDS FOR DISHCARGE/RE-USE OF WASTEWATER Parameter

Unit

DM Sewer

Irrigation Water

Ammoniacal Nitrogen

mg/l

40