PM_2.5 Emissions from Aluminum Smelters: Coefficients and Environmental Impact

ABSTRACT

From 2004 to 2009, aiming to better understand implications for its smelters, Rio Tinto Alcan conducted a detailed study of PM_2.5 and PM₁₀ (particulate matter [PM] ≤ 2.5 and 10 μm in aerodynamic diameter, respectively) in its facilities. This involved a two-level study: part 1, emission quantification; and part 2, assessment of aluminum smelter contribution to the surrounding environment. In the first part, U.S. Environmental Protection Agency Other Test Method (OTM) OTM27 and OTM28 are assessed as relevant and efficient methods for measuring fine particle emissions from aluminum smelter stacks. Rio Tinto Alcan has also developed a safe and robust method called CYCLEX to measure PM_2.5 and condensable particulate matter (CPM) at the roof vents of potrooms. This work aims to determine the PM_2.5 emission coefficients of 17, 55, and 417 g·t⁻¹ of aluminum produced (including CPM) in anode baking furnace exhaust (fume treatment center), at potroom scrubber stacks (gas treatment centers), and at potroom roof vents, respectively. Results indicate that roof vents are the primary PM_2.5 emitters (85% of all smelter emissions) and that 71% of all smelter PM_2.5 comes from CPM. In the second part, preliminary inorganic speciation studies are conducted by scanning electron microscopy–energy-dispersive X-ray analysis and by isotopic ratios to track smelter emissions to their surrounding environment. This paper releases the first speciation results for an aluminum smelter, and the preliminary isotopic ratio study indicates a 3% impact in terms of PM_2.5 emissions for a representative smelter in an urban area.

IMPLICATIONS

Aluminum smelters tend to continuously improve their competitiveness by incrementally increasing production. In this context, assessing the effect of major contaminants is overriding, and ambient air modeling is often the preferred way to do so. Fine particles fit this category, and the primary aluminum industry needs to accurately know their emission factors to obtain representative modeling. Moreover, not all aluminum smelters have a method to measure PM_2.5 at roof vents, the primary emission outlets. Therefore, this paper describes the first-rate PM_2.5 measurement methods for aluminum smelter roof vents without down-comers. It also provides insight for environmental managers for tracking PM_2.5 emissions in plant surroundings.

ACKNOWLEDGMENTS

The author thanks Claude Perron (ARDC), Jacques Bélanger and Rock Emond (Alma Works), Ghassan Dugaish and Jamie Coomes (Sebree Works), and Paul Siegel and his team (Air Quality Services, Kentucky) for sampling and technical support. Rio Tinto Alcan also acknowledges Professor André Poirier from UQAM-GEOTOP for all of the work with isotopes. Rio Tinto Alcan also gives special thanks to Yvan Lavoie and Jacques Labrie (now retired from Rio Tinto Alcan) for the first works on the PM_2.5 program.