Prevention of PCDD/F formation and minimization of their emission at the stack of a secondary aluminium casting plant

Results of an extensive 5 year study on a full-scale plant with the specific aim to investigate polychlorinated dibenzo-p-dioxin (PCDD) and polychlorinated dibenzo furan (PCDF) formation and release in a secondary aluminum casting plant are reported. PCDD and PCDF concentrations were evaluated for all the gaseous and solid streams (no liquid stream was present) as well as for the flue gas upstream and downstream of every single unit of the flue gas cleaning system. The study highlights PCDD and PCDF formation particularly in the narrow 320-360°C range. To prevent formation reactions and/or minimize PCDD and PCDF concentration at the stack, effects of the fabric filter substitution, a quenching chamber and a postcombustor installation together with working conditions are investigated. The flue gas cleaning system results in PCDD and PCDF emission at stack of 0.1-0.2 ng I-TEQ/N m³ and in a mass flow of 250-550 nmol/h. The total PCDD and PCDF release into the environment is 0.06 g I-TEQ/yr and the corresponding emission factor, 0.35 μg I-TEQ/ton. It is shown that the global effects of the technological innovation on the reaction mechanisms are the prevention of PCDD/F formation by de novo synthesis and the minimization of their emission. © 2008 American Chemical Society.