EHS Env Guidelines

PCFC ENVIRONMENTAL GUIDELINES (EGs)
TABLE OF CONTENTS
EG No. Description
1. 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
2. Large Boilers and Furnaces
2.1: General Guidelines
2.2: Technical Guidelines for Steam Boiler Installation
3. Chemical Fertilizer Works
4. Ammonia Works
5. Sulphuric Acid Works
6. Lead Works
7. Mineral Works
8. Iron and Steel Works-Foundries
9. Secondary Aluminum Works
10. Chemical Incineration Works
11. Cement Works
12. Di-isocyanates Works
13. Petroleum Works – Refineries
14. Chlorine and Hydrochloric Acid Works
15. Iron and Steel Works
16. Montreal Protocol for Ozone Depleting Substances
17. 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
17.5: PCFC Requirements for Handling, Export of Radioactive Substances

18. 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
19. Environmental Management Tools (EMT)
20. Guidelines for Conducting Environmental Impact Assessment (EIA)
Study in PCFC/Pre-qualified Consultants list for EIA/RA Studies.
21. Best Available Techniques (BAT) and Best Practicable Environmental Option (BPEO)
22. Guidance for Linear Soakaways Installation

23 Guidance for Groundwater Monitoring Wells Installation
24. Energy Efficiency
25. EHS Standards References
26. DUCAMZ Environmental Guidelines.
27. Guidelines for Cleanliness
PCFC-EGs-Table of Contents i Revised: 23/04/03
28. General Environmental Guidelines for Manufacturing/Assembly/Service Industries.
29. EHS Performance Audits

30. Guidelines for Conducting Waste Audits in PCFC.
31. Environmental Guidelines for Gold and Diamond Facilities in DMCC
32. Energy, Water Conservation and Management Guidelines
33. Glass Recycling
34. Environmental Reporting
35. Cleaner Production, Waste Minimization and RRR Options
36. Waste Management in PCFC
PCFC-EGs-Table of Contents ii Revised:23/04/03
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 Page 1 of 4 Revised:23/04/03
1.2 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-by-
case basis air dispersion modeling would be required from the clients.
1.3 GENERAL INDUSTRY AIR EMISSIONS GUIDELINES
a. Particulate matter Emission

Limit
(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.
Iron oxide fume from oxygen refining 75 mg/m3

*Petroleum - solids from catalytic crackers 100 mg/m3
*Petroleum - furnace carbon black 5 mg/m3
Phosphorus (as P2 O5) 5 mg/m3
Tar fumes 20 mg/m3
Vinyl Chloride 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.
(vii) All abrasive blasters operating in PCFC shall use a recyclable non-metallurgical abrasive
material.
b. Gaseous Emissions Emission

Limits
Amines - total amine 5 p.p.m v/v

- trimethylamine 1 p.p.m v/v
Asphalt fumes 5 mg/m3
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
EMISSION LIMITS
SUBSTANCE SYMBOL SOURCES (mg/Nm3)
Visible Emissions Combustion sources 250
Other sources none
Carbon Monoxide CO All sources 500
Nitrogen Oxides Combustion sources Gas fuel-350
(Expressed as nitrogen NOx Liquid fuel-500
dioxide) Material producing 1500
industries
Other sources 200

Sulphur Dioxide SO2 Combustion sources 500
Material producing 2000
industries
Other sources 1000
Sulphur Trioxide Material producing 150
Including Sulphuric Acid Mist SO3 industries
(Expressed as sulphur trioxide) Other sources 50
Total Suspended Particles Combustion sources 250
TSP Cement Industries 50
Other sources 150
Ammonia and Ammonium NH3 Material producing 50
Compounds (expressed as industries
ammonia) Other sources 10
Benzene C6H6 All sources 5
Iron Fe Iron & Steel foundries 100
Lead and its compounds Pb All sources 5
(expressed as lead)
Antimony and its Compounds Sb Material producing 5
(Expressed as antimony) industries
Other sources 1
Arsenic and its Compounds As All sources 1
(expressed as arsenic)
Cadmium and its compounds Cd All sources 1
(expressed as cadmium)
Mercury and its compounds Hg All sources 0.5
(expressed as mercury)
Nickel and its compounds Ni All sources 1
(expressed as nickel)
Copper and its compounds Cu All sources 5

(expressed as copper)
Hydrogen Sulphide H2S All sources 5
Chloride Cl Chlorine Works 200
Other sources 10
Hydrogen Chloride HCI Chlorine Works 200
Other sources 20
Hydrogen Fluoride HF All sources 2
Silicon Fluoride SiF4 All sources 10
Fluoride and its Compounds - Aluminum smelters 20
F
Including HF & SiF4 Other sources 50
(expressed fluoride)
Formaldehyde CH20 Material producing 20
industries
Other sources 2
Carbon C Anode production 250
Waste incineration 50
Total Volatile Organic Compounds VOC All sources 20
(expressed as total organic

carbon -TOC)
Dioxins and Furans All sources 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.

LARGE BOILERS AND FURNACES
2.1 GENERAL GUIDELINES
(i) 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.
A. 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.
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) Details of the steam boiler including capacity, fuel type (with sulphur content < 1%), fuel rate, fuel
sulphur content etc. have to be provided.
(ii) Boiler room height and any adjacent building height to be provided. Boiler chimney height
calculation will be provided by PCFC to the client.
(iii) 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.
(iv) 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. Conditions mentioned under the title ‘Large Boilers and Furnaces’ should be fulfilled and
acknowledged.
b. Proper sampling point to be provided on the chimney for emission quality checks.

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 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.
C 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.
D 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.

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.
E 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.
F 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.
G 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.
H 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.

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.
(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.

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.
(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.
(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.
PCFC-EG#5 Page 1 of 2 Revised: 23/04/03

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:
Plant Rated Capacity Height
Up to 400 tonnes/day 60 meters

600 “ 75 “
800 “ 85 “
1000 “ 95 “
(iii) The height may need to be increased to allow for special local circumstances.
(iv) The linear velocity of waste gases in the chimney shall not exceed 9m/s.

LEAD WORKS
1 INTRODUCTION
These notes apply to:
a. works in which compounds of lead are produced by the application of heat:
i. lead is extracted or recovered from any material containing lead or its compounds; or
ii. lead is refined; or
iii lead is applied as a surface coating to other metals by spraying; or
b. 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.
(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.

(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) recycling within the process by means of a directly connected closed handling

system.
ii) conversion into a non-dusty form by feeding into a continuous fusion furnace.
iii) discharging directly from the arrestment plant into bags or drums in an enclosed
filling booth extracted to a filter.
iv) direct filling into containers which can be charged unopened into furnaces.
b. Another option is the wet pelletising of dust, but this requires careful control to produce a
stable pellet which will not break down again.
(iv) 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.
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.

(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.

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.
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 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.
E Surge piles and storage
i. 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.

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.
F 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.
3 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.

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.
(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.
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 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.
C 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.
D General
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.
(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 Chimney Height, m.
7 or below 21
10 23
15 26
20 28
25 30
(ii) 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.

SECONDARY ALUMINIUM WORKS
1 INTRODUCTION
(i) These notes apply to works in which:
a. Aluminum swarf is degreased by the application of heat; or

b. Aluminum or aluminum alloys are recovered from aluminum or aluminum scrap
fabricated metal, swarf, skimmings, drosses or other residues by melting; or
c. aluminum is recovered from slag; or
d. 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.
(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.

A Treatment of Oily swarf and contaminated scrap
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.
B 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.

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.
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 semi-
metals or metalloids.
The following limits will also apply:
Phosphorus compounds, calculated as P 5 mg/m3

Total acidity, calculated as sulphur trioxide 150 mg/m3
Hydrogen chloride 20 mg/m3
Hydrogen fluoride 2 mg/m3

(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.
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. Pipeline systems for bulk liquids or sludges;

b. Drum handling facilities for liquids, sludges or solids;
c. Systems for handling packaged solids;
d. 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.
B 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.

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.
C 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.

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 carry-
over 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.
D 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.
5 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.

(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.

CEMENT WORKS
1 INTRODUCTION
These notes apply to works in which:
a. cement clinker is produced; or

b. cement clinker is handled and ground; or
c. 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.
(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.
(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.
(ii) 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 Dry Process (m)
30 60
60 73
90 85
120 94
240 126
(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.

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 SAMPLING, ASSESSMENT OF EMISSIONS AND MONITORING
(i) 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.

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 = (0.0086 VT)1/2
where H = chimney height in metres,
V = volume of emission, cubic meters per hour,

T = 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.

(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.

(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.

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.
(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.
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 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.
C 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.
(ii) 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.
(ii) 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.

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”.
(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.
(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.
(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.
(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.

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.

(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.

(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.
7 BASIC OXYGEN STEEL PLANTS

(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.

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 Trichlorofluoromethane
CFC-12 Dichlodifluoromethane
CFC-113 Trichlorotrifluoromethane
CFC-114 Dichlorotetrafluoromethane
CFC-115 Chloropentafluoromethane
R-500 Dichlorodifluoro/difluoromethane
R-502 Chlorodifluoro/Chloropentafluoromethane
Halon 1211 Bromochlorodifluoromethane
Halon 1301 Bromotrifluoromethane
Halon 2402 Dibromotetrafluoromethane
CCl4 Carbon Tetrachloride
CH3CCl3 Methyl Chloroform
CH3Br Methyl Bromide
HBFC Hydrobromofluorocarbons
3 GENERAL REQUIREMENTS
(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 Refrigeration and air conditioning,

o Foam manufacturing,
o Fire protection; and
o 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 Maintained leak free,

o Supplied with gases from existing supplies or recycled sources; and
o Converted to use approved gases.
iii. The venting of controlled refrigerants during equipment maintenance shall not be permitted.
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.
B 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.
C 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.
D 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.
E 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.
PCFC-EG#16 Page 3 of 3 Revised:23 /04/03

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. dust of any kind, when present at a substantial concentration in air;
v 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.
b) 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.

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 ppm mg/m3 ppm mg/m3
Acrylonitrle CH2 = CHCN 2 4 - -

Ammonia NH3 25 18 - 0.5
Arsenic & compounds except As - 0.2
arsine and lead arsenate as As
Buta 1.3-diene CH2 = CHCH=CH2 10 - - -
2-Butoxyethanol C4H9OCH2CH2OH 25 120 - -
Cadmium & cadmium compounds
except cadmium oxide fume and Cd - 0.05 - -
cadmium sulphide pigments (as Cd)
Cadmium oxide fume (as Cd) CdO - 0.05 - 0.05
Cadmium sulphide pigments
(respirable dust as Cd) CdS - 0.04 - -
Carbon disulphide CS2 10 30 - -Dichloromethane
CH2Cl2 100 350 - -
2.2’ Dichloro-4.4’ methylene
dianiline (MbOCA) CH2 (C6H3CINH2)2 - 0.005 - -
2-Ethoxyethanol C2H2OCH2CH2OH 10 37 - -
2-Ethoxvethvi acetate C2H5CCH2CH2OOCCH3 10 54 - -
Ethylene dibromide BrCH2CH2Br 1 8 - -
Ethylene oxide CH2CH2O 1 2 - -
Formaldehyde HCHO 1 1.2 2 2.5
Hydrogen cyanide HCN - - 10 10
Isocyanates. all (as NCO) - 0.02 - 0.07
Man-made mineral fibre - 5 - -
1-Methoxypropan-2 ol CH3OCH2CHOHCH3 100 360 - -
2-Methoxyethanol CH3OCH2CH2OH 5 16 - -
2-Methoxyethyl acetate CH2COOCH2CH2OCH3 5 24 - -
Polychlorinated biphenys (PCB’s) C12 H10-nCln - 0.5 - 1.0
Rubber process dust - 8 - -
Rubber fume - 0.75 - -
Styrene C6H5CH=CH2 100 420 250 1050
1.1.1. Trichloroethane CH3CCl3 350 1900 450 2450
Trichloroethylene CCl2=CHCl 100 535 150 802
Vinyl chloride+ CH2=CHCl 7 - - -
Vinylidene chloride CH2=CCl2 5 20 - -
Wood dust (hard wood) - 5 - -
. 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.
d) Control of Exposure to substances hazardous to health

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”.
- Aflatoxins
- 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.
Class 1 : Explosives
Class 1 : is divided into 5 classes as follows:

Class 1.1 : Substances and articles which have a mass explosion hazard.
Class 1.2 : 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 3.1 : 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 4.1 : 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.
Class 5 : Oxidizing Substances (Agents) And Organic Peroxides
Class 5 is subdivided as follows:-

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:
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
(v) Packing : The packing of dangerous goods shall be :
i. : well made and in good condition;

ii : 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
iii : capable of withstanding the ordinary risks of handling.
(vi) 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
A 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 above-
ground 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. 50
2.1 5
2.2 5
2.3 15
3.1 10
4.1/4.2/4.3 5
5.1/5.2 5
6.1/6.2/6.3 5
8 5
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.
- 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.
C. Spillages:
All dangerous goods shall be stored on impervious surfaces capable of containing spills. Some
means of limiting the effects of leakage are:
1. Facilities for collecting spilled liquid

2. Sand or suitable absorbing material for containment or absorption.
3. Provision to seal leaking drums.
4. Provision to rinse away spilled substance
5. Ventilation
D. 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.
F. 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.
- 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.
G. 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.

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

Subsidiary (Note 1) (Note 2) Colouring of Label
Risk Category
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
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)

APPENDIX - I
Class or Class Label Subsidiary Risk Label Colouring of Label
Subsidiary (Note 1) (Note 2)
Risk Category
3.1 and 3.2

and lines on a background of the colour Red
4.1
Black lettering, symbol, numeral(if any) and lines
on white background 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

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)

APPENDIX I
Class or Class Label Subsidiary Risk Label
Subsidiary (Note 1) (Note 2) Colour of Label
Risk Category
6.1 (a)
on a white background.
6.1 (b)
on a white background.
6.2
N.A. Black lettering, symbol, numeral and lines on a
white background
7.
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
(Category II) colour Red.
8.
Upper background white. Black
symbol and lines. Lower back-
ground back. White lettering and
numeral (if any).

APPENDIX - II
DANGEROUS GOODS SEGREGATION REQUIREMENT
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
NA - Not applicable may be stored in the same room.

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

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) fully-refrigerated, where the liquid is stored at its bubble point at near-atmospheric

pressure; or
b) full pressure, where the liquid is stored at ambient temperature; or
c) 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 low-
expansion 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 high-
impact 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.

TABLE - 17B
PRODUCTS COMMONLY STORED AS LIQUEFIED GASES.
GAS BOILING LIQUID VAPOUR CRITICAL

POINT AT DENSITY PRESSURE TEMP. (oC)
AT AT 30 oC
1 BAR ABS BOILING (BAR BAS)
( oC) POINT
(KG/M3)
Can be stored without

refrigeration
11 883 2.7 195
Ethylene oxide 0 602 3.6 152
n-butane -4 650 4.1 152
Butadiene (1, 3) -6 626 4.3 146
Butylene (oC) -12 595 5.0 135
Isobutane -33 682 14.6 133
Ammonia -42 582 13.0 97
Propane -48 614 15.7 92
Propylene
Require refrigeration
-89 546 - 32
Ethane -104 568 - 9
Ethylene -162 424 - -82
Methane (LNG) -183 1140 - -119
Oxygen -196 808 - -147
Nitrogen

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 full-
pressure 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 semi-
refrigerated 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. Double-
compartment 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.

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.

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. Gases. Part 1: General
Requirements.
d) PCFC Health and Safety Manual.

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.

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 Type and size of point or diffuse source (e.g. industrial process).

ii Type of discharges (e.g. origin, average composion).
iii State of waste (e.g. solid, liquid, sludge, slurry).
iv Total amount (volume discharged, e.g. per year).
v Discharge pattern (continuous, intermittent, seasonally variable, etc.).
vi Concentrations with respect to relevant constituents of substances as appropriate.
vii Physical, chemical and biochemical properties of the waste discharges.
B. CHARACTERISTICS OF DISCHARGE CONSTITUENTS WITH RESPECT TO THEIR

HARMFULNESS
i Persistence (physical, chemical, biological) in the marine environment.

ii Toxicity and other harmful effects.
iii Accumulation in biological materials or sediments.
iv Biochemical transformation producing harmful compounds.
v Adverse effects on the oxygen content and balance.
vi 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.
C. CHARACTERISTICS OF DISCHARGE SITE AND RECEIVING ENVIRONMENT
i Hydrographic meteorological, geological and topographical characteristics of the coastal area.

ii 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.
iii Initial dilution achieved at the point of discharge into the receiving environment.
iv Dispersion characteristics such as effects of currents, tides and wind on horizontal transport and
vertical mixing.
v Receiving water characteristics with respect to physical, chemical, biological and ecological
conditions in the discharge area.
vi Capacity of the receiving marine environment to receive waste discharges without undesirable
effects.
D. 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 Alternative treatment processes;

ii Re-use or elimination methods;
iii On-land disposal alternatives;
iv Appropriate low-waste technologies.
E 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.
iii Effects on other legitimate uses of the sea.
18.4 WASTEWATER CRITERIA AT POINT OF DISCHARGE TO MARINE

ENVIRONMENT/HARBOUR: STANDARDS FOR DISCHARGE OF WASTE WATER TO HARBOUR
(1)/
MAX. ALLOWABLE
PARAMETERS (2) SYMBOL UNIT STANDARD (7)
Physical Properties
Colour - Colour units 50
Total Suspended Solids TSS mg/1 50
Floating Particles - mg/m3 None
pH - pH units 6-9(6)
Temperature(3) T C 35 (max)
Total Dissolved Solids TDS mg/1 1500
Turbidity - NTU 75
Inorganic Chemical Properties
+
Ammonia Total as (N) NH4 mg/1 2
Biochemical Oxygen Demand BOD5 mg/1 50
Chemical Oxygen Demand COD 100
Chlorine Residual (4)Total Cl- mg/1 1.0
Cyanide CN mg/1 0.05
Dissolved Oxygen(5) DO mg/1 >3
Fluoride F mg/1 20
Nitrate NO3-N mg/1 40
Sulfide S-2 mg/1 0.1
Total Kjeldahl Nitrogen as (N) TKN mg/1 10
Total Phosphorus, as (P) PO4-3 mg/1 2
Trace Metals
Aluminum Al mg/1 20
Antimony Sb mg/1 0.1
Arsenic As mg/1 0.05
Barium Ba mg/1 2
Beryllium Be mg/1 0.05
Cadmium Cd mg/1 0.05
Chromium, total Cr mg/1 0.2
Chromium, VI Cr+6 mg/1 0.15
Cobalt Co mg/1 0.2

Copper Cu mg/1 0.5
Cyanide CN mg/1 0.1
Fluoride F mg/1 25
Iron Fe mg/1 2
Lead Pb mg/1 0.1
Manganese Mn mg/1 0.2
Mercury Hg mg/1 0.001
Nickel Ni mg/1 0.1
Selenium Se mg/1 0.02
Silver Ag mg/1 0.005
Zinc Zn mg/1 0.5
Organic Chemical Properties
Halogenated Hydrocarbons
and Pesticides mg/1 Nil
Hydrocarbons HC mg/1 15
Oil & Grease O&G mg/1 10
Phenols - mg/1 0.1
Solvent - mg/1 none
Total Organic Carbon TOC mg/1 75
Biological Properties
Colon Group TC No./100 cm2 5000
Egg Parasites - - None
Fecal Coliform Bacteria - Cells/100 ml 1000
Total Coliform - MPN/100ml 1000
Warm Parasites - 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.

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

VALUE
Physical
Temperature °C 45
Total Dissolved Solids mg/l 3000
Total Suspended Solids mg/l 500
Chemical
Aluminium mg/l 30
Ammonia, Total (as N)a,b mg/l 40
Arsenic mg/l 0.5
Barium mg/l 2.0
Biological Oxygen Demand (BOD5) mg/l 1000
Boron a,b mg/l 2.0
Cadmium mg/l 0.3
Chemical Oxygen Demand (COD) mg/l 3000
Chloride a,b mg/l 700
Chromium – Total mg/l 1.0
Chromium – Hexavalent mg/l 0.25
Cobalt mg/l 2.0
Copper mg/l 1.0
Cyanide compounds mg/l 1.0
Detergents mg/l 30
Emulsified Tar, Oil & Grease mg/l 150
Fluorideb mg/l 30
Free Chlorine mg/l 10
Iron mg/l 25
Lead mg/l 1.0
Manganese mg/l 1.0
Mercury mg/l 0.015
Metals (Total)d mg/l 10
Nickel mg/l 1.0
Non Chlorinated Pesticides mg/l 5
Oil and Grease mg/l 50
pH c pH units 6-9
Phenols mg/l 50
Phosphorus, Total (as P) mg/l 30
Sodium a.b mg/l 1000
Sodium Absorption Ratio (SAR) a.b SAR units 20
Silver mg/l 1.0
Sulfates (Total) mg/l 500
Sulfides mg/l 6
Synthetic Detergents mg/l 100
Tar/Oils mg/l 20
Total Organic Carbon (TOC) mg/l 1000
Zinc e mg/l 2.0
NOTES
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.

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 Page 1of 6 Revised:23/04/03
JAFZA hereby requires that:

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,
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.
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.
D 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. The type of waste permitted to be handled.

b. The quantity which may be handled.
c. How the waste must be handled, and
d. 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.
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. A time limit within which a clean up must be completed.

b. Requirements for sampling and testing.
c. Standards prescribing acceptable residual levels in the environment.
d. The means by which any wastes are to be treated and disposed of.
e. Any procedures for conducting the clean up.
f. 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 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.
F 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.
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.
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.

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:
“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
Stage 5: Identify BPEO

- justify choice
Stage 6: Review the BPEO
- sensitivity testing
- ensure there is an audit trail

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.

2. GROUNDWATER MONITORING WELL/BOREHOLE DIAGRAM

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.
For more information refer to useful web sites like:

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.
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. Energy-
efficient motors can cut this energy use by nearly 15%.
i www.oit.doe.gov/bestpractices/
ii www.oitdev.nrel.gov/
6 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.
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.
i www.cdiac.esd.ornl.gov/
ii www.rrede.nrel.gov/
8 COMBUSTION
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.
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.
i www.energy.gov/
ii www.dpa.gov/
10 LIGHTING
Energy efficient lights/bulbs are commercially available. Let us use it and save energy!
i www.eefd.lbl.gov/
ii www.ornl.gov/hybridlighting
Be energy smart. Let us adopt energy efficient machines/products!

EHS STANDARDS REFERENCE
Alphabetical Subject Index
S.No. Standard Subject UAE/Gulf Standard No.

1- ABATTOIRS 713
Hygienic regulations
2- ABRASIVE WHEEL MACHINES

Safety 70
3- ACETYLENE
Industrial Safety and health regulations 56
Transportable containers 56
4- AFLATOXINS 841
Maximum limits of mycotoxins permitted in foods
5- AIR POLLUTION see pollutant gases
6- AMMONIA
Liquid 483
Safety 59
7- ASBESTOS CEMENT
Flat sheets 487
Pipe fitting 481
Pipes, for sewage 33
8- ASHTRYS
Plastics 476
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
11- BAKERY PRODUCTS

Biscuits 989
Biscuits, test methods 990
Cakes 342
Cakes, test methods 341
10- BACKING POWDER

Test methods 291
12- BATTERIES
Lead acid starters 34
Lead acid starters, test methods 35
13- BEANS
Beans 1036
Frozen green beans 344
14- BEEF
Fresh, chilled and frozen 997
15- BLANKETS
Acrylic blankets, test methods 753
16- BOILERS
Code of practice, part 4:
Comprehensive procedure for thermal 374
performance tests
Industrial Safety and health regulations 215
Requirements part 8 1338
17- BUILDING AND CONSTRUCTION WORK

Industrial safety and health regulations 215
18- BUILDINGS
Building facilities, safety 79
Fire protection, safety 208
Heat insulation 977
Modular coordination 406
Sanitation, safety and health 54
19- BURGER MEAT 948
20- BUSES see motor vehicles

Pilgrim buses, safety requirements 967
21- BUTANE – PROPANE MIXTURE

Commercial, household 672
22- CAKES 342

Mixes 852
Test, methods 341
23- CAMEL
Fresh, chilled and frozen meat 834
24- CANE SUGAR see sugar
25- CANNED FOODS

Baby foods 355
Chickpeas 838
26- CARBONATED DRINKS 18

Carbon dioxide content determination 12
Phosphoric acid content determination 14
27- CARCINOGENS

28- CARGO HANDLING
29- CEMENT
Hydraulic, chemical analysis 938
30- CENTRIFUGAL PUMPS

Performance tests 288
31- CEREALS
Cereals and pulses-Part2: Sampling 952
Hidden insect infestation, sampling 952
Samollina 843
Storage, control of attack by pests 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 259
Corn flakes, test methods 258
Macaroni, spaghetti and vermicelli 163
Macaroni, spaghetti and vermicelli, test methods 164
Plant baby foods, sampling methods
Sampling methods (as grains) 180
245
34- CHEESE
Cheddar cheese 336
Chemical analysis 171
Processed, with vegetable oils 182
White, domiati and feta cheese 831
35- CHEMICAL PLANTS

36- CHEWING GUM 709

Test methods 708
37- CHICKENS
Chilled 322
Frozen 986
Chilled fish 380
38- CHICKPEAS
Canned 838
39- CHIPS (FOO) see fried potatoes
40- CHLORINE
Liquid, sampling 528
Liquid, water content determination 534
41- CHLOROFLOUROCARBONS
For industrial use 110
For industrial use, degree of purity determination 109
42- CHOCOLATE 567
43- CIGARETTES see also tobacco and tobacco 597

products.
Alkaloid determination 101
Carbon monoxide determination 292
Sampling 598
Smoking machine-definitions and standard 103
conditions
44- COFFEE
Caffeine content determination 720
Green coffee beans 442
Green Coffee in bags, sampling 410
Vocabulary 850
44- COLD STORAGE

Fruits & vegetables, physical condition in cold 434
stores
Oranges 225
Pears 321
45- COLORANTS (FOOD) 23
Test methods 22
46- COMPOST
Municipal solid waste 901
47- COMPOUND FERTILIZERS

Test methods 879
48- COMPRESSED GAS

Safety 61
49- COMPRESSED GAS EQUIPMENT

Safety 215
50- COOLANTS
See engine coolants
51- CORN
Puffed 784
Puffed, test methods 784
52- CORNED BEEF

Canned 504
53- CORN FLAKES 259

Test methods 258
54- CRUDE OIL

Standard test for cloud point 560
55- CUSTARD
Powder 853
56- CYLINDERS
Dissolved acetylene, basic requirements 744
57- DATES
Prepackaged 656
Whole, prepacked, test method 781, 657

58- DETERGENTS
Anionic – active matter
Liquid detergents for dish washing, test methods 391
Sampling division
Synthetic powdered detergents 256
151
59- DIAMMONIUM PHOSPHATE
Fertilizer 694
60- DICHLORODIFLUOROMETHANE
See chlorofluorocarbons
61- DICHLOROTETRAFLUROMETHANE
See chlorofluorocarbons
62- DRAINAGE See sewage and drainage
63- DRIED FOODS

Conditions of storage 168
64- EDIBLE OILS AND FATS

Storage, transport and handling 1018
Vegetable, Blanded 658
Vegetable ghee 991
65- EGGS
Chemical testing 445
Chicken 1002
66- ENVIRONMENTAL CONTROL

67- EXPIRATION PERIODS

Food products, part 1 150
Food products, part 2 1023
68- EXPLOSIVES
Dusts, explosives and blasting agents, safety and 210
regulations
Transportation of explosive substances 975
69- FERTILIZERS
Ammonium sulphate 297
Diammonium phosphate 694
Compound 803
Compound, test methods 879
Monoammonium phosphate 693
Organic 555
Organic, test methods 556
Singly superphosphate 339
Superphosphate, test methods 878
Triple superphosphate 745
70- FIRE EXTINGUISHERS
Dry chemical powder, multipurpose
Phosphate 340
Portable, dry powder 637
Portable, foam 636

71- FIRE PROTECTION
Buildings safety 208
72- FISH
Canned pacific salmon 524
Chilled 380
Handling fresh fish at sea, general specification 514
Hygienic practice for preparation and storing
Microbiological tests 1026
Physical and chemical tests
Shrimps, frozen 655
Smoked 589
582
270
73- 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
74- FLAVORINGS
Use in foodstuffs 707
75- FLAVOURED ARTIFICAL
Powders 848
76- FRLOURESCENT LAMPS
Ballast’s for high pressure mercury vapor lamps 368
Ballast’s, for high pressure mercury vapor lamps,
test methods 369
77- 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
78- FOOD FLAVORINGS 707
79- FOOD HYGIENE
Fresh meat 815
80- FOOD PACKAGING
Packages, General requirements 838
Plastics cups and containers for packing beverages 462
81- 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
82- FOOD 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.
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
83- FOOD TESTING
Antioxidants permitted for use in food products 795
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
Meat and meat products – I (-) – hydroxyproline 105
Vegetable fats and oils, fatty acids determination,
part 2 106
Vegetable products, chloride content 275
determination
Vegetables, canned, microbiological tests 313
Vegetables, caned, physical and chemical tests
178
177
84- FOOD TRANSPORATION 815
85- FRESH VEGETABLES
Onions 1030
Potatoes 1029
Vegetables marrow 1033
86-- FREEZERS
Household electric freezers 923
Household electric freezers, test methods 924
87-- FRIED POTATOES 286
Test methods 285
88-- 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
Revised:23/04/03
89- FRUIT DRINKS

Flavoured artificial powder 848
Fruit drink 794
90- Fruits See also tomatoes.
Net weight and drained weight determination 244
Water insoluble solids contents determination
Water melon 239
1035
91- FRUIT NECTARS
Mango nectar 249
Mixed fruit nectars 846
92- FUELS See automotive fuels, aviation, fuels,
gasoline, liquid fuels
93- GAS CONTAINERS
Pressure regulations, Lpg. 586
Pressure regulations, lpg., test methods 587
94- GAS CYLINDERS See cylinders, Personnel
requirements for professions 472
95- GASES See hazardous materials
Dissolved acetylene 557
Dissolved acetylene, test methods 559
Liquefied petroleum 672
Liquefied petroleum, test methods 673
Oxygen, medical use 563
Oxygen, medical use, test methods 564
Oxygen industrial 139
Oxygen industrial, test methods 138
96- GASOLINE See also automotive fuels, aviation
fuels.
97- GLASS BOTTLES
98- GLUTEN-FREE FOODS 1021
99- GOAT MEAT
Organs and viscera 835
100- GRAIN (FOOD) See cereal, food Products, wheat
grains
101- GRAPE FRUIT JUICE 490
102- GREEN BEANS
103- HAZARDOUS Materials See also industrial safety
and health regulations
Bulk plants, safety 64
Gases, hydrogen, safety 57
Gases, LPG, safety 60
Gases, nitrous oxide and oxygen, safety 58
Spray finishing paints 66
104- HEALTH AND SAFETY REGULATIONS See
industrial safety and health regulations
105- HONEY 147
106- HYDROGEN
107- HYGIENE
Food plants and personnel 21
Poultry abattoirs, personnel 713
108- INDUSTRIAL AND BULK PLANTS
Revised:23/04/03
109- INDUSTRIAL SAFETY AND HEALTH REGULATIONS
Equipment, forging machines 71

Equipment, machinery, general requirements 124
Equipment, materials handling
Equipment, machinery, power press 214
Equipment, mills, plastic and rubber industry 72
Petroleum industries 75
Processing paints
Refineries 74
Service station 65
Tanks, flammable materials 65
Vehicle mounted work platforms 65
Welding, cutting and brazing 62
80
220
110- JAMS 640
111- JELLIES 193
112- KEROSENE
113- LABAN AND LABENH 816
114- LABELING
Pre-packaged foods 9
Tobacco products 246
115- LAMPS
Ballast’s for high pressure mercury vapor lamps 369
High pressure mercury vapour lamps
829
116- LEAD ACID BATTERIES 34
117- LIQUEFIED PETROLEUM GAES
118- LIVESTOCK TRANSPORTATION
Sheep & goat 714
119- LPG See liquefied petroleum gases
120- LUBRICATING OILS
Demulsification number determination 131
Diesel oil 477
121- MACARONI 163
Test methods 164
122- MAIZE OIL
Edible 114
123- MALT BEVERAGE 1027
Test methodos 1028
124- MANGO JUICE 249
125- MANGOES
Canned 951
Guide to storage 847
126- MARMALADES 640
127- MEAT
Ash determination 993
Beef and buffalo fresh, chilled and frozen 83
Starch content determination 89
Total fat content 85
Total phosphorus content determination 107
128- MICROBIOLOGICAL TESTING
Cheese 179
Detection of salmonella 287
Drinking and mineral water 818
Genera guidance 810
Preparation of samples 261
Sterility test 590
Water non-routine tests 378
Revised:23/04/03
129- MILK
Detection of salmonella 994
Dried 10
Liquid, microbiological tests 571
Physical and chemical analysis 570
Raw 174
Sterilized 985
130- MILK PRODUCTS
Cream 651
131- MINERAL WATER
Bottled natural 987
Determination of arsenic 117
Determination of barium 154
Determination of borate 642
Non-routine microbiological tests 379
Sampling 111
Unbottled drinking water 149
132- MONOAMMONIUM PHOSPHATE
Fertilizer 693
133- MUTTON See also meat
134- MUSTARD SEED OIL
135- MOZZARELLA CHEESE 833
136- OCCUPATIONAL SAFETY See industrial safety
137- ORGANIC FERTILIZERS 555
138- PACKAGING See also this (containers)
Food Packages 839
Plastic bottles for chemical materials and products 132
Plastic cups for beverages 462

Polyethylene films used for packaging non- 393
foodstuffs
139- PERSONAL PROTECTIVE EQUIPMENT See
industrial safety and health regulations
140- PETROLEUM INDUSTRY See also refineries
Safety 74
141- POLLUTANT GASES
Motor vehicles, diesel engines, exhaust gaseous 414
pollutants determination
Motor vehicles, diesel engines, limits of pollutants 144
emitted to the atmosphere
142- Quality assurance inspection and test 9003
143- RADIOACTINE MATERIALS
145- RAW MILK 174
146- REFINERIES
147- SAFETY
Fire safety, colors & signs 522
148- SEMOLINA 843
149- SLAUGHTERING
Animal slaughtering requirements 993
150- STERILIZED MILK 985
151- STORAGE See also cold storage, expiration
periods
Cereals and pulses, control of attack by pests 721
Chilled and frozen foods, general requirements 323
Revised:23/04/03
152- 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
153- SUGAR AND SUGAR PRODUCTS See also
Gulucose
154- TANKS
Equipment, industrial safety 215
Hazardous materials, industrial safety 62
Portable hazardous materials, industrial safety 63
155- TOLUENE
For industrial and commercial use 891
For industrial and commercial use, test methods 892
156- UTENSILS See cooking utensils
157- VEGETABLE See also tomatoes
Alcohol insoluble solids determination 299
Alcohol insoluble solids determination, method for 331
fresh or quick frozen peas 243
Alkalinity of total ash determination 244
Apparent viscosity determination 299
Canned microbiological tests 178
Canned, physical and chemical tests 177
Carrots 1038
Vegetables marrow 1033
Ware potatoes, storage 310
Water insoluble solids content determination 239
158- VEGETABLE OILS AND FATS See also oilseeds
Edible, arachis oil
Edible, food additives 1023
Edible, maize oil 19
144
159- VERMICELLI 163
160 WATER
Bottled drinking water 1025
Drinking and mineral water, arsenic determination 177
642
Drinking and mineral water, calcium determination 641
Drinking and mineral water, fluoride 117

determination
Revised:23/04/03
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
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.
3 ANTIFREEZE
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.
4 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.
Revised:23/04/03
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
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.
7 FREON (CFC’s)
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.
8 HOT TANK SOLUTION
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.
9 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.

10 PAINT WASTE
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.
11 PRESSURIZED SPRAY CANS
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.
12 SHOP TOWELS
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.
13 SOLVENTS & SOLVENT TANKS
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.
14 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.
Revised:23/04/03
15 SUMP SLUDGES
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.
16 TRANSMISSION FILTERS
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.
17 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.
Make sure that your container for wastes is placed in a secure area and train your workers.
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
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).
Dispose filters in accordance with PCFC procedures.
Don’t put filters in your waste skip.
20 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.

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.
Revised:23/04/03
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. SCOPE AND RESPONSIBILITES ( i.e from cradle – to grave)
(i) 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.
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.
Revised:23/04/03
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.”
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.
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.
Revised:23/04/03
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.
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
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.
Revised:23/04/03
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, 1,1,1-
trichloroehtane, 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.
Revised:23/04/03
B Air Emissions Performance Testing

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 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.
C 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 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.
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.
Revised:23/04/03
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.
Revised:23/04/03
Attachment –1
SOURCE EMISSION CRITERIA
GENERAL: STATIONARY SOURCES
AIR POLLUTANTS EMISSION LIMITS FOR STATIONARY SOURCES
SUBSTANCE SYMBOL SOURCES EMISSION LIMITS

(mg/Nm3)
Other sources none
(Expressed as nitrogen dioxide) NOx Liquid fuel-500
industries
Other sources 200

industries
Other sources 1000
Sulphur Trioxide Material producing 150
Including Sulphuric Acid Mist SO3 industries
(Expressed as sulphur trioxide) Other sources 50
Other sources 150
Ammonia and Ammonium NH3 Material producing 50
Compounds (expressed as industries
ammonia) Other sources 10
Lead and its compounds Pb All sources 5
(expressed as lead)
Antimony and its Compounds Sb Material producing 5
(Expressed as antimony) industries
Other sources 1
Arsenic and its Compounds As All sources 1
(expressed as arsenic)
Mercury and its compounds Hg All sources 0.5
(expressed as mercury)
Nickel and its compounds Ni All sources 1
(expressed as nickel)
Copper and its compounds Cu All sources 5
(expressed as copper)
Other sources 10
Other sources 20
Revised:23/04/03
Fluoride and its Compounds - Aluminum smelters 20
F
Formaldehyde CH20 Material producing 20
industries
Other sources 2
Total Volatile Organic VOC All sources 20
Compounds
(expressed as total organic
carbon -TOC)
Dioxins and Furans All sources 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.
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.

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.

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
Sulphur Dioxide
150 24 hours
60 1 year
CO 30 mg/m3 1 hour
Carbon Monoxide
10 mg/m3 8 hour
NO2 400 1 hour
Nitrogen Dioxide
150 24 hours
O3 200 1 hour
Ozone
120 8 hour
TSP 230 24 hour
Total Suspended Particles
90 1year
Particulate Matter (with 10
microns or less in PM10 150 24 hours
diameter)
Lead Pb 1 1 year
Revised:23/04/03
Attachment –3
STANDARDS FOR DISCHARGE OF WASTE WATER TO HARBOUR (1)
MAX. ALLOWABLE
PARAMETERS (es2) SYMBOL UNIT STANDARD (7)
Physical Properties
Colour - Colour units 50
Total Suspended Solids TSS mg/1 50
Floating Particles - mg/m3 None
pH - pH units 6-9(6)
Temperature(3) T C 35 (max)
Total Dissolved Solids TDS mg/1 1500
Turbidity - NTU 75
Inorganic Chemical Properties
+
Ammonia Total as (N) NH4 mg/1 2
Biochemical Oxygen Demand BOD5 mg/1 50
Chemical Oxygen Demand COD 100
Chlorine Residual (4)Total Cl- mg/1 1.0
Cyanide CN mg/1 0.05
Dissolved Oxygen(5) DO mg/1 >3
-
Fluoride F mg/1 20
Nitrate NO3-N mg/1 40
Sulfide S-2 mg/1 0.1
Total Kjeldahl Nitrogen as (N) TKN mg/1 10
Total Phosphorus, as (P) PO4-3 mg/1 2
Trace Metals
Aluminum Al mg/1 20
Antimony Sb mg/1 0.1
Arsenic As mg/1 0.05
Barium Ba mg/1 2
Beryllium Be mg/1 0.05
Cadmium Cd mg/1 0.05
Chromium, total Cr mg/1 0.2
Chromium, VI Cr+6 mg/1 0.15
Cobalt Co mg/1 0.2
Copper Cu mg/1 0.5
Cyanide CN mg/1 0.1
Fluoride F mg/1 25
Iron Fe mg/1 2
Lead Pb mg/1 0.1
Manganese Mn mg/1 0.2
Mercury Hg mg/1 0.001
Nickel Ni mg/1 0.1
Selenium Se mg/1 0.02
Silver Ag mg/1 0.005
Zinc Zn mg/1 0.5
Revised:23/04/03
Organic Chemical Properties

Halogenated Hydrocarbons mg/1 Nil
and Pesticides
Hydrocarbons HC mg/1 15
Oil & Grease O&G mg/1 10
Phenols - mg/1 0.1
Solvent - mg/1 none
Total Organic Carbon TOC mg/1 75
Biological Properties
Colon Group TC No./100 cm2 5000
Egg Parasites - - None
Fecal Coliform Bacteria - Cells/100 ml 1000
Total Coliform - MPN/100ml 1000
Warm Parasites - 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.
Revised:23/04/03
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.
Revised:23/04/03
(ii) Grade-B:
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.
Revised:23/04/03
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.
Revised:23/04/03
EHS Performance Audit checklist
A Applicable Standards Yes No

A1 Have all the necessary licenses/permits etc. relating to EHS
requirements been obtained?
A2 Are the licenses/permits for EHS standards being complied with?
A3 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?
A4 Have any problem areas discussed in A2 and A3 been highlighted and
rectified?
Have the deficiencies in EIA /RA and design methodologies been
A5 officially recorded and fed back to the appropriate consultants who will
be involved in future EIA/RA and design work?
B Design Issues
B1 Have the initial objectives been met? (e.g. plant efficiency, air emissions,
noise control, etc.)
B2 If not, have the reasons for such failings been identified?
B3 Has consideration been given to whether the designs selected were
appropriate in the light of B2?
B4 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?
C Waste Issues
C1 Does the pollution control/abatement technology employed remove
pollutants at the guaranteed efficiencies?
C2 Do the monitoring techniques employed detect down to the guaranteed
levels?
C3 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
C4 regards attaining the desired environmental standards been
highlighted?
Have the deficiencies /potential improvements form B4 been officially
C5 recorded for future reference?
D Health & Safety Issues

D1 Have all Health and Safety Issue been addressed as per RA Study?
Revised:23/04/03
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.
Revised:23/04/03
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.
Revised:23/04/03
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. 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.
v 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

Product
Mass
Accumulate
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.
Revised:23/04/03
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 Page 4 of 5

Revised:23/04/03
b. Scope of Audit
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.
c. Results of Audit
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.
d. 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
Revised:23/04/03
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.

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 pre-
treated 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.
Revised:23/04/03
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;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.
3 SOLID WASTE
DMCC companies are to implement the following practices for managing solid wastes generated in the course of
operating the facility:

• 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.
i Air Emissions Performance Testing

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
Revised:23/04/03
5. Key Issues for Environment Control

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.
iv Hazardous process compounds

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 closed-
loop 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.” Closed-
loop systems also facilitate recovery processes to reclaim metals from the plating operations.
Revised:23/04/03
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.
Revised:23/04/03
Attachment –1
SOURCE EMISSION CRITERIA
GENERAL: STATIONARY SOURCES
AIR POLLUTANTS EMISSION LIMITS FOR STATIONARY SOURCES
SUBSTANCE SYMBOL SOURCES EMISSION LIMITS

(mg/Nm3)
Other sources none
(Expressed as nitrogen dioxide) NOx Liquid fuel-500
Material producing industries 1500
Other sources
200
Material producing industries 2000
Other sources
1000
Sulphur Trioxide Material producing industries 150
Including Sulphuric Acid Mist SO3 Other sources
(Expressed as sulphur trioxide) 50
Other sources 150
Ammonia and Ammonium Compounds NH3 Material producing industries 50
(expressed as ammonia) Other sources
10
Lead and its compounds (expressed as Pb All sources 5
lead)
Antimony and its Compounds Sb Material producing industries 5
(Expressed as antimony) Other sources
1
Arsenic and its Compounds (expressed As All sources 1
as arsenic)
Mercury and its compounds (expressed Hg All sources 0.5
as mercury)
Nickel and its compounds (expressed Ni All sources 1
as nickel)
Copper and its compounds (expressed Cu All sources 5
as copper)

Other sources 10
Other sources 20
Fluoride and its Compounds F- Aluminum smelters 20
Formaldehyde CH20 Material producing industries 20
Other sources
2
Total Volatile Organic Compounds VOC All sources 20
(expressed as total organic carbon -
TOC)
Dioxins and Furans All sources 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.
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.
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.
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
Sulphur Dioxide
150 24 hours
60 1 year
CO 30 mg/m3 1 hour
Carbon Monoxide
10 mg/m3 8 hour
NO2 400 1 hour
Nitrogen Dioxide
150 24 hours
O3 200 1 hour
Ozone
120 8 hour
TSP 230 24 hour
Total Suspended Particles
90 1year
Particulate Matter (with 10 PM10
microns or less in diameter) 150 24 hours
Lead Pb 1 1 year

Attachment –3
DUBAI MUNICIPALITY (DM) STANDARDS FOR DISHCARGE/RE-USE OF WASTEWATER
Parameter Unit DM Irrigation

Sewer Water
Ammoniacal Nitrogen mg/l 40 <1

BOD5 (5 days) mg/l 1000 10
Chemical Oxygen Demand (COD) mg/l 3000 50
Chlorides mg/l ….. 200
Chlorine Residual (Total) mg/l 0.5 0.5
Detergents mg/l 30 …..
Feacal Coliform MPN/100ml ….. <5
(80% samples)
Fluorides (F) mg/l ….. 1
Free Chlorine mg/l 10 …..
Non Chlorinated Pesticide mg/l 5 …..
O & G (Emulsified) mg/l 150 …..
O & G (nonsoluble) mg/l 50 5
pH units 6-10 6.5 -8.5
Phenols mg/l 50 0.10
Phosphorous (total as P) mg/l 30 20
Reduced sulphur compounds (as S) mg/l 10 …..
Sulphides as S mg/l ….. 0.05
Suspended Solids (SS) mg/l 500 10
O
Temperature C 45 …..
Total Dissolved Solids (TDS) mg/l 3000 1000
Total Nitrogen mg/l ….. 30

Total Organic Nitrogen (Kjeldhal) mg/l ….. 5
Total Sulphates mg/l 500 200
Metals (total) mg/l 10 …..

Aluminium (Al) mg/l ….. 2
Arsenic (As) mg/l 0.50 0.05
Barium mg/l ….. 1
Beryllium mg/l ….. 0.1

Boron mg/l 2 2
Cadmium (Cd) mg/l 0.30 0.01
+6
Chromium (Cr ), Hexavalent mg/l ….. …..
Chromium (Cr), Total mg/l 1.0 0.1
Cobalt mg/l ….. 0.1
Copper (Cu) mg/l 1.0 0.2
Cyanides mg/l 0.05 0.05
Iron (Fe)-Total mg/l ….. 2.0
Lead (Pb) mg/l 1.0 0.50
Magnesium mg/l ….. 100
Manganese (Mn) mg/l 1.0 0.2
Mercury (Hg) mg/l 0.010 0.001
Molybdenum mg/l ….. 0.01
Nickel (Ni) mg/l 1.00 0.20
Selenium (Se) mg/l ….. 0.02
Silver (Ag) mg/l 1.0 …..
Sodium mg/l ….. 200
Zinc (Zn) mg/l 2.0 2.0
Gross Alpha Activity Bq/l 10 …..
Gross Beta Activity Bq/l 100 …..
Revised:23/04/03
Attachment-4
NOISE ALLOWABLE LIMITS IN DIFFERENT AREAS
ALLOWABLE LIMITS FOR NOISE LEVEL (dB)*

AREA
Day Night
(7 a.m. – 8 p.m.) (8 p.m. – 7a.m.)
Residential Area With Light Traffic 40-50 30-40
Residential Areas In The Downtown 45-55 35-45
Residential Areas Which Include Some 50-60 40-50

Workshops & Commercial Business Or
Residential Areas Near The Highways
Commercial Areas & Downtown 55-65 45-55
Industrial Areas (Heavy Industry) 60-70 50-60
*: Exposure time for certain level of noise (hour)
Revised:23/04/03
ENERGY, WATER CONSERVATION AND MANAGEMENT GUIDELINES
1. INTRODUCTION:
Energy conservation and management is a managerial issue as well as technical one. While there is
no doubt that technical knowledge is required to identify and implement energy saving measures, it
is our organization’s management philosophy that drives a successful energy conservation
programme.
We tend to overlook the many small and large energy wastage that is taking place all around us, all
the time. Some everyday examples:
⇒ Incandescent bulbs
⇒ Idling pumps
⇒ Computers “ON” when not in use
⇒ Outdated chillers with no controls
⇒ Leaking water pipes
In themselves, these may appear insignificant or normal, but the sum total of these makes up a rather
sorry picture for energy and resources wastage. Energy wastage also means:
⇒ Operating equipment inefficiently, i.e. no load or part – load conditions;
⇒ Using over-designed equipment
⇒ Using the inappropriate equipment at the inappropriate place;
⇒ Human error & insensitivity
An effective energy conservation programme is achieved through a combination of proper

knowledge, correct approach and a strong management commitment.
PCFC has prepared this guide to motivate our clients and make them aware about energy and water
conservation and to reduce the consumption of the same. It also emphasizes 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 and water conservation has direct commercial benefits and adds a
competitive edge. Improvements in the way PCFC clients use energy and water conservation will
enhance working conditions, reduce operating costs and improve productivity and profitability as
well as contribute in saving our planet and environment.
2. BACKGROUND:
While energy and water conservations are at the heart of economic development, their 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 water conservation and ideas concerning
practical actions that can be taken to make PCFC more energy and water conservation efficient.
PCFC stands ready to contribute towards achieving such goal.
3. ENERGY CONSERVATION PROGRAMME (ECP)
An ECP can easily identify energy wastage means in a system and provide solutions to avoid these
losses, thereby making the system more efficient.
The objective of an ECP is to achieve the same output required but by utilizing less energy input. In
fact, in cases, an effective ECP may improve the conditions and boost production levels.
The first step of an ECP is a Detailed Energy Study (DES), the objective of which is to identify
opportunities and methods of savings/conserving process energy requirements, which are termed
Energy Saving Measures. This is the micro-level approach.
At the macro-level energy conservation (ENCON) needs to be measured and benchmarked.

Benchmarking norms need to be set that are accurate, practical and reflect true scenarios.
A three pronged approach needs to be followed while conducting a DES, namely:
⇒ Capacity utilization of existing/new equipment

⇒ Fine tuning of these equipment
⇒ Technology up gradation
All three being equally important for achieving reduction in energy consumption.
As part of the macro-level methodology, one has to understand that any system/process requires an
energy input. This is converted into:
⇒ Productive output or theoretical requirement (work done)

⇒ Unavoidable losses (laws of thermodynamics)
⇒ Avoidable losses (target of energy conservation programme)
A detailed energy study should:

⇒ Concentrate on avoidable losses
⇒ Quantify these losses
⇒ Identify ways and means of reducing these avoidable losses, and
⇒ Implement the energy conservation measures identified.
4 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.

i www.energy.gov/
ii www.osti.gov/
5. 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.

i www.epa.gov/
ii www.pnl.gov/
iii www.ost.gov/
6. MOTORS:
A Major causes of energy wastage in motors include:

⇒ Use of less efficient motors
⇒ Oversized/under loaded motors
⇒ Improper supply voltage
⇒ Voltage fluctuations
⇒ Poor power factor
⇒ Less efficient-driven equipment
⇒ Idle running
B Impact of voltage optimization on motors include:

⇒Reduction in voltage dependent losses – drop in Magnetization current
⇒Capacity reduces
⇒PF improves
⇒Load current drops
⇒Load factor improves
⇒Efficiency improves
Almost all motors in operation today, operate at varying load at different times.
Motor-driven equipment accounts for nearly 60% of the electricity consumed by industries. Energy-
efficient motors can cut this energy use by nearly 15%.

i www.oit.doe.gov/bestpractices/
ii www.oitdev.nrel.gov/
Revised:23/04/03
7. AIR CONDITIONING (AC)

In facilities in UAE, AC load comprises the major portion of the overall electricity consumption,
ranging anywhere between 60 to 75% of the total energy consumption. This is true for buildings,
both commercial and residential. In industries, the share of AC will vary depending on type of
process. For example, in cold stores, AC may consume approximately 95% of the overall energy
requirement while in foundries, AC share may be negligible. The wastewater from ACs should be
used for plants/ garden, especially in the evening to ensure minimum evaporation.
The AC load mentioned above includes the consumption of the actual air-condition units (chillers,
package units, window AC, split units, etc) chilled water pumps, air handling units and ventilation
fans (if any). A typical building’s energy consumption in UAE shows that A/C amount for more 56%,
lighting is more than 37% and usage is more than 6%.
If facility is operational 24hrs and lighting is ON all the time. Hence, the AC share is slightly less than
usual. Industries normally opt for chillers or package unit AC’s.
A centralized AC system is the most efficient in terms of economies of scale. This is also easier to
control and energy conservation techniques may be applied to both at the end – user level as well as
the chiller plant level.
From the energy conservation point of view, the following issues need to be addressed while
installing or operating AC system:
(i) During the procuring of air-conditioning equipment, check the energy consumption per unit
refrigeration. Although a chiller with low energy consumption may have higher initial cost, but in the
long run, it will consume less energy and therefore would be cheaper to operate.
(ii) Watch out for the amount of glass area. If the glass area is large compared to overall exposed area of
the facility, it is advisable to install double glazed or even triple glazed glass. In addition to reducing
heat load, this will also remove the problem of external condensation on high humidity days.
(iii) For retrofit on existing facilities with single glazed glass, window films may be applied to reduce the
head load (and thereby air-conditioning load).
(iv) For facilities with large exposed areas (roofs and walls) application of solar reflective paint (at both
design stage and retrofit applications) can cut down heat gains through these areas by up to 50%
depending on the quality of the paint applied.
(v) Particularly in office complexes, it is natural hum tendency to leave thermostat ON even when not
inside. While it is inadvisable to turn OFF the air-conditioning completely due to adverse impact of
humidity and certain temperature requirement of equipment, the set points may be raised during
unoccupied periods. This is possible through utilization of programmable thermostats that come in
one-day or seven – day programmable varieties. It is best to install these during design stage so that
the net investment is minimized.
(vi) The cold exhaust air from a facility can be used to pre-cool the fresh air intake, thereby reducing
load on the chillers. Waste heat recovery is possible in facilities with centralized exhaust system. At
the design stage, it is important to ensure that the fresh air intake to a facility is physically located in
close proximity to the centralized exhaust system. In industries, inlet air to a boiler may be pre-
heated by waste hot air thrown out into the atmosphere.
(vii) Chilled water pumps (CHWP) have a tendency to operate 24hrs at rated speed. During lean hours,
particularly in office complexes, the heat load is less and therefore, speed of a CHWP can be varied
to meet demand. A variable speed drive with either a temperature sensing mechanism or a simple
time schedule can be used to reduce the speed of CHWPs without affecting comfort conditions.
(viii) Nature of lights used in a facility also play a role in the heat load of the facility. Incandescent bulbs
and halogen low voltage lamps generate more heat than light (in fact more than 90% of the electrical
energy input to such lamps is converted into heat) Usage of compact fluorescent fixtures that operate
“cool” can substantially reduce load on chillers, particularly in facilities that use of large number of
lighting points.
(ix) Chiller technology has been evolving over the years and the kW/TR consumption of chillers have
drastically reduced from more than 1 kW/TR to the range of 0.5 kW/TR. This means that a new chiller
will actually consume less than half the energy compared to an old chiller and yet produce the same
comfort conditions. In existing old facilities using chillers more than 15 years old, a full – scale chiller
replacement can lead to savings that will help pay back for additional investment in 2 years time.
Revised:23/04/03
(x) Polarized refrigerant additives when injected into existing package units operate as an internal
cleaning mechanism. With cleaner heat exchanges, heat transfer efficiency improves and this leads
to higher overall efficiency, thereby reducing energy consumption for same desired comfort
conditions.
8. 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.

i www.ciac.lln.gov/
ii www.sandia.gov/
9. COMPRESSED AIR 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.

i www.cdiac.esd.ornl.gov/
ii www.rrede.nrel.gov/
10. COMBUSTION AND TRANSPORT:
Boilers, furnaces and motor vehicles all rely on combustion/ burners to operate. These should,
however, operate on environmentally friendly fuels for their clean and efficient output. Emissions of
pollutants such as nitrous oxides (NOx), Carbon Monoxide (CO), Particulates and Sulphur Dioxide
(SO2) are always of environmental concern in combustion processes. Always use energy efficient
equipment and appliances. Opt for car pooling and shared vehicles, when feasible, to reduce
pollution from vehicles. Go for eco-friendly options like unleaded petrol, catalytic converters, etc.

i www.http.lle.etd.lbl.gov/
ii www.ca.sandia.gov/CRF/
11. 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.

i www.energy.gov/
ii www.dpa.gov/
12. LIGHTING:
The total lighting concept includes:

⇒ The right light
⇒ At the right place
⇒ At the right cost
Revised:23/04/03
Lighting terminology is explained below
Flux emitted by lamp - Lumens
Luminous Efficacy - Lumens/Watt
Illuminace - Lumens/sq. meter
(Also known as lux)
Colour Rendering index - Colours of surfaces
Illuminated given light sources
Basic Components of lighting

Lamp or light source
Control gear
Luminaire /fixture
Comparison of various lamps is given below:
Type Watt Lumens Efficacy

GLS 100 1380 14
Fluorescent 36 2450 68
Slim 40 2770 69
Conventional 36 3250 90
Color – 80 series 250 13500 54
HPMV 250 27000 108
HPS V 250 17000 68
Metal halide 20 1200 60
The following lighting energy saving techniques can be utilized depending on application and requirement:
(i) At the design stage and even for retrofit applications, guidelines on lux level requirement in various
areas should be used.
(ii) Whenever possible, use of incandescent, halogen low voltage and mercury vapour lamps are to be
avoided. In areas like corridors, office areas, food courts, washrooms and for external lighting
application, compact fluorescent, metal halide and sodium vapour lamps are most desirable from the
energy conservation point of view.
(iii) Use of high efficiency reflectors can cut down lighting energy consumption (particularly in 4x18-watt or
2x36 watt florescent fixtures) by 50%.
(iv) In warehouses and factories, use of translucent sheets on the roof is recommended for utilizing
maximum daylight.
(v) Electronic ballasts are highly energy efficient and in most facilities, these are replacing conventional
chokes.
(vi) The traditional problems with compact fluorescent lamps (CFLs) have been their shape and color-
rendering index. Manufactures have been able to overcome these problems and CFLs are now
available in various shapes as well as colors. In fact, one manufacturer has even developed as standard
CFL replacement for halogen low voltage lamp. A 50-Watt halogen low voltage lamp can be directly
replaced with a 13-Watt such fixture!
(vii) The right light at the right place is particularly noticeable in corridors. In some facilities, halogen low
voltage fixtures are used for general lighting. While in themselves these fixtures are beautiful, they do
not have uniform spread of light an invariable tend to create dark spots, in addition to consuming more
energy.
(viii) Grouping of fixtures has specific applications in open offices areas where there are extended lunch
breaks. It is preferable to have many switches at higher initial investment than one Switch for all lamps.
(ix) In factories and warehouses where color rendering is not sensitive issue, it is best to use high pressure
sodium vapour(HPSV) lamps or Metal Halide (MHI) lamps instead of the traditional Mercury Vapour
lamps. The latter can be directly replaced with HPSV fixtures of almost half the rating and yet produce
the same lux.
FC-EG#32 Page 6 of 8
Revised:23/04/03
(x) While fluorescent fixtures are becoming commonplace, it is indeed unfortunate that some facilities still
have conventional fat fluorescent tubes. Simply replacing these slim tubes can generate 10% saving
from each lamp.
(xi) Occupancy sensors (OCC) for office cabins and toilets with time delay action should be used for
energy savings. The added advantage is that the same OCC can be use to control all lighting an AC
with in that area.
(xii) Lighting energy saver that reduce the supply voltage to discharge lights can be use to save up to 20%
where existing light levels are higher than recommended.
(xiii) For external lighting, the most appropriate energy saving technique is the use of photo- sensors. This
can achieve even higher savings than timer control and does not require to be adjusted depending on
weather conditions or seasons.
Energy efficient lights/bulbs are commercially available. Let us use it and save energy!

i www.lesskwh.com
ii www.positive-energy.com
iii www.ecsave.com
iv www.kwhsavings.com
13. GREEN BUILDING
Green Building incorporates several Green features

⇒ Efficient use of water
⇒ Energy efficient & eco- friendly equipment
⇒ Use of renewable/solar energy
⇒ Use of recycled/ recyclable materials
⇒ Effective use of landscapes
⇒ Effective control and building management systems
⇒ Indoor air quality for human safety and comfort
Green building rating covers the following:

⇒ Rating reflects the extend of Green
⇒ Extent of Green
⇒ Local Conditions
⇒ Economic factors
⇒ Rating programmes
For more information refer to useful websites like:

i www.epa.gov/greenbuilding
ii www.nesea.org/buildings
iii www.buildinggreen.com
14. WATER CONSERVATION
Avoid wasting water while brushing/ showering/ shaving as it can save resources and your bills.
Water saving measures have the lowest payback periods (in months) and are easy to a achieve
through simple techniques, as listed below:
A Aerators in taps of wash basins
Aerators inject air bubbles in the water stream flowing from the taps, thereby providing a sensation
of full flow. These air bubbles occupy the space that would otherwise be occupied by water and
hence the flow rate reduces. Aerators may be fitted on taps in washbasins. While these are effective
everywhere, the maximum savings occur where water consumption is inherently high, like sinks.
Revised:23/04/03
B Adaptors in Showerheads
Adaptors have a similar function to that of aerators but are used in showerheads.
C Urinal Sensors
In most old facilities urinals are flushed by an overhead flush tank that flushes the urinals when it is
full. This happens irrespective of the utilization level of the urinals. A simple urinal sensor hooked to
the flush tank through a pneumatic valve will ensure that flushing takes place only when there is
requirement.
D Flush Tanks in toilets

The olden day toilet flush tanks have bigger capacity and sometime may be even of 11 liters. Newer
toilet flush tanks are more efficient and utilize only about 6 liters of water for every flush.
E Waste water recycling

Facilities with laundries themselves can theoretically recycle the entire wastewater generated by
the washing cycles. This can be done by installing a reverse osmosis plant within the complex.
⇒ Theoretically 100%waste water can be recovered and recycled

⇒ Considering system losses, more than 90% water can be recovered practically
⇒ This not only reduces water consumption but also reduces sewerage charges- double benefit
⇒ RO plants can match the purity of municipality water
F Ozone wash
⇒ Ozone laundry systems use ozone as a cleansing agent
⇒ This saves on water used for washing
⇒ This also saves on chemicals
⇒ Ozone levels need to be closely monitored from the point of view of corrosion.
For more information refer to useful websites like:

i www.swcs.org
ii www.waterwiser.org
iii www.h2ouse.org
Reminder!! Segregate wastes to promote recycling and conserve energy at the same time. For
example, paper, aluminum cans, plastic/ PET bottles, glass, oil, used ink/ toner cartridges.
Let us conserve energy and water conservation and manage it smartly. Adopt energy efficient
equipment, machines and products!
TOGETHER IN TO THE FUTURE!

GLASS RECYCLING
1. INTRODUCTION
Ports, Customs and Free Zone Corporation (PCFC) has been certified for EMS ISO 14001 and has
taken up Environmental Management System as a continuous improvement method for the
satisfaction of its customer.
Recycling, along with source reduction, and disposal in landfills, is a key component of an integrated
municipal solid waste.
The supply of scrap glass has three components: transition glass, preconsumer cullet, and post
consumer cullet.
Cullet is simply crushed scrap glass. Transition glass is made up of unmarket- able glass products
created by glass manufacturers. Preconsumer cullet is finished glass that breaks at bottling or
distribution plant. Most transition glass and much preconsumer cullet are remelted by the plant.
2. FACTS ABOUT GLASS
Many types of glass can be recycled. Glass food and beverage containers are 100 percent recyclable
and can be reused an infinite number of times. The only glass items that cannot be recycled are light
bulbs, ceramic glass, dishes, and plate glass.
There are three primary colors of glass: green, clear, and brown. Find out which colors your local
recycler takes. If more than one color is accepted, you may be required to separate your glass by
color.
3. STRATEGIES FOR GLASS RECYCLING
A Alternative Uses
Many non-returnable glass containers are suitable for household uses such as food stuffs and do it
your self bits and pieces.
B Recycling
For glass remaining after exhausting the scope for returning or other uses, recycling is preferred. It
takes 2,000-3,000 bottles and jars to make a tonne of ‘cullet’ (crushed glass). The average household
discards 1.4 Kilos of glass or 4 to 5 containers per week. PCFC has recognized this waste as a source
of income. It has launched a glass recycling programme although it’s PHS/Education Unit of EHS
Department /PCFC some FZ Cos. are in the process of setting up glass recycling schemes.
4. ADVANTAGES OF GLASS RECYCLING
A Raw Material Conservation

In the manufacture of new glass, up to 40% of the raw material may be in the form of cullet. The use
of old glass can achieve considerable savings in raw material and the energy needed to melt the
glass. While the main components for container glass i.e.14% soda ash and 12% limestone are
imported. Their supply and transport have environmental impacts. These can be reduced by
recycling glass.

B Energy Conservation
The addition of cullet assists in the melting process of glass manufacture and as recycled glass melts
at a lower temperature in the furnace than raw materials, less fuel is required. On average, for every
additional 10% of cullet used in the raw material batch, energy costs are reduced by 1%. Recycling
can contribute to an improvement in our balance of payments.
C Savings in the Cost of Waste Disposal
It is estimated that glass products constitute approximately 7.5% of domestic waste. Recycling
reduces the work and expense incurred by in disposing of this. It also reduces the demand for
expensive landfill space.
D Public Participation and Environmental Awareness
Glass recycling is a practical way for everyone to contribute to conservation and protection of the
environment. In the process a person’s awareness of, and appreciation for, the wise managements
of our natural resources are increased. Recycling schemes help to promote a general recycling
mentality among the public.
E Environmental Improvement
Recycling should reduce the amount of carelessly disposed of (broken) glass in the environment. A
greater appreciation of the value of waste glass will help to eliminate one feature of the litter
problem.
F Source of Income
The potential for glass recycling to become a source of income for deserving causes should be
examined carefully by organizations or groups with funding problems.
G Strategic Plan /Guidelines for Glass Recycling
The operation of a successful glass recycling scheme requires detailed planning, development and
supervision. Before NGOs, charity organizations, schools, other organizations or individuals set up
recycling schemes, they should consider the following:
i Co-operation with local authorities and commercial organizations is essential.
ii Identification of collector of source for disposing of collected glass.
iii Person responsible for planning, development and operation of the scheme must be
designated.
iv Identify whether there are sources of bulk supplies of bottles, which could be included in a
collecting e.g. restaurants and hotels; or better still if these sources could deliver themselves to
Recycling Center.
v Identify suitable sites for the location of glass Recycling Skips/ bottle banks. Sites should be
regularly visited by large numbers of people, highly visible in prominent locations e.g. Round
About in FZ.
vi Bottle banks should consist of three separate containers and should be attractive in appearance;
easily cleaned and maintained; colour coded white, green and brown; easy to use.
vii The scheme needs to be supported by a comprehensive publicity and educational campaign. A”
bottle bank code” could be drawn up for the proper use of bottle banks. Promotional campaigns
for the use of bottle banks need to be repeated at regular intervals.

viii Sponsorship would need to be found. Other costs are publicity material, maintenance and
transport. Could costs be shared with other organizations engaged in recycling.
ix A poorly maintained bottle bank discourages any further use by the public. Constant removal of
graffiti, litter, etc. is necessary. Over-filling can result if not emptied regularly. Users should be
asked not to leave empty boxes or bags around the bank.
x Examine the existing schemes in the area/Community.
5. THE SUPPLY OF CULLET
A Types of Glass
i Acceptable:
Commercial container glass i.e. jars and bottles(including .Jam jars, coffee jars, salad cream and
sauce bottles).
ii Unacceptable:
Ctrystal glass, Pyrex, plate glass or windows, television tubes, opal glass, e.g. Malibu bottles
where a large amount of foil is glued to the bottle, car windscreens.
B Glass Colours
All deliveries must be separated prior to delivery, according to colour, i.e. clear, amber, or green
glass containers. Bottles which are very light green in colour should be with the green cullet.
C Contamination
i Paper labels on bottles are quite acceptable.
ii All loads to be free of metal caps. (steel crown caps) and aluminum caps, particular attention
being paid to eliminating rings and bands on the necks of bottles together with the foil
decoration.
iii Please note, porcelain, pottery, stones, ceramic tiles and lead foil are totally unacceptable. Cullet
loads found to contain any of these items will be rejected completely.
iv Bottle bank users could be asked to rinse their bottles to avoid smells.
6. FUTURE TRENDS
The success of glass against aluminum and plastic in the marketplace will affect the amount of cullet the
glass industry will demand. Observers predict that the glass container industry will continue to see
modest growth over the years. Growth in the container industry will dictate the overall capacity to use
cullet. Consumer demand for recycled containers will also affect use of cullet.
To increase the use of cullet, existing collection and beneficiation units must improve operations to al
level that can guarantee cullet quality and quantity. Glass industry observers also speculate that if
prices or regulations changed enough to make it more worthwhile to use cullet, more companies would
be motivated to do so.
With the above tips we hope that we can minimize glass waste and eventually reduce environmental impacts
and encourage its recycling.

ENVIRONMENTAL REPORTING
1. AIR ENVI RONMENT
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 Table 2-B.
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.
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.
A Air Emissions Performance Tests
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 Table 2.B 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 pollutant (s) 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. 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.
2 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 water quality criteria and wastewater discharge criteria
specified in earlier sections of this document.
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
is required to sample/analyze effluents continuously and demonstrate compliance with the discharge
criteria specified earlier. A monthly analysis report is required. For groundwater appropriate
number of boreholes will be installed for quarterly monitoring and reporting. For some effluent
parameters, a continuous monitoring and quality reporting program is required on a case-by-case
basis.
A 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.
3 SOLIDE/HAZARDOUS WASTES
All FZ companies are required to closely follow PCFC/DM relevant rules and requirements (see
relevant PCFC-ER section and pertinent EG). A semi-annual wastes generation/disposal details
report is required.
4 NOISE ENVIRONMENT
In line with Authority’s requirements (Section 6) for premises a noise performance testing, at the
boundary fenceline, would be conducted within one month upon normal operation. On a case-by-
case basis an annual noise level testing and reporting is required.

Environmental Guideline No.35
CLEANER PRODUCTION, WASTE MINIMIZATION AND RRR OPTIONS
1 WASTE
In broad term waste include any non-product discharge from a process in gaseous, liquid and solid
phases.
2 CLEANER PRODUCTION
Cleaner Production is the continuous application of an integrated preventive environmental strategy

to process and products to reduce risks to humans and the environment.
For production process, cleaner production includes conserving raw materials and energy,
eliminating toxic raw materials, and reducing the quantity and toxicity of all emissions and wastes
before they leave a process.
For products, the strategy focuses on reducing impacts along the entire life cycle of the product,
from raw material extraction to the ultimate disposal of the product.
3 RRR OPTIONS
In the paste Waste Management concentrated on end-of-pipe treatment. However, at present

emergence of a different philosophy includes:
Waste prevention
Waste reduction/re-use/recycle techniques i.e RRR options.
4 WASTE MINIMIZATION
It means the reduction of waste, to the extent feasible, at the source.

Based on the belief that “Prevention is better than cure!”.
A Why Minimize waste?
Increasingly stringent legislation

Rising disposal costs
Possible fines and clean-up costs
It makes commercial sense
Demand for ‘greener’ products
More responsible attitude towards environment
Environmental performance
B Waste Minimization Benefits
It could reduce:
Production cost
On-site waste monitoring/treatment costs
Handling, transport and off-site disposal costs
Raw material costs
Energy and water costs
Long-term environmental Liability costs
The risk of spills and accidents

It could improve
Overall operation efficiency

Income through sale of re-usable waste
The safety of employees
The company’s image
C Waste Audit
To minimize waste generation a key tool – a systematic audit of waste generating /handling activities
should be conducted. Its purpose includes:
Identify the waste generated and examine where, how and why it is being created;
Identify costs involved;
Set waste reduction targets which are realistic;
Identify opportunities for waste prevention, reuse/recycling of waste produced;
Make workers more aware of the need to reduce the waste generated; and
Develop more efficient monitoring system.
A waste minimization audit will help to identify the various option for minimizing waste; options which
can then be evaluated to assess the technical and economic impacts and select the suitable technique.
D Waste Minimization Techniques
There are various waste minimization techniques, which PCFC entities can adopt. For Example:
Source Reduction
Good Housekeeping
Recycling
Technology changes
Process changes
Use of alternative raw materials
Re-use
Solvent recovery
Reclamation
Recycling of byproducts
Production Innovation
Modifications to plant
Alternative use of waste products
Treatment
Further elaboration of some techniques is as given below:
i. Raw material changes
Less toxic alternatives

Replace solvent based raw materials
Change specifications
Redesign finished product
ii. Good Housekeeping

Floating ceiling storage
Spilling controls
Planned maintenance
Sensors and meters
iii. Technology changes
Mechanical for chemical

Membrane technologies
Micro processing
Non solvent paints and inks
iv. Process changes
Closed loop for single pass

Catalyst changes
Production scheduling
Clean procedures
v. Re-use
Solvent recovery
Process water recycle
Scrap metal recycle
Plastics recycle
Paper recycle
Glass recycle
Aluminum goods recycle
vi. Reclamation
Ultra filtration
Ion exchange
Adsorption
Condensation
vii. Production Innovation
New uses for rejects/waste streams

Conversion of wastes to saleable products
Product design to aid recycling
E Cleaner Production/Waste Minimization Pay-off
A clean, healthy environment and sustainable industrial development with economic returns for
generations to come.

WASTE MANAGEMENT IN PCFC
1. INTRODUCTION
All solid/hazardous waste generated in PCFC/Free Zone companies is to be disposed of as per

PCFC/DM guidelines. Cleaner Production Waste Minimization and RRR (Reuse, Recovery and
Recycle) options (see relevant EG) techniques should be adopted by all Free Zone companies.
2 WASTE CLASSIFICATION
(i) Wastes generated in PCFC are classified in to one of the following categories:
a) Hazardous Waste:
These wastes are defined as any solid, semi-solid, liquid, or contained gaseous waste, or
combination of such wastes, which may because of its quantity, concentration, physical or
chemical characteristics pose a hazard or potential hazard to human health or the
environment when improperly treated, stored, transported, disposed of or otherwise
managed.
b) Non-hazardous Industrial Waste:

These wastes includes solid, liquid, semi-liquid or contained gaseous materials or
wastes resulting from industrial, operations and sludge from industrial wastewater
treatment or air pollution control facilities, provided that they are not hazardous,
municipal or inert wastes as otherwise defined in PCFC Rules and Requirements (3rd
Edition)/DM Technical Guidelines -TGs).
c) Domestic or Municipal Waste:

Such wastes include garbage, refuse, food waste, office waste, waste vegetation and other
decomposable material resulting from operation of Labour camps/residential, commercial,
municipal, industrial or establishments and from community activities.
d) Inert Waste:
Inert wastes are those wastes which are not biologically or chemically active in the natural
environment, such as glass, concrete and brick materials, broken clay and manufactured
rubber products.
(ii) Waste generators shall, through PCFC/DM approved laboratories, test the waste and classify their
wastes according to above Section.
(iii) A hazardous waste may be reclassified provided the hazardous waste is treated in such a way that
he resulting material no longer exhibits the characteristics that made it hazardous, or it is
acceptably recycled.
3 WASTE DISPOSAL GUIDELINES
PCFC/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 treatment/landfill facilities. Their “Waste Disposal of Hazardous Waste
Application” should be filled for PCFC/DM approval (DM-TG No. 26 refers).
The following management measures for handling hazardous wastes and materials should be
implemented:
Revised:23/04/03
(i) All hazardous (ignitable, reactive, flammable, radioactive, corrosive and toxic) materials must be
stored in clearly labeled containers or vessels.
(ii) DM has recently issued a new Technical Guidelines #70 (October 2002 draft) on “Control and
Disposal of Unwanted Merchandise “to discourage such waste disposal to their landfill. It’s Scope
covers:
a. DM Guidelines for the control of unwanted merchandise which may end up as waste into any of
Municipal waste treatment or landfill site.
b. Unwanted merchandise is defined, within the context of this Guideline, as any imported or
locally produced product, which is unsold to and has not reached the intended end
user/consumer. It may include used electronic products where efficacy has become interior to or
obsolete by the availability of similar new products.
c. This Guideline shall be interpreted and enforced in parallel with DM/EPSS Technical Guideline
26 (EPSS TG 26) on the Disposal of Hazardous Wastes and the DM Policy on Imported Hazardous
Wastes.
d. The primary objective of this Guideline is to provide means of controlling the waste at the point
of generation and for the owner, its authorized person or party and all relevant parties to take all
possible means of disposing the merchandise through beneficial means.
(iii) 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.
(iv) 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.
(v) Solid/Hazardous should be stored in a designated “Solid /Hazardous Waste Facility” (see above
Sections).
(vi) 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.
(vii) Several chemicals classified as ozone - depleting substances (ODSs) are scheduled for phase out
under Montreal Protocol on Substances that deplete the Ozone Layer (see relevant EG).
(viii) Any waste generated from decontamination of sites (as per DM-TG#54) should be disposed as per
DM/PCFC requirements.
(ix) All hazardous wastes generated within JAFZ shall be treated or disposed of at DM hazardous waste
treatment facilities within a maximum of 180-365 days of the waste being generated, unless otherwise
approved by the Authority.
4 CLEANER PRODUCTION, WASTE MINIMIZATION AND RRR OPTIONS GUIDELINES
It is emphasized to minimize the generation of waste and adopt cleaner production practices. Free
Zone companies should adopt reuse, recovery or recycling (RRR) options for waste being generated
(see relevant EG).
Free Zone Companies are to implement the following practices for managing solid wastes generated
in the course of operating the facility:
• If recycling or reclamation is not practical, wastes must be disposed of in an environmentally
acceptable manner and in compliance with DM/PCFC regulations.
Revised:23/04/03
5 WASTE TRANSPORTATION GUIDELINES

(i) No wastes generated within JAFZ shall be transported outside the boundary of Dubai for disposal
unless otherwise approved by DM/PCFC.
(ii) Wastes may be transported outside the boundary of Dubai for recycling, recovery or reuse
provided that written approval is obtained from DM and PCFC/EHS Dept. in advance of any such
waste transportation. Such approval shall also be dependent on the recycling or reuse facility
receiving the waste being in compliance with DM/PCFC Regulations, guidelines or standards for
transport, storage, treatment and recordkeeping for such wastes.
(iii) A transporter shall not transport hazardous or non-hazardous industrial waste from a generator
unless it is accompanied by DM/PCFC approved waste application (refer to DM Tech. Guideline –
26).
(iv) The generator shall ensure that all wastes are placed in waste compatible containers that properly
contain the waste to prevent any spillage or leakage during transportation from the generator’s
facility.
(v) The generator shall clearly label all hazardous waste containers with the following minimum
information regarding the waste to be transported:
a) Hazardous Waste
b) Generator’s name
c) Date of waste generation
d) Identification of the type of waste on the individual container.
(vi) The generator shall only utilize waste transporters that are registered with DM/PCFC to transport
hazardous and non-hazardous industrial waste to the proper waste disposal or waste treatment
facilities.
(vii) All vehicles transporting hazardous wastes shall carry placards in accordance with the DM/United
Nations chemical hazard classification system for the transport of dangerous goods.
(viii) All vehicles and containers used to transport waste shall be operated and maintained such that the
release of liquid, litter, dust, solids or odor are prevented while in transit.
(ix) Containers of hazardous waste shall be secured during transport to prevent movement or
dislodgment under normal transportation conditions.
(x) Totally enclosed compactor-type vehicles and skips shall be used for collection of municipal wastes.
Vehicles and container systems for industrial non-hazardous and hazardous wastes shall be suitable
for the specific materials being transported.
(xi) In the event of an accident, spill or discharge involving hazardous waste in transit, and where the
integrity of the container(s) has been compromised, transfer of the waste material shall occur using
collection methods and containers compatible with the hazardous material being collected.
(xii) The transporter shall deliver the entire quantity of the waste which they accepted from a generator,
or other transporter, to the designated DM treatment or disposal facility.
6. NON-HAZARDOUS INDUSTRIAL WASTE & DOMESTIC/MUNICIPAL WASTE DISPOSAL

GUIDELINES
(i) All non-hazardous industrial waste and domestic/municipal waste generated within PCFC shall be
disposed of at DM approved waste disposal facility.
(ii) Owners and operators of facilities that deliver municipal waste to DM Landfill shall follow DM/EPSS
procedures before disposal of such materials.
Revised:23/04/03
(iii) Municipal waste and non-hazardous industrial waste shall be disposed as segregated, at all times
after exhausting RRR options use.
(iv) Regular disposal of non-hazardous industrial waste and municipal waste from industrial facilities shall
be the responsibility of the generator.
7. INERT WASTE DISPOSAL GUIDELINES
(i) All inert waste shall be disposed of DM waste disposal facilities after exhausting RRR options use.
(ii) Owners and operators of facilities that collect and deliver inert waste to DM Landfill shall follow the
DM procedures before disposal of such materials.
(iii) Construction debris and demolition waste shall be collected and removed to the designated solid
waste disposal area on a regular basis. These wastes shall not be allowed to accumulate such that the
material presents a safety hazard for workers or members of the public, or create a nuisance to the
community.
(iv) Used garnet waste after blasting operations shall be reused/recycled to cement making/road making
etc companies.
8 WASTE TRANSPORTER REGISTRATION GUIDELINES
(i) All transporters of hazardous and non-hazardous industrial waste shall register with DM before
transporting hazardous and non-hazardous industrial waste.
(ii) The owner or operator of a waste transport shall be responsible for compliance with DM/PCFC
relevant Regulations. Demonstrated failure to comply with the DM/PCFC requirements relative to
waste transport and disposal may lead to Authority’s revoking the waste transport and or
registration.
Revised:23/04/03

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PCFC ENVIRONMENTAL GUIDELINES (EGs)

17.5: PCFC Requirements for Handling, Export of Radioactive Substances

22. Guidance for Linear Soakaways Installation

28. General Environmental Guidelines for Manufacturing/Assembly/Service Industries.

29. EHS Performance Audits

ENVIRONMENTAL GUIDELINE No.1

1.1 AIR ENVIRONMENT GENERAL GUIDELINES:

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

f. Emissions shall be monitored continuously wherever practicable.

h. A good standard of housekeeping is essential.

1.2 CHIMNEYS AND DISPERSION MODELING

1.3 GENERAL INDUSTRY AIR EMISSIONS GUIDELINES

a. Particulate matter Emission

Iron oxide fume from oxygen refining 75 mg/m3

b. Gaseous Emissions Emission

Amines - total amine 5 p.p.m v/v

1.4 SOURCE EMISSION CRITERIA - AIR POLLUTANTS

Other sources 200

Copper and its compounds Cu All sources 5

(expressed as total organic

8. VOC limit is for unburned hydrocarbons (uncontrolled).

ENVIRONMENTAL GUIDELINE No.2

2.1 GENERAL GUIDELINES

A. Sampling, Measurement Of Emissions And Monitoring

B. Emission Limits And Controls

2.2 TECHNICAL GUIDELINES FOR STEAM BOILER INSTALLATION

PCFC-EG#2 Page 2 of 2 Revised:23/04/03

2 SAMPLING, MEASUREMENT OF EMISSIONS AND MONITORING

3 EMISSION LIMITS AND CONTROLS

A Phosphate Rock Processing

B Superphosphate and Phosphoric Acid Plant

C Granulation and Prilling Plant

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

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

PCFC-EG#3 Page 1 of 2 Revised:23/04/03

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

G Material Handling and Storage

PCFC-EG#3 Page 2 of 2 Revised:23/04/03

2 EMISSION LIMITS AND CONTROLS

PCFC-EG#4 Page 1 of 1 Revised:23/04/03

2 SAMPLING, MEASUREMENT OF EMISSION AND MONITORING

3 EMISSION LIMITS AND CONTROLS

PCFC-EG#5 Page 1 of 2 Revised: 23/04/03

Plant Rated Capacity Height

Up to 400 tonnes/day 60 meters

PCFC-EG#5 Page 2 of 2 Revised:23/04/03

These notes apply to:

a. works in which compounds of lead are produced by the application of heat:

b. works in which compounds of lead are manufactured, extracted, recovered or used in

2 SAMPLING AND MEASUREMENT OF EMISSIONS AND MONITORING

3 EMISSION LIMITS AND CONTROLS

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

4 MATERIALS HANDLING AND STORAGE

PCFC-EG#6 Page 1 of 3 Revised:23/04/03

a. Preferred practices include:

i) recycling within the process by means of a directly connected closed handling

a. transport of materials from stockpiles to process by fully enclosed mechanical conveying

e. all conveyors external to buildings shall be enclosed.

Preferred practices include:

a. the provision of lock chambers, where furnaces are top charged.

PCFC-EG#6 Page 2 of 3 Revised:23/04/03

a. preclude the access of private vehicles to the works area.

d. a single exit route for vehicles to the site.