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REPORT
Preliminary Environmental, Health, and SafetyReview (PEHSR)
Caustic Soda Plant ICAD 1
Prepared for:
Al Ghaith Industries
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441!!"#
Au$ust %!11
Prepared by:
&RS 'ororation A*u +ha*i
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Project Title: 'austi Soda Plant I'A+ 1
Report Title: Preliminary Environmental, Health, and Safety Review (PEHSR)
Project No: 441!!"#Report Ref: 441!!"#-REP-!!1
Status: Initial Issue
Client Contact Name: Almamoon Al-.aadani
Client Company Name: Al Ghaith Industries
Issued By: &RS 'ororation A*u +ha*i
Document Production / Approval Record
Issue No: Name Sinature Date Position
Preared*y
+avid /ona$han Air 0uality Sientist
'heedandaroved*y
Andrew 2 3ilson Prinial 'onsultant
Document Revision Record
Issue No Date Details of Revisions
1 Au$ust %!11 +raft PEHSR Issued
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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!I"ITATI#N
&RS has reared this Reort for the sole use of in aordane with the A$reement under whih our
servies were erformed5 6o other warranty, e7ressed or imlied, is made as to the rofessional
advie inluded in this Reort or any other servies rovided *y us5 8his Reort may not *e relied
uon *y any other arty without the rior and e7ress written a$reement of &RS5 &nless otherwise
stated in this Reort, the assessments made assume that the sites and failities will ontinue to *e
used for their urrent urose without si$nifiant han$e5 8he onlusions and reommendations
ontained in this Reort are *ased uon information rovided *y others and uon the assumtion that
all relevant information has *een rovided *y those arties from whom it has *een re9uested5
Information o*tained from third arties has not *een indeendently verified *y &RS, unless otherwise
stated in the Reort5
C#P$RI%&T
: 8his Reort is the oyri$ht of &RS 'ororation ;imited5 Any unauthorised rerodution or usa$e
*y any erson other than the addressee is stritly rohi*ited5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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C#NT'NTS
Section Pae No
() INTR#D*CTI#N (+
1515 Summary 'rror, Boo-mar- not defined)15%5 6eed for Proverview %?%51515 &nloadin$ and Stora$e of Salt @
%515%5
.rine Purifiation Proess 4!%5155
Eletrolysis Proess 44%51545 .rine +ehlorination 4"%515#5 Hydro$en Gas Proessin$ 4?%515"5 'hlorine Gas 'oolin$ 4?%515?5 'austi 'onentration Blain$ Plant 4?%515=5 Sodium Hyohlorite Plant 4@%515@5 Hydrohlori Aid Plant #1%5151!5 +emineraliCed water system #%%515115 'oolin$ water unit #%%5151%5 'hilled water system #%51515 'omressed air system #%515145 Steam suly system #
%5151#5
'ontrol and instrumentation system #%5151"5
.a$$in$ &nit #4%5151?5 8ransortation System #4%5151=5 Baility 'onstrution #4%5151@5Air Emissions 'ontrol ##%515%!5 3astewater 8reatment and /ana$ement #=%515%15 Solid 3aste 8reatment and /ana$ement #@%515%%5 Bire and 8o7i Gas Release Prevention and 'ontrol "!
1) 'N2IR#N"'NTA! BAS'!IN' C#NDITI#NS 3.
51515 General Environmental Settin$ "%515%5 Seismiity "%
5155
Re$ional /eteorolo$y "51545
Air 0uality "515#5 8errestrial Eolo$y "=515"5 /arine Eolo$y"=515?5 Soil and Groundwater .aseline Assessments "=515=5 Soio-eonomi Environment "@515@5 6oise 0uality ?5151!5Arhaeolo$ial, Paleontolo$ial and 'ultural Herita$e .aseline 'onditions
?
4) ID'NTI5ICATI#N #5 P#T'NTIA! 'N2IR#N"'NT6 &'A!T&6 AND SA5'T$&A7ARDS AND I"PACTS 04
4515
Air Emissions ?4
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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C#NT'NTS
Section Pae No
Aendi7 A -
Bi$ures
Photo$rahs
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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() '8'C*TI2' S*""AR$
8.'
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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.) INTR#D*CTI#N
.)() Project Title and Project Proponent
8he title of the roosed Pro .o7 4=##, A*u +ha*i,
&nited Ara* Emirates
8el @?1 % "4 "#
Ba7 @?1 % "4 ?4
Email eterKmuellerursor5om
===)urscorp)eu
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e %
mailto:[email protected]_mailto:[email protected]_ -
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8his PEHSR was reared *y /r5 +avid /ona$han (Air 0uality Sientist) and reviewed
*y /r5 Andrew 2 3ilson (Prinial 'onsultant)5 In addition to the a*ove-mentioned ro
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disersion modellin$ aa$es (suh as AER/>+O A+/S) in suort of EIAOHSEIA wor
in the oil and $as, land develoment and heavy industry setors5 He is an e7eriened
ro
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inludin$ eolo$ial surveyor, tehnial advisor, lead author, and roH), 'austi Blaes, Hydrohlori
aid and Sodium Hyohlorite5 'hlorine $as shall *e roessed throu$h oolin$5 Sodium
Hyohlorite shall *e rodued as a *y rodut under 3aste Air +ehlorination
(environmental ontrol measures)5
8he main roduts and the lanned rodution aaity of the roosed lant are as
follows
Produt'aaity er
day'aaity er year
H'l - %Q wOw solution 1?@ /8 O +ay #@,!!! /8Oear
'austi Soda -1!!Q ?! /8O +ay %,1!! /8Oear
Sodium Hyohlorite -
1%Q?! /8O +at %,1!! /8Oear
8his PEHSR study will fous on onstrution, ommissionin$ and oeration of the
Pro
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.)4) ustification and C9ronoloy for t9e Development of a P'R
.y omletin$ this PEHSR &RS and Al Ghaith have *een a*le to effetively assess the
assoiated riss and rovide a definite solution to all environmental, health and safetyriss that are resent in onstrutin$ and oeratin$ the 'hlor-Alali Plant5 As suh, a
more detailed ostly EIA is not neessary5
8he o*
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In order to omlete this PEHSR the followin$ shedule has *een followed5 A ro
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Ta;le .(( Project Sc9edule
8he followin$ rovides a roosed roee-
1 % 4 # " ? = @ 1! 11 1% 1 14 1# 1" 1? 1= 1@ %! %1 %%
Ni >ff /eetin$ (1 day)
HAJI+OE6FI+ 3orsho (%
days)
HAJI+O E6FI+ Re$ister
+raft Sreadsheet to Al Ghaith
Al Ghaith Review and 'omment
PEHSR Study Reort
+raft Reort
Al Ghaith Review and 'omment
Binal +raft Reort
Jones'or Review and 'omment
Binal Reort
EA+ Review and 'omment
Binal Reort (Issue % ifneessary)
EA+ Aroval
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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1) !'%A! 5RA"'>#R? AND STANDARDS
8his setion outlines the ey environmental re$ulations in the &AE that will *e onsidered*oth in terms of the soe and nature of the PEHSR, and in the overall onstrution and
oeration of the roosed ProE3, formally the Bederal Environmental
A$eny (BEA) esta*lished in 1@@, is the rinial environmental institution in the &AE5
8he />E3 develos environmental oliies that are imlemented and enfored as a
minimum level of environmental due dili$ene *y the various mem*er Emirates within
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e (
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their area of
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+eveloment of natural resoures and onservation of *iolo$ial diversity in the
re$ion and the e7loitation of suh resoures with onsideration of resent and
future $enerations (i5e5 the rinile of Inter-$enerational E9uity)5
Protetion of soiety, human health and the health of other livin$ reatures from
ativities and ats that are environmentally harmful or imede authoriCed use of
the environmental settin$5
Protetion of the &AE environment from the harmful effets of ativities undertaen
outside the re$ion of the &AE5
'omliane with international and re$ional onventions ratified or aroved *y the
&AE re$ardin$ environmental rotetion, ontrol of ollution and onservation of
natural resoures5
In addition to the re9uirements of Bederal ;aw %4, a num*er of E7eutive Re$ulationsdeal with seifi environmental areas, inludin$
Re$ulation for the Environmental Effets of Installations5 8his re$ulation re9uires an
EIA to *e arried out for ertain ro
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E7eutive 'ounil +eision 6o5 (?)
As suh, EA+ is the nominated authority for imlementin$ laws inludin$ Bederal ;aw 6o5
(%4) for 1@@@ and +eision 6o5 4% of %!!@ 'onernin$ the Environment, Health and
Safety /ana$ement System in A*u +ha*i Emirate (DEHS/S ;aw)
8he 'ometent Authority for this ro
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&nited 6ation Bramewor 'onvention on 'limate 'han$e for the year 1@@%M
Nyoto Protool, 1@@?M
Fienna 'onvention for the Protetion of the >Cone ;ayer of 1@=#M
/ontreal Protool on >Cone +eletin$ Su*stanes of 1@=? and /ontreal
Amendments (;ondon 1@@!, 'oenha$en 1@=%, /ontreal 1@=?, .eir$ani Pollutants (P>Ps) %!!1M
International onvention on 'ivil ;ia*ility for >il Pollution +ama$e (';') 1@"@M
International onvention on the Esta*lishment of an International Bund for
'omensation for >il Pollution +ama$e 1@?1M and
Prior Informed 'onsent Proedure for 'ertain HaCardous 'hemials and Pestiides
in International 8rade (PI' 'onvention) 1@@=5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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4) PR#'CT D'SCRIPTI#N
4)() Statement of Need
'hlorine is essential to hemial industryM more than =#Q of all harmaeutials and
more than half the roduts mareted *y the hemial industries are derivatives of
'hlorine hemistry5 Almost 1,#!! of these roduts are used in different industrial and
eonomi setors suh as health, a$ro-food, *uildin$, te7tiles, transort, leisure ativities,
osmetis et5
3ith every tonne of 'hlorine that is rodued 151 tonnes of 'austi Soda are also made5
/ore than half of the 'austi Soda manufatured is used in the hemial industry and the
rest $oes into roduts suh as soa and te7tiles, or is used in water treatment,
aluminium rodution and oil refinin$5
8he &AE $overnment has esta*lished heavy industry in order to inrease diversifiation
of the eonomy5 Borei$n firms have *een emloyed to rovide e7ertise in lannin$,
onstrution, mana$ement and maretin$ in return for minority shares in the omanies5
>il revenues have funded the onstrution of lants and the develoment of
infrastrutureM natural $as has *een used as a soure of ower and as feedsto5
Petroleum and natural $as industries and their related manufaturin$ are the *asis of the
national eonomy in the &AE5
A limited loal rodution of 'austi Soda e7ists in A*u +ha*i, hene the re9uirement to
develo a loal manufaturin$ lant that will rovide additional suly to the re9uired
industries5
4).) Project !ocation and Scale
8he 'hlor-Alali Plant will *e loated in A*u +ha*i Emirate aro7imately %!m south-
east of A*u +ha*i 'ity5 8he ro
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5iure 4( Reional !ocation of ICAD(
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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5iure 4. Site !ocation
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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4)1) Project and Activity Description
8he roosed 'hlor-Alali Plant will rodue hydrohlori aid (H'l), sodium hydro7ide
(austi soda) and sodium hyohlorite (6a>'l) *y eletrolysis of *rineOsalt solution(sodium hloride) utiliCin$ mem*rane ell tehnolo$y5 8his tehnolo$y is a roven,
environmentally-safe eletrolysis roess5
8he main roduts and lanned rodution aaity of the roosed hlor-alali ro
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Sodium *isulfite (6aHS>) will *e used for dehlorination of *rine and in the final
sta$e to eliminate hlorineM and
Sodium hydro7ide (6a>H) will *e used for removal of ma$nesium and heavymetals5
8he roosed ro
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5iure 41 5lo= Diaram of C9lorAl-ali Industrial Process
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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8he followin$ are the ma
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4)1)() *nloadin and Storae of Salt
/ain raw materials will *e transorted via road from (where) to the roosed
'hlor-Alali Plant5 8he salt and other raw materials will *e unloaded from trus and will*e moved to a dediated stora$e area utiliCin$ front-end loaders5 8his stora$e area will
*e rovided with a onrete-lined ad and sheet-metal shadin$5 It is e7eted that
aro7imately 1%! tons of salt will *e *rou$ht to the 'hlor-Alali Plant on a daily *asis5
+etails of the roosed stora$e failities are rovided inTa;le 4 1*elow5
Ta;le 41 Proposed Storae 5acilities
S! NoStorae
materials
Proposed capacity
and description
Remar-s
Remar-s
1 Salt
#!,!!! 8ons 'overed
shed with wind
rotetion
8he stora$e areas for li9uid
hemial (austi soda, H'l and
6a>'l) a*ove-$round stora$e
tans will have ontainment
dies to ontain 11! erent
aaity of its entire volume of
tans within the ontainment5
8he stora$e area will *e of full
reinfored onrete floorin$ with
eo7y oatin$ to avoid any
$round ontamination in ase of
silla$es5
8he stora$e area will also *e
rovided with reoveryO draina$e
system to transfer the li9uid into
other stora$e tan immediately5
A6SI standards will *e followed
for onstrution of the stora$e
tans5
Paint used on the stora$e tanswill *e eo7y aint with three
different layers of seial
oatin$5
/S+Ss will *e loated at the
stora$e failities to $uide
ersonnel in ase of sills5
%'austi Soda
(#!Q)
4 tans 7 !! m
? m diameter 7= m hei$ht
/ild steel
%Q H'l
" tans 7 1#! m
#5# m diameter 7? m hei$ht
Ru**er-lined frominside5
4Sodium
Hyohlorite
4 tans 7 1!! m
45# m diameter 7" m hei$ht
BRP or deraane-lined
#'austi soda
Blaes
#,!!! m
'overed Shed
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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4)1).) Brine Purification Process
/ae-u *rine for the roess is reared *y dissolvin$ rystal 6a'l salt into the return
*rine from the mem*rane ell eletrolysers, and is treated with hemials so as toreiitate the imurities of raw salt5
Beed to the eletrolysers re9uires hi$hly urified *rine free of any metalli imurities5
8his is erformed *y re oated filter and ion e7han$e resins under seondary *rine
urifiation failities5 8he lant will have a reyled 6a'l *rine stream as well as
deleted return *rine stream as er roess re9uirements5
4)1).)() Primary Brine Purification
8he return *rine is fed to the salt saturator5 8his will *e saturated with mae-uL salt5
/aeu rystal salt is ontinuously sulied to the saturator *y salt feeder (ay-loader)5
8emerature of the return *rine is ontrolled *y return *rine heater so as to maintain thesaturated *rine temerature within "!-"# T'5
8he lear saturated raw *rine overflows from the feed omartment of the saturator to the
lear *rine omartment and fed to the reator with the hel of ums5 8he density of
*rine is ontrolled automatially5 'hemials, suh as austi soda, *arium ar*onate and
sodium ar*onate shall *e added to the saturated raw *rine flow5
+issolved imurities of raw *rine ('a, /$ and S>4) are onentrated as 'a'>, /$
(>H)% .aS>4from the solution in the reator5 8he e7ess >H-is maintained *y hel of
automati H measurement ontrol5
8his susension solution is sent to the enter well of *rine larifier for sedimentation and
removal of the solid imurities5
Bloulent is also added to the stream of susension solution5 'larified *rine overflows
from *rine larifier to larified *rine tan5 Slurry from larifier slurry it and filter slurry it
is sent to slud$e filter ress to reover the *rine in the slurry5 Reovered *rine is fed to
return *rine tan5 8he *arium slud$e o*tained durin$ roessin$ shall *e dried and
stored in the imervious landfill inside the lant area5 As suh, the 9uestion of *arium
slud$e disosal does not arise5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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5iure 44 Brine Clarifier
8he larified *rine from larified *rine tan is then filtered throu$h rimary *rine filters
aed with anthraite oal as filter media5 /em*rane tye eletrolysers need hi$h
9uality *rine free from metalli imurities for trou*le free mem*rane ell eletrolyser
oeration5 Burther urifiation of *rine from the rimary *rine setion is arried out in theseondary *rine andle filtration and ion e7han$e resin adsortion system5
5iure 4@ Ant9racite 5ilters
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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4)1).).) Secondary Brine Purification System
Candle filtration
In the mem*rane ell *ased austi O hlorine lant, the ontent of susended solid in the
filtered *rine must *e et very-very low *eause susended solids a*ove a ertain level
will lu$ the ion e7han$e resin5 'are is taen while desi$nin$ a *rine filtration system
for smooth oeration of the eletrolyser5 8he system emloyed *y Al Ghaith will have a
ar*on andles filtration system with automati han$e over valves and se9uene
ontroller5 8he oeratin$ roess of a andle filter onsists of four sta$es
1 Prearation of Pre-oat
8he re9uired 9uantity of the filtrate *rine is filled into the filter5 8his ste is erformed
immediately after the omletion of washin$ ste e7et the initial start5 Alhaellulose
of the re9uired 9uantity is dosed into a re-oat tan5 3hen the Dre-oat tan dosa$eomletion *utton has *een ushed and the re9uired time has assed, filtered *rine is
filled into the re-oat tan and a$itation *e$ins5
% Biltration
3hen saturated *rine asses throu$h re-oat layers formed on surfae of filter elements
from ustream to downstream, the fine imurities are traed and removed5 .ody feed is
automatially erformed durin$ reirulation and filtration roess5
3ashin$
8he imurities attahed and alha-ellulose on the surfae of filter elements are removedand washed *y flushin$ the lean *rine throu$h filter elements from inside to outside5 .y
washin$ filter elements are restored *a to ori$inal state *efore reuse5 Immediately after
omletion of washin$ roess (e7et initial start u) filtered *rine of re9uired 9uantity is
filled into the *rine filter5 Alha-ellulose of the re9uired 9uantity is dosed into the re-
oat tan5 After dosin$ of alha-ellulose filtered *rine is filled into the re-oat tan and
a$itation is started5
4 Pre-oat
Biltered *rine mi7ed with alha-ellulose is sent into the filter5 Alha-ellulose owder is
attahed evenly on the surfae of filter elements and the re-oat layers with alha-ellulose are formed5 8he layers ontri*ute to ahieve a fine filtration 9uality *y
reventin$ filter elements from *lindin$, whih $ives hi$her washin$ effiieny of filter
elements5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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Ion 'c9ane System
Any traes of alium and ma$nesium ion or other multivalent ations still resent in the
*rine are harmful to the eletrolyCer mem*rane5 8hese are removed after hemial
treatment and sedimentation in rimary *rine urifiation and further are removed *y ion-
e7han$e resin as a seondary urifiation ste5 Al Ghaith lan to imlement a -tower
a*sor*er merry-$o-round tye ion-e7han$e system5 Ion e7han$e resin is filled into all
the olumns5
8wo olumns are normally on line in series and while the third under$oes re$eneration5
After 1" hours the rimary olumn is swithed off-line for resin re$eneration and the
seond olumn is elevated to rimary osition, while the re$enerated olumn is swithed
into the osition of seondary olumn5 8he resin in the off-line olumn, in whih a lar$e
amount of multivalent ations have *een a*sor*ed, is re$enerated *y hydrohlori aid
and austi soda5 As er yle eah olumn is re$enerated after every % hours5 As all
the olumns are onneted throu$h automatially oerated valves, swithin$ taes lae
automatially throu$h the ro$ramma*le lo$i ontroller5
5iure 43 Ion 'c9ane Resin Columns
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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Blow indiation and ontrol valves are installed in all the li9uid lines onneted to the ion
e7han$e system in order to automatially ontrol the flow rates5
8he resin re$eneration roess involves the followin$ stes5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e %"
3ashin$ with water (*rine dislaement)
.awash with water
H'l re$eneration
3ashin$ with water
'austi re$eneration
3ashin$ with water
Relaement of water with *rine
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4)1)1) 'lectrolysis Process
8he eletrolysis setion omrises of the mem*rane eletrolyser and assoiated
e9uiment5
4)1)1)() "em;rane 'lectrolyser
8he eletrolyser assem*ly onsists of a num*er of *i-olar tye ell frames with a metal
anode and the ativated athode, the ion-e7han$e mem*rane, filter ress tye units for
mountin$ ell frames, su*-headers for feedin$ urified *rine and atholyte, su*-headers
for dishar$in$ eletrolysis roduts, and hoses for onnetin$ ell frames with su*-
headers5
A hi$hly urified *rine solution will *e fed to eah eletrolyser manifold and then
distri*uted to eah anode ham*er where it then deomoses into hlorine and sodium
ions5 8he *rine flow rate to eah eletrolyser iruit will *e monitored *y a flow ontrollere9uied with individual feed *rine *ranh ie5
5iure 40 'lectrolyer cell in operational reference plants IN'#S A?CCE
A two-hase roess stream of deleted *rine and wet hlorine $as overflows from eah
anode ham*er and is searated at the olletion manifold5 8he deleted *rine will flow
*y $ravity throu$h the *ranh ie and ommon header into the deleted *rine tan,
while the hlorine $as will *e sent to hlorine $as roessin$ setion5
+eleted *rine will *e umed to deleted *rine dehlorination system *y level ontroller5
8wo hydrohlori aid additions have *een onsidered for the *rine reylin$ system in
order to maintain a low o7y$en onentration in the hlorine $as5 >ne will *e loated at
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Al Ghaith Industries
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the inlet of the deleted *rine tan, while the other will *e situated at the ell feed *rine
line5
8wo tyes of hlorine $as seal ots will *e installed to rotet the eletrolysers from
e7essive ressure sur$in$ in roess uset onditions one for ositive ressure relief
and another for ne$ative ressure5 'hlorine $as header ressure in the ell room will *e
maintained *y the ressure ontrol of hlorine at ooler inlet5 Reyled austi will *e fed
to eletrolyser manifold throu$h a austi heat e7han$er and then distri*uted to eah
athode ham*er5 8he reyle austi flow rate will *e ontrolled *y the flow ontroller
installed in the austi feed line5
5iure 4+ Cat9olyte System
A two-hase stream of austi solution and wet hydro$en $as overflows from eah
athode ham*er and is searated at the olletion manifold e9uied with eletrolyser5
8he austi solution flows throu$h the ommon header into the austi reyle tan *y
$ravity5
Gas Proessin$ Setion
8he hydro$en $as ressure will *e maintained *y ressure ontrol sheme5 8o revent
an e7essive ositive ressure, a hydro$en vent sta will *e installed5 8his sta will
also serve as a $as ur$e system durin$ lant start u oerations5
After leavin$ the austi reyle tan, the austi solution will $o diretly to the rodut
stora$e tan and the reyle austi stream to the eletrolyser5 8he austi heat
e7han$er heats or ools the reyled austi to maintain the eletrolyser oeratin$
temerature at =# to @! T'5 8he eletrolyser austi stren$th will *e monitored *y the
austi density indiator, and normally et at aro7imately % wtQ5 8his is the otimum
onentration for mem*rane erformane *y ontrollin$ the +/ water feed 9uantity into
the reyled austi stream5
+urin$ start-u, the austi heat e7han$er will warm the eletrolyte in the eletrolyser,
aeleratin$ to full urrent load attainment without e7essive volta$e5 8o detet
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Al Ghaith Industries
Project Number 441!!"#
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a*normalities of eletrolyser, volta$e and temerature monitorin$ systems have *een
inluded in the lant desi$n5
4)1)4) Brine Dec9lorination
+eleted *rine from deleted *rine tan will *e taen to a *rine de-hlorination setion to
mae return *rine, whih is free from hlorine5 A tyial *rine de-hlorination setion
onsists of aed tower where vauum is maintained with the hel of steam e'l, *ut not 'l%
to hloride5 Return *rine will *e re$ularly tested to detet the resene of free hlorine
*efore this enters the return *rine tan5
4)1)@) &ydroen %as Processin
Hydro$en $as is $enerated durin$ eletrolysis at *etween =# to @! T'5 8he $as will *e
introdued to the hydro$en $as oolers first with oolin$ water and then with hilled water,
where it will *e ooled to aro7imately 1= T'5 Brom hydro$en ooler $as, hydro$en $as
will *e taen to vent (durin$ start-u) or to the H'l aid synthesis unit5
4)1)3) C9lorine %as Coolin
8he hlorine $as oolin$ system is aa*le of rovidin$ $aseous hlorine5 6o rovision
has *een made for li9uefied hlorine rodution and stora$e5
8he hlorine $as oolin$ setion omrises of hlorine $as oolers (rimary seondary)
and a mist eliminator5 'hlorine $as omin$ from the eletrolyser at @! T' will *e
saturated with water vaors and will ontain traes of sodium hloride5 8he hlorine $as
will *e ooled to *etween 4! to 4# T' in the hlorine ooler with oolin$ water and then
u to -%!T' in the hilled water ooler5
+urin$ oolin$, lar$e 9uantities of water vaors $et ondensed5 8he water vaor will *e
olleted in the seal ot5 Entrained water vaors and salt traes are removed in the mist
eliminator5 A small 9uantity of roess water will *e added in the hlorine line in order to
dissolve entrained salt artiles5
4)1)0) Caustic Concentration 5la-in Plant
8his setion of the lant will have fle7i*ility to oerate on only #!Q austi soda
rodution (Mode A) and flain$ (Mode B) and rodution of *oth (Mode C)5 All the
three are desri*ed *elow5
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Al Ghaith Industries
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4)1)0)() "ode A 'vaporation only
8he %Q mem*rane ell li9uor will *e fed to the first sta$e fallin$ film evaorator
oeratin$ on rodut side under a vauum5 +urin$ a sin$le ass, the austi solution is
evaorated to aro7imately =Q5 8he $enerated vaors are led via dut to a water
ooled surfae ondenser where they are indiretly ondensed5 Inert $asses are sued
off *y a waterin$ vauum um5 8he =Q austi solution dishar$ed from the *ottom
art of the first sta$e evaorator *y means of um is heated to a temerature of 1" T'
throu$h heat e7han$e5
+urin$ a sin$le ass throu$h the seond sta$e fallin$ film evaorator oeratin$ on
rodut side at atmosheri ressure, the austi solution is onentrated to #!Q5 8he
vaor $enerated within is used to heat the first effet evaorator5
8he seond sta$e evaorator will *e heated *y steam5 8he steam ondensate will *e
used to reheat the =Q solution and returns at *attery limit5 8he vaor ondensate will
*e olleted in a 8an and leaves the lant at a temerature of aro75 ? !'5 8he #!Q
'austi solution will *e dishar$ed from the *ottom art of the seond sta$e *y means of
um (P-1%!1 AO.)5 It will *e ooled down to 4# 'hlor-Alali Plant T' *efore *ein$ sent to
.attery ;imit throu$h heat e7han$e5
4)1)0).) "ode B Concentration/ 5la-in
8he %Q mem*rane ell li9uor will *e fed to the first sta$e fallin$ film evaorator
oeratin$ on rodut side under a vauum of a*out 11 m*ar a*s5 +urin$ a sin$le ass
throu$h the evaorator, the austi solution will *e evaorated to aro7imately 4"Q5
8he $enerated vaors will *e led via dut to a surfae ondenser, where they will *eindiretly ondensed *y oolin$ water5 Inert $ases are sued off *y waterin$ vauum
um5
8he 4"Q austi solution, whih will *e dishar$ed from the *ottom art of the first sta$e
evaorator *y means of um, is heated to a temerature of 1%= T' (tyial value)
throu$h heat e7han$er5 +urin$ a sin$le ass throu$h the seond sta$e fallin$ film
evaorator oeratin$ on rodut side at atmosheri ressure, the austi solution will *e
onentrated to a*out "1Q5 8he vaor $enerated will *e used to heat the first effet
evaorator alon$ with the vaor omin$ from the onentration and flain$ unit5 8he
seond sta$e evaorator will *e heated *y steam5 8he steam ondensate will *e used to
reheat the 4"Q solution and returns at *attery limit5 8he vaor ondensate will *eolleted in a tan and will leave the lant at a temerature of aro75 ?4 T'5
8he "1Q austi solution from the evaoration will *e fed to a seially desi$ned fallin$
film onentrator5 +urin$ a sin$le ass throu$h this onentrator, the 6a>H solution will
*e dehydrated from "1Q u to a*out @=5#Q5 8he onentrator oerates on rodut side
under atmosheri ressure and the $enerated vaor will *e used to heat the first sta$e
evaorator in the evaoration lant5
8he heat re9uired for the onentration from "1Q u to @=5#Q is transferred *y molten
salt5 8he heat transfer salt is irulated *y um throu$h natural $as fired heater, where
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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it is heated to aro7imately 4! T'5 8he flue $ases ass throu$h a om*ustion air re-
heater and are then vented throu$h a sta into the atmoshere5 8he *urner laed on
to of the molten salt heater, is desi$ned for oeration with reheated om*ustion air5
8he hi$hly onentrated austi melt leaves the final onentrator throu$h seal ot and is
fed *y $ravity to a seially desi$ned flain$ mahine, where it is roessed into flaes at
low temerature5 8he flaes are fed *y $ravity to a semi-automati *a$$in$ sale5 8he
*a$$in$ sale is of air ti$ht desi$n in order to avoid moisture i-u of the hy$rosoi
flaes5 8he filled *a$ will *e transorted via a onveyor to the *a$ losin$ mahine5 8he
*a$ is a dou*le walled *a$ with a PE inline and a PP woven outer *a$5 8he PE inline is
losed manually *y a drill *inder and the PP woven outer *a$ will *e losed *y a sewin$
mahine5
4)1)0)1) "ode C 'vaporation and Concentration/ 5la-in
In this mode li9uid austi and flaes an *e rodued at the same time5 8he roess
desrition is, in rinile, the same as for /ode . onentration and flain$5
However, the roess arameters are sli$htly different5 8he onentration after the first
evaoration sta$e is a*out 4!Q 6a>H5 8he onentration after the seond evaoration
sta$e is #!Q 6a>H5
After the seond evaoration sta$e the austi flow is slit into two streams, one feedin$
the final onentrator and the seond one leadin$ to the *attery limit5 8he austi $oin$
to the *attery limit is asses throu$h a set of two heat e7han$ers where the austi is
ooled down to a temerature of 4# T'5
8he onentration lant is worin$ with the same rinile as desri*ed under mode .
e7et that the feed onentration is #!Q instead of "1Q 6a>H5 8he lant is ontrolled
*y instruments to ensure fully automati oeration of the roess5 >eratin$ ersonnel
are re9uired only at the *a$$in$ and *a$ losin$ station5 However, start u and shut
down of the lant re9uires some manual interations5
4)1)+) Sodium &ypoc9lorite Plant
It is mandatory to install 3aste Air +ehlorination (3A+) in the 'hlor-Alali Plant in order
to omly with the re9uirements of the alia*le environmental le$islation5 +urin$ start
u and shut down of the lant, hlorine from the ell house is sent to the sodium
hyohlorite lant5 In ase of any leaa$e or e7ess ressure in the roess, hlorine will
*e sued *y the 3A+ setion5 8he waste hlorine header will *e onneted to all
vulnera*le oints where there is a hane of any hlorine leaa$e inludin$ vents and
seal ots5
8he sodium hyohlorite lant onsists of the followin$ setions
'hlorine Sution SystemM
1stSta$e A*sortion SystemM
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Al Ghaith Industries
Project Number 441!!"#
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%ndsta$e A*sortion SystemM and
'hlorine Sution System5
'hlorine $as from hlorine setion as well as any leaed hlorine is sued into the lant
throu$h a sution *lower5 8his *lower handles only una*sor*ed air and water vaors5
(ststae a;sorption
8he 1ststa$e a*sortion system shall onsist of austi irulation tan, irulation um,
hilled water PHE and aed olumn a*sor*er5 8he 1sta*sor*er will fae onentrated
hlorine5 8he ma7imum hlorine will $et a*sor*ed at this sta$e5 +iluted austi will *e
irulated in the a*sor*er from austi irulation tan and umed for a*sortion of
hlorine from assin$ throu$h hilled water PHE to remove the heat of reation5 3hen
the *ath is ready the same is transferred to sodium hyohlorite stora$e tan and fresh
diluted austi is taen from olishin$ tower O %nda*sor*er tan5
8he reation in the sodium hyohlorite lant an *e summariCed as *elow
. Na#& F Cl.Na#Cl F NaCl F &.#
6ormally to $et a sta*le rodut, 1! to %! $lof e7ess alali is maintained in the rodut
and *efore transferrin$ it is ensured that availa*le hlorine is 1#! $l5
.ndStae A;sorption System
Sine some hlorine will esae from 1sta*sor*er the %ndsta$e a*sortion system will *e
installed to a*sor* the remainin$ hlorine from waste air5
Additionally, this system will onsist of one aed a*sor*er with one irulation tan,
irulation ums and late heat e7han$er5
The 2ndstage system consists of:
'hlorine Sution SystemM
'austi +ilution and >ver Head 8anM
1stSta$e A*sortion SystemM and
%ndsta$e A*sortion System5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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5iure 4G .ndStae A;sorption System
4)1)G) &ydroc9loric Acid Plant
4)1)G)() Principle of #peration
H'; is rodued as a $as from the om*ustion of hydro$en and hlorine $ases, then
a*sor*ed into water and ooled5 8he om*ustion roess is ontrolled to rovide ultimate
safety5
+urin$ the om*ustion roess, hlorine and hydro$en reat in e9ual volume to rodue
H'l $as5
H% 'l% %H'l
(Gas) (Gas) (Gas)
8his e7othermi reation $enerates a flame temerature of around %,#!!T', and a heat
load of aro7imately 1,!!! 'al O $ of H'l when roduin$ a ooled Q a9ueous
hase of H'l5 8he om*ustion roess is oerated with a sli$ht e7ess of H% over
stoihiometri onditions oeratin$ the system with this e7ess of H% ensures the
omlete 'om*ustion of hlorine $as, thus reventin$ it from esain$ into atmoshere
and roduin$ a ure hydrohlori aid5
4)1)G).) Synt9esis *nit
8he heart of the roess is synthesis unit (or inte$rated *urner a*sor*er), onstruted of
imre$nated $rahite materials enased in a water-ooled shell5 8he funtions O roess
stes of the synthesis unit inlude
'om*ustionM
Gas oolin$M
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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A*sortionM and
Solution oolin$5
Hydro$en and hlorine $as enter the to of the synthesis unit and are *urnt into a seifi
*urner desi$ned to ensure the omlete om*ustion5 8he *urner onsists of seial
tu*es fitted inside whih are easily remova*le for maintenane5
8he addition of a*sortion water to the H'l $as is arried out at the to of the unit5 8he
$ases and a*sortion water are then ooled down in vertial hannels at ounter urrent
of servie side oolin$ water iruit5 8he wetted arts of unit are of the seleted material
to avoid any orrosion5
At the *ottom outlet of a*sor*er, the H'l solution is searated from the $as whih is
roessed in a tail $as tower sru**er to reover the remainin$ non-a*sor*ed H'l $as5
8he synthesis unit is normally oerated lose to atmosheri ressure, *ut it is roteted
a$ainst over ressuriCation with a ruture dis5 At the *ottom of assem*ly, and vented to
a sum ot *eneath the synthesis unit5
4)1)G)1) Tail %as To=er:
8he urose of the tail $as tower is to a*sor* or to sru* the $ases omin$ from the
*ottom of a*sor*er5 8he $as omonents are mainly inert with some *urnt hydro$en and
a little una*sor*ed H'l5 8he a*sortion water enters the to of the tail $as tower throu$h
a distri*utor and flows downwards over a ain$ as the $ases flow uwards to *e
e7hausted to atmoshere5 +urin$ this oeration, the remainin$ H'l will *e a*sor*ed5
4)1)G)4) Safety:
8he overall ontrol hilosohy of the H'l synthesis system desi$n is Dfail-safe, whih is
defined *y oenin$ ontats under a*normal onditions5 8he followin$ safety interlos
are rovided to either revent the system from *ein$ started or to ause the system to
shut down the ur$e itself5
Blame failureM
;ow oolin$ water flowM
;ow a*sortion water flowM
Safety dis *reaa$eM
Fery hi$h level in *uffer tanM
;ow 6% $as ressure while ur$in$ the unit durin$ startuM and
;ow instrument air ressure $au$es5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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+urin$ oeration, if either of the a*ove events ours, the synthesis unit shuts itself down
that a ur$e with nitro$en an *e arried out5
4)1)(H)Demineralied =ater system
8he roess raw water will *e +/ *y means of ion e7han$e treatment5 8he +/ water
rodution unit onsists of ationi and anioni e7han$ers, a de$asser (to redue the
'>% *efore feedin$ the anioni e7han$er), and a hemial dosin$ system for resin
re$eneration5 8he resin re$eneration will *e erformed with diluted solutions of
hydrohlori aid and sodium hydro7ide5 8his unit will *e desi$ned to *e oerated
automatially *y means of a Pro$ramma*le ;o$i 'ontroller (P;')5 8he effluent from the
+/ unit will *e mainly water with traes of aid and will *e direted to wastewater
neutraliCation it5
'oolin$ water unit
A losed-iruit oolin$ water unit will *e installed at the roosed lant and will onsist of
indued draft tye oolin$ towers5 8he warm oolin$ water will *e disersed uniformly
over the entire oolin$ area *y a distri*ution system5 8he air used for oolin$ will *e
drawn u *y fans loated on the to of the oolin$ tower5 8he ooled water will *e
olleted in a water *asin *eneath the tower5 8he olleted ooled water will *e umed
to various roess units in lant, olleted *a in the oolin$ water *asin and umed
*a to the oolin$ tower5
8he oolin$ water will *e treated with hemials in order to revent metal orrosion, sale
formation, and *iolo$ial foulin$, and thus hel in inreasin$ system oeratin$ effiieny
and the omosition of the *leed-off sent to drain5
4)1)(() C9illed =ater system
A hillin$ unit will *e installed at the lant to rodue hilled water5 8he hillin$ unit will
inlude a vaor a*sortion system to avoid the use of any >Cone-deletin$ refri$erant5
8he hilled water will *e used at various sta$es of the roess stream5
4)1)(.)Compressed air system
8he air omression unit will onsist of two omressors (oerational and stand-*y) for
the suly of 1!!Q of the omressed air demand for lant and instrument air5
Even thou$h the mem*rane lant will *e oerated ontinuously, variations of instrument
air re9uirement an our5 8he instrument air vessel will omensate these variations
and allow smooth oeration of air system5
8he omressed air system will also inlude a dryer whih will onsist of two units that
an *e used alternatively as an a*sor*er ham*er or in ase of re$eneration as desor*er
ham*er5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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In addition, the dry air system will *e used for air *lanetin$ (throu$h various inlets) the
austi flaes, startin$ from the hoers u to the *a$$in$ area, in order to revent the
flaes from a*sor*in$ the moisture5
4)1)(1)Steam supply system
A natural-$as fired *oiler omlete with a low-6o7*urner, a om*ustion air fan, and an
automati ontrol (for safety oeration) will *e installed at the lant to $enerate steam5
4)1)(4)Control and instrumentation system
8he lant will *e e9uied with a entral ontrol system ena*lin$ an automati oeration
of main roess units and hein$ the ritial arameters (temeratures, feed rate, li9uid
levels, et)5 8hese arameters are monitored with re-alarms and sensors5 Interlos
will also *e rovided for ersonal safety and material rotetion5 In addition, loal ontrolanels will *e rovided at the *urner system, srayin$ areas and at the *a$$in$ units5
+etails of roosed online monitorin$ system are rovided *elow inTa;le 4 4)
Ta;le 44: Proposed #nline "onitorin System
Type Description
'hlorine and hydro$ensensors
'austi Plant how many
/etersH meter, >RP
'ondutivity
Folta$e monitorin$e9uiment
'ell House
Proess ontrol e9uiment
All the roess arameters (temerature, ressure,flow et)
AnalyCers are lined with an Automated +'S withsafety tri lo$is
4)1)(@)Bain *nit
A *a$$in$ unit will *e installed to wei$h and automatially fill the austi flaes into *a$s5
8he system will onsist of an eletroni wei$hin$ sale and a fully automati fill and seal-
tye aa$in$ mahine, and will *e oerational 1" hours er day5
4)1)(3)Transportation System
8ransortation of main raw materials from I'A+ 1 to the roosed lant will *e via road5
In addition, finished roduts will *e transorted via road for distri*ution within the &AE
and *eyond5
Standard >eratin$ Proedures (S>P) will *e reared to ensure the followin$
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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8ransortation is arried out safely in omliane all alia*le EA+
rulesOre$ulations and international onventionsM
/aterials to *e transorted are within allowa*le wei$ht and volume limitsM
6o leaa$eOsilla$e of the materials from the vehiles ours durin$
transortation and loadin$Ounloadin$M and
Fehile oeratorsOdrivers follow alia*le &AE traffi lawsOre$ulations5
4)1)(0)5acility Construction
8he followin$ ma
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Sta for Sodium hyohlorite tower ('l%$as)M
Sta for natural-$as fired *oiler (SP/, 6>7, S>7, 'H4, '>%)M
Sta for Blain$ &nit (SP/, 6>7, S>7, 'H4, '>%)5
8he rimary soure of air ontaminants durin$ the onstrution hase will *e the various
internal om*ustion en$ines used at the onstrution site, whih will inlude *oth non-
road onstrution e9uiment and some on-road vehiles5 8hese mo*ile soures will emit
ar*on mono7ide ('>), volatile or$ani omounds (F>'s), nitro$en o7ides (6> 7) and
sulfur dio7ide (S>%) into the atmoshere5
8he oeratin$ horseower of the e9uiment was estimated as the avera$e horseower
for a seifi tye of e9uiment utiliCin$ the &SEPA non-road emission fators5
Burthermore, sine the seifi num*er and tye of e9uiment to *e used onsite at any$iven time has not yet *een finaliCed, a onservative estimate of the tye and num*er of
onstrution e9uiment to *e used has *een assumed5 8he orresondin$ 6EFES
emission fators are resented in 8a*le 4 -#*elow5 8he ma7imum monthly and daily
estimated emissions durin$ the onstrution eriod are summariCed in 8a*le 4 -"5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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Ta;le 4@: Construction 'uipment Air 'mission 5actors)
'pected Construction
'uipment
9pC#
/;9p9rE
2#Cs
/;9p9rE
N#
/;9p9rE
S#.
/;9p9rEPlate 'omators = 51 !5= @5 !5@
Rollers @@ 51 !5=% @5 1
E7avators 14 #5% !5?1 1!5?# !5@
'ranes 1@4 45% 15%@ 1!5 !5@
>ff-Hi$hway 8rus 4=@ %5= !5=" @5" !5=?
8ratorsO;oadersO.ahoes ?? "5= 154 1!51 !5@
+umersO8enders % %5= !5=" @5" !5=@
Generators U #! h %% # 15%% = !5@
Air 'omressors U #! h ? # 15%% = !5@
474 &se (Petrol Buel)V 6OA %5!" !5!4 !514 !54!
474 &se (+iesel Buel)V 6OA !5"1 !51# !5% !54!
.usV 6OA 15#" !54@ 5@ !54!
#!! NFA Generators #! #5! 15%% =5! !5@
Air 'omressors #! #5! 15%% =5! !5@
Ta;le 43: Construction 'missions 'stimates)
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e (
Construction Perioddays/mont9E .3
'stimated Pea- Construction 'missions!ent9 of =or-in days9rs/dayE (H
'pected Construction'uipment 9p Jty
C# 2#Cs N# S#.-/mont9E -/mont9E -/mont9E -/mont9E
Plate 'omators = 1 "5! 15" 1?5@ 15=
Rollers @@ 1 "5! 15" 1?5@ 15=
E7avators 14 1 45! 151 115@ 15%
'ranes 1@4 % 45= 15 145 1544
>ff-Hi$hway 8rus 4=@ 1 5! !5= =5@ !5@
8ratorsO;oadersO.ahoes ?? % 115@ 5% #5? 5"
+umersO8enders % 1 "5! 15" 1?5@ 15=Generators U #! h %% 115@ 5% #5? 5"
Air 'omressors U #! h ? % %5= "54 ?154 ?5%
474 &se (Petrol Buelled) VVV 1! #@5# 1"5! 1?=5# 1=
474 &se (+iesel Buelled) VVV # #@5# 1"5! 1?=5# 1=
.us VVV # "5! 15" 1?5@ 15=
Total 'stimated 'missions-/mont9E
%!% #4 "!" "1
'stimated 'missions -/dayE ?5= %51 %5 %54
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8he movement of soils durin$ onstrution ativities will *e antiiated to lead to the
$eneration of air*orne dust5 8he ourrene and si$nifiane of dust $enerated *y earth-
movin$ oerations will *e diffiult to estimate aurately, and deends uon
meteorolo$ial and $round onditions at the time and loation of the earthwor5
Fery small 9uantities of '>% emissions are released durin$ the urifiation of *rine with
sodium ar*onate5 It is estimated that 1! $rams of ar*on dio7ide are released er ton of
austi soda rodution5 Bu$itive '>% emissions are also liely from the hlorine
destrution unit and handlin$5
+urin$ loadin$ of austi and 6a>'l, fu$itive emissions are not antiiated5 However,
fu$itive emissions are liely durin$ H'l loadin$5
Control measures to minimie air emissions
8he deleted *rine from the eletrolysis setion, ontainin$ free hlorine, will *e
de-hlorinated in a *rine de-hlorination tan where most of the free hlorine will
*e stried out *y vauum and the stried hlorine $as will *e sent to the main
hlorine $as header5 8he de-hlorinated *rine leavin$ the de-hlorination tan
will *e allowed to reat with sodium *isulfite solution at a H of @-@5# for further
removal of hlorineM
All hlorine-ontainin$ waste $as streams will *e direted to the hlorine
a*sortion unit5 8he hlorine a*sortion unit will *e desi$ned with a treatment
aaity suffiient to a*sor* the full ell-room rodution to revent emissions of
hlorine $as in the event of emer$enies andOor irre$ular lant oeration untilthe lant an *e shut down5 8he hlorine a*sortion unit desi$n will ena*le the
lant to lower the hlorine ontent in the emitted $as to less than 15?% mv (#
m$O6m) in the worst-ase senario omared to EA+s ermissi*le limits of %!
mv5 In addition, the emitted H'l vaor will *e less than "5?! mv (1!
m$O6m) in the worst-ase senario omared to &S EPALs ermissi*le limits of
1% mvM
8he steam *oiler and the flain$ unit will inlude low 6o7*urners to effetively
redue 6o7 emissions to meet the EA+ ermissi*le limit of ## m$O6m5 S>7
emissions will *e *elow the /oELs ermissi*le limit of #!! m$O6mM
Re$ular annual insetion of *oiler and flain$ unit will *e onduted to avoid
any e7ess ar*on dio7ide releaseM and
A sru**in$ unit with @#Q effiieny will *e rovided to ontrol fu$itive emissions
durin$ H'l loadin$5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e 4!
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4)1)(G)>aste=ater Treatment and "anaement
>aste=ater sources
3aste water $enerated at the lant will ori$inate from various oerations as listed
*elow
+urin$ re$eneration of the ion-e7han$e resins (emloyed durin$ seondary
*rine urifiation roess), wastewater ontainin$ trae amounts of dissolved
metals (niel, Cin, iron, oer) will *e $eneratedM
+urin$ urifiation of the *rine, hi$h onentration of hloride, hlorates, and
o7idants may aumulate5 'hlorates may also form as *y-roduts durin$
eletrolysis5 +ue to the reylin$ of the *rine, the followin$ omonents may
*uild-uM
o Sulfate ions may often have a ne$ative effet on the eletrolysis roess
(dama$es the anode oatin$)5 .leedin$ of the *rine treatment system will *e
onduted eriodially to redue the levels of sodium sulfate andOor sodium
hlorate in the ells5 3astewater will *e $enerated as result of *leedin$ of
the iruit5
o 'hlorinated hydroar*ons may *e formed in a reation *etween or$ani
ontaminants in the eletrolyCer and free o7idants5 Releases of hlorinated
hydroar*ons will normally *e very low (aro7imately %! $Oyear), tyially
!5!-151" $rams er ton of hlorine rodued5
3astewater resultin$ from wash-outs of unit omonents, e7haust air sru**er,
and floorsM
3astewater $enerated as a result of austi evaorationM and
Sanitary wastewater $enerated durin$ onstrution and oerational hases5
.ased on internationally aeted standard of !5%# m of sanitary wastewater
$enerated er erson er day, the onstrution sanitary wastewater for estimated
#!! worers will *e 1%# mOday, and the oerational sanitary wastewater for 4#
emloyees will *e 1% mOday5
As mentioned earlier, with the e7etion of *lowdown water, the roosed lant will not
have any wastewater dishar$e from the oolin$ water unit5
Control measures to minimie effluent
Reylin$ of *rine (removin$ imurities) *y ion-e7han$e resin unit5 Su*se9uent
re$eneration of resins will *e aomlished *y usin$ austi soda and aidwashin$M
&sin$ sent aid to ontrol H in roess and wastewater streamsM
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e 41
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Removal of reiitated salts from the *rine throu$h deantationOlarifiation and
filtrationM
/inimiCin$ the dishar$e of hlorate to water *y alyin$ aid onditions in theanolyte (H 1-%)5 Also, hlorate destrution in the *rine iruit will *e onduted to
remove hlorate *efore ur$in$M
Removal of *rine filtration slud$e *y flushin$ with a wea H'l solution5 8he aid
will ause the reiitate to dissolve and the resultant solution will *e dishar$ed
with the li9uid effluent to the onsite wastewater treatment lantM and
Reylin$ of water, wherever ossi*le, utiliCin$ Reverse >smosis (R>) unit5
4)1).H)Solid >aste Treatment and "anaement
Solid wastes $enerated at the 'hlor-Alali Plant durin$ the *rine urifiation will onsist of
used materials suh as re-oat and feed material made of ellulose5 8he re-oat filter
slud$e from the *rine softener will onsist mainly of alha-ellulose, ontaminated with
iron hydro7ide and silia5 Sent mem*ranes and $asets from mem*rane ells will *e
other waste streams remainin$ after their servie life5 8he solid waste $enerated at the
roosed lant will *e mana$ed as er a 3aste /ana$ement Plan (3/P)5
>n a $eneral level, waste will *e stored in a dediated area and will *e disosed followin$
relevant EA+ re$ulations5
4)1).()5ire and Toic %as Release Prevention and Control
8he e9uiment onfi$uration at the roosed lant will onform to *est raties for
modern 'hlor-Alali lants5
+ue to vulnera*ility of fire and to7i $ases in any 'hlor-Alali lant (diret and indiret),
the followin$ effetive reventive and ontrol measures will *e taen at the roosed Al
Ghaith lant to minimiCe fire or other haCards and onse9uential dama$es
Installation of fire detetion and alarm systemM
Installation of hydrant systemM
Installation of automatially ativated hi$h veloity srinler systemM
Plaement of orta*le fire e7tin$uishersM
8ie-u of hydro$en $as $enerated in the ell room to the $as headerM
&se of Wintrinsially safeW eletrial e9uiment in the seleted lant areasM
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e 4%
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A little amount of hydro$en $as will *e vented to the atmoshere durin$ uset
onditions throu$h safety release valves5 Fentin$ system will *e so desi$ned that
onentration level of hydro$en in air will *e always less than 1Q with followin$
au7iliary e9uiment
o Blame arrestor in the vent lineM
o Blame sensor near vent ointM
o Automati ur$in$ of steam in the vent ie (interlo with flame sensor
will *e rovided)M
o Sta hei$ht will *e desi$ned as er the standard $uidelines5
Installation of hlorine a*sortion unit desi$ned with a treatment aaity
suffiient to a*sor* the full ell-room rodution in the event of emer$eniesM
Installation of hlorine and hydro$en $as detetors in the eletrolysis ell roomM
Imlementation of 3aste Air +ehlorination (3A+) in the sodium hyo lant for
neutraliCin$ 9uantity of waste $as arisin$ out of eletrolyCerLs oeration5 8his
system, utiliCin$ dou*le-sta$e sru**in$ mehanism, will *e desi$ned to
neutraliCe all hlorine rodued at full aaity for 1# minutesM
8he omosition of the vent stream that will *e vented from hlorine a*sortion
unit and 3A+ durin$ the normal oeration will *e as follows
Air saturated with water @@5@@@@Q
'hlorine $as !5!!!!!4#Q
H'l 6il
Entire e9uiment will *e *aed-u *y emer$eny ower $enerator setM
>eration of ontrol and instrumentation system ena*lin$ an automati oeration
of the unit *y ontrollin$ the imortant roess arameters suh as temerature,
feed rate and li9uid levels, monitorin$ the ritial arameters with re-alarms, and
interlos for ersonal safety and material rotetionM and
8ransortation of the raw materials and finished $oods (in and out of the lant,resetively) will *e onduted safely and will *e in omliane with alia*le
&AE rules and re$ulations and international onventions5
4)4) Project Status and Sc9edule
4)4)() Current Status
8he 'hlor-Alali Pro
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Su*mission of initial draft PEHSR to Jonesor on %? Au$ust %!11M
AndX5
4)4).) Project Sc9edule
8he urrent ro
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@) 'N2IR#N"'NT6 I"PACTS6 "ITI%ATI#N AND "#NIT#RIN%
@)() Air Juality
@)()() Description of t9e 'nvironment
@)()()() Reional Climate and "eteoroloy
8he limate of the re$ion is *i-seasonal, haraterised *y hi$h temeratures and low
rainfall5 8he summers (/ay to >to*er) are distintly hot, with daytime temeratures
re$ularly e7eedin$ 4!T'5 Rainfall ours oasionally durin$ the summer, *ut is
$enerally restrited to the ooler winter months (6ovem*er to Aril) when temeratures
an dro to 4T' in some areas (usually inland) at ni$ht5 Seasonal flutuations in
temeratures are less well ronouned alon$ the oast, where they are *uffered *y the
maritime influene5
Annual rainfall amounts vary aordin$ to loation, *ut reiitation $enerally dereases
from north-east to southwest alon$ the &AE5 'oastal areas suh as A*u +ha*i reeive
a*out =! mm of rain annually5
Bo$ ours on 1 days or an avera$e of 1!" hours er year near the oast5 Also near the
oast fo$ is more fre9uent in winter (?" days on avera$e) than in summer to (4= days on
avera$e)5 Bo$ inidene an last from half an hour to 1! hours, deendin$ on the time of
formation and the weather onditions5
Humidity eas in 2uly and Au$ust at over @!Q, and dereases throu$h >to*er, with theleast ourrin$ from 6ovem*er throu$h to Aril5 8he humidity over the ooler months an
fall to 1!-%!Q5
8he weather durin$ muh of the year is dominated *y a rid$e of hi$h ressure e7tendin$
southwards into entral Saudi Ara*ia with lower ressure over the eastern Gulf5 8he
result of this is the revailin$ winds from the north and north western 9uadrants, nown
*y their Ara*i name shamalL, meanin$ northL5 Shamals our mainly durin$ the ooler
months, however they an also our durin$ the hot season, tyially 2une and 2uly5
Alon$ the western oastal lain, sea *reeCes tend to dominate with li$ht south south-
easterlies at ni$ht *ein$ relaed *y moderate northwesterly winds durin$ daytime5 A
stron$ northerly shamal is usually reeded in the &AE *y stron$ southerly winds, raisin$desert sands and reduin$ visi*ility5 8he shift to northerly winds may *e 9uite sudden
and an *e aomanied *y rain, thunderstorms, or dust storms5
@)()().) Am;ient Air Juality
8he main soure of air ollutants in /usaffah is traffi in addition to different industrial
ativities, all ontri*utin$ to emissions from small worshos and lar$er industrial
roesses in the area5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e 4#
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"odelled Air Juality
'omuter modellin$ was used *y EA+ to assess imats of emissions from stas and
traffi on am*ient air 9uality in different areas5 Imats of eah soure was *e modelled
searately, thus allowin$ the identifiation of its ontri*ution to the o*served attern5 8he
simulation model used rodued hourly avera$es and ma7ima, "-months avera$es and
ma7ima, and yearly avera$es and ma7ima5
N#.
8he air ollution disersion alulations show that inside the A*u +ha*i ity, due to
emission onditions and revailin$ wind, traffi is the main ontri*utor to imat of
nitro$en o7ides5 8he roosed one-hour air 9uality $uideline for 6>% (%!! Y$Om) is
e7eeded inside A*u +ha*i ity with the emissions from traffi alone (Error Referene
soure not found), *ut not in /usaffah5 However, oint soures lie ower lants will $ive
inreased imat downwind in revailin$ wind diretions5 8heir ontri*ution, added to the
ontri*ution from traffi, an lead to e7eedane of the roosed air 9uality $uidelines in
areas outside the ity entre (Error Referene soure not found) where these $uidelines
were not e7eeded with the ontri*ution from traffi alone5 A$ain, the resent one-hour
air 9uality $uideline for 6>%is not e7eeded in /usaffah5
5iure @(H (9our averae N#.concentrations K/m1E from traffic emissions in A;u D9a;i
city 'AD6 .HH0E
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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5iure @(( "aimum (9our averae N#.concentrations K/m1E from traffic and industrial
emissions in A;u D9a;i city 'AD6 .HH0E
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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S#.
8he ma7imum 1-hour S>%onentrations in A*u +ha*i ity and surroundin$s does not
e7eed the one-hour air 9uality $uideline for S>%(#! Y$Om), *ut it reahes a ma7imum
of %#! Y$Omin /IA (Error Referene soure not found)5 In the entre of A*u +ha*i ity
the ma7imum 1-hour S>%onentrations are *etween 1!! and 1%# Y$Om5
5iure @(. "aimum (9our averae S#.concentration K/m1E from traffic and industrial
emissions in A;u D9a;i city 'AD6 .HH0E
Additionally, air 9uality in /IA was also measured in %!!= *y a mo*ile la*oratory over a
1!-day eriod durin$ the summer months5 8he mean measured values were avera$ed Z
to 1 hour, = hour, %4 hour andOor 1 year values for the arameters for whih alia*leEA+ Am*ient Air 0uality Standards (AA0S) e7ist5 6either the measurements nor the
alulated avera$ed values (Error Referene soure not found)e7hi*ited e7eedanes
of the EA+ AA0S arameters, e7et P/1!5 Bor P/1!, the 1!-day measured value mean
and the alulated avera$ed value *oth e7eeded the resetive EA+ AA0S5 8his an
*e attri*uted to the emissions from industrial ativity with in /IA as well as the naturally
hi$h levels of P/1!ourrin$ in the re$ion due to its sandy to land rofile (EA+, %!!?)5
Z8his avera$in$ was arried out usin$ an in-house alulation method5 8he avera$ed values were derived fromthe 1!-day measured mean value5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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Ta;le @0 Am;ient Air Juality in "usaffa9
Parameter(Hday "easured 2alues
/m1ECalculated
Averaed 2aluecompared to
"eanE
AverainPeriod
'AD
AAJS
"ean "inimum "aimum
/m1E
6> =5? 45# 44"546OA 6OA 6OA
6> %!5% ! 1%!5@
6>% #%5= 5 1%!5%1#=5! 1 hour 4!!
=5? %4 hour 1#!
S>% 145? 15@ "?5%
445! 1 hour #!
%5 %4 hour 1#!
?5% 1 year "!
H%S @5? %5" %45 6OA 6OA 6OA
'> !5" !51 15#15= 1 hour !,!!!
15% = hour 1!,!!!
> 4154 ! 1%"51%5@ 1 hour %!!
=15? = hour 1%!
P/1! 1# %= #?% %145! %4 hour 1#!
/ore reently, the A+6>' arried out ontinuous air 9uality monitorin$ emloyin$ a
mo*ile air 9uality monitorin$ station (trailer) ositioned at the ES6AA+ /IA site *etween
11 /ay, %!!@ and %? Setem*er, %!!@5 8he arameters monitored were S>%, 6>%, >,
'>, P/1!, 6/H', 'H4and H%S5 +etails of the monitorin$ methodolo$y and reortin$ are
availa*le in the Am*ient Air 0uality /onitorin$ at ES6AA+ reort rodued *y 6ahla
/edial Sulies (6ahla /edial Sulies, %!!@)5
In summary, the monitorin$ results demonstrated that 6>%1 hour and %4 hour avera$ed
onentrations, S>%1 hour and %4 hour avera$ed onentrations, and '> 1 hour and =
hour avera$ed onentrations were in omliane with their alia*le orresondin$
Am*ient Air 0uality Standards (AA0S)5
Bor >, the 1 hour avera$ed onentration was in omliane with the alia*le
orresondin$ AA0S5 8he = hour avera$ed onentration, however, e7eeded the
alia*le orresondin$ AA0S @, ", % and % times in /ay, 2une, 2uly and Au$ust %!!@
resetively5
Bor P/1!, %4 hour avera$ed onentration e7eeded the alia*le orresondin$A+6>' AA0S , %1, %%, 1= and " times in /ay, 2une, 2uly and Au$ust %!!@ resetively5
Aordin$ to the survey reort (6ahla /edial Sulies, %!!@), these e7eedanes an
*e attri*uted to a dust haCe eisode ourrin$ over the /iddle East durin$ the monitorin$
eriod5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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@)().) 'nvironmental Impact Prediction and 'valuation
@)().)() 'missions from #peration of 5uelConsumin 2e9icles and 'uipment
Construction
+urin$ the onstrution eriod, oeration of vehiles and onstrution e9uiment with
internal om*ustion en$ines will lead to e7haust emissions of om*ustion roduts
inludin$ 6>%, S>%, '> and P/1!5 Small amounts of volatile or$ani ar*on omounds
(F>') may also *e emitted from un*urned fuel in the e9uiment en$ine e7hausts or other
fu$itive emission soures suh as fuel ie fittin$s5
8he air emissions inventory for all onstrution ativities is resented in 8a*le 4-4 and 4-
#, in Setion 4551=5
+ue to the industrial nature of the Pro7*urners for its sin$le steam *oiler and flain$ unit that will
omly with EA+ e9uiment-seifi emission standards5 8he air emissions inventory for
all onstrution ativities is resented in 8a*le 4-4 and 4-#, in Setion 4551=5
/ost of the emission soures are not e7eted to have hi$h riteria or GHG emissions5
8he GHG emissions from these stas will *e mostly '>%and ne$li$i*le 9uantities of
/ethane durin$ ertain hases of the roess yle5 8he roess will also *e e9uied
for hydro$en ventin$ durin$ emer$enies5 8hese ventin$ events will *e of very *rief
duration and are not e7eted to have any si$nifiant imat on the air 9uality5
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
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8he rimary riteria air ontaminants of interest for the 'hlor-Alali Plant ro 7
and S>%, *oth of whih are om*ustion derived5 8he roosed 'hlor-Alali Plant will emit
an overall total of # tons 6>7Oyear and % tons S>%Oyear5 Sine the roosed ro
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suh as i$arettes as well as environmental fators suh as *uild-u of hi$h temeratures
within the hemials stora$e area due to hi$h am*ient temeratures5 Suh a situation
would lead to emission of tyial om*ustion roduts5
It is to *e noted, however, that air 9uality imats from any of the afore-mentioned events
would *e short-term in nature i5e5 only resent until the fire is e7tin$uished or the fuel runs
out5
8herefore, it is onsidered that the overall environmental imat to air 9uality in the
Pro
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8he &SEPA has determined that hlorine is not a ersistent ollutant, in that it hotolyCes
raidly to hydrohlori aid (H'l), a muh less to7i su*stane, followin$ the release5
'hlorine, as a owerful o7idiCer, attas the lun$s, ausin$ inflammation (neumonitis)
and fluid aumulation (ulmonary edema), and is intensely irritatin$ to the eyesM
rolon$ed andOor aute e7osure may *e fatal5 8a*le # -= *elow summariCes tyial
symtoms of e7osure to various onentrations of hlorine5
Ta;le @+: Summary of C9lorine &ealt9 'ffects
Concentration ppm in airE &ealt9 'ffects
1- m /ild muous mem*rane irritation
#-1# m &er resiratory trat irritation
! m Immediate hest ain, vomitin$, shortness of *reath(dsynea) and ou$h
4!-"! m Inflammation of lun$ tissues (to7i neumonitis) andfluid aumulation (ulmonary edema)
4! m +eath within ! minutes
1,!!! m +eath within a few minutes
8he Emer$eny Resonse Plannin$ Guideline ;evel % (ERPG-%) value for hlorine $as is
m, whih is set as end oint onentrations for hlorine $as lume durin$ emer$eny
resonse5
ERPG-% is the ma7imum air*orne onentration *elow whih it is *elieved that nearly all
individuals ould *e e7osed for u to one hour without e7erienin$ or develoin$
irreversi*le or other serious health effets or symtoms whih ould imair an individualLs
a*ility to tae rotetive ation5
8he Amerian Industrial Hy$iene Assoiation (AIHA) u*lishes ERPG levels for various
hemials (httOOwww5aiha5or$O'ommitteesOdoumentsOer$levels5df 5)5 If an EPRG-%
value has *een u*lished, the Emer$eny Resonse Guideline uses this num*er for
settin$ the Protetive Ation +istane (PA+)5 If an ERPG-% value has not *een
esta*lished, the PA+ is set at !5!1 7 ;ethal 'onentration (;') #!5
8he other useful e7osure limits for hlorine are resented *elow in 8a*le # -@.
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e #
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Ta;le @G: #t9er *seful 'posure !imits for C9lorine
Standard Settin Body Permissi;le 'posure6
ppmE
Description
6ational Institute of
>uational Safety and
Health (6I>SH)
!5# Reommended E7osure
;imit (RE;)
Amerian 'onferene of
Governmental Industrial
Hy$ienist (A'GIH)
!5# 8hreshold ;imit Falue (8;F)
8ime 3ei$hted Avera$e
(83A)
&N Health and Safety
E7eutive (HSE)
!5# ;on$-term e7osure limit (=
hour), >E;
&SEPA !5# Environmental air limit
>uational Safety and
Health Administration
(>SHA)
15! Permissi*le E7osure ;imit
(PE;)
6I>SH 15! Short 8erm E7osure ;imit
(S8E;)
A'GIH 15! S8E;
&N HSE 15! S8E;, >E;
6I>SH 1! Immediately +an$erous to
;ife or Health (I+;H)
8herefore, it is onsidered that the overall environmental imat to air 9uality in the
Pro
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*oth hases, as well as movement of flamma*le su*stanes off site5 In the events of a
fire ourrin$ due to an aident durin$ the deommissionin$ ativities, tyial
om*ustion roduts will *e emitted5 Similar to the onstrution hase, it is e7eted that
air 9uality imats from any of the afore-mentioned events would only our until the fireis e7tin$uished5
8herefore, it is onsidered that the overall environmental imat to air 9uality in the
Pro
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Some of these ativities will *e inluded under soe 1 if the ertinent emission soures
are owned or ontrolled *y the omany (e5$5, if the transortation of roduts is done in
vehiles owned or ontrolled *y the omany)5
GHG emissions from the 'hlor-Alali Plant will onsist rimarily of nominal 9uantities of
'>%5 '>% emissions from normal oeration of the natural $as fired units (*oiler and
flain$ unit) were estimated usin$ &SEPA AP-4% emission fators, and are rovided in
8a*le 4 -#and 8a*le 4 -"5 8hese estimates amount to a total of only ##%1 tOyear of '>%5
8his roortion is e7eted to *e si$nifiantly lower *ased on future estimates of national
'>%emissions when the 'hlor-Alali Plant is oerational5
Bu$itive emission of '>% is liely durin$ the urifiation of *rine with sodium ar*onate,
and it is estimated that 1! $m of ar*on dio7ide is released er ton of austi soda
rodution5 Bu$itive '>% emission is also liely from the hlorine destrution unit and
handlin$5
It is onsidered that the overall environmental imat to air 9uality in the Pro
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@)()1) "itiation "easures
@)()1)() Potential "itiation "easures
Impact
DescriptionP9ase
Score
Ris- Potential "itiation
Applica;le
'nvironmental
Standard / !imits
P
ro;a;ility
Co
nseuence
Emissions from
>eration of
Buel-'onsumin$
Fehiles and
Plant E9uiment
'onstrutionRare
/inor
!o=
Adot traffi routin$ to ma7imise travel on aved roads
wherever ossi*le5
Enfore seed restritions
Ensure minimiCation of dou*le-handlin$
Ensure wet suression of unaved routes
Ensure re$ular maintenane of onstrution mahinery
and vehiles to ensure effiient oeration
EA+ Am*ient Air
0uality Standards
for the Emirate of
A*u +ha*i
3H> Air 0uality
Guidelines %!!#
IB' EHS
Guidelines on Air
Emissions and
Am*ient Air
0uality %!!?
>eration;i1ely
/inor
!o=
Enfore seed restritions
Ensure minimiCation of dou*le-handlin$
Ensure re$ular maintenane of onstrution mahinery
and vehiles to ensure effiient oeration
Re$ular maintenane of the G8s aordin$ tomanufaturer seifiations to limit otential for non-
desi$n emissions due to malfuntion
+eommissionin$Rare
/inor
!o= Same as for the 'onstrution Phase
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e #&
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Impact
DescriptionP9ase
Score
Ris- Potential "itiation
Applica;le
'nvironmental
Standard / !imitsPro;a;ility
Conseuence
Emissions of
Greenhouse
Gases
'onstrution,
oeration and
deommissionin$;i1ely
Insi$nifiant
!o=
Ensure valves on refri$erant $as ylinders are normally
et shut
&se of alternate refri$erants that do not have a GHG
imat5
6ot Alia*le
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e #'
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Impact
DescriptionP9ase
Score
Ris- Potential "itiation
Applica;le
'nvironmental
Standard / !imitsPro;a;ility
Conseuence
Emissions from
Aidental
Events
'onstrutionRare
/inor
!o=
Ensure aroriate internal wirin$ is utilised in
onstrution mahinery and it is run aordin$ to the
manufaturerLs seifiations as well as re$ularlyinseted and maintained5
Preare a ro Air 0uality
Guidelines %!!#
IB' EHS
Guidelines on Air
Emissions and
Am*ient Air
0uality %!!?>eration
R
are
/
a
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PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e "!
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@)()1).) Selected "itiation "easures
'missions from #peration of 5uelConsumin 2e9icles and 'uipment
+onstruction
8he overall otential for si$nifiant adverse imats from onstrution-$enerated dust is
onsidered to *e unliely due to the followin$ reasons
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sru**er to rodue sodium hyohlorite5 8he hlorine a*sortion unit will *e desi$ned
with a treatment aaity suffiient to a*sor* the full ell-room rodution in the event of
emer$enies5
8he hlorine a*sortion unit will lower the hlorine ontent in the emitted $as durin$
oeration to less than 15?% mv (# m$O6m) in the worst-ase senario omared to %!
mv of &SEPALs ermissi*le limits - /a7imum Ahieva*le 'ontrol 8ehnolo$y (/A'8)5
In addition, the emitted H'l vaour will *e less than "5?! mv (1! m$O6 m) in the worst-
ase senario omared to 1% mv of &SEPALs ermissi*le limits (/A'8) 5
All of the hydro$en $as rodued durin$ eletrolysis of salt in the rodution will *e used
onsite as hemial feedsto for rodution of H'l in the H'l synthesis unit5 8he
hydro$en $as will *e safely handled in the rodution of H'l *y rovidin$ an emer$eny
vent in the roess line5 8he entire vent system will *e desi$ned to inlude a flame sensor
and a steam and nitro$en ur$in$ mehanisms5 In addition, the roess safety reliefvalves will *e onneted to vent system, and durin$ roess uset, these safety relief
valves will *e ativated for ventin$ the hydro$en $as to avoid unsafe onditions5 8he
'hlor-Alali Plant will also install hydro$en $as holder in the system to minimiCe the
roess usets and to redue ventin$5
+urin$ loadin$ of austi and 6a>'l, fu$itive emissions are not antiiated5 However,
fu$itive emissions are liely durin$ H'l loadin$5 A small sru**in$ unit with an effiieny
of @#Q will *e rovided to ontrol these fu$itive emissions durin$ H'l loadin$5
E7eted H'l onentration at the loadin$ area will *e less than !5!m (!5!# m$Om )
and the H'l onentration in the sru**er outlet durin$ loadin$ oeration will *e
aro7imately !51? m (!5%# m$Om)5
In summary, the air emissions under normal oerations for the Al Ghaith 'hlor-Alali
ro
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However, the *est form of miti$ation would *e to utiliCe alternate refri$erant $as that does
not have a GHG imat5
'missions from Accidental 'vents
+onstruction
8he EP' Site Environmental /ana$er will ensure that aroriate internal wirin$ is
utilised in onstrution mahinery and it is run aordin$ to the manufaturerLs
seifiations in order to redue the otential for a fire ourrin$ due to a short-iruit and
therefore the resultin$ om*ustion emissions5 Additionally, it will also *e ensured that the
mahinery is re$ularly inseted and maintained in order to redue the otential for non-
desi$n erformane of the e9uiment and therefore resultin$ hi$her diret e7haust
emissions5
8he EP' Site Environmental /ana$er will also ensure that flamma*le hemials on siteare temorarily stored in aordane with the manufaturerLs and /S+S re9uirements, in
order to redue the otential for an aidental fire ourrin$5
As a further fire reventative measure, the EP' Site Environmental /ana$er will also
enfore an indoor no-smoin$ oliy within the site *uildin$s (i5e5 offies) to redue the
otential for human-indued fires ourrin$5 Relevant emloyees will also *e trained in
the measures to *e followed in ase a fire *reas out so that it an *e ontrolled soon
after *rea-out and the ris to emloyeesL health redued5
8he EP' Site Environmental /ana$er will also reare a ro
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E7ess hlorine vented to the sru**er an delete the ative sru**in$ material and
ause over-hlorination of the sru**er5 8his will result in release of to7i hlorine $as5
8herefore, ative safe$uards will *e inororated within sru**in$ mehanism to avoid
over-hlorination5
Bollowin$ ative safe$uards will *e inluded in the sru**ers to revent over-hlorination
Emer$eny and automati shut-off of hlorine uon hi$h >7idation-Redution
Potential (>RP) alarms5 >RP will tra the onentration of austi in the
sru**er li9uidM
Automati or remote austi in
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@)()4) "onitorin Proram
@)()4)() "onitorin Proram for Compliance =it9 Selected "itiation "easures
'missions from #peration of 5uelConsumin 2e9icles and Plant 'uipment
Project P9ase "onitorin Activity 5reuency Responsi;ility Reportin
'onstrution
Site traffi usin$ aved roads +ailyEP' Site Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
Site traffi followin$ seed restritions +ailyEP' Site Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
3et suression of unaved roads +ailyEP' Site Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
/aintenane of site vehiles and
onstrution mahinery/onthly
EP' Site Environmental
/ana$er
3eely Environmental Insetion
'helist,
0uarterly Environmental Audit
Reort
>eration
Site traffi followin$ seed restritions +ailyAl Ghaith Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
+ou*le-handlin$ of vehiles minimiCed +ailyAl Ghaith Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
/aintenane of site vehiles and lant
mahinery/onthly
Al Ghaith Environmental
/ana$er
3eely Environmental Insetion
'helist,
0uarterly Environmental Audit
Reort
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e "#
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Project P9ase "onitorin Activity 5reuency Responsi;ility Reportin
+eommissionin$
Site traffi usin$ aved roads +aily
Al Ghaith Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
Site traffi followin$ seed restritions +aily
Al Ghaith Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
3et suression of unaved roads +aily
Al Ghaith Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental Insetion
'helist
/aintenane of site vehiles and
onstrution mahinery/onthly
Al Ghaith Environmental
/ana$er
3eely Environmental Insetion
'helist,
0uarterly Environmental Audit
Reort
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e ""
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'missions of %reen9ouse %ases
Project P9ase "onitorin Activity 5reuency Responsi;ility Reportin
'onstrutionShuttin$ off safety valves on refri$erant
$as ontainin$ ylinders+aily
EP' Site
Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental
Insetion 'helist
>erationGas *oiler stas emissions
- 'onentrations of '>%0uarterly
Al Ghaith
>erations /ana$er
0uarterly Environmental Reort
to EA+
+eommissionin$Shuttin$ off safety valves on refri$erant
$as ontainin$ ylinders+aily
Al Ghaith
Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental
Insetion 'helist
'missions from Accidental 'vents
Project P9ase "onitorin Activity 5reuency Responsi;ility Reportin
'onstrutionAroriate internal wirin$ utiliCed in
onstrution mahinery3eely
EP' Site
/aintenane
'oordinator
3eely Bield /aintenane
Reort
/aintenane of site vehiles and
onstrution mahinery/onthly
EP' Site
Environmental
/ana$er
3eely Environmental
Insetion 'helist,
0uarterly Environmental Audit
Reort
Blamma*le hemials aroriately
stored+aily
EP' Site
Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental
Insetion 'helist
Indoor no-smoin$ oliy enfored +aily EP' Site
Environmental
/ana$er
+aily Bield HSE Reort,
3eely Environmental
Insetion 'helist
PEHSR Chlor-Alkali Plant
Al Ghaith Industries
Project Number 441!!"#
Pa$e "&
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Project P9ase "onitorin Activity 5reuency Responsi;ility Reportin
Bire resonse roedure doumented
and relevant emloyees trained in it0uarterly
EP' Site
Environmental
/ana$er
0uarterly Environmental Audit
Reort
>eration
'ontrolled Aess of lant
ersonnelOvisitors to site+aily
Al Ghaith
Environmental
/ana$er
6OA
Aroriate Plant +isaster /ana$ement
Plan imlemented>ne
Al Ghaith Healthand Safety
/ana$er O Al
Ghaith E7eutive
/ana$ement
Proess O >erational Proedure
+oumentation
Bire resonse roedure doumented
and relevant emloyees trained in it0uarterly
Al Ghaith
Environmental
/ana$er
0uarterly Environmental Audit
Reort
+eommissionin$
Aroriate internal wirin$ utilised in
ontration mahinery3eely
EP' Site
/aintenane
'oordinator
3eely Bield /aintenane
Reort
/aintenane of site vehiles and
onstrution mahinery/onthly
EP' Site
Environmental
/ana$er
3eely Environmental
Insetion 'helist,
0uarterly Environmental Audit
Reort
Blamma*le hemials aroriately
stored+aily
EP' Site
Environmental
/ana$er
+aily Bield HSE