JSC Ulba Metallurgical Plant Experience from Operation with

JSC “Ulba Metallurgical Plant” Experience from Operation with Beryllium V. Savchuk, Ph. D JSC “Ulba Metallurgical Plant” 070005, 102, Abay Ave, Ust-Kamenogorsk, Kazakhstan Tel: (7232) 298219 Email: Savchuk. VV@ulba. kz

JSC “Ulba Metallurgical Plant” Beryllium Production at UMP Hydrometallurgical Production of Be hydroxide from ore concentrates Metallurgical Production of Be ingots, Be alloys and master alloys based on Al, Cu and Ni Production of Structural Be (powder, compact billets, finished products)

JSC “Ulba Metallurgical Plant” Beryllium Products Be Ingots Cu. Be Master Alloy

JSC “Ulba Metallurgical Plant” Beryllium Billets VHP Billet CIP Forging Powder Forging

JSC “Ulba Metallurgical Plant” Finished Be Products Reflector for Russia Reflector for Japan

JSC “Ulba Metallurgical Plant” Experimental Be Products Be 17 Ta 2 Be-Cu-SS

JSC “Ulba Metallurgical Plant” Technological processes Casting of Cu. Be Master Alloy Hot Forging Billet from Be Powder

JSC “Ulba Metallurgical Plant” Machining of Be Turning Trepanning Drill Boring

JSC “Ulba Metallurgical Plant” Equipment of Be Production Electro Arc Furnace Vacuum Refining Induction Furnace for Semicontinuous Casting

JSC “Ulba Metallurgical Plant” Equipment of Be Production Cold Isostatic Press Vacuum Hot Pressed Furnace Hot Isostatic Press

JSC “Ulba Metallurgical Plant” Equipment of Be Production Hydraulic Presses for Hot Forging and Extrusion (capacity 600 -800 ton) Hydraulic Press for Hot Forging and Extrusion (capacity – 7500 ton)

JSC “Ulba Metallurgical Plant” Packing of Ве Products Production area, where beryllium products are packed, are equipped with input and exhaust ventilation; When packing beryllium products, production personnel has appropriate personal protection equipment; Beryllium products as powder, ingots, pieces, articles, waste are packed: n into inner package - polyethylene (polypropylene) bag; n the inner package is placed into metal and polypropylene drums, wooden cases. Type and design of the shipping package and requirements to the products are defined in supply contracts, where it is possible, if agreed with the customer, to use different package ensuring products safety; Vacuum and inert gas packaging is applied sometimes.

JSC “Ulba Metallurgical Plant” Packing of Be Products Be Hydroxide Cu. Be Master Alloy Cu. Be Slabs

JSC “Ulba Metallurgical Plant” Potential Health Effects Inhaling particulate containing beryllium may cause a serious, chronic lung disease called Chronic Beryllium Disease (CBD) in some individuals. Ingestion can occur from hand, clothing, food and drink contact with particulate during hand to mouth activities such as eating, drinking, smoking, nail biting, etc. The health effect of ingestion of beryllium in the form found in this product is unknown. Skin. Particulate that becomes lodged under the skin has the potential to induce sensitization and skin lesions. Eyes. Exposure may result from direct contact with airborne particulate or contact to the eye with contaminated hands or clothing. Damage can result from irritation or mechanical injury to the eyes by particulate

JSC “Ulba Metallurgical Plant” Governmental Regulation The working personnel should have the medical admission for works with Beryllium; The working personnel and visitors should be instructed on security measures at works with Beryllium; The administration should provide the personnel and visitors with the special clothes, footwear and other means of an individual protection; Shift duration should be no more than 6 -8 hours per day and 36 hours per working week; The enterprise should carry out the control over working conditions and a state of environment, including: 1) Content of Be in air of a working zone and a state of environment (air and water); 2) Ventilation overall performance; 3) Be impurity of scrap metal; 4) Light exposure, noise level and vibrations on workplaces; 5) Microclimate parameters on workplaces (humidity, temperature).

JSC “Ulba Metallurgical Plant” Medical Requirement Any person starting work with Beryllium shall have a medical examination: X-ray study; Total blood and urine analysis; Lung function test; Electrocardiogram test; Inspection at practitioners: ophthalmologist, dermatologist, neurologist, otolaryngologist, dentist, allergist and gynecologist for women. Based on the examination results therapist shall make up a summary and, if necessary, require additional examination by the professional pathologist, cancer specialist and hematologist. Further all workers should pass such medical examination annually.

JSC “Ulba Metallurgical Plant” Governmental Regulation. Permissible Limit of Be Concentration Object Air of Production Area Atmospheric air Water Surfaces into Production Rooms: Smooth Surfaces (metal, oil color, enamel, etc. ) Porous Surfaces (brick, concrete, etc. ) Unit Value (no more) μg/m 3 1, 0 μg/m 3 0, 01 μg/l 0, 3 mg/m 2 2, 0 mg/m 2 5, 0 Surfaces into office buildings and personal service rooms Recycle Scrap (steel, non ferrous metals, etc. ) Working Clothes: Synthetic outwear Cotton outwear Underwear Safety Shoes mg/m 2 0, 5 mg/m 2 mg/m 2 5, 0 1, 0 2, 5 0, 5 2, 0

JSC “Ulba Metallurgical Plant” Zones of Be Manufacture Sanitary Zone. Access to production areas of Beryllium Production in street clothes is prohibited, wearing special working clothes and shoes is mandatory. Special working clothes include underclothing, a suit made of blended fabric, socks, a cap, cotton gloves, and special working shoes. The first zone is zone of permanent stay of the personnel as well as location of devices and equipment designated for monitoring and control of the technological process. The second zone is for repair and transportation, limited stay of the personnel. It serves for transport of the raw material and the finished products. Access to the first and the second zones is allowed only for those wearing additional PPE. The third zone is designated for the process equipment. Depending on the process purpose and nature, the equipment should be located in canyons, boxes, chambers, etc. Permanent stay of the personnel in this zone is prohibited.

JSC “Ulba Metallurgical Plant” Respiratory Protection and Protective Clothing Respirator Lepestock (Leaf) - 200

JSC “Ulba Metallurgical Plant” Zones of Be Manufacture The Sanitary Zone includes: Input room 1 for street clothes and shoes; Input room 2 for clean work undress, outwears and respirator; Input room 3 for safety boots and entry into Production Zone 1; Output room 1 for take off safety boots and work outwears; Output room 2 for strip of the skin and take off respirator; Output room 3 - shower room and steam bath (sauna) for sweating and cleaning skin Going in Input room 1 of the Sanitary Zone

JSC “Ulba Metallurgical Plant” Exhaust and Input Ventilation All working areas should be equipped with the exhaust and input ventilation; The air should flow from cleaner rooms to dirtier rooms; The possibility of dirty air penetration into input systems should be excluded; The choice of air cleaning method depends on the character of different technological processes. Should be minimum two cleaning steps; As the last step of cleaning the filters with the degree of purification minimum 99. 99% are used; Gas and dust cleaning equipment is located at the isolated areas and separate buildings; All filtering, gas and dust cleaning systems should be made from noncombustible or flame-resistant fabric; The local and general exhaust ventilation systems should be equipped with redundant fans.

JSC “Ulba Metallurgical Plant” Filtering Equipment

JSC “Ulba Metallurgical Plant” Obligatory Documentation for the Ventilation and Filtering Systems The Documentation included: Logbook the maintenance instruction and to repair of the systems; The instructions of technology and repair of the systems; The schedules of air pipes cleaning and replacement of solutions in wet cleaning systems; The schedules of the repair works; Passports of all ventilation systems with layout schemes of air pipes; The operation of the ventilation and cleaning systems is monitored for efficiency during the process of exploitation according to the schedules, approved by technical manager of the company. The results of the inspection are executed as a certificate and are registered in the passport of the system.

JSC “Ulba Metallurgical Plant” Monitoring of Air in the Work Places We use two ways: Continuous sampling during one shift with using the fixed sampling devices; Short-time sampling with using portable aspiration devises; Short-time sampling is applied for auxiliary rooms and workplaces examinations; Beryllium emission rate through stationary sources (after cleaning in gas treatment units) is monitored daily; Records on beryllium concentration in the air of the working areas are stored for 45 years, those on beryllium emission through SSE are kept for 5 years.

JSC “Ulba Metallurgical Plant” Portable Aspiration Devices

JSC “Ulba Metallurgical Plant” Beryllium Cleaning Techniques The Beryllium Production area is maintained clean and cleaned of production waste on regular basis. Wet clearing of floors in working areas be done on shift basis. Full wet cleaning of the equipment, walls, ceilings and etc. becomes two times a month Vacuum cleaning devices must be used for remove dust, powder, chips and others dry Be products from surfaces. The floor contamination level should not be higher than the maximum permissible level after the cleaning. Use vacuum cleaners with high efficiency particulate air. All electrical systems should be de-energized, as necessary, before beginning wet cleaning. Do not use compressed air, brooms, or conventional vacuum cleaners to remove a dust from a surface as this activity can result to air pollution of Be.

JSC “Ulba Metallurgical Plant” Safety Signs There are specific markings on entry points. These requirements have become established by Kazakh government. As we have many production lines (chemical, metallurgy, powder production, machine working and etc. ) so we use many different signs. Safety prohibiting signs Warning signs Ordering signs Fire safety signs Evacuation, medical and sanitary signs Information signs

JSC “Ulba Metallurgical Plant” Thank you for attention