JSC “Ulba Metallurgical Plant”
Experience from Operation with Beryllium
V. Savchuk, PhD
JSC “Ulba Metallurgical Plant”
070005, 102, Abay Ave,
Ust-Kamenogorsk, Kazakhstan
Tel: (7232) 298219
Email: [email protected]
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
Be Ingots
CuBe 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
Be17Ta2
Be-Cu-SS
JSC “Ulba Metallurgical Plant”
Technological processes
Casting of CuBe 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
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:

into inner package - polyethylene (polypropylene) bag;

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
CuBe Master Alloy
CuBe 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 the 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.)
Surfaces into office buildings and personal service
rooms
Recycle Scrap (steel, non ferrous metals, etc.)
Working Clothes:
Synthetic outwear
Cotton outwear
Underwear
Safety Shoes
Unit
μg/m3
μg/m3
μg/l
Value (no more)
1,0
0, 01
0, 3
mg/m2
mg/m2
2,0
5,0
mg/m2
0,5
mg/m2
5,0
mg/m2
mg/m2
mg/m2
mg/m2
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