Alba’s Line 5 not only has the largest potline in the world, it is also environmentally the safest, thanks to the installation of a state-of-the-art double-duct system.

Each of the 336 cells or pots is connected to the Fumes Treatment Centre. There are two different aspects to keeping the environment clean from Potline 5 gases. One is the efficiency of capturing gases and the other is the efficiency of treatment.
“In conventional potrooms the concern is treatment efficiency, which measures the performance of their gas treatment centre; with the double-duct system you improve on the capturing efficiency, which makes sure you will not have fugitive fumes escaping from the roof,” explained Wajd Salah Ali Al Madani, Alba’s acting general manager for administration.
The cells have hoods that make sure all the fumes are captured. When an operation is performed on the pots, a few hoods have to be opened and some fumes escape outside. However the other duct ensues that the fugitive fumes are captured. “In this way we improve on capturing efficiency by more than 80 per cent,” estimates Al Madani.  It is for the first time that such a technology has been used in an AP30 potroom.
“We didn’t stop at the double duct. We installed a continuous roof monitoring system that enables us to instantaneously measure the fugitive fumes,” Al Madani explained.  “The roof monitoring system is at the potline and it tells if there’s a problem, which could occur when, for example, a hood is opened by mistake.
“Also, in addition to the roof monitoring, we have continuous monitoring on the inlet and outlet of the gas treatment centre.”
To meet international standards on dust control, six air-quality monitoring stations have been installed at various places. Four of these are at the southern end of the Alba complex and two at a nearby village. One of the six stations is continuously monitored while the others are monitored periodically.
Other environmental measures include introduction of the latest technology at the new power station. All the turbines have been equipped with low nitrous oxide emission burners. Additionally, combined cycle power stations have been installed to increase the efficiency of gas utilisation.
Among Alba’s facilities is a modern sewage treatment plant.
The company’s environmental accomplishments are in line with Bahrain’s and international regulatory authorities’ requirements. Before the construction of Potline 5, the company was required to obtain all the environment permits from a local authority. It conducted an environment impact analysis  (EIA) analysis, which studied all aspects of the expansion and its impact on the atmosphere, soil, water and so on. The study recommended several measures that Alba implemented, and, consequently, the company met the standards required by Bahrain and international environmental bodies. “Analysis after the construction of Potline 5 has shown Alba has not fallen behind in maintaining the required standards,” said Al Madani.
A full report and analysis is submitted to the local authority on a quarterly basis.
An Alba study also considered the requirements of the future Line 6 project and concluded it would have no negative effect on the environment.
Alba has also done well in controlling perfluorocarbon (PFC) pollution. In 2003 it engaged a consultant working with the London-based International Aluminium Institute, which has among its members all major smelters in the world. “The consultant did a full study on PFCs and concluded we are well within international standards and even ahead of many smelters in the world,” said Al Madani. He added that Alba had a plan to continuously reduce its PFCs by improving the technology of the processes used in the potrooms.
One indicator that the environment surrounding Alba is safe can be seen by the proliferation of a forest within the complex. The six-acre patch of trees lies on the southern border, which bears the brunt of winds moving north to south from the plant complex.  Wajd notes that humans have 16 times higher tolerance to fluorides than flora and fauna, so the presence of a flourishing forest indicates fluoride levels are safe.
The fruits from the forest are tested regularly in the laboratory and have shown to be cleaner or less contaminated than fruit available in the market. The vegetables find their way into the company cafeteria.
Since 1989 Alba has invested more than $500 million on environmental controls, and an example that it does not baulk at spending is a project at Power Station 3 to convert all the turbines to low nitrous oxide emissions. The project is a voluntary initiative and the company will be spending $26 million.
“The expenditure of $500 million was realised before any legislation, showing our pro-active approach to the environment and our commitment to utilise the latest technology in the field,” remarked Al Madani, who was a carbon project manager before assuming his present post. He started as a trainee engineer after completing his master’s in engineering from Duke University, US, and has worked in various departments including engineering, maintenance, potrooms, carbon and Potline 5 on his way to administration.
“Alba’s very aggressive plans have given employees the opportunity to get exposed to the latest technology and management systems. The company also has a strong commitment to training and development, which is reflected in the Bahrainisation level of 88 per cent,” he comments.