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HJ 1181-2021: (Guidelines for feasible technologies for pollution prevention and control in the automobile industry)
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(Guidelines for feasible technologies for pollution prevention and control in the automobile industry)
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HJ 1181-2021
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Standard similar to HJ 1181-2021 HJ 1347.1 HJ 1347.2 HJ 1346.1 Basic data | Standard ID | HJ 1181-2021 (HJ1181-2021) | | Description (Translated English) | (Guidelines for feasible technologies for pollution prevention and control in the automobile industry) | | Sector / Industry | Environmental Protection Industry Standard | | Word Count Estimation | 45,482 | | Issuing agency(ies) | Ministry of Ecology and Environment | HJ 1181-2021: (Guidelines for feasible technologies for pollution prevention and control in the automobile industry)
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(Guidelines for feasible technologies for pollution prevention and control in the automobile industry)
National Ecological Environment Standard of the People's Republic of China
Guidance on Feasible Technologies for Pollution Prevention and Control in the Automobile Industry
Guideline on available techniques of pollution prevention and control for
automotive industry
This electronic version is the official standard text, which is reviewed and typeset by the Environmental Standards Institute of the Ministry of Ecology and Environment.
Published on 2021-05-12
2021-05-12 Implementation
Released by the Ministry of Ecology and Environment
directory
Foreword...ii
1 Scope...1
2 Normative references...1
3 Terms and Definitions...2
4 Industrial production and generation of pollutants...4
5 Pollution Prevention Techniques...6
6 Pollution control technology...10
7 Environmental management measures...17
8 Possible technologies for pollution prevention...20
Appendix A (informative appendix) Auto industry product category, list of main products and parts and its process composition... 28
Appendix B (informative appendix) Automobile industry production process and main pollution-producing nodes... 29
Appendix C (Informative Appendix) Production Process of Main Products, Parts and Accessories of the Automobile Industry...31
Appendix D (informative appendix) Mass ratio of main components of coating materials in the automotive industry...33
Appendix E (informative appendix) Pollutant production concentration levels and emission methods of each process in the automobile industry...34
Appendix F (informative appendix) The main process composition of the spraying system in the coating process of the automobile industry...40
Appendix G (informative appendix) VOCs generation and emission levels per unit coating area of different products in the automotive industry...41
Guidance on Feasible Technologies for Pollution Prevention and Control in the Automobile Industry
1 Scope of application
This standard proposes feasible technologies for the prevention and control of exhaust gas, waste water, solid waste and noise pollution in the automobile industry.
This standard can be used as the environmental impact assessment of automobile industry enterprises or production facilities construction projects, the formulation and revision of national pollutant discharge standards, and the
A reference for licensing management and pollution prevention technology selection.
This standard does not apply to the pollution prevention and control of casting and electroplating processes in the production of the automobile industry.
2 Normative references
This standard refers to the following documents or clauses thereof. For dated references, only the dated version applies to this standard.
For undated references, the latest edition (including all amendments) applies to this standard.
GB 5085 Hazardous Waste Identification Standard
GB 8978 Integrated Wastewater Discharge Standard
GB 9078 Industrial Furnace Air Pollutant Emission Standard
GB 12348 Industrial Enterprise Boundary Environmental Noise Emission Standard
GB 14554 Emission Standard of Odor Pollutants
GB 16297 Comprehensive Emission Standard of Air Pollutants
GB 18484 Standard for Pollution Control of Hazardous Waste Incineration
GB 18597 Hazardous Waste Storage Pollution Control Standard
GB 18599 General Industrial Solid Waste Storage and Landfill Pollution Control Standard
GB 20952 Gas Station Air Pollutant Emission Standard
GB 24409 Limits of Hazardous Substances in Vehicle Coatings
GB 33372 Adhesive volatile organic compound limit
GB 34330 General Rules for the Identification Standard of Solid Waste
GB 37822 Volatile organic compound fugitive emission control standard
GB 38508 Cleaning agent volatile organic compound content limit
GB 50014 Design Specification for Outdoor Drainage
GB 50156 Specification for Design and Construction of Automobile Refueling Station
GB/T 3730.1 Terms and Definitions of Types of Automobiles and Trailers
GB/T 4754-2017 National Economic Industry Classification
GB/T 15089 Classification of Motor Vehicles and Trailers
GB/T 16758 Classification and technical conditions of exhaust hoods
GB/T 17350 Special Purpose Vehicles and Special Trailers Terminology, Codes and Compilation Methods
GB/T 38597 Technical requirements for coating products with low volatile organic compound content
GB/T 39198 General Solid Waste Classification and Code
GB/T 50934 Technical Specification for Anti-seepage of Petrochemical Engineering
3.4
special purpose vehicle
Vehicles equipped with special equipment and special functions, used to undertake special transportation tasks or special operations and other special purposes. Specialize
Vehicles are divided into van vehicles, tank vehicles, dump trucks, warehouse grid vehicles, hoisting vehicles, special structure vehicles, etc. special purpose car
It is generally manufactured on the basis of automobile chassis.
3.5
special purpose trailer
Trailers equipped with special equipment and special functions are used to undertake special transportation tasks or special operations and other special purposes. Specialize
Trailers are divided into van trailers, tank trailers, dump trailers, warehouse grid trailers, hoisting trailers, special structure trailers, etc. Special Trailer
It has the function of a special vehicle only in combination with a tractor.
3.6
parts and accessories
Including engine parts, trailer parts, auto parts and accessories, etc. From the aspects of structure, material, production process and fouling characteristics, it can be
Divided into assembly parts, riveting parts, core parts, brazing parts, resin parts, powder metallurgy parts and other parts
Components.
3.7
available techniques of pollution prevention and control
According to my country's environmental demand and economic level in a certain period of time, comprehensive use of pollution prevention technology and pollution control technology in the process of pollution prevention and control
technology and environmental management measures to stably meet the national pollutant discharge standards and large-scale application of technology.
3.8
spray system spray painting system
The general term for the combination of the same or dissimilar spray coatings to achieve the intended purpose and effect of spraying, including primers, primers, and paints
Spraying and drying of coatings such as (or natural topcoat) and varnish. Generally expressed in mCnB, where C and B respectively represent spraying operation and drying
operations, m and n represent the times of spraying and drying operations, respectively.
3.9
volatile organic compounds (VOCs)
Organic compounds participating in atmospheric photochemical reactions, or organic compounds determined according to relevant regulations.
When characterizing the overall emission of VOCs, according to industry characteristics and environmental management requirements, total volatile organic compounds (with TVOC) can be used.
expressed), non-methane total hydrocarbons (expressed as NMHC) as pollutant control items.
3.10
total volatile organic compounds (TVOC)
The specified monitoring method is used to measure the single VOCs substances in the exhaust gas, and the total amount of the VOCs substances is obtained by adding them up.
The sum of the mass concentrations of VOCs substances. In actual work, according to the expected analysis results, single-item VOCs accounting for more than 90% of the total should be analyzed.
Take the measurements and add up.
3.11
non-methane hydrocarbons (NMHC)
Using the specified monitoring method, the sum of the gaseous organic compounds, excluding methane, for which the hydrogen flame ionization detector responds, in terms of carbon mass
concentration meter.
3.12
oil mist
In the production process of automobile and engine parts, the volatilization of mineral oil used in wet machining, heat treatment of metal materials, etc.
The product of its thermal decomposition or cracking, its existence forms include vapor, droplet, etc.
3.13
Volatile organic compound emissions per unit coating area specific VOCs emission
In the painting process, the primer, putty, glue, solvent scrubbing, spraying, drying, waxing and repairing etc.
The cumulative VOCs emissions in the process and equipment cleaning, in g/m2.
3.14
VOCs-containing materials
This standard refers to raw and auxiliary materials, products and wastes (slag, liquid) with a mass proportion of VOCs greater than or equal to 10%, as well as organic polymer raw materials.
Auxiliary materials and waste (slag, liquid).
3.15
fugitive emission
Irregular emissions of air pollutants not through exhaust stacks, including open workplaces, and through crevices, vents, open doors and windows
and discharges like openings (holes), etc.
3.16
airtight closed/close
Contaminants are not in contact with the ambient air, or are isolated from the ambient air by sealing materials, sealing equipment, or operating methods.
3.17
closed space
A closed area or closed building formed by using a complete envelope to block pollutants, workplaces, etc. from the surrounding space.
Except for personnel, vehicles, equipment, and materials entering and leaving the closed area or closed building, as well as the exhaust pipes and vents established according to law, the doors and windows shall be closed.
Windows and other openings (holes) should be kept closed at all times.
4 Industrial production and generation of pollutants
4.1 Production process
4.1.1 The production process of the automobile industry includes blanking, forging, casting, stamping, machining, powder metallurgy, welding, riveting, resin fiber
There are 17 main production processes and
Two auxiliary production processes, such as industrial furnace and public environmental protection. For the product categories of the automobile industry, the list of main products and parts, and their process composition, see
Appendix A.
4.1.2 See Appendix B for the production process and main pollution-producing nodes of the automobile industry, and Appendix C for the production process of the main products, parts and accessories of the automobile industry.
4.1.3 The production raw materials of the automobile industry mainly include steel, resin materials, casting and forging blanks, and parts and accessories. steel including metal
Sheets, coils, profiles and ingots, etc. Resin materials mainly include resin particles, fiber materials and foam materials. Parts and Accessories Master
To include engine, transmission (box), motor, battery and tires, etc.
4.1.4 The production accessories for the automobile industry mainly include adhesive materials, welding materials, pretreatment materials, conversion coating treatment materials, coating materials,
Product test materials, product filling liquids and maintenance and repair materials for various mechanical equipment. The bonding material is mainly an adhesive (adhesive).
Welding materials mainly include various welding wires, electrodes and brazing materials. Chemical pretreatment materials mainly include chemical degreasing materials and hydrochloric acid, nitric acid
and other pickling materials. The conversion coating treatment materials mainly include surface conditioning agents, phosphating agents, passivating agents, silane treatment agents and zirconium treatment agents.
Coating materials mainly include primer, adhesive (weld sealant, primer coating, damping coating, skirt glue, etc.), putty, middle coating,
Paints, varnishes, natural topcoats, thinners, cleaning solvents and protective waxes, etc. The main components are shown in Appendix D. Product test materials are mainly steam
Oil, diesel and natural gas, etc. Product filling liquid mainly includes gasoline, diesel, antifreeze, gear oil, refrigerant and engine oil. Various machines
The maintenance and repair materials of mechanical equipment include solvent oil, anti-rust oil, engine oil, lubricating oil and hydraulic oil.
4.1.5 Fuels mainly include fuel oil and natural gas.
4.2 Generation of pollutants
4.2.1 Generation of exhaust pollutants
4.2.1.1 Cutting and blanking of medium and thick plates and profiles, mechanical pretreatment of workpieces, metal powder preparation and powder material transportation, arc welding, laser
Particles are generated during welding and seam grinding, dry machining of castings, body coating and putty grinding.
4.2.1.2 Oil mist is generated in the process of oil immersion, infiltration post-treatment, semi-dry and wet machining, and oil quenching heat treatment of powder metallurgy workpieces.
4.2.1.3 Trace amounts of hydrogen sulfide (H2S) and ammonia are produced by the leakage of atmosphere materials during heat treatment such as carburizing, nitriding, sulfurizing and carbonitriding
(NH3), the combustion of the atmosphere material produces a small amount of sulfur dioxide (SO2) and nitrogen oxides (NOx).
4.2.1.4 Chemical pretreatment Hydrochloric acid, sulfuric acid and nitric acid are used for pickling to produce hydrogen chloride (HCl), sulfuric acid mist and NOx respectively.
4.2.1.5 Particulate matter (mainly paint mist) and VOCs are generated in the painting process, among which the paint mist is generated in the spraying process, and the particulate matter is mainly generated in the
In the process of putty grinding, VOCs are mainly generated in the spraying, leveling/heat leveling and drying processes;
Solvent scrubbing, protective wax injection, paint film repair, paint residue treatment and drying, solvent cleaning of grids and tool carriers, cleaning and maintenance of spray booths, etc.
A small amount of VOCs are generated, and a small amount of VOCs are generated during the gluing process.
4.2.1.6 Processes such as injection, extrusion, foaming (including finished body cavity foaming), pultrusion, and resin fiber pasting produce a small amount of VOCs.
4.2.1.7 In the process of component assembly and product assembly, trace amounts of VOCs are generated during the use of adhesives.
4.2.1.8 Engine and vehicle factory inspection and product development The engine thermal test produces particulate matter, NOx and VOCs, etc.
4.2.1.9 Particulate matter, SO2 and NOx are generated in the workpiece heating furnace and oil and gas heating devices in forging, heat treatment and other processes.
4.2.1.10 See Appendix E Table E.1 for the production links, production levels and emission methods of waste gas pollutants in different processes.
4.2.2 Generation of wastewater pollutants
4.2.2.1 Die scrubbing in stamping process and parts cleaning in wet machining and assembly process produce high-concentration oily wastewater, powder metallurgy
The process of gold, quenching oil heat treatment, product testing and testing produces low-concentration oily wastewater, the main pollutants are petroleum, chemical oxygen demand (COD)
and suspended solids (SS).
4.2.2.2 The pickling process in the pretreatment process produces pickling wastewater, and the main pollutants are acids; the replacement of the degreasing tank liquid produces high-concentration degreasing
Wastewater, workpiece cleaning produces low-concentration degreasing wastewater, and the main pollutants are petroleum, COD, total phosphorus/phosphate and SS.
4.2.2.3 The surface adjustment of the workpiece in the conversion film treatment process produces phosphorus-containing wastewater, and the main pollutants are total phosphorus/phosphate; nickel-containing phosphating bath is replaced
High-concentration nickel-containing wastewater is produced, and workpiece cleaning produces low-concentration nickel-containing wastewater. The main pollutants are total nickel, total zinc, total phosphorus/phosphate; chromium-containing
Chromium-containing wastewater is produced from the cleaning of passivation workpieces, and the main pollutants are total chromium and hexavalent chromium;
Workpiece cleaning produces low-concentration fluorine-containing wastewater, and the main pollutant is fluoride.
4.2.2.4 The electrophoresis tank in the coating process is regularly cleaned to produce high-concentration electrophoresis wastewater, the workpiece cleaning produces low-concentration electrophoresis wastewater, and the workpiece is wetted.
Grinding produces grinding waste water, paint spraying waste water is produced in the wet separation process of paint mist in the spray booth, and cleaning waste water is produced in the grid and tool cleaning process.
The main pollutants are SS and COD.
4.2.2.5 The air humidity adjustment of the workshop central air-conditioning system, the process pure water, and the softened water preparation system produce production wastewater. The main pollutants are.
SS; The equipment cooling circulating water system produces production wastewater, and the main pollutants are SS and total phosphorus/phosphate.
4.2.2.6 Some plant areas such as chemical warehouses and wastewater treatment stations may generate polluted initial rainwater, and the main pollutants are COD, SS, etc.
4.2.2.7 The domestic sewage produced by the office, canteen and workshop living facilities in the factory area, the main pollutants are COD, ammonia nitrogen (NH3-N), total phosphorus/
Phosphate, animal and vegetable oils and SS, etc.
4.2.2.8 See Appendix E Table E.2 for the production links, production levels and discharge methods of wastewater pollutants in different processes.
4.2.3 Generation of solid waste
4.2.3.1 Metal scraps are produced in the blanking and stamping process. Dry machining produces dry metal chips. Wet Machining Produces Wet Metal Cuts
Chips (cutting fluid seeps out during natural storage) and waste cutting fluid, the cutting fluid filtration system produces waste filter material containing cutting fluid, and parts cleaning products
Raw wet metal chips. Wet metal chips are dehydrated to produce waste cutting fluid and dehydrated metal chips (pressed, filtered, filtered to remove oil to achieve no dripping after standing)
leaking metal chips).
4.2.3.2 Mineral oil-containing wastes (oil-containing rags and gloves, etc.) are generated by the scrubbing of workpieces in the processes of stamping, machining, and assembly. Oil Quenching Heat Treatment
Produces waste mineral oil. The process of honing, grinding and grinding produces waste mineral oil and sludge. Chemical degreasing tank fluid filtration system produces waste mineral oil and contains
Waste filter material for mineral oil. Regular maintenance and repair of mechanical equipment produces waste solvent oil, waste anti-rust oil, waste engine oil, waste lubricating oil, waste
Hydraulic oil and wipes containing mineral oil, etc.
4.2.3.3 Arc welding produces waste welding wire and solder, and brazing welding produces waste brazing materials. Welding, painting, assembly process bonding, sealing
and other processes produce waste adhesives. The resin fiber processing process uses acid, alkali or organic solvent to clean the container equipment to produce peeling resinous, viscous
Debris, waste resin produced during pasting process.
4.2.3.4 In the heat treatment process, cyanide is used for metal heat treatment to produce quenching pool residue, quenching wastewater treatment sludge, and cyanide-containing heat treatment furnace
The maintenance process produces waste lining, the heat treatment carburizing furnace produces heat treatment carburizing cyanide slag, and the metal heat treatment process salt bath (kettle) cleaning produces cyanide containing cyanide
Residues and cyanide-containing waste liquids, cyanide-containing residues are generated during cyanide heat treatment and annealing operations.
4.2.3.5 Waste acid is generated from the phosphating process pipeline cleaning in the conversion film treatment process. The filtration system of nickel-containing phosphating bath produces phosphating slag and nickel-containing waste
filter material. Zirconization and silane treatment produce a small amount of fluorine-containing waste residue.
4.2.3.6 In the painting process, the workpiece is scrubbed, the paint pipeline and spray gun are cleaned, and the equipment is cleaned to generate waste solvent. Paint mixing and spraying produce waste paint,
Waste thinner. The cleaning operation of the spray booth, the filter unit of the circulating air system of the spray booth, and the high-efficiency filter device for the exhaust gas paint mist containing VOCs, etc.
material waste. The paint mist control system in the spray booth produces paint residue, waste limestone powder, and waste filter materials, and the VOCs pollution control system produces VOCs containing VOCs.
waste activated carbon, waste molecular sieve and waste ceramic heat storage materials. Mercury-containing waste is generated when mercury-containing fluorescent tubes and other mercury-containing electric light sources are used in the painting process
thing. The body cavity is injected with protective wax to produce waste paraffin.
4.2.3.7 Assembly Process Battery assembly produces waste circuit boards and waste electronic plug-ins. The assembly process and public works generate waste battery cells, waste electricity
Pool bags and waste lead-acid batteries.
4.2.3.8 Asbestos-containing waste is generated during the production of vehicle brake linings. The dust removal system of each process produces dust dust, the bag type dust removal system and each
The central air conditioning system in the workshop produces waste filter material (filter bags, filter cartridges). Forging, heat treatment and other processes, workpiece heating furnace flue gas denitration, engine test
Test and product research and development of exhaust gas denitrification and other waste catalysts. Coal-fired industrial kilns produce coal ash slag.
4.2.3.9 Waste ion exchange resins are produced in the preparation of pure water, softened water and wastewater treatment in public works. Nickel-containing wastewater treatment produces nickel-containing sludge,
Chromium-containing wastewater treatment produces chromium-containing sludge, fluorine-containing wastewater treatment produces fluorine-containing sludge, and oil-containing wastewater treatment produces oil-containing scum and sludge. production waste
Water physicochemical treatment produces physicochemical sludge and activated carbon, comprehensive wastewater biochemical treatment produces biochemical treatment sludge, and advanced treatment produces waste activated carbon.
Ultrafiltration of waste cutting fluid produces waste concentrate (the main component is mineral oil). Pyrolysis of paint residues and paint-containing wastes produces residues and fly ash. raw material,
Chemical packaging and transportation generate waste packaging materials.
4.2.3.10 See Appendix E Table E.3 for the generation links and hazardous characteristics of solid wastes (including hazardous wastes) in different processes of the automobile industry.
4.2.4 Generation of noise
The noise in the production process of the automobile industry is mainly generated by production equipment (such as material, machining, stamping, welding, painting, assembly and inspection).
test equipment, etc.) and auxiliary production equipment (such as conveying machinery, pumps and fans, etc.).
5 Pollution Prevention Technologies
5.1 General principles
5.1.1 Automobile industry enterprises should optimize the design of automobile products, select clean raw and auxiliary materials on the premise of meeting the functional requirements of products, and do their best to
Reduce the number of coating jobs and film thickness.
5.1.2 Parts and accessories should be formed as far as possible with high utilization rate of raw materials, high dimensional accuracy, less processing volume in subsequent processes, and less energy consumption
Precision blanking and precision forming technologies, such as stamping, laser cutting, plasma cutting, precision casting, die forging, tire die forging, precision rolling, spinning
and powder metallurgy.
5.1.3 Resin materials, parts and accessories in production raw materials (mainly referring to lithium batteries for new energy vehicles), adhesive materials in production auxiliary materials,
And other production raw materials and production auxiliary materials made of fluororesin or fluororubber, and perfluorooctanoic acid (PFOA) and its salts are not used in the production process
class and related compounds.
5.1.4 Pretreatment process Chemical degreasing and conversion film treatment process should use low-phosphorus, non-toxic and harmless raw and auxiliary materials and energy-saving, water-saving, environmental protection
and other cleaner production processes. The coating process should choose the energy-saving coating process and technology based on the low VOCs content coating to improve the profit of raw and auxiliary materials.
usage rate.
5.1.5 A cascaded use and recycling system of water resources should be established.
The quantity and quality of water resources are matched with the quantity and quality of production water in each process link, so that the effluent from the previous process link is used as another process.
The water supply in the process or treated and reused inside the process to achieve optimal utilization of water resources.
5.2 Air pollution prevention technology
5.2.1 Raw and auxiliary materials and fuel substitution technology
5.2.1.1 Alternative technologies for high-solid solvent-based coatings
This technology is mainly suitable for the coating process of passenger cars, trucks and cabs, passenger cars and other stamped and welded parts. high solids solvent
Type coatings use organic solvents as dispersion medium, and use synthetic oligomers instead of natural or synthetic resins as film-forming substances to reduce the viscosity of coatings.
It is made by a certain paint matching process, supplemented by various pigments, fillers and auxiliaries. High solids solvent type
The coating should meet the product technical requirements of GB 24409 and GB/T 38597.
High-solids solvent-based coatings include high-solids solvent-based intermediate paints, high-solids solvent-based primers, and high-solids solvent-based natural finish
For paints and high-solid solvent-based varnishes, the mass proportion of VOCs is generally 30% to 45%, 40% to 58%, 30% to 50% and 35% to 48%.
Automobile industry enterprises use high-solid solvent-based coatings to replace solvent-based coatings, and the production of VOCs can generally be reduced by more than 20%.
5.2.1.2 Alternative technologies for water-based coatings
The technology is mainly suitable for the coating process of passenger cars, trucks and cabs, passenger cars and other stamped and welded parts. water-based paint
As a solvent or dispersion medium, natural or synthetic resins are used as...
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