Case Study

Emissions control network at an aluminium plant in the Middle East

Aluminium company
Sector:

Need

A leading aluminium plant in the Middle East, with production capacity to supply markets in the United States, Europe and beyond, plays a key role in the global aluminium economy. Its complex industrial processes —including calcination plants and seawater desalination units— required effective internal controls to mitigate emissions.

The situation became more difficult because the regional environmental authority had very strict rules. They required regular checks and constant monitoring in all the industrial plants. The main elements measured were dust particles, gases (SOx, NOx, VOCs, H2S, CH4, HF, HCl) and heavy metals, all critical to ensure environmental safety.

In this context, the client needed a precise and reliable environmental monitoring solution, capable of demonstrating regulatory compliance, reinforcing its its commitment to sustainability and transparency, and operating under harsh local conditions such as high humidity and saline environments. Since installing reference stations was not enough, the company sought robust instruments adapted to the environment, capable of providing greater coverage and near-reference data quality and traceable according to international standards.

Thanks to the Kunak AIR Pro network of stations, the customer has managed to comply with strict environmental regulations while improving its internal processes and reinforcing its commitment to sustainability.
Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.Monitorización ambiental en planta de aluminio: cumplimiento normativo, datos en tiempo real y reducción del impacto.

Solution

To tackle this challenge, and in collaboration with Envipro, Kunak deployed a network of 13 Kunak AIR Pro stations, designed to monitor multiple pollutants with high precision. These devices, equipped with advanced sensors, enable continuous measurement of particulate matter, gases, and other key compounds, achieving strong correlations with nearby reference stations.

The company wanted robust instruments adapted to the environment, able to cover a wider area and provide data close to existing reference stations, traceable to international standards. In addition, automatic reporting tools were implemented to streamline communication with the environmental authority, ensuring regulatory compliance. To guarantee data security, all collected information is stored on a local server, providing the privacy required by the client.

Beyond meeting regulatory requirements, this customised network delivers real-time data to enhance decision-making and optimise internal processes.

The environmental monitoring project at the aluminium plant showcases how Kunak’s advanced technology can become a transformative solution for industry, ensuring compliance, driving efficiency, and contributing to the mitigation of environmental impacts.

Results

The deployment of the Kunak AIR Pro network has transformed the aluminium plant’s environmental monitoring strategy. Thanks to the near-reference accuracy of the stations, the client can now demonstrate to regulatory authorities an effective control of its emissions, ensuring compliance with the region’s strict environmental standards.

The data collected not only reinforces transparency and credibility, but also enables the identification of opportunities to improve internal processes, helping to reduce the environmental impact of operations.

Real-time monitoring, combined with automatic reporting tools, has significantly reduced the administrative workload and optimised data management. Moreover, the robustness of the sensors against humidity and salinity ensures uninterrupted monitoring even under extreme conditions.

Key benefits

  • Regulatory compliance: guaranteed adherence to strict environmental regulations.
  • Real-time monitoring: instant data for quick response and informed decision-making.
  • Process optimisation: greater operational efficiency and reduced emissions.
  • Automatic reporting: streamlined regulatory submissions, reducing administrative tasks.
  • Resilience in adverse conditions: robust and reliable sensors for humid and saline environments.
  • Privacy and security: local data storage, providing full control over information.

Project details

Customer: Aluminium company

User: Aluminium company

Location: Middle East

Sector:

Year: 2025

Parameters:

  • Particulate matter
  • Gases (SOx, NOx, VOC, H2S, CH4, HF, HCl)
  • Heavy metals
  • Wind speed and direction
  • Noise
  • Temperature, humidity, pressure, and dew point

Solutions

  • AIR ProProfessional air quality monitoring station
    Air quality monitor

    AIR Pro

    The most accurate air quality monitoring station

    SENSOR-BASED | BEST AVAILABLE ACCURACY

    Benefits

    • Multi-pollutant
    • Smart cartridge system
    • Fully autonomous
    • Real-time data
    • Proven accuracy
    See more
  • AIR CloudAir quality software
    Air quality software - Kunak AIR Cloud

    AIR Cloud

    Multipurpose air quality software for professionals

    REAL-TIME DATA | ALWAYS UPDATED

    Benefits

    • Secure and condifential
    • Air quality reporting
    • Advanced data analysis and visualisation
    • Reliable data guaranteed
    • Data sharing and integration
    See more
  • Particulate MatterReliable real-time data on suspended particles

    Particulate Matter

    Reliable information about particulate matter

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Optical particle counter
    • Up to R2 >0.9
    • Range: 0-1,000 | 0-2,000 | 0-10,000 ppb
    • Resolution: 1 μg/m3
    • 24 months of operating life
    See more
  • Sulphur dioxideReliable real-time data on SO2
    Sulphur_dioxide

    Sulphur dioxide

    Reliable information about sulphur dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.7
    • Range: 0-10,000 ppb
    • Resolution: 1 ppb
    • 24 months of operating life
    See more
  • Nitrogen dioxideReliable real-time data on NO2
    Nitreogen_dioxide

    Nitrogen dioxide

    Reliable information about nitrogen dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.85
    • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 24 months of operating life
    See more
  • Volatile organic compoundsReliable real-time data on VOCs
    Volatile_organic_compounds

    Volatile organic compounds

    Reliable information about volatile organic compounds

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Photoionization detector
    • R2 >0.99
    • Range: 0-3,000 ppb (Type A) | 0-40 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 10,000 hours of operating life
    See more
  • MethaneReliable real-time data on CH4

    Methane

    Reliable information about sulphur dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • NDIR
    • Typical accuracy (MAE): ±3 % F.S.
    • Range: 0-50,000 ppm
    • Resolution: 500 ppm
    • > 7 years of operating life
    See more
  • Hydrogen sulfide sensorReliable real-time data on H2S
    Hydrogen-sulfide

    Hydrogen sulfide sensor

    Reliable information about hydrogen sulfide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.8
    • Range: 0-2,000 ppb (Type A) | 0-20 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 24 months of operating life
    See more
Air quality monitor

AIR Pro

The most accurate air quality monitoring station

SENSOR-BASED | BEST AVAILABLE ACCURACY

Benefits

  • Multi-pollutant
  • Smart cartridge system
  • Fully autonomous
  • Real-time data
  • Proven accuracy
See more
Air quality software - Kunak AIR Cloud

AIR Cloud

Multipurpose air quality software for professionals

REAL-TIME DATA | ALWAYS UPDATED

Benefits

  • Secure and condifential
  • Air quality reporting
  • Advanced data analysis and visualisation
  • Reliable data guaranteed
  • Data sharing and integration
See more

Particulate Matter

Reliable information about particulate matter

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Optical particle counter
  • Up to R2 >0.9
  • Range: 0-1,000 | 0-2,000 | 0-10,000 ppb
  • Resolution: 1 μg/m3
  • 24 months of operating life
See more
Sulphur_dioxide

Sulphur dioxide

Reliable information about sulphur dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.7
  • Range: 0-10,000 ppb
  • Resolution: 1 ppb
  • 24 months of operating life
See more
Nitreogen_dioxide

Nitrogen dioxide

Reliable information about nitrogen dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.85
  • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 24 months of operating life
See more
Volatile_organic_compounds

Volatile organic compounds

Reliable information about volatile organic compounds

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Photoionization detector
  • R2 >0.99
  • Range: 0-3,000 ppb (Type A) | 0-40 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 10,000 hours of operating life
See more

Methane

Reliable information about sulphur dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • NDIR
  • Typical accuracy (MAE): ±3 % F.S.
  • Range: 0-50,000 ppm
  • Resolution: 500 ppm
  • > 7 years of operating life
See more
Hydrogen-sulfide

Hydrogen sulfide sensor

Reliable information about hydrogen sulfide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.8
  • Range: 0-2,000 ppb (Type A) | 0-20 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 24 months of operating life
See more