The present study was undertaken to investigate the effect of raw materials on PCDD/F emission from secondary aluminum smelters (ALS). Four plants each of aluminum ingot smelters (over 50% ingot) and secondary ALS (over 70% waste or recycled aluminum) were selected and the results compared. The secondary ALS yield much higher PCDD/Fs than the aluminum ingot smelters, or 7.94-22.76 ng/Nm(3) versus 0.57-2.67 ng/Nm(3), due to the large percentage of waste or recycled aluminum used. As for air pollution control devices (APCDs), the wet scrubber system in one of the aluminum ingot smelters exhibits an adverse effect on PCDD/F removal, due to the continuous recycle of the contaminated water through the scrubber system. Another ingot plant equipped with cartridge filter, there is a significant reduction in PCDD/F TEQ (52%). The powdered activated carbon injection at 2 kg/h (I 10 mg/Nm(3)) in one ALS reduces 70% of the total PCDD/Fs. The average emission factor of four secondary ALS is much higher than that of aluminum ingot smelters, or 20-fold higher based on either raw materials or product. Consequently, more attention should be paid to the emission reduction of PCDD/Fs from the secondary ALS, including installation of a secondary burner, additional APCDs and the pre-cleaning of raw materials. (c) 2007 Elsevier B.V. All rights reserved.