(MERAF) for the Base Metals Smelting Sector - CCME

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Figure 8: Inco Thompson Nickel Refinery Matte Anodes Scrap Matte Separation and Grinding Spent Anodes Electrorefining Nickel Cathodes Cathode Cleaning and Shearing Nickel To Markets Anolyte Anode Sludge To Smelter Hydrogen Sulphide Copper Residue Copper/Arsenic Removal Revert to Smelter Sulphuriic Acid, Air Nickel Replenishment Purified Electrolyte Chlorine Cobalt/Iron Removal Basic Nickel Carbonate Cobalt/Nickel/Iron Residue Chlorine, Soda Ash, Sulphuric Acid, Sulphur Dioxide Cobalt Purification Cobalt Oxide To Market Iron Hydroxide To Smelter 64
3.2.5. Falconbridge Limited, Kidd Metallurgical Division, Timmins, Ontario 83 Figure 9, Figure 10, and Figure 11 contain schematic block flow diagrams for the Zinc Plant, Copper Smelter and Copper Refinery respectively. Each shows the general sequence of the major unit operations in each facility, from the receipt of raw materials to the production of metals. When these unit operations are referred to in the text, the corresponding words starts with an upper case letter. These diagrams are highly simplified and are included solely to aid in the discussion and understanding of the pollution control at the facility. 3.2.5.1. Zinc plant The Zinc Plant which began operation in 1972, is based on standard electrolytic zinc plant technology. Zinc concentrates are first roasted in two standard Lurgi fluid bed roasters to remove the sulphur and produce a calcine (primarily zinc oxide). The sulphur in the concentrate is converted to sulphur dioxide (SO 2 ) and collected in the off-gas. The off-gas is cleaned, dried and sent to the (Roaster) Acid Plant where it is converted to sulphuric acid. The Acid Plant is a Monsanto single-absorption plant with a design conversion efficiency of approximately 98%. After the roasting process, the calcine is leached with sulphuric acid to dissolve the zinc and the resultant zinc sulphate solution is further treated to remove impurities. Iron, which is co-extracted with the zinc, is precipitated as sodium jarosite and sent to tailings for disposal. Recovery, purification, melting and casting of cadmium metal also takes place in the Zinc Leach Plant. The zinc sulphate solution (neutral solution) is then cooled and pumped to storage tanks, from which it is fed continuously to the circulating electrolyte in the Electrolytic Cellhouse. In the electrowinning process, direct current is applied, forcing the zinc to deposit onto aluminum cathodes. The cathodes are then removed from the cells and the zinc is stripped off. The zinc sheets are then melted in one of two induction furnaces and cast into either 25 kg slabs or jumbos weighing in excess of one tonne. In 1983/84 a pressure leach system was installed to increase the capacity of the Zinc Plant. This system utilizes oxygen and high temperature in an autoclave to directly produce zinc sulphate from the zinc concentrate, thus eliminating the need for roasting. Approximately 20% of the zinc concentrate is processed using this system. Both the residue and the zinc solution from this circuit are routed to the conventional circuit for final treatment. 83 Hatch Associates, Review of Environmental Releases for the Base Metals Smelting Sector, prepared for Environment Canada, dated November 2000 65
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FINAL REPORT Multi-pollutant Emissi
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Acknowledgments The principal autho
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Summary The purpose of the report i
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• Recommendations to address info
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• The Minerals and Metals Foundat
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The next series of tables illustrat
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1,800.00 1,600.00 1,400.00 1,200.00
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S.4 Current emission management pra
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− The EPA has started developing
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T.1 Technical Options for Emission
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The predicted future releases and t
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Noranda Gaspé Rest of Sector** Sit
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Recommendation #3 It is also recomm
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2.4.8. Leaching ...................
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4.1.11.6. Mercury..................
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Figure 35: 2000 Nickel - Air Emissi
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Table 34: World Bank Guidelines for
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1. Introduction The purpose of the
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strong surrogate for fine particles
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• These sectors are common to mos
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(a) have or may have an immediate o
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2. INDUSTRY PROFILE 2.1. Sector Def
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2.3. Base Metals Smelting Processes
Page 51 and 52: 2.3.1. Pretreatment Pretreatment of
Page 53 and 54: Metallic impurities either dissolve
Page 55 and 56: 2.4. Environmental Concerns 29 The
Page 57 and 58: sulphur dioxide in the off-gases th
Page 59 and 60: 2.5. Canadian Base Metals Smelters
Page 61 and 62: ammonium sulphate fertilizers. The
Page 63 and 64: The copper smelter uses pyrometallu
Page 65 and 66: copper, zinc, cadmium and indium, a
Page 67 and 68: 2.6.6.2. Noranda Inc., Division CEZ
Page 69 and 70: 2.7. Key Industrial Associations Ex
Page 71 and 72: In terms of tonnage, zinc ranks fir
Page 73 and 74: Table 4: Canadian Base Metals Expor
Page 75 and 76: ased 62 pricing system. In response
Page 77 and 78: The LME has a multi-tiered membersh
Page 79 and 80: The BMSS IT held ten meetings betwe
Page 81 and 82: 3.1.1.2. Smelters Emissions Testing
Page 83 and 84: achieve their commitments, are publ
Page 85 and 86: All the companies mentioned in this
Page 87 and 88: emoved for processing in the Copper
Page 89 and 90: Lead Concentrate Zinc Residue Lead
Page 91 and 92: 3.2.2. Sherritt International Corpo
Page 93 and 94: 3.2.2.5. Cobalt conversion and redu
Page 95 and 96: Figure 4: Sherritt Metals Refinery
Page 97 and 98: The blister copper is then treated
Page 99 and 100: Figure 6: Hudson Bay Mining and Sme
Page 101: Figure 7: Inco Thompson Nickel Smel
Page 105 and 106: electrostatic precipitator dust fro
Page 107 and 108: Figure 10: Falconbridge Kidd Copper
Page 109 and 110: 3.2.6. Falconbridge, Sudbury Divisi
Page 111 and 112: Figure 12: Falconbridge Sudbury Nic
Page 113 and 114: from the fluid bed roasters are tre
Page 115 and 116: Figure 14: Inco Copper Cliff Nickel
Page 117 and 118: 3.2.8. Inco Port Colborne 87 Figure
Page 119 and 120: 3.2.9. Noranda Inc., Horne Smelter,
Page 121 and 122: Figure 17: Noranda Horne Copper Sme
Page 123 and 124: Figure 18: Noranda CEZ Zinc Plant T
Page 125 and 126: Fugitive emissions from the TBRC op
Page 127 and 128: 3.2.12. Noranda Inc., Division Mine
Page 129 and 130: Figure 20: Noranda Gaspé Copper Sm
Page 131 and 132: with water to preserve the environm
Page 133 and 134: 3.3. Analysis of Emissions 3.3.1. T
Page 135 and 136: Table 6: Historical Trends of Total
Page 137 and 138: Table 8: Historical Trends of Arsen
Page 139 and 140: Table 10: Historical Trends of Lead
Page 141 and 142: Table 12: Historical Trends of Nick
Page 143 and 144: 350 300 250 200 150 100 Total Secto
Page 145 and 146: 1,400.00 1,200.00 1,000.00 800.00 6
Page 147 and 148: Table 13: Releases of Dioxins and F
Page 149 and 150: 3.4. Other Current Emissions Inform
Page 151 and 152: Sulphur Dioxide - Air EPI 4500 4000
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Cadium - Air EPI 0.2 0.15 0.1 0.05
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Mercury- Air EPI 9 8 7 6 5 4 3 2 1
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4. CURRENT EMISSION MANAGEMENT PRAC
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The “Alberta Ambient Air Quality
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4.1.9. New Brunswick New Brunswick
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4.1.11.1. Particulate Matter Table
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Table 15: Canadian Ambient Particul
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Sulphur Dioxide Releases from Coppe
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4.1.11.3. Arsenic Table 18 shows th
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4.1.11.5. Lead Table 22 shows the C
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4.1.11.6. Mercury Table 24 shows th
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4.1.11.7. Nickel Table 26 shows the
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New Source Performance Standards (N
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Table 31: US National Emission Stan
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In the permitting process, faciliti
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Table 34: World Bank Guidelines for
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4.2.4. Australia Air quality is con
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Table 39: Australia/New South Wales
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4.2.5. Japan Environmental quality
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Sulphur dioxide, particulate matter
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Table 47: Germany Particulate Matte
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Table 51: The Netherlands Sulphur D
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Table 53: France Particulate Matter
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The Environment Protection (Prescri
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Table 60: United Kingdom Releases t
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4.2.12. Other European Countries Ta
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4.3. Best Available Techniques for
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4.4. Options and Preliminary Cost E
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plant. It would be possible to inst
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4.4.2. Inco Limited, Thompson Divis
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4.4.3. Falconbridge, Sudbury Divisi
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4.4.4. Inco Limited, Sudbury/Copper
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4.4.5. Noranda Inc., Horne Smelter,
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4.4.6. Noranda Inc., Division Mines
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Table 78: Technical Options for Emi
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Site Option for Reduction By 2008 O
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Site Option for Reduction By 2008 O
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Noranda Horne Site Option for Reduc
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5. CONCLUSIONS AND RECOMMENDATIONS
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Appendix A: Health and Environmenta
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List of Acronyms AAQ AAQC ARET BACT
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UN/ECE URL USEPA VCR VOC United Nat
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at the anode and selectively plates
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Sinter: Slag: Slag cleaning: Top Bl
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(MERAF) for the Base Metals Smelting Sector - CCME

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