(MERAF) for the Base Metals Smelting Sector - CCME

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Figure 11: Falconbridge Kidd Copper Refinery COPPER ANODES FROM SMELTER ELECTROLYTIC REFINING Copper Cathodes to Markets Scrap to Kidd Copper Smelter Slime SULPHURIC ACID Commercial Electrolyte ELECTROLYTIC RECIRCULATION Return Electrolyte PRIMARY LIBERATION Primary Liberator Cathodes To Markets SLIME SLURRY THICKENING Slimes ELECTROLYTE FILTRATION SECONDARY LIBERATION Secondary Liberator Cathodes To Kidd Copper Smelter COPPER REMOVAL ELECTROLYTE Electrolytic Bleed To Zinc Plant Hydrogen Peroxide SELENIUM LEACHING Selenous Acid NEUTRALIZING PLANT Soda Ash SLIME CONVERSION Soda Ash METAL / ACID SEPARATION APU NEUTRALIZATION SLIME FILTRATION Sodium Sulphate FILTRATION Ni/Cu Cake To Falc. Sudbury Smelter Filtrate Acetic Acid LEAD REMOVAL POLISHING FILTRATION To Tailings Pond CENTRIFUGE Leach Acetate Solids To Thickener Dried Leach Slimes To Market 70
3.2.6. Falconbridge, Sudbury Division, Sudbury, Ontario 85 Figure 12 contains a schematic block flow diagram for Falconbridge’s Nickel/Copper Smelter in Sudbury. This shows the general sequence of the major unit operations, 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. This diagram is highly simplified and is included solely to aid in the discussion and understanding of the pollution control at the facility. Nickel-copper concentrate is received from the Strathcona concentrator as a slurry which is repulped to a consistent density prior to processing in the fluidized bed roasters. Most of the nickel, copper, iron and sulphur in the smelter feed is contained in sulphide minerals. Silica is proportioned to ensure a low viscosity FeO-CaO-SiO 2 slag, with low nickel and copper content, in the subsequent smelting step. The roasters oxidize part of the iron and approximately 60% of the sulphide sulphur. Roaster off-gases are treated by a cyclone and electrostatic precipitator to remove dust. The cleaned gases are treated by a single absorption sulphuric acid plant to remove sulphur dioxide before being released to the atmosphere. Weak acid from the gas cleaning section of the acid plant is neutralized with lime. The solid product from the roasters is charged to an electric furnace for smelting together with custom concentrate and coke. The non-ferrous gangue minerals, fluxes and iron oxides separate to form a molten oxide slag over the molten nickel-copper-iron sulphide matte phase. Electric furnace slag is granulated and pumped to the slag disposal area where the water is drained and recycled. Offgases from the electric furnace are treated by cyclones and an electrostatic precipitator for removal of dusts containing metals before being released to the atmosphere. All dusts recovered from electric furnace off-gases are returned to the electric furnace. Electric furnace matte is transferred to conventional Peirce Smith converters where iron and sulphide sulphur are further oxidized to iron oxide and sulphur dioxide. Iron oxide and fluxes combine to form a molten oxide slag over the molten nickel-copper matte, which also contains cobalt and some iron. The higher density matte separates from the converter slag and is granulated, dewatered, then shipped to Falconbridge’s Nikkelverk refinery in Norway. Converter slag contains economic concentrations of metals and is cleaned prior to disposal. Off-gases from the electric furnace are treated by cyclones and an electrostatic precipitator for removal of dusts containing metals before being 85 Hatch Associates, Review of Environmental Releases for the Base Metals Smelting Sector, prepared for Environment Canada, dated November 2000 71
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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
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2.3.1. Pretreatment Pretreatment of
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Metallic impurities either dissolve
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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 and 102: Figure 7: Inco Thompson Nickel Smel
Page 103 and 104: 3.2.5. Falconbridge Limited, Kidd M
Page 105 and 106: electrostatic precipitator dust fro
Page 107: Figure 10: Falconbridge Kidd Copper
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
Page 153 and 154: Cadium - Air EPI 0.2 0.15 0.1 0.05
Page 155 and 156: Mercury- Air EPI 9 8 7 6 5 4 3 2 1
Page 157 and 158: 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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