(MERAF) for the Base Metals Smelting Sector - CCME

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Figure 16: Inco Port Colborne Input/Output Diagram REAGENTS NATURAL GAS / BUNKER C ELECTRICITY WATER AIR COBALT - NICHEL CARBONATE FEEDSTOCK PORT COLBORNE REFINERY ELECTROLYTIC COBALT ROUNDS NICKEL CARBONATE MISCELLANEOUS BY-PRODUCTS TREATED EFFLUENT WATER SCRUBBED, VENT AIR TO ATMOSPHERE 80
3.2.9. Noranda Inc., Horne Smelter, Rouyn-Noranda, Québec 88 Figure 17 contains a schematic block flow diagram for the Copper Smelter. 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. The diagram is highly simplified and is included solely to aid in the discussion and understanding of the pollution control at the facility. Copper concentrates and fluxing materials (silica) are proportioned to form a low viscosity FeO-SiO 2 slag with low copper content on smelting. New feed is mixed with recycled slag concentrate and dust from the smelter and processed in a single Noranda Reactor. Most of the copper in the smelter feed is contained in sulphide minerals and reports to the molten sulphide matte phase, while the bulk of the non-sulphide gangue forms an oxide slag containing copper at low, but economically recoverable concentrations. The higher density matte separates from the slag, which is combined with converter slag and is slowly cooled, ground and processed by flotation to recover most of the contained copper. Off-gases from the Noranda Reactor are treated by a dry electrostatic precipitator to remove total particulate matter. The clean reactor off-gases are then directed to a single absorption sulphuric acid plant for recovery of sulphur dioxide. Dust is returned to the reactor for recovery of copper and is also bled from the circuit to control impurity levels and reduce emissions. The gas cleaning section of the acid plant includes a mercury tower to minimize mercury emissions and ensure acid quality. Weak acid solution from the acid plant is neutralized with lime and mixed to react with a ferric sulphate solution to precipitate metals in solution, combined with mill tailings from slag flotation and co-deposited in the tailings impoundment area. Part of the Noranda reactor matte is processed in the Noranda Continuous Converter in order to produce semi-blister copper. The semi-blister copper is treated in a desulphurization vessel to complete the sulphur oxidation prior to the anode furnace. Initially, oxygen-enriched air is used to convert iron sulphide to iron oxide, which combines with added flux to form an oxide slag that then separates itself from the copper sulphide matte phase. The rest of the reactor matte is processed in Peirce Smith Converters in batches. The blister copper is then directed toward the anode furnace. In the course of these two processes, the slag treated along with the Noranda reactor slag produces a slag concentrate, which is returned to the reactor. The blister copper is processed in an anode-refining furnace to remove most of the dissolved oxygen and sulphur. The copper is then cast into anodes which are shipped to Noranda’s Canadian Copper Refinery (CCR) for the final refining step. 88 Hatch Associates, Review of Environmental Releases for the Base Metals Smelting Sector, prepared for Environment Canada, dated November 2000 81
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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
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sulphur dioxide in the off-gases th
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2.5. Canadian Base Metals Smelters
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ammonium sulphate fertilizers. The
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The copper smelter uses pyrometallu
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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 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: 3.2.8. Inco Port Colborne 87 Figure
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
Page 159 and 160: The “Alberta Ambient Air Quality
Page 161 and 162: 4.1.9. New Brunswick New Brunswick
Page 163 and 164: 4.1.11.1. Particulate Matter Table
Page 165 and 166: Table 15: Canadian Ambient Particul
Page 167 and 168: 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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