(MERAF) for the Base Metals Smelting Sector - CCME

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• Hudson Bay Mining and Smelting is commissioning a $30 million improvement system for gas handling in 2000/2001 which should result in a 30% decrease in particulate matter releases • The “Stack Tap Hole” at Noranda Horne, which was used to discharge secondary gases from the Noranda Reactor and the Noranda Continuous Converter, is no longer functional as of May 2000. The gases are now collected and treated through a baghouse with lime injection and directed through the converter stack (“Stack #2”) • Reductions in releases at Noranda Horne have occurred due to increasing percentage of matte being processed through the Noranda continuous converter, since 1998 reported data. • On March 28, 2002, Noranda announced the permanent closure of its Gaspé smelter effective April 30, 2002. 4.4.1. Hudson Bay Mining & Smelting Co. Ltd., Flin Flon, Manitoba The two measures which offer the greatest reduction potential are: • Copper Smelter modernization including gas scrubbing and recovery of sulphur dioxide to produce sulphuric acid. • Processing the copper concentrate by using a hydrometallurgical process. In both cases, an accompanying significant increase in throughput would improve the economics of the projects considerably, but such an increase would only be possible if sufficient supply of economic concentrates were available. The best option is the hydrometallurgical approach, which has the potential for the maximum reduction of air emissions of pollutants while recovering elemental sulphur that can be stored or shipped more economically and safely than sulphuric acid. The implementation schedule would be longer than for a smelter modernization, since this process still requires development and would have to be tested first on a pilot plant scale. There are a number of pressure leaching technologies under development. Given the state of the development of the technology, installation of a facility by 2008 might not be achievable. Further, this option could only be justified if it were feasible to increase the copper capacity to approximately 150,000 tonnes per year. Current production at the Copper Smelter is approximately 80,000 tonnes per year. Copper smelter modernization using currently available proven technology has a shorter implementation schedule, compared with a hydrometallurgical facility. However, the minimum economic capacity of a modern copper smelter is approximately 250,000 to 350,000 tonnes per year, considerably higher than the current production. The SO 2 is converted to sulphuric acid (rather than sulphur) which is more costly and difficult to ship. The proposed technology would be flash smelting followed by flash converting, and a double absorption, contact acid 170
plant. It would be possible to install a facility by 2004, and it could be phased. The costs associated with producing acid and moving it to distant markets might make this option uneconomical. In the interim, additional improvements to the present system would reduce total particulate matter and CEPA toxics in the range of 10 to 50%, depending on the substance and its specific characteristics. Table 67 provides a summary of the potential emission reductions in 2008 and beyond 2008 for the Hudson Bay Mining & Smelting complex. Table 67: Hudson Bay Mining & Smelting Emission Reductions in 2008 and Beyond Parameter 1988 1998 2008 projection 2015 projection Total Particulate Matter Sulphur Dioxide (tonnes) (tonnes) (tonnes) % reduction from 1988 (tonnes) % reduction from 1988 5,156 1,359 930 82% 100 98% 265,804 185,200 185,200 30% 9,260 97% Arsenic 40.62 13.2 12 70% 1 97% Cadmium 57.59 4 93% 1 99% Lead 254 95.87 75 70% 9 96% Mercury 19.9 1.55 1 95% 0.1 99% Nickel Not significant Table 68 contains a summary of options to reduce air emissions. 171
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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
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2.6.6.2. Noranda Inc., Division CEZ
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2.7. Key Industrial Associations Ex
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In terms of tonnage, zinc ranks fir
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Table 4: Canadian Base Metals Expor
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ased 62 pricing system. In response
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The LME has a multi-tiered membersh
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The BMSS IT held ten meetings betwe
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3.1.1.2. Smelters Emissions Testing
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achieve their commitments, are publ
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All the companies mentioned in this
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emoved for processing in the Copper
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Lead Concentrate Zinc Residue Lead
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3.2.2. Sherritt International Corpo
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3.2.2.5. Cobalt conversion and redu
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Figure 4: Sherritt Metals Refinery
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The blister copper is then treated
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Figure 6: Hudson Bay Mining and Sme
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Figure 7: Inco Thompson Nickel Smel
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3.2.5. Falconbridge Limited, Kidd M
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electrostatic precipitator dust fro
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Figure 10: Falconbridge Kidd Copper
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3.2.6. Falconbridge, Sudbury Divisi
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Figure 12: Falconbridge Sudbury Nic
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from the fluid bed roasters are tre
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Figure 14: Inco Copper Cliff Nickel
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3.2.8. Inco Port Colborne 87 Figure
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3.2.9. Noranda Inc., Horne Smelter,
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Figure 17: Noranda Horne Copper Sme
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Figure 18: Noranda CEZ Zinc Plant T
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Fugitive emissions from the TBRC op
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3.2.12. Noranda Inc., Division Mine
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Figure 20: Noranda Gaspé Copper Sm
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with water to preserve the environm
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3.3. Analysis of Emissions 3.3.1. T
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Table 6: Historical Trends of Total
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Table 8: Historical Trends of Arsen
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Table 10: Historical Trends of Lead
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Table 12: Historical Trends of Nick
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350 300 250 200 150 100 Total Secto
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1,400.00 1,200.00 1,000.00 800.00 6
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Table 13: Releases of Dioxins and F
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3.4. Other Current Emissions Inform
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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
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
Page 169 and 170: 4.1.11.3. Arsenic Table 18 shows th
Page 171 and 172: 4.1.11.5. Lead Table 22 shows the C
Page 173 and 174: 4.1.11.6. Mercury Table 24 shows th
Page 175 and 176: 4.1.11.7. Nickel Table 26 shows the
Page 177 and 178: New Source Performance Standards (N
Page 179 and 180: Table 31: US National Emission Stan
Page 181 and 182: In the permitting process, faciliti
Page 183 and 184: Table 34: World Bank Guidelines for
Page 185 and 186: 4.2.4. Australia Air quality is con
Page 187 and 188: Table 39: Australia/New South Wales
Page 189 and 190: 4.2.5. Japan Environmental quality
Page 191 and 192: Sulphur dioxide, particulate matter
Page 193 and 194: Table 47: Germany Particulate Matte
Page 195 and 196: Table 51: The Netherlands Sulphur D
Page 197 and 198: Table 53: France Particulate Matter
Page 199 and 200: The Environment Protection (Prescri
Page 201 and 202: Table 60: United Kingdom Releases t
Page 203 and 204: 4.2.12. Other European Countries Ta
Page 205 and 206: 4.3. Best Available Techniques for
Page 207: 4.4. Options and Preliminary Cost E
Page 211 and 212: 4.4.2. Inco Limited, Thompson Divis
Page 213 and 214: 4.4.3. Falconbridge, Sudbury Divisi
Page 215 and 216: 4.4.4. Inco Limited, Sudbury/Copper
Page 217 and 218: 4.4.5. Noranda Inc., Horne Smelter,
Page 219 and 220: 4.4.6. Noranda Inc., Division Mines
Page 221 and 222: Table 78: Technical Options for Emi
Page 223 and 224: Site Option for Reduction By 2008 O
Page 225 and 226: Site Option for Reduction By 2008 O
Page 227 and 228: Noranda Horne Site Option for Reduc
Page 229 and 230: 5. CONCLUSIONS AND RECOMMENDATIONS
Page 231 and 232: Appendix A: Health and Environmenta
Page 233 and 234: List of Acronyms AAQ AAQC ARET BACT
Page 235 and 236: UN/ECE URL USEPA VCR VOC United Nat
Page 237 and 238: at the anode and selectively plates
Page 239: Sinter: Slag: Slag cleaning: Top Bl
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(MERAF) for the Base Metals Smelting Sector - CCME

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