(MERAF) for the Base Metals Smelting Sector - CCME

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for the CEPA-toxics, Particulate Matter (PM) and Sulphur Dioxide (SO 2 ) and to assess releases to air on a site-specific basis for each parameter for the most recent (1998) data. Potential release reduction options were analyzed and future releases were predicted (2008 and beyond). In its report 20 on the releases from Base Metals Smelters, Hatch Associates conducted an analysis to identify where further reductions could be made in releases by the application of technically feasible methods. Two time periods were chosen for the analysis: By 2008 and Beyond 2008. These dates correspond to the dates specified in Recommendation #1 of the Strategic Options Report dealing with Release Reduction Targets and Schedules. However, for the purposes of this report, the “Beyond 2008” option is given a finite time frame of “By 2015”. In complement to the information found in the Hatch Associates Reports, information from organizations such as Natural Resources Canada, the Mining Association of Canada, individual company websites, etc. was used to conduct this Analysis Foundation. While reading this report, it is important to keep in mind the main assumptions that support the facts and figures presented. It is assumed that: • the current facility capacities will remain unchanged; • no new facilities will be opened between now and 2015; • no existing facilities will be closed between now and 2015; • no new major players will join or leave the market between now and 2015. These assumptions may not reveal to be correct thirteen years from now. Hence, the possibility of new facilities at Voisey’s Bay or somewhere else does exist; however, this possibility is not considered for the purpose of this report because of inherent uncertainties and because such a new facility would likely have very low emissions and contribute a small fraction of the sector’s releases. Also, on March 28, 2002, Noranda Inc. announced that, effective April 30, 2002, it permanently closed its Gaspé copper smelter, located in Murdochville. Noranda had previously announced on November 30, 2001, that it would temporarily close the smelter for only a six month period 21 . Finally, it should be noted that the industry is in a period of global consolidation. 20 Hatch Associates, Review of Environmental Releases for the Base Metals Smelting Sector, prepared for Environment Canada, dated November 2000. 21 Noranda Inc. Press Release, March 28, 2002. URL: http://www.noranda.ca/ 8
2. INDUSTRY PROFILE 2.1. Sector Definition The Canadian base metals smelting and refining sector is composed of primary producers of cobalt, copper, lead, nickel, and zinc. Depending upon the origin of the ore or scrap metal, various coproduct metals such as gold, silver, indium, germanium, cadmium, bismuth, and selenium may also be recovered. Primary smelting and refining generally produces metals directly from ore concentrates, while secondary smelting and refining produce metals from recyclable materials. Most primary smelters have the technical capability to supplement primary concentrate feed with recyclable materials. Several smelters are using recyclable materials, where technical, logistical and economic factors are favorable. Examples of recyclable material feedstock include post-consumer goods such as telephone and computer components, metal parts, bars, turnings, sheets, and wire that is off-specification or worn out. Lead has a developed recycling market, due to the relatively short product life of lead acid batteries and the relative ease of segregating batteries at source for collection and recycling. However, secondary lead smelters are not part of this study. They are being addressed under another Environment Canada initiative pursuant to a recommendation of the Strategic Options for the Management of Toxic Substances from the Base Metals Smelting Sector - Report of the Stakeholder Consultations, June 23, 1997 22 . 2.2. Information on Base Metals The following information on base metals was derived from information found on the London Metal Exchange 23 and Natural Resources Canada 24 Websites. There are many other information sources that could have been used. However, this section is not intended to give a comprehensive use pattern of each base metal, but to provide an overview of their main applications. 2.2.1. Cobalt A major use of cobalt is in superalloys of iron, nickel and other metals to make Alnico, an alloy of high strength, wear and corrosion-resistant characteristics at elevated temperatures This alloy has many important uses including jet aircraft engines and stationary gas turbines for pipeline compressors. Cobalt-based alloys are also used in magnet steels and stainless steels where high abrasionresistant qualities are required. Another use is in electroplating. Cobalt oxide is 22 Environment Canada URL: http://www.ec.gc.ca/sop/en/index.cfm?actn=s1 23 The London Metal Exchange Limited, 2001. URL: www.lme.co.uk 24 Natural Resources Canada, Minerals and Metals Sector, Minerals and Mining Statistics Division. URL: www.nrcan.gc.ca 9
Page 1 and 2: FINAL REPORT Multi-pollutant Emissi
Page 3 and 4: Acknowledgments The principal autho
Page 5 and 6: Summary The purpose of the report i
Page 7 and 8: • Recommendations to address info
Page 9 and 10: • The Minerals and Metals Foundat
Page 11 and 12: The next series of tables illustrat
Page 13 and 14: 1,800.00 1,600.00 1,400.00 1,200.00
Page 15 and 16: S.4 Current emission management pra
Page 17 and 18: − The EPA has started developing
Page 19 and 20: T.1 Technical Options for Emission
Page 25 and 26: The predicted future releases and t
Page 27 and 28: Noranda Gaspé Rest of Sector** Sit
Page 29 and 30: Recommendation #3 It is also recomm
Page 31 and 32: 2.4.8. Leaching ...................
Page 33 and 34: 4.1.11.6. Mercury..................
Page 35 and 36: Figure 35: 2000 Nickel - Air Emissi
Page 37 and 38: Table 34: World Bank Guidelines for
Page 39 and 40: 1. Introduction The purpose of the
Page 41 and 42: strong surrogate for fine particles
Page 43 and 44: • These sectors are common to mos
Page 45: (a) have or may have an immediate o
Page 49 and 50: 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
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Figure 6: Hudson Bay Mining and Sme
Page 101 and 102:
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
Page 109 and 110:
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
Page 115 and 116:
Figure 14: Inco Copper Cliff Nickel
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3.2.8. Inco Port Colborne 87 Figure
Page 119 and 120:
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
Page 137 and 138:
Table 8: Historical Trends of Arsen
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Table 10: Historical Trends of Lead
Page 141 and 142:
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
Page 147 and 148:
Table 13: Releases of Dioxins and F
Page 149 and 150:
3.4. Other Current Emissions Inform
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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
Page 161 and 162:
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
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
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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
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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 and 208:
4.4. Options and Preliminary Cost E
Page 209 and 210:
plant. It would be possible to inst
Page 211 and 212:
4.4.2. Inco Limited, Thompson Divis
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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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