(MERAF) for the Base Metals Smelting Sector - CCME

More documents

Recommendations

Info

Mining and Milling Mineral Concentrate Recycled Feedstock Smelting / Refining sintering roasting smelting converting fire-refining electrorefining carbonyl refining leaching electrowinning casting Air Emissions e.g. TPM, PM 10 , PM 2.5 , SO 2 , metals, NO x , CO 2 , etc. Refined Metals Copper, Nickel, Lead, Zinc, Silver, Cobalt, Gold, Cadmium, and Other co-products By-Products Sulphuric acid, Liquid sulphur dioxide, Sulphur, Gypsum, Other Legend TPM: Total Particulate Matter PM 10 : Particulate Matter less than 10 microns PM 2.5 : Particulate Matter less than 2.5 microns TSS: Total Suspended Solids 12
2.3.1. Pretreatment Pretreatment of feed materials includes drying of slurry concentrates, milling, sorting and separation of scrap material, and feed proportioning. Pretreatment is conducted to ensure feeds are in appropriate condition and proportions for initial processing. 2.3.2. Sintering Sintering is used to agglomerate fine concentrate particles and to oxidize the roast, releasing the sulphur in the ore as sulphur dioxide and converting the minerals into oxides having suitable characteristics for feeding into the blast furnace. Sintering may be used in the primary production of lead in Canada. The concentrates are blended with recycled sinter fines and other process materials and are fed in a layer into the sintering furnace. The feed is ignited with gas burners and conveyed over a series of windboxes through which air is blown. The sinter product is then crushed and screened to the correct size. Undersize material is cooled and recycled back through the process. 2.3.3. Roasting Roasting is the conventional technique used in the pyrometallurgical processing of copper, nickel and zinc sulphide concentrates. During roasting, the sulphur is removed by adding air and simultaneously heating and drying the concentrate to achieve a sulphur content favourable for smelting. The sulphur is released as sulphur dioxide (SO 2 ). Roasting to completion eliminates the sulphur and produces the metal oxide for reduction by carbon or carbon monoxide, or for leaching in a sulphuric acid solution followed by electrowinning. Incomplete roasting is used to remove excess sulphur in copper and nickel sulphides in preparation for the matte smelting process. The SO 2 produced is usually converted to sulphuric acid, or sometimes liquefied. 2.3.4. Smelting Smelting serves two functions – one to melt the concentrates to a molten state and second to separate the metal of value from other less desirable metals, impurities and gangue materials. Concentrates are fed to the furnace along with fluxing agents, fuel (oil, natural gas), and oxygen (in the form of air, technical oxygen or oxygen enriched air). High temperatures from combustion and oxidation in the smelting furnace cause the feed materials to melt. Separation of the metal of value from other impurities and gangue materials occurs through fluxing, where the siliceous fluxing agent forms a silica-iron-sulphur slag. Some impurities are also separated from the metal of value through oxidation and volatilization (e.g., sulphur, some metal compounds). 13
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 and 46: (a) have or may have an immediate o
Page 47 and 48: 2. INDUSTRY PROFILE 2.1. Sector Def
Page 49: 2.3. Base Metals Smelting Processes
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 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 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
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 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
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
show all

(MERAF) for the Base Metals Smelting Sector - CCME

Create successful ePaper yourself

Delete template?

Save as template?