(MERAF) for the Base Metals Smelting Sector - CCME

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3.2.3. Hudson Bay Mining & Smelting (HBM&S) , Flin Flon, Manitoba 80,81 Figure 5 and Figure 6 contain schematic block flow diagrams for the Copper Smelter and Zinc Plant respectively. Each 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. These diagrams are highly simplified and are included solely to aid in the discussion and understanding of the pollution control at the facility. 3.2.3.1. Copper smelter The smelter treats HBM&S copper concentrates from Flin Flon, Snow Lake and Ruttan, purchased copper concentrates, and recycle residues and flux. Total feed to the roasters is nominally 1,300 tonnes per day of concentrate, flux, and dust, with dust totalling 45 tonnes per day. The feed is blended and charged to multiple hearth roasters where it is dried and partially oxidized. The gas from the roasters which contains PM and SO 2 are cleaned in an electrostatic precipitator and then released to the atmosphere via a tall stack. The collected PM is recycled. The roaster product (calcine), recycle dust and converter slag are smelted in a Reverberatory Furnace. This operation separates the bulk of the non-sulphide gangue and flux into a molten slag which is tapped intermittently and dumped. The copper and iron sulphide minerals form a molten matte which separates below the slag because of its higher density. It is also tapped intermittently into ladles. The reverberatory gases, and other volatile impurities pass to an electrostatic precipitator for PM removal prior to release to the atmosphere. This matte is then processed in Peirce-Smith converters on a batch basis with air. The first step converts the iron sulphide to iron oxide. Iron oxide combines with added flux to form a slag which separates from the copper sulphide. This slag is recycled to the reverberatory furnace where its relatively high copper content is recovered as it mixes with the molten bath in the reverberatory furnace. As the converting operation continues, the copper sulphide is then converted to blister copper which contains only small quantities of sulphur and oxygen. The conversion of sulphides to oxides with air produces converter off-gases containing substantial quantities of sulphur dioxide, total particulate matter (TPM) and volatile impurities. Converter off-gases are combined with those from the reverberatory furnace for electrostatic precipitator PM removal. 80 Hatch Associates, Review of Environmental Releases for the Base Metals Smelting Sector, prepared for Environment Canada, dated November 2000 81 Modifications made to process flow sheets based on personal communication from Wayne Fraser, Hudson Bay Mining & Smelting to Serge Langdeau April 10, 2002 58
The blister copper is then treated in an anode refining furnace for the removal of most of the small quantities of oxygen and sulphur dissolved in the copper. The refined copper is cast into anodes which then have the proper composition and shape for electrorefining. Anodes are currently shipped to an external electrolytic refinery for the final refining step. Anode production capacity is approximately 80,000 tonnes per year. 3.2.3.2. Zinc plant Zinc concentrates are processed in the zinc pressure leaching facility along with zinc ferrite residue from the former calcine leaching circuit. The zinc concentrate is reground and transferred to the two stage pressure leaching process in which partially neutralized returned acid is used to leach fresh concentrates. Then the partially leached concentrates are leached with fresh return acid. The second stage pressure leach underflow is filtered and washed before being directed to an impoundment area. This material may be treated in the future for either sulphur or precious metals recovery or both. The pressure leach liquor is partially neutralized by zinc hydroxide sludge in a Gypsum Removal. Copper is removed from the partially neutralized pressure leach liquor by cementation with zinc dust. This copper removal liquor is then transferred for further neutralization to precipitate residual iron. The iron removal liquor is then purified with zinc dust and transferred to electrowinning wherein the zinc is electrodeposited on cathodes, regenerating sulphuric acid. The zinc is removed from the cathode, then melted, alloyed, and cast for sale. Return acid (spent electrolyte) from electrowinning is recycled to the pressure leaching stages, and to the atmospheric Ferrite Leach step. The latter treats a stockpile of ferrite residue. The upgraded ferrite leach residue is treated in the copper smelter for precious metal recovery while ferrite leach liquor is directed to the first stage pressure leach. Zinc-rich dust from the copper smelter and zinc casting plant dross are passed through a kiln for halogen removal and then leached in a small quantity of return acid. The dust leach liquor is combined with wash liquors, and contacted with lime in the waste water treatment circuit to recover zinc as a zinc hydroxide sludge. This sludge is recycled to the gypsum removal and iron removal steps to be used for neutralizing. 59
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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
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 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: Figure 4: Sherritt Metals Refinery
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
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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
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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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