WP2: Technology Assessment

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NATIONAL TECHNICAL UNIVERSITY OF ATHENS SCHOOL OF
MINING AND METALLURGICAL ENGINEERING SECTION OF
METALLURGY AND MATERIALS TECHNOLOGY LABORATORY OF
METALLURGY

• WP2 Technology Assessment

Dimitrios Panias Ioanna Giannopoulou
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Metallurgical Industries under study

• Primary Copper production
• Balkhash Copper Plant Cathodic copper
  production (Kazakhstan)
• Geskazgan Copper Plant Cathodic copper
  production (Kazakhstan)
• Primary Zinc production
• Balkhash Zinc Plant Cathodic zinc production
  (Kazakhstan)
• Primary Aluminum production
• Zaporozhye Aluminum Mill Aluminum and Alumina
  production (Ukraine)
• Iron and Steel production
• Kosogorsky Metallurgical Plant Cast iron
  production (Russia)
• West-Siberian Integrated Steel Mill Steel
  production (Russia)
• JSC Zaporozhstal Integrated Iron Steel Works
  Iron Steel production (Ukraine)
• Temirtau Metallurgical Plant Cast iron and
  Steel production (Kazakhstan)
• Ferroalloys production
• Kuznetsk Ferroalloys Works Ferrosilicium
  production (Russia)
• JSC Zaporozhye Ferroalloy Plant Ferrosilicon
  and Silicomanganese production (Ukraine)

Search for Best Available Techniques in the
production stages, in which dusts are generated
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Definition of Best Available Techniques - BAT

• The term Best Available Techniques is defined
  in Article 2(11) of Council Directive 96/61/EC
  (IPPC Directive) as
• the most effective and advanced stage in the
  development of activities and their methods of
  operation, which indicate the practical
  suitability of particular techniques for
  providing in principle the basis for emission
  limit values designed to prevent and, where that
  is not practicable, generally to reduce emissions
  and the impacts on the environment as a whole.
• Article 2(11) goes on to clarify further this
  definition as follows
• techniques includes both the technology used
  and the way in which the installation is
  designed, built, maintained, operated and
  decommissioned
• available techniques are those developed on a
  scale which allows implementation in the relevant
  industrial sector, under economically and
  technically viable conditions, taking into
  consideration the costs and advantages
• best means most effective in achieving a high
  general level of protection of the environment as
  a whole.

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Methodology in WP2 on searching for production BAT

1. Typical flow diagram of the production process
   for each one of the industrial sectors under study

1. Identification of the production stages where
   dusts are produced

• Search for Best Available Production Techniques
  in these stages
• Reference Document of E.C. on BAT in Non-Ferrous
  Metals Industries
• Reference Document of E.C. on BAT in Iron and
  Steal Production
• Reference Document of E.C. on BAT in Ferrous
  Metals Processing Industry
• Other documents (publications, patents, etc.)

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The E.C. Reference Documents on BAT
Article 16(2) of IPPC Directive requires the
Commission to organize an exchange of
information between Member States and the
industries concerned on best available
techniques, associated monitoring and
developments in them and to publish the results
of exchange.
The aim of Reference Documents on BAT is to
reflect accurately the exchange of information
and to provide reference information for the
guidance of industry, Member States and the
public on achievable emission and consumption
levels when using specific techniques. By
providing relevant information on BAT these
documents should act as valuable tools to drive
environmental performance. Reference Documents
on BAT do not set legally binding standards. The
appropriate limit values for any specific case
will need to be determined taking into account
the objectives of the IPPC Directive and the
local considerations.
Best Available Techniques are influenced by a
number of factors and for this reason, a
methodology of examining the existing techniques
is necessary for their consideration to BAT.
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Case study 1 Primary Copper Production
Typical flow diagram of Primary Copper production
process - Pyrometallurgical Route
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Considering and determining BAT

• Methodology used in examining the existing
  techniques on Primary Copper Production Industry
  
• Is the process industrially proven and reliable?
• Are there limitations in the feed material that
  can be processed? (e.g. in primary smelting some
  processes are suited for clean concentrate and
  others for complex feed smelting).
• The type of feed and other metals contained in it
  (e.g. Pb, Zn) influences process selection.
• Are there production level constraints? (e.g. a
  proven upper limit or a minimum throughput
  required to be economic).
• Can latest and efficient collection and abatement
  techniques be applied to the process?
• Can the process and abatement combinations
  achieve the lowest emission levels?
• Are there other aspects related to processes
  (such as safety)?

• Main factors affecting the choice of BAT in
  Non-Ferrous Metals Industry
• The choice of process depends strongly on the raw
  materials that are available to a particular site
  (composition, presence of other included metals,
  size distribution including the potential to form
  dust and degree of contamination by organic
  material). Raw materials may be primary raw
  materials available from single or multiple
  sources, secondary raw materials of varying
  quality or a combination of primary and secondary
  raw materials.
• The process must be suitable for use with the
  best gas collection and abatement systems that
  are available. The fume collection and abatement
  processes used will depend on the characteristics
  of the main processes (processes that avoid ladle
  transfers are easier to seal, processes that are
  able to treat recycled materials more easily
  reduce the wider environmental impact by
  preventing disposal).
• The water and waste issues have been taken into
  account, in particular the minimization of wastes
  and the potential to reuse residues and water
  within the process or by other processes.
• The energy used by the process and abatement
  processes.

• The key environmental issues of the refined
  copper industry are air and water pollution
• SO2 emission
• Dust
• Metal oxide fumes
• Organic compounds
• Wastewater
• Residues (furnace linings, sludge, filter dust,
  slag, etc.)

Charge Preparation
Drying
Roasting
Smelting
Converting
Fire-Refining Anode Casting
Slag treatment
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BAT for Charge Preparation
Charge Preparation
Raw materials
Coal and coke
Fuel and other oils
Fluxes
If dust forming
Concentrates
Copper Products - Cathodes, wire-rod, copper billets and cakes
Fine dust
Coars dust (raw material or granulated slag)
Lump (raw material or slag)
Whole Items
Swarf
Cable
Circuit Boards
Process Residues for recovery
Wastes for Disposal (e.g. furnace linings)
Best Available Techniques
S t o r age Covered Bays, Silos
S t o r age Tanks or drums in bunded areas
S t o r age Open on concrete
S t o r age Enclosed (Silo) if required
S t o r age Enclosed unless non-dust forming
S t o r age Open concrete area or covered storage
S t o r age Enclosed
S t o r age Covered Bays
S t o r age Open
S t o r age Open or Covered Bays
S t o r age Covered storage
S t o r age Open
S t o r age Covered Bays
S t o r age Open, covered or enclosed depending on dust formation
S t o r age Open, covered or enclosed bays or sealed (drums) depending on the material
Handling Covered conveyors if non dusty. Pneumatic.
Handling Secure pipeline or manual syste
Handling Enclosed conveyors with dust collection. Pneumatic
Handling Enclosed with dust collection. Pneumatic
Handling  
Handling Enclosed with dust collection. Pneumatic
Handling Mechanical loader
Handling Mechanical loader
Handling Mechanical loader
Handling Charge skips
Handling Mechanical loader
Handling Mechanical loader
Handling Depends on conditions
Handling Depends on conditions
Pre-treatment  
Pre-treatment  
Pre-treatment Blending with concentrates or other materials
Pre-treatment Blending using conveyors. Drying
Pre-treatment  
Pre-treatment Blending, Agglomeration
Pre-treatment De-oiling if necessary
Pre-treatment  
Pre-treatment  
Pre-treatment Swarf drying or de-oiling
Pre-treatment De-coating
Pre-treatment Grinding density separation
Pre-treatment  
Pre-treatment
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BAT for Drying
Drying
Best Available Techniques
Direct drying - heat from a burner or a steam jet.
Indirectly - steam or hot air in heat exchanger coils.
Drying at low temperatures.
Furnaces
Flash dryers. Steam coil dryers. Fluidized Bed Dryers.
Rotary Kiln.
Raw Materials
Concentrates.
Ores, Concentrates.
Comment
Extraction and abatement system for collecting dusty gases is necessary.
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BAT for Roasting and Smelting
Roasting and Smelting
Best Available Techniques
Outokumpu Flash Furnace (high oxygen enrichment for normal copper concentrate) smelting to matte
Matte conversion in Peirce-Smith Converter (or similar) to blister copper
Slag cleaning in Electric Furnace or by flotation
Partial roasting of concentrates in a Fluid Bed Roaster
Electric Furnace Smelting to matte
Matte conversion to blister copper in Peirce-Smith Converter
Slag cleaning by fuming
ISA Smelt Furnace to produce matte
Matte conversion to blister copper in Peirce-Smith Converter
Noranda / EI Teniente Furnace Smelting to matte
Matte conversion to blister copper in Peirce-Smith Converter
Contop Smelting Furnace to produce matte
Peirce-Smith Converter for matte conversion to blister copper
INCO Flash Furnace smelting to matte
Peirce-Smith Converter for matte conversion to blister copper
Raw materials
Concentrate and copper scrap.
Normal and complex concentrates, low grade secondary materials, copper scrap.
Concentrate and copper scrap.
Concentrate and copper scrap.
Copper concentrate.
Copper concentrate.
Advantages
High smelting rate. High quality matte. Long furnace lining life (5-10 years).
Compact.
High smelting rate. Variety of fuels.
Compact. Low cost.
High Bi and Zn removal.
High smelting rate. High quality matte.
Disadvantages
Comparatively higher investment but lower operating cost.
Two stages process.
Requires a settler to separate matte and slag.
Short furnace lining life ( 2 years).
Low throughput.
Autogeneous 100 O2 used resulting in a narrow operating window.
Gas Collection
Sealed Furnace.
Sealed Furnace.
Hooded.
Hooded.
Sealed.
Sealed.
Abatement techniques
Process gas Acid Plant. Collection and cleaning techniques for fumes. Water treatment plants.

According to the E. C. Reference Document on BAT
in the Non-Ferrous Metals Industry the
information available for the Baiyin and the
Vanyucov smelting processes is limited and at the
moment, it does not allow an evaluation to be
made in regard to their potential as BAT. tm
137, Copper Expert Group 1998.
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BAT for Roasting and Smelting
Integrated Smelting Processes
Best Available Techniques
Mitsubishi Continuous, Coupled Process
Outokumpu - Kennecott Flash Smelting and Converting Process Continuous, Uncoupled Process
Furnaces
3 interconnected furnaces Bath Smelting furnace, Electric slag cleaning furnace and Converting Furnace.
Outokumpu Flash furnace for smelting and converting.
Advantages
High smelting rate. Do not depend on ladle transfer of molten matte and other materials and is therefore inherently cleaner technique.
Surge storage of ground matte. No ladle transfer.
Disadvantages
Some limitations in feed. Coupled unit operation with effect on efficiency of the complete line. Sulphur content of blister copper.
Comparatively higher investment cost but low direct operating cost.
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BAT for Converting
Converting
Batch Converting
Best Available Techniques
Peirce-Smith Converter
Hoboken Converter
ISA Smelt Furnace
Raw material
Molten matte
Capacity
100 - 250 t per batch of copper
50 - 100 t per batch of copper
40 000 t per year
Gas collection
Primary and Secondary hoods.
Siphon for primary gas collection
Hoofs, gas cooling and cleaning
Advantages
Simple proven technology. Melting of anodes and other scrap. Robust and flexible. Good metallurgical performance. Fuming off included metals, such as Pb and Zn, which can then be recovered.
Gas collection easier.
Operation under reducing conditions (oxidization of Fe, elimination of Zn or Sn). 
Disadvantages
Relies on land transfers.
Blockages in goose neck. Ladle transfer.
 
Continuous Converting
Best Available Techniques
Mitsubishi process Converter
Kennecott - Outokumpu Flash Converter
Advantages
Clean process. Emission control does not rely as much on maintenance and operation care. High SO2 in off-gases.
High SO2 in off-gases. Surge storage of matte.
Raw material
Ground matte.
Molten matte.
Capacity
Up to 240000 t of copper per year.
Up to 300000 t of copper per year
Gas collection
Sealed.
Sealed.
Disadvantages
Difficult arrangement in existing plants. Closely coupled with smelting process.
To day only applied in one smelter in EU. A second one is under construction.
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BAT for Fire-refining Anode casting
Fire-Refining Anode Casting
Best Available Techniques
Anode Furnace
Reverberatory Furnace
Contimelt (continuous process)
Raw material
Blister or black copper. Molten feed.
Blister copper. Copper scrap. Solid and molten feed.
Blister copper. High grade copper scrap. Anode scrap. Solid feed.
Furnace
Rotary furnace with submerged tuyeres.
Rectangular or circular Bath furnace
2 interconnected furnaces a hearth shaft furnace and a drum furnace.
Gas collection
Enclosure system.
Hoods and covered launders.
Enclosure system.
Comment
Satisfactory recovery rate.
Low melting efficiency.
Controlled operating conditions. Heat recovery.

• Casting of molten copper from the Anode Furnace
  into a casting wheel a series of anode shaped
  moulds on the circumference of a rotating table.
• As an alternative to the stop-to-cast mould on a
  wheel system, copper anodes are produced
  continuously using a Hazelett twin belt caster. A
  copper strip with the desired anode thickness is
  produced. From the strip anodes can be obtained
  by shearing into the traditional anode shape or,
• According to the Contilanod system by casting
  anode lugs in special side dam blocs spaced in
  defined intervals in the caster. The pre-formed
  anodes plates are cut off using a plasma torch or
  special shears. Advantage uniformity of the
  anodes produced Disadvantage carefully
  maintenance, high operating cost.

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BAT for Slag treatment
Slag treatment
Process sources of slag Smelter, Converter, Slag
Furnace, Refining (anode) Furnace
Best Available Techniques
Electric Furnace
Slow cooling separation of copper rich portion (concentrate flotation unit)
Internal Recycle
Rotary Furnace - injection of coal into the slag bath
Comment
Decopperized slag (from slag furnace) has several useful properties that allow its use in civil engineering sector (abrasive and construction materials) and as a short-blasting medium.
Good operation for slags rich in copper, such as converter slag.
Re-circulation of slags from smelter, converter and refining furnace into the smelting furnace.

The use and the recycling of slags produced in
the different production stages is considered to
be part of the process.
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Future Work on WP2 for production BAT

• Complete the search for production BAT in the
  case of Primary Copper production
• Perform same work for the following industrial
  sectors
• Primary Zinc production
• Primary Aluminum and Alumina production
• Iron and Steel production
• Ferroalloys production

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Thank you for your attention!