1. WP2: Technology Assessment Dimitrios Panias Ioanna Giannopoulou NATIONAL TECHNICAL UNIVERSITY OF ATHENS SCHOOL OF MINING AND METALLURGICAL ENGINEERING SECTION OF METALLURGY AND MATERIALS TECHNOLOGY LABORATORY OF METALLURGY

2. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Metallurgical Industries under study Search for Best Available Techniques in the production stages, in which dusts are generated 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)

3. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 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.

4. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 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 2.Identification of the production stages where dusts are produced 3.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.)

5. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 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. 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. 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.

6. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Case study 1: Primary Copper Production Typical flow diagram of Primary Copper production process - Pyrometallurgical Route

7. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 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. 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)? Considering and determining BAT Charge Preparation Drying Roasting Smelting Converting Fire-Refining & Anode Casting Slag treatment The key environmental issues of the refined copper industry are air and water pollution:  SO 2 emission  Dust  Metal oxide fumes  Organic compounds  Wastewater  Residues (furnace linings, sludge, filter dust, slag, etc.)

8. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Drying Roasting Smelting Converting Fire-refining & Anode casting Slag treatment Charge Preparation 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) StorageStorage Covered Bays, Silos Tanks or drums in bunded areas Open on concrete Enclosed (Silo) if required Enclosed unless non-dust forming Open concrete area or covered storage Enclosed Covered Bays Open Open or Covered Bays Covered storage Open Covered Bays Open, covered or enclosed depending on dust formation Open, covered or enclosed bays or sealed (drums) depending on the material HandlingHandling Covered conveyors if non dusty. Pneumatic. Secure pipeline or manual syste Enclosed conveyors with dust collection. Pneumatic Enclosed with dust collection. Pneumatic Enclosed with dust collection. Pneumatic Mechanical loader Charge skips Mechanical loader Depends on conditions Pre-treatmentPre-treatment Blending with concentrates or other materials Blending using conveyors. Drying Blending, Agglomeration De-oiling if necessary Swarf drying or de-oiling De-coating Grinding + density separation Best Available Techniques

9. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Charge Preparation Converting Fire-refining & Anode casting Slag treatment Roasting Smelting Charge Preparation Roasting Smelting Converting Fire-refining & Anode casting Slag treatment Drying 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.

10. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Charge Preparation Drying Converting Fire-refining & Anode casting Slag treatment Roasting Smelting BAT for “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. Copper concentrate. Roasting and Smelting Abatement techniques Process gas: Acid Plant. Collection and cleaning techniques for fumes. Water treatment plants. 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% O 2 used resulting in a narrow operating window. Gas Collection Sealed Furnace. Hooded. Sealed. 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].

11. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 BAT for “Roasting and Smelting” Best Available Techniques Mitsubishi Continuous, Coupled Process Outokumpu - Kennecott Flash Smelting and Converting Process Continuous, Uncoupled Process Integrated Smelting Processes 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. Mitsubishi Process Sealed furnaces, capacity up to ~ 240000 t of copper/y Outokumpu - Kennecott Process Sealed furnaces, capacity up to ~ 300000 t of copper/year

12. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Charge Preparation Drying Roasting Smelting Fire-refining & Anode casting Slag treatment Converting BAT for “Converting” 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. Batch Converting The Peirce - Smith Converter Transfer of materials is a potential source of fugitive fume that contains dust, metals and sulphur dioxide. The ladle or skip used for feeding can interfere with the efficient positioning of the fume collector hoods. Good operation of the converter therefore relies on the use of primary and secondary fume collection hoods during charging and pouring to collect as much fugitive fume as possible. Dusts, fluxes, carburant, scrap etc. can be added through the hood. Automatic controls can prevent blowing during the periods that the converter is “rolled out” or “rolled in” again. These processes and the techniques for control and fume collection are suitable for use with new and existing installations and are techniques to be consider. Continuous Converting Best Available Techniques Mitsubishi process Converter Kennecott - Outokumpu Flash Converter 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. Advantages Clean process. Emission control does not rely as much on maintenance and operation care. High SO 2 in off-gases. High SO 2 in off-gases. Surge storage of matte. 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.

13. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Charge Preparation Drying Roasting Smelting Converting Slag treatment Fire-refining & Anode casting 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.

14. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 BAT for “Slag treatment” Charge Preparation Drying Roasting Smelting Converting Fire-refining & Anode casting Slag treatment 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 Process sources of slag: Smelter, Converter, Slag Furnace, Refining (anode) Furnace 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.

15. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Future Work on WP2 for production BAT 1.Complete the search for production BAT in the case of Primary Copper production 2.Perform same work for the following industrial sectors: Primary Zinc production Primary Aluminum and Alumina production Iron and Steel production Ferroalloys production

16. 2 nd Progress Meeting Aachen - Germany, 31 - 08 - 2007 Thank you for your attention!