a global approach: emissions releases and cross-media

NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY

Husamuddin Ahmadzai, Tekn dr

CEng, CP(E), FIMMM, FAusIMM

73rd Meeting of the BEAC WGE Subgroup for Hotspots Exclusion

Skellefteå, Sweden, 13th of November 2018

1

A Global Approach: Emissions – Releases and Cross-media

Aspects in Assessments – BAT- BEP

NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 18-11-22 2

• Executive Summary

• Preface

• Scope

• Gen Info Ec & X-media Eff

• Costing Methodology

• Evaluating the Alternatives

• Economic Viability in Sector

• Concluding Remarks


Contents

• Environmental quality guidance

• Performance criteria, economic & cross media assessment

• Global approach for example NF smelter

• Release to air, water, soil

• SOx, NOx, GHG, ODS; Dust; Metals e.g. Pb, Hg, As, Cd; POPs

• Waste management, remediation, safety

• BAT-BEP performance comparison, existing

• Calculation – methodology (2 levels)

• Conclusion


Environmental AIR

Quality Guidance Legislation: E.g. Directive

2001/81/EC on National

Emission Ceilings (NEC

Directive). Provides upper limits

for four pollutants (SO2, NOx,

VOC and NH3) responsible for

• acidification,

• eutrophication

• ground-level ozone pollution


Environmental Quality (EQ) Guidance

Parameter EQ- norm, SE

NOx 20 µg/m3 (2010)

SOx 5-20 µg/m3 (2005)

PM PM10 = 15 µg/m3 (2020)

PM 2.5 = 12 µg/m3 (2010)

Pb

As

Cd

Ni

0.5 µg/m3 (2001)

6 ng/m3 (2013)

5 ng/m3 (2013)

20 ng/m3 (2013)

PAH (BaP) 0.1 ng/m3 (2020)

VOC Benzene, Ethene 1 µg/m3 (2020)

Cross media addresses

the likely cost and

benefits of measures as

well as aiming to protect

the environment taken

as a whole to avoid

creating a new and

more serious

environmental problem

when solving another


SO2, µg/m3 iso-lines Modell calculation depict that contemporary deposition result

in a pH of about 4.5 closest to Rönnskärsverken.

Environmental Quality Guidance SE miljö KN

SO2 (2001)

µg/m3

H = 200

D = 100

Y (veg) = 20

Y (kultur) = 20


Fluoride, µg F/g-pine needlees, iso-lines

Environmental Quality Guidance


Performance Interplay – Cross Media - Economics

Air

Waste/SoilWater

BAT – BEP

incl. Cross-mediaPerformance

Resource

Energy

Release

Cost/Benefit

Internalise costs


Yearly mean concentration of SO2 (micro gm/m3)

originating from the smelter complex.

Map depicting the infrastructure of the

Saindak integrated smelter complex.

Saindak Integrated Smelter Project Pre-assessment 1992


Township

Over-burden

Open pit mine

Concentrator and

Copper Smelter

Tailing pond

Saindak Integrated Smelter Project – Current situation


Global Approach BAT-BEPIndividual – integrated assessment . Internalise costs

and benefits. Set overall limits for SO2, Dust, HM,

POPs release, energy use, waste management,

performance criteria for containment, mitigation

equipment, remediation, monitoring

"Bubble approach"


Global Approach – Cross Media

a) Comprehensive; b) Simple • Environmental quality, Impact

Assessment, flora, fauna, health, relics

• integrated assessment: plant operation, chemicals, infrastructure, safety, monitoring

• Legislative security, value addition

• Ambitious, flexibility to the stakeholders

• Transparency of contributions and mitigation measures

• Air, water (process, precipitation, percolation, sanitary), waste, remediation, fugitive emissions

• BAT-BEP

• Cu, Pb, Zn, Cd, Hg, As, Ni

• Dioxins, Particulate, SO2, NOx, Brominated Fire Retardants

• Noise, temperature

• Resource use, Energy

• Chemical use

• Transportation

• Safety

• Waste treatment and handling

• Remediation

• Economic guarantee


“A” = pre-investment production,

“B” = increased production vis-à-vis the pre-investment production during the expected remaining lifetime

of the pre-investment facility

“C” = production beyond the pre-investment facility lifetime.

Increase of production

Pre-investment output of facility during its remaining technical/economic life (A); and Additional output

related to increased capacity and extended operating life (B+C). Baseline “B” = existing sources of energy

efficient production. Baseline for “C” = energy efficient new technologies; or a relevant most energy

efficient existing technologies.


Global Permit

• NOx, SOx

• Waste water: Cu, Pb, Zn, As, Ni, Cd

• Discharge of metals– cooling water,

– precipitation and run-off waters,

– sanitary water, process water:

• Cu, Pb, Zn, As, Ni, Cd, Hg, Dioxin

• Waste deposit after closure.– target: 1-10 kg Cd/y; 1-10 gm/y of Hg;

– Percolation of max 1 l/m2-y after closure

• Economic Guarantee for remediation (e.g. SEK 760 million)

• Operations as per to submitted descriptions

• Emission SO2 (load)

• Dust and Heavy Metals (load)

– PM:, Cu; Zn; Cd; As, Hg

• Filtration equipment performance (conc)

– Fabric Filter, ESP; Scrubbers

• Discharge Central WWTP (conc)

– Cu , Pb, Zn, As, Ni, Cd, Hg

• Discharge sanitary WWTP (conc)

– Cu , Pb, Zn, As, Ni, Cd, Hg, BOD7, Ptot

• Noise: 40 – 50 dB (A). Peak, night

• Storage of waste

• Handling & design of waste deposit

• Monitoring and control programme

• Supervisory authorities


Combined Processes


Results for Complex Processes, Existing, New

NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 18-11-22 1818-11-22 18

Energy consumption (kWh/per ton)

metal & by-products (1983-20xx),

w.r.t. electricity, oil and coal.

0

500

1 000

1 500

2 000

2 500

3 000

3 500

19

70

19

75

19

80

19

85

19

90

19

95

20

00

20

05

Ton/år

3.6 ton

Utsläpps-

minskning

99.9 %

3245 ton

Metal discharge Cu+Zn+Pb+As 1970-2008


Release Cu % Pb % Zn % Cd % As % Hg %

Actual Release

Regulated discharge

Granulation-water

Diffuse via groundwater

Diffuse via Eastern Pond

Diffuse via fugitive dust

Regulated emissions

13

41

7

0

31

8

12

15

1

0

32

40

9

66

9

0

8

8

57

3

7

0

3

30

46

15

15

16

1

7

50

-

0

0

-

50

Total 100 100 100 100 100 100

Bubble Approach – Enables harnessing relevant measures


Need for Enabling of Superior Performance - Global

SO2, kg/t Cu


1999

tailings pond approx. 50 ha (1 x 0,5 km). Volume of tailings 8Mm3 / 12M tons. Dam length 2,7 km; Height up

to 25m. Thickness of the tailings approx. 20 m

2001 - 2003


Spring 2012 – 3 years since completion.

Detailed design & construction: Cost ca €21M


Waste: Hazardous waste from Rönnskär activities include Hg, Cd, Pb, As in

varying amounts. Hg-content in historic waste stored at Rönnskärsverket ranges

from 0,01 till ca 7 w%. Waste with Hg > 0,1 % is to be stored underground.

(Swedish Hg waste regulation SFS 2001:1063/2009:15).


Profitable Investment – Rönnskär Smelter 03/05/2010


Boliden: 03/05/2010 – Contemporary Capacity

# Capacity Rönnskär Smelter Tonnes per year, Copper (Cu)

1 Copper Plant (El+Flash) 200,000 – 240,000

2 TBRC, New + existing 75,000 – 120,000

3 Total (2012) 315,000- 360,000

# Rönnskär Kg

SO2/t-

Cu

1 Rv – TBRC/Kaldo 2.7

2 Rv – general 12-19.5


BAT – Release Comparison# Specific Release Rönnskär (2008) Aurubis (2011)

1 SO2, kg/t-Cu 18,3 4,2

2 Dust to air, g/t-Cu 140 93

3 Metals to water, g/t-Cu 17,0 1,5

Smelter Plants Asia (Japan, Korea): < 2 till 4 kg SO2 per ton Copper

Smelter Plants USA (Kennecott): < 3 kg SO2 per ton Copper

Smelter Plant, DE (Aurubis, Hamburg, 2011): 4,3 kg SO2 per ton Copper

Smelter Plant, DE (Aurubis, Lünen, 2011): 3,7 kg SO2 per ton Copper


Kennecott-Outokumpu – Garfield Smelter, USA

Capacity Kennecott USA Rönnskär

Copper concentrate 1-2 million t/y 600,000 -610,000 t/y

Emission Source SO2 emission (actual) ppm

Garfield H2SO4 plant (cap. 145 t/h) 100 ppm (30-60)

Rönnskär CSK (H2SO4 plant cap. ca 70 t/h

& SO2 plant cap. 6 t/h )

Up to 560 (average 70 – 105)


Two to 3 PSCs (13’ x30’) needed for production (100k-150k t/y blister copper).

• 2 Converters Blow gas volume ca. 150,000 Nm3/h.

• Continuous flash converting gas volume ca 10,000 to 13,000 Nm3/h.

90 % less volume reduces size of down-stream treatment system and size of sulphur

abatement unit(s)/sulphuric acid plant

Gas cleaning system comprise 40 - 50% of the total capital cost of a metallurgical acid plant.

Comparison of size of direct blister flash

smelting furnace (Olympic Dam) and

matte flash smelting furnace (Huelva) Ref: I.V.

Kojo and P. Hanniala (1994).

Direct blister production:

Glogow II (Poland (1978)), Olympic Dam, Australia

(1988); Gecamines Smelter (Zaire), Kennecott (1995).

Yanggu Xiangguang Copper Co., China (2007);

Tongling Non-Ferrous Metals Group Co.Ltd., China

(2012) Jinchuan Non-ferrous Metals Co,

Fangchenggang, China,(2013).

Conventional technology uses Peirce Smith Converters

(PSC).


Overall operating cost 10-15 $/t acid


30

ca 17 tonnes in Control tonnes/y

Emission to air > 99 % 0.1-0.15

Discharge to water > 99,5% 0.02 - 0.05

Waste (Hg-sludge) Site deposit 16.8

S products (610 k) 0.1 ppm 0.06-0.1

Hg Balance at the Rönnskär Smelter

NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 31

Investments and Cost Hg removal

Pre-project


Post-project


Cost Estimate of Mercury Removal

33

Unit Abatement Cost (5%, 10 y; capital recovery factor 0,1295)

Investment cost for Hg plant: USD 2.2 million

Annual Operating cost up to USD 2000

Unit Abatement Cost USD 145 / kg Hg

Cost Estimate Sulphuric Acid Plant (SAP) operations:

Description Specific Unit COST USD (215 t/d) – 74kt SAP

Electricity 100 kWh/t acid

Cold start 1/y; 60t fuel/start

Water make-up 19 m3/t acid

Lime neutralisation 28 kg/t acid

Labour/Maintenance 7 $/t acid

Mercury removal 3 cents/t acid

Mercury removal 0.2 percent add 17 USD per ton sulphuric acid


Cost Estimate of Mercury Removal

34

Operating Costs Sulphuric Acid Plant (1000 t/d) range 12-23 USD/t acid and depends on SO2 gas tenor (4-12 % SO2).

For USD 17/t acid, removing Hg, adds a cost less than 3 cent/t acid for a 215 t/d SAP.

Current (Q1 2015) Sulphuric Acid spot price (China) about USD 65-70/t. Difficult to predict.

Transportation cost $30-100/t cost-in-freight

NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 11/22/201835

Sulphuric Acid Quality Requirement/2010• Water clear appearance (40 Hazen max.)

• Contaminants [ppm]

Mercury (Hg) < 0.5

Iron (Fe) < 25

Nickel (Ni) < 1

Chromium (Cr) < 1.5

Manganese (Mn) < 0.3

Sulphur dioxide (SO2) < 30

Chloride (Cl-) < 2

Flouride (F-) < 5

Ammonium (NH4+) < 1

Nitrate (NO3-) < 5

Arsenic (As) < 0.2

Copper (Cu) < 0.2

Cadmium (Cd) < 0.02

Lead (Pb) < 0.3

Zinc (Zn) < 0.1

Antimony (Sb) < 0.02

Bismuth (Bi) < 0.02

Selenium (Se) < 0.1


No End Use Percentage

1 Phosphoric acid and Fertilizer Production 70

2 Copper Leaching 5

3 Petroleum Alkylation 4

4 Pulp and Paper 3

5 Ammonium Sulphate 2

6 Aluminium Sulphate 1

7 Other 15

Total 100

Sulphuric Acid End Uses


Air emissions of mercury from non-ferrous metals production

processes


130-180€/t20-50€/t


Onsan Korea - Outokumpu Flash

Capacity Onsan Korea Rönnskär

Cu-cathod (Outokumpu) 350,000 t/y 300,000 t/y

Cu (Outokumpu+Mitsubishi) 426,000 t/y

Sulphuric acid (capacity) SO2 exit/ conc. emitted

Onsan 1,360,000 t/yr < 50 ppm

<2 kg/t , 2005

EU: upper end of the range for the production of sulphuric

acid in a double contact/ double absorption plant from

680 mg/Nm3 to 770 mg/Nm3


Gross Energy Consumption, 2006

Production Total

Conc. Treated Power Nat Gas Coal Oil Other Combust Grand Tot

kt MJt MJ/t MJ/t MJ/t MJ/t MJ/t MJ/t

Flash 758 1304 722 148 562 157 1588 2892

Mitsubishi 636 1452 880 663 773 0 2317 3769

Mixed 877 1282 426 569 1342 94 2432 3714

Reactors 701 1207 942 511 367 148 1968 3175

Reverbatory 286 902 0 3638 2421 1514 7573 8475

Shaft Furnace 362 731 533 0 328 2757 3618 4349


Levy for NOx: € 4/kg; Tax for S: € 3/kg

Value of 100 t S at € 3/kg = € 300 000; Balance attributed to NOx reduction = € 900 000

UAC for NOx (€ 900 000/250 000 kg) = € 3.6/kg (this is below the EUR 4/kg levy) and the investment

represents value for money.

Conclusion: The abatement of other pollutants into various media can be taken into account with

respect to shadow prices (levies) and assessed in light of the accumulative advantage

offered by an investment.

REF: Swedish EPA Report 4705 Beräkningar av kostnader för miljöskyddsinvesteringar; 1996/03

Cross Media – Method: Unit Abatement Cost (UAC)

Pre-project Post-project Abatement, t/y

NOx 500 250 250

SO2 400 200 200 (100 t - S/y)

Costs € Annual Cost, € Comment

Investment 6 144 400 1 000 000* * Basis Capital Recovery

Operating 200 000 200 000 Factor = 0.16275

Total 1 200 000 (10%, 10y)




Cross Media Method 2 - Comparison of Costs and ‘Benefits’

(BREF Econ. & Cross Media, July 2006)




Cross Media Method 2 Comparison of costs and ‘benefits’


Cross Media Method 2 Comparison of costs and ‘benefits’

In the above case, option 1 offers a better balance of costs and benefits as

shown by a higher benefit ratio of 2.31 versus 1.68.


Global Permit – Al SmelterSB+PB PF+PB PB+PB SB = Söderberg Technology

98 000 98 000 98 000 t/år PF = Söderberg Point Feeder Technology

930 405 000 948 349 000 957 460 000 kr/år PB = Prebake Technology

9 494 9 700 9 770 kr/t PFC = Poly Fluoro Carbon (CF4+C2F6)

628 200 305 700 88 200 kg/år SS = Suspended Solids

30 000 33 750 - kg/år A&W = Air and water media

395 700 343 200 88 200 kg/år

1 705 1 721 1 439 GWh/år

2 208 422 1 891 295 1 598 066 t/år (PFC+El(marginal, 33%)+grafit)

(minus = increase)

317 127 610 356 t/år (PFC+El(marginal, 33%)+grafit)

17 944 000 - 27 055 000 - kr/år

322 500 540 000 kg/år

3 750 - 30 000 kg/år

52 500 307 500 kg/år

16 - 266 GWh/år

2 - 30 MW-el

UAC in kr/kg

PM+PB PB+PB

Dust & SS 56 50 kr/kg

Tar (A&W) (increase) 902 kr/kg

Ftot (A&W) 342 88 kr/kg

Energy (increase) 102 kr/MWh

CO2 57 44 kr/tCO2

CO2 6 4 EUR/t CO2

Analys nuvarande metod, NPV

Cash flow


Shadow Prices – Nordic/EU 2017

18-11-22 46

ReferenceNEFCO, Environmental and

Sustainability Guidelines;

27 September 2017


Conclusion• "Global Approach" in assessment, including Cross Media evaluation of the

environment & plant operations

• Encompasses air, water, waste, remediation, fugitive/diffuse release

• Robust, flexible and innovative in resolving old and new issues

• Linkage to Environmental Quality, Impact Assessment, and benefit to flora, fauna, human health, safety and environment in general

• Applicable to existing and new plants

• Legislative security to the operator and regulator

• Encourage ambitious goals for the stakeholders

• Transparent contributions, mitigation measures, cross media cost and benefits

• Horses for the courses. Risk related. Investment Projects, other projects.

– Level 1 (simple)

– Level 2 (moderate)

– Level three (comprehensive)

• Company and Sector Analyses – Needs strengthening


Thank You!

a global approach: emissions releases and cross-media

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