a global approach: emissions releases and cross-media
TRANSCRIPT
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 18-11-22 3
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 18-11-22 4
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY 18-11-22 5
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
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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
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Fluoride, µg F/g-pine needlees, iso-lines
Environmental Quality Guidance
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
Performance Interplay – Cross Media - Economics
Air
Waste/SoilWater
BAT – BEP
incl. Cross-mediaPerformance
Resource
Energy
Release
Cost/Benefit
Internalise costs
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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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
Township
Over-burden
Open pit mine
Concentrator and
Copper Smelter
Tailing pond
Saindak Integrated Smelter Project – Current situation
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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"
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
“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.
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
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
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Combined Processes
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Combined Processes
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Results for Complex Processes, Existing, New
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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
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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
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Need for Enabling of Superior Performance - Global
SO2, kg/t Cu
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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
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Spring 2012 – 3 years since completion.
Detailed design & construction: Cost ca €21M
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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).
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Profitable Investment – Rönnskär Smelter 03/05/2010
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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
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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
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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)
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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).
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Overall operating cost 10-15 $/t acid
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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
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Investments and Cost Hg removal
Pre-project
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Post-project
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
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
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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
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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
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Air emissions of mercury from non-ferrous metals production
processes
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130-180€/t20-50€/t
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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
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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
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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)
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Spring 2012 – 3 years since completion.
Detailed design & construction: Cost ca €21M
Cross Media Method 2 - Comparison of Costs and ‘Benefits’
(BREF Econ. & Cross Media, July 2006)
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Spring 2012 – 3 years since completion.
Detailed design & construction: Cost ca €21M
Cross Media Method 2 Comparison of costs and ‘benefits’
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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.
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
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
NATURVÅRDSVERKET/SWEDISH ENVIRONMENTAL PROTECTION AGENCY
Shadow Prices – Nordic/EU 2017
18-11-22 46
ReferenceNEFCO, Environmental and
Sustainability Guidelines;
27 September 2017
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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
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Thank You!