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www.fcx.com CONNECTING THE FUTURE ® Welcome Turkish Delegation Twinning IPPC 12 July 2012

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Page 1: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

www.fcx.com CONNECTING THE FUTURE®

WelcomeTurkish Delegation

Twinning IPPC

12 July 2012

Page 2: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Atlantic Copper en Europa

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Page 3: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Atlantic Copper en Huelva

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Page 4: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

UBICACIÓN

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Page 5: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Page 6: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

1873: British investors founded the RIO TINTO COMPANY LTD.

1873-1970: Mining and Smelting operations at Riotinto village, 75 Km northwest of Huelva.

1970: Huelva Smelter & Refinery start-up. Initial capacity 40,000 tpy cathodes.

1975: Commissioning of the Flash furnace (Outokumpu) and Tankhouse expansion to 108,000 tpy cathodes.

1985: First tonnage oxygen plant (over the fence supply).

1993: Acquisition of 100% RTM capital by Freeport McMoRan Copper & Gold, Inc.

1994-1996: Huelva Expansion Project.

1996: Atlantic Copper is born.

History

Page 7: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Flowsheet

Oxygen

Gypsum Plant

Concentrate

Cathodes Anodes

Sulfuric acid

Iron Silicate

Flue dust

Page 8: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Smelter

H2SO4 876.000 tpa

Slag 545.000 tpa

Gold (in slime) 11 tpa

Silver (in slime) 61 tpa

Anodes 13.000 tpa

Cathodes 247.000 tpaRefinery

Concentrates 913.000 tpa

Scrap 34.000 tpa

AC 2011 Production Rates

Page 9: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

IPPC History

1996: Directive 96/61 IPPC.

2001: Non Ferrous Metals BREF.

2002: Law 16/2002 IPPC transposition.

2003: Voluntary Agreement:

2005: Apply for Environmental Integrated Permit (AAI) according to IPPC directive.

2007: AAI issued by the Andalusian Environmental Council.

2010: Directive 2010/75/UE Industrial Emissions Directive

Page 10: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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NFM BREF: addresses the industrial activities specified in section 2.5 a, b Annex I Directive 96/61 and Directive 2010/75 IED

BAT: 'best available techniques` 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 impact on the environment as a whole.

- 'techniques` shall include both the technology used and the way in which the installation is designed, built, maintained, operated and decommissioned.

- 'available` techniques shall mean 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, whether or not the techniques are used or produced inside the Member State in question, as long as they are reasonably accessible to the operator,

- 'best` shall mean most effective in achieving a high general level of protection of the environment as a whole.

AC use BAT Techniques described in NFM BREF

IPPC directive

Page 11: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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AIR:Smelter: Improved dust collection in concentrate silos buildings. Enclosed belt conveyors

Improvement in storage of raw materialsFitting, paving and cleaning of roads and parking areas for vehiclesEnvironmental improvements at calcium sulphate charging installationEnclosure storage facilities of secondary material and new crushing plant.Bag filters in rotary dryer. Redesign and modification of the steam dryers bag filters New wet electrofilter after the gas scrubbers of Anode furnacesRedesign/replacement of launders and stand boxes of furnace´s tappingsRecirculation of Flash furnace tapping gas to the process Replacement of primary hood for convertersReplacement of the converters scrap chargersInstallation of the secondary hood for the convertersAbatement of particulate and SO2 from converter secondary emissions

Tank house: Gas capture for the electrolyte purification cells, sections 27,28 and 29

WATER:Canalization and isolation of cooling water in the acid plantsUnification of the discharges of Liquid Effluent Treatment and Gypsum PlantsReuse waste water to processes.

WASTE:New press filter to minimize the neutralization cake of the Gypsum PlantOptimize waste temporary storage facilities.Reducción, recycling, reuse of wastes.

Projects carried out since 2003

Page 12: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Improved dust collection in concentrate buildings.

Page 13: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Bag filters in rotary dryer

Page 14: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Recirculation of Flash furnace tapping gas to the process

Page 15: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Converters Secondary Hoods

Page 16: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Page 17: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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SO2 and dust abatement from converter secondary emissions

Page 18: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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New wet electrofilter after gas scrubbers. Anode furnaces

Page 19: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

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Secondary materials Crushing plant

Page 20: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Environmental Performance

Note: Emissions based on average values

Evolution of SO2 emissions (% 1999) Evolution of particle emissions (% 1999)

10088

68.8

0

20

40

60

80

100

1999 2005 2011

100

2911.7

0

20

40

60

80

100

1999 2005 2011

Page 21: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Cumulative Environmental Investment

14.9

14.9

58.7

58.7

62.2

62.2

62.962

.964.0

64.0

68.5

68.5

79.2

79.2

87.3

87.3

89.7

89.7

92.2

92.2

98.6

98.6

102.6

102.

6

112.9

112.

9

134.0

134

147.3

147.

3

162.1

162.

1

171.9

171.

9

175.8

0

100

1994 1996 1998 2000 2002 2004 2006 2008 2010

Mill

on

es

de

Eu

ros

Source: Environmental declaration

Page 22: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Certificate for Total Quality Management System (ISO 9001) since 1994.

Certificate for Environmental Management System (ISO 14001) since 1998.

Registered in the European System Eco-Management and Audit Scheme (EMAS) since 1999.

All Atlantic Copper technologies and processes are Best Available Techniques (BAT) as per EU Directive 96/61 IPPC.

IPPC Integrated Environmental Permit (AAI) awarded in November 2007.

Certificate for OHSAS 18001(Occupational Health and Safety Advisory Services) since 2010.

Certificate for UNE-EN 50001 Energy Management System since 2011.

Management Systems

Page 23: IPPC Visit 12072012R2 [Modo de compatibilidad] · (ISO 9001) since 1994. Certificate for Environmental Management System (ISO 14001) since 1998. Registered in the European System

Before going to the Plant:Reception of Individual protective items

• Helmets• Gloves• Safety glasses• Masks• Hearing protection

Specific risks during the visit to the Plant:• Presence of SO2 gases• Metallic dust• Projection of incandescent metals• Splashing of corrosive liquids

Instructions during the visit to the Plant:• Follow the instructions of your guide • Stay with your group• Use the handrails on stairways• In case of emergency (a continuous siren

blast lasting one minute) closely follow the instructions of your guide.

Safety Information