ippc visit 12072012r2 [modo de compatibilidad] · (iso 9001) since 1994. certificate for...
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www.fcx.com CONNECTING THE FUTURE®
WelcomeTurkish Delegation
Twinning IPPC
12 July 2012
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Atlantic Copper en Europa
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Atlantic Copper en Huelva
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UBICACIÓN
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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
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Flowsheet
Oxygen
Gypsum Plant
Concentrate
Cathodes Anodes
Sulfuric acid
Iron Silicate
Flue dust
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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
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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
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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
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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
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Improved dust collection in concentrate buildings.
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Bag filters in rotary dryer
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Recirculation of Flash furnace tapping gas to the process
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Converters Secondary Hoods
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SO2 and dust abatement from converter secondary emissions
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New wet electrofilter after gas scrubbers. Anode furnaces
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Secondary materials Crushing plant
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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
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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
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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
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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