Reference Document on Best Available Techniques in the Non

8,35
MB Ferrous Metals Industries (adopted Dec 2001)

807
stron

1104
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2002
rok

Preface xix

1 General Information .1

1.1 Processes covered in the scope of the work1

1.2 Industry Overview.2

1.2.1 Non-ferrous metals and alloys .2

1.2.2 Scope of the industry .2

1.2.3 Structure of the industry 3

1.2.4 Economics of the industry .3

1.2.5 Environmental performance 4

1.3 Copper and its’ Alloys 5

1.3.1 General .5

1.3.2 Sources of materials.5

1.3.3 Production and consumption .6

1.3.4 Production sites.7

1.3.5 Environmental issues .10

1.4 Aluminium.12

1.4.1 General .12

1.4.2 Sources of materials.12

1.4.3 Production and consumption .12

1.4.4 Production sites13

1.4.5 Environmental issues .14

1.5 Zinc, Lead and Cadmium15

1.5.1 Zinc.15

1.5.1.1 General.15

1.5.1.2 Sources of materials16

1.5.1.3 Production and consumption.16

1.5.1.4 Production sites.18

1.5.1.5 Environmental issues 19

1.5.2 Lead 19

1.5.2.1 General.19

1.5.2.2 Sources of materials20

1.5.2.3 Production and consumption.20

1.5.2.4 Production sites.21

1.5.2.5 Environmental issues 22

1.5.3 Cadmium 23

1.5.3.1 General.23

1.5.3.2 Source of materials .23

1.5.3.3 Production and consumption.23

1.5.3.4 Environmental issues 24

1.6 Precious Metals26

1.6.1 General .26

1.6.2 Sources of materials.26

1.6.3 Production and consumption .27

1.6.4 Production sites28

1.6.5 Environmental issues .28

1.7 Mercury .29

1.7.1 General .29

1.7.2 Sources of materials.29

1.7.3 Production and consumption .29

1.7.4 Environmental issues .30

1.8 Refractory Metals .31

1.8.1 General .31

1.8.2 Sources of materials.32

1.8.3 Production and consumption .34

1.8.4 Production sites34

1.8.5 Environmental issues .35

1.9 Ferro-Alloys.37

1.9.1 General .37

1.9.2 Sources of material 38

1.9.3 Production and consumption. 39

1.9.4 Production sites . 42

1.9.5 Environmental issues. 42

1.10 Alkali and Alkaline Earth Metals. 43

1.10.1 General . 43

1.10.2 Sources of materials 43

1.10.3 Production and consumption. 44

1.10.4 Production sites . 46

1.10.5 Environmental issues. 46

1.11 Nickel and Cobalt 48

1.11.1 Nickel . 48

1.11.1.1 General . 48

1.11.1.2 Sources of materials . 48

1.11.1.3 Production and consumption 49

1.11.1.4 Production sites 50

1.11.1.5 Environmental issues 50

1.11.2 Cobalt. 52

1.11.2.1 General . 52

1.11.2.2 Sources of materials . 52

1.11.2.3 Production and consumption 52

1.11.2.4 Production sites 53

1.11.2.5 Environmental issues 54

1.12 Carbon and Graphite 55

1.12.1 General . 55

1.12.2 Sources of materials 55

1.12.3 Production and consumption. 56

1.12.4 Production sites . 57

1.12.5 Environmental issues. 58

2 Common Processes and Equipment 61

2.1 Organisation of the chapter 61

2.1.1 Installations that produce a number of metals or have associated processes on-site. 62

2.2 Emission measurement and use of emission data. 63

2.2.1 Measurement of emissions 63

2.2.1.1 Sampling locations . 63

2.2.1.2 Components and parameters. . 64

2.2.1.3 Reference conditions 64

2.2.1.4 Continuous measurement . 64

2.2.2 Reporting emission data 65

2.2.2.1 Interrelationship between concentration and specific emissions. . 66

2.2.2.2 Uses of emission data . 67

2.3 Management systems . 68

2.3.1 Management policy and commitment . 68

2.3.2 Design and maintenance 69

2.3.3 Training 69

2.4 Receipt, storage and handling of raw materials and residues. 70

2.4.1 Applied processes and techniques. 70

2.4.1.1 Ores and concentrates. 70

2.4.1.2 Secondary raw materials 71

2.4.1.3 Fuels 72

2.4.1.4 Process chemicals and gases 73

2.4.1.5 Residues . 74

2.4.2 Present emissions and consumption levels 74

2.4.3 Techniques to consider in the determination of BAT 75

2.5 Pre-processing and transfer of Raw Materials 77

2.5.1 Applied processes and techniques. 77

2.5.1.1 Thawing. 77

2.5.1.2 Drying . 77

2.5.1.3 Crushing and size reduction . 77

2.5.1.4 Battery breaking . 78

2.5.1.5 Blending . 78

2.5.1.6 Briquetting, pelletising and other agglomeration methods. 78

2.5.1.7 Sintering and calcination 79

2.5.1.8 Fuming processes79

2.5.1.9 De-coating and de-oiling 80

2.5.1.10 Incineration and pyrolysis.80

2.5.1.11 Leaching procedures.80

2.5.1.12 Separation techniques .81

2.5.1.13 Transfer and charging systems81

2.5.2 Present emission and consumption levels81

2.5.3 Techniques to consider in the determination of BAT82

2.6 Metal Production and Process Control Techniques 84

2.6.1 Furnaces for roasting, calcining etc .85

2.6.1.1 Rotary kilns.85

2.6.1.2 Fluidised bed roaster.86

2.6.1.3 Herreshoff furnace 86

2.6.1.4 Sintering furnaces .87

2.6.2 Smelting furnaces 88

2.6.2.1 Reverberatory furnace.88

2.6.2.2 The blast furnace (and Imperial Smelting Furnace)89

2.6.2.3 Electric arc furnaces90

2.6.2.4 Electric (resistance) furnace92

2.6.2.5 Refractory lined pits and crucibles .93

2.6.2.6 The ISA Smelt/Ausmelt furnace.93

2.6.2.7 The Top Blown Rotary furnace 94

2.6.2.8 The Noranda, El Teniente, Baiyin and Vanyucov processes 95

2.6.2.9 The Mitsubishi process .96

2.6.2.10 QSL furnace97