10th Joint EIONET and the Task Force on Emission Inventories and Projections Meeting

1. Towards the AEI Guidebook Maintenance Plan: additions to the NickelProduction ChapterOutline of 2009 contribution in-kind of Belarus to EMEP Sergey Kakareka, Tamara Kukharchyk Institute for Nature Management National Academy of Sciences Minsk, Belarus 10th Joint EIONET and the Task Force on Emission Inventories and Projections Meeting 11-12May 2009, Vienna, Austria

2. Summary • Included into presentation: • 1. Rationale • 2. Proposed additions to the 2.C.5.cNickel production chapter • - Overview of nickel products and industry • - Principal technologies and schemes • - Emissions and abatement • - Tier 1 and Tier 2 EF tables

3. Current status of the 2.C.5.c Nickel production chapter • - too schematic description of technological processes; • - Tier1 EF are relevant only for hydrometallurgical technology. • If applied these factors for total Europe nickel production annual SOx emission in Europe will be about 8-9 thous. tonneswhile real emissions in EMEP domain from nickel production are about 20 times higher, in extended EMEP domain – 100-120 times higher; • - no Tier1 EF for pyrometallurgic technology; • - no TIER 2 EF which are necessary for accurate and complete emission inventory from nickel production.

4. Proposed additions into: Overview Nickel products At the market nickel is presented in different brands. Metallic nickel is divided into two main classes: refined nickel (nickel cathodes (greatest), briquettes, granules, rondelles, powder/flakers etc.) and chargenickel (ferronickel, nickel oxide sinter, secondary nickel). Less part of nickel is produced also as nickel chemicals.

5. World nickel production (USGS data) World nickel production in 2005 according to USGS amounted 1,3 mln. tons Main types of nickel products: • Metal • Ferronickel • Chemicals • Oxide sinter & oxides World nickel production by types of products

6. World primary nickel production by country %, (2005) Main primary nickel production countries Russian Federation – 287 thous. t ; Japan – 167 thous. t; Canada – 140 thous. t; Australia – 122 thous.t

7. Nickel primary production in Europe, % (2005) Nickel primary production in Europe in 2005 amounted 509 thous. tons • Main primary nickel production countries in Europe • Russian Federation – 287 thous. t • Norway – 85 thous. t • Finland – 44 thous. t • United Kingdom – 37 thous. t

8. Production of nickel by types of process in Europe Nickel from ore (full cycle of nickel production):- Russian Federation- Greece (ferronickel)- Macedonia (ferronickel)Nickel from matte: - Norway - Finland - France - United Kingdom Ratio of nickel production by type in Europe

9. Main smelter and refinery nickel facilities in Europe

10. Technologies and main processes in nickel production • Pyrometallurgical technology: • from sulfidic ores: ore concentration–roasting-smelting-converting-smelting-refining; • from silicate ore: smelting-converting-smelting-refining); specificity: coke or coal as fuel, pyrites as additives; • from laterite ore: drying calcining-smelting-converting to matte or ferronickel. • Hydrometallurgical technology: • from laterite ores: ammoniacal leaching-hydrogen reduction to oxide sinter; • from matte: chloride or sulfuric acid leaching or carbonyl process - refining.

11. Matte Converter matte Electric smelting Converting Flash smelting Electric smelting Electric refining Roasting Ni catodes Sintering Copper production Ore concentration S, H2SO4 production into: Description of sources Principal scheme of nickel production:pyrometallurgical technology (sulfidic Ni-Cu ores)

12. Matte Converter matte Reduction sulfidyzing smelting (shaft furnaces) Converting Flash smelting Electric smelting Electric refining Ni cathodes Furnace charge preparation Principal scheme of nickel production: Pyrometallurgical reduction sulfidyzing technology, nickel silicate oxidized ores

13. Matte Chloride leaching Sulfidic acid leaching Carbonyl process Refining Principal scheme of nickel production:hydrometallurgical technology, nickel from matte (EC)

14. into: Emissions and control Particulate emission: battery cyclones, ESP, wet scrubbers at agglomeration and smelting stages. Level of abatement: 92-99% (EECCA). SOx – waste gases washing with further sulfur or sulfuric acid production. Level of desulfurization - up to 75%. SOx emission depends on sulfur content in ore, technology, SOx content in waste gases, possibilities of sulfur from gases utilization.

15. into: Methods Tier 1 Emission factors for refinery nickel production without smelter stage(hydrometallurgical technology, EC)

16. Tier 1 Emission factors for refinery nickel production with smelter stage (nickel-copper sulfidic ornickel silicate oxidized ores, pyrometallurgical technology,EECCA)

17. Tier 2 Emission factors for nickel production. Pyrometallurgical technology, nickel-copper sulfidic ores, limited SOx control. EECCA

18. Tier 2 Emission factors for nickel production. Pyrometallurgic technology, nickel-copper sulfidic ore or converter matte, average level of SOx control. EECCA

19. Tier 2 Emission factors for nickel production. Reduction sulfidyzing technology, oxidized silicate nickel ore, limited or no SOx control. EECCA

20. Tier 2 Emission factors for ferronickel production. Pyrometallurgical technology. EC

21. Application of results SOx emission by 50x50 EMEP grid in 2006, tonnes (WebDab) Spatial resolution of SOx emission can be improved. For instance, it is seen that Cola Peninsula SOx emissions in Webdab (32.4 thous. tones for 2005), used for EMEP modeling are underestimated taking into account nickel-copper production facilities in this region.

22. Uncertainties - SOx and PM emission factors seems rather low uncertainty; - HM emission factors are highly uncertain (except Ni and Cu); As, Pb, Cd emissions are expected when pyrite is used in technological process.

23. Concluding remarks • - proposed addition aimed at improvement of applicability of the Guidebook chapter for real life emission inventory work; • - it is difficult to divide emission by product when different products (metals: nickel, copper, cobalt etc. ) are produced at the same plant: special comments are necessary in Data Quality section which will allow to exclude double counting or missing sources; • - sources of statistical data need to be shown; • bibliography to be improved.

24. Plans for 2010 in-kind: - further improvements to the GB in view of POPs, HM and overall in view of EECCA countries technological specificity.

25. Thank You for Your attention!