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Assesment of utili zed technologies and comparasion with Best Available Techniques

Assesment of utili zed technologies and comparasion with Best Available Techniques. Authors: Ž eljko Kamberovi ć , Ph.D. metallurgy Marija Kora ć , M.Sc. metallurgy. Mapped locations in Serbia. The Šabac Plant. US Steel Serbia. Zajača, Loznica. Thermal Power Plant Kostolac.

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Assesment of utili zed technologies and comparasion with Best Available Techniques

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  1. Assesment of utilized technologies and comparasion with Best Available Techniques Authors: Željko Kamberović, Ph.D. metallurgy Marija Korać, M.Sc. metallurgy

  2. Workshop, Belgrade, dec. 10th 2007

  3. Mapped locations in Serbia The Šabac Plant US Steel Serbia Zajača, Loznica Thermal Power Plant Kostolac Thermal Power Plant Kolubara RTB Bor, Bor Rudnik, Rudnik Trepča Complex Workshop, Belgrade, dec. 10th 2007

  4. OBJECTIVES • Comparison of the technologies currently used by the mining and metallurgical industries with BEST AVAILABLE TECHNIQUES in the relevant fields • Evaluation of potential technological improvements in the same fields, focusing at the prevention of the regional water resources contamination and remediation of the polluted surface-, ground- water. Workshop, Belgrade, dec. 10th 2007

  5. BATs for the metallurgical industries • SERBIA METALLURGICAL INDUSTRIES • US steel: Iron and steel production • Sabac Plant: primary Zn production • Zajaca AD: secondary Pb production • RTB BOR : primary copper production • SERBIA ELECTRIC POWER PLANTS • Kostolac : electric power plant • Kolubara : electric power plant Workshop, Belgrade, dec. 10th 2007

  6. Mining activities • RTB Bor, TREPCA • Rudnik, Rudnik • Rudnik flotation tailings are tailings of canyon type. Dam of the tailing is on 495m and it is made from hydrocyclone sand, and slurry fraction is transported to settling lake, distant from the top of the dam 200-300m. Pulp pipe line is 2km long, diamenter 150cm. Tailings is designed and build providing work of Rudnik in the next 40 years. Retention time of slurry fraction is long, 1-2 years, allowing enough time for settling of mineralar particles, dissolution and bonding of flotation agents. Annual quantity of tailings is 200 000t. In wastewaters no toxic materies in amounts over discharge limits are detected. Nearest settlement is town Rudnik on 5-6km from tailings. Workshop, Belgrade, dec. 10th 2007

  7. Trepca complex • Passive tailings are: • Marevački Stream – Novo Brdo, Gračanica, Gornje Polje – Zvečan, Žitkovac, • Gornji Krnjin – Leposavić and Veliko i Malo Polje – Rudnica with total area of 147ha. • Active flotation tailings are, although they are not in function for pas five years, • Dečkin Stream – flotation Badovac Žarkov Stream – flotation First Tunel, Bostanište – flotation Kopaonik – Leposavić, Kukanjica Stream – flotation Suva Ruda – Rudnica with total area of 90ha. Workshop, Belgrade, dec. 10th 2007

  8. Flotation tailings Marevci is from processing of lead-zinc ores and is located beside Marevacka river. On this flotation tailing is astimately disposed 651.000 t ( 345.000 m3) of tailings on area of 6ha. • Flotation tailings Gracanica is located beside river Gracanka approximately 3km from monastery Gracanica. Near the tailings is road Pristina-Gnjilane-Vranje. Here is deisposed tailings from lead-zinc processing. Total area of tailings is 40ha with average height of 20m where 11. 235.000 t (5,9 miliona m3) tailings is disposed. • Flotation tailings Gornje polje is located on right bank of river Ibar,3 km north from Kosovska Mitrovica. Near the tailings are road and rail.Tailings is devided in two parts by Kutlovacki stream. Total area of tailings is 50ha with average height of 10-12m where 15.000.000 t (8.150.000 m3) tailings is disposed. • Flotation tailings Zitkovac is located 1.4 km north from Zvecan on theritory of Zitkovac village at the left bank of river Ibar near the road and rail. Total area of tailings is 26ha with average height of 19-22m where 7.050.000 t tailings is disposed. • Flotation tailings Gornji Krnjin (Upper Krnjin) is located 900m north from flotation plant on the right bank of river Ibar. Total area of tailings is 7ha with average height of 12-14m where 2.600.000 t tailings is disposed. • Flotation tailings Velilko and Malo Polje (Big and Small Field) are on the right bank of river Ibar closeby rail and road. Total area of tailings is 18ha where 2.750.000 t of tailings from magnetite and copper concentrate production and 850.000t of tailings from lead and zinc concentrate production are disposed. • Flotation tailings Deckin Stream is built up above village Badovac in basin Deckin stream, nearby is road Priština – Gnjilanje – Vranje. Tailings is in operation since 1988 and for the time of exploitation disposed was 1.970.000t of tailings on area of 18ha. • Flotation tailings Zarkov Stream is basin Zarkov Stream near the road Kraljevo-Skoplje. Exploitation of this tailings started in 1974 and up to now is disposed 11.970.000 t of tailings on 22ha. • Flotation tailings Bostaniste, Leposavic is near right bank of river Ibar on 1.2 km from flotation Kopaonik. Dam of flotation tailings is built by hydraulic methiod from hydrocyclone sand. Small fractions are depositet in tailings lake, and clarified waters are trough collector are drained out of tailings. Up to now on area of 30ha 3.340.000 t of tailings is disposed. • Flotation tailings Kukanjica, Rudnica is located within village of Rudnica and occupies area of 19ha and up to now disposed is 1.080.000t of tailings. Workshop, Belgrade, dec. 10th 2007

  9. General principles of BATs BATs involve Raw materials handling Process control Gas collection and abatement Prevention and destruction of dioxins Metallurgical process Emissions to air/ to water Process residues Toxic compounds Workshop, Belgrade, dec. 10th 2007

  10. Iron and steel production Workshop, Belgrade, dec. 10th 2007

  11. Emission to water • The water management in an integrated steelworks primarily depends on the local conditions, • fresh water and on legal requirements. • Figure 1 gives an example of water management with an indication of the water treatment of an integrated steelworks with surplus of intake water availability, thus explaining the presence of many once-through cooling systems, resulting in a specific water consumption of more than 100 m3/t steel. At sites with very low fresh water availability there is a need to save water as much as possible. In such cases the specific water consumption can be less than 5-10 m3/t steel Workshop, Belgrade, dec. 10th 2007

  12. Workshop, Belgrade, dec. 10th 2007

  13. US Steel Serbia • Direct recipient of ww is Ralja river • 2 collectors, no ww flow measurement • 12 samples × 4 sampling points per year • Increased ammonia (CII), phosphate, suspended materials, BOD5 & COD (Ralja upstream CI&II) • 2 industrial water recirculation systems A&B • 90% of water in recirculation system (according to design) • No significant release of recirculation water to surface water • Underground water • Some points increased content of Al, Ba, B, Co, Cu, Mg, Mn, Ni, Zn Workshop, Belgrade, dec. 10th 2007

  14. Flow sheet of using and treatment of cooling and technical water in blast furnace complex USSS use in total 245m3 ind water/t of product Source: Study of environmental impact of Blast furnace 1 in US Steel Serbia Workshop, Belgrade, dec. 10th 2007

  15. Gases • For sinter plants the following techniques or combination of techniques are considered as BAT: • Waste gas de-dusting by application of: • Advanced electrostatic precipitation (ESP) (moving electrode ESP, ESP pulse system, high voltage operation of ESP), or • Electrostatic precipitation plus fabric filter, or • Pre-dedusting (e.g. ESP or cyclones) plus high pressure wet scrubbing system. • Using these techniques dust emission concentrations <50 mg/Nm3 are achieved in normal operation. In case of application of a fabric filter, emissions of 10-20 mg/Nm3 are achieved. Workshop, Belgrade, dec. 10th 2007

  16. Waste gas recirculation, • Minimisation of PCDD/F emissions • Minimisation of heavy metal emissions • Lowering the hydrocarbon content of the sinter feed and avoidance of anthracite as fuel. • Recovery of residue heat. • Minimisation of SO2 emissions, by for example: • Lowering the sulphur input • With wet waste gas desulphurisation, • Minimisation of NOx emissions by, for example: • Waste gas recirculation • Waste gas denitrification, applying • Regenerative activated carbon process • Selective catalytic reduction. Workshop, Belgrade, dec. 10th 2007

  17. BAT-Integrated steelworks Workshop, Belgrade, dec. 10th 2007

  18. US Steel Serbia • Per t of steel 600 kg of by-products and secondary meterials • BF slag 250-500 kg/t Fe, CR slag 130-150 kg/t steel • More than several projects on recycling of these products in past 10 years! CONCLUSION →air pollution →degradation of environment →risky work conditions Workshop, Belgrade, dec. 10th 2007

  19. RTB Bor 5 mil. tonscat. Cu • WW treatment plant • Lime milk neutralization trough two tanks • Out off work • See: http://www.labmet.ntua.gr/intreat/ • Treatment of part of mining and metallurgical blue waters is performed in existing cementation plant • Government conditioned new owner to change smelting technology Workshop, Belgrade, dec. 10th 2007

  20. Copper Reverberatory Furnace 1879Butte, Montana Workshop, Belgrade, dec. 10th 2007

  21. BAT-Primary Cu production Workshop, Belgrade, dec. 10th 2007

  22. Copper converting Workshop, Belgrade, dec. 10th 2007

  23. Flash Smelting 1950s Workshop, Belgrade, dec. 10th 2007

  24. Outokumpu Flash Smelting Process, 'Metallurgical innovation of the 20th century' ASM Historical Landmark status Workshop, Belgrade, dec. 10th 2007

  25. SO2 versus So Workshop, Belgrade, dec. 10th 2007

  26. SO2 versus So Workshop, Belgrade, dec. 10th 2007

  27. HYDROMETALLURGY H2SO4, H2SO4 + Fe2(SO4)3, chloride solutions e.g. FeCl2, amonnia chloride hydroxyphenyl oximes C6H3 (R)(OH) CNOHR* R= C9H19 or C12H25 R*= H, CH3 ili C6H5 Workshop, Belgrade, dec. 10th 2007

  28. RTB Zajaca & MONBAT PLC, Indjija • Currently in construction • Water treatment seems to be according to BAT Workshop, Belgrade, dec. 10th 2007

  29. BAT-Secondary Pb Workshop, Belgrade, dec. 10th 2007

  30. Other locations • The Sabac zinc plant • currently out of work • in process of ownership transformation • contact with new owner • total water treatment reconstruction! • The Trepca Complex • currently hope for renewing of metallurgical activities • in future new smelter could be built Workshop, Belgrade, dec. 10th 2007

  31. BAT-Zn hydrometallurgy Workshop, Belgrade, dec. 10th 2007

  32. Techniques that can be used to reach the SO2 levels, BAT Workshop, Belgrade, dec. 10th 2007

  33. Jarosite and Pb-Ag slimes from leaching • Jarosite • According to the “European Waste catalogue of Hazardous Waste List” jarosite is characterized as ”hazardous waste”. • Re-design of the leaching process • Restricting the process to neutral leaching only is one alternative method that can be used to avoid the production of intractable wastes (jarosite). In this case iron remains in the leach residue along with a significant portion of the zinc. This residue is used as the feed for a pyrometallurgical process to recover the zinc, lead, silver, sulphur and to bring the iron into a slag. • Controlled Disposal • If the modification of the leaching process is not feasible, then techniques to render the jarosite residue inert should be used if possible. The effective washing and precipitation of the leachable metals as sulphides before disposal should be considered. Moreover, the solubility of the residue should be monitored using a standard leachate test. (Council Directive 1999-3 on the landfill of waste). • Pb-Ag slime • BAT for the treatment of this kind of slime is the recovery of Ag. However there are no BATs available for the recovery of Ag so this is an open area for research. The Pb-Ag slime could be processed further in a lead smelter (during lead smelting and refining the precious metals are concentrated in a Pb-Zn-Ag alloy) or leached with MgCl2 or CaCl2. Workshop, Belgrade, dec. 10th 2007

  34. ENERGY PRODUCTION • Wastes arising from the lignite combustion plants are of three types: liquids (mainly oil contaminated waste waters), solids (fly ash) and gases (SO2 , CO2 , NOx emissions, dusts). Workshop, Belgrade, dec. 10th 2007

  35. Utilization possibilities of combustion residues and by-production Workshop, Belgrade, dec. 10th 2007

  36. BATs for de-dusting off-gases from lignite-fired combustion plants Workshop, Belgrade, dec. 10th 2007

  37. Workshop, Belgrade, dec. 10th 2007

  38. BATs for prevention and control of SO2 from lignite power production plants Workshop, Belgrade, dec. 10th 2007

  39. Conclusion • Comparison of BAT’s and currently used technologies in mining and metalurgical industry of Serbia showed that only one plant could be considered as BAT (Monbat, Indjija) • Significant effort for technological improvement is visible in companies with constant production level and appropriate profit (US Steel Serbia, Smederevo) Workshop, Belgrade, dec. 10th 2007

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