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TECHNICAL NOTE on BEST AVAILABLE TECHNOLOGIES NOT ENTAILING EXCESSIVE COSTS for HEAVY METAL EMISSIONS from NON-FERROUS INDUSTRIAL PLANTS Final Report - May 1991

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TECHNICAL NOTE on BEST AVAILABLE TECHNOLOGIES NOT ENTAILING EXCESSIVE COSTS for HEAVY METAL EMISSIONS from NON-FERROUS INDUSTRIAL PLANTS Final Report - May 1991 I - 2~637t.Pf TECHNICAL NOTE ON BEST AVAILABLE TECHNOLOGIES NOT ENTAILING EXCESSIVE COSTS FOR HEAVY METAL EMISSIONS FROM NON-FERROUS INDUSTRIAL PLANTS Final report - May 1991 *** EUROPEAN This document has been prepared for use within the Commission. It does not necessarily represent the Commission's official position. Cataloguing data can be found at the end of this publication. Luxembourg: Office for Official Publications of the European Communities, 1994 ISBN 92-826-5097-9 0 ECSC-EC-EAEC, Brussels Luxembourg, 1994 Reproduction is authorized, except for commercial purposes, provided the Cn,,.C" ir ...-l,..",..,-A,.-A European Commission Technical Note on Best Available Technologies Not Entailing Excessive Costs for Heavy Metal Emissions from Non-Ferrous Industrial Plants FINAL REPORT May 1991 Document This document has been prepared for use within the Commission. It does not necessarily represent the Coomission's official position. Copyright ECSC-EC-EAEC. Erussel - Luxembourg. 1994 Reproduction is authorized, except for commercial purposes, provided the source is acknowledged. Environmental Consultancy -~ ~ Technical Note on Best Avaliable Technologies Not entailing Excessive Costs €or Heavy Metal Emissions from Non-Ferrous Industrial Plants Editor: K.-H. Zierock FINAL REPORT May 1991 Final Report to etudy contract B 6611-90-6693 CONTENTS PAGE PREFACE 1 PART Ax GENERAL ASPECTS 3 AI Introduction 3 AI1 Legal Provisions of Member States Relevant for Plant Authorisation 3 AI11 Processes and Installations Included in this Technical Note 4 AIV Heavy Metals And Their Compounds Emitted by Non-Ferrous Industrial Plants 9 AV References to Part A 19 PART Bx mVY METAL EMISSIONS CAUSED BY NOH-FERROUS SNDUSTRIAt PLANTS AND THEIR CONTROL 20 BI Introduction 20 BII Emissions of Heavy Metals Caused by Non-Ferrous Industrial Plants 24 BIII Air Pollution Control Technology 21 BIV Cross-Media Aspects 36 BV Monitoring of Emissions 36 BVI References to Part B 60 PART cx CONSIDERATIONS WIT€i REGARD TO PARTICULAR PROCESSES 63 CI Introduction 63 CI I Lead Works 63 CIII Copper Works 79 cIV Zinc Works 93 cv Tin Works 101 CVI References to Part C 110 PART DI ANNEXES 111 DI Examples of the Performance Characte- ristics of Dust Collectors 111 DI I Example of Emissions Figures of Primary Lead Production 117 DIII Plant Authorisation Procedures in ~~ EC Member States 118 -~ DIV Recommended emission limits for lead-, copper-, and zinc-works 148 1 PREFACE The Council of the European Communities adopted a Directive (Com- mission 1984) on June 28, 1984 aimed at the provision of measures and procedures to prevent or reduce air pollution from stationary sources (i.e. industrial process or utility plant). The basis of the Directive is the requirement that a wide range of industrial processes shall be subject to prior authorization by competent authorities in each Member States. A key element of Directive is the concept of the Best Available Technology "that does not en- tail excessive costs" (BAT) to prevent or reduce air pollution, that must be incorporated into a plant prior to the issue of an authorization to operate. Member States were required to bring into force the relevant administrative infrastructure and natio- nal legislation necessary for full compliance with the provisions of the Directive by no later than 30 June 1987. An important provision of the Directive (Article 7 ) requires Mem- ber States to exchange (amoungst themselves and the Commission), information concerning (amoungst others) measures forthe preven- tion and reduction of air pollution as well as technical proces- ses and equipment (including BAT). The principle aim of Article 7 is to ensure that the necessary background information is made available (via information exchange) so as to ensure a harmonious implementation of the Directive in all Member States. In this regard, BAT is to be interpreted as the technology (or set of technologies) which operating experience has adequately demonstrated to be the best technology commercially available as regards the minimisation of emissions to atmosphere, providing it has been proven to be economically viable when applied to the industrial sector concerned. Application for authorizations will generally be deemed to meet BAT criteria if the performance of the proposed plant, under normal operating conditions, in terms of emissions to atmosphere, is guaranteed to be equivalent or better than that of the designated BAT. However, the provisions of the Directive also enable Authorization Authorities to consid- er whether, because of the individual characteristics of a plant or its local environment, the BAT guidance fully applies and whe- ther the criteria therefore need to be interpreted differently to take account of the particular characteristics of the plant and its environment. It is the Commissions intention, via the information exchange framework, to identify both BAT and the emission values associat- ed with this designated BAT. Such emission values will then become the principle by which future applications for authoriza- tion will be judged by the Authorization Authorities in Member States. This will give industry the flexibility to incorporate any reasonable measures provided the proposed plants meet the emission values and conform to broad principles of acceptable design practice. 2 The Commission has taken the initiative in this regard by esta- blishing a Working Group of experts to designate BAT pertaining __ to the production, storage and handling of heavy metals. This ~ technical note summarizes the Working Group’s deliberations and it is intended that it will be used as a set of advisory guide- lines by both industry and authorization authorities alike for ~~ the prior authorization of new plants and of existing plants - undergoing major dfication, thereby ensuring the intended and consistent implementation of Directive 84/360/EEC throughout the Community. For existing plants, special circumstances (proce- dures) apply which are outlined in Article 13 of the above men- tioned Directive. As new processes, equipment or technologies are developed, and proven to be economically viable and consistently to better any emissions values associated with the designated BAT, so the inno- vation will become the deaiganted R%!T and the dssion values associated with this new technology would become the emiaeions valuea by which future applications for authorisation would be measured. This is consistent with the evolutionary nature inhe- rent in the BAT concept. 3 PART Ai GENERAL ASPECTS AI Jntroducti0g The European Community (EC) is one of the greatest consum- ers of non-ferrous heavy metals in the world. In addition to the large amount of heavy metals imported from many non-EC countries, substantial production and domestic re- covery of heavy metals takes place in most EC Member States (Table AI(a) provides an overview). Of course, the importance and magnitude of production differs among Mem- ber States, as shown in Table AI(b) for a few selected heavy metals. In total, there are about 3000 non-ferrous heavy metal works in operation in the EC Member States, and several hundred are of a size that is worth taking into considera- tion. However, many of these works are part of larger non- ferrous heavy metal plants, so that the number of impor- tant plants within the EC might only be in the order of 40-50. Table AI(c) provides some background figures. This part of the Technical Note provides some background information of general interest concerning: 0 The legal requirements laid down in national legis- lation on non-ferrous heavy metal plants, as far as the requirements on authorisation and emission li- mit and guideline values are concerned. 0 The definition of the kind of plants and works dealt with in this note; 0 The emissions associated with non-ferrous heavy metal works and the identification of those which are of greatest relevance for human health and the environment. AII Leaal Provieions of Member States Relevant for Authoriaatioa Each Member State ha8 authorisation procedures of its own covering installation where non-ferrous metals are pro- cessed or where they are packaged and/or loaded in bulk. A brief summary of the relevant national provisions is given in Annex DIII. 4 AI11 Processes and Installations Included in thi s Tec hnic a1 -This technical note covers heavy metal emissions from the following sectors: i) roasting and sintering plants with a capacity of more than 1,000 tonnes of metal ore per year, ii) plants for the production and smelting of non- ferrous metals, having installations with a total capacity of more than 1 tonne for heavy metals or 0.5 tonnes for light metals. In the following section, a few additional coments are given in order to define in more detail the installations and processes which fall under these two headings. Under point i), all processes concerning the primary pro- cessing are included; that is: preparation of raw mate- rial, sintering and roasting, and subsequent pyro- or hy- droprocessing. In practical terms, all processes and treatments carried out in roasting and sintering plants after the delivery of the raw material and before shipping of the final product are covered. A large number of processes are applied in the non-ferrous metal industry, and in each of the processes a large num- ber of different steps of material treatment are used. It would go far beyond the scope of this technical note to describe them all in greater detail. However, the description of best available technology given in this note in principle includes them all, that means : - with regard to raw material preparation, the stor- age and handling of material as well as the crush- ing, screening, pelletising and all chemical treat- ments are included. Process steps carried out in order to beneficiate ores before entering the work- shop are not included; - with regard to sintering and roasting, all kinds of technologies used in this process step are covered, e.g.
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