Report on Best Available Techniques (BAT) in Copper Production FINAL DRAFT Deutsch-Französisches Institut für Umweltforschung (DFIU) French-German Institute for Environmental Research University of Karlsruhe (TH) o. Prof. Dr. O. Rentz Dipl.-Ing. Martin Krippner, Dipl.-Ing. Stephan Hähre, Dr. Frank Schultmann Karlsruhe, March 1999 On behalf of the German Federal Environmental Agency, Berlin (UBA) in the frame of the Research Project 109 05 006 Contents 221 CONTENTS 0 PREFACE ....................................................................................................................................................... 231 1 GENERAL INFORMATION........................................................................................................................ 233 1.1 PRODUCTION AND USE OF COPPER ............................................................................................................. 233 1.2 FIRST INDICATION OF ENVIRONMENTAL CONCERNS REGARDING THE PRODUCTION OF COPPER .................. 235 1.2.1 Emissions into the atmosphere.......................................................................................................... 235 1.2.2 Potential releases into water............................................................................................................. 236 1.2.3 Solid materials generated ................................................................................................................. 237 2 APPLIED PROCESS TECHNOLOGY AND ABATEMENT TECHNIQUES IN COPPER PRODUCTION.................................................................................................................................................. 239 2.1 INTRODUCTION AND SCOPE OF THE STUDY................................................................................................. 239 2.2 BASIC DESCRIPTION OF COPPER PRODUCTION ............................................................................................ 240 2.2.1 Primary copper production............................................................................................................... 240 2.2.2 Secondary copper production........................................................................................................... 252 2.2.3 Further processing of copper cathodes ............................................................................................ 262 2.2.4 Plants for copper production and further processing of copper cathodes........................................ 266 3 PROCESS TECHNOLOGY, ABATEMENT TECHNIQUES AND PRESENT CONSUMPTION/EMISSION LEVELS IN GERMAN COPPER PRODUCTION ................................... 270 3.1 COPPER PRODUCTION AT NORDDEUTSCHE AFFINERIE AKTIENGESELLSCHAFT........................................... 270 3.1.1 Primary smelting plant ..................................................................................................................... 272 3.1.2 Secondary smelting plant.................................................................................................................. 277 3.1.3 Electrolysis plant for primary and secondary copper....................................................................... 283 3.1.4 Characteristics of fabrics filters at NA ............................................................................................. 285 3.1.5 Further processing of copper at NA ................................................................................................. 287 3.1.6 Waste water treatment plant ............................................................................................................. 289 3.1.7 Summarised data on outputs and environmental concerns at NA .................................................... 290 3.2 SECONDARY COPPER PRODUCTION AT HÜTTENWERKE KAYSER AG.......................................................... 293 3.2.1 Blast furnaces ................................................................................................................................... 294 3.2.2 Scrap converters (Pierce-Smith type) ............................................................................................... 298 3.2.3 Reverberatory anode furnaces.......................................................................................................... 299 3.2.4 Electrolysis plant .............................................................................................................................. 300 3.2.5 Electrolyte purification ..................................................................................................................... 301 3.2.6 Tin-lead alloy plant........................................................................................................................... 302 3.2.7 Characteristics of fabric filters at HK............................................................................................... 303 3.2.8 Waste water treatment ...................................................................................................................... 304 3.2.9 Summarised data on outputs and environmental concerns at HK.................................................... 304 3.3 COPPER PRODUCTION AT MANSFELDER KUPFER UND MESSING GMBH, HETTSTEDT ................................ 306 3.3.1 Blast furnace..................................................................................................................................... 307 3.3.2 Converter .......................................................................................................................................... 310 3.3.3 Anode plant....................................................................................................................................... 312 3.3.4 Electrolytic plant............................................................................................................................... 315 3.3.5 Characteristics of fabric filters at MKM........................................................................................... 315 3.3.6 Further processing of copper at MKM ............................................................................................. 316 3.3.7 Summarised data on outputs and environmental concerns at MKM ................................................ 316 3.4 FABRICATION OF WIRE ROD AT FRIEDRICH KEMPER GMBH & CO KG, DUISBURG AND LACROIX & KRESS GMBH, BRAMSCHE ......................................................................................................................................... 318 222 Contents 3.5 FABRICATION OF SEMI-FINISHED PRODUCTS FROM COPPER AND COPPER ALLOYS ...................................... 320 3.5.1 Melting.............................................................................................................................................. 321 3.5.2 Casting.............................................................................................................................................. 325 3.5.3 Fabrication of Sheet and Strip.......................................................................................................... 326 3.5.4 Fabrication of Copper and Copper Alloy Tubes, Rods and Sections ............................................... 330 3.5.5 Waste water treatment ...................................................................................................................... 333 3.5.6 Summarised data on outputs and environmental concerns of the fabrication of semi-finished products ................................................................................................................................................................... 334 4 GERMAN CANDIDATE BEST AVAILABLE TECHNIQUES (BAT) FOR INTEGRATED POLLUTION PREVENTION AND CONTROL IN THE COPPER PRODUCTION ............................... 340 4.1 GENERAL PROVISIONS AND REQUIREMENTS FOR THE PREVENTION AND CONTROL OF ENVIRONMENTAL POLLUTION....................................................................................................................................................... 341 4.1.1 Monitoring of emissions.................................................................................................................... 341 4.1.2 Techniques to prevent and control emissions into the atmosphere................................................... 344 4.1.3 Water management ........................................................................................................................... 348 4.1.4 Management of by-products and wastes........................................................................................... 350 4.1.5 Energy aspects .................................................................................................................................. 352 4.1.6 Noise aspects/abatement techniques................................................................................................. 353 4.1.7 Plant safety aspects........................................................................................................................... 354 4.1.8 Plant operation and decommissioning.............................................................................................. 355 4.2 ................................................................................................................................................................... 356 4.2 CANDIDATE BAT FOR COPPER PRODUCTION ............................................................................................