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DKL Engineering, Inc.
		
Handbook of Sulphuric Acid Manufacturing
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Acid Plant Database January 4, 2020
| Owner | Glencore Sudbury Integrated Nickel Operations  | 
    
	  | 
  
| Location | Longyear 
	Drive Falconbridge, Ontario Canada P0M 1S0  | 
  |
| Background | 
	Formerly Falconbridge Limited
	
	![]() Formerly Falconbridge Nickel Mines Limited Formerly Xstrata Nickel ![]()  | 
  |
| Website | 
	www.glencore.com
	 www.glencore.ca www.sudburyino.ca  | 
  |
| Plant | Sudbury Smelter | |
| Coordinates | 46º 34' 43" N, 80º 48' 7" W | |
| Type of Plant | Metallurgical | |
| Gas Source | 
	Nickel (2) Roaster, Electric Furnace  | 
  |
| Hot Gas Cleaning | - | |
| Wet Gas Cleaning | Peabody Scrubber - (4) Primary WESP - 2 Secondary WESP | |
| Contact Section | Drying Tower - Blower - Cold HX (SS) - Inter HX (SS) - Hot HX (SS) - Bed 1 - Hot HX (TS) - Bed 2 - Inter HX (TS) - Bed 3 - 3/4 HX (SS) (air cooled) - Bed 4 - Cold HX (TS) - Tailgas HX (TS) - Absorber - Tailgas HX (SS) - Smelter Stack | |
| Plant Capacity | 1168 MTPD | |
| SA/DA | 
	Original: 3 SA 2008 - 4 SA (with installation of an interbed heat exchanger)  | 
  |
| Status | Operating | |
| Year Built | 1978 | |
| Technology | MECS | |
| Contractor | Simon-Carves FENCO | |
| Equipment | 
	Blower Supplier: Allis Chalmers Delivery Year: Model: D48JR Quantity: 1 Flow Rate: 131334 CFM Pressure Rise: 7.587 psi (210" WC) Driver: Electric Motor Converter Fabricator: Lopes Ltd. Material: 304 SS Diameter: 44'-0" Height: 85'-0" Weight: 400,000 lb   
	
	![]()  | 
  |
| Remarks | 2010 - Drying Tower replaced with an Outotec designed tower. Wardrop provided engineering. | |
| Pictures |     | 
  |
| General | The processing facilities operated by the Sudbury Smelter include a smelter and a sulphuric acid plant. The Sudbury Smelter smelts nickel-copper concentrate from the Sudbury and Raglan mines and processes custom feed materials. It is capable of producing 130,000 tonnes of nickel-copper matte annually. The smelter's electric furnace converts the mineral concentrate into a high-grade matte containing nickel, copper, cobalt and platinum group metals. The smelted and granulated matte is sent by rail to Quebec City, then shipped overseas to Falconbridge Nikkelverk in Norway for refining into pure metals. | |
| References | - | |
| News | 
	 
	January 28, 2016 - Sudbury's 
	second largest mining company, Glencore's Sudbury Integrated Nickel 
	Operations, has received approval to exceed emission standards while it 
	upgrades its Falconbridge smelter. 
	Glencore officials are pleased with the Ministry of Environment and 
	Climate Change's recent decision to grant approval of its site-specific 
	standard application for nickel at the smelter, said company spokeswoman 
	Yonaniko Grenon.  "This approval 
	allows us the required time to research, design and implement the 
	technologies and processes required to further reduce nickel emissions from 
	our Sudbury smelter facility while maintaining compliance with Ontario's Air 
	Quality Regulation," she said.  
	Before it submitted its application, Glencore held consultation sessions 
	with key stakeholders, among them the Falconbridge Citizens' Committee. It 
	also held an open house and sent a letter to Falconbridge residents 
	providing an overview of the standards process, said Grenon. 
	The June 2014 open house was staffed by a number of technical 
	experts, including representatives from the Ministry of Environment and 
	Climate Change.  Glencore just 
	received approval for the smelter for dioxide, cadmium and nickel 
	site-specific standards from the ministry. 
	Improvements have been made as part of these site-specific standard 
	approvals, said Grenon. The initial work focused on reducing sulphur dioxide 
	emissions.  Sudbury INO applied 
	for the site-specific for the smelter's nickel emissions to air in 2014 and 
	it was approved by the Ministry of the Environment and Climate Change in 
	December 2015, she said.  The 
	ministry approved Glencore's request for a site-specific standard for nickel 
	and nickel compounds at the smelter after an in-depth technical review, said 
	ministry spokesman Lindsay Davidson. 
	Site-specific standards require companies to invest in the best 
	available technology and practices to reduce emissions over time. "This 
	ensures industries are continually improving their performance and 
	decreasing emissions to better protect the environment," he said. 
	Glencore has made significant investments in state-of-the art 
	technology, said Davidson, and will continue investing in its facility to 
	reduce air emissions.  The 
	ministry closely monitors a company's progress as it works to reduce air 
	emissions as much as possible with technology-based solutions and best 
	practices.  Public participation 
	plays an important role in the ministry's review of proposals for 
	site-specific standards, said Lindsay. A draft site-specific standard 
	approval for Glencore was posted on the Environmental Registry for a 45-day 
	public review and no comments were received. 
	The city's largest miner, Vale Ltd., received approval from the 
	ministry for a site-specific standard for nickel in December 2011 and for 
	sulphur dioxide in December 2012. The nickel site-specific standard expires 
	Dec. 28, 2021, and the approval for sulphur dioxide Dec. 31, 2017. Davidson 
	said Vale is operating in compliance with the site-specific standards. 
	Due to the current economic climate, with nickel prices at an 
	all-time low, Vale has advised the ministry some of Clean Atmospheric 
	Emissions Reduction project will be delayed, said Davidson. 
	The Clean AER project will reduce sulphur emissions by 85 per cent, 
	and reduce dust and metal emissions and greenhouse gases by 40 per cent. 
	Davidson said Vale has told the ministry it expects to be in 
	compliance with the provincial standard for sulphur dioxide by the end of 
	2017.  At a meeting last week of 
	the Sudbury branch of the Canadian Institute of Mining, Metallurgy and 
	Petroleum, the director of the Clean AER project, Dave Marshall, told the 
	audience Vale has completed 55 per cent of the work for the $1-billion 
	project.  Marshall said $625 
	million has been invested and the project is on target for completion by 
	January 2018.  
	
	
	www.thesudburystar.com/  
	November 24, 2010 
	January 22, 2010 - Xstrata Nickel cut production at its 
	Falconbridge smelter Thursday afternoon because the weather was causing an 
	inversion effect, where the plume is closer to the ground, said a 
	spokesperson from the Ministry of the Environment.  
	Kate Jordan said the ministry received three complaints from the public 
	about a sulphur haze over the Ramsey Lake area starting at about 3 p.m.  
	"Once we received complaints, we followed up first with Inco to ensure that 
	it wasn't anything that was happening at the smelter in Copper Cliff," 
	Jordan said.  Inco's plume, 
	however, was travelling away from the city, she said.  "Then our environmental officer followed up with Xstrata and 
	they were already aware of the situation and had cut back operations," 
	Jordan said.   Jordan said 
	the weather conditions were causing an "inversion" where the plume is lower 
	than it would be normally.  
	"They do monitor for it. They know when they see that that condition is 
	going to be present, they cut back operation," Jordan said.  Dominique Dionne, vice-president of corporate affairs at 
	Xstrata in Toronto, said the smelter was brought down when the problem 
	occurred.  "We have systems that 
	tell us when there is an exceedance (in emissions) and we haven't had any of 
	that so far," she said.  Jordan 
	said the ministry was in contact with Xstrata Thursday afternoon.  
	"Based on all the information that was provided by the company in our 
	discussions with them, we don't have any immediate concerns for impacts to 
	the environment or to public health," Jordan said.  | 
  |
MTPD - Metric Tonne per Day           
STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per 
Annum
SA - Single Absorption
DA - Double Absorption  
* Coordinates can be used to 
locate plant on Google Earth