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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