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Outotec and EnvironmentKalle Hrkki President, Pori Research Center CMD Seville May 15, 2008
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Outotec Oyj
CMD 2008 Seville, Spain
ContentGeneral Ferroalloy technologies Flash Smelting and Converting technologies Acid plant technologies Mineral Processing - Hydrometallurgy
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Outotec Oyj
CMD 2008 Seville, Spain
Award-winning clean technologiesFlash Smelting - Flash Converting technology for sulfidic copper oresASM Historical Landmark award in 2001; The cleanest copper smelting technology in the world
Ferrochrome processWinner of the 2007 Cleantech Finland competition Qualified for the European Business Awards for the Environment 2008 competition; Because of its cleanness and energyefficiency.
A new copper production methodQuality Innovation of the Year 2007 by Excellence Finland Because of low investment, low operating cost and environmental sustainability.
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Outotec Oyj
CMD 2008 Seville, Spain
Clean technologies as a booster for competitiveness and economic growthOur customers want to produce metals competitively. Only those producers survive in the long run who use sustainable technologies. Profitability and environmentally sound technologies can and must go hand in hand.
Copper smelter, refinery, precious metals and sulfuric acid plant in Yanggu, China
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Outotec Oyj
CMD 2008 Seville, Spain
Environmentally sound technologiesTechnology development is the key toeffective use of raw materials lower energy consumption lower water consumption less emissions better working environment
In improving the environmental conditions of a metallurgical plant, it is important to evaluate the whole production chain, from ore to metal.
Outotec Ferroalloy Technology Economical and Environmental Benefits
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Outotec Oyj
CMD 2008 Seville, Spain
Ferrochrome Process
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Outotec Oyj
CMD 2008 Seville, Spain
Advantages of SBSTM technologyLower investment and operation costs. Furnace gas rich in CO from the electric furnace. used as fuel. High efficient use of cooling gases of the sintered pellets. Low exhaust gas temperatures. Profitable and high grade pellets for smelting.
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Outotec Oyj
CMD 2008 Seville, Spain
Profitable pelletsSpherical, equally sized, hard and porous pellets. Constant chemical and physical properties. High refractoriness under load. High reducibility.
Ideal charging material for smelting.
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Outotec Oyj
CMD 2008 Seville, Spain
Benefits of using high quality pelletsBetter submerged electric arc furnace operation. Average load and power factor are higher. Energy consumption is significantly lower. Electrode paste consumption is lower. Continuous and even operation. High furnace availability.
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Outotec Oyj
CMD 2008 Seville, Spain
Outotec FeCr smelting process Automatic batching system. Preheating in a stationary shaft kiln. Smelting furnace is closed and sealed. Patented power contol system. Cleaning of CO-gas. Slag is granulated.
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Outotec Oyj
CMD 2008 Seville, Spain
Electric power consumption in smelting depending on chromite qualityRUN-OF-MINES, BRIQUETTES, FINES
Power consumption kWh/t
5 000
LUMPY ORE 4 000
PELLETS
3 000
Preheated
CHROMITE QUALITY
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Outotec Oyj
CMD 2008 Seville, Spain
Without Technology Development the CO2 emissions would have been almost 5 fold compared to the actual amountsCO2 emissions in FeCr production in Tornio With and without technology development600 000 CO2 EMISSIONS, ACTUAL 500 000 CO2 EMISSIONS, tpa CO2 EMISSIONS WITHOUT IMPROVEMENTS
400 000
300 000
200 000
100 000
0 1970
1975
1980
1985
1990 YEAR
1995
2000
2005
2010
Flash Smelting & Flash Converting
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Outotec Oyj
CMD 2008 Seville, Spain
Outotec Copper Flash Smelting / Converting Technology
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Outotec Oyj
CMD 2008 Seville, Spain
Flash Smelting Technology Flexible SolutionFlash Smelting has been applied for smelting ofcopper concentrates (matte and blister production), copper matte (i.e. Flash Converting), nickel concentrates,
Copper Flash Smelters have been designed, built and operated for smelting of copper concentrates containing as low as 14 % copper and as high as 55 % copper; Flash Smelting can use any kind of additional fuel like natural gas, fuel oil, recycled oil, coal or coke; with the benefit of being able to utilize high-sulphur fuels, too.
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Outotec Oyj
CMD 2008 Seville, Spain
Advantages of Flash ConvertingClosed processlow gas and dust emissions good working conditions
Continuous low-volume process gas flow, rich in SO2less gas cooling and cleaning capacity required low CAPEX/OPEX possibility for liquid SO2 production
Continuous processhigh automation degree, good process control
Smelting and Converting separatedhigh on-line availability
High capacity with one small-sized converting furnaceno converter aisle, no cranes less maintenance, low CAPEX
Proven Flash Smelting technology
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Outotec Oyj
CMD 2008 Seville, Spain
Sulphur capture development in copper smeltingSulfur capture in Cu Smelting Brook Hunt database 2005100 90 80 SULFUR CAPTURE, % 70 60 50 40 30 20 10 0 S capture Outokumpu Flash Smelters S capture by other smelters
Most economic way to close the gap is to change smelting technology to Flash Smelting and Flash ConvertingS capture average
19 92 19 93 19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 20 04 05 ( 20 F) 06 ( 20 F) 07 ( 20 F) 08 ( 20 F) 09 ( 20 F) 10 (F )YEAR
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Outotec Oyj
CMD 2008 Seville, Spain
Energy consumption in copper smelters(based on Brook Hunt data)60 Total net energy concumption,GJ/t Cu Outokumpu Flash Other Smelters Power (Other Smelters)
50
40
30
20
10
0 0 100 000 200 000 300 000 400 000 500 000 Total Cu-Production, tpa
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Outotec Oyj
CMD 2008 Seville, Spain
KOKKOLA RNNSKR (SWEDEN) GLOGOW HAMBURG (GERMANY) SALT LAKE CITY SAN MANUEL HIDALGO (USA) PIRDOP (BULGARIA) BAIA MARE (ROMANIA) SAMSUN HUELVA (SPAIN) KHATOON-ABAD (IRAN) (TURKEY) KOSAKA HITACHI ASHIO TAMANO PASAR DAHEJ KHETRI GHATSILA (INDIA) CAMACARI (BRAZIL) CHUQUICAMATA CHAGRES (CHILE) FORTALEZA (BRAZIL) KALGOORLIE TENNANT CREEK OLYMPIC DAM MOUNT MORGAN (AUSTRALIA) KONKOLA (ZAMBIA) SELEBI-PHIKWE (BOTSWANA) JINCHANG YANGGU TONGLING GUIXI (CHINA) (PHILIPPINES) TOYO SAGANOSEKI (JAPAN) (POLAND) HARJAVALTA (FINLAND) NORILSK (RUSSIA)
ONSAN (SOUTH KOREA)
LA CARIDAD (MEXICO)
Flash Smelters around the world
Cu SMELTING Cu CONVERTING DIRECT TO BLISTER Ni SMELTING NOT IN OPERATION
Acid Plant Technologies
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Outotec Oyj
CMD 2008 Seville, Spain
Sulphuric Acid Plants from Smelter Off-gas1. Feed material: Off gas from metallurgical processes (melting, roasting, etc.) (SO2 content 2%-60% vol) 2. Products: Sulphuric acid ( 94,0 - 98,5% H2SO4) 3. Applications: Cleaning of metallurgical off gas (ore roasting, metal smelting and converting, etc.) 4. Capacity range: 50 5.000 tpd (product H2So4) 5. Investment costs: 5 - 200 Mio USD
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Outotec Oyj
CMD 2008 Seville, Spain
Our experience in sulphuric acid plantsMore than 80 Years in H2SO4 technology Over 600 acid plants built world wide Smelting, roasting, off-gas cleaning, acid plants single supplier Worlds largest metallurgical acid plant: 4,200 mtpd (1.5 MM t/a) Worlds largest sulphur burning plant 4,800 mtpd (1.7 MM t/a) Super project Maaden 3 x 4,500 mtpd (de-bottlenecked 5,000 t/d)
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Outotec Oyj
CMD 2008 Seville, Spain
LURECTM @ Yanggu Xiangguang Copper Co (capacity 2,300 mtpd)Conventional acid plant: 12 vol% => high gas volume => high invetment cost
LURECTM operates at 1618%-vol. SO2 5 Bed Converter with 3 integrated Heat Exchangers High Pressure Steam Production
Mineral Processing - Hydrometallurgy
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Outotec Oyj
CMD 2008 Seville, Spain
Mineral Processing - HydrometallurgyORE
CRUSHING
GRINDING
FLOTATION
FLOTATION TAILINGS
BIOHEAP LEACHING OF ORE ORE LEACHING
CONCENTRATE
CONCENTRATE LEACHING
LEACH RESIDUESOLUTION PURIFICATION
REDUCTION
METAL
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Outotec Oyj
CMD 2008 Seville, Spain
Energy-efficient grinding technologyEfficiency in the grinding circuit improves the overall performance of the concentrator. Outotec provides Advanced Control Tools (ACT) for grinding circuits:Desired particle size distribution is achieved and maintained. Throughput of the mil is optimized.
This ensures cost-effective, troublefree and efficient operation of grinding circuit.
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Outotec Oyj
CMD 2008 Seville, Spain
Advanced Flotation technologyOutotec sets new standards for Superior flotation performance: aeration, mixing and froth removing. Low operating and maintenance costs and high equipment reliability. The wide range of available cell sizes, including the world largest operating flotation cell (TC- 300) permits plant design to be compact, economical and efficient.
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Outotec Oyj
CMD 2008 Seville, Spain
Leading Thickener TechnologyThe revolutionary SUPAFLO High Rate Thickener concept has pioneered and redefined the methods of clarification and thickening around the world over the past decade.
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Outotec Oyj
CMD 2008 Seville, Spain
Paste thickeningOutotec leads the industry with thickening technologies for base metals and minerals slurries, using:High rate, High Compression, Paste Thickeners.
Why use Paste Thickeners?To efficiently use water (water shortage in mine-sites). Underflow (paste/solids) does not require filtration. De-watering a slurry to a paste will lead to environmentally sustainable tailings management. Paste might be used for refilling degraded mine-areas (rehabilitation of mine-sites).
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Outotec Oyj
CMD 2008 Seville, Spain
Outotec hydrometallurgical processesStandard HydroCopper Zn hydrometallurgy (direct zinc concentrate leach technology) SX technology Customer specific tailored Different unit processes (known performance) Equipment selection
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Outotec Oyj
CMD 2008 Seville, Spain
The HydroCopper - process HydroCopper is a chloride media based leaching process:
Copper concentrates. Secondary Copper raw materials.
Operating at athmospheric pressure and T = 80 -100 C. Final product copper rod. No concentrate transportation!!
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Outotec Oyj
CMD 2008 Seville, Spain
Customized process solutionWhat is a customized process solution?Utilization of existing knowledge and references. Adaptation of the knowledge for a customer specific case.
Customized process to treat customer specific raw materialLeaching Impurity control Residue control Product control.
Environmental aspects taken into account.
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Outotec Oyj
CMD 2008 Seville, Spain
Mine to metal conceptMINE CONCENTRATOR HydroCopper END PRODUCT
No concentrate transportation. Local sosio-economic impacts.
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Outotec Oyj
CMD 2008 Seville, Spain
Mine to Metal Longer lifetime for mine
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Outotec Oyj
CMD 2008 Seville, Spain
SummaryOur customers want to produce metals competitively. Only those producers survive in the long run who use sustainable technologies. Profitability and environmentally sound technologies can and must go hand in hand. Technology development is the key. It is important to evaluate the whole production chain, from ore to metal.
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Outotec Oyj
CMD 2008 Seville, Spain
More out of ore!