Towards the AEI Guidebook Maintenance Plan: Towards the AEI Guidebook Maintenance Plan: additions to the Nickeladditions to the Nickel Production ChapterProduction Chapter

Outline of 2009 contribution in-kind of Belarus to EMEPOutline of 2009 contribution in-kind of Belarus to EMEP

10th Joint EIONET and the Task Force on 10th Joint EIONET and the Task Force on Emission Inventories and Projections Emission Inventories and Projections MeetingMeeting

1111--1212 May 2009, Vienna, AustriaMay 2009, Vienna, Austria

Sergey Kakareka, Tamara KukharchykSergey Kakareka, Tamara Kukharchyk

Institute for Nature ManagementNational Academy of Sciences

Minsk, Belarus

SummarySummary

Included into presentation:Included into presentation:1. Rationale1. Rationale

2. Proposed additions to the 2. Proposed additions to the 2.C.5.c2.C.5.c Nickel production Nickel production

chapterchapter

- Overview of nickel products and industry- Overview of nickel products and industry

- Principal technologies and schemes- Principal technologies and schemes

- Emissions and abatement- Emissions and abatement

- Tier 1 and Tier 2 EF tables- Tier 1 and Tier 2 EF tables

Current status of the 2.C.5.c Nickel production Current status of the 2.C.5.c Nickel production chapterchapter

- too schematic description of technological processes;

- Tier1 EF are relevant only for hydrometallurgical technology. If applied these factors for total Europe nickel production

annual SOx emission in Europe will be about 8-9 thous. tonnes while real emissions in EMEP domain from nickel production are about 20 times higher, in extended EMEP domain – 100-120 times higher;

- no Tier1 EF for pyrometallurgic technology;

- no TIER 2 EF which are necessary for accurate and complete emission inventory from nickel production.

Proposed additions

into: Overview

Nickel products At the market nickel is presented in different brands. Metallic nickel is divided into two main classes: refined nickel (nickel cathodes (greatest), briquettes, granules, rondelles, powder/flakers etc.) and charge nickel (ferronickel, nickel oxide sinter, secondary nickel). Less part of nickel is produced also as nickel chemicals.

World nickel production World nickel production (USGS data)(USGS data)

World nickel production in World nickel production in 2005 according to USGS 2005 according to USGS amounted 1,3 mln. tonsamounted 1,3 mln. tons

metal58%

ferronickel22%

unspesified11%

oxide sinter and oxides

8%chemicals

1%

World nickel production by types of productsWorld nickel production by types of products

Main types of nickel Main types of nickel products: products:MetalMetalFerronickelFerronickelChemicalsChemicalsOxide sinter & Oxide sinter & oxidesoxides

World primary nickel production by country %, World primary nickel production by country %, (2005)(2005)

Russia22%

Japan13%

Canada11%Australia

9%

Others27%

China7%

Norway7%

Colombia4%

Main primary nickel production countriesRussian Federation – 287 thous. t ; Japan – 167 thous. t;

Canada – 140 thous. t; Australia – 122 thous.t

Nickel primary production in Europe, % (2005)Nickel primary production in Europe, % (2005)

Main primary nickel production countries in EuropeRussian Federation – 287 thous. tNorway – 85 thous. tFinland – 44 thous. tUnited Kingdom – 37 thous. t

Russia56%

Norway17%

United Kingdom

7%

Finland9%

Greece4%

Ukraine3%

France2% Others

2%Nickel primary Nickel primary production in production in Europe in 2005 Europe in 2005 amounted amounted

509 thous. tons509 thous. tons

Production of nickel by types of process in EuropeProduction of nickel by types of process in Europe

Ratio of nickel production by type Ratio of nickel production by type in Europein Europe

nickel from ore

62%

nickel from matte38%

Nickel from ore (full cycle of Nickel from ore (full cycle of nickel production):nickel production):- Russian Federation- Russian Federation- Greece (ferronickel)- Greece (ferronickel)- Macedonia (ferronickel)- Macedonia (ferronickel)

Nickel from matte:Nickel from matte: - Norway - Norway - Finland - Finland - France- France - United Kingdom - United Kingdom

Main smelter and refinery nickel facilities in Main smelter and refinery nickel facilities in EuropeEurope

Technologies and main processes in nickel Technologies and main processes in nickel productionproduction

Pyrometallurgical technology:Pyrometallurgical technology:

• from sulfidic ores: ore concentration–roasting-smelting-from sulfidic ores: ore concentration–roasting-smelting-converting-smelting-refining;converting-smelting-refining;

• from silicate ore: smelting-converting-smelting-refining); from silicate ore: smelting-converting-smelting-refining); specificity: coke or coal as fuel, pyrites as additives;specificity: coke or coal as fuel, pyrites as additives;

• from laterite ore: drying calcining-smelting-converting to from laterite ore: drying calcining-smelting-converting to matte or ferronickel.matte or ferronickel.

Hydrometallurgical technology:Hydrometallurgical technology:

• from laterite ores: ammoniacal leaching-hydrogen from laterite ores: ammoniacal leaching-hydrogen reduction to oxide sinter;reduction to oxide sinter;

• from matte: chloride or sulfuric acid leaching or carbonyl from matte: chloride or sulfuric acid leaching or carbonyl process - refining.process - refining.

Principal scheme of nickel production:Principal scheme of nickel production: pyrometallurgical technology (sulfidic Ni-Cu ores)pyrometallurgical technology (sulfidic Ni-Cu ores)

Copperproduction

S, H2SO4 production

Converting Flashsmelting

Ore concentration

Sintering

Roasting

Electric smelting

Electric refining

Converter matte

Ni catodes

Matte

Electricsmelting

into: Description of sourcesinto: Description of sources

Principal scheme of nickel production:Principal scheme of nickel production:Pyrometallurgical reduction sulfidyzing technology, nickel Pyrometallurgical reduction sulfidyzing technology, nickel

silicate oxidized oressilicate oxidized ores

Furnace charge preparation

Reduction sulfidyzing

smelting (shaft furnaces)

ConvertingElectric

smelting

Converter matte

Matte

Flashsmelting

Electricrefining

Ni cathodes

Principal scheme of nickel production:Principal scheme of nickel production: hydrometallurgical technology, nickel from matte (EC)hydrometallurgical technology, nickel from matte (EC)

MatteMatte

Sulfidic acid leaching

Chloride leaching Carbonyl process

Refining

Particulate emission: battery cyclones, ESP, wet scrubbers Particulate emission: battery cyclones, ESP, wet scrubbers at agglomeration and smelting stages. Level of abatement: at agglomeration and smelting stages. Level of abatement: 92-99% (EECCA).92-99% (EECCA).

SOx – waste gases washing with further sulfur or sulfuric SOx – waste gases washing with further sulfur or sulfuric acid production. Level of acid production. Level of desulfurization - up to 75%.desulfurization - up to 75%.

SOx emission depends on sulfur content in ore, technology, SOx emission depends on sulfur content in ore, technology, SOx content in waste gases, possibilities of sulfur from SOx content in waste gases, possibilities of sulfur from gases utilization.gases utilization.

into: Emissions and controlinto: Emissions and control

Tier 1 Emission factors for refinery nickel production Tier 1 Emission factors for refinery nickel production without smelter stagewithout smelter stage (hydrometallurgical technology, EC)(hydrometallurgical technology, EC)

into: Methodsinto: Methods

Tier 1 default emission factors

  Code Name

NFR Source Category 2.C.5.c Nickel production

Fuel NA not applicable

Pollutant Value Unit 95% confidence interval

Reference

Lower Upper

SOx 18 kg/Mg nickel 9 40  

TSP 0,66 kg/Mg nickel 0,33 1,32Eur.Comm. (2001)

As 1,6 g/Mg nickel 0,50 5,00Eur.Comm. (2001)

Cu 28,0 g/Mg nickel 8,00 100,00Eur.Comm. (2001)

Ni 42.0 g/Mg nickel 21.0 84.0Eur.Comm. (2001)

Tier 1 Emission factors for refinery nickel production Tier 1 Emission factors for refinery nickel production with smelter stagewith smelter stage ( (nickel-copper sulnickel-copper sulffidic idic oror nickel silicate nickel silicate oxidized ores, oxidized ores, pyrometallurgicapyrometallurgicall technology technology,, EECCA)EECCA)

Tier 1 emission factors for source category 2.C.5.c, nickel production

  Code Name

NFR Source Category 2.C.5.a nickel production

Fuel NA not applicable

Pollutant Value Unit 95% confidence interval

Reference

Lower Upper

SOx 3600,0 kg/Mg nickel 1200,0 10800  

TSP 100,0 kg/Mg nickel 33,3 300  

As 0,1 kg/Mg nickel 0,0 0,3  

Cd 0,1 kg/Mg nickel 0,03 0,3  

Cu 1,0 kg/Mg nickel 0 3  

Ni 2,8 kg/Mg nickel 0,9 8,4  

Pb 0,2 kg/Mg nickel 0,1 0,6  

Zn 0,1 kg/Mg nickel 0,0 0,3  

Tier 2 Emission factors for nickel production.Tier 2 Emission factors for nickel production. Pyrometallurgical technology, Pyrometallurgical technology, nickel-copper sulnickel-copper sulfifidic oredic ores, s, limited SOx control. EECCAlimited SOx control. EECCA

Tier 2 emission factors for source category 2.C.5.c, nickel production

  Code Name

NFR Source Category 2.C.5.a nickel production

Fuel NA not applicable

Technologies/Practices nickel-copper sulfidic ore, pyrometallurgica technology (roasting kilns with fluidized bed)

Region or regional conditions

EECCA

Abatement technologies Dust control ~ 95% (ESP), limited SOx control (desulfurisation level ~ 10%),

Pollutant Value Unit 95% confidence interval Reference

Lower Upper

SOx 4500,0 kg/Mg nickel 1500,0 13500  

TSP 30,0 kg/Mg nickel 10,0 90  

As 0,1 kg/Mg nickel 0,0 0,3  

Cd 0,1 kg/Mg nickel 0,03 0,3  

Cu 1,0 kg/Mg nickel 0 3  

Ni 4,6 kg/Mg nickel 1,5 13,8  

Pb 0,2 kg/Mg nickel 0,1 0,6  

Zn 0,1 kg/Mg nickel 0,0 0,3  

Tier 2 Emission factors for nickel production.Tier 2 Emission factors for nickel production. Pyrometallurgic technology, Pyrometallurgic technology, nickel-copper sulnickel-copper sulffidic oreidic ore or or converter matte, average level of SOx control. EECCAconverter matte, average level of SOx control. EECCA

Tier 2 emission factors for source category 2.C.5.c, nickel production

  Code Name

NFR Source Category 2.C.5.a nickel production

Fuel NA not applicable

Technologies/Practices nickel-copper sulfidic ore, converter matte, pyrometallurgical technology

Region or regional conditions

EECCA

Abatement technologies High efficiency of dust abatement (98%) (ESP, WSB), average level of SOx abatement (desulfurisation – 30-75%)

Pollutant Value Unit 95% confidence interval Reference

Lower Upper

SOx 700,0 kg/Mg nickel 233,3 2100  

TSP 60,0 kg/Mg nickel 20,0 180  

As 0,1 kg/Mg nickel 0,0 0,3  

Cd 0,1 kg/Mg nickel 0,03 0,3  

Cu 1,0 kg/Mg nickel 0 3  

Ni 3,3 kg/Mg nickel 1,1 9,9  

Pb 0,2 kg/Mg nickel 0,1 0,6  

Zn 0,1 kg/Mg nickel 0,0 0,3  

Tier 2 emission factors for source category 2.C.5.c, nickel production

  Code Name

NFR Source Category 2.C.5.a nickel production

Fuel NA coke

Technologies/Practices Silicate nickel (oxidized) ore, reduction sulfidyzing pyrometallurgical technology (shaft furnaces)

Region or regional conditions

EECCA

Abatement technologies Average level of dust abatement (90%), no or limited SOx control

Pollutant Value Unit 95% confidence interval Reference

Lower Upper

SOx 7000,0 kg/Mg nickel 2333,3 21000  

TSP 850,0 kg/Mg nickel 283,3 2550  

As 0,1 kg/Mg nickel 0,0 0,3  

Cd 0,1 kg/Mg nickel 0,03 0,3  

Cu 1,0 kg/Mg nickel 0 3  

Ni 2,2 kg/Mg nickel 0,7 6,6  

Pb 0,3 kg/Mg nickel 0,1 0,9  

Zn 0,1 kg/Mg nickel 0,0 0,3  

Tier 2 Emission factors for nickel production.Tier 2 Emission factors for nickel production.Reduction sulfidyzing technology, oxidized silicate nickel ore, Reduction sulfidyzing technology, oxidized silicate nickel ore, limited or no SOx control. EECCAlimited or no SOx control. EECCA

Tier 2 Emission factors for ferronickel production.Tier 2 Emission factors for ferronickel production.Pyrometallurgical technology. ECPyrometallurgical technology. EC

Tier 2 emission factors for source category 2.C.5.c, ferronickel production

  Code Name

NFR Source Category 2.C.5.a nickel production

Fuel NA not applicable

Technologies/Practices ferronickel production, smelting

Region or regional conditions EC

Abatement technologies limited control

Pollutant Value Unit 95% confidence interval

Reference

Lower Upper

SOx 195,0 kg/Mg nickel 65,0 585  

PM10 35,0 kg/Mg nickel 11,7 105  

Cr 20,0 g/Mg nickel      

Ni 4,2 g/Mg nickel 1,4 12,6  

Application of resultsApplication of results

Spatial resolution of SOx emission can be improved. For instance, it is Spatial resolution of SOx emission can be improved. For instance, it is seen that Cola Peninsula SOx emissions in Webdab (32.4 thous. tones seen that Cola Peninsula SOx emissions in Webdab (32.4 thous. tones for 2005), used for EMEP modeling are underestimated taking into for 2005), used for EMEP modeling are underestimated taking into account nickel-copper production facilities in this region.account nickel-copper production facilities in this region.

SOx emission by 50x50 EMEP grid in 2006, tonnes (WebDab)SOx emission by 50x50 EMEP grid in 2006, tonnes (WebDab)

- SOx and PM emission factors seems rather low - SOx and PM emission factors seems rather low uncertainty;uncertainty;

- HM emission factors are highly uncertain (except Ni - HM emission factors are highly uncertain (except Ni and Cu); As, Pb, Cd emissions are expected when and Cu); As, Pb, Cd emissions are expected when pyrite is used in technological process.pyrite is used in technological process.

UncertaintiesUncertainties

- proposed addition aimed at improvement of - proposed addition aimed at improvement of applicability of the Guidebook chapter for real life applicability of the Guidebook chapter for real life emission inventory work;emission inventory work;- it is difficult to divide emission by product when - it is difficult to divide emission by product when different products (metals: nickel, copper, cobalt etc. ) different products (metals: nickel, copper, cobalt etc. ) are produced at the same plant: special comments are are produced at the same plant: special comments are necessary in Data Quality section which will allow to necessary in Data Quality section which will allow to exclude double counting or missing sources;exclude double counting or missing sources; - sources of statistical data need to be shown;- sources of statistical data need to be shown;- bibliography to be improved.bibliography to be improved.

Concluding remarksConcluding remarks

Plans for 2010 in-kind:Plans for 2010 in-kind:

- further improvements to the GB in view of POPs, HM - further improvements to the GB in view of POPs, HM and overall in view of EECCA countries technological and overall in view of EECCA countries technological specificity.specificity.

Thank You for Your attention!Thank You for Your attention!