HELSINKI COMMISSION HELCOM PITF 19/2002Programme Implementation Task Force 19th Meeting Stockholm, Sweden, 18-19 November 2002

Agenda Item 5.2 Possible changes in the List of Hot Spots

Document code: 5.2/13

Date: 04.11.2002

Submitted by: Sweden

PROPOSAL FOR DELETION OF JCP HOT SPOT NO.1 - RÖNNSKÄRVERKEN Sweden presents the enclosed proposal for deletion of the industrial Hot Spot No. 1– Boliden Mineral AB’s Smelter Plant “Rönnskärverken”, Skelleftehamn. The Hot Spot was discussed at the Eighth PITF Regional Workshop in Stockholm (May 2002). The proposal has also been forwarded to the HELCOM LAND 6/2002 meeting (11-14 November) in order to receive the technical advice whether the requirements for deletion are fulfilled. This advice will be presented to the Meeting. The Meeting is invited to consider the proposal and to decide, as appropriate.

Note by Secretariat: FOR REASONS OF ECONOMY, THE DELEGATES ARE KINDLY REQUESTED TO BRING THEIR OWN COPIES OF THE DOCUMENTS TO THE MEETING Page 1 of

total 19

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Proposal for Deletion of Hot Spot No.1: Boliden Mineral AB's Smelter Plant Rönnskärsverken, Skelleftehamn.

Submitted by Sweden

(Ref: HELCOM PITF Criteria for Inclusion and Deletion of Hot Spots, 21 May 1999) General Information about Rönnskär 2002 The Rönnskär smelter in Skelleftehamn, northern Sweden, extracts metals and chemicals from mineral concentrates and various recycling materials. The main products are copper, lead, gold, silver and zinc clinker. Examples of by-products are liquid sulphur dioxide, sulphuric acid, selenium and nickel sulphate. Production figures are presented in Table 1 and process flow sheet is presented in Figure 1. Figure 1. Rönnskär's flow sheet

SecondaryRawMaterials

CopperConc.

Lead Conc.Dryer

FluidizedBed Roaster

ElectricSmelting Furnace

Fuming Plant

Kaldo Plant Lead Refinery

Converter Aisle

Anode Casting Plant

PreciousMetalsPlant

Sulphur Products Plant

ElectrolyticRefinery

SulphuricAcidSulphurDioxide

GoldSilverSeleniumPt/Pd-sludge

Dryer

CopperCopper SulphateCrude Nickel SulphateLead

Zinc ClinkerIron Sand

Copper Flow

Electronic Scrap

A more detailed description of the process flow sheet is presented in Appendix no 1.

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Production Capacity Rönnskär has 850 employees, of which 100 are women. The production capacity compared with that permitted is: Product Actual capacity Permitted capacity Copper 240,000 tonnes 300,000 tonnes Lead 40,000 tonnes 120,000 tonnes Gold 14,000 kgs 30,000 kgs Silver 450,000 kgs 750,000 kgs Zinc clinker 41,000 tonnes 80,000 tonnes Sulphuric acid 600,000 tonnes --- Liquid sulphur dioxide 60,000 tonnes --- Historical Review 1928 – 1930 The Rönnskär smelter was built to extract metal values from the Boliden mine, found in 1924. 1930 – 1933 Start-up of the copper smelter, tank house (electrolysis plant) and precious metals plant. 1942 – 1976 Continuous growth and production increases. The electric furnace replaces the old reverberatory copper smelting furnace. The lead plant, sulphuric acid plant and fuming plant are added. 1977 – 1997 Substantial environmental investments in filters and water purification. The Kaldo plant was built and recycling of electronic waste started. Arsenic production stopped in 1989. 1998 – 2000 The production capacity for copper is increased by 70% by rebuilding, and by introducing a new smelting process. This was carried out during full production in the units being replaced. A Multitude of Raw Materials The integration with Boliden’s own mines ensures daily arrivals of concentrates. A daily train shuttle transports concentrates from Boliden’s Aitik mine in the Arctic Circle. Concentrates from Boliden’s concentrator in the Skellefte ore arrive by truck. Concentrates arrive from countries such as Chile, Indonesia, Argentina and Australia. Rönnskär’s enlarged harbour can take vessels of up to 50,000 t. Rönnskär is a world leader in the recycling of base metals. Values are extracted from scrap and other waste containing metal. Copper ashes from the brass industry, scraped printed circuit boards, sorted metal fractions from dismantlers and shredders, copper cables, old silver coins etc. Zinc is recovered from slags and ashes as well as from steel making dust. Materials are sampled and verified on arrival to define metal values and check for unwanted impurities that may disrupt the processes. Sampling is based on proven methods, well-defined routines and experienced personnel. Sampling is of utmost importance to the profitability of recycling.

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Sustainable Extraction of Metals The sustainable use of metals is based on profitable production, efficient use of resources and minimal environmental impact. Rönnskär makes this possible through low costs, recycling, high recovery rates and first-rate environmental care. Emissions and impact are continuously monitored according to a detailed programme. Monthly reports are produced and sent to the county authority. Energy Energy consumption has decreased steadily since the 1980s. Despite continuing increases in metal production, energy consumption has decreased. New processes, cost-consciousness and better procedures have reduced the consumption of electricity, oil and coal. Waste energy is recovered as electricity and is also used for district heating. Slag - a Resource The by-product Boliden Iron Sand (granulated slag) is an example of increased sustainable reuse of slag and thus saving natural resources. The slag, which is cleaned in the fuming plant, is granulated and the product’s favourable insulating and draining properties make it particularly suitable for road construction and blasting. The low leachability of Boliden Iron Sand is recognised and well documented. Rönnskär +200 expansion project Boliden’s Rönnskär smelter has 1998-2000 undergone substantial changes. A major expansion has transformed Rönnskär into a world-class smelter with processes to extract and recycle base metals and precious metals. The new Rönnskär extracts high-purity copper at low cost and with minimal environmental impact. Proven and best available technology combined with experienced personnel results in high availability. The production capacity was increased by 100.000 tonnes to a total copper capacity of 240.000 tonnes. The project was a 2000 MSEK investment including: Harbour expansion Belt conveyor systems, reduces dust emission & internal truck transports New copper furnace - Flash smelter Enlarged converter hall, new converters w. new charge system New ventilation system & filter New Anode casting plant Expanded electrolysis plant (tank house) New sulphuric acid plant New oxygen plant (operated by Air Liquide)

The environmental considerations were estimated to cost about 700 MSEK (about 30% of the project cost).

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Rönnskär uses Best Available Technology and Best Environmental Practices (Ref: 1 Art. 16(2) IPPC Directive 96/61/EC); IPPC Reference Document on BAT in the Mon-ferrous Metals Industries, December 2001; Ref 2: OSPAR Recommendation 98/1 for Non-ferrous Metal Industry) The Rönnskär smelter plant comprises today a multitude of different process equipment, which meet BAT/BEP demands (IPPC Directive 96/61/EC; OSPAR Recommendation 98/1 for Non-ferrous Metal Industry, see Appendix 1:4). Some examples of applied BAT-technology are: Fluidized bed roasting of concentrates with Oxygen enrichment Slag fuming for Zn recovery from slag & secondary material Oxygen reduction by ammonia in enlarged rotary furnace Kaldo furnace for electronics recycling & autogenous lead smelting Conventional converting, spectroscopic process control (1994) Upgraded electric smelting, new cooling system (1995) Enlarged electro refinery, converted to ISA technology (1995) New gas handling in Kaldo plant for smelting of electronic scrap (1997) New precious metals plant including TBRC (Kaldo) (1997) Upgraded infra structure: expanded harbor & belt conveyor system for copper-

concentrates in order to reduce diffuse dust emission (1999) New sulphuric acid plant including a new process for Hg-cleaning (1999) New oxygen plant, operated by Air Liquide (2000) Large production expansion (+70 %) with a new flash furnace and modernized

process units (1998-2000) The gradual up-grading of the plant has resulted in a modern smelter with meeting strict environmental standards, domestic as well as those of the EU, OSPAR and HELCOM1. Emissions The emissions from Rönnskär 2001 are presented in Table 1. The recipient for effluent water is the Bothnian bay. All limit values are met. Table 1. Emissions to air and water for 2001 compared to limit and guideline values Substance (tonnes)

Dust Cu Pb Zn Cd As Hg SO2 NOx

Emission to air 56.8 1.7 5.0 9.0 0.14 0.36 0.11 3,954 116 Limit values, air 75*) 8*) 12*) 20*) 0.3*) 1.0*) 0.2*) 4,500 250**)

Discharge, water - 0.98 0.72 3.23 0.057 0.65 0.035 - - Limit values, water - 2.0 2.0 4.0 0.1 1.0 0.070 - - *) Guideline value 1999 – 2000, limit value from 2001. **) Guideline value. A historical review of the discharges to water is presented in Figure 2. Since 1970 the metal discharges has been reduced by 99.8 %. This is mainly the result of effective water purification measures. During the last decade (1992-2001) the metal discharge to the sea was reduced from 7.9 tonnes to 5.6 tonnes corresponding to a reduction by 30 %.

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Figure 2. Metal discharge from Rönnskär to the Bothnian Bay 1970-2001.

0 .0

5 0 0 .0

1 0 0 0 .0

1 5 0 0 .0

2 0 0 0 .0

2 5 0 0 .0

3 0 0 0 .0

3 5 0 0 .0

1970

1972

1974

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

T onne s/ye ar M e ta l d is c h a rg e C u +Zn +P b +A s

3245 t3245 t

5.6 t5.6 t

Average decrease 99.8%

Average decrease 99.8%

Looking back at the emissions to air substantial reductions have been achieved. This is the result of large investments in filter equipment, new processes, closure of some plants, improved maintenance and practice, and education of process operators. During the last decade (1992-2001) the dust discharge to the air has been reduced from 200 tonnes to 57 tonnes i.e. equal to a reduction by 70 %. Figure 3. Dust and sulphur dioxide emission 1970-2001.

Emission of dust and sulpur dioxide 1970-2001

0

500

1000

1500

2000

2500

3000

1970

1972

1974

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

TONNES Dust

05000100001500020000250003000035000400004500050000

Dust

SO2

TONNES SO2

Energy and Water Use In 2001 1,800,000 m3 of sweet water were used. The energy input amounted to 570 GWh of electricity, 118 GWh of fuel oil, 418 GWh of coal and coke, 0.7 GWh of diesel oil (vehicles) and 8 GWh of LPG. Coal is used as a reducing agent in the recycling of zinc in the slag fuming plant. The condenser turbine recovered 18 GWh of electricity. During 1983 – 2001, energy consumption has been reduced by 16 %, whilst metal production has increased by 61 %.

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Water and sewage management In 1970 water purification was introduced at Rönnskär based on lime precipitation. The cleaning effect was however limited. A water strategy was established which was based on separate treatment of discharged water containing different levels of contamination. The Rönnskär smelter has four separated piping systems for the effluent water. Water with high metal content is pumped to the water treatment plant at Rönnskär. Cooling water with low metal content is discharged to the sea. The sewage water is pumped to the community’s treatment plant. The four water systems and flow rates are described in Table 2. Table 2. Water treatment for effluent water.

Water type Flow m3/h Metal content Pumped to

Processwater

150 High Rönnskärs treatmentplant

Rain & washwater

50 Varying Rönnskärs treatmentplant

Cooling water 5000 Low The recipient

Sewagewater

10 Low The communitystreatment plant

Water type Flow m3/h Metal content Pumped to

Processwater

150 High Rönnskärs treatmentplant

Rain & washwater

50 Varying Rönnskärs treatmentplant

Cooling water 5000 Low The recipient

Sewagewater

10 Low The communitystreatment plant

In 1978 a water treatment plant was built at Rönnskär. The capacity of the plant is 200 m3/h. The technique is based on metal precipitation with sulphide followed by precipitation with lime. The metal rich sulphide sludge is reciculated to the process. The lime sludge, which has low metal content, is landfilled. The process is very effective and has gradually been optimised. The process control was further improved by the installation of an on-stream x-ray analyser equipment in 2001. The flow sheet of the water treatment plant is described in Figure 4.

R a in a n d W a s hW a te r

P ro c e s s W a te rL

L

S ed im e n ta t io n P o n d

R e a c tio n T a n k

S u p h id e s lu d g eR e c y c le d to P ro c e s s

T h ic k e n e rF A p H

FF

p H

S u lfu r ic A c id

C a u s tic S o d a

S o d iu m S u lfid e

P o ly m e r

L

H y d ra te d L im e

S u p p ly T a n k

F lu o rid eP re c ip ita tio nT a n k

S e d im e n ta tio n

In e rt S lu d g e to S to ra g e

E fflu e n tW a te r

Ap H

L

A

Figure 4. Rönnskär’s water purification plant

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As a precipitation agent, green liquor containing sulphide from the pulp and paper industry is used. The purification process is very effective. The assays of cleaned water are displayed in Table 3. In the same table the assays of discharged cooling water is presented. Table 3. Assays of discharged water 2001 from Rönnskär. Parameter Cu

(mg/l) Pb (mg/l)

Zn (mg/l)

Cd (mg/l)

As (mg/l)

Hg (mg/l)

Ni (mg/l)

COD (mg/l)

Cleaned water 0.015 0.014 0.158 0.001 0.126 0.0007 0.005 na Cooling water *) 0.022 0.016 0.073 0.001 0.015 0.001 0.008 13 Guidance value for cleaned water accord. to permit

0.05

0.1

0.5

0.005

0.5

0.005

---

---

HELCOM recommendation (23/11**)

0.5

0.5

2.0

0.2

---

0.05

1.0

250

*) Cleaned water is mixed w. cooling water before effluent sampling **) Recommendation for chemical industry superseding Recommendation 20/E6. The assays of discharged water do not exceed the HELCOM recommendation. Management of Emission to Air An extensive investment program in air cleaning devices has been implemented since 1970. This has resulted in large emission reductions of dust, metals and SO2. The start-up of the first sulphuric acid plant in the 1950´s was the first step towards reduction of the SO2 emission. A special sampling team carries out a comprehensive control program. 37 textile filters are supervised. The total filter area of the filters is 31000 m2 and the volume of filtered air is about 2 Mm3 per hour. The dust content in cleaned air after textile filters must be kept under 5 mg/m3. To keep a good filter performance it is crucial that supervision and maintenance is carried out in accordance to established routines. Modern textile filters are effective and can clean the dust content in filtrated air below 1mg/m3. Sulphur fixation rate is 99% and is the result of an effective ventilation system, good process control and bets available proven technique at the sulphuric acid/sulphur dioxide plant. The technique at the sulphur plant includes double absorption, mercury removal, polishing the off-gases by selenium and carbon filters, polishing off-gases by lime-carbon injection.

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Environmental monitoring Emission control Rönnskär is operated in accordance with a permit from the Swedish Licensing Board for Environmental Protection. The permit includes overall regulations and limit values for emissions into the air and water. The emissions of the smelter and their impact on the environment are monitored in accordance with a detailed programme. On a monthly basis, emission reports are sent to the County Administrative Board, which is the supervisory agency. In addition, the performance of approximately 40 filters and scrubbers is monitored. Every year 600 water samples, 1,300 dust samples and 50 calibration samples for SO2 are taken. Seven major sources for emissions of sulphur dioxide are recorded continuously. A four member sampling team conducts the emission control. Local studies Sulphur deposition is monitored in Sweden on more than 100 observation points. The deposition levels of metals and sulphur in Lake Holmsvattnet, 17 kms SW of Rönnskär, are relatively low, and in many cases lower than the background levels found in southern Sweden. In Figure 5 the sulphur deposition over Sweden is presented.

1998-991998-99 1999-20001999-2000

IVL Svenska Miljöinstitutet ABIVL Svenska Miljöinstitutet AB

Figure 5. Sulphur deposition over Sweden 1998-2000. http://www.ivl.se/miljo/projekt/kron/deps9899.asp Moss samples are taken in 5-year intervals in order to monitor metal deposition. In Figure 6 the moss assays of Pb in Sweden are presented. The influence from Rönnskär in northern Sweden has substantially decreased since 1975.

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1975 1980 1985 1990 1995

Figure 6. Pb in moss samples 1975-1995. http://www.environ.se/ The sulphur dioxide content in ambient air was measured 3 kms W of Rönnskär. The average content was 4 µg/m3, which is well below the current environmental quality norm (20 µg/m3. Lead levels in ambient air were measured in the vicinity (2.5 kms) of Rönnskär. The results are presented in Table 4. Lead levels were well below the Swedish environmental quality norm. Table 4 Lead in ambient air 2.5 km from Rönnskär Sampling period Pb in ambient air (ug/m3) Air quality standard (1year) 0.5 1999-10-12 -- 2000-01-04 0.029 2000-01-04- -- 2000-04-17 0.022 2000-04-17 – 2000-09-28 0.057

Vegetables are collected every 5 years from private gardens in the vicinity of Rönnskär and are analysed by the National Food Administration (NFA). The results are presented in Figures 7 and 8. Lead and cadmium assays in salad and berries have decreased continuously since the sampling started. As shown in Figures 7 and 8, the metal assays are lower than the limit value 0.2 mg/kg. Since the impact from arsenic is so low today the NFA in Sweden have decided not to discontinue arsenic assaying.

0.000

0.040

0.080

0.120

0.160

1985 1990 1995 2000

mg/kg

Lim it = 0.2 mg/kg

0.000

0.200

0.400

0.600

0.800

1985 1990 1995 2000

mg/kg

Limit = 0.2 mg/kg

Figure 7. Cadmium in salad

Figure 8. Lead in red currants.

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Samples of the mollusc Lymnea Palustris has been taken in 5 year intervals on 13 locations at the coast of Bothnia from 33 km north of Rönnskär to 90 km south. The assays show elevated grades around the smelter but the affected area is decreasing. A gradual recovery can be observed and elevated grades were 1999 found in a limited area from 3km north to 7 km south of the smelter. The results are shown in Figure 9. Figure 9. Hg assays of Lymnea Palustris 1989, 1994 and 1999.

00.050.1

0.150.2

0.250.3

0.350.4

33 km

, Bred

viken

22 km

, Herr

udden

8 km, S

nusan

3 km, G

råsida

n

2 km, G

åsören

0,8 km

, Näsu

dden,

Rö

3 km, Lå

ngsku

ttun

7 km, T

ällön

12,5 k

m Skallön

25 km

, Bjur

öklubb

44 km

, Brän

nögru

nd

66 km

, Näsu

dden, G

90 km

, Rata

n

Hg

mg/

kg Hg-89

Hg-94

Hg-99

"Background"

1,4

NorrNorth South

Herrings were sampled at 12 locations by the Swedish coast from Haparanda to Gävle. Metals and persistent organic substances were analysed. The results show that herring captured in Skellefteå Bay have good quality and none of the assays peaked in the Skellefteå Bay. Condensed results are shown in Figure 10.

0.000.100.200.300.400.500.600.700.800.90

Cu Pb Cd Hg

Index

HaparandaSkellefteå bayÖrnsköldsvikSundsvallGävle

Ref. ”Bottniska viken 1997 - årsrapport från den marina miljöövervakningen”Ref. ”Bottniska viken 1997 - årsrapport från den marina miljöövervakningen”

Figure 10. Metal assays in herring from Bothnian Bay.

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Numerous studies on humans have been carried out on humans in Rönnskär’s surroundings. In 1989-91 an extensive study of metal exposure on pregnant women living in the vicinity of Rönnskär was carried out in co-operation with the University of Umeå. Approximately 500 women participated. As a reference location Holmsund 130 km south Rönnskär was chosen. Assays carried out were: Pb and Cd in blood, As in urine and Hg in hair. Västerbottens Läns Landsting presented the results in a report in 1993. The results showed no difference in pregnancy outcome or metal concentrations between the Rönnskär area and Holmsund. Conclusion The Rönnskär smelter has carried out substantial environmental improvements since it was labelled ”Hot Spot No. 1”. The Rönnskär smelter today is a world-class plant operating environmentally adapted acknowledged Best Available Technologies and Practices (BAT/BEP). The radically reduced emissions have given positive environmental effects in the surroundings including the Bothnian Bay. Local studies show that the recovery process is in progress. The environmental effects that still can be observed are, however, determined by the large historical discharges. Referring to the facts presented above Sweden proposes that the Rönnskär smelter should be deleted from the HELCOM Hot-Spot List.

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Appendix 1:1 Rönnskär’s process flow sheet

SecondaryRawMaterials

CopperConc.

Lead Conc.Dryer

FluidizedBed Roaster

ElectricSmelting Furnace

Fuming Plant

Kaldo Plant Lead Refinery

Converter Aisle

Anode Casting Plant

PreciousMetalsPlant

Sulphur Products Plant

ElectrolyticRefinery

SulphuricAcidSulphurDioxide

GoldSilverSeleniumPt/Pd-sludge

Dryer

CopperCopper SulphateCrude Nickel SulphateLead

Zinc ClinkerIron Sand

Copper Flow

Electronic Scrap

Conveyor transport system from harbour to storage The new raw material handling system allows for rapid discharging of vessels, reliable sampling, and weighing of raw materials. It also minimises environmental impact. Raw materials are transported on covered conveyor belts. On-line sampling and weighing are carried out. Indoor storage of concentrates prevents dusting and freezing. Concentrates heading for the flash furnace are blended in the new continuous, circular bedding plant. Electric furnace The feed, calcine, dried ashes and reverts are fed to the furnace by chutes. The electric current passing the liquid slag supplies the energy required for melting. An upper layer of slag and a lower layer of matte are formed. The zinc-containing slag is transferred to the fuming plant. The matte, containing approximately 55 % copper along with iron, zinc, lead, precious metals, nickel and selenium is transferred to the converters. Flash furnace Copper concentrates are blended and dried prior to smelting by oxygen-enriched air. An upper layer of slag and a lower layer of matte are formed. The slag is cooled and crushed and sent to the Boliden concentrator. The matte contains approximately 70 % copper, together with minor elements and precious metals. The matte is transferred to the converters by ladle. Converter aisle The conversion of matte removes iron, sulphur and other impurities by oxidation with air injected through tuyeres. Sulphur is combusted, and iron, zinc and lead are slagged. The slag is returned to the electric furnace. The product, blister copper, which contains approximately 97 % copper, is transferred by ladle to the anode furnaces. A large filter is installed for the cleaning of the converter hall ventilation air. Anode casting plant Liquid blister copper from the converter aisle is deoxidised using liquid ammonia. The anode copper, containing 98 % copper, is then cast into anodes on the twin wheel. This is Europe’s first twin wheel caster.

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Appendix 1:2 Electrolytic refinery In the electrolytic refinery, anodes are converted into copper cathodes. Stainless steel sheets are used as cathodes. Using direct current, copper is selectively transferred by the electrolyte to the cathodes. Other chemical elements, such as precious metals, but also impurities settle as anode slimes. The slime is pumped to the precious metals plant. The cathodes are separated from the steel plates, bundled, sampled and weighed. A truck loads the high purity cathodes onto the Copper Shuttle, which leaves for domestic customers several days a week. Sulphur products plant The process gases from the copper and lead plants contain substantial amounts of sulphur dioxide. The gases are blended in a central washing tower. After cooling and dust removal, they are fed to the sulphur products plant. Sulphuric acid is produced by the double absorption method. Liquid sulphur dioxide is produced using in-house technology. Kaldo plant The Kaldo furnace is used for lead smelting and treating electronic scrap. Lead is extracted in two stages. Lead concentrates are smelted autogenously in the Kaldo furnace. The bullion is transferred to the lead refinery to produce high purity lead that is cast into 42 kg ingots. Electronic scrap is melted into black copper. The melt is transferred to the converter aisle. Fuming plant In the fuming plant, zinc clinker is extracted from slags and steel mill dust. In the fuming furnace, zinc and lead are vaporised by coal injection. The deoxidised metal dust is further refined at the clinker plant to obtain a product that is low in halogens. Zinc clinker, which contains approximately 70 – 75 % zinc, is exported to the Norzink zinc smelter in Norway. Precious metals plant Anode slimes, containing gold, silver, palladium and platinum together with impurities are pressure leached. From the solvent copper telluride and nickel sulphate is recovered. The leach residues are dried and after the addition of fluxes smelted in the precious metals Kaldo. During smelting, selenium is recovered. The converted silver is cast into silver anodes. A high intensity electrolytic refining produces high purity silver and gold slimes. The gold slimes are leached and high purity gold as well as palladium/platinum sludge are precipitated. The silver is granulated and the gold is cast into 12.5 kg bars or granulated.

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Appendix 1:3 Important installations of air cleaning devices at Rönnskär 1963 ESP-filters & textile filters installed in fuming plant 1972 Scrubber installed in fuming plant 1975 Textile filters installed in lead Kaldo plant 1979 Filtration of converter ventilation gas, step 1 1981 Filtration of converter ventilation gas, step 2 1983 Textile filter installed in clinker plant 1985 Restoration of ESP-filters in fuming plant, new textile filter in Kaldo 1986 Filter for furnace gas installed at copper plant 1987 Textile filter installed at PM plant 1993 Textile filters installed for converter ventilation gas 1997 New filter & scrubber at the PM plant 1997 New scrubber & textile filter in Kaldo plant 1999 New 12000-m2 textile filter for converter ventilation & flash 2000 Belt conveyor transport system from harbour to storage 2001 New equipment for dioxin cleaning w. active coal in fuming plant Important investments in the sulphur products plant at Rönnskär 1953 Sulphuric acid plant no 1 started production 1965 Sulphuric acid plant no 2 started production 1970 New converter off-gas system 1971 Sulphur dioxide plant no 1 started production 1977 Sulphur dioxide plant no 2, replaced no 1 1985 Double absorption in Sulphur dioxide plant no 2 1989 The old Pb furnace closed, primary lead smelting in Kaldo plant reducing SO2 emissions by 5000 tpy 2000 New plant for Sulphuric acid was built to take care of the increased production

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Appendix 1:4

Implementation Report on compliance with OSPAR Recommendation 98/1 concerning

Best Available Techniques and Best Environmental Practice for the Primary Non-Ferrous Metal Industry (Zinc, Copper, Lead and Nickel Works)

Country: SWEDEN

Reservation applies no Is measure applicable in your country?

yes

If not applicable, then state why not (e.g. no relevant plant) ..................................................................................................................................... ..................................................................................................................................... ..................................................................................................................................... ................................................................................................................................................. Means of Implementation:

by legislation by administrative action

by negotiated agreement

yes yes n.a. Please provide information on:

a. specific measures taken to give effect to this measure; See ANNEX I b. any special difficulties encountered, such as practical or legal problems, in the

implementation of this measure. N.a. c. the reasons for not having fully implemented this measure should be spelt out

clearly and plans for full implementation should be reported. N.a. ................................................................................................................................................. a) See Annex I ......................................................................................................................... b) Not applicable (n.a.) ............................................................................................................ c) N.a. ...................................................................................................................................... Contracting Parties should report on additional techniques which can achieve equal or better environmental protection, or which are more appropriate in certain geographical situations which are also acceptable, than those described in the Description of BAT for the Primary Production of Non-Ferrous Metals. Please provide information concerning:

a. the development of company energy plans and the introduction of energy management plans; See Annex I, §60-62.

b. applied and planned specific measures (if possible including typical performances); See Annex I, §60-62

c. the development of waste management plans. See Annex I, §60-62

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ANNEX I

OSPAR Recommendation 98/1 concerning Best Available Techniques and Best Environmental Practice for the Primary Non-Ferrous Metal Industry (Zinc, Copper, Lead and Nickel Works)

IMPLEMENTATION REPORT: SWEDEN

1. General Provisions and Requirements: Additional techniques: Not applicable (n.a.) 2. Storage and handling of raw materials: Implemented 3. Stockpiles and stockpiling or blending operations: Implemented 4. Raw materials should be received wetted and/or in sealed containers and/or in enclosed vehicles. Implemented. 5. In case of longer lasting storage a crust-forming agent can be applied. N.a. 6. Tipping to stockpiles: Implemented 7. For the storage and handling of hazardous substances, the strictest measures, roofing and complete side coverage

should be applied: implemented. 8. Transfer operations: a, b, c Implemented. 9. Totally closed facilities: Implemented. 10. Traffic and roadways: Roads should be cleaned, well defined and well maintained. Implemented during summer

season. Not practical during arctic winter conditions. 11. Drains should be fitted with interceptor points in order to prevent blocking. N.a. 12. Site vehicle restrictions: Implemented. 13. Wheels of vehicles should be washed before exiting the site. Impracticable in arctic conditions. 14. Facilities that wash vehicles may be polluted with heavy metals, discharges should be treated before release.

Implemented 15. Recycling: Implemented. 16. Atmospheric Pollution: Implemented where necessary. 17. In as much as dust-containing waste gases cannot be collected: N.a. 18. Recycling operations: Wetting when practicable. Implemented. 19. Transfer of drosses and slags for crushing should be in enclosed containers. Wet media slag granulation

practised. 20. Fine collected dust: Closed system capture implemented. 21. Process containment: Extraction of fumes/arrestment. Implemented. 22. Methods of containment: Where practical, containment should employ primary, secondary and tertiary stages:

Implemented. 23. The above emissions should be extracted to filters. Implemented for significant points. 24. High capacity vacuum cleaning systems should be used for housekeeping within the process area: Implemented

where necessary. 25. Fabric filter units: Appropriate design, placement and control implemented. 26. Direct Emissions of Vaporous or Gaseous Substances: Implemented for mercury, dioxins. 27. Sulphur dioxide control: Implemented

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28. The installation for sulphur dioxide removal should be monitored, operated and maintained adequately:

Implemented. 29. Continuous stable operation of the purification process, be it a sulphuric acid plant (as is most common at

smelters), or some other kind of abatement process, should be maintained: Implemented. 30. Sulphur dioxide pollution abatement: Implemented. Use double contact process for sulphuric acid. In addition,

absorption & condensation processes for SO2 recovery. Implemented. 31. Tail gases do not meet the air quality standards of the affected area: N.a. 32. Copper works: Measure to minimise fluctuations in volume and composition: Implemented. 33. Individual stages of copper extraction should be carried out in continuous processes and avoid any discontinuous

stages. Processes, where possible, should be autogenous and designed for optimum energy and resource conservation. Implemented by roaster and use of flash technology.

34. Zinc works: Practice zinc fuming. N.a. 35. The sulphur dioxide concentration should be kept as high and steady as possible, (e.g.: with the aid of fluid-bed

technology for the roasting step). N.a. 36. Lead works: Implemented. 37. Sintering machines: N.a. 38. Nickel works: N.a. (process oxidised materials) 39. Sulphur dioxide streams from nickel sulphide ores roasting facilities: N.a 40. Mercury should be removed from gas streams by wet and/or dry methods. Implemented. 41. Alternatively, where the gas is being used as sulphuric acid plant feed, the mercury may be left in the gas and

removed instead from the product acid. Implemented on polishing stages. 42. Impure metallic mercury/should be removed and treated as a dangerous and toxic waste. Implemented. Internal

recycling to the roaster should be allowed only for streams where appropriate facilities are installed which enable safe mercury removal. Implemented.

43. Wastewater originating from wet gas treatment for mercury removal in metallurgical plants should be treated in

an appropriate treatment plant. Implemented 44. Direct Emissions of Particulate Matter (Fumes and Dust): Direct emissions of particulate matter shall be

minimised using appropriate waste gas cleaning techniques. Implemented. 45. Electrostatic precipitators: Implemented to the extent practicable. 46. Scrubbers: N.a. 47. When using scrubbers, recirculation of scrubbing water in combination with water treatment

(sedimentation/filtration) should be applied. Implemented. 48. Fabric filters are the most effective dust collectors for dry gases. Implemented. 49. Preference should be given to use fabric filters and dry electrostatic precipitators to remove particles from flue

gas. Implemented. 50. Prevention of Water Pollution: Uncontaminated water, (e.g. from cooling systems), should not be discharged to

the central treatment plant. Cooling systems should be designed and maintained so as to prevent contamination of the cooling water. Process water, polluted run off from the industrial area and drainwater from bulk and waste storage should be treated in a wastewater treatment plant. Implemented.

51. The wastewater treatment plant should at least consist of preferred treatment steps. Implemented. 52. All contaminated surface runoff should be collected and treated as waste process water. Implemented to the

extent possible. 53. When possible, purified water, after its treatment, should be re-used. Implemented. 54. Table 1 measures: Implemented.

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55. The plant monitoring system should be designed to alert plant operating personnel when a spill occurs to enable them to take immediate corrective action. Implemented.

56. Waste Management and the Prevention of Soil Pollution. Implemented to a large extent and on going additional

investigations for permanent disposal are underway. 57. Waste reduction should be accomplished through company waste-plan: Implemented. Additional plans for

permanent disposal underway. 58. The company waste-plan should, inter alia, comprise an inventory of the entire production process indicating

possible waste and raw material saving measures. Implemented. 59. Energy conservation: Energy saving should be accomplished through the development of a company energy plan

by the operator, including the introduction of an energy management plan inter alia, comprise an inventory of the entire production process indicating possible energy saving measures. Implemented.

60. Energy utilisation at the largest smelter in Sweden has been reduced from about 1300 GWh per year use in the

early 1980s to less than 900 GWh by 2000. 61. A special investigation for permanent disposal of hazardous waste for the smelter was prepared for the Swedish

EPA in 1991. This investigation is currently being updated and supplemented with additional information for a decision by the Swedish EPA.

62. Permitted production, emissions to air and discharges to water are summarised in Table below Description Early 1980s Current Production Emissions Discharge

Cu: 140.000 t/y Pb: 120.000 t/y ZnO: 65.000 t/y Ni-products: 3.500 t/y SO2 < 10.000 t/y Dust < 400 t/y Sigma heavy metals < ca 58 t/y

Cu: 200.000 t/y Pb: 120.000 t/y ZnO: 80.000 t/y Ni-products: 6000 t/y SO2 = < 4.500 t/y Dust: 75 t/y Sigma heavy metals < ca 7.5 t/y

End Implementation Report Rec. 98/1 Non Ferrous Cu, Zn, Ni, Pb. SWEDEN