Official Journal of the European Union

COMMISSION IMPLEMENTING DECISION (EU) 2016/1032

of 13 June 2016

establishing best available techniques (BAT) conclusions, under Directive 2010/75/EU of the European Parliament and of the Council, for the non-ferrous metals industries

(notified under document C(2016) 3563)

(Text with EEA relevance)

THE EUROPEAN COMMISSION,

Having regard to the Treaty on the Functioning of the European Union,

Having regard to Directive 2010/75/EU of the European Parliament and of the Council of 24 November 2010 on industrial emissions (integrated pollution prevention and control) (1), and in particular Article 13(5) thereof,

Whereas:

Best available techniques (BAT) conclusions are the reference for setting permit conditions for installations covered by Chapter II of Directive 2010/75/EU and competent authorities should set emission limit values which ensure that, under normal operating conditions, emissions do not exceed the emission levels associated with the best available techniques as laid down in the BAT conclusions.

The forum composed of representatives of Member States, the industries concerned and non-governmental organisations promoting environmental protection, established by Commission Decision of 16 May 2011 (2) , provided the Commission on 4 December 2014 with its opinion on the proposed content of the BAT reference document for the non-ferrous metals industries. That opinion is publicly available.

The BAT conclusions set out in the Annex to this Decision are the key element of that BAT reference document.

The measures provided for in this Decision are in accordance with the opinion of the Committee established by Article 75(1) of Directive 2010/75/EU,

HAS ADOPTED THIS DECISION:

Article 1

The best available techniques (BAT) conclusions for the non-ferrous metals industries, as set out in the Annex, are adopted.

Article 2

This Decision is addressed to the Member States.

(1) OJ L 334, 17.12.2010, p. 17.

(2) OJ C 146, 17.5.2011, p. 3.

ANNEX

BAT CONCLUSIONS FOR THE NON-FERROUS METALS INDUSTRIES

SCOPE

These BAT conclusions concern certain activities specified in Sections 2.1, 2.5 and 6.8 of Annex I to Directive 2010/75/EU, namely:

— 2.1: Metal ore (including sulphide ore) roasting or sintering;

— 2.5: Processing of non-ferrous metals:

(a) production of non-ferrous crude metals from ore, concentrates or secondary raw materials by metallurgical, chemical or electrolytic processes;

(b) melting, including the alloyage, of non-ferrous metals, including recovered products and operation of non-ferrous metal foundries, with a melting capacity exceeding 4 tonnes per day for lead and cadmium or 20 tonnes per day for all other metals;

— 6.8: Production of carbon (hard-burnt coal) or electrographite by means of incineration or graphitisation.

In particular, these BAT conclusions cover the following processes and activities:

— primary and secondary production of non-ferrous metals;

— the production of zinc oxide from fumes during the production of other metals;

— the production of nickel compounds from liquors during the production of a metal;

— the production of silicon-calcium (CaSi) and silicon (Si) in the same furnace as the production of ferro-silicon;

— the production of aluminium oxide from bauxite prior to the production of primary aluminium, where this is an integral part of the production of the metal;

— the recycling of aluminium salt slag;

— the production of carbon and/or graphite electrodes.

These BAT conclusions do not address the following activities or processes:

— Iron ore sintering. This is covered in the BAT conclusions for Iron and Steel production.

— The production of sulphuric acid based on SO2 gases from non-ferrous metals production. This is covered in the BAT conclusions on Large Volume Inorganic Chemicals-Ammonia, Acids and Fertilisers.

— Foundries covered in the BAT conclusions for the Smitheries and Foundries Industry.

Other reference documents which could be of relevance for the activities covered in these BAT conclusions are the following.

Reference document Subject Energy Efficiency (ENE) General aspects of energy efficiency Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical Sector (CWW) Waste water treatment techniques to reduce emissions of metals to water Large Volume Inorganic Chemicals-Ammonia, Acids and Fertilisers (LVIC-AAF) Sulphuric acid production Industrial Cooling Systems (ICS) Indirect cooling with water and/or air Emissions from Storage (EFS) Storage and handling of materials Economics and Cross-media Effects (ECM) Economics and cross-media effects of techniques Monitoring of Emissions to Air and Water from IED installations (ROM) Monitoring of emissions to air and water Waste Treatments Industries (WT) Waste handling and treatment Large Combustion Plants (LCP) Combustion plants generating steam and/or electricity Surface Treatment Using Organic Solvents (STS) Non-acid pickling Surface Treatment of Metals and Plastics (STM) Acid pickling

DEFINITIONS

For the purposes of these BAT conclusions, the following definitions apply:

Term used Definition New plant A plant first permitted at the site of the installation following the publication of these BAT conclusions or a complete replacement of a plant on the existing foundations of the installation following the publication of these BAT conclusions Existing plant A plant that is not a new plant Major upgrade A major change in the design or technology of a plant and with major adjustments or replacements of the process units and associated equipment Primary emissions Emissions directly vented from the furnaces that are not spread to the areas surrounding the furnaces Secondary emissions Emissions escaping from the furnace lining or during operations such as charging or tapping and which are captured with a hood or enclosure (such as doghouse) Primary production Production of metals using ores and concentrates Secondary production Production of metals using residues and/or scraps, including remelting and alloying processes Continuous measurement Measurement using an ‘automated measuring system’ permanently installed on site for the continuous monitoring of emissions Periodic measurement Determination of a measurand (a particular quantity subject to measurement) at specified time intervals using manual or automated methods

GENERAL CONSIDERATIONS

Best Available Techniques

The techniques listed and described in these BAT conclusions are neither prescriptive nor exhaustive. Other techniques may be used that ensure at least an equivalent level of environmental protection.

Unless otherwise stated, the BAT conclusions are generally applicable.

Emission levels to air associated with BAT

Emission levels associated with the best available techniques (BAT-AELs) for emissions to air given in these BAT conclusions refer to standard conditions: dry gas at a temperature of 273,15 K, and a pressure of 101,3 kPa.

Averaging periods for emissions to air

For averaging periods for emissions to air, the following definitions apply.

Daily average Average over a period of 24 hours of valid half-hourly or hourly averages obtained by continuous measurements Average over the sampling period Average value of three consecutive measurements of at least 30 minutes each, unless otherwise stated (1)

Averaging periods for emissions to water

For averaging periods for emissions to water, the following definition applies.

Daily average Average over a sampling period of 24 hours taken as a flow-proportional composite sample (or as a time-proportional composite sample provided that sufficient flow stability is demonstrated) (2)

ACRONYMS

Term Meaning BaP Benzo[a]pyrene ESP Electrostatic precipitator I-TEQ International toxic equivalency derived by applying international toxic equivalence factors, as defined in Annex VI, part 2 of Directive 2010/75/EU NOX The sum of nitrogen monoxide (NO) and nitrogen dioxide (NO2), expressed as NO2 PCDD/F Polychlorinated dibenzo-p-dioxins and dibenzofurans (17 congeners) PAH Polycyclic aromatic hydrocarbons TVOC Total volatile organic carbon; total volatile organic compounds which are measured by a flame ionisation detector (FID) and expressed as total carbon VOC Volatile organic compounds as defined in Article 3(45) of Directive 2010/75/EU

1.1. GENERAL BAT CONCLUSIONS

Any relevant process-specific BAT conclusions in Sections 1.2 to 1.9 apply in addition to the general BAT conclusions in this section.

1.1.1. Environmental management systems (EMS)

BAT 1. In order to improve the overall environmental performance, BAT is to implement and adhere to an environmental management system (EMS) that incorporates all of the following features:

(a) commitment of the management, including senior management;

(b) definition of an environmental policy that includes the continuous improvement of the installation by the management;

(c) planning and establishing the necessary procedures, objectives and targets, in conjunction with financial planning and investment;

(d) implementation of procedures paying particular attention to: (i) structure and responsibility, (ii) recruitment, training, awareness and competence, (iii) communication, (iv) employee involvement, (v) documentation, (vi) effective process control, (vii) maintenance programmes, (viii) emergency preparedness and response, (ix) safeguarding compliance with environmental legislation;

(e) checking performance and taking corrective action, paying particular attention to: (i) monitoring and measurement (see also the Reference Report on Monitoring of emissions to Air and Water from IED installations-ROM), (ii) corrective and preventive action, (iii) maintenance of records, (iv) independent (where practicable) internal or external auditing in order to determine whether or not the EMS conforms to planned arrangements and has been properly implemented and maintained;

(f) review of the EMS and its continuing suitability, adequacy and effectiveness by senior management;

(g) following the development of cleaner technologies;

(h) consideration for the environmental impacts from the eventual decommissioning of the installation at the stage of designing a new plant, and throughout its operating life;

(i) application of sectoral benchmarking on a regular basis.

The establishment and implementation of an action plan on diffuse dust emissions (see BAT 6) and the application of a maintenance management system which especially addresses the performance of dust abatement systems (see BAT 4) are also a part of the EMS.

Applicability

The scope (e.g. level of detail) and nature of the EMS (e.g. standardised or non-standardised) will generally be related to the nature, scale and complexity of the installation, and the range of environmental impacts it may have.

1.1.2. Energy management

BAT 2. In order to use energy efficiently, BAT is to use a combination of the techniques given below.

Technique Applicability a Energy efficiency management system (e.g. ISO 50001) Generally applicable b Regenerative or recuperative burners Generally applicable c Heat recovery (e.g. steam, hot water, hot air) from waste process heat Only applicable for pyrometallurgical processes d Regenerative thermal oxidiser Only applicable when the abatement of a combustible pollutant is required e Preheat the furnace charge, combustion air or fuel using the heat recovered from hot gases from the melting stage Only applicable for roasting or smelting of sulphide ore/concentrate and for other pyrometallurgical processes f Raise the temperature of the leaching liquors using steam or hot water from waste heat recovery Only applicable for alumina or hydrometallurgical processes g Use hot gases from the launder as preheated combustion air Only applicable for pyrometallurgical processes h Use oxygen-enriched air or pure oxygen in the burners to reduce energy consumption by allowing autogenous smelting or the complete combustion of carbonaceous material Only applicable for furnaces that use raw materials containing sulphur or carbon i Dry concentrates and wet raw materials at low temperatures Only applicable when drying is performed j Recover the chemical energy content of the carbon monoxide produced in an electric or shaft/blast furnace by using the exhaust gases as a fuel, after the removal of metals, in other production processes or to produce steam/hot water or electricity Only applicable to exhaust gases with a CO content > 10 vol-%. Applicability is also influenced by the composition of the exhaust gas and the unavailability of a continuous flow (i.e. batch processes) k Recirculate the flue-gas back through an oxy-fuel burner to recover the energy contained in the total organic carbon present Generally applicable l Suitable insulation for high temperature equipment such as steam and hot water pipes Generally applicable m Use the heat generated from the production of sulphuric acid from sulphur dioxide to preheat gas directed to the sulphuric acid plant or to generate steam and/or hot water Only applicable for non-ferrous metals plants including sulphuric acid or liquid SO2 production n Use high efficiency electric motors equipped with variable-frequency drive, for equipment such as fans Generally applicable o Use control systems that automatically activate the air extraction system or adjust the extraction rate depending on actual emissions Generally applicable

1.1.3. Process control

BAT 3. In order to improve overall environmental performance, BAT is to ensure stable process operation by using a process control system together with a combination of the techniques given below.

Technique a Inspect and select input materials according to the process and the abatement techniques applied b Good mixing of the feed materials to achieve optimum conversion efficiency and reduce emissions and rejects c Feed weighing and metering systems d Processors to control material feed rate, critical process parameters and conditions including the alarm, combustion conditions and gas additions e On-line monitoring of the furnace temperature, furnace pressure and gas flow f Monitor the critical process parameters of the air emission abatement plant such as gas temperature, reagent metering, pressure drop, ESP current and voltage, scrubbing liquid flow and pH and gaseous components (e.g. O2, CO, VOC) g Control dust and mercury in the exhaust gas before transfer to the sulphuric acid plant for plants including sulphuric acid or liquid SO2 production h On-line monitoring of vibrations to detect blockages and possible equipment failure i On-line monitoring of the current, voltage and electrical contact temperatures in electrolytic processes j Temperature monitoring and control at melting and smelting furnaces to prevent the generation of metal and metal oxide fumes through overheating k Processor to control the reagents feeding and the performance of the waste water treatment plant, through on-line monitoring of temperature, turbidity, pH, conductivity and flow

BAT 4. In order to reduce channelled dust and metal emissions to air, BAT is to apply a maintenance management system which especially addresses the performance of dust abatement systems as part of the environmental management system (see BAT 1).

1.1.4. Diffuse emissions

1.1.4.1. General approach for the prevention of diffuse emissions

BAT 5. In order to prevent or, where this is not practicable, to reduce diffuse emissions to air and water, BAT is to collect diffuse emissions as much as possible nearest to the source and treat them.

BAT 6. In order to prevent or, where this is not practicable, to reduce diffuse dust emissions to air, BAT is to set up and implement an action plan on diffuse dust emissions, as part of the environmental management system (see BAT 1), that incorporates both of the following measures:

a. identify the most relevant diffuse dust emission sources (using e.g. EN 15445);

b. define and implement appropriate actions and techniques to prevent or reduce diffuse emissions over a given time frame.

1.1.4.2. Diffuse emissions from the storage, handling and transport of raw materials

BAT 7. In order to prevent diffuse emissions from the storage of raw materials, BAT is to use a combination of the techniques given below.

Technique a Enclosed buildings or silos/bins for storing dust-forming materials such as concentrates, fluxes and fine materials b Covered storage of non-dust-forming materials such as concentrates, fluxes, solid fuels, bulk materials and coke and secondary materials that contain water-soluble organic compounds c Sealed packaging of dust-forming materials or secondary materials that contain water-soluble organic compounds d Covered bays for storing material which has been pelletised or agglomerated e Use water sprays and fog sprays with or without additives such as latex for dust-forming materials f Dust/gas extraction devices placed at the transfer and tipping points for dust-forming materials g Certified pressure vessels for storing chlorine gas or mixtures that contain chlorine h Tank construction materials that are resistant to the contained materials i Reliable leak detection systems and display of tank’s level, with an alarm to prevent overfills j Store reactive materials in double-walled tanks or tanks placed in chemical-resistant bunds of the same capacity and use a storage area that is impermeable and resistant to the material stored k Design storage areas so that — any leaks from tanks and delivery systems are intercepted and contained in bunds that have a capacity capable of containing at least the volume of the largest storage tank within the bund; — delivery points are within the bund to collect any spilled material l Use inert gas blanketing for the storage of materials that react with air m Collect and treat emissions from storage with an abatement system designed to treat the compounds stored. Collect and treat before discharge any water that washes dust away. n Regular cleaning of the storage area and, when needed, moistening with water o Place the longitudinal axis of the heap parallel to the prevailing wind direction in the case of outdoor storage p Protective planting, windbreak fences or upwind mounts to lower the wind velocity in the case of outdoor storage q One heap instead of several where feasible in the case of outdoor storage r Use oil and solid interceptors for the drainage of open outdoor storage areas. Use of concreted areas that have kerbs or other containment devices for the storage of material that can release oil, such as swarf

Applicability

BAT 7. e is not applicable to processes that require dry materials or ores/concentrates that naturally contain sufficient humidity to prevent dust formation. The applicability may be limited in regions with water shortages or with very low temperatures

BAT 8. In order to prevent diffuse emissions from the handling and transport of raw materials, BAT is to use a combination of the techniques given below.

Technique a Enclosed conveyors or pneumatic systems to transfer and handle dust-forming concentrates and fluxes and fine-grained material b Covered conveyors to handle non-dust-forming solid materials c Extraction of dust from delivery points, silo vents, pneumatic transfer systems and conveyor transfer points, and connection to a filtration system (for dust-forming materials) d Closed bags or drums to handle materials with dispersible or water-soluble components e Suitable containers to handle pelletised materials f Sprinkling to moisten the materials at handling points g Minimise transport distances h Reduce the drop height of conveyor belts, mechanical shovels or grabs i Adjust the speed of open belt conveyors (< 3,5 m/s) j Minimise the speed of descent or free fall height of the materials k Place transfer conveyors and pipelines in safe, open areas above ground so that leaks can be detected quickly and damage from vehicles and other equipment can be prevented. If buried pipelines are used for non-hazardous materials, document and mark their course and adopt safe excavation systems l Automatic resealing of delivery connections for handling liquid and liquefied gas m Back-vent displaced gases to the delivery vehicle to reduce emissions of VOC n Wash wheels and chassis of vehicles used to deliver or handle dusty materials o Use planned campaigns for road sweeping p Segregate incompatible materials (e.g. oxidising agents and organic materials) q Minimise material transfers between processes

Applicability

BAT 8.n. may not be applicable when ice could be formed.

1.1.4.3. Diffuse emissions from metal production

BAT 9. In order to prevent or, where this is not practicable, to reduce diffuse emissions from metal production, BAT is to optimise the efficiency of off-gas collection and treatment by using a combination of the techniques given below.

Technique Applicability a Thermal or mechanical pretreatment of secondary raw material to minimise organic contamination of the furnace feed Generally applicable b Use a closed furnace with a properly designed dedusting system or seal the furnace and other process units with an adequate vent system The applicability may be restricted by safety constraints (e.g. type/design of the furnace, risk of explosion) c Use a secondary hood for furnace operations such as charging and tapping The applicability may be restricted by safety constraints (e.g. type/design of the furnace, risk of explosion) d Dust or fume collection where dusty material transfers take place (e.g. furnace charging and tapping points, covered launders) Generally applicable e Optimise the design and operation of hooding and ductwork to capture fumes arising from the feed port and from hot metal, matte or slag tapping and transfers in covered launders For existing plants, the applicability may be limited by space and plant configuration restrictions f Furnace/reactor enclosures such as ‘house-in-house’ or ‘doghouse’ for tapping and charging operations For existing plants, the applicability may be limited by space and plant configuration restrictions g Optimise the off-gas flow from the furnace through computerised fluid dynamics studies and tracers Generally applicable h Charging systems for semi-closed furnaces to add raw materials in small amounts Generally applicable i Treat the collected emissions in an adequate abatement system Generally applicable

1.1.5. Monitoring of emissions to air

BAT 10. BAT is to monitor the stack emissions to air with at least the frequency given below and in accordance with EN standards. If EN standards are not available, BAT is to use ISO, national or other international standards that ensure the provision of data of an equivalent scientific quality.

Parameter Monitoring associated with Minimum monitoring frequency Standard(s) Dust (4) Copper: BAT 38, BAT 39, BAT 40, BAT 43, BAT 44, BAT 45 Aluminium: BAT 56, BAT 58, BAT 59, BAT 60, BAT 61, BAT 67, BAT 81, BAT 88 Lead, Tin: BAT 94, BAT 96, BAT 97 Zinc, Cadmium: BAT 119, BAT 122 Precious metals: BAT 140 Ferro-alloys: BAT 155, BAT 156, BAT 157, BAT 158 Nickel, Cobalt: BAT 171 Other non-ferrous metals: emissions from production stages such as raw material pretreatment, charging, smelting, melting and tapping Continuous (3) EN 13284-2 Copper: BAT 37, BAT 38, BAT 40, BAT 41, BAT 42, BAT 43, BAT 44, BAT 45 Aluminium: BAT 56, BAT 58, BAT 59, BAT 60, BAT 61, BAT 66, BAT 67, BAT 68, BAT 80, BAT 81, BAT 82, BAT 88 Lead, Tin: BAT 94, BAT 95, BAT 96, BAT 97 Zinc, Cadmium: BAT 113, BAT 119, BAT 121, BAT 122, BAT 128, BAT 132 Precious metals: BAT 140 Ferro-alloys: BAT 154, BAT 155, BAT 156, BAT 157, BAT 158 Nickel, Cobalt: BAT 171 Carbon/graphite: BAT 178, BAT 179, BAT 180, BAT 181 Other non-ferrous metals: emissions from production stages such as raw material pretreatment, charging, smelting, melting and tapping Once per year (3) EN 13284-1 Antimony and its compounds, expressed as Sb Lead, Tin: BAT 96, BAT 97 Once per year EN 14385 Arsenic and its compounds, expressed as As Copper: BAT 37, BAT 38, BAT 39, BAT 40, BAT 42, BAT 43, BAT 44, BAT 45 Lead, Tin: BAT 96, BAT 97 Zinc: BAT 122 Once per year EN 14385 Cadmium and its compounds, expressed as Cd Copper: BAT 37, BAT 38, BAT 39, BAT 40, BAT 41, BAT 42, BAT 43, BAT 44, BAT 45 Lead, Tin: BAT 94, BAT 95, BAT 96, BAT 97 Zinc, Cadmium: BAT 122, BAT 132 Ferro-alloys: BAT 156 Once per year EN 14385 Chromium (VI) Ferro-alloys: BAT 156 Once per year No EN standard available Copper and its compounds, expressed as Cu Copper: BAT 37, BAT 38, BAT 39, BAT 40, BAT 42, BAT 43, BAT 44, BAT 45 Lead, Tin: BAT 96, BAT 97 Once per year EN 14385 Nickel and its compounds, expressed as Ni Nickel, Cobalt: BAT 172, BAT 173 Once per year EN 14385 Lead and its compounds, expressed as Pb Copper: BAT 37, BAT 38, BAT 39, BAT 40, BAT 41, BAT 42, BAT 43, BAT 44, BAT 45 Lead, Tin: BAT 94, BAT 95, BAT 96, BAT 97 Ferro-alloys: BAT 156 Once per year EN 14385 Thallium and its compounds, expressed as Tl Ferro-alloys: BAT 156 Once per year EN 14385 Zinc and its compounds, expressed as Zn Zinc, Cadmium: BAT 113, BAT 114, BAT 119, BAT 121, BAT 122, BAT 128, BAT 132 Once per year EN 14385 Other metals, if relevant (5) Copper: BAT 37, BAT 38, BAT 39, BAT 40, BAT 41, BAT 42, BAT 43, BAT 44, BAT 45 Lead, Tin: BAT 94, BAT 95, BAT 96, BAT 97 Zinc, Cadmium: BAT 113, BAT 119, BAT 121, BAT 122, BAT 128, BAT 132 Precious metals: BAT 140 Ferro-alloys: BAT 154, BAT 155, BAT 156, BAT 157, BAT 158 Nickel, Cobalt: BAT 171 Other non-ferrous metals Once per year EN 14385 Mercury and its compounds, expressed as Hg Copper, Aluminium, Lead, Tin, Zinc, Cadmium, Ferro-alloys, Nickel, Cobalt, Other non-ferrous metals: BAT 11 Continuous or once per year (3) EN 14884 EN 13211 SO2 Copper: BAT 49 Aluminium: BAT 60, BAT 69 Lead, Tin: BAT 100 Precious metals: BAT 142, BAT 143 Nickel, Cobalt: BAT 174 Other non-ferrous metals (8) (9) Continuous or once per year (3) (6) EN 14791 Zinc, Cadmium: BAT 120 Continuous Carbon/graphite: BAT 182 Once per year NOX, expressed as NO2 Copper, Aluminium, Lead, Tin, FeSi, Si (pyrometallurgical processes): BAT 13 Precious metals: BAT 141 Other non-ferrous metals (9) Continuous or once per year (3) EN 14792 Carbon/graphite Once per year TVOC Copper: BAT 46 Aluminium: BAT 83 Lead, Tin: BAT 98 Zinc, Cadmium: BAT 123 Other non-ferrous metals (10) Continuous or once per year (3) EN 12619 Ferro-alloys: BAT 160 Carbon/graphite: BAT 183 Once per year Formaldehyde Carbon/graphite: BAT 183 Once per year No EN standard available Phenol Carbon/graphite: BAT 183 Once per year No EN standard available PCDD/F Copper: BAT 48 Aluminium: BAT 83 Lead, Tin: BAT 99 Zinc, Cadmium: BAT 123 Precious metals: BAT 146 Ferro-alloys: BAT 159 Other non-ferrous metals (7) (9) Once per year EN 1948 parts 1, 2 and 3 H2SO4 Copper: BAT 50 Zinc, Cadmium: BAT 114 Once per year No EN standard available NH3 Aluminium: BAT 89 Precious metals: BAT 145 Nickel, Cobalt: BAT 175 Once per year No EN standard available Benzo-[a]-pyrene Aluminium: BAT 59, BAT 60, BAT 61 Ferro-alloys: BAT 160 Carbon/graphite: BAT 178, BAT 179, BAT 180, BAT 181 Once per year ISO 11338-1 ISO 11338-2 Gaseous fluorides, expressed as HF Aluminium: BAT 60, BAT 61, BAT 67 Continuous (3) ISO 15713 Aluminium: BAT 60, BAT 67, BAT 84 Zinc, Cadmium: BAT 124 Once per year (3) Total fluorides Aluminium: BAT 60, BAT 67 Once per year No EN standard available Gaseous chlorides, expressed as HCl Aluminium: BAT 84 Continuous or once per year (3) EN 1911 Zinc, Cadmium: BAT 124 Precious metals: BAT 144 Once per year Cl2 Aluminium: BAT 84 Precious metals: BAT 144 Nickel, Cobalt: BAT 172 Once per year No EN standard available H2S Aluminium: BAT 89 Once per year No EN standard available PH3 Aluminium: BAT 89 Once per year No EN standard available Sum of AsH3 and SbH3 Zinc, Cadmium: BAT 114 Once per year No EN standard available Note: ‘other non-ferrous metals’ means the production of non-ferrous metals other than those dealt with specifically in Sections 1.2 to 1.8.

1.1.6. Mercury emissions

BAT 11. In order to reduce mercury emissions to air (other than those that are routed to the sulphuric acid plant) from a pyrometallurgical process, BAT is to use one or both of the techniques given below.

Technique a Use raw materials with a low mercury content, including by cooperating with providers in order to remove mercury from secondary materials. b Use adsorbents (e.g. activated carbon, selenium) in combination with dust filtration (11)

BAT-associated emission levels: See Table 1.

Table 1

BAT-associated emission levels for mercury emissions to air (other than those that are routed to the sulphuric acid plant) from a pyrometallurgical process using raw materials containing mercury

Parameter BAT-AEL (mg/Nm3) (12) (13) Mercury and its compounds, expressed as Hg 0,01-0,05

The associated monitoring is in BAT 10.

1.1.7. Sulphur dioxide emissions

BAT 12. In order to reduce emissions of SO2 from off-gases with a high SO2 content and to avoid the generation of waste from the flue-gas cleaning system, BAT is to recover sulphur by producing sulphuric acid or liquid SO2.

Applicability

Only applicable to plants producing copper, lead, primary zinc, silver, nickel and/or molybdenum.

1.1.8. NOX emissions

BAT 13. In order to prevent NOX emissions to air from a pyrometallurgical process, BAT is to use one of the techniques given below.

Technique (14) a Low-NOX burners b Oxy-fuel burners c Flue-gas recirculation (back through the burner to reduce the temperature of the flame) in the case of oxy-fuel burners

The associated monitoring is in BAT 10.

1.1.9. Emissions to water, including their monitoring

BAT 14. In order to prevent or reduce the generation of waste water, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Measure the amount of fresh water used and the amount of waste water discharged Generally applicable b Reuse waste water from cleaning operations (including anode and cathode rinse water) and spills in the same process Generally applicable c Reuse weak acid streams generated in a wet ESP and wet scrubbers Applicability may be restricted depending on the metal and solid content of the waste water d Reuse waste water from slag granulation Applicability may be restricted depending on the metal and solid content of the waste water e Reuse surface run-off water Generally applicable f Use a closed circuit cooling system Applicability may be restricted when a low temperature is required for process reasons g Reuse treated water from the waste water treatment plant Applicability may be restricted by the salt content

BAT 15. In order to prevent the contamination of water and to reduce emissions to water, BAT is to segregate uncontaminated waste water streams from waste water streams requiring treatment.

Applicability

The segregation of uncontaminated rainwater may not be applicable in the case of existing waste water collection systems.

BAT 16. BAT is to use ISO 5667 for water sampling and to monitor the emissions to water at the point where the emission leaves the installation at least once per month (15) and in accordance with EN standards. If EN standards are not available, BAT is to use ISO, national or other international standards that ensure the provision of data of an equivalent scientific quality.

Parameter Applicable for the production of (16) Standard(s) Mercury (Hg) Copper, Lead, Tin, Zinc, Cadmium, Precious metals, Ferro-alloys, Nickel, Cobalt, and other non-ferrous metals EN ISO 17852, EN ISO 12846 Iron (Fe) Copper, Lead, Tin, Zinc, Cadmium, Precious metals, Ferro-alloys, Nickel, Cobalt, and other non-ferrous metals EN ISO 11885 EN ISO 15586 EN ISO 17294-2 Arsenic (As) Copper, Lead, Tin, Zinc, Cadmium, Precious metals, Ferro-alloys, Nickel, and Cobalt Cadmium (Cd) Copper (Cu) Nickel (Ni) Lead (Pb) Zinc (Zn) Silver (Ag) Precious metals Aluminium (Al) Aluminium Cobalt (Co) Nickel, and Cobalt Chromium total (Cr) Ferro-alloys Chromium(VI) (Cr(VI)) Ferro-alloys EN ISO 10304-3 EN ISO 23913 Antimony (Sb) Copper, Lead, and Tin EN ISO 11885 EN ISO 15586 EN ISO 17294-2 Tin (Sn) Copper, Lead, and Tin Other metals, if relevant (17) Aluminium, Ferro-alloys, and other non-ferrous metals Sulphate (SO4 2-) Copper, Lead, Tin, Zinc, Cadmium, Precious metals, Nickel, Cobalt, and other non-ferrous metals EN ISO 10304-1 Fluoride (F-) Primary aluminium Total suspended solids (TSS) Aluminium EN 872

BAT 17. In order to reduce emissions to water, BAT is to treat the leakages from the storage of liquids and the waste water from non-ferrous metals production, including from the washing stage in the Waelz kiln process, and to remove metals and sulphates by using a combination of the techniques given below.

Technique (18) Applicability a Chemical precipitation Generally applicable b Sedimentation Generally applicable c Filtration Generally applicable d Flotation Generally applicable e Ultrafiltration Only applicable to specific streams in non-ferrous metals production f Activated carbon filtration Generally applicable g Reverse osmosis Only applicable to specific streams in non-ferrous metals production

BAT-associated emission levels

The BAT-associated emission levels (BAT-AELs) for direct emissions to a receiving water body from the production of copper, lead, tin, zinc, cadmium, precious metals, nickel, cobalt and ferro-alloys are given in Table 2.

These BAT-AELs apply at the point where the emission leaves the installation.

Table 2

BAT-associated emission levels for direct emissions to a receiving water body from the production of copper, lead, tin, zinc (including the waste water from the washing stage in the Waelz kiln process), cadmium, precious metals, nickel, cobalt and ferro-alloys

BAT-AEL (mg/l) (daily average) Parameter Production of Copper Lead and/or Tin Zinc and/or Cadmium Precious metals Nickel and/or Cobalt Ferro-alloys Silver (Ag) NR ≤ 0,6 NR Arsenic (As) ≤ 0,1 (19) ≤ 0,1 ≤ 0,1 ≤ 0,1 ≤ 0,3 ≤ 0,1 Cadmium (Cd) 0,02–0,1 ≤ 0,1 ≤ 0,1 ≤ 0,05 ≤ 0,1 ≤ 0,05 Cobalt (Co) NR ≤ 0,1 NR 0,1-0,5 NR Chromium total (Cr) NR ≤ 0,2 Chromium (VI) (Cr(VI)) NR ≤ 0,05 Copper (Cu) 0,05-0,5 ≤ 0,2 ≤ 0,1 ≤ 0,3 ≤ 0,5 ≤ 0,5 Mercury (Hg) 0,005–0,02 ≤ 0,05 ≤ 0,05 ≤ 0,05 ≤ 0,05 ≤ 0,05 Nickel (Ni) ≤ 0,5 ≤ 0,5 ≤ 0,1 ≤ 0,5 ≤ 2 ≤ 2 Lead (Pb) ≤ 0,5 ≤ 0,5 ≤ 0,2 ≤ 0,5 ≤ 0,5 ≤ 0,2 Zinc (Zn) ≤ 1 ≤ 1 ≤ 1 ≤ 0,4 ≤ 1 ≤ 1 NR: Not relevant

The associated monitoring is in BAT 16.

1.1.10. Noise

BAT 18. In order to reduce noise emissions, BAT is to use one or a combination of the techniques given below.

Technique a Use embankments to screen the source of noise b Enclose noisy plants or components in sound-absorbing structures c Use anti-vibration supports and interconnections for equipment d Orientation of noise-emitting machinery e Change the frequency of the sound

1.1.11. Odour

BAT 19. In order to reduce odour emissions, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Appropriate storage and handling of odorous materials Generally applicable b Minimise the use of odorous materials Generally applicable c Careful design, operation and maintenance of any equipment that could generate odour emissions Generally applicable d Afterburner or filtration techniques, including biofilters Applicable only in limited cases (e.g. in the impregnation stage during speciality production in the carbon and graphite sector)

1.2. BAT CONCLUSIONS FOR COPPER PRODUCTION

1.2.1. Secondary materials

BAT 20. In order to increase the secondary materials’ recovery yield from scrap, BAT is to separate non-metallic constituents and metals other than copper by using one or a combination of the techniques given below.

Technique a Manual separation of large visible constituents b Magnetic separation of ferrous metals c Optical or eddy current separation of aluminium d Relative density separation of different metallic and non-metallic constituents (using a fluid with a different density or air)

1.2.2. Energy

BAT 21. In order to use energy efficiently in primary copper production, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Optimise the use of the energy contained in the concentrate using a flash smelting furnace Only applicable for new plants and for major upgrades of existing plants b Use the hot process gases from the melting stages to heat up the furnace charge Only applicable to shaft furnaces c Cover the concentrates during transport and storage Generally applicable d Use the excess heat produced during the primary smelting or converting stages to melt secondary materials containing copper Generally applicable e Use the heat in the gases from anode furnaces in a cascade for other processes such as drying Generally applicable

BAT 22. In order to use energy efficiently in secondary copper production, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Reduce the water content of the feed material Applicability is limited when the moisture content of the materials is used as a technique to reduce diffuse emissions b Produce steam by recovering excess heat from the smelting furnace to heat up the electrolyte in refineries and/or to produce electricity in a co-generation installation Applicable if an economically viable demand of steam exists c Melt scraps using the excess heat that is produced during the smelting or converting process Generally applicable d Holding furnace between processing stages Only applicable for batch-wise operated smelters where a buffer capacity of molten material is required e Preheat the furnace charge using the hot process gases from the melting stages Only applicable to shaft furnaces

BAT 23. In order to use energy efficiently in electrorefining and electrowinning operations, BAT is to use a combination of the techniques given below.

Technique Applicability a Apply insulation and covers to electrolysis tanks Generally applicable b Addition of surfactants to the electrowinning cells Generally applicable c Improved cell design for lower energy consumption by optimisation of the following parameters: space between anode and cathode, anode geometry, current density, electrolyte composition and temperature Only applicable for new plants and for major upgrades of existing plants d Use of stainless steel cathode blanks Only applicable for new plants and for major upgrades of existing plants e Automatic cathode/anode changes to achieve an accurate placement of the electrodes into the cell Only applicable for new plants and for major upgrades of existing plants f Short circuit detection and quality control to ensure that electrodes are straight and flat and that the anode is exact in weight Generally applicable

1.2.3. Air emissions

BAT 24. In order to reduce secondary emissions to air from furnaces and auxiliary devices in primary copper production and to optimise the performance of the abatement system, BAT is to collect, mix and treat secondary emissions in a centralised off-gas cleaning system.

Description

Secondary emissions from various sources are collected, mixed, and treated in a single centralised off-gas cleaning system, designed to effectively treat the pollutants present in each of the flows. Care is taken not to mix streams which are not chemically compatible and to avoid undesirable chemical reactions among the different collected flows.

Applicability

The applicability may be limited for existing plants by their design and layout.

1.2.3.1. Diffuse emissions

BAT 25. In order to prevent or reduce diffuse emissions from pretreatment (such as blending, drying, mixing, homogenisation, screening and pelletisation) of primary and secondary materials, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Use enclosed conveyers or pneumatic transfer systems for dusty materials Generally applicable b Carry out activities with dusty materials such as mixing in an enclosed building For existing plants, application may be difficult due to the space requirements c Use dust suppression systems such as water cannons or water sprinklers Not applicable for mixing operations carried out indoors. Not applicable for processes that require dry materials. The application is also limited in regions with water shortages or with very low temperatures d Use enclosed equipment for operations with dusty material (such as drying, mixing, milling, air separation and pelletisation) with an air extraction system connected to an abatement system Generally applicable e Use an extraction system for dusty and gaseous emissions, such as a hood in combination with a dust and gas abatement system Generally applicable

BAT 26. In order to prevent or reduce diffuse emissions from charging, smelting and tapping operations in primary and secondary copper smelters and from holding and melting furnaces, BAT is to use a combination of the techniques given below.

Technique Applicability a Briquetting and pelletisation of raw materials Applicable only when the process and the furnace can use pelletised raw materials b Enclosed charging system such as single jet burner, door sealing (20), closed conveyers or feeders equipped with an air extraction system in combination with a dust and gas abatement system The jet burner is applicable only for flash furnaces c Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation Generally applicable d Capture hood/enclosures at charging and tapping points in combination with an off-gas abatement system (e.g. housing/tunnel for ladle operation during tapping, and which is closed with a movable door/barrier equipped with a ventilation and abatement system) Generally applicable e Encapsulate the furnace in vented housing Generally applicable f Maintain furnace sealing Generally applicable g Hold the temperature in the furnace at the lowest required level Generally applicable h Boosted suction systems (20) Generally applicable i Enclosed building in combination with other techniques to collect the diffuse emissions Generally applicable j Double bell charging system for shaft/blast furnaces Generally applicable k Select and feed the raw materials according to the type of furnace and abatement techniques used Generally applicable l Use of lids on throats of rotary anode furnace Generally applicable

BAT 27. In order to reduce diffuse emissions from Peirce-Smith converter (PS) furnace in primary and secondary copper production, BAT is to use a combination of the techniques given below.

Technique a Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation b Oxygen enrichment c Primary hood over the converter opening to collect and transfer the primary emissions to an abatement system d Addition of materials (e.g. scrap and flux) through the hood e System of secondary hoods in addition to the main one to capture emissions during charging and tapping operations f Furnace located in enclosed building g Apply motor-driven secondary hoods, to move them according to the process stage, to increase the efficiency of the collection of secondary emissions h Boosted suction systems (21) and automatic control to prevent blowing when the converter is ‘rolled out’ or ‘rolled in’

BAT 28. In order to reduce diffuse emissions from a Hoboken converter furnace in primary copper production, BAT is to use a combination of the techniques given below.

Technique a Operate furnace and gas route under negative pressure during charging, skimming and tapping operations b Oxygen enrichment c Mouth with closed lids during operation d Boosted suction systems (22)

BAT 29. In order to reduce diffuse emissions from the matte conversion process, BAT is to use a flash converting furnace.

Applicability

Applicable only to new plants or major upgrades of existing plants.

BAT 30. In order to reduce diffuse emissions from a top-blown rotary converter (TBRC) furnace in secondary copper production, BAT is to use a combination of the techniques given below.

Technique Applicability a Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation Generally applicable b Oxygen enrichment Generally applicable c Furnace located in enclosed building in combination with techniques to collect and transfer diffuse emissions from charging and tapping to an abatement system Generally applicable d Primary hood over the converter opening to collect and transfer the primary emissions to an abatement system Generally applicable e Hoods or crane integrated hood to collect and transfer the emissions from charging and tapping operations to an abatement system For existing plants, a crane integrated hood is only applicable to major upgrades of the furnace hall f Addition of materials (e.g. scrap and flux) through the hood Generally applicable g Boosted suction system (23) Generally applicable

BAT 31. In order to reduce diffuse emissions from copper recovery with a slag concentrator, BAT is to use the techniques given below.

Technique a Dust suppression techniques such as a water spray for handling, storage and crushing of slag b Grinding and flotation performed with water c Delivery of the slag to the final storage area via hydro transport in a closed pipeline d Maintain a water layer in the pond or use a dust suppressant such as lime milk in dry areas

BAT 32. In order to reduce diffuse emissions from copper-rich slag furnace treatment, BAT is to use a combination of the techniques given below.

Technique a Dust suppression techniques such as a water spray for handling, storage and crushing of the final slag b Operation of the furnace under negative pressure c Enclosed furnace d Housing, enclosure and hood to collect and transfer the emissions to an abatement system e Covered launder

BAT 33. In order to reduce diffuse emissions from anode casting in primary and secondary copper production, BAT is to use one or a combination of the techniques given below.

Technique a Use an enclosed tundish b Use a closed intermediate ladle c Use a hood, equipped with an air extraction system, over the casting ladle and over the casting wheel

BAT 34. In order to reduce diffuse emissions from electrolysis cells, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Addition of surfactants to the electrowinning cells Generally applicable b Use covers or a hood to collect and transfer the emissions to an abatement system Only applicable for electrowinning cells or refining cells for low-purity anodes. Not applicable when the cell needs to remain uncovered to maintain the cell temperature at workable levels (approximately 65 °C) c Closed and fixed pipelines for transferring the electrolyte solutions Generally applicable d Gas extraction from the washing chambers of the cathode stripping machine and anode scrap washing machine Generally applicable

BAT 35. In order to reduce diffuse emissions from the casting of copper alloys, BAT is to use one or a combination of the techniques given below.

Technique a Use enclosures or hoods to collect and transfer the emissions to an abatement system b Use covering for the melts in holding and casting furnaces c Boosted suction system (24)

BAT 36. In order to reduce diffuse emissions from non-acid and acid pickling, BAT is to use one of the techniques given below.

Technique Applicability a Encapsulate the pickling line with a solution of isopropanol operating in a closed circuit Only applicable for pickling of copper wire rod in continuous operations b Encapsulate the pickling line to collect and transfer the emissions to an abatement system Only applicable for acid pickling in continuous operations

1.2.3.2. Channelled dust emissions

Descriptions of the techniques mentioned in this section are given in Section 1.10.

The BAT-associated emission levels are all given in Table 3.

BAT 37. In order to reduce dust and metal emissions to air from the reception, storage, handling, transport, metering, mixing, blending, crushing, drying, cutting and screening of raw materials, and the pyrolytic treatment of copper turnings in primary and secondary copper production, BAT is to use a bag filter.

BAT 38. In order to reduce dust and metal emissions to air from concentrate drying in primary copper production, BAT is to use a bag filter.

Applicability

In the event of a high organic carbon content in the concentrates (e.g. around 10 wt-%), bag filters may not be applicable (due to blinding of the bags) and other techniques (e.g. ESP) may be used.

BAT 39. In order to reduce dust and metal emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant or power plant) from the primary copper smelter and converter, BAT is to use a bag filter and/or a wet scrubber.

BAT 40. In order to reduce dust and metal emissions to air (other than those that are routed to the sulphuric acid plant) from the secondary copper smelter and converter and from the processing of secondary copper intermediates, BAT is to use a bag filter.

BAT 41. In order to reduce dust and metal emissions to air from the secondary copper holding furnace, BAT is to use a bag filter.

BAT 42. In order to reduce dust and metal emissions to air from copper-rich slag furnace processing, BAT is to use a bag filter or a scrubber in combination with an ESP.

BAT 43. In order to reduce dust and metal emissions to air from the anode furnace in primary and secondary copper production, BAT is to use a bag filter or a scrubber in combination with an ESP.

BAT 44. In order to reduce dust and metal emissions to air from anode casting in primary and secondary copper production, BAT is to use a bag filter or, in the case of off-gases with a water content close to the dew point, a wet scrubber or a demister.

BAT 45. In order to reduce dust and metal emissions to air from a copper melting furnace, BAT is to select and feed the raw materials according to the furnace type and the abatement system used and to use a bag filter.

Table 3

BAT-associated emission levels for dust emissions to air from copper production

Parameter BAT Process BAT-AEL (mg/Nm3) Dust BAT 37 Reception, storage, handling, transport, metering, mixing, blending, crushing, drying, cutting and screening of raw materials, and the pyrolytic treatment of copper turnings in primary and secondary copper production 2-5 (25) (28) BAT 38 Concentrate drying in primary copper production 3-5 (26) (28) (29) BAT 39 Primary copper smelter and converter (emissions other than those that are routed to the sulphuric acid or liquid SO2 plant or power plant) 2-5 (27) (28) BAT 40 Secondary copper smelter and converter and processing of secondary copper intermediates (emissions other than those that are routed to the sulphuric acid plant) 2-4 (26) (28) BAT 41 Secondary copper holding furnace ≤ 5 (25) BAT 42 Copper-rich slag furnace processing 2-5 (25) (30) BAT 43 Anode furnace (in primary and secondary copper production) 2-5 (26) (30) BAT 44 Anode casting (in primary and secondary copper production) ≤ 5-15 (26) (31) BAT 45 Copper melting furnace 2-5 (26) (32)

The associated monitoring is in BAT 10.

1.2.3.3. Organic compound emissions

BAT 46. In order to reduce organic compound emissions to air from the pyrolytic treatment of copper turnings, and the drying, smelting and melting of secondary raw materials, BAT is to use one of the techniques given below.

Technique (33) Applicability a Afterburner or post-combustion chamber or regenerative thermal oxidiser The applicability is restricted by the energy content of the off-gases that need to be treated, as off-gases with a lower energy content require a higher fuel use b Injection of adsorbent in combination with a bag filter Generally applicable c Design of furnace and the abatement techniques according to the raw materials available Only applicable to new furnaces or major upgrades of existing furnaces d Select and feed the raw materials according to the furnace and the abatement techniques used Generally applicable e Thermal destruction of TVOC at high temperatures in the furnace (> 1 000 °C) Generally applicable

BAT-associated emission levels: See Table 4.

Table 4

BAT-associated emission levels for emissions to air of TVOC from the pyrolytic treatment of copper turnings, and the drying, smelting and melting of secondary raw materials

The associated monitoring is in BAT 10.

BAT 47. In order to reduce organic compound emissions to air from solvent extraction in hydrometallurgical copper production, BAT is to use both of the techniques given below and to determine the VOC emissions annually, e.g. through mass balance.

Technique a Process reagent (solvent) with lower steam pressure b Closed equipment such as closed mixing tanks, closed settlers and closed storage tanks

BAT 48. In order to reduce PCDD/F emissions to air from the pyrolytic treatment of copper turnings, smelting, melting, fire refining and converting operations in secondary copper production, BAT is to use one or a combination of the techniques given below.

Technique a Select and feed the raw materials according to the furnace and the abatement techniques used b Optimise combustion conditions to reduce the emissions of organic compounds c Use charging systems, for a semi-closed furnace, to give small additions of raw material d Thermal destruction of PCDD/F in the furnace at high temperatures (> 850 °C) e Use oxygen injection in the upper zone of the furnace f Internal burner system g Post-combustion chamber or afterburner or regenerative thermal oxidiser (36) h Avoid exhaust systems with a high dust build-up for temperatures > 250 °C i Rapid quenching (36) j Injection of adsorption agent in combination with an efficient dust collection system (36)

BAT-associated emission levels: See Table 5.

Table 5

BAT-associated emission levels for PCDD/F emissions to air from the pyrolytic treatment of copper turnings, smelting, melting, fire refining and converting operations in secondary copper production

The associated monitoring is in BAT 10.

1.2.3.4. Sulphur dioxide emissions

Descriptions of the techniques mentioned in this section are given in Section 1.10.

BAT 49. In order to reduce SO2 emissions (other than those that are routed to the sulphuric acid or liquid SO2 plant or power plant) from primary and secondary copper production, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Dry or semi-dry scrubber Generally applicable b Wet scrubber Applicability may be limited in the following cases: — very high off-gas flow rates (due to the significant amounts of waste and waste water generated) — in arid areas (due to the large volume of water necessary and the need for waste water treatment) c Polyether-based absorption/desorption system Not applicable in the case of secondary copper production. Not applicable in the absence of a sulphuric acid or liquid SO2 plant

BAT-associated emission levels: See Table 6.

Table 6

BAT-associated emission levels for SO2 emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant or power plant) from primary and secondary copper production

Parameter Process BAT-AEL (mg/Nm3) (38) SO2 Primary copper production 50-500 (39) Secondary copper production 50-300

The associated monitoring is in BAT 10.

1.2.3.5. Acid emissions

BAT 50. In order to reduce acid gas emissions to air from exhaust gases from the electrowinning cells, the electrorefining cells, the washing chamber of the cathode stripping machine and the anode scrap washing machine, BAT is to use a wet scrubber or a demister.

1.2.4. Soil and groundwater

BAT 51. In order to prevent soil and groundwater contamination from copper recovery in the slag concentrator, BAT is to use a drainage system in cooling areas and a correct design of the final slag storage area to collect overflow water and avoid fluid leakage.

BAT 52. In order to prevent soil and groundwater contamination from the electrolysis in primary and secondary copper production, BAT is to use a combination of the techniques given below.

Technique a Use of a sealed drainage system b Use of impermeable and acid-resistant floors c Use of double-walled tanks or placement in resistant bunds with impermeable floors

1.2.5. Waste water generation

BAT 53. In order to prevent the generation of waste water from primary and secondary copper production, BAT is to use one or a combination of the techniques given below.

Technique a Use the steam condensate for heating the electrolysis cells, to wash the copper cathodes or send it back to steam boiler b Reuse the water collected from the cooling area, flotation process and hydro transportation of final slag in the slag concentration process c Recycle the pickling solutions and the rinse water d Treat the residues (crude) from the solvent extraction step in hydrometallurgical copper production to recover the organic solution content e Centrifuge the slurry from cleaning and settlers from the solvent extraction step in hydrometallurgical copper production f Reuse the electrolysis bleed after the metal removal stage in the electrowinning and/or the leaching process

1.2.6. Waste

BAT 54. In order to reduce the quantities of waste sent for disposal from primary and secondary copper production, BAT is to organise operations so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below.

Technique Applicability a Recover metals from the dust and slime coming from the dust abatement system Generally applicable b Reuse or sell the calcium compounds (e.g. gypsum) generated by the abatement of SO2 Applicability may be restricted depending on the metal content and on the availability of a market c Regenerate or recycle the spent catalysts Generally applicable d Recover metal from the waste water treatment slime Applicability may be restricted depending on the metal content and on the availability of a market/process e Use weak acid in the leaching process or for gypsum production Generally applicable f Recover the copper content from the rich slag in the slag furnace or slag flotation plant g Use the final slag from furnaces as an abrasive or (road) construction material or for another viable application Applicability may be restricted depending on the metal content and on the availability of a market h Use the furnace lining for recovery of metals or reuse as refractory material i Use the slag from the slag flotation as an abrasive or construction material or for another viable application j Use the skimming from the melting furnaces to recover the metal content Generally applicable k Use the spent electrolyte bleed to recover copper and nickel. Reuse the remaining acid to make up the new electrolyte or to produce gypsum l Use the spent anode as a cooling material in pyrometallurgical copper refining or remelting m Use anode slime to recover precious metals n Use the gypsum from the waste water treatment plant in the pyrometallurgical process or for sale Applicability may be restricted depending on the quality of the generated gypsum o Recover metals from sludge Generally applicable p Reuse the depleted electrolyte from the hydrometallurgical copper process as a leaching agent Applicability may be restricted depending on the metal content and on the availability of a market/process q Recycle copper scales from rolling in a copper smelter Generally applicable r Recover metals from the spent acid pickling solution and reuse the cleaned acid solution

1.3. BAT CONCLUSIONS FOR ALUMINIUM PRODUCTION INCLUDING ALUMINA AND ANODE PRODUCTION

1.3.1. Alumina production

1.3.1.1. Energy

BAT 55. In order to use energy efficiently during the production of alumina from bauxite, BAT is to use one or a combination of the techniques given below.

Technique Description Applicability a Plate heat exchangers Plate heat exchangers allow a higher heat recovery from the liquor flowing to the precipitation area in comparison with other techniques such as flash cooling plants Applicable if the energy from the cooling fluid can be reused in the process and if the condensate balance and the liquor conditions allow it b Circulating fluidised bed calciners Circulating fluidised bed calciners have a much higher energy efficiency than rotary kilns, since the heat recovery from the alumina and the flue-gas is greater Only applicable to smelter-grade aluminas. Not applicable to speciality/non-smelter-grade aluminas, as these require a higher level of calcination that can currently only be achieved with a rotary kiln c Single stream digestion design The slurry is heated up in one circuit without using live steam and therefore without dilution of the slurry (in contrast to the double-stream digestion design) Only applicable to new plants d Selection of the bauxite Bauxite with a higher moisture content carries more water into the process, which increases the energy need for evaporation. In addition, bauxites with a high monohydrate content (boehmite and/or diaspore) require a higher pressure and temperature in the digestion process, leading to higher energy consumption Applicable within the constraints related to the specific design of the plant, since some plants are specifically designed for a certain quality of bauxite, which limits the use of alternative bauxite sources

1.3.1.2. Air emissions

BAT 56. In order to reduce dust and metal emissions from alumina calcination, BAT is to use a bag filter or an ESP.

1.3.1.3. Waste

BAT 57. In order to reduce the quantities of waste sent for disposal and to improve the disposal of bauxite residues from alumina production, BAT is to use one or both of the techniques given below.

Technique a Reduce the volume of bauxite residues by compacting in order to minimise the moisture content, e.g. using vacuum or high-pressure filters to form a semi-dry cake b Reduce/minimise the alkalinity remaining in the bauxite residues in order to allow disposal of the residues in a landfill

1.3.2. Anode production

1.3.2.1. Air emissions

1.3.2.1.1. Dust, PAH and fluoride emissions from the paste plant

BAT 58. In order to reduce dust emissions to air from a paste plant (removing coke dust from operations such as coke storage and grinding), BAT is to use a bag filter.

BAT-associated emission levels: See Table 7.

BAT 59. In order to reduce dust and PAH emissions to air from a paste plant (hot pitch storage, paste mixing, cooling and forming), BAT is to use one or a combination of the techniques given below.

Technique (40) a Dry scrubber using coke as the adsorbent agent, with or without precooling, followed by a bag filter b Regenerative thermal oxidiser c Catalytic thermal oxidiser

BAT-associated emission levels: See Table 7.

Table 7

BAT-associated emission levels for dust and BaP (as an indicator of PAH) emissions to air from a paste plant

Parameter Process BAT-AEL (mg/Nm3) Dust — Hot pitch storage, paste mixing, cooling and forming — Removing coke dust from operations such as coke storage and grinding 2-5 (41) BaP Hot pitch storage, paste mixing, cooling and forming 0,001-0,01 (42)

The associated monitoring is in BAT 10.

1.3.2.1.2. Dust, sulphur dioxide, PAH and fluoride emissions from the baking plant

BAT 60. In order to reduce dust, sulphur dioxide, PAH and fluoride emissions to air from a baking plant in an anode production plant integrated with a primary aluminium smelter, BAT is to use one or a combination of the techniques given below.

Technique (43) Applicability a Use of raw materials and fuels containing a low amount of sulphur Generally applicable for reducing SO2 emissions b Dry scrubber using alumina as the adsorbent agent followed by a bag filter Generally applicable for reducing dust, PAH and fluoride emissions c Wet scrubber Applicability for reducing dust, SO2, PAH and fluoride emissions may be limited in the following cases: — very high off-gas flow rates (due to the significant amounts of waste and waste water generated) — in arid areas (due to the large volume of water necessary and the need for waste water treatment) d Regenerative thermal oxidiser in combination with a dust abatement system Generally applicable for reducing dust and PAH emissions.

BAT-associated emission levels: See Table 8.

Table 8

BAT-associated emission levels for dust, BaP (as an indicator of PAH) and fluoride emissions to air from a baking plant in an anode production plant integrated with a primary aluminium smelter

Parameter BAT-AEL (mg/Nm3) Dust 2-5 (44) BaP 0,001-0,01 (45) HF 0,3-0,5 (44) Total fluorides ≤ 0,8 (45)

The associated monitoring is in BAT 10.

BAT 61. In order to reduce dust, PAH and fluoride emissions to air from a baking plant in a stand-alone anode production plant, BAT is to use a pre-filtration unit and a regenerative thermal oxidiser followed by a dry scrubber (e.g. lime bed).

BAT-associated emission levels: See Table 9.

Table 9

BAT-associated emission levels for dust, BaP (as an indicator of PAH) and fluoride emissions to air from a baking plant in a stand-alone anode production plant

Parameter BAT-AEL (mg/Nm3) Dust 2-5 (46) BaP 0,001-0,01 (47) HF ≤ 3 (46)

The associated monitoring is in BAT 10.

1.3.2.2. Waste water generation

BAT 62. In order to prevent the generation of waste water from anode baking, BAT is to use a closed water cycle.

Applicability

Generally applicable to new plants and major upgrades. The applicability may be limited due to water quality and/or product quality requirements.

1.3.2.3. Waste

BAT 63. In order to reduce the quantities of waste sent for disposal, BAT is to recycle carbon dust from the coke filter as a scrubbing medium.

Applicability

There may be restrictions on applicability depending on the ash content of the carbon dust.

1.3.3. Primary aluminium production

1.3.3.1. Air emissions

BAT 64. In order to prevent or collect diffuse emissions from electrolytic cells in primary aluminium production using the Søderberg technology, BAT is to use a combination of the techniques given below.

Technique a Use of paste with a pitch content between 25 % and 28 % (dry paste) b Upgrade the manifold design to allow closed point feeding operations and improved off-gas collection efficiency c Alumina point feeding d Increased anode height combined with the treatment in BAT 67 e Anode top hooding when high current density anodes are used, connected to the treatment in BAT 67

Description

BAT 64(c): Point feeding of alumina avoids the regular crust-breaking (such as during manual side feed or bar broken feed), and thus reduces the associated fluoride and dust emissions.

BAT 64(d): An increased anode height helps to achieve lower temperatures in the anode top, resulting in lower emissions to air.

BAT-associated emission levels: See Table 12.

BAT 65. In order to prevent or collect diffuse emissions from electrolytic cells in primary aluminium production using prebaked anodes, BAT is to use a combination of the techniques given below.

Technique a Automatic multiple point feeding of alumina b Complete hood coverage of the cell and adequate off-gas extraction rates (to lead the off-gas to the treatment in BAT 67) taking into account fluoride generation from bath and carbon anode consumption c Boosted suction system connected to the abatement techniques listed in BAT 67 d Minimisation of the time for changing anodes and other activities that require cell hoods to be removed e Efficient process control system avoiding process deviations that might otherwise lead to increased cell evolution and emissions f Use of a programmed system for cell operations and maintenance g Use of established efficient cleaning methods in the rodding plant to recover fluorides and carbon h Storage of removed anodes in a compartment near the cell, connected to the treatment in BAT 67, or storage of the butts in confined boxes

Applicability

BAT 65.c and h are not applicable to existing plants

BAT-associated emission levels: See Table 12.

1.3.3.1.1. Channelled dust and fluoride emissions

BAT 66. In order to reduce dust emissions from the storage, handling and transport of raw materials, BAT is to use a bag filter.

BAT-associated emission levels: See Table 10.

Table 10

BAT-associated emission levels for dust from the storage, handling and transport of raw materials

Parameter BAT-AEL (mg/Nm3) (48) Dust ≤ 5-10

The associated monitoring is in BAT 10.

BAT 67. In order to reduce dust, metal and fluoride emissions to air from electrolytic cells, BAT is to use one of the techniques given below.

Technique (49) Applicability a Dry scrubber using alumina as the adsorbent agent followed by a bag filter Generally applicable b Dry scrubber using alumina as the adsorbent agent followed by a bag filter and a wet scrubber Applicability may be limited in the following cases: — very high off-gas flow rates (due to the significant amounts of waste and waste water generated) — in arid areas (due to the large volume of water necessary and the need for waste water treatment)

BAT-associated emission levels: See Table 11 and Table 12.

Table 11

BAT-associated emission levels for dust and fluoride emissions to air from electrolytic cells

Parameter BAT-AEL (mg/Nm3) Dust 2-5 (50) HF ≤ 1,0 (50) Total fluorides ≤ 1,5 (51)

The associated monitoring is in BAT 10.

1.3.3.1.2. Total emissions of dust and fluorides

BAT-associated emission levels for the total emissions of dust and fluoride to air from the electrolysis house (collected from the electrolytic cells and roof vents): See Table 12.

Table 12

BAT-associated emission levels for the total emissions of dust and fluoride to air from the electrolysis house (collected from the electrolytic cells and roof vents)

Parameter BAT BAT-AELs for existing plants (kg/t Al) (52) (53) BAT-AELs for new plants (kg/t Al) (52) Dust Combination of BAT 64, BAT 65 and BAT 67 ≤ 1,2 ≤ 0,6 Total fluorides ≤ 0,6 ≤ 0,35

The associated monitoring is in BAT 10.

BAT 68. In order to prevent or reduce dust and metal emissions to air from melting and molten metal treatment and casting in primary aluminium production, BAT is to use one or both of the techniques given below.

Technique a Use of liquid metal from electrolysis and uncontaminated aluminium material, i.e. solid material free of substances such as paint, plastic or oil (e.g. the top and the bottom part of the billets that are cut for quality reasons) b Bag filter (54)

BAT-associated emission levels: See Table 13.

Table 13

BAT-associated emission levels for dust emissions to air from melting and molten metal treatment and casting in primary aluminium production

The associated monitoring is in BAT 10.

1.3.3.1.3. Sulphur dioxide emissions

BAT 69. In order to reduce emissions to air from electrolytic cells, BAT is to use one or both of the techniques given below.

Technique Applicability a Use of low-sulphur anodes Generally applicable b Wet scrubber (57) Applicability may be limited in the following cases: — very high off-gas flow rates (due to the significant amounts of waste and waste water generated) — in arid areas (due to the large volume of water necessary and the need for waste water treatment)

Description

BAT 69(a): Anodes containing less than 1,5 % sulphur as a yearly average can be produced by an appropriate combination of the raw materials used. A minimum sulphur content of 0,9 % as a yearly average is required for the viability of the electrolysis process.

BAT-associated emission levels: See Table 14.

Table 14

BAT-associated emission levels for SO2 emissions to air from electrolytic cells

The associated monitoring is in BAT 10.

1.3.3.1.4. Perfluorocarbon emissions

BAT 70. In order to reduce perfluorocarbon emissions to air from primary aluminium production, BAT is to use all of the techniques given below.

Technique Applicability a Automatic multiple point feeding of alumina Generally applicable b Computer control of the electrolysis process based on active cell databases and monitoring of cell operating parameters Generally applicable c Automatic anode effect suppression Not applicable to Søderberg cells because the anode design (one piece only) does not allow the bath flow associated with this technique

Description

BAT 70(c): The anode effect takes place when the alumina content of the electrolyte falls below 1-2 %. During anode effects, instead of decomposing alumina, the cryolite bath is decomposed into metal and fluoride ions, the latter forming gaseous perfluorocarbons, which react with the carbon anode.

1.3.3.1.5. PAH and CO emissions

BAT 71. In order to reduce CO and PAH emissions to air from primary aluminium production using the Søderberg technology, BAT is to combust the CO and the PAH in the cell exhaust gas.

1.3.3.2. Waste water generation

BAT 72. In order to prevent the generation of waste water, BAT is to reuse or recycle cooling water and treated waste water, including rainwater, within the process.

Applicability

Generally applicable to new plants and major upgrades. The applicability may be limited due to water quality and/or product quality requirements. The amount of cooling water, treated waste water and rainwater that is reused or recycled cannot be higher than the amount of water needed for the process.

1.3.3.3. Waste

BAT 73. In order to reduce the disposal of spent pot lining, BAT is to organise operations on site so as to facilitate its external recycling, such as in cement manufacturing in the salt slag recovery process, as a carburiser in the steel or ferro-alloy industry or as a secondary raw material (e.g. rock wool), depending on the end consumer’s requirements.

1.3.4. Secondary aluminium production

1.3.4.1. Secondary materials

BAT 74. In order to increase the raw materials’ yield, BAT is to separate non-metallic constituents and metals other than aluminium by using one or a combination of the techniques given below depending on the constituents of the treated materials.

Technique a Magnetic separation of ferrous metals b Eddy current separation (using moving electromagnetic fields) of aluminium from the other constituents c Relative density separation (using a fluid with a different density) of different metals and non-metallic constituents

1.3.4.2. Energy

BAT 75. In order to use energy efficiently, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Preheating of the furnace charge with the exhaust gas Only applicable for non-rotating furnaces b Recirculation of the gases with unburnt hydrocarbons back into the burner system Only applicable for reverberatory furnaces and dryers c Supply the liquid metal for direct moulding Applicability is limited by the time needed for the transportation (maximum 4-5 hours)

1.3.4.3. Air emissions

BAT 76. In order to prevent or reduce emissions to air, BAT is to remove oil and organic compounds from the swarf before the smelting stage using centrifugation and/or drying (60).

Applicability

Centrifugation is only applicable to highly oil-contaminated swarf, when it is applied before the drying. The removal of oil and organic compounds may not be needed if the furnace and the abatement system are designed to handle the organic material.

1.3.4.3.1. Diffuse emissions

BAT 77. In order to prevent or reduce diffuse emissions from the pretreatment of scraps, BAT is to use one or both of the techniques given below.

Technique a Closed or pneumatic conveyor, with an air extraction system b Enclosures or hoods for the charging and for the discharge points, with an air extraction system

BAT 78. In order to prevent or reduce diffuse emissions from the charging and discharging/tapping of melting furnaces, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Placing a hood on top of the furnace door and at the taphole with off-gas extraction connected to a filtration system Generally applicable b Fume collection enclosure that covers both the charging and tapping zones Only applicable for stationary drum furnaces c Sealed furnace door (61) Generally applicable d Sealed charging carriage Only applicable for non-rotating furnaces e Boosted suction system that can be modified according to the process needed (61) Generally applicable

Description

BAT 78(a) and (b): Consist of applying a covering with extraction to collect and handle the off-gases from the process.

BAT 78(d): The skip seals against the open furnace door during the discharge of scrap and maintains furnace sealing during this stage.

BAT 79. In order to reduce emissions from skimmings/dross treatment, BAT is to use one or a combination of the techniques given below.

Technique a Cooling of skimmings/dross, as soon as they are skimmed from the furnace, in sealed containers under inert gas b Prevention of wetting of the skimmings/dross c Compaction of skimmings/dross with an air extraction and dust abatement system

1.3.4.3.2. Channelled dust emissions

BAT 80. In order to reduce dust and metal emissions from the swarf drying and the removal of oil and organic compounds from the swarf, from the crushing, milling and dry separation of non-metallic constituents and metals other than aluminium, and from the storage, handling and transport in secondary aluminium production, BAT is to use a bag filter.

BAT-associated emission levels: See Table 15.

Table 15

BAT-associated emission levels for dust emissions to air from the swarf drying and the removal of oil and organic compounds from the swarf, from the crushing, milling and dry separation of non-metallic constituents and metals other than aluminium, and from the storage, handling and transport in secondary aluminium production

Parameter BAT-AEL (mg/Nm3) (62) Dust ≤ 5

The associated monitoring is in BAT 10.

BAT 81. In order to reduce dust and metal emissions to air from furnace processes such as charging, melting, tapping and molten metal treatment in secondary aluminium production, BAT is to use a bag filter.

BAT-associated emission levels: See Table 16.

Table 16

BAT-associated emission levels for dust emissions to air from furnace processes such as charging, melting, tapping and molten metal treatment in secondary aluminium production

Parameter BAT-AEL (mg/Nm3) (63) Dust 2-5

The associated monitoring is in BAT 10.

BAT 82. In order to reduce dust and metal emissions to air from remelting in secondary aluminium production, BAT is to use one or a combination of the techniques given below.

Technique a Use of uncontaminated aluminium material i.e. solid material free of substances such as paint, plastic or oil (e.g. billets) b Optimise combustion conditions to reduce the emissions of dust c Bag filter

BAT-associated emission levels: See Table 17.

Table 17

BAT-associated emission levels for dust from remelting in secondary aluminium production

The associated monitoring is in BAT 10.

1.3.4.3.3. Organic compound emissions

BAT 83. In order to reduce emissions to air of organic compounds and PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g. swarf) and from the melting furnace, BAT is to use a bag filter in combination with at least one of the techniques given below.

Technique (66) a Select and feed the raw materials according to the furnace and the abatement techniques used b Internal burner system for melting furnaces c Afterburner d Rapid quenching e Activated carbon injection

BAT-associated emission levels: See Table 18.

Table 18

BAT-associated emission levels for emissions to air of TVOC and PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g. swarf) and from the melting furnace

Parameter Unit BAT-AEL TVOC mg/Nm3 ≤ 10-30 (67) PCDD/F ng I-TEQ/Nm3 ≤ 0,1 (68)

The associated monitoring is in BAT 10.

1.3.4.3.4. Acid emissions

BAT 84. In order to reduce emissions to air of HCl, Cl2 and HF from the thermal treatment of contaminated secondary raw materials (e.g. swarf), the melting furnace, and remelting and molten metal treatment, BAT is to use one or a combination of the techniques given below.

Technique a Select and feed the raw materials according to the furnace and the abatement techniques used (69) b Ca(OH)2 or sodium bicarbonate injection in combination with a bag filter (69) c Control of the refining process, adapting the quantity of refining gas used to remove the contaminants present into the molten metals d Use of dilute chlorine with inert gas in the refining process

Description

BAT 84(d): Using chlorine diluted with inert gas instead of only pure chlorine, to reduce the emission of chlorine. Refining can also be performed using only the inert gas.

BAT-associated emission levels: See Table 19.

Table 19

BAT-associated emission levels for HCl, Cl2 and HF emissions to air from the thermal treatment of contaminated secondary raw materials (e.g. swarf), the melting furnace, and remelting and molten metal treatment

Parameter BAT-AEL (mg/Nm3) HCl ≤ 5-10 (70) Cl2 ≤ 1 (71) (72) HF ≤ 1 (73)

The associated monitoring is in BAT 10.

1.3.4.4. Waste

BAT 85. In order to reduce the quantities of waste sent for disposal from secondary aluminium production, BAT is to organise operations on site so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below.

Technique a Reuse collected dust in the process in the case of a melting furnace using salt cover or in the salt slag recovery process b Full recycling of the salt slag c Apply skimmings/dross treatment to recover aluminium in the case of furnaces that do not use salt cover

BAT 86. In order to reduce the quantities of salt slag produced from secondary aluminium production, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Increase the quality of raw material used through the separation of the non-metallic constituents and metals other than aluminium for scraps where aluminium is mixed with other constituents Generally applicable b Remove oil and organic constituents from contaminated swarf before melting Generally applicable c Metal pumping or stirring Not applicable for rotary furnaces d Tilting rotary furnace There may be restrictions on the use of this furnace due to the size of the feed materials

1.3.5. Salt slag recycling process

1.3.5.1. Diffuse emissions

BAT 87. In order to prevent or reduce diffuse emissions from the salt slag recycling process, BAT is to use one or both of the techniques given below.

Technique a Enclose equipment with gas extraction connected to a filtration system b Hood with gas extraction connected to a filtration system

1.3.5.2. Channelled dust emissions

BAT 88. In order to reduce dust and metal emissions to air from crushing and dry milling associated with the salt slag recovery process, BAT is to use a bag filter.

BAT-associated emission levels: See Table 20.

Table 20

BAT-associated emission levels for dust emissions to air from crushing and dry milling associated with the salt slag recovery process

Parameter BAT-AEL (mg/Nm3) (74) Dust 2-5

The associated monitoring is in BAT 10.

1.3.5.3. Gaseous compounds

BAT 89. In order to reduce gaseous emissions to air from wet milling and leaching from the salt slag recovery process, BAT is to use one or a combination of the techniques given below.

Technique (75) a Activated carbon injection b Afterburner c Wet scrubber with H2SO4 solution

BAT-associated emission levels: See Table 21.

Table 21

BAT-associated emission levels for gaseous emissions to air from wet milling and leaching from the salt slag recovery process

Parameter BAT-AEL (mg/Nm3) (76) NH3 ≤ 10 PH3 ≤ 0,5 H2S ≤ 2

The associated monitoring is in BAT 10.

1.4. BAT CONCLUSIONS FOR LEAD AND/OR TIN PRODUCTION

1.4.1. Air emissions

1.4.1.1. Diffuse emissions

BAT 90. In order to prevent or reduce diffuse emissions from preparation (such as metering, mixing, blending, crushing, cutting, screening) of primary and secondary materials (excluding batteries), BAT is to use one or a combination of the techniques given below.

Technique Applicability a Enclosed conveyer or pneumatic transfer system for dusty material Generally applicable b Enclosed equipment. When dusty materials are used the emissions are collected and sent to an abatement system Only applicable for feed blends prepared with a dosing bin or loss-in-weight system c Mixing of raw materials carried out in an enclosed building Only applicable for dusty materials. For existing plants, application may be difficult due to the space required d Dust suppression systems such as water sprays Only applicable for mixing carried out outdoors e Pelletisation of raw materials Applicable only when the process and the furnace can use pelletised raw materials

BAT 91. In order to prevent or reduce diffuse emissions from material pretreatment (such as drying, dismantling, sintering, briquetting, pelletising and battery crushing, screening and classifying) in primary lead and secondary lead and/or tin production, BAT is to use one or both of the techniques given below.

Technique a Enclosed conveyer or pneumatic transfer system for dusty material b Enclosed equipment. When dusty materials are used the emissions are collected and sent to an abatement system

BAT 92. In order to prevent or reduce diffuse emissions from charging, smelting and tapping operations in lead and/or tin production, and from pre-decoppering operations in primary lead production, BAT is to use an appropriate combination of the techniques given below.

Technique Applicability a Encapsulated charging system with an air extraction system Generally applicable b Sealed or enclosed furnaces with door sealing (77) for processes with a discontinuous feed and output Generally applicable c Operate furnace and gas routes under negative pressure and at a sufficient gas extraction rate to prevent pressurisation Generally applicable d Capture hood/enclosures at charging and tapping points Generally applicable e Enclosed building Generally applicable f Complete hood coverage with an air extraction system In existing plants or major upgrades of existing plants, application may be difficult due to the space requirements g Maintain furnace sealing Generally applicable h Maintain the temperature in the furnace at the lowest required level Generally applicable i Apply a hood at the tapping point, ladles and drossing area with an air extraction system Generally applicable j Pretreatment of dusty raw material, such as pelletisation Applicable only when the process and the furnace can use pelletised raw materials k Apply a doghouse for ladles during tapping Generally applicable l An air extraction system for charging and tapping area connected to a filtration system Generally applicable

BAT 93. In order to prevent or reduce diffuse emissions from remelting, refining and casting in primary and secondary lead and/or tin production, BAT is to use a combination of the techniques given below.

Technique a Hood on the crucible furnace or kettle with an air extraction system b Lids to close the kettle during the refining reactions and addition of chemicals c Hood with air extraction system at launders and tapping points d Temperature control of the melt e Closed mechanical skimmers for removal of dusty dross/residues

1.4.1.2. Channelled dust emissions

BAT 94. In order to reduce dust and metal emissions to air from raw material preparation (such as reception, handling, storage, metering, mixing, blending, drying, crushing, cutting and screening) in primary and secondary lead/or and tin production, BAT is to use a bag filter.

BAT-associated emission levels: See Table 22.

Table 22

BAT-associated emission levels for dust emissions to air from raw material preparation in primary and secondary lead and/or tin production

Parameter BAT-AEL (mg/Nm3) (78) Dust ≤ 5

The associated monitoring is in BAT 10.

BAT 95. In order to reduce dust and metal emissions to air from battery preparation (crushing, screening and classifying), BAT is to use a bag filter or a wet scrubber.

BAT-associated emission levels: See Table 23.

Table 23

BAT-associated emission levels for dust emissions to air from battery preparation (crushing, screening and classifying)

Parameter BAT-AEL (mg/Nm3) (79) Dust ≤ 5

The associated monitoring is in BAT 10.

BAT 96. In order to reduce dust and metal emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant) from charging, smelting and tapping in primary and secondary lead and/or tin production, BAT is to use a bag filter.

BAT-associated emission levels: See Table 24.

Table 24

BAT-associated emission levels for dust and lead emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant) from charging, smelting and tapping in primary and secondary lead and/or tin production

Parameter BAT-AEL (mg/Nm3) Dust 2-4 (80) (81) Pb ≤ 1 (82)

The associated monitoring is in BAT 10.

BAT 97. In order to reduce dust and metal emissions to air from remelting, refining and casting in primary and secondary lead and/or tin production, BAT is to use the techniques given below.

Technique a For pyrometallurgical processes: maintain the temperature of the melt bath at the lowest possible level according to the process stage in combination with a bag filter b For hydrometallurgical processes: use a wet scrubber

BAT-associated emission levels: See Table 25.

Table 25

BAT-associated emission levels for dust and lead emissions to air from remelting, refining and casting in primary and secondary lead and/or tin production

Parameter BAT-AEL (mg/Nm3) Dust 2-4 (83) (84) Pb ≤ 1 (85)

The associated monitoring is in BAT 10.

1.4.1.3. Organic compound emissions

BAT 98. In order to reduce emissions of organic compounds to air from the raw material drying and smelting process in secondary lead and/or tin production, BAT is to use one or a combination of the techniques given below.

Technique (86) Applicability a Select and feed the raw materials according to the furnace and the abatement techniques used Generally applicable b Optimise combustion conditions to reduce the emissions of organic compounds Generally applicable c Afterburner or regenerative thermal oxidiser The applicability is restricted by the energy content of the off-gases that need to be treated, as off-gases with a lower energy content lead to a higher use of fuels

BAT-associated emission levels: See Table 26.

Table 26

BAT-associated emission levels for TVOC emissions to air from the raw material drying and smelting process in secondary lead and/or tin production

Parameter BAT-AEL (mg/Nm3) (87) TVOC 10-40

The associated monitoring is in BAT 10.

BAT 99. In order to reduce PCDD/F emissions to air from the smelting of secondary lead and/or tin raw materials, BAT is to use one or a combination of the techniques given below.

Technique a Select and feed the raw materials according to the furnace and the abatement techniques used (88) b Use charging systems, for a semi-closed furnace, to give small additions of raw material (88) c Internal burner system (88) for melting furnaces d Afterburner or regenerative thermal oxidiser (88) e Avoid exhaust systems with a high dust build-up at temperatures > 250 °C (88) f Rapid quenching (88) g Injection of adsorption agent in combination with efficient dust collection system (88) h Use of efficient dust collection system i Use of oxygen injection in the upper zone of the furnace j Optimise combustion conditions to reduce the emissions of organic compounds (88)

BAT-associated emission levels: See Table 27.

Table 27

BAT-associated emission levels for PCDD/F emissions to air from the smelting of secondary lead and/or tin raw materials

The associated monitoring is in BAT 10.

1.4.1.4. Sulphur dioxide emissions

BAT 100. In order to prevent or reduce SO2 emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant) from charging, smelting and tapping in primary and secondary lead and/or tin production, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Alkaline leaching of raw materials that contain sulphur in the form of sulphate Generally applicable b Dry or semi-dry scrubber (90) Generally applicable c Wet scrubber (90) Applicability may be limited in the following cases: — very high off-gas flow rates (due to the significant amounts of waste and waste water generated) — in arid areas (due to the large volume of water necessary and the need for waste water treatment) d Fixation of sulphur in the smelt phase Only applicable for secondary lead production

Description

BAT 100(a): An alkali salt solution is used to remove sulphates from secondary materials prior to smelting.

BAT 100(d): The fixation of sulphur in the smelt phase is achieved by adding iron and soda (Na2CO3) in the smelters which react with the sulphur contained in the raw materials to form Na2S-FeS slag.

BAT-associated emission levels: See Table 28.

Table 28

BAT-associated emission levels for SO2 emissions to air (other than those that are routed to the sulphuric acid or liquid SO2 plant) from charging, smelting and tapping in primary and secondary lead and/or tin production

The associated monitoring is in BAT 10.

1.4.2. Soil and groundwater protection

BAT 101. In order to prevent the contamination of soil and groundwater from battery storage, crushing, screening and classifying operations, BAT is to use an acid-resistant floor surface and a system for the collection of acid spillages.

1.4.3. Waste water generation and treatment

BAT 102. In order to prevent the generation of waste water from the alkaline leaching process, BAT is to reuse the water from the sodium sulphate crystallisation of the alkali salt solution.

BAT 103. In order to reduce emissions to water from battery preparation when the acid mist is sent to the waste water treatment plant, BAT is to operate an adequately designed waste water treatment plant to abate the pollutants contained in this stream.

1.4.4. Waste

BAT 104. In order to reduce the quantities of waste sent for disposal from primary lead production, BAT is to organise operations on site so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below.

Technique Applicability a Reuse of the dust from the dust removal system in the lead production process Generally applicable b Se and Te recovery from wet or dry gas cleaning dust/sludge The applicability can be limited by the quantity of mercury present c Ag, Au, Bi, Sb and Cu recovery from the refining dross Generally applicable d Recovery of metals from the waste water treatment sludge Direct smelting of the waste water treatment plant sludge might be limited by the presence of elements such as As, Tl and Cd e Addition of flux materials that make the slag more suitable for external use Generally applicable

BAT 105. In order to allow the recovery of the polypropylene and polyethylene content of the lead battery, BAT is to separate it from the batteries prior to smelting.

Applicability

This may not be applicable for shaft furnaces due to the gas permeability provided by undismantled (whole) batteries, which is required by the furnace operations.

BAT 106. In order to reuse or recover the sulphuric acid collected from the battery recovery process, BAT is to organise operations on site so as to facilitate its internal or external reuse or recycling, including one or a combination of the techniques given below.

Technique Applicability a Reuse as a pickling agent Generally applicable depending on the local conditions such as presence of the pickling process and compatibility of the impurities present in the acid with the process b Reuse as raw material in a chemical plant Applicability may be restricted depending on the local availability of a chemical plant c Regeneration of the acid by cracking Only applicable when a sulphuric acid or liquid sulphur dioxide plant is present d Production of gypsum Only applicable if the impurities present in the recovery acid do not affect the gypsum quality or if gypsum of a lower quality can be used for other purposes such as a flux agent e Production of sodium sulphate Only applicable for the alkaline leaching process

BAT 107. In order to reduce the quantities of waste sent for disposal from secondary lead and/or tin production, BAT is to organise operations on site so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below.

Technique a Reuse the residues in the smelting process to recover lead and other metals b Treat the residues and the wastes in dedicated plants for material recovery c Treat the residues and the wastes so that they can be used for other applications

1.5. BAT CONCLUSIONS FOR ZINC AND/OR CADMIUM PRODUCTION

1.5.1. Primary zinc production

1.5.1.1. Hydrometallurgical zinc production

1.5.1.1.1. Energy

BAT 108. In order to use energy efficiently, BAT is to recover heat from the off-gases produced in the roaster using one or a combination of the techniques given below.

Technique Applicability a Use a waste heat boiler and turbines to produce electricity Applicability may be restricted depending on energy prices and the energy policy of the Member State b Use a waste heat boiler and turbines to produce mechanical energy to be used within the process Generally applicable c Use a waste heat boiler to produce heat to be used within the process and/or for office heating Generally applicable

1.5.1.1.2. Air emissions

1.5.1.1.2.1. Diffuse emissions

BAT 109. In order to reduce diffuse dust emissions to air from the roaster feed preparation and the feeding itself, BAT is to use one or both of the techniques given below.

Technique a Wet feeding b Completely enclosed process equipment connected to an abatement system

BAT 110. In order to reduce diffuse dust emissions to air from calcine processing, BAT is to use one or both of the techniques given below.

Technique a Perform operations under negative pressure b Completely enclosed process equipment connected to an abatement system

BAT 111. In order to reduce diffuse emissions to air from leaching, solid-liquid separation and purification, BAT is to use one or a combination of the techniques given below.

Technique Applicability a Cover tanks with a lid Generally applicable b Cover process liquid inlet and outlet launders Generally applicable c Connect tanks to a central mechanical draught abatement system or to a single tank abatement system Generally applicable d Cover vacuum filters with hoods and connect them to an abatement system Only applicable to the filtering of hot liquids in the leaching and solid-liquid separation stages

BAT 112. In order to reduce diffuse emissions to air from electrowinning, BAT is to use additives, especially foaming agents, in the electrowinning cells.

1.5.1.1.2.2. Channelled emissions

BAT 113. In order to reduce dust and metal emissions to air from the handling and storage of raw materials, dry roaster feed preparation, dry roaster feeding and calcine processing, BAT is to use a bag filter.

BAT-associated emission levels: See Table 29.

Table 29

BAT-associated emission levels for dust