Chapter 11
11 BAT CONCLUSIONS
Scope
These BAT conclusions concern the following activities specified in Annex I of Directive
2010/75/EU, ("Processing of non-ferrous metals"), namely:

Activity 2.1: Metal ore (including sulphide ore) roasting and sintering;

Activity 2.5: Processing of non-ferrous metals, including:
"(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 metals foundries, with a melting capacity exceeding 4
tonnes per day for lead and cadmium or 20 tonnes per day for all other metals.";

Activity 6.8: Production of carbon (hard-burnt coal) or electrographite by means of
incineration or graphitisation.
These BAT conclusions cover the following processes and activities:









The production of both primary and secondary non-ferrous metals.
The production of zinc oxide from fumes during the production of other metals.
The production of nickel compounds from liquors produced 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. This is an integral part of the production of the metal when performed at the
smelter and is therefore included in this document.
The recovery of SO2 from off-gases with a high SO2 content ( > 1 % v/v SO2) for the
production of sulphuric acid or liquefied sulphur dioxide and the related SO2 emissions
from these plants when integrated with non-ferrous metals production. The other
environmental aspects are covered in the Large Volume Inorganic Chemicals –
Ammonia, Acid and Fertilisers BAT conclusions.
The recycling of aluminium salt slag. This is an integral part of the recovery of
aluminium metal and salt when performed at the melter and is therefore included in this
document. when integrated with non-ferrous metals production.
The production of carbon and graphite electrodes. This activity is included because of
the similarity of part of the process to the production of anodes at some aluminium
smelters as an integral part of the production process.
The rolling, drawing and pressing of non-ferrous metals, when directly integrated with
the production of the metal.
The following processes and activities are not covered in these BAT conclusions:




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.
Foundry processes. These are covered in the BAT conclusions for the Smitheries and
Foundries Industry.
The production of radioactive metals.
The production of components such as semi-conductors.
Other reference documents which are of relevance for the activities covered in these BAT
conclusions are the following:
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Chapter 11
Reference documents
Energy Efficiency (ENE)
Common Waste Water and Waste Gas
Treatment/Management Systems in the
Chemical Sector (CWW)
Subject Activity
General aspects of energy efficiency
Waste water treatment techniques to reduce
emissions of metals to water
Large Volume Inorganic Chemicals, Ammonia,
Acids and Fertiliser Industries (LVIC-AAF)
Industrial Cooling Systems (ICS)
Emissions from Storage (EFS)
Economics and Cross-Media Effects (ECM)
Monitoring of emissions to air and water from
IED installations Reference Report on
Monitoring (ROM)
Waste Treatment Industries (WT)
Large Combustion Plants (LCP)
Surface Treatment Using Organic Solvents
(STS)
Surface Treatment of Metals and Plastics (STM)
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Sulphuric acid production
Industrial cooling systems, e.g. cooling towers,
plate heat exchangers
Storage and handling of materials Emissions
from tanks, pipework and stored chemicals and
fuels
Economics and cross-media effects of
techniques
Monitoring of emissions to air and water
Waste handling and treatment and recovery
Generation of steam and electricity by
combustion plants with a rated thermal input of
≥ 50 MWth
Non-acid pickling of copper rod and semis
copper and copper alloy
Acid pickling of copper rod and semis copper
and copper alloy
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General considerations
Best Available Techniques
The techniques listed and described in these following 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, these BAT conclusions presented in this document are generally
applicable.
Emission levels to air associated with BAT
Emission levels to air associated with the best available techniques (BAT-AELs) for emission to
air given in these BAT conclusions refer to standard conditions: dry gas at a temperature of
273.15 K, and pressure of 101.3 kPa, without correction of the oxygen content of the flue offgases.
Averaging periods for emissions to air
For averaging periods of emissions to air, the following definitions apply:
Daily average value
Average over the sampling
period
Average over a period of 24 hours based on valid half-hourly or
hourly averages from measured by continuous measurement under
Normal Operating Conditions
Average of three consecutive over the sampling duration of periodic
measurements samples of at least 30 minutes each, unless otherwise
stated (1) under normal operating conditions.
(1) For batch processes, a representative number of measurements over the total batch time or a continuous
measurement over the total batch time can be used. different number and timing of emissions measurements can
be used in order to obtain an average representative of the process emissions variations.
Averaging periods for emissions to water
For averaging periods of emissions to water, the following definition applies:
Daily average
Average over a sampling period of 24 hours taken as a flowproportional composite sample or as a time-proportional sample
provided that in case sufficient flow stability is demonstrated (1)
(1) For discontinuous flows, a different sampling procedure yielding representative results (e.g. grab sampling) can
be used.
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Chapter 11
Definitions
For the purpose of these BAT conclusions, the following general definitions apply:
Term used
New plant
Definition
A plant first permitted operated 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
New installation
An installation (as defined in Article 3(3) of Directive 2010/75/EU) first
permitted following the publication of these BAT conclusions or a
complete replacement of an installation following the publication of these
BAT conclusions
Existing installation
An installation that is not a new installation
A major change in design or technology of a plant and with major
adjustments or replacements of the process units and associated
equipment
Emissions directly vented from the furnaces that are not mixed with the
furnace surrounding areas
Emissions escaping from the furnace lining or during operations such as
charging or tapping and captured with a hood or enclosure (such as dog
house)
Production of metals using ores and concentrates
Production of metals using residues and/or scraps, including remelting
and alloying processes
Measurements made with an automated measuring system (AMS)
permanently installed on site for the continuous monitoring of emissions
Determination of a measurand at specified time intervals using manual or
automated methods
Major plant upgrade
Primary emissions
Secondary emissions
Primary production
Secondary production
Continuous
measurement
Periodic measurement
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Abbreviations/Acronyms
Term
BaP
BSS
E2MS
ESP
DON
NOX
Meaning
Benzo-[a]-pyrene
Boosted suction system
Energy efficiency management system
Electrostatic precipitator
Direct Outokumpu nickel process
International toxicity equivalent derived by applying international toxicity equivalency
factors, as defined in Annex VI, part 2 of Directive 2010/75/EU
The sum of nitrogen oxide (NO) and nitrogen dioxide (NO 2) expressed as NO2
PCDD/F
Polychlorinated dibenzodioxins/furans (17 congeners)
PAH
SOX
Polycyclic aromatic hydrocarbons
The sum of sulphur dioxide (SO2) and sulphur trioxide (SO3) expressed as SO2
Total organic carbon; the sum of all gaseous and vaporous organic compounds expressed
as C.
I-TEQ
TVOC
VOC
Any Volatile organic compounds as defined in well as the fraction of creosote, having at
293.15 K a vapour pressure of 0.01 kPa or more, or having a corresponding volatility
under the particular conditions of use (Article 3 of Directive 2010/75/EU)
WSA
Wet sulphuric acid process
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Chapter 11
11.1
General BAT Conclusions
Any relevant process specific BAT conclusions included in Sections 11.2 to 11.9 apply in
addition to the general BAT conclusions mentioned in this section.
11.1.1
Environmental management systems (EMS)
BAT 1.
In order to improve the overall environmental performance of non-ferrous
metal plants, BAT is to implement and adhere to an environmental management system
(EMS) that incorporates all of the following features: (based on Section 2.12.1)
a.
b.
c.
d.
commitment of the management, including senior management;
definition of an environmental policy that includes the continuous improvement of the
installation by the management;
planning and establishing the necessary procedures, objectives and targets, in conjunction
with financial planning and investment;
implementation of procedures paying particular attention to:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
e.
checking performance and taking corrective action, paying particular attention to:
i.
ii.
iii.
iv.
f.
g.
h.
i.
structure and responsibility
recruitment, training, awareness and competence
communication
employees involvement
documentation
effective efficient process control
maintenance programmes
emergency preparedness and response
safeguarding compliance with environmental legislation;
monitoring and measurement (see also the Reference Report Document on the
General Principles of Monitoring)
corrective and preventive action
maintenance of records
independent (where practicable) internal or and external auditing in order to
determine whether or not the EMS conforms to planned arrangements and has been
properly implemented and maintained;
review of the EMS and its continuing suitability, adequacy and effectiveness by senior
management;
following the development of cleaner technologies;
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;
application of sectorial benchmarking on a regular basis.
The set-up and implementation of an action plan on diffuse dust emissions (see BAT 5 ter) is
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.
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11.1.2
Energy management
BAT 2.
In order to use energy efficiently, BAT is to use a combination of the following
techniques given below. (based on Section 2.12.2)
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
Technique
Energy efficiency management system (e.g. ISO
50001 E2MS)
Regenerative or recuperative burners
Production of steam or hot water Heat recovery
(e.g. steam, hot water, hot air) from waste
process heat
Regenerative afterburners
Preheat the furnace charge, combustion air or
fuel using the heat recovered from hot gases from
the melting stage
Raise the temperature of the leaching liquors
using steam or hot water from waste heat
recovery
Preheat the combustion air using the Use of hot
gases from the launder as preheated combustion
air
Use of oxygen-enriched air or pure oxygen in the
burners to reduce energy consumption by
allowing autogenic smelting or the complete
combustion of carbonaceous material
Generally applicable
Generally applicable
Only applicable for pyrometallurgical process
Only applicable when the abatement of a
combustible pollutant is required
Only applicable for roasting or smelting of
sulphide ore/concentrate and for other
pyrometallurgical processes
Only
applicable
for
hydrometallurgical processes
alumina
or
Only applicable for pyrometallurgical processes
Only applicable for furnaces that use raw
materials containing sulphur or carbon raw
materials contents
Applicability may be restricted by the durability
of the furnace lining and metal infiltration into
the lining
Low mass refractory
Drying of concentrates and raw wet materials at
low temperatures before smelting
Recovery of the chemical energy content of the
carbon monoxide produced in an electric or
shaft/blast furnace by using the exhaust off-gases
as a fuel, after the removal of metals, in other
production processes or to produce steam/hot
water or electricity
Recirculate contaminated waste the flue-gas offgas back through an oxy-fuel burner to recover
the energy of the total organic carbon present
Suitable insulation for high temperature
installations such as steam and hot water pipes
Use the heat generated from the production of
sulphuric acid from the sulphur dioxide to
preheat gas directed to the sulphuric acid plant or
to generate steam and/or hot water
Use high efficiency electric engines equipped
with a frequency drive for equipment, such as
fans
Control systems that automatically activate the
extraction system or adjust the extraction rate
depending on actual emissions switch on dust or
fume extraction only when no emissions are arise
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Applicability
Generally Only applicable when drying is
performed
Only applicable to exhaust off-gases with a CO
content in the exhaust gases > 10 % v/v.
Applicability is also influenced by the
composition of the exhaust off-gas and the
unavailability of a continuous flow (i.e. batch
processes)
Generally applicable
Generally applicable
Only applicable for non-ferrous metals plants
including sulphuric acid or liquid SO2
production
Generally applicable
Generally applicable
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Description
(i) A low-mass refractory absorbs less heat due to its lower density. Furnaces can be heated and
cooled using less energy. The thermal efficiency of the furnace could be also improved because
the lower thermal conductivity of a low-mass refractory allows the lining to be thinner and
therefore the furnace can be smaller. As the furnace is smaller, there is a lower surface exposure
and so less heat is lost. The fast response of the low-mass refractory to temperature changes also
allows more accurate control, and uniform temperature distribution within the furnace.
11.1.3
Process control and emissions monitoring
BAT 3.
In order to improve overall environmental performance achieve a stable
process operation, BAT is to ensure stable process operation by using implement a process
control system together with, and to use a combination of the following techniques given
below. (based on Section 2.12.3)
a
b
c
d
e
f
g
h
i
j
k
Technique
Inspection and selection of input materials according to the process
and the abatement techniques applied
Good mixing of different feed materials to achieve optimum
conversion efficiency and reduce emissions and rejects
Feed weighing and metering systems
Micro Processors to control material feed rate, critical process
parameters and conditions including the alarm, combustion
conditions and gas additions.
On-line monitoring of the furnace temperature, furnace pressure
and gas flow
Monitoring of the critical process parameters of the air abatement
plant such as gas temperature, reagent metering, pressure drop,
ESP current and voltage, scrubber liquor flow and pH and gaseous
components (e.g. O2, CO, VOC) to control critical process
parameters
Monitoring Control of dust and mercury in the exhaust off-gas
before sending transfer to the sulphuric acid plant
On-line monitoring of vibrations to detect blockages and possible
equipment failure
On-line monitoring of the current, voltage and electrical contact
temperatures
Temperature monitoring and control to prevent the production of
metal and metal oxide fumes through overheating
Micro Processor to control the reagents feeding and plant
performance, with on-line monitoring of temperature, turbidity,
pH, conductivity and flow
Applicability
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable to all
furnaces
Generally applicable
Only applicable to for nonferrous
metals
plants
including sulphuric acid or
liquid SO2 production
Generally applicable
Only
applicable
to
electrolytic processes
Only applicable to melting
and smelting furnaces
Only applicable to waste
water treatment plants
BAT 3 bis.
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 EMS (see BAT 1).
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BAT 4.
BAT is to monitor the stack emissions to air mentioned in the following table
and to use the indicated monitoring techniques with at least the minimum frequency given
and in accordance with EN standards. If EN standards are not available, BAT is to use
ISO, national or other international standards which ensure the provision of data of an
equivalent scientific quality.
Parameter (1)
Minimum monitoring frequency (2) (3)
Continuous or periodic (at least three consecutive
measurements once per year)
a
Dust
b
Mercury and its compounds expressed as
Hg
c
Other relevant metals (4)
d
NOx expressed as NO2 (5)
e
VOC
f
TVOC
Periodic (at least three consecutive measurements once
per year)
Periodic (at least three consecutive measurements once
per year)
Periodic (at least three consecutive measurements once
per year)
Periodic (at least three consecutive measurements once
per year)
Continuous or periodic (at least three consecutive
measurements once per year)
g PCDD/F
Periodic (at least one measurement once per year)
(1) The monitoring of these parameters apply to the production of non-ferrous metals not included in
Sections...
(2) More frequent monitoring (including the selection between continuous or periodic measurements)
should be chosen taking into account local environmental conditions and plant specificities such as
capacity, type of raw materials used, etc.
(3) For small dust emission sources (< 10 000 Nm3/h) from the storage and handling of raw materials,
monitoring could be based on the measurement of surrogate parameters (such as the pressure drop).
(4) The metals to be monitored depend to a large extent on the composition of the raw materials used.
(5) For furnaces using oxygen enriched burners, the emissions are expressed in terms of grams of NO x
emitted per tonne of melted metal produced, as an average over the sampling period for the continuous
smelter/melter process. For the batch smelter/melter process, the emissions are expressed as an average of
all the batch process operations.
BAT 5.
BAT is to monitor emissions, before the discharge of the waste water into the
receiving water, of the parameters mentioned in the following table with at least the
minimum frequency given and in accordance with EN standards. If EN standards are not
available, BAT is to use ISO, national or other international standards which ensure the
provision of data of an equivalent scientific quality.
Parameter (1)
Minimum monitoring frequency (2)
a Hg
b Other relevant metals (3)
Once a month
c Fe
d SO42(1) The monitoring of these parameters apply to the production of non-ferrous metals not included in
Sections….
(2) While respecting this minimum monitoring frequency, the monitoring frequency should be chosen
taking into account local conditions such as the type of receiving media, the load of metals present in the
waste water, etc.
(3) The metals to be monitored depend to a large extent on the composition of the raw materials used.
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Chapter 11
11.1.4
11.1.4.1
Diffuse emissions
General approach for the prevention of diffuse emissions from the
storage, handling and transport of raw materials
BAT 5 bis.
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. (based on Section 2.12.4)
BAT 5 ter.
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 all of the
following features: (based on Section 2.12.4)
a. identification of the most relevant diffuse dust emissions sources (e.g. EN 15445);
b. definition and implementation of appropriate actions and techniques to prevent or
reduce diffuse emissions over a given time frame.
BAT 6.
In order to prevent diffuse emissions from the storage of raw materials, BAT
is to use a combination of the following techniques given below. (based on Section 2.12.4)
Technique
a
Enclosed buildings or silos/bins
b
Covered storage
c
Sealed packaging
d
Covered bays
e
Use of water sprays and fog sprays with or
without additives such as latex
f
g
h
i
j
k
l
1080
Dust/gas extraction devices placed at the
transfer and tipping points
Certified pressure vessels for chlorine gas or
mixtures that contain chlorine
Construction materials for the tanks resistant to
the contained materials
Reliable leak detection systems and display of
tanks level, with an alarm to prevent overfills
Double wall tanks or drums placed in bunded
areas to store liquid fuels, solvents and other
oils
Storage of sulphuric acid and other reactive
materials in double-walled tanks or tanks
placed in chemically-resistant bunds of the
same capacity. The storage area should be
impermeable and resistant to the material
stored
Design storage areas so that any leaks from
July 2014
Applicability
Applicable to the storage of dust-forming
materials such as concentrates, fluxes and fine
materials
Applicable to the 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
Applicable to the storage of dust-forming
materials or secondary materials that contain
water soluble organic compound
Applicable if the material has been
pelletised/agglomerated
Applicable for dust forming materials. Not
applicable to processes that require dry
materials or ores/concentrates that naturally
contain sufficient water to prevent dust
formation. The application is also limited in
regions with water shortage or with very low
winter temperatures
Applicable to the storage of dust forming
materials
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
MR/GC/EIPPCB/NFM_Draft_3
m
n
o
p
q
r
s
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
should be within the bund to collect any spilled
material
Use inert gases blanketing for the storage of
materials that react with air
Collection and treatment of emissions from the
storage with an abatement system designed to
treat the chemical species that are stored. Any
water that washes dust away should be also
collected and treated before discharge
Regular cleaning of the storage area and, when
needed, moistening with water
Placement of the longitudinal axis of the heap
parallel with the prevailing wind direction
Protective planting, windbreak fences or
upwind mounts to lower the wind velocity
One heap instead of several ones where
feasible
Use of oil and solid interceptors for the
drainage of open storage areas. Use of
concreted areas that have curbs or other
containment devices for the storage of material
that can release oil, such as swarf
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Generally applicable
Generally applicable for the storage of gases.
For the storage of liquids, any leakage could be
collected and treated
Generally applicable
Applicable if outdoor storage is used
Applicable if outdoor storage is used
Applicable if outdoor storage is used
Applicable if outdoor storage is used
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BAT 7.
In order to prevent diffuse emissions from the handling and transport of raw
materials, BAT is to use a combination of the following techniques given below. (based on
Section 2.12.4)
a
b
c
d
Technique
Enclosed conveyors or pneumatic systems to transfer and handle dust-forming
concentrates and fluxes and fine grained material
Applicability
Generally
applicable
Covered conveyors to handle non-dust-forming solid materials
Generally
applicable
Extraction of dust from delivery points, silo vents, pneumatic transfer systems
and conveyor transfer points, and connection to a filtration system
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
Keep transport distances as short as possible
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
Placement of 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 nonhazardous materials, their course should be documented and marked and safe
excavation systems adopted
l
Automatic resealing of delivery connections
m
Back venting of displaced gases to the delivery vehicle to reduce emissions of
VOCs.
n
Washing of wheels and chassis of vehicles used to deliver or handle dusty
materials
o
Use of planned campaigns for road sweeping
p
Segregation of incompatible materials (e.g. oxidising agents and organic
materials)
q
Minimisation of material transfers between processes
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Applicable to dustforming materials
Generally
applicable
Generally
applicable
Generally
applicable
Generally
applicable
Generally
applicable
Applicable when
open belt
conveyors are used
Generally
applicable
Generally
applicable
Applicable for
handling of liquid
and liquefied gas
Generally
applicable
Not applicable
when ice could be
formed
Generally
applicable
Generally
applicable
Generally
applicable
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11.1.4.2
Prevention of diffuse emissions from metal production
BAT 8.
In order to prevent or, where this is not practicable, to reduce diffuse
emissions, BAT is to optimise the efficiency of off-gas collection and treatment by , BAT is
to using a combination of the following techniques given below. (based on Section 2.12.4)
a
b
Technique
Application of Thermal or mechanical pretreatment of
secondary raw material to minimise organic
contamination of the furnace feed
Use of a sealed closed furnace with a properly designed
dedusting system or sealing of the furnace and other
process units equipped with an adequate vent system
c
Use of a secondary hood for furnace operations such as
charging and tapping semi-sealed furnace only where
sealed furnaces are not available
d
Dust or fume collection where dusty material transfers
take place (e.g. furnace charging and tapping points,
covered launders)
Optimisation of 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 and tapping.
Furnace/reactor enclosures such as 'House-in-House' or
'Dog House' for tapping and charging operations to
prevent the emission of fumes into the air
e
f
g
h
i
Optimisation of the gas flow from the furnace through
computerised fluid dynamics studies and tracers to model
the flow of furnace gases
Charging systems to add raw materials in small portions
Treatment of the collected emissions in an adequate
abatement system
Applicability
Generally applicable Applicable
for secondary raw materials
Generally applicable The
applicability may be restricted due
to safety constraints (e.g.
type/design of the furnace, risk of
explosion)
Generally applicable The
applicability may be restricted due
to safety constraints (e.g.
type/design of the furnace, risk of
explosion)
Generally applicable
Generally applicable For existing
plants, applicability may be limited
due to space and plant
configuration restrictions
Generally Only applicable for a
new plant or a major upgrade of an
existing plant, due to space
requirements For existing plants,
applicability may be limited due to
space and plant configuration
restrictions
Generally applicable
Only applicable for semi-closed
furnaces
Generally applicable
14.1.4 bis Pretreatment of strong gases (> 1% v/v SO2) before sending
them for SO2 recovery within the production of copper, lead, primary zinc,
silver, nickel and molybdenum
BAT 8 bis.
In order to allow the recovery of SO2 from strong gases (> 1 % v/v SO2),
BAT is to pretreat them using a combination of the techniques given below. (based on
Section 2.12.5.5, 3.3.3.2, 3.3.3.3, 3.3.4.1, 3.3.4.3, 5.3.3.1.1, 5.3.4.3, 6.3.1.2.1, 7.3.3, 8.3.3.1.5
and 9.3.1.3.2)
Technique (1)
Applicability
Techniques to reduce dust
a Hot ESP with or without cyclones as first treatment stage
b Wet scrubber
c Wet ESP
Techniques to reduce mercury
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Chapter 11
d
Boliden-Norzink process with the recovery of the scrubbing solution
and production of mercury metal
Bolchem process and filtering of mercury sulphide to allow the acid
to be returned to the absorption stage
f Outotec process
g Sodium thiocyanate process
Activated carbon filter to remove mercury vapour and PCDD/F from
h
the gas stream
i Tynfos-Miltec application
j Lurgi process
k Boliden/Contec process
l DOWA adsorption process
(1) Descriptions of the techniques are given in Section 11.10
e
11.1.5
Generally applicable
SO2 emissions from high strong strength gases ( > 1% v/v SO2)
from copper, lead, primary zinc, nickel and molybdenum
production
BAT 9.
In order to reduce the SO2 emissions of SO2 to air from in off-gases with
highly variable SO2 content and/or an high SO2 content between ( > 1 % v/v SO2 but ≤
and 4.5 % v/v), BAT is to recover SO2 by producing sulphuric acid using a single
contact/single absorption process in combination with primary or secondary emissions
reduction measures.
Applicability
Only applicable to plants producing copper, lead, primary zinc and molybdenum.
Description
In a single contact/single absorption process, SO2 is converted into SO3 using a series of four
catalyst beds, in which the SO3 reacts with water in the absorber to form H2SO4. A Wet gas
Sulphuric Acid (WSA) process or tail gas treatment, such as polyether-based
absorption/desorption, scrubber with ZnO, is applied to increase the sulphur recovered and to
reduce the emission of SO2.
BAT-associated emission levels
See Table 11.1.
Table 11.1: BAT-associated emissions levels for SO2 emissions to air from off-gases with highly
variable SO2 content and/or an SO2 content between 1 % v/v and 4.5 % v/v single
contact/single absorption processes
Parameter
Unit
BAT-AEL (1)
SO2
mg/Nm3
100 – 450
1
( ) As a daily average based on continuous measurement.
The associated monitoring is in BAT 17, BAT 94, BAT 119 and BAT 162.
BAT 10.
In order to reduce the SO2 emissions to air from in off-gases with high a stable
SO2 content exceeding (> 4.5 % v/v SO2), BAT is to recover SO2 by producing sulphuric
acid using a double contact/double absorption process.
Applicability
Only applicable to plants producing copper, lead, primary zinc, silver and nickel.
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Description
In double contact/double absorption processes, SO2 is converted into SO3 using two stages of
catalysis. Between the two stages, an absorber is used to remove the SO3 from the gas stream
and produce liquid H2SO4.
BAT-associated emission environmental performance levels
See Table 11.2.
Table 11.2: BAT-associated emission environmental performance levels for SO2 emissions to air
from off-gases with stable and an SO2 content exceeding 4.5 % v/v double
contact/double absorption processes
Parameter
SO2
BAT-AEPL (1) (2)
(conversion rate)
99.7 – 99.92 %
BAT-AEL (1) (2) (3) (4) (mg/Nm3)
200 – 770
(1) These conversion rates relate to the conversion including the absorption tower, they do not include the effect of
tail gas scrubbing.
(1) (2) As daily average based on continuous measurement.
(2) (3) The lower end of the range is associated with the use of cryogenic process or absorption in cold water followed
by stripping.
(3) (4) While ensuring the achievement of a SO2 conversion rate of at least 99.7 % v/v as a daily average. The
conversion includes ing the absorption tower and does , they do not include the effect of tail gas scrubbing the BATAEPL.
The associated monitoring is in BAT 17, BAT 94, BAT 119 , BAT 148 and BAT 180.
11.1.6
Removal of mercury
BAT 11.
In order to reduce mercury emissions to air other than those that are sent to
the sulphuric acid plant from a pyrometallurgical processes using raw materials with
containing mercury content, BAT is to use one or both a combination of the following
techniques given below. (based on Section 2.12.5.5 )
a
a
b
b
c
d
e
f
g
h
i
j
Technique (1)
Efficient dust filtration, such as a bag filter or ESP
Use of raw materials with a low mercury content
Use Injection of adsorbents (e.g. activated carbon, selenium) in combination
with followed by dust filtration (1)
Boliden-Norzink process with the recovery of the scrubbing solution and
production of mercury metal
Bolchem process and filtering of mercury sulphide to allow the acid to be
returned to the absorption stage
Outotec process
Sodium thiocyanate process
Activated carbon filter to remove mercury vapour and PCDD/F from the gas
stream
Tynfos-Miltec application
Lurgi process
Boliden/Contec process
DOWA adsorption process
Applicability
Generally
applicable
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 11(a): This includes cooperating with the providers in order to remove mercury from
secondary materials.
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Chapter 11
BAT-associated emission levels
See Table 11.3.
Table 11.3: BAT-associated emission levels for mercury emissions to air other than those that are
sent to the sulphuric acid plant Hg from a pyrometallurgical process using raw
materials with containing mercury Hg content
Parameter
Mercury and its compounds,
expressed as Hg
Unit
BAT-AEL (1) (2)
mg/Nm3
≤ 0.01 – 0.05
1
( ) As a daily average or as an average over the sampling period (periodic measurement of at least half an hour).
(2) The lower end of the range is associated with the use of adsorbents (e.g. activated carbon, selenium) in
combination with dust filtration, except for processes using Waelz kilns.
The associated monitoring is in BAT 17, BAT 94, BAT 119, BAT 162, BAT 180 and BAT
209bis.
11.1.7
Reduction of NOX emissions
BAT 12.
In order to prevent NOX emissions to air from a pyrometallurgical process,
BAT is to use one of the following process-integrated techniques given below. (based on
Section 2.12.5.2 )
Technique (1)
a
b
c
Applicability
Low-NOX burners
Oxy-fuel burners
Flue-gas recirculation (back through the burner to reduce the
temperature of the flame)
Generally applicable
Only applicable
firing burners
for
oxy-fuel
(1) Descriptions of the techniques are given in Section Section 11.10
11.1.8
Water and waste water management
BAT 13.
In order to prevent or reduce the generation of waste water, BAT is to use one
or a combination of the following process-integrated techniques given below. (based on
Section 2.12.6.1)
a
b
Technique
Measuring the amount of water used and
discharged
Returning to the process of the waste water from
cleaning operations (including anode and cathode
rinse water) and spills
c
Reuse of weak acid streams generated in wet ESP
and wet scrubbers
d
Reuse of waste water from slag granulation
e
Reuse of surface run-off water
f
Use of a closed circuit cooling system
g
Reuse of treated water from the waste water
treatment plant
Applicability
Generally applicable
Generally applicable
Applicable, Applicability may be restricted
depending on the metal and solid content of the
waste water
Applicable Applicability may be restricted
depending on the metal and solid content of the
waste water
Generally applicable
Generally applicable Applicability may be
restricted when, for process reasons, a low
temperature is required
Applicability may be restricted by the salt
content
BAT 13 bis. In order to prevent the contamination of uncontaminated water and to
reduce emissions to water, BAT is to segregate uncontaminated waste water streams from
other waste water streams that require treatment.
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Applicability
The segregation of uncontaminated rainwater may not be applicable in existing installations.
BAT 13 ter.
For water sampling, BAT is to use ISO 5667.
BAT 14.
In order to reduce emissions to water, BAT is to treat the waste water from
non-ferrous metals' production, including the washing stage in the Waelz kiln process, to
remove metals and sulphates by using a combination of the following techniques given
below. (based on Section 2.12.6.2 )
a
b
c
d
Technique (1)
Chemical precipitation
Sedimentation
Filtration
Flotation
e
Ultrafiltration
f
Activated carbon filtration
g
Reverse osmosis
Applicability
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally Applicability may be
water flows Only applicable
streams in NFM production
Generally applicable
Generally Applicability may be
water flows Only applicable
streams in NFM production
restricted for high
to specificpartial
restricted for high
to specificpartial
(1) Descriptions of the techniques are given in Section 11.10
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BAT-associated emission levels
The BAT-associated emission levels for direct emissions to a receiving water body from the
production of copper, lead and tin, zinc and cadmium, precious metals, nickel and cobalt and
ferro-alloys are given in Table 11.4. These BAT-AELs apply at the point where the emission
leaves the installation.
Table 11.4: BAT-associated emissions levels for direct emissions to a receiving water body from
the production, water emissions from copper, lead and tin, zinc (including the waste
water from the washing stage in the Waelz kiln process) and cadmium, precious
metals, nickel and cobalt and ferro-alloys production
Sector
Copper
Parameter
Ag
As
Cd
Co
Cr total
Cr (VI)
Cu
Fe
Hg
Ni
Pb
Sb
Sn
SO42Zn
NR
≤ 0.1 (2)
0.02 – 0.1
NR
NR
NR
0.05 – 0.5
≤1
0.005 – 0.02
≤ 0.5
≤ 0.5
≤ 0.3
≤1
≤ 1000
≤1
BAT-AEL (mg/l) (1) (2) (3)
Zinc and
Lead and
Precious
Cadmium
Tin
metals
3
()
NR
NR
≤ 0.6
≤ 0.1
≤ 0.1
≤ 0.1
≤ 0.1
≤ 0.1
≤ 0.05 0.3
≤ 0.1
NR
NR
NR
NR
NR
NR
NR
NR
≤ 0.2
≤ 0.1
≤ 0.3
≤1
≤1
≤2
≤ 0.05
≤ 0.05
≤ 0.05
≤ 0.5
≤ 0.1
≤ 0.5
≤ 0.5
≤ 0.2
≤ 0.5
≤ 0.6
NR
NR
≤1
NR
NR
≤ 1000
≤ 1000
≤ 1000
≤1
≤1
≤ 0.4
Nickel and
Cobalt
Ferro-alloys
NR
≤ 0.3
≤ 0.1 0.5
0.1 – 0.5
NR
NR
≤ 0.5
≤2
≤ 0.05
≤2
≤ 0.5
NR
NR
≤ 1000
≤1
NR
≤ 0.1
≤ 0.05
NR
≤ 0.2
≤ 0.05
≤ 0.5
≤2
≤ 0.05
≤2
≤ 0.2
NR
NR
NR
≤1
NR: Not relevant
(1) The relevance of the pollutants listed in the table depends on the raw materials used, the air emission abatement system
applied and on the process used to produce the metals.
(1) As a daily average. based on 24-hours flow-proportional composite samples.
(2) In case of high arsenic content in the total input of the plant, the BAT-AEL may be up to 0.2 mg/l.
(3) The BAT-AELs refer to a point after the waste water treatment plant. For associated monitoring, see BAT 5.
The associated monitoring is in BAT 18, BAT 95, BAT 120, BAT 149, BAT 163 and BAT 181.
Note to the TWG: data not provided for the emissions to water from alumina, anode, primary
aluminium, secondary aluminium and carbon and graphite electrode production.
11.1.9
Noise
BAT 15.
In order to reduce noise emissions, BAT is to use one or a combination of the
following techniques given below. (based on Section 2.12.8 )
a
b
c
d
e
1088
Technique
Use of embankments to screen the source of noise
Enclosure of noisy plants or components in sound-absorbing structures
Use of anti-vibration supports and interconnections for equipment
Orientation of noise-emitting machinery
Change of the frequency of the sound
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11.1.10
Odour
BAT 16.
In order to reduce odour emissions, BAT is to use one or a combination of the
following techniques given below. (based on Section 2.12.9)
Technique
Appropriate storage and handling of odorous
materials
Minimisation of the use of odorous materials
Generally applicable
c
Careful design, operation and maintenance of
any equipment that could generate realise
odour emissions
Applicable during major upgrades of existing plants
d
Afterburner
or
including biofilters
Applicable only in limited cases (e.g. in the
impregnation stage during speciality production in
the carbon and graphite sector)
a
b
filtration
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techniques,
Applicability
Generally applicable
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11.2
BAT conclusions for copper production
11.2.1
Monitoring
BAT 4 and 5 do not apply to the copper sector.
11.2.1.1
Monitoring of emissions to air
BAT 17.
BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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 (4)
a
b
c
d
e
Minimum monitoring
frequency (1)
Standard(s)
EN 13284-2
Continuous
EN 13284-1
Periodic (at least three
consecutive measurements
once per year)
34, 34bis, 35, 37, 38,
39, 40, 41, 42, 43
EN 14385
Periodic (at least once per
year)
34, 35, 36, 37, 39, 40,
41, 42
EN 14385
Periodic (at least once per
year)
34, 34bis, 35, 36, 37,
38, 39, 40, 41, 42, 43
EN 14385
Periodic (at least once per
year)
34, 35, 36, 37, 39, 40,
41, 42
2
Dust ( )
Arsenic and its
compounds,
expressed as As
Cadmium and its
compounds,
expressed as Cd
Copper and its
compounds,
expressed as Cu
Lead and its
compounds,
expressed as Pb
f
Other metals, if
relevant (3)
g
Mercury and its
compounds,
expressed as Hg
Periodic (at least three
consecutive measurements
once per year)
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
EN 14385
EN 14385
EN 13211
SOX expressed as
SO2
EN 14791
NOX, expressed
as NO2 (3)
EN 14792
j
TVOC as C
EN 12619
EN 13526
k
VOC (4)
l
PCDD/F
m
H2SO4
i
1090
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Continuous
or periodic (at least three
consecutive measurements
once per year)
No EN or ISO
standard available
EN 1948 part 1,
2, 3 and 5
No EN or ISO
standard available
Yearly mass balance
34, 34bis, 35, 36, 37,
38, 39, 40, 41, 42, 43
11
11
47, 48, 49, 50, 51
12
12
44
44
45
Periodic (at least one
measurement once per year)
Periodic (at least three
consecutive measurements
once per year)
July 2014
34, 34bis, 35, 36, 37,
38, 39, 40, 41, 42, 43
9, 10, 47, 48, 49, 50,
51
Continuous
h
Monitoring
associated with BAT
35, 36, 37, 39, 40, 41,
42, 43
46
52
MR/GC/EIPPCB/NFM_Draft_3
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous
measurement is not applicable, more frequent periodic monitoring is performed.More frequent monitoring
(including the choice between continuous or periodic measurement) should may be chosen taking into account
based on local environmental conditions and plant specificities such as capacity, mass flow of the pollutant and
type of raw materials used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials,
monitoring could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) For furnaces using oxygen enriched burners, the emissions are expressed in terms of grams of NOx emitted per
tonne of melted metal produced, as an average over the sampling period for the continuous smelter/melter process.
For the batch smelter/melter process, the emissions are expressed as an average of all the batch process operations.
(3) The metals monitored depend on the composition of the raw materials used.
(4) Related to BAT 45, a Mass balance can be used to calculate the volatile organic carbon (VOC) emissions on a
yearly basis.
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11.2.1.2
Monitoring of emissions to water
BAT 18.
BAT is to monitor the emissions to, before the discharge of the waste water
into the receiving water at the point where the emission leaves the installation, of the
parameters mentioned in the following table with at least the minimum 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
Standard(s)
a
b
c
d
e
f
g
As
Cd
Cu
Fe
Ni
Pb
Zn
EN ISO 11885
EN ISO 17294-2
h
Hg
i
SO42-
j
k
Sb
Sn
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
EN ISO 10304-1
No EN or ISO standard
available
EN ISO 11885
EN ISO 17294-2
Minimum monitoring
frequency (1)
Monitoring associated
with
At least once a month
BAT 14
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media, the load of metals present in the waste
water.
11.2.2
Secondary materials
BAT 19.
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 following techniques given below. (based on Section 3.3.2.1)
a
b
c
d
Technique
Manual separation for the separation of large
visible constituents
Magnetic separation for the separation of ferric
metals
Optical or eddy current separation for the
separation of aluminium
Relative density separation for the separation of
different metal and non-metal constituents
Applicability
Applicable for the separation of large visible
constituents
Applicable for the separation of ferric metals
Applicable for the separation of aluminium
Applicable for the separation of different
metal and non-metal constituents
Description
BAT 19 (d): The differences in densities of the various materials are used to separate them. This
is achieved using a fluid with a different density or air.
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11.2.3
Energy
BAT 20.
In order to use energy efficiently in primary copper production, BAT is to use
one or a combination of the following techniques given below. (based on Section 3.3.8.1)
Technique
Optimise the use of the concentrate energy using a flash smelting
furnace
Applicability
Only Generally 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 incoming charge
Generally Only applicable
to for shaft furnaces
c
d
Cover the concentrates during transport and storage
Use the excess heat produced during primary smelting or
converting stages to melt secondary containing copper materials
Use the heat in the gases from anode furnaces in cascade for
other processes such as drying
Generally applicable
Generally applicable
a
e
Generally applicable
BAT 21.
In order to use energy efficiently in secondary copper production, BAT is to
use one or a combination of the following techniques given below. (based on Section
3.3.8.2)
Technique
a
b
c
cd
Reduce the water content of feed material
Produce steam by recovering excess heat from an anode the
smelting furnace to heat up the electrolyte in refineries and/or
to produce electricity in a co-generation installation
Applying insulation and covers to electrolysis tanks
To melt scraps using the excess heat that is produced during
the smelting or converting process
d
Holding furnace between processing stages
E
Preheat the furnace charge using the hot process gases from
melting stages
Applicability
Generally applicable The
Applicability is limited when
the moisture content of the
materials is used as a technique
to reduce diffuse emissions
Generally Applicable if an
economically viable demand
exists
Generally applicable
Generally applicable
Only applicable for batch wise
operated smelters where a
buffer capacity of molten
material is required
Only applicable to shaft furnace
BAT 21 bis.
In order to use energy efficiently in electrorefining and electrowinning
operations, BAT is to use a combination of the techniques given below. (based on Section
3.3.3.8)
a
b
c
d
e
f
Technique
Apply insulation and covers of to electrolysis tanks
Addition of surfactants to the electrowinning cells
Improved cell design by optimisation of the following
parameters: space between anode and cathode, anode
geometry, current density, electrolyte composition and
temperature
Use of stainless steel cathode blanks
Automatic cathode/anode changes to achieve an accurate
placement of the electrodes into the cell
Short circuit detection and quality control to ensure that
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Applicability
Generally applicable
Generally applicable
Only applicable for new plants and for
major upgrades of existing plants
Only applicable for new plants and for
major upgrades of existing plants
Only applicable for new plants and for
major upgrades of existing plants
Generally applicable
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electrodes are straight, flat and anode exact in weight
Description
BAT 21 bis (c): Optimised cell design achieves lower energy consumption for electrorefining
through the optimisation of the following parameters: space between anode and cathode, anode
geometry, current density, electrolyte composition and temperature.
11.2.4
Air emissions
BAT 22.
In order to reduce secondary emissions to air from furnace 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 flue-gases in a centralised offgas flue-gas cleaning system. (based on Section 3.3.3.6)
Description
Secondary emissions flue-gases from various sources are collected, mixed, and treated in a
single centralised off-gas flue-gas cleaning system, designed to accommodate effectively the
pollutants present in each of the flows. Care should be taken to avoid chemical reactions among
the different collected flows.
Applicability
Applicable for secondary emissions flue-gases that are chemically compatible. The applicability
may be limited by the design and layout of the existing plants.
11.2.4.1
Diffuse emissions
BAT 23.
In order to prevent or reduce diffuse emissions from material 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 following techniques
given below. (based on Section 3.3.2.1)
a
Technique
Use of enclosed conveyers or pneumatic
transfer systems
b
Carrying out activities with dusty materials
such as mixing in an enclosed building
c
Use of dust suppression systems such as water
cannons or water sprinklers
d
Use of enclosed equipment with gas
extraction system, connected to an abatement
system
e
Use of an extraction system such as a hood in
combination with a dust and gas abatement
system
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Applicability
Generally applicable for dusty materials
Generally applicable. For existing plants,
application may be difficult due to the space
requirements
Not applicable for mixing operations carried out
indoors outdoors. Not applicable for process
that requires dry materials. The application is
also limited in region with water shortage or
with very low winter temperature
Only applicable for feed blend prepared with a
dosing bin or loss-in-weight system, for
operations with dusty material such as drying,
mixing, milling, air separation and pelletisation
Generally applicable for dusty and gaseous
emissions
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BAT 24.
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 furnace, BAT is to use a combination of the following techniques given below.
(based on Sections 3.3.3.1, 3.3.3.2, 3.3.3.5, 3.3.4.1, 3.3.4.2, 3.3.4.4 , 3.3.5.1 and 3.3.5.3)
Technique
a
b
c
cd
e
df
eg
h
fi
gj
K
hl
i
j
k
l
Briquetting and pelletisation of raw materials
Enclosed charging system such as single jet burner,
double bell, door sealing, closed conveyers or feeders
equipped with a gas extraction system in combination
with a dust and gas abatement system
Sealed or enclosed furnaces with door sealing
Operating the furnace and gas route under negative
pressure and a sufficient gas extraction rate to prevent
pressurisation
Charging systems to add raw materials in small portions
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
closed with a movable door/barrier equipped with a
ventilation and abatement system)
Encapsulation of the furnace in extractable housing
Complete hood coverage with a gas extraction and
abatement system
Maintain furnace sealing
Hold the temperature in the furnace at the lowest required
level
Covered lauders
Boosted suction systems (1)
Enclosed building in combination with other techniques
to collect the diffuse emissions
Applicability
Applicable only when the process
and the furnace can use pelletised
raw materials
Generally applicable depending on
the type of furnaces. The jet burner
is applicable only for flash furnaces
Generally applicable
Generally applicable
Applicable for semi-closed furnaces
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Only applicable
furnaces
Double-bell charging system
Select and feed the raw materials according to the type of
furnace and abatement techniques used
Use of lids on throats of rotary anode furnace
for
shaft/blast
Generally applicable
Generally applicable
(1) Description of the technique is given in Section 14.10.
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BAT 25.
In order to reduce diffuse emissions from Peirce-Smith converter (PS)
furnaces in primary and secondary copper production, BAT is to use a combination of the
following techniques given below. (based on Sections 3.3.3.3 and 3.3.4.3)
Technique
Operating the furnace and gas route under negative
pressure and a sufficient gas extraction rate to prevent the
pressurisation
Oxygen enrichment
Primary hood over the converter opening to collect and
transfer the primary off-gases to an abatement system
Addition of materials (e.g. scrap and flux) through the
hood
System of secondary hoods in addition to the main one to
capture emissions during charging and tapping operations
a
b
c
d
e
Furnace located in enclosed building equipped with a gas
extraction and abatement system
f
Apply motor driven secondary hoods, to move them,
according to the process stage, to increase the efficiency
of the collection of secondary emissions
Boosted suction systems (1) and automatic control to
prevent blowing when the converter is "rolled out" or
"rolled in"
g
h
Applicability
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable for new plants.
In existing plants or major upgrades,
application may be difficult due to
the space requirements
Generally applicable
Generally applicable
(1) Description of the technique is given in Section 11.10.
BAT 26.
In order to reduce diffuse emissions from a Hoboken converter furnace in
primary copper production, BAT is to use a combination of the following techniques given
below. (based on Section 3.3.3.3)
Technique
a
b
c
d
Furnace and gas route operating under negative pressure during charging, skimming and
tapping operations
Oxygen enrichment
Mouth with closed lids to prevent emissions during operation
Boosted suction systems (1)
(1) Description of the technique is given in Section 11.10.
BAT 26 bis.
In order to reduce diffuse emissions from the matte conversion process,
BAT is to use a flash converting furnace. (based on Section 3.3.3)
Applicability
Applicable only to new plants or major upgrades of existing plants.
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BAT 27.
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
following techniques given below. (based on Sections 3.3.3.3 and 3.3.4.3)
Technique
Operating the furnace and gas route under negative
pressure and with sufficient gas extraction rate to prevent
the pressurisation
Oxygen enrichment
Furnace located in enclosed building in combination with
techniques to collect and transfer diffuse emissions from
charging and tapping to an abatement system (e.g. housein-house) with gas extraction equipped with an abatement
system
Primary hood over the converter opening to collect and
transfer the primary off-gases to an abatement system
a
b
c
d
Hoods or crane hood to collect and transfer the emissions
from for charging and tapping operations connected with
to an abatement system
e
Addition of materials (e.g. scrap and flux) through the
hood
Boosted suction system (1)
f
g
Applicability
Generally applicable
Generally applicable
Generally applicable Applicable to
tapping and charging operations
Generally applicable
Generally applicable. For existing
plants, a crane hood is only
applicable during to the major
upgrade of the furnace hall
Generally applicable
Generally applicable
(1) Description of the technique is given in Section 11.10
BAT 28.
In order to reduce diffuse emissions from copper recovery with a slag
concentrator, BAT is to use the following techniques given below. (based on Section
3.3.3.4.1)
a
b
c
d
Technique
Dust suppression techniques such as a water spray for handling, storage and crushing of slag
Grinding and flotation performed with water
Delivery of the slag to the final storage area via hydro transport in closed pipeline
Maintaining a water layer in the pond or using dust suppressant such as lime milk in dry areas
BAT 29.
In order to reduce diffuse emissions from copper-rich slag furnace treatment
heat processing and cleaning, BAT is to use a combination of the techniques given below.
dust suppression system such as a water spray for handling, storage and crushing of the
final slag. (based on Section 3.3.3.4.2)
a
b
c
d
e
Technique
Dust suppression techniques such as a water spray for
handling, storage and crushing of the final slag
Operation of the furnace under negative pressure
Enclosed furnace
Housing, enclosure and hood to collect and transfer the
emissions to an abatement system
Covered launder
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Applicability
Only applicable for handling, storage
and crushing of the final slag
Generally applicable
Generally applicable
Generally applicable
Generally applicable
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BAT 30.
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 following
techniques given below. (based on Section 3.3.3.7)
a
b
c
Technique
Use of enclosed tundish
Use of closed intermediate ladle
Use of a hood over the casting ladle and over the casting
wheel, equipped with an extraction system
BAT 31.
In order to reduce diffuse emissions from electrolysis cell, BAT is to use one or
a combination of the following techniques given below. (based on Section 3.3.3.8)
Technique
Addition
of
surfactants
electrowinning cells
a
Applicability
to
the
Use of covers or a hood to collect and
transfer the emissions with air extraction
connected to an abatement system
b
Use of closed storage tanks and Closed and
fixed pipelines for transferring the
electrolyte solutions
Gas extraction from the washing chambers
of the cathode stripping machine and anode
scrap washing machine
c
d
Generally applicable
Only applicable for electrowinning cells or
refining cells for high impurity anode, except
when the cell needs to remain uncovered to
maintain the cell temperature at workable levels
(c. 65 °C)
Generally applicable
Generally applicable
BAT 32.
In order to reduce diffuse emissions from casting of copper alloys, BAT is to
use one or a combination of the following techniques given below. (based on Section
3.3.5.1)
a
b
c
Technique
Use of enclosures or hoods to collect and transfer the emissions equipped with flue-gas
extraction connected to an abatement system
Use of covering for the melts in holding and in casting furnace
Boosted suction system (1)
(1) Description of the technique is given in Section 11.10
BAT 33.
In order to reduce diffuse emissions from non-acid and acid pickling, BAT is
to use one of the following techniques given below. (based on Section 3.3.5.2)
Technique
a
Encapsulated pickling line with a solution of isopropanol
alcohol operating in a closed circuit
b
Encapsulated pickling line to collect and transfer the
emissions with an air extraction system connected to an
abatement system
11.2.4.2
Applicability
Generally Only applicable for
pickling of copper wire rod, in
continuous operations
Generally Only applicable for the
acid
pickling,
in
continuous
operations
Channelled dust emissions
Descriptions of the techniques mentioned in this Section are given in Section 11.10
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BAT 34.
In order to reduce dust and metal emissions to air from raw materials'
reception, storage, handling, transport, metering, mixing, blending, crushing, drying,
cutting and screening of raw materials, and pyrolytic treatment of copper turnings in
primary and secondary copper production, BAT is to use a bag filter. (based on Section
3.3.1.1, 3.3.1.2, 3.3.2.1 and 3.3.2.1 bis)
BAT-associated emission levels
See Table 11.5
Table 11.5: BAT-associated emission levels for dust emissions to air from raw materials'
reception, storage, handling, transport, metering, mixing, blending, crushing, drying,
cutting and screening of raw materials, and pyrolytic treatment of copper turnings in
primary and secondary copper production
Parameter
Dust
Unit
mg/Nm³
BAT-AEL (1) (2)
2–5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead, copper,
arsenic and cadmium are above the following: 1 mg/Nm3 for lead and copper, and 0.05 mg/Nm3 for arsenic and
cadmium.
The associated monitoring is in BAT 17.
BAT 34 bis.
In order to reduce dust and metal emissions to air from pyrolytic
treatment of copper turning and raw material drying, BAT is to use a bag filter. (based on
Sections 3.3.2.1 and 3.3.2.1 bis)
BAT-associated emission levels
See Table 14.5 bis.
Table 14.5 bis: BAT-associated emission level for dust emissions to air from pyrolytic treatment of
copper turning and raw materials drying
Parameter
Unit
BAT-AEL (1)
Dust
mg/Nm³
≤5
(1) As an average over the sampling period
The associated monitoring is in BAT 17.
BAT 35.
In order to reduce dust and metal emissions to air from concentrate drying in
primary copper production, BAT is to use a bag filter. or an ESP. one of the following
techniques: (based on Section 3.3.2.2)
Technique
a
b
Bag filter
ESP
Applicability
In the event of high organic carbon content in the concentrates (e.g. around 10% w/w), bag
filters might not be applicable due to blinding of the bags and other techniques (e.g. ESP) might
be used.
BAT-associated emission levels
See Table 11.6.
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Table 11.6: BAT-associated emission levels for dust emissions to air from concentrate drying in
primary copper production
Parameter
Dust
BAT-AEL (1) (2) (3)
3 – 5 ≤ 5 – 10
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) When the concentrates used have high organic carbon content (e.g. around 10% w/w), emissions up to 10
mg/Nm3 can be expected.
(3) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead, copper,
arsenic and cadmium are above the following: 1 mg/Nm3 for lead and copper, and 0.05 mg/Nm3 for arsenic and
cadmium.
The associated monitoring is in BAT 17.
BAT 36.
In order to reduce dust and metal in primary and secondary emissions to air
other than those that are sent to the sulphuric acid or liquid SO2 plant or power plant,
from the primary copper smelter and converter, BAT is to use one or both a combination
of the following techniques given below. (based on Sections 3.3.3.2 and 3.3.3.3)
a
ab
bc
d
Technique
Use of a dust pretreatment system, such as a cyclone, or settling
chamber in combination with one of the technique listed below
Bag filter
Wet scrubber ESP
ESP
Applicability
Applicable for flue-gas with a
high dust content
Generally applicable
Generally applicable
Generally applicable
BAT-associated emission level
See Table 11.7
Table 11.7: BAT-associated emission levels for dust emissions to air, lead and arsenic in primary
and secondary emissions other than those that are sent to the sulphuric acid or liquid
SO2 plant or power plant from the primary copper smelter and converter
Parameter
Dust
Pb
As
BAT-AEL (1) (2)
2 – 5 ≤ 5 – 10 (1)
1 – 3 (2)
≤ 1 (2)
Unit
mg/Nm³
mg/Nm³
mg/Nm³
(1) As a daily average for continuous measurements.
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead, copper,
arsenic and cadmium are above the following: 1 mg/Nm3 for lead and copper, and 0.05 mg/Nm3 for arsenic and
cadmium.
(2) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17.
BAT 37.
In order to reduce dust and metal emissions to air in primary and secondary
emissions other than those that are sent to the sulphuric acid plant from the secondary
copper smelter and converter and from secondary copper intermediates, BAT is to use a
bag filter. one or a combination of the following techniques: (based on Sections 3.3.4.1,
3.3.4.3 and 3.3.5.3)
a
b
c
d
Technique
Bag filter
Hot ESP
Wet ESP
Absorbent agent, such as activated carbon injection, for the reduction of metals.
BAT-associated emission level
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See Table 11.8.
Table 11.8: BAT-associated emission levels for dust emissions to air other than those that are sent
to the sulphuric acid plant, lead and arsenic in primary and secondary emissions from
the secondary copper smelter and converter and from secondary copper intermediates
Parameter
Dust
Pb
As
Unit
mg/Nm³
mg/Nm³
mg/Nm³
BAT-AEL (1) (2)
2 – 4 ≤ 5 (1)
≤ 1 – 3 (2)
≤ 1 ( 2)
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead, copper,
arsenic and cadmium are above the following: 1 mg/Nm3 for lead and copper, and 0.05 mg/Nm3 for arsenic and
cadmium.
(2) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17.
BAT 38.
In order to reduce dust and metal emissions to air in primary and secondary
emissions from the secondary copper holding furnace, BAT is to use a bag filter. (based on
Section 3.3.4.2)
BAT-associated emission levels
See Table 11.9.
Table 11.9: BAT-associated emission levels for dust emissions to air in primary and secondary
emissions from the secondary copper holding furnace
Parameter
Dust
Unit
mg/Nm³
BAT-AEL (1)
≤5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17.
BAT 39.
In order to reduce dust and metal emissions to air from copper-rich slag
furnace processing treatment heat processing and cleaning, BAT is to use a bag filter or a
scrubber in combination with an ESP. one of the following techniques: (based on Section
3.3.3.4.2)
Technique
a
b
Bag filter
ESP
BAT-associated emission levels
See Table 11.10.
Table 11.10: BAT-associated emission levels for dust emissions to air and lead from copper-rich
slag furnace processingtreatment heat processing and cleaning
Parameter
Dust
Pb
Unit
mg/Nm³
mg/Nm³
BAT-AEL (1) (2)
2 – 5 ( 1)
≤ 3 ( 2)
(1) As a daily average for continuous measurements or As an average over the sampling period (periodic
measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead are above 1
mg/Nm3.
(2) As an average over the sampling period (periodic measurements of at least half an hour).
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The associated monitoring is in BAT 17
BAT 40.
In order to reduce dust and metal emissions to air in primary and secondary
emissions 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. (based on Section 3.3.3.5)
BAT-associated emission levels
See Table 11.11.
Table 11.11: BAT-associated emission levels for dust emissions to air and metals in primary and
secondary emissions from the anode furnace in primary and secondary copper
production
Parameter
Dust
Pb
As
BAT-AEL (1) (2)
2 – 5 (1)
1 – 3 (2)
≤ 1 (2)
Unit
mg/Nm³
mg/Nm³
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of lead, copper,
arsenic and cadmium are above the following: 1 mg/Nm3 for lead and copper, and 0.05 mg/Nm3 for arsenic and
cadmium.
(2) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17.
BAT 41.
In order to reduce dust and metal emissions to air from anode casting in
primary and secondary copper production, BAT is to use one of the following techniques
given below. (based on Section 3.3.3.7)
Technique (1)
a
Bag filter
b
Wet scrubber or demister
Applicability
Not applicable for treating for flue off-gases with
a water content close to the dew point
Applicable only for treating flue off-gases with a
high water content
BAT-associated emission levels
See
Table 11.12.
Table 11.12: BAT-associated emission levels for dust emissions to air, lead and arsenic from anode
casting in primary and secondary copper production
Parameter
Dust
Pb
As
BAT-AEL (1)
≤ 5 – 15 (1) (2)
≤ 1 (3)
≤ 1 (3)
Unit
mg/Nm³
mg/Nm³
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a bag filter. When the flue-gas has a water content
close to the dew point and wet techniques have to be used the BAT-AEL is ≤ 15.
(3) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17 .
BAT 42.
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 and the
abatement system used and to use a bag filter. (based on Section 3.3.5.1)
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BAT-associated emission levels
See Table 11.13.
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Table 11.13: BAT-associated emission levels for dust emissions to air, lead and arsenic from a
copper melting furnace
Parameter
Dust
Pb
As
BAT-AEL (1) (2)
2 –5 (1)
≤ 1 (2)
≤ 1 (2)
Unit
mg/Nm³
mg/Nm³
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of copper are above
1 mg/Nm3.
(2) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17.
BAT 43.
In order to reduce dust and metal emissions to air from lead and tin
production from secondary copper intermediates, BAT is to use a bag filter. (based on
Section 3.3.5.3)
BAT-associated emission levels
See Table 11.14.
Table 11.14: BAT-associated emission levels for dust emissions to air from lead and tin production
from secondary copper intermediates production
Parameter
Dust
BAT-AEL (1)
≤3–5
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 17.
11.2.4.3
Organic compound emissions
BAT 44.
In order to reduce organic compound emissions to air from pyrolytic
treatment of copper turnings, and drying drying, de-oiling, smelting and melting of
secondary raw materials, BAT is to use one of the following techniques given below.
(based on Sections 3.3.2.1, 3.3.2.1 bis, 3.3.4.1, 3.3.4.3, and 3.3.5.1)
Technique (1)
a
Afterburner or post-combustion
chamber
b
Regenerative afterburner
c
d
e
Injection of absorbent in
combination with a bag filter
Design of furnace and the
abatement techniques according
to the raw materials available
Select and feed the raw materials
according to the furnace and the
abatement techniques used
1104
Applicability
Generally applicable The applicability is restricted by the energy
content of the off-gases that need to be treated. Off-gases with a
lower energy content lead to a higher fuel use, which implies an
increase in the cross-media effects
The applicability is restricted by the energy content of the offgases that need to be treated. Off-gases with a lower energy
content lead to a fuel higher use, which implies an increase in the
cross-media effects. Not applicable when the increased
investment cost is not balanced by the reduction of the fuel
expenses
Generally applicable
Only applicable to new or major upgraded furnaces
Generally applicable
July 2014
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Thermal destruction of TVOC at
high temperatures in the furnace
(> 1000 °C)
f
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.15.
Table 11.15: BAT-associated emission levels for organic compound emissions to air from the
pyrolytic treatment of copper turnings, during and drying, smelting and melting of
secondary raw materials drying, de-oiling
Parameter
TVOC as C
BAT-AEL (1) (2)
3 – 30 ≤ 10 – 40
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a regenerative afterburner.
The associated monitoring is in BAT 17.
BAT 45.
In order to reduce the emission to air of organic compounds from solvent
extraction in hydrometallurgical copper production, BAT is to use both a combination of
the following techniques given below. (based on Section 3.3.3.10)
a
b
Technique
Select the Process reagent (solvent) with the lower steam pressure
Closed equipment such as closed mixing tanks, closed settlers and closed storage tanks
BAT 46.
In order to reduce PCDD/F emissions to air in secondary copper production
from 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 following techniques given below. (based on Sections 3.3.2.1 bis, 3.3.3.5, 3.3.4.1.1,
3.3.4.1.2 and 3.3.5.1)
a
b
c
d
e
f
g
h
i
j
Technique
Select and feed the ion of raw material
according to the furnace and the abatement
techniques used
Optimum Optimise combustion conditions for
the abatement of emissions of organic
compounds
Use of charging systems, for a semi-closed
furnace, to give small additions of raw material
Thermal destruction of PCDD/F in the furnace
at high temperatures (> 850 °C)
Use of oxygen injection in the upper zone of the
furnace
Internal burner system
Use of post-combustion chamber or afterburner
or regenerative afterburner (1)
Avoid exhaust system with high dust coating for
temperature > 250 °C
Rapid quenching (1)
Injection of absorption agent in combination
with Use of efficient dust collection system (1)
Applicability
Generally applicable
Generally applicable
Applicable for a semi-closed furnace
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10.
Description
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BAT 46 (a): The raw materials should be selected in such a way that the furnace and the
abatement system used to achieve the required abatement performance could treat the
contaminants contained in the feeding properly.
BAT 46 (b): ActOptimise on combustion conditions: Good mixing between air or oxygen and
carbon content, control of the temperature of the gases and resident time to oxidise the organic
carbon comprises PCDD/F.
BAT 46 (c): Add raw material in small portions in semi-closed furnaces to reduce the furnace
cooling effect during charging. This maintains a higher gas temperature and prevents the
reformation of PCDD/F.
BAT 46 (f): The exhaust off-gas is directed through the burner flame and the organic carbon is
converted with oxygen to CO2.
BAT 46 (h): The presence of dust at temperature above 250 °C promotes the de novo PCDD/F
synthesis.
BAT 46 (j): and (k) PCDD/F may be absorbed onto dust and hence emissions can be reduced
using an efficient dust filtration system. The use of a specific absorbing agents promote this
process and reduce the emission of PCDD/F.
BAT-associated emission levels
See Table 11.16.
Table 11.16: BAT-associated emission levels for PCDD/F emissions to air from pyrolytic treatment
of copper turnings, smelting, melting, fire refining and converting operations in
secondary copper production
Plant
BAT-AEL(1)
New plant or major upgrade
≤ 0.1
PCDD/F
ng I-TEQ/Nm³
Existing plant
0.1 – 0.3
(1) As an average over a the sampling sampling period(periodic measurements of at least six hours).
Parameter
Unit
The associated monitoring is in BAT 17.
11.2.4.4
SO2 emissions
Descriptions of the techniques mentioned in this Section are given in Section 11.10.
BAT 47.
In order to reduce SO2 emissions from concentrate drying, BAT is to use one
of the following techniques: (based on Section 3.3.2.2)
a
Technique
Dry or semi-dry scrubber
b
Wet scrubber
Applicability
Generally applicable
For existing plants, applicable if the
waste water treatment plant could treat
the pollutant present into the scrubber´s
effluent and the resulting water can be
discharged
BAT-associated emission levels
See Table 11.17
Table 11.17: BAT-associated emission levels for SO2 from concentrate drying
Parameter
Unit
BAT-AEL (1)
SO2
mg/Nm³
≤ 300
1
( ) As a daily average for continuous measurements or as an average over the sampling period
(periodic measurements of at least half an hour).
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BAT 48.
In order to reduce SO2 emissions in off-gases with a low SO2 content ( < 1 %
v/v SO2 ) other than those that are sent to the sulphuric acid or liquid SO2 plant or power
plant from primary copper production concentrate roasting, primary smelters and
converters, BAT is to use one or a combination of the following techniques given below.
(based on Sections 3.3.2.2, 3.3.2.3, 3.3.3.2, 3.3.3.3, 3.3.3.4.2, 3.3.3.6 and 3.3.3.9)
Technique
a
Dry or semi-dry scrubber
b
Wet scrubber
c
Polyether-based
absorption/desorption system
Applicability
Generally applicable Generally Applicable to new plants.
For existing plants, lime injection cannot be applied
without retrofitting the existing abatement system when
temperature, moisture content and contact time are not
sufficient and the existing filter capacity cannot take the
additional dust load
Applicability may be limited in the following cases:
- very high off-gas flow rates: due to the cross-media
effects (significant amounts of waste and waste water);
- in arid areas by the large volume of water necessary and
the need for waste water treatment and the related crossmedia effects
Applicable to new plants. For existing plants, applicability
may be restricted applicable if the waste water treatment
plant cannot could treat the pollutant present into the
scrubber´s effluent and the resulting water cannot be
recycled to the process or discharged
Not Only Not applicable in the absence ofwhen a
sulphuric acid or a liquid SO2 plant is not available
BAT-associated emission levels
See Table 11.18
Table 11.18: BAT-associated emission levels for SO2 emissions to air other than those that are sent
to the sulphuric acid or liquid SO2 plant or power plant in off-gases with a low SO2
content (< 1 % v/v SO2) from primary copper production concentrate roasting,
primary smelters and converters
Parameter
SO2
BAT-AEL (1) (2)
200 50 – 500
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period.
(2) In the case of using a wet scrubber or a concentrate with a low sulphur content, the BAT-AEL can go up to 350
mg/Nm3. Within the lower and the upper ends of the range the emission level attainable is highly dependent on the
content of sulphur in the concentrate used, the techniques applied and on whether the plant is an existing one, an
upgraded one or a new one is associated with the use of a wet scrubber.
The associated monitoring is in BAT 17.
BAT 49.
In order to reduce SO2 emissions to air in off-gases with a low SO2 content ( <
1 % SO2 ) other than those that are sent to the sulphuric acid or liquid SO2 plant or power
plant, from the secondary copper productionsmelter and converter, BAT is to use one or a
combination of the following techniques given below. (based on Sections 3.3.3.5, 3.3.3.9,
3.3.4.1 and 3.3.4.3)
Technique
a
Dry or semi-dry scrubber
MR/GC/EIPPCB/NFM_Draft_3
Applicability
Generally applicable Generally Applicable to new plants. For
existing plants, lime injection cannot be applied without
retrofitting the existing abatement system when temperature,
moisture content and contact time are not sufficient and the
existing filter capacity cannot take the additional dust load
July 2014
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b
Wet scrubber
Applicability may be limited in the following cases:
- very high off-gas flow rates: due to the cross-media effects
(significant amounts of waste and waste water);
- in arid areas by the large volume of water necessary and the
need for waste water treatment and the related cross-media
effects
Applicable to new plants. For existing plants, applicability
may be restricted applicable if the waste water treatment plant
cannot could treat the pollutant present into the scrubber´s
effluent and the resulting water cannot be recycled to the
process or discharged
BAT-associated emission levels
See Table 11.19.
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Table 11.19: BAT-associated emission levels for SO2 emissions to air other than those that are sent
to the sulphuric acid or liquid SO2 plant or power plant in off-gases with a low SO2
content (< 1 % v/v SO2) from the secondary copper production smelter and converter
Parameter
SO2
BAT-AEL (1) (2)
100 50 – 300
Unit
mg/Nm³
(1) As a daily average or as an average over the sampling period.for continuous measurements.
(2) Within the lower and the upper ends of the range the emission level achievable is highly dependent on the
content of sulphur in the raw materials used, the techniques applied and on whether the plant is an existing one, an
upgraded one or a new one. is associated with secondary copper production using raw materials with low sulphur
content.
The associated monitoring is in BAT 17.
BAT 50.
In order to reduce SO2 emissions from copper rich slag heat processing and
cleaning, BAT is to use one or a combination of the following techniques: (based on
3.3.3.4.2, and 3.3.3.9)
Technique
a
Dry or semi-dry scrubber
b
Wet scrubber
Applicability
Generally applicable For existing plants the
applicability could be limited by technical
constrains (temperature of the off-gases,
moisture content, contact time existing filter
capacity, space requirement)
For existing plants, applicable if the waste
water treatment plant could treat the pollutant
present into the scrubber´s effluent and the
resulting water can be recycled to the process
or discharged
BAT-associated emission levels
See Table 11.20.
Table 11.20: BAT-associated emission levels for SO2 from copper rich slag furnace treatment and
cleaning
Parameter
Unit
BAT-AEL (1)
SO2
mg/Nm³
≤ 200
1
( ) As a daily average for continuous measurements or as an average over the sampling period
(periodic measurements of at least half an hour).
BAT 51.
In order to reduce SO2 emissions to air from melting and fire refining (anode
furnace) and casting in primary and secondary copper production, BAT is to use one of
the following techniques given below. (based on Sections 3.3.3.5 and 3.3.3.9)
Technique
a
Dry or semi-dry scrubber
b
Wet scrubber
Applicability
Generally Applicable to new plants. For existing plants, lime
injection cannot be applied without retrofitting the existing
abatement system when temperature, moisture content and
contact time are not sufficient and the existing filter capacity
cannot take the additional dust load
Applicable to new plants. For existing plants, applicability
may be restricted applicable if the waste water treatment plant
cannot could treat the pollutant present into the scrubber´s
effluent and the resulting water cannot be recycled to the
process or discharged
BAT-associated emission levels
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1109
Chapter 11
See Table 11.21
1110
July 2014
MR/GC/EIPPCB/NFM_Draft_3
Table 11.21: BAT-associated emission levels for SO2 emissions to air from melting and fire refining
(anode furnace) and casting in primary and secondary copper production
Parameter
SO2
BAT-AEL (1)
100 – 400 ≤ 300
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) Within the lower and the upper ends of the range the emission level achievable is highly dependent on the
content of sulphur in the raw materials/concentrate used, the techniques applied and on whether the plant is an
existing one, an upgraded one or a new one.
The associated monitoring is in BAT 17.
11.2.4.5
Acid emissions
BAT 52.
In order to reduce acid gas emissions to air from electrorefining and
electrowinning processes exhaust gases from the electrowinning cell, the electrorefining
cell for high impurity anodes, the washing chamber of the cathode stripping machine and
the anode scrap washing machine, BAT is to use one of the following techniques given
below. (based on Section 3.3.3.8)
Technique (1)
a
b
Applicability
Generally applicable
Generally applicable
Wet scrubber
Demister
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.21
Table 11.22: BAT-associated emission levels for acid gas emissions to air from exhaust gases from
the electrowinning cell, the electrorefining cell for high impurity anodes, the washing
chamber of the cathode stripping machine and the anode scrap washing machine
electrorefining and electrowinning processes
Parameter
H2SO4
BAT-AEL (1)
≤1
Unit
mg/Nm³
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 17
11.2.5
Soil and groundwater protection
BAT 53.
In order to prevent soil and groundwater contamination from copper recovery
in the slag concentrator, BAT is to use all of the following techniques given below. (based
on Section 3.3.3.4.1)
a
b
Technique
Use of the drainage system at cooling areas
Correct design of the final slag storage area to
collect overflow water and avoid fluid leakage
Applicability
Generally applicable
Generally applicable
BAT 54.
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 following
techniques given below. (based on Section 3.3.3.8)
a
b
Technique
Use of sealed the drainage system
Use of impermeable and acid-resistant floors
MR/GC/EIPPCB/NFM_Draft_3
Applicability
Generally applicable
Generally applicable
July 2014
1111
Chapter 11
c
Use of double-walled tanks or placement in
resistant bunds with impermeable floors
11.2.6
Generally applicable
Waste water generationemissions
BAT 55.
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 following
techniques given below. (based on Sections 3.3.3.4.1, 3.3.3.4.2, 3.3.3.4.2 and 3.3.6.1)
a
b
c
d
e
f
1112
Technique
Use of the steam condensate used for heating the
electrolysis cells, to wash the copper cathodes or
send it back to steam boiler
Use the water collected from the cooling area,
flotation process and hydro transportation of final
slag by the drainage system back in the slag
concentration process
Recycling the pickling solutions and the rinse water
Treatment of the residues (crude) to recovery the
organic solution content
Use of the centrifugation for the treatment of the
slurry from cleaning and settlers
Reuse the electrolysis bleed after the metals' removal
stage the electrowinning and/or the leaching process
July 2014
Applicability
Generally applicable
Generally applicable
Generally applicable
Only applicable to solvent extraction step
in hydrometallurgical copper production
Only applicable to solvent extraction step
in hydrometallurgical copper production
Generally applicable
MR/GC/EIPPCB/NFM_Draft_3
11.2.7
Waste
BAT 56.
In order to reduce the quantities of waste sent for disposal from primary and
secondary copper production, BAT is to organise operations on the site so as to facilitate
process residues waste reuse or, failing that, process residues waste recycling, including
one or a combination of the following techniques given below. (based on Section 3.3.7.1,
3.3.7.1)
Technique
a
Reuse or sale of the sulphuric acid coming from gas
cleaning wet scrubber
b
Recovery of metals from the dust and slime coming
from the dust abatement system
c
Reuse or sale of the calcium compounds (e.g.
gypsum) generated by the abatement of SO2
d
Regeneration or recycling of the spent catalysts
e
Recovery of metal from the waste water treatment
slime
f
g
h
i
j
k
l
m
n
o
p
q
r
s
Use of the weak acid in the leaching process or for
gypsum production
Recovery of the copper content from the rich slag in
the slag furnace or slag flotation plant
Use of the final slag from furnaces as an abrasive or
(road) construction material or for another viable
application
Use of the furnace lining for recovery of metals or
reuse as refractory materials
Use of the slag coming from the slag flotation as an
abrasive or construction material or for another
viable application
Use of the skimming from the melting furnaces to
recover the metal content
Use of the spent electrolyte bleed to recover copper
and nickel. Reuse of the remaining acid to make up
the new electrolyte or to produce gypsum
Use of the spent anode as a cooling material in
pyrometallurgical copper refining or remelting
Use of anode slime to recover precious metals
Use of the gypsum from the waste water treatment
plant in the pyrometallurgical process or selling it for
sale
Recovery of metals from the sludge
Reuse of the depleted electrolyte coming from the
hydrometallurgical copper process as a leaching
agent
Recovery of copper scales from rolling in a copper
smelter
Recovery of metals from the spent acid pickling
solution and reuse of the cleaned acid solution
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Applicability
Applicability
may
be
restricted
depending on the metal content and on
the availability of a market/process
Generally applicable
Generally Applicability may be restricted
depending on the metal content and on
the availability of a market
Generally applicable
Generally Applicability may be restricted
depending on the metal content and on
the availability of a market/process
Generally applicable
Generally applicable
Applicability
may
be
restricted
depending on the metal content and on
the availability of a market
Generally Applicability may be restricted
depending on the metal content and on
the availability of a market/process
Applicability
may
be
restricted
depending on the metal content and on
the availability of a market
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Applicability
may
be
restricted
depending on the quality of the generated
gypsum
Generally applicable
Generally Applicability may be restricted
depending on the metal content and on
the availability of a market/process
Generally applicable
Generally applicable
1113
Chapter 11
11.3
BAT conclusions for aluminium production including
alumina and anodes production
11.3.1
Monitoring
BAT 4 and 5 do not apply to the aluminium sector.
11.3.1.1
Monitoring of emissions to air
BAT 57.
BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
a
b
Standard(s)
EN 13284- 2
Continuous
EN 13284-1
Periodic (at least three
consecutive measurements once
per year)
Dust (2)
SOX
expressed as
SO2
c
NOX,
expressed as
NO2
d
NH3
e
Benzo- [a]pyrene
f
All gaseous
fluorides,
expressed as
HF
Continuous
EN 14791
EN 14792
No EN or ISO
standard available
ISO 11338–1
ISO 11338–2
ISO 15713
g
Total
fluorides
h
All gaseous
chlorides,
expressed as
HCl
EN 1911
Chlorine,
expressed as
Cl2
No EN or ISO
standard available
i
j
1114
Minimum monitoring
frequency (1)
TVOC
No EN or ISO
standard available
63, 70
Periodic measurement (at least
three consecutive measurements
once per year) or mass balance (3)
Continuous
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
63, 70
12
12
93
61, 61 bis, 62, 62 bis
Continuous
62, 62 bis, 69, 88
Periodic (at least three
consecutive measurements once
per year)
62, 62 bis, 69, 88
Periodic (at least once per year)
62, 69, 69 bis
Continuous
EN 12619
EN 13526
Monitoring
associated with BAT
59, 61, 61 bis, 62, 62
bis, 68, 69, 69 bis, 69
ter, 82, 83, 84, 85, 86,
92
59, 61, 61 bis, 62, 62
bis, 68, 69, 69 bis, 69
ter, 82, 83, 84, 85, 86,
92
88
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Continuous
or Periodic (at least three
consecutive measurements once
per year)
July 2014
88
88, 93
87
87
MR/GC/EIPPCB/NFM_Draft_3
EN 1948 part 1, 2, 3
and 5
k
PCDD/F
l
H2S
No EN or ISO
standard available
m
PH3
No EN or ISO
standard available
Periodic (at least one
measurement once per year)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
87
93
93
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed. More frequent monitoring (including the choice
between continuous or periodic measurement) should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(³) Related to BAT 70(a), a mass balance can be used to calculate SO2 emissions, based on the measurement of the
sulphur content of each of the anode batches consumed. the daily measurement of the sulphur content in the anodes.
BAT 57bis. BAT is to monitor the emissions to water at the point where the emission
leaves the installation 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
a
b
c
d
Al
Other
metals, if
relevant (2)
Fluorides
(3)
Total
suspended
solids
Standard(s)
Minimum monitoring
frequency (1)
Monitoring associated
with
At least once a month
BAT 14
EN ISO 11885
EN ISO 17294-2
EN ISO 10304-1
No EN or ISO standard
available
EN 872
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability. More frequent
monitoring may be chosen taking into account local environmental conditions such as the type of receiving media,
the load of metals present in the waste water.
(2) The metals monitored depend on the composition of the raw material used.
(3) Applicable to primary aluminium production.
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1115
Chapter 11
11.3.2
11.3.2.1
BAT conclusions for alumina production
Energy
BAT 58.
In order to use energy efficiently during the production of alumina from
bauxite, BAT is to use one or a combination of the following techniques given below.
(based on Section 4.3.1.4.)
a
b
c
Technique
Plate heat exchangers
Applicability
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
Circulating fluid bed
calciners
Only applicable only to smelter grade aluminas. Not applicable to
speciality/non-smelter grade aluminas, as these require a higher level of
calcination, that currently can only be achieved with a rotary kiln
Single stream
digestion design (e.g.
tube digester)
Only applicable to new plants (plants with a double-stream digestion design
cannot be converted to tube digestion without a total redesign and rebuilding
of the plant; and in many cases there will be insufficient space available)
Selection of the
bauxite
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
d
Description
BAT 58(a): Plate heat exchangers allow a higher heat recovery from the liquor flowing to the
precipitation in comparison with other techniques such as flash cooling plants.
BAT 58(b): Circulating fluid bed calciners have a much higher energy efficiency than rotary
kilns, since the heat recovery from the alumina and the flue-gas is greater.
BAT 58(c): By using the single stream digestion design (e.g. tube digester), the slurry is heated
up in one circuit without using live steam. Heating up to the digestion temperature is therefore
achieved without dilution of the slurry, in contrast contrary to what happens in the doublestream digestion design.
(d) The quality of the bauxite ore has an influence on over the energy consumption. Bauxite
with a higher moisture content carries more water into the process, which then needs to be
evaporated. In addition, bauxites with a high mono-hydrate content (boehmite and/or diaspore)
require higher pressure and temperature in the digestion process, leading to higher energy
consumption.
11.3.2.2
Air emissions
12.3.1.2.2 Channelled dust emissions
BAT 59.
In order to reduce dust and metal emissions from alumina calcination, BAT is
to use one a bag filter or an ESP. of the following techniques. (based on Section 4.3.1.2)
Technique (1)
a
b
Bag filter
ESP
(1) Descriptions of the techniques are given in Section 14.10.
11.3.2.3
Waste
BAT 60.
In order to reduce the quantities of waste sent for disposal and to improve the
disposal of bauxite residues from aluminium production, BAT is to use one or both a
combination of the following techniques given below. (based on Section 4.3.1.3)
Technique
1116
July 2014
Applicability
MR/GC/EIPPCB/NFM_Draft_3
a
b
Reducing the volume of bauxite residues by compacting
Reducing/minimising the alkalinity remaining in the bauxite residue
Generally applicable
Generally applicable
Description
BAT60 (a): Volume reduction of bauxite residues is achieved by minimising the moisture
content by using e.g. vacuum or high-pressure filters to form a semi-dry cake.
BAT60 (b): Minimisation of the alkalinity allows disposal of the residues in a landfill.
11.3.3
BAT conclusions for anode production
11.3.3.1
Air emissions
11.3.3.1.1
Channelled dust, PAH and fluorides emissions
BAT 61.
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. (based
on Section 4.3.2.2)
BAT-associated emission levels
See Table 11.23.
Table 11.23: BAT-associated emission levels for dust emissions to air from a paste plant (removing
coke dust from operations such as coke storage and grinding)
Parameter
Dust
Unit
mg/Nm3
BAT-AEL
2 – 5 (1)
(1) As a daily average or as an average over the sampling period.
The associated monitoring is in BAT 57.
BAT 61 bis. In order to reduce dust and PAH emissions to air from a paste plant (hot
pitch storage, past mixing, cooling and forming), BAT is to use one or a combination of the
techniques given below. (based on Section 4.3.2.2)
Technique (1)
a
Dry scrubber using coke as adsorbent agent, with or without pre-cooling, followed by a bag filter
b
Regenerative thermal oxidiser
c
Catalytic thermal oxidiser
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 14.23 bis.
Table 14.23 bis: BAT-associated emission levels for dust and BaP (as an indicator of PAH)
emissions to air from a paste plant (hot pitch storage, paste mixing, cooling and
forming)
Parameter
Dust
BaP
Unit
mg/Nm3
mg/Nm3
BAT-AEL
2 – 5 (1)
0.001 – 0.01 (2)
(1) As a daily average for continuous measurement or as an average over the sampling period. (periodic measurement
of at least half an hour).
(2) As an average over the sampling period. (periodic measurements of at least half an hour).
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Chapter 11
The associated monitoring is in BAT 57 .
BAT 62.
In order to reduce dust, PAH and fluorides emissions to air from the a baking
plant in an anode production plant integrated with a primary aluminium smelter, BAT is
to use one or a combination of the following techniques given below. (based on Section
4.3.2.3)
a
Technique (1)
Dry
scrubber
using
alumina as the adsorbent
agent followed by a bag
filter
b
Wet scrubber
c
Regenerative
thermal
oxidiser in combination
with a dust abatement
system
Applicability
Generally applicable
Applicability may be limited in the following cases:
- very high exhaust off-gas flow rates: due to the cross-media effects
(significant amounts of waste and waste water);
- in arid areas by the large volume of water necessary and the need for
waste water treatment and the related cross-media effects
Applicable to new plants. For existing plants, applicability may be
restricted applicable if the waste water treatment plant cannot could treat
the pollutant present into the scrubber´s effluent and the resulting water
cannot be recycled to the process or discharged
Generally applicable. This technique is best applied in plants that do not
have access to alumina (stand-alone plants). When installed in existing
plants with access to alumina, a regenerative thermal oxidiser ishas to be
complemented with further dust filtration techniques
(1) Descriptions of the techniques are given in Section Section 11.10.
BAT-associated emission levels
See Table 11.24.
Table 11.24: BAT-associated emission levels for dust, BaP (as an indicator of PAH) and fluorides
emissions to air from the a baking plant in an anode production plant integrated with
a primary aluminium smelter
Parameter
Dust
BaP
HF
Total fluorides
Unit
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
BAT-AEL
2 – 5 (1)≤ 5-10
0.001 – 0.01 (2) (3)
≤ 0.2 0.3 – 0.5 (1)
≤ 0.8 – 1.5 (2) (4)
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) As an average over the sampling period. (periodic measurements of at least half an hour).
(3) The lower end of the range is associated with the use of a combination of a wet scrubber and a regenerative
thermal oxidiser.
(4) The lower end of the range is associated with the use of a wet scrubber or a dry scrubber with alumina followed by
a bag filter. The upper end of the range is associated with the use of a regenerative thermal oxidiser.
The associated monitoring is in BAT 57.
BAT 62 bis. In order to reduce dust, PAH and fluorides 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). (based on Section
4.3.2.3, 4.3.2.3, 4.3.2.3)
BAT-associated emission levels
See Table 14.24 bis.
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July 2014
MR/GC/EIPPCB/NFM_Draft_3
Table 14.24 bis: BAT-associated emission levels for dust, BaP (as an indicator of PAH) and
fluorides emissions to air from a baking plant in a stand-alone anode production plant
Parameter
Dust
BaP
HF
Unit
mg/Nm3
mg/Nm3
mg/Nm3
BAT-AEL
2 – 5 (1) ≤ 5
0.001 – 0.01 (2)
≤ 3 (1)
(1) As a daily average.
(2) As an average over the sampling period.
The associated monitoring is in BAT 57.
11.3.3.1.2
Sulphur dioxide
BAT 63.
In order to reduce sulphur dioxide emissions to air from thea baking plant in
an anode production plant integrated with a primary aluminium smelter, BAT is to use
one or both a combination of the following techniques given below. (based on Section
4.3.2.3)
a
a
b
Technique (1)
Dry
scrubber
using
alumina or lime as
adsorbent agent followed
by, bag filter
Use of raw materials and
fuels containing a low
amount of sulphur
Wet scrubber (1)
Applicability
Generally applicable
Generally applicable
Applicability may be limited in the following cases:
- very high exhaust off-gas flow rates: due to the cross-media effects
(significant amounts of waste and waste water);
- in arid areas by the large volume of water necessary and the need for
waste water treatment and the related cross-media effects
Applicable to new plants. For existing plants, applicability may be
restricted applicable if the waste water treatment plant cannot could
treat the pollutant present into the scrubber´s effluent and the resulting
water cannot be recycled to the process or discharged
(1) Descriptions of the techniques are given in Section Section 11.10
BAT-associated emission levels
See Table 11.25.
Table 11.25: BAT-associated emission levels for SO2 from the baking plant
Parameter
SO2
Unit
mg/Nm3
BAT-AEL (1) (2)
35-150
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a combination of a wet scrubber and a dry scrubber with
alumina followed by a bag filter. The upper end of the range is associated with the use of a dry scrubber with alumina
followed by a bag filter.
11.3.3.2
Waste water generation treatment and reuse
BAT 64.
In order to prevent the generation of waste water from anode baking, BAT is
to use a closed water cycle. (based on Section 4.3.2.3)
Applicability
MR/GC/EIPPCB/NFM_Draft_3
July 2014
1119
Chapter 11
Generally applicable.
11.3.3.3
Waste
BAT 65.
In order to reduce the quantities of wastes sent for disposal, BAT is to
userecycle carbon dust from the coke filter as a scrubbing media. (based on Section
4.3.2.3)
Applicability
There may be restrictions on applicability depending on the ash content of the carbon dust.
11.3.4
11.3.4.1
BAT conclusions for primary aluminium production
Air emissions
BAT 66.
In order to prevent or collect diffuse emissions from both the cells and the cell
room electrolytic cells in primary aluminium production using Söderberg technology,
BAT is to use a combination of the following techniques given below. (based on Section
4.3.3.3)
a
b
c
d
e
Technique
Use of paste with a pitch content between 25 and 28%
(dry paste)
Upgrade the manifold design to allow closed-point
feeding operations and improved off-gas collection
efficiency
Alumina point feeding
Increased anode height combined with the abatement
techniques listed treatment in BAT 69
Anode top hooding connected to the abatement techniques
listedtreatment in BAT 69
Applicability
Generally applicable
Generally applicable
Generally applicable
Generally applicable Applicable when
high current density anodes are used
Only applicable when high low current
density anodes are used
Description
BAT 66(c): The use of point feeding of alumina avoids the regular crust breaking necessary in
other Söderberg technologies (such as manual side feed or bar broken feed), and subsequently
reduces the fluoride and dust emissions associated with these operations.
BAT 66 (d): An increased anode height helps to achieve lower temperatures in the anode top,
resulting in lower air emissions.
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MR/GC/EIPPCB/NFM_Draft_3
BAT 67.
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 following techniques given below. (based on Section 4.3.3.4)
Technique
Automatic multiple point feeding of alumina
Complete hood coverage of the cell, robust
cell hoods and adequate extraction rates (to
lead the off-gas to the abatement techniques
treatment in BAT 69) taking into account
fluoride evolution from bath and carbon anode
consumption
Boosted suction system connected to the
abatement techniques listed in BAT 69
Applicability
Generally applicable
Generally applicable
d
Minimisation of the time for changing anodes
and other activities that need cell hoods to be
removed
Generally applicable
e
Efficient process control system avoiding
process excursions that might otherwise lead
to increased cell evolutions and emissions
Generally applicable
f
Use of a programmed system for cell
operations and maintenance
The use of established efficient cleaning
methods in the rodding plant to recover
fluorides and carbon
Generally applicable
Storage of removed anodes in a compartment
near the cell, connected to the treatment in
BAT 69 , or storage of the butts in confined
boxes
Only applicable to new plants
a
b
c
g
h
Only applicable to new plants or plants undergoing a
complete retrofit, since its inclusion should be
considered during the initial design of the plant. It is
not applicable to potlines fitted with single hoods on
each side, since it would have no effect while these
are fully open
Generally applicable
Description
BAT 67(d): Actions that require the removal of cell hoods, increase diffuse emissions.
Therefore, minimisation of the time devoted to these actions can reduce such emissions.
BAT-associated environmental performance level
The BAT – associated environmental performance level is a hooding efficiency ≥ 98.5 %, to be
assessed at least once a year. This BAT-AEPL is not applicable to plants that can measure roof
emissions.
11.3.4.1.1
Channelled dust and fluorides emissions
BAT 68.
In order to reduce dust emissions from the storage, handling and transport of
raw materials, BAT is to use a bag filter. (based on Section 4.3.3.1 )
BAT-associated emission levels
See Table 11.26.
Table 11.26: BAT-associated emission levels for dust from the storage, handling and transport of
raw materials
Parameter
Dust
BAT-AEL (1)
≤ 5 – 10
Unit
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
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BAT 69.
In order to reduce dust, metal and fluorides channelled emissions to air
collected from the electrolytic cells, BAT is to use one of the following techniques given
below. (based on Section 4.3.3.5)
a
b
Technique (1)
Dry scrubber using alumina
as adsorbent agent followed
by a bag filter
Dry scrubber using alumina
as adsorbent agent followed
by a bag filter and a wet
scrubber
Applicability
Generally applicable
Applicability of the wet scrubber may be limited in the following
cases:
- very high off-gas flow rates: due to the cross-media effects
(significant amounts of waste and waste water);
- in arid areas by the large volume of water necessary and the need for
waste water treatment and the related cross-media effects
Applicable to new plants. For existing plants, the applicability of the
wet scrubber may be restricted applicable if the waste water treatment
plant cannot could treat the pollutant present into the scrubber´s
effluent and the resulting water cannot be recycled to the process or
discharged
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.27.
Table 11.27: BAT-associated emission levels for channelled dust and fluorides emissions to air
collected from the electrolytic cells
Unit
mg/Nm3
mg/Nm3
mg/Nm3
Parameter
Dust
HF
Total fluorides
BAT-AEL
2 – 5 (1) ≤ 5-10
≤ 1.0 (1) (2)
≤ 1.5 (2)
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 57.
BAT 69 bis. In order to reduce the total dust and fluorides emissions to air from the
electrolysis house (collected from the electrolytic cells and roof vents), BAT is to apply a
combination of BAT 66, BAT 67 and BAT 69. (based on Section 4.3.3.5)
BAT-associated emission levels
See Table 14.27 bis.
Table 14.27 bis: BAT-associated emission levels for the total dust and fluorides emissions to air
from the electrolysis house (collected from the electrolytic cells and roof vents)
Parameter
Unit
Dust
Total fluorides
kg/t Al
kg/t Al
BAT-AELs for
existing plants (1) (2)
≤ 1.2
≤ 0.6
BAT-AELs for
new plants (1)
≤ 0.6
≤ 0.35
(1) As mass of pollutant emitted during a year from the electrolysis house divided by the mass of liquid aluminium
produced in the same year.
(2) These BAT-AELs are not applicable to plants that due to their configuration cannot measure roof emissions.
The associated monitoring is in BAT 57.
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BAT 69 ter. 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. (based on Section 4.3.3.8)
Technique
a
Use of liquid metal coming from electrolysis and uncontaminated aluminium material
b
Bag filter (1)
(1) Description of the technique is given in Section 11.10
Description
BAT 69 ter(a): Uncontaminated aluminium material means 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).
BAT-associated emission levels
See Table 14.27 ter.
Table 14.27 ter: BAT-associated emission levels for dust emissions to air from melting and molten
metal treatment and casting in primary aluminium production
Parameter
Dust
Unit
mg/Nm3
BAT-AEL(1) (2)
2 - 25 ≤ 5 - 20
(1) As an average of the samples obtained over a year.
(2) The lower end of the range is associated with the use of a bag filter.
The associated monitoring is in BAT 57.
11.3.4.1.2
Sulphur dioxide
BAT 70.
In order to reduce sulphur dioxide emissions to air from electrolytic cells,
BAT is to use one or both a combination of the following techniques given below. (based
on Sections 4.3.3.6 and 4.3.3.7)
Technique
a
Use of low
sulphur
anodes
b
Wet scrubber
(1)
Applicability
Generally applicable. Applicable taking into account technical constraints (a
minimum sulphur content of 1.2 % is required in order to obtain anodes suitable for
the electrolysis process) and economic limitations (lower sulphur cokes being more
expensive than higher sulphur cokes)
Applicability of the wet scrubber may be limited in the following cases:
- very high off-gas flow rates: due to the cross-media effects (significant amounts of
waste and waste water);
- in arid areas by the large volume of water necessary and the need for waste water
treatment and the related cross-media effects
Applicable to new plants. For existing plants, applicability may be restricted
applicable if the waste water treatment plant cannot could treat the pollutant present
into the scrubber´s effluent and the resulting water cannot be recycled to the process
or discharged
(1) Description of the technique is given in Section 11.10
Description
BAT 70(a): Anodes containing less than 1.5 % sulphur as a yearly average can be produced by
an appropriate combination of the raw materials used in their production. A minimum sulphur
content of 0.9 % as a yearly average is required for the viability of the electrolysis process. The
use of anodes with low sulphur coke (below 2% S) helps with reducing SO2 emissions.
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BAT-associated emission levels
See Table 11.28
Table 11.28: BAT-associated emission levels for SO2 emissions to air from electrolytic cells
Parameter
SO2
Unit
kg/t Al mg/Nm3
BAT-AEL (1) (1) (2)
≤ 2.5– 15 40– 175
(1) For alumina with a sulphur content higher than 300 ppm, the BAT-AEL values are ≤ 45– 200 mg/Nm3.
(1) As mass of pollutant emitted during a year divided by the mass of liquid aluminium produced in the same year. As
a yearly average. daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a wet scrubber. The higher end of the range is associated
with the use of low sulphur anodes.
The associated monitoring is in BAT 57.
11.3.4.1.3
Perfluorocarbons
BAT 71.
In order to reduce perfluorocarbon emissions to air from primary aluminium
production, BAT is to use all of the following techniques given below. (based on Section
4.3.3.2)
a
b
c
Technique
Automatic multiple point feeding of
alumina
Computer control of the electrolysis
process based on active cell databases and
monitoring of cell operating parameters
Automatic anode effect suppression
Applicability
Generally applicable
Generally applicable
Applicable to prebaked cells. Not applicable to
Soderberg cells because the anode design (one piece
only) does not allow the bath flow associated with this
technique
Description
BAT 71(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 PFC, which react with the carbon anode.
BAT-associated environmental performance levels
The BAT-associated environmental performance level achieved by applying these techniques is
0.2 to 0.5 anode effects per cell per day, with a duration of 0.5 to 2 minutes for each effect.
11.3.4.1.4
PAHs and CO
BAT 72.
In order to reduce CO and PAH emissions to air from both from pots and the
pot room in primary aluminium production using Soderberg technology, BAT is to
combust the CO and the PAHs in the cell exhaust gas. (based on Section 4.3.3.3)
11.3.4.2
Waste water generationtreatment and reuse
BAT 73.
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. (based on
Section 4.2.3.3)
Applicability
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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.
11.3.4.3
Waste
BAT 74.
In order to reduce the disposal of spent pot lining, BAT is to organise
operations on the site so as to facilitate its external recycling, including using one or a
combination of the following techniques given below. (based on Section 4.3.3.9)
a
b
Technique
Use of spent pot lining in cement
manufacturing
Use of spent pot lining as a carburiser in steel
or ferro-alloy industry
Applicability
ApplicableApplicability
may
be
restricted
depending on the end consumer´s requirements
Use of spent pot lining as a secondary raw
material (rock wool, salt slag recovery, etc.)
c
11.3.5
11.3.5.1
BAT conclusions for secondary aluminium production
Secondary materials
BAT 75.
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
following techniques given below depending on the constituents of the treated materials.
(based on Section 4.3.4.2)
a
b
c
Technique
Magnetic separation for the separation of
ferric metals
Eddy current separation for the separation of
aluminium from the other constituents
Relative density separation for the
separation of different metals and non-metal
constituents
Applicability
Generally applicable for the separation of ferric
metals
Generally applicable for the separation of
aluminium from the other constituents
Generally applicable for the separation of
different metals and non-metal constituents
Description
BAT 75 (a): A magnetic force is applied in order to separate iron from other materials.
BAT 75 (b): Moving electromagnetic fields are used to separate aluminium from other
materials.
BAT 75 (c): The differences in densities of the various materials are used to separate them. This
is achieved using a fluid with a different density.
11.3.5.2
Energy
BAT 76.
In order to use energy efficiently, BAT is to use one or a combination of the
following techniques given below. (based on Sections 4.3.4.3, 4.3.4.5, and 4.3.4.9)
Technique
a
Preheating of the furnace charge by the exhaust off-gas
b
Recirculation of the gases with unburnt hydrocarbons
back into the burner system
c
Supply the liquid metal for direct moulding
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Applicability
Only applicable for non-rotating
furnaces
Only applicable for reverberatory
furnaces and dryers
Applicability is limited by the time
needed
for
the
transportation
(maximum 4 – 5 hours)
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11.3.5.3
Air emissions
BAT 77.
In order to prevent or reduce emissions to air, BAT is to remove oil and
organic compounds from the swarf before the smelting stage by using one or both a
combination of the following techniques given below. (based on Section 4.3.4.3)
a
Technique
Centrifugation
b
Drying
Applicability (1)
Only applicable to highly oil contaminated swarf
Generally applicable. For swarf highly contaminated
centrifugation is applied before the drying
by
oil,
(1) The removal of oil and organic compounds may not be needed where the furnace and the abatement system are
designed to handle the organic material.
Description
BAT 77 (a): Centrifugation is a mechanical method to separate the oil from the swarf. To
increase the velocity of the sedimentation process, a centrifugation force is applied to the swarf
and the oil is separated.
BAT 77 (b): The swarf drying process uses a rotary drum heated indirectly. To remove the oil, a
pyrolytic process takes place at a temperature between 300 and 400 °C.
11.3.5.3.1
Diffuse emissions
BAT 78.
In order to prevent or reduce diffuse emissions from the pretreatment of
scraps, BAT is to use one or both a combination of the following techniques given below.
(based on Sections 4.3.4.2 and 4.3.4.3)
a
b
Technique
Closed or pneumatic conveyor, with an air extraction system
Closure or hoods for the charging and for the discharge points, with an air extraction system
BAT 79.
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
following techniques given below. (based on Section 4.3.4.5)
c
Technique
Placing a hood on top of the furnace door and at the
tapping hole with off-gases extraction connected to a
filtration system
Fume collection enclosure that covers both the
charging and tapping zones
Sealed furnace door
d
Sealed charging carriage
e
Boosted suction system that can be modified according
to the process needed
a
b
Applicability
Generally applicable
Only applicable for stationary drum
furnaces
Generally applicable
Only applicable at non-rotating
furnaces
Generally applicable
Description
BAT 79 (a) and (b): Consists in applying a covering with extraction to collect and handle the
off-gases coming from the process.
BAT 79 (c): The furnace door is designed to provide efficient sealing to avoid the escaping of
diffuse emissions and to maintain the positive pressure inside the furnace during the smelting
stage.
BAT 79 (d): The skip seals against the open furnace door during the discharge of scrap and
maintains furnace sealing during this stage.
BAT 79 (e): The boosted suction system is designed to modify the extraction fan capacity based
on the sources of the fumes that change over the charging, melting and tapping cycles.
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Automated control of the burner rate during charging is also applied to ensure a minimum gas
flow during operations with the door opened.
BAT 80.
In order to reduce diffuse emissions from launders and casters, BAT is to use
a fume extraction system. (based on Section 4.3.4.10)
Description
A fume extraction system is a combination of equipment designed for the effective collection of
the emissions coming from a process.
Applicability
Applicable for the online refinery system.
Note for TWG: more precise figures on the applicability issue are needed
BAT 81.
In order to reduce the emissions from skimming/dross treatment, BAT is to
use one or a combination of the following techniques given below. (based on Section
4.3.4.11)
a
b
c
Technique
Cooling of skimming/dross, as soon as they are skimmed from the furnace, in sealed
containers under inert gas
Prevention of wetting of the skimming/dross
Compaction of skimming/dross with an air extraction and dust abatement system.
Description
BAT 81 (a): The use of a sealed container and inert gas blanket avoids contact of the
skimming/dross with the air moisture, that otherwise could cause the release of gaseous
emissions and aluminium loss.
BAT 81 (b): Skimming/dross reacts with the water to produce ammonia and other gases.
BAT 81 (c): Compressing the skimming/dross reduces the air surface exposure and the relative
emissions.
11.3.5.3.2
Channelled dust emissions
BAT 82.
In order to reduce dust emissions from the storage, handling and transport in
secondary aluminium production, BAT is to use a bag filter. (based in Section 4.3.4.1)
BAT-associated emission levels
See Table 11.29.
Table 11.29: BAT-associated emission levels for dust from storage, handling and transport
operations in secondary aluminium production
Parameter
Dust
BAT-AEL(1)
≤5
Unit
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 57
BAT 83.
In order to reduce dust and metal emissions to air from the crushing, milling
and dry separation of non-metallic constituents and metals other than aluminium, BAT is
to use a bag filter. (based on Section 4.3.4.2)
BAT-associated emission levels
See Table 11.30.
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Table 11.30: BAT-associated emission levels for dust emissions to air from crushing, milling and
dry separation of non-metallic constituents and metals other than aluminium
Parameter
Dust
BAT-AEL (1)
≤5
Unit
mg/Nm3
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 57
BAT 84.
In order to reduce dust and metal emissions to air from drying and the
removal of oil and organic compounds from the swarf, BAT is to use a bag filter. (based on
Section 4.3.4.3)
BAT-associated emission levels
See Table 11.31.
Table 11.31: BAT-associated emission levels for dust emissions to air from drying and the removal
of oil and organic compounds from the swarf
Parameter
Dust
BAT-AEL (1)
≤5
Unit
mg/Nm3
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 57.
BAT 85.
In order to reduce dust and metal emissions to air from furnace processes
such as charging, melting, remelting, tapping and molten metal treatment in secondary
aluminium production, BAT is to use a bag filter. (based on Sections 4.3.4.6 and 4.3.4.9)
BAT-associated emission levels
See Table 11.32.
Table 11.32: 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
Dust
BAT-AEL (1)
2–5
Unit
mg/Nm3
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 57.
BAT 86.
In order to reduce dust and metal emissions to air from the remelting, molten
metal treatment and casting operations in secondary aluminium production, BAT is to use
one or a combination of the techniques given below.a bag filter. (based on Section 4.3.4.10)
a
b
c
Technique
Use of uncontaminated aluminium material
Combustion conditions optimised for the reduction of dust
Bag filter
Description
BAT 86(a): Uncontaminated aluminium material means solid material free of substances such
as paint, plastic or oil (e.g. billets).
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BAT-associated emission level
See Table 11.33
Table 11.33: BAT-associated emission levels for dust from the remelting, molten metal treatment
and casting operations in secondary aluminium production
Parameter
Unit
BAT-AEL (1) (2)
3
Dust
mg/Nm
2–5
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
(2) For furnaces designed and using only uncontaminated raw material, for which dust emissions are
below 1 kg/h, the upper end of the BAT-AEL is 25 mg/Nm3 as an average of the samples obtained over
a year.
11.3.5.3.3
Organic compound emissions
BAT 87.
In order to reduce the emissions to air of organic compounds emissions and
PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g. swarf)
drying of swarf and the melting furnace, BAT is to use a bag filter in combination with
one or a combination of the following techniques given below together with. (based on
Sections 4.3.4.7 and 4.3.4.8)
a
b
c
d
e
Technique
Select and feed the ion of raw material
according to the furnace and the
abatement techniques used
Internal burner system
Afterburner (1)
Rapid quenching (1)
Activated carbon injection (1)
Applicability
Generally applicable
Only applicable for in case of melting furnaces
Generally applicable
Generally applicable
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 87 (a): The raw materials are should be selected in such a way that the contaminants
contained in the feeding could be treated properly by the furnace and the abatement system used
to achieve improve the required environmental abatement performance.
BAT 87 (b): The exhaust off-gas is directed through the burner flame and the organic carbon is
converted with oxygen to CO2.
BAT-associated emission levels
See Table 11.34
Table 11.34: BAT-associated emission levels for emissions to air of organic compounds and
PCDD/F from the thermal treatment of contaminated secondary raw materials (e.g.
swarf) drying of swarf and the melting furnace
Parameter
TVOC as C
PCDD/F
Unit
mg/Nm3
ng I-TEQ/Nm³
BAT-AEL
≤ 10 – 30 (1)
≤ 0.1 (2)
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour)
(2) As an average over the a sampling period (periodic measurements of at least six hours.)
The associated monitoring is in BAT 57.
11.3.5.3.4
Acid emissions
BAT 88.
In order to reduce the emissions to air of HCl, Cl2 and HF from the thermal
treatment of contaminated secondary raw materials (e.g. swarf) drying of swarf, melting
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furnace, remelting and molten metal treatment and casting, BAT is to use one or a
combination of the following techniques given below. (based on Sections 4.3.4.7 and
4.3.4.8)
Technique
Select and feed the ion of raw material according to the
furnace and the abatement techniques used
Ca(OH)2 or sodium bicarbonate injection in
combination with a bag filter (1)
Control of the refining process adapting the quantity of
refining gas used to remove the contaminants present
into the molten metals
a
b
c
d
Use of a mix of dilute chlorine with and inert gas
Applicability
Generally applicable
Generally applicable
Generally applicable for the refining
process
Generally Only applicable for the
refining process
(1) Description of the technique is given in Section 11.10
Description
BAT 88 (a): The raw material is selected in such a way that the contaminants contained in the
feeding can be treated properly by the furnace and the abatement system used to improve
achieve the required environmental performance.
BAT 88 (c): The blowing of refining gas can be adapted according to the amount of
contaminants present in the molten metal.
BAT 88 (d): Using chlorine with inert gas instead of just pure chlorine, to reduce the emission
of this gas. The inert gas itself could also be used.
BAT-associated emission levels
See Table 11.35
Table 11.35: BAT-associated emission levels for HCl, Cl2 and HF emissions to air from the thermal
treatment of contaminated secondary raw materials (e.g. swarf) drying of swarf,
melting furnace, remelting and molten metal treatment and casting
Parameter
HCl
Cl2
HF
Unit
mg/Nm3
mg/Nm3
mg/Nm3
BAT-AEL
≤ 5 – 10 (1)
≤ 1 (2) (3)
≤ 1 2 (4)
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour). For refining, the BAT-AEL refers to the average concentration during
chlorination. For refining, the monitoring of the emissions is should be carried out during the chlorination.
(2) As an average over the sampling period (periodic measurements of at least half hours). For refining, the BATAEL refers to the average concentration during chlorination.For refining, the monitoring of the emissions is should
be carried out during the chlorination.
(3) The chlorine emissions are related to refining processes carried out with chemicals containing chlorine.
(4) As an average over the sampling period (periodic measurements of at least three half hours).
The associated monitoring is in BAT 57.
11.3.5.4
Waste
BAT 89.
In order to reduce the quantities of waste sent for disposal from secondary
aluminium process production, BAT is to organise operations on the site so as to facilitate
process residues waste reuse or, failing that, process residues waste recycling, including
one or a combination of the following techniques given below. (based on Sections 4.3.4.4,
4.3.4.11 and 4.3.5.1)
Technique
a
1130
Applicability
Generally Only applicable for the
melting furnace using salt or salt slag
recovery process
Reuse collected dust in the process
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b
c
Fully recycling of the salt slag
Appling skimming/dross treatment
aluminium
to
recover
Generally applicable
Generally applicable for furnaces that do
not use salt cover
BAT 90.
In order to reduce the quantities of salt slag produced from secondary
aluminium production, BAT is to use one or a combination of the following techniques
given below. (based on Sections 4.3.4.2, 4.3.4.3, 4.3.4.11 and 4.3.4.12.2)
a
b
Technique
Increase the quality of raw material used through
the separation of the non-metallic constituents and
metals other than aluminium
Remove oil and organic constituents from swarf
before melting
c
Metal pumping or stirring
d
The tilting rotary furnaces
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Applicability
Only applicable for scraps where aluminium
is mixed with other constituents
Only applicable to a contaminated swarf
Only Not applicable for rotary reverberatory
furnaces
Generally applicable to new furnaces. There
are restrictions on the use of this furnace
due to the size of the feed materials. For
example, only small raw materials, such as
used beverage cans (UBC) or shredded
scraps, may be fed
July 2014
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11.3.6
11.3.6.1
BAT conclusion for the salt slag recycling process
Diffuse emissions
BAT 91.
In order to prevent or reduce diffuse emissions from the salt slag recycling
process, BAT is to use one or both a combination of the following techniques given below.
(based on Section 4.3.4.12.2)
Technique (1)
Enclose equipment with gas extraction connected to a
a
filtration system
Hood with gas extraction connected to a filtration
b
system.
(1) Descriptions of the techniques are given in Section 14.10.
11.3.6.2
Applicability
Generally applicable
Generally applicable
Channelled dust emissions
BAT 92.
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. (based on
Section 4.3.5.3.1)
Applicability
Generally applicable
BAT-associated emission levels
See Table 11.36
Table 11.36: BAT-associated emission levels for dust emissions to air from crushing and dry
milling associated with the salt slag recovery process
Parameter
Dust
BAT-AEL(1)
2–5
Unit
mg/Nm3
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 57.
11.3.6.3
Gaseous compounds
BAT 93.
In order to reduce gaseous emissions to air from wet milling and from the
leaching from the salt slag recovery process, BAT is to use one or a combination of the
following techniques given below. (based on Sections 4.3.5.3.2, 4.3.5.3.3 and 4.3.5.3.4 )
a
b
c
Technique (1)
Activated carbon injection
Afterburner
Wet scrubber with H2SO4 solution
Applicability
Generally applicable
Generally applicable
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10
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BAT-associated emission levels
See Table 11.37.
Table 11.37: BAT-associated emission levels for gaseous emissions to air from wet milling and from
the leaching from the salt slag recovery process
Parameter
NH3
PH3
H2S
Cl2 as HCl
Unit
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
BAT-AEL (1)
≤ 10
≤ 0.5
≤2
≤ 10
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 57.
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Chapter 11
11.4
BAT conclusions for lead and tin production
11.4.1
Monitoring
BAT 4 and 5 do not apply to the lead and tin sectors.
11.4.1.1
Monitoring of emissions to air
BAT 94.
BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
a
b
c
d
e
f
Standard(s)
Minimum monitoring
frequency (1)
EN 13284- 2
Continuous
EN 13284-1
Periodic (at least three
consecutive measurements
once per year)
104, 105, 106, 107, 108,
109
EN 14385
Periodic (at least once per
year)
108, 109
EN 14385
Periodic (at least once per
year)
108, 109
EN 14385
Periodic (at least once per
year)
104, 105, 106, 107, 108,
109
EN 14385
Periodic (at least once per
year)
108, 109
2
Dust ( )
Antimony and its
compounds,
expressed as Sb
Arsenic and its
compounds,
expressed as As
Cadmium and its
compounds,
expressed as Cd
Copper and its
compounds,
expressed as Cu
Lead and its
compounds,
expressed as Pb
EN 14385
g
Mercury and its
compounds,
expressed as Hg
EN 13211
h
Other metals, if
relevant (3)
Antimony and its
compounds
expressed as Sb
EN 14385
i
SOX expressed as
SO2
j
NOX, expressed
as NO2 (3)
EN 14792
k
TVOC
EN 12619
EN 13526
l
PCDD/F
EN 1948 part 1,
2, 3 and 5
1134
EN 14791
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Periodic (at least one
measurement once per year)
July 2014
Monitoring associated
with BAT
104, 105, 106, 107, 108,
109
104, 105, 106, 107, 108,
109
11
11
104, 105, 106, 107, 108,
109
9, 10, 111
111
12
12
110
110
112
MR/GC/EIPPCB/NFM_Draft_3
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement
is not applicable, more frequent periodic monitoring is performed. More frequent monitoring (including the choice
between continuous or periodic measurement) should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant and type of raw
materials used.
(2) For small sources (< 10 000 Nm³/h) of dust emission from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used. (3) For furnaces using oxygen
enriched burners, the emissions are expressed in terms of grams of NOx emitted per tonne of melted metal
produced, as an average over the sampling period for the continuous smelter/melter process. For the batch
smelter/melter process, the emissions are expressed as an average of all the batch process operations.
11.4.1.2
Monitoring of emissions to water
BAT 95.
BAT is to monitor the emissions to, before the discharge of the waste water
into the receiving water at the point where the emissions leaves the installation, of the
parameters mentioned in the following table with at least the minimum 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
Standard(s)
a
b
c
d
e
f
g
As
Cd
Cu
Fe
Ni
Pb
Zn
EN ISO 11885
EN ISO 17294-2
h
Hg
i
SO42-
j
k
Sb
Sn
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
EN ISO 10304-1
No EN or ISO
standard available
EN ISO 11885
EN ISO 17294-2
Minimum Monitoring frequency
(1)
Monitoring associated
with
At least once a month
BAT 14
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability. While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media, the load of metals present in the waste
water.
11.4.2
Energy
BAT 96.
In order to use energy efficiently in the production process, BAT is to use a
boiler to recover energy from the furnaces off-gases. (based on Section 5.3.8.1)
Applicability
Generally applicable in primary production processes and in secondary smelting and refining
operations.
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Chapter 11
11.4.3
11.4.3.1
Air emissions
Diffuse emissions
BAT 97.
In order to prevent or reduce diffuse emissions from material 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
following techniques given below. (based on Section 5.3.2.1)
a
b
c
d
e
Technique
Enclosed conveyer or pneumatic transfer system
for dusty material
Enclosed equipment. When dusty materials are
used the emissions are collected and sent to an
abatement system
Mixing of raw materials carried out in enclosed
building
Dust suppression systems such as water sprays
Pelletisation of raw materials
Applicability
Generally applicable Applicable for dusty
materials
Only applicable for feed blends prepared with
a dosing bin or loss-in-weight system
Only applicable for dusty materials. For
existing plants, application may be difficult
due to the space required
Only applicable for mixing carried out
outdoors
Only applicable only when the process and
the furnace can use pelletised raw materials
BAT 98.
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 of primary and secondary materials lead and tin production,
BAT is to use one or both a combination of the following techniques given below. (based
on Sections 5.3.2.2, 5.3.2.3, and 5.3.2.4)
a
b
Technique
Enclosed conveyer or pneumatic transfer system
for dusty material
Enclosed equipment. When dusty materials are
used the emissions are collected and sent to an
abatement system with gas extraction system.
Applicability
Applicable for dusty materials
Generally applicable
BAT 99.
In order to prevent or reduce diffuse emissions from dismantling, sintering,
roasting, briquetting and pelletising of primary and secondary materials, BAT is to use the
following techniques: (based on Section 5.3.2.3)
a
b
Technique
Applicability
Enclosed conveyer or pneumatic transfer
Applicable for dusty materials
system
Encapsulated equipment with gas extraction
Generally applicable
system
BAT 100. In order to prevent or reduce diffuse emissions from battery crushing,
screening and classifying operations, BAT is to use enclosed equipment with a gas
extraction system. (based on Section 5.3.2.4)
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BAT 101. In order to prevent or reduce diffuse emission from charging, smelting,
tapping and pre-decoppering operations in primary lead production, BAT is to use a
combination of the following techniques given below. (based on Sections 5.3.3.1 and
5.3.3.2)
a
b
Technique
Encapsulated charging system such as double bell,
closed conveyers and feeders, equipped with a gas
extraction system
Sealed or enclosed furnaces with door sealing
ef
Furnace and gas routes operating under negative
pressure and a sufficient gas extraction rate to prevent
the pressurisation
Capture hood/enclosures at charging and tapping points
Tertiary fume collection such as a "house-in-house"
system
Enclosed building
fg
Complete hood coverage with a gas extraction system
gh
Maintain furnace sealing
Maintain the temperature in the furnace at the lowest
required level
A gas extraction system for charging and tapping area
connected with to a filtration system
c
d
e
hi
ij
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July 2014
Applicability
Generally applicable
Generally The door sealing is
applicable only for processes with a
discontinuous feed and output
Generally applicable
Generally applicable
Applicable for new plants or major
upgrade of existing plants
Generally applicable
Generally Applicable for new plants.
In existing plants or major upgrades
of existing plants, application may
be difficult due to the space
requirements
Generally applicable
Generally applicable
Generally applicable
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Chapter 11
BAT 102. In order to prevent or reduce diffuse emissions from charging, smelting and
tapping operation in secondary lead and tin production, BAT is to use one or a
combination of the following techniques given below. (based on Section 5.3.4.1)
a
b
Technique
Encapsulated charging system with a gas extraction
system
Sealed or enclosed furnaces with door sealing
ef
Furnace and gas routes operating under negative
pressure and a sufficient gas extraction rate to prevent
the pressurisation
Capture hood/enclosures at charging and tapping
points
Tertiary fume collection such as a "house-in-house"
system
Enclosed building
fg
Complete hood coverage with a gas extraction system
gh
Maintain furnace sealing
Maintain the temperature in the furnace at the lowest
required level
Applying hood at the tapping point, ladles and
drossing area with a gas extraction system
c
d
e
hi
ij
jk
Pretreatment of dusty raw material, such as
pelletisation
kl
Applying a dog house for ladles during tapping
Applicability
Generally applicable
Generally The door sealing is only
applicable for processes with a
discontinuous feed and output
Generally applicable
Generally applicable
Applicable for new plants or major
upgrade of existing plants
Generally applicable
Generally Applicable for new plants. In
existing plants or major upgrades of
existing plants, application may be
difficult due to the space requirements
Generally applicable
Generally applicable
Generally applicable
Applicable only when the process and
the furnace can use pelletised raw
materials
Generally applicable
BAT 103. In order to prevent or reduce diffuse emissions from remelting, refining and
casting in primary and secondary lead and tin production, BAT is to use a combination of
the following techniques given below. (based on Sections 5.3.3.1 and 5.3.4.1)
a
b
c
d
e
1138
Technique
Hood on the crucible furnace or kettle with a gas extraction system
Lids to close the kettle during the refining reactions and addition of chemicals
Hood with gas extraction system at launders and tapping points
Temperature control of the melt
Closed mechanical skimmers for removal of dusty dross/residues
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11.4.3.2
Channelled dust emissions
BAT 104. In order to reduce dust and metal emissions to air from raw materials
preparation (such as reception, handling, storage, metering, mixing, blending, drying,
crushing, cutting and screening) in primary and secondary lead and tin production, BAT
is to use a bag filter. (based on Sections 5.3.1 and 5.3.2,)
BAT-associated emission levels
See Table 11.38
Table 11.38: BAT-associated emission levels for dust emissions to air from raw materials
preparation reception, handling, storage, metering, mixing, blending, crushing,
cutting and screening in primary and secondary lead and tin production
Parameter
Dust
Unit
mg/Nm³
BAT-AEL (1)
≤5
(1) As a daily average or as an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 94
BAT 105. In order to reduce dust emissions from the drying of raw materials in primary
and secondary lead and tin production, BAT is to use a bag filter. (based on Section
5.3.2.2)
BAT-associated emission levels
See Table 11.39
Table 11.39: BAT-associated emission levels for dust from the drying of raw materials in primary
and secondary lead and tin production
Parameter
Dust
Unit
mg/Nm³
BAT-AEL (1)
≤5
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
BAT 106. In order to reduce dust emissions from dismantling, sintering, roasting,
briquetting and pelletising of raw materials in primary and secondary lead and tin
production, BAT is to use a bag filter. (based on Section 5.3.2.3)
BAT-associated emission levels
See Table 11.40
Table 11.40: BAT-associated emission levels for dust from dismantling, sintering, roasting,
briquetting and pelletising of raw materials in primary and secondary lead and tin
production
Parameter
Dust
Unit
mg/Nm³
BAT-AEL (1)
≤5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
BAT 107. 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. one of
the following techniques: (see Section 5.3.2.4)
Technique (1)
a
b
Bag filter
Wet scrubber
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Chapter 11
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.41.
Table 11.41:
BAT-associated emission levels for dust emissions to air from battery preparation
(crushing, screening and classifying)
Parameter
Unit
BAT-AEL (1)
Dust
mg/Nm³
≤5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
The associated monitoring is in BAT 94.
BAT 108. In order to reduce dust and metal emissions to air other than those that are
sent to the sulphuric acid or liquid SO2 plant from charging, smelting and tapping in
primary and secondary lead and tin production smelters, BAT is to use a bag filter. one or
a combination of the following techniques: (based on Sections 5.3.3.1, 5.3.4.1, and 5.3.4.2)
Techniques (1)
a
Bag filter
b
Wet ESP
c
Dry ESP
1
( ) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.42.
Table 11.42: BAT-associated emission levels for dust and lead emissions to air and lead other than
those that are sent to the sulphuric acid or liquid SO2 plant from charging, smelting
and tapping in primary and secondary lead and tin production smelter
Parameter
Dust
Pb
BAT-AEL(1)
2 – 4 (1) (2) ≤ 5
≤ 1 (3) 1 – 3 (2) (3)
Unit
mg/Nm³
mg/Nm³
(1) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of copper, arsenic
and cadmium are above the following: 1 mg/Nm3 for copper, and 0.05 mg/Nm3 for arsenic and cadmium.
(2) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) The emission of Pb highly depends on the raw materials used.
(3) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 94.
BAT 109. In order to reduce dust and metal emissions to air from remelting, refining
and casting in primary and secondary lead and tin production, BAT is to use a
combination of the following techniques given below. (based on Section 5.3.5.1)
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.
a
b
c
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Techniques
Maintaining the temperature of the melt bath at the lowest possible level according to the
process stage
Bag filter (1)
Wet scrubber for the hydrometallurgical process to treat gases with saturated water content (1)
July 2014
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(1) Description of the technique is given in Section 11.10.
BAT-associated emission levels
See Table 11.43.
Table 11.43: BAT-associated emission levels for dust and lead emissions to air, lead and antimony
from remelting, refining and casting in primary and secondary lead production
Parameter
Dust
Pb
Sb
BAT-AEL (1)
2 – 4 (1) (2) ≤ 5 (1)
≤ 1 ( 3)
≤ 1(2)
Unit
mg/Nm³
mg/Nm³
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of copper, arsenic,
cadmium and antimony are above the following: 1 mg/Nm3 for copper and antimony, and 0.05 mg/Nm3 for arsenic
and cadmium.
(3) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 94.
11.4.3.3
Organic compound emissions
BAT 110. In order to reduce emissions of organic compounds to air from the raw
material drying and smelting process in secondary lead and tin production, BAT is to use
an afterburner one or a combination of the techniques given below. (based on Sections,
5.3.2.2, 5.3.4.4, 5.3.4.5 and 5.3.4.6)
a
b
c
Technique
Select and feed the raw material
according to the furnace and the
abatement techniques used
Optimise combustion conditions for the
abatement reduction of emissions of
organic compounds
Afterburner or regenerative afterburner
(1)
Applicability
Generally applicable
Generally applicable
The applicability is restricted by the energy content of
the off-gases that need to be treated. Off-gases with a
lower energy content lead to a higher use of fuels,
which implies an increase in the cross-media effects
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 110 (a): The raw materials should be selected in such a way that the furnace and the
abatement system used to achieve the required environmental performance could properly treat
the contaminants contained in the feed.
BAT 110 (b): Improvements to the combustion conditions can include the use of enriched air or
pure oxygen, enhanced or improved mixing of oxygen with combustibles, and raising of the
combustion temperature or residence time at high temperatures.
BAT-associated emission levels
See Table 11.44.
Table 11.44: BAT-associated emission levels for organic compound emissions to air from the raw
material drying and smelting process in secondary lead production
Parameter
TVOC as C
Unit
mg/Nm³
BAT-AEL (1)
10 – 40 ≤ 10 20 – 50
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 94.
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Chapter 11
11.4.3.4
SO2 emissions
BAT 111. In order to prevent or reduce emissions of SO2 emissions to air in off-gases
other than those that are sent to the sulphuric acid or liquid SO2 plant with a low SO2
content ( < 1 % v/v SO2) from the charging, smelting and tapping in primary and
secondary lead and tin production smelting process, BAT is to use one or a combination of
the following techniques given below. (based on Sections 5.3.2.5, 5.3.3.1 and 5.3.4.3 )
Technique
a
Alkaline leaching
b
Dry or semi-dry scrubber (1)
c
Wet scrubber (1)
d
Fixation of sulphur in the smelt phase
Applicability
Only applicable for material that contains sulphur in
the form of sulphate
Generally applicable. Generally Applicable to new
plants. For existing plants, lime injection cannot be
applied without retrofitting the existing abatement
system when temperature, moisture content and contact
time are not sufficient and the existing filter capacity
cannot take the additional dust load
Applicability of the wet scrubber may be limited in the
following cases:
- very high off-gas flow rates (e.g. >100 000 Nm3/h):
due to the cross-media effects (significant amounts of
waste and waste water);
- in arid areas by the large volume of water necessary
and the need for waste water treatment and the related
cross-media effects
Applicable to new plants. For existing plants,
applicability may be restricted applicable if the waste
water treatment plant cannot could treat the pollutant
present into the scrubber´s effluent and the resulting
water cannot be recycled to the process or discharged
Only applicable for secondary lead production
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 111 (a): Alkaline leaching uses an alkali salt solution to remove sulphates from secondary
materials prior to smelting.
BAT 111 (d): Iron or and soda (Na2CO3) in the smelters react with the sulphur contained in the
raw materials to form Na2S-FeS slag a matte, such as iron sulphate. This prevents the formation
of SO2 and hence its emission.
BAT-associated emission levels
See Table 11.45.
Table 11.45: BAT-associated emission levels for SO2 emissions to air in off-gases other than those
that are sent to the sulphuric acid or liquid SO2 plant or power plant with a low SO2
content ( < 1 % v/v SO2) from charging, smelting and tapping in primary and
secondary lead and tin production smelting process
Parameter
SO2
BAT-AEL (1) (2)
50 – 350 200 – 500
Unit
mg/Nm³
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
(2) When wet scrubbers are not applicable, the upper end of the BAT-AEL is 500 mg/Nm3. Within the lower and
the upper ends of the range, the achievable emissions depend on the content of S in the raw materials/concentrate
and fuel used, the techniques applied and if the plant is an existing one, an upgraded one or a new one. The lower
end of the range is associated with the use of secondary lead production raw materials with low sulphur content.
The upper end of the range is associated with the use of only secondary techniques.
The associated monitoring is in BAT 94.
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11.4.3.5
PCDD/F emissions
BAT 112. In order to reduce PCDD/F emissions to air from the smelting of secondary
lead and tin raw materials, BAT is to use one or a combination of the following techniques
given below. (based on Sections 5.3.4.4, 5.3.4.5 and 5.3.4.6)
a
b
c
d
e
f
g
h
i
j
Technique
Select and feed the tion of raw material
according to the furnace and the
abatement techniques used
Charging systems to add raw materials
in small portions
Internal burner system
Afterburner or regenerative afterburner
(1)
Avoid exhaust systems with high dust
coating at temperatures > 250 °C
Rapid quenching to avoid de novo
PCDD/F synthesis (1)
Injection of absorption agent combined
with a filtration system
Use of efficient dust collection system
Use of oxygen injection in the upper
zone of the furnace
Optimise combustion conditions for the
abatement reduction of emissions of
organic compounds
Applicability
Generally applicable
Only applicable for semi-closed furnace
Only applicable for melting furnace
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 112 (a): The raw materials are should be selected in such a way that the furnace and the
abatement system used to achieve the required environmental performance could properly treat
the contaminants contained in the feed.
BAT 112 (b): Small additions of raw material to a semi-closed furnaces reduce the furnace
cooling during charging.
BAT 112 (c): The exhaust off-gas is directed through the burner flame and the organic carbon is
converted with oxygen to CO2.
BAT 112 (g): and (h) PCDD/F may be absorbed onto dust or a specific absorbent agent such as
activated carbon, and the emissions can then be reduced using high efficient dust filtration.
BAT 112 (j): Improvements to the combustion conditions can include the use of enriched air or
pure oxygen, enhanced or improved mixing of oxygen with combustibles, and raising of the
combustion temperature or residence time at high temperatures.
BAT-associated emission levels
See Table 11.46
Table 11.46: BAT-associated emission levels for PCDD/F emissions to air from the smelting of
secondary lead and tin raw materials
Parameter
Unit
PCDD/F
ng I-TEQ/Nm³
Plant
New or major upgrade
Existing
BAT-AEL (1)
≤ 0.1
0.1 – 0.3
(1) As an average over the a sampling period of (periodic measurements between four and of at least six hours.
The associated monitoring is in BAT 94.
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Chapter 11
11.4.4
Soil and groundwater protection
BAT 113. In order to prevent the contamination of the soil and groundwater from
battery storage, crushing, screening and classifying operations, BAT is to use an acidresistant floor surface and a system for the collection of the acid spillage. (based on Section
5.3.2.4)
11.4.5
Waste water generation and treatment emissions
BAT 114. In order to prevent the generation of waste water from the alkaline leaching
process, BAT is to reuse the water coming from the crystallisation of the alkali salt
solution. (based on Section 5.3.2.4)
Description
In the alkaline leaching process, the water resulting from the crystallisation of sodium sulphate
is reused in the same process for the alkali salt solution.
BAT 115. 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. (based on
Section 5.3.2.4)
11.4.6
Waste
BAT 116. In order to reduce the quantities of waste sent for disposal from primary lead
production, BAT is to organise operations on the site so as to facilitate process residues
waste reuse or, failing that, process residues waste recycling, including one or a
combination of the following techniques given below. (based on Section 5.3.7.1)
a
Technique
Hot ESP dust Reuse of the dust from the dust
removal system in the lead production process
b
Se and Te recovery from wet or dry gas cleaning
dust/sludge
c
Ag, Au, Bi, Sb and Cu, and As recovery from the
refining dross
d
Recovery of metals from the waste water treatment
sludge
e
Addition of flux materials that help the external use
of the slag
Applicability
Generally applicable
Generally The applicability can be
limited by the quantity of mercury
present
Generally applicable for furnaces that do
not use salt to cover the melt
Generally applicable Direct smelting of
the waste water treatment plant sludge
might be limited by the presence of
smelting-disturbing elements such as As,
Tl and Cd
Generally applicable
BAT 116 bis. In order to allow the recovery of the polypropylene and polythylene
content of the lead battery, BAT is to separate it from the batteries prior to smelting.
(based on Section 5.3.7.2)
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.
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BAT 117. In order to reuse or recover the sulphuric acid collected from the battery
recovery process, BAT is to use one or a combination of the following techniques given
below. (based on Section 5.3.7.2)
Technique
a
Pickling agent
b
As raw material in a chemical plant
c
Regeneration of the acid by cracking
d
Production of gypsum
e
Production of sodium sulphate
Applicability
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
Applicable Applicability may be restricted
depending on the local availability of a chemical
plant
Only applicable when sulphuric acid or liquid
sulphur dioxide plant is present
Only applicable if the impurities present in the
recovery acid do not affect the gypsum quality
or gypsum of a lower quality can be used for
other purposes such as a flux agent
Only applicable for the alkaline leaching
process
BAT 118. In order to reduce the quantities of wastes sent for disposal from secondary
lead and tin production, BAT is to organise operations on the site so as to facilitate process
residues waste reuse or, failing that, process residues waste recycling, including one or a
combination of the following techniques given below. (based on Section 5.3.7.3)
a
b
c
Technique
Reuse the residues in the smelting process to recover
lead and other metals
Treat the residues and the wastes in dedicated plants
for material recovery
Treat the residues and the wastes so that they can be
used for other applications
MR/GC/EIPPCB/NFM_Draft_3
July 2014
Applicability
Generally applicable
Generally applicable
Generally applicable
1145
Chapter 11
11.5
BAT conclusions for zinc and cadmium production
11.5.1
Monitoring
BAT 4 and 5 do not apply to the zinc and cadmium sectors.
11.5.1.1
Monitoring of emissions to air
BAT 119. BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
a
c
Mercury and its
compounds,
expressed as Hg
e
f
g
h
EN 13284- 2
Continuous
EN 13284-1
Periodic (at least three
consecutive measurements once
per year)
126, 127, 133, 135,
136, 142, 146
EN 14385
Periodic (at least once per year)
136, 146
11
No EN or ISO
standard available
EN 14385
Continuous
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
EN 14385
Periodic (at least once per year)
126, 133, 135, 136,
142, 146
EN 14791
Continuous
9, 10, 134
Dust ( )
Cadmium and its
compounds,
expressed as Cd
d
Minimum monitoring
frequency (1)
2
b
Zinc and its
compounds,
expressed as Zn
Other metals, if
relevant (3)
SO2x expressed as
SO2
All gaseous
fluorides,
expressed as HF
All gaseous
chlorides,
expressed as HCl
EN 13211
ISO 15713
EN 1911
i
TVOC
EN 12619
EN 13526
j
PCDD/F
EN 1948 part 1, 2,
3 and 5
k
Sum of AsH3 and
SbH3
No EN or ISO
standard available
j
SbH3
No EN or ISO
standard available
l
H2SO4
No EN or ISO
standard available
1146
Monitoring
associated with
BAT
133, 136
Standard(s)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Continuous
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least one
measurement once per year)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least once per year)
July 2014
11
126, 128, 133, 135,
136, 142, 146
138
138
137
137
137
128
128
128
MR/GC/EIPPCB/NFM_Draft_3
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed. More frequent monitoring (including the choice
between continuous or periodic measurements) should may be chosen taking into account based on local
environmental conditions and plant specificities such as mass flow of the pollutant, capacity, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used.
11.5.1.2
Monitoring of emissions to water
BAT 120. BAT is to monitor the emissions to water at the point where the emission
leaves the installation, before the discharge of the waste water into the receiving water, of
the parameters mentioned in the following table with at least the minimum 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
a
b
c
d
e
f
g
As
Cd
Cu
Fe
Ni
Pb
Zn
h
Hg
i
SO42-
Standard(s)
Minimum monitoring
frequency (1)
Monitoring
associated with
EN ISO 11885
EN ISO 17294-2
At least once a month
BAT 14 and 140
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
EN ISO 10304-1
No EN or ISO standard
available
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media, the load of metals present in the waste
water.
11.5.2
Primary zinc production
11.5.2.1
Hydrometallurgical zinc production
11.5.2.1.1
Energy
BAT 121. In order to use energy efficiently, BAT is to recover heat from off-gases
produced in the roaster by using one or a combination of the following techniques given
below. (based on Section 6.3.1.2.9)
Technique
Applicability
Applicable depending
energy prices
a
Using a waste heat boiler and turbines to produce electricity
b
Using a waste heat boiler and turbines to produce mechanical energy
to be used within the process
Generally applicable
c
Using a waste heat boiler to produce heat to be used within the
process and/or for office heating
Generally applicable
11.5.2.1.2
on
Air emissions
MR/GC/EIPPCB/NFM_Draft_3
July 2014
1147
Chapter 11
11.5.2.1.2.1
Diffuse emissions
BAT 122. 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 a combination of the
following techniques given below. (based on Section 6.3.1.2.1)
a
b
Technique
Wet feeding
Completely enclosed process equipment connected to an abatement system
BAT 123. In order to reduce diffuse dust emissions to air from calcine processing, BAT
is to use one or both a combination of the following techniques given below. (based on
Section 6.3.1.2.2)
a
b
Technique
Perform operations under negative pressure
Completely enclosed process equipment connected to an abatement system
BAT 124. 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 following
techniques given below. (based on Sections 6.3.1.2.3 and 6.3.1.2.4)
a
b
c
d
Technique
Cover tanks with a lid
Cover process liquid inlet and outlet launders
Connect tanks to a central mechanical draft
abatement system or to a single tank abatement
system
Cover vacuum filters with hoods and connect them
to an abatement system
Applicability
Generally applicable
Generally applicable
Generally applicable
Only applicable to the filtering of hot liquids in
leaching and solid/liquid separation stages
BAT 125. In order to reduce diffuse mists emissions to air from electrowinning, BAT is
to use additives, especially foaming agents, in the electrowinning cells. (based on Section
6.3.1.2.5.2)
11.5.2.1.2.2
Channelled dust emissions
BAT 126. 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. (based on Sections 6.3.1.1, 6.3.1.2.1 and 6.3.1.2.2)
BAT-associated emission levels
See Table 11.47.
Table 11.47: BAT-associated emission levels for dust emissions to air from the handling and
storage of raw materials, dry roaster feed preparation, dry roaster feeding and calcine
processing
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
≤5
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119.
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BAT 127. In order to reduce dust emissions from roasting, BAT is to use a combination
of the following techniques: (based on Section 6.3.1.2.1)
a
b
c
Technique (1)
Hot ESP with or without cyclones as a first stage
Scrubber
Wet ESP
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.48
Table 11.48:
BAT-associated emission levels for dust from roasting
Parameter
Unit
BAT-AEL (1)
3
Dust
mg/Nm
≤5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
11.5.2.1.2.3
Aerosol and mist emissions
BAT 128. In order to reduce zinc and SO3 sulphuric acid mists emissions to air from
leaching, purification and electrolysis, and to reduce arsane and stibane stibine emissions
from purification, BAT is to use one or a combination of the following techniques given
below. (based on Sections 6.3.1.2.3, 6.3.1.2.4.1 and 6.3.1.2.5.1)
Technique (1)
a
b
c
Applicability
Generally applicable
Generally applicable
Generally applicable
Wet scrubber
Demister
Centrifugal system
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.49.
Table 11.49: BAT-associated emission levels for zinc and SO3 sulphuric acid mist emissions to air
from leaching, purification and electrolysis and arsane and stibane stibine emissions
from purification
Parameter
Zn
H2SO43
Sum of AsH3 and SbH3
SbH3
BAT-AEL (1)
≤1
< 10 - 35
≤ 0.5 0.25
≤ 0.25
Unit
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119
11.5.2.1.3
Soil and groundwater protectioncontamination
BAT 129. In order to prevent soil and groundwater contamination, BAT is to use all of
the following techniques given below. (based on Sections 6.3.1.2.3, 6.3.1.2.4.1 and
6.3.1.2.5.3)
a
b
c
Technique
Watertight bunded area for tanks used during leaching
Safety basins for tanks Watertight bunded area for tanks
used during purification
Secondary containment system of the cell houses
MR/GC/EIPPCB/NFM_Draft_3
July 2014
Applicability
Applicable to the leaching tanks
Applicable to the purification tanks
Applicable to the cell houses
1149
Chapter 11
11.5.2.1.4
Waste water generation
BAT 130. In order to reduce water consumption and prevent the generation of waste
water, BAT is to use a combination of the following techniques given below. (based on
Section 6.3.1.2.6)
a
b
c
Technique
Return of the bleed from the boiler and the water from the closed cooling circuits of the roaster and
the sulphuric acid plant to the wet gas cleaning or the leaching stage
Return of the waste water from cleaning operations/spills of the roaster, the sulphuric acid plant, the
electrolysis and the casting to the leaching stage
Return of the waste water from cleaning operations/spills of the leaching and purification, from the
filter cake washing and the wet gas scrubbing to the leaching and/or purification stages
11.5.2.1.5
Waste
BAT 131. In order to reduce the quantities of waste sent for disposal, BAT is to organise
operations on the site so as to facilitate process residues waste reuse or, failing that,
process residues waste recycling, including one or a combination of the following
techniques given below. (see Section 6.3.1.2.7)
a
b
Technique
Reuse of the dust, collected in the concentrate storage and
handling, within the process (together with the concentrate
feed)
Reuse of the dust collected in the roasting process via the
calcine silo
c
Recycling of residues containing lead and silver wastes as raw
material in an external plant
d
Recycling of residues containing Cu, Co, Ni, Cd, MnMd wastes
as raw material in an external plant to obtain a saleable product
Applicability
Generally applicable
Generally applicable
Applicable depending on local
conditions Applicable depending
on the metal content and on the
availability of a market/process
Applicable depending on local
conditions Applicable depending
on the metal content and on the
availability of a market/process
BAT 132. In order to make the leaching waste suitable for final disposalimprove the
disposal of leaching wastes, BAT is to use one of the following techniques given below. (see
Section 6.3.1.2.8)
Technique
a
Pyrometallurgical
treatment in a Waelz kiln
b
Jarofix process
c
Sulphidation process
d
Compacting iron residues
Applicability
Only applicable to neutral leaching wastes that do not contain too
muchmany zinc ferrites and/or do not contain high concentrations of
precious metals
Only applicable to jarosite iron residues. Limited applicability due to an
existing patent
Only applicable to jarosite iron residues and direct leach residues
Only applicable to goethite residues and gypsum-rich sludge from the
waste water treatment plant
Description
(a) The use of a Waelz furnace to process leaching wastes avoids the long-term storage of
jarosite or goethite.
BAT 132(b): The Jarofix process consists of mixing jarosite precipitates formed during the
leaching of zinc ferrites, with preset ratios of Portland cement, lime and water. This technique
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July 2014
MR/GC/EIPPCB/NFM_Draft_3
allows stabilisation of the jarosite residues in such a way that they can meet the non-hazardous
wastes landfill criteria established in Council Decision 2033/33/CE.
BAT 132(c): The sulphidation process consists of the addition of NaOH and Na2S to the jarosite
precipitates residues in an elutriating tank and in sulphidation reactors. This technique allows
stabilisation of the jarosite residues in such a way that they can meet the hazardous wastes
landfill criteria established in Council Decision 2033/33/CE.
BAT 132(d): Compacting iron residues consists of reducing the moisture content by means of
filters and the addition of lime or other agents.
11.5.2.2
Pyrometallurgical zinc production
11.5.2.2.1
Air emissions
11.5.2.2.1.1
Channelled dust emissions
BAT 133. In order to reduce dust and metal emissions to air other than those that are
sent to the sulphuric acid plant from pyrometallurgical zinc production, BAT is to use a
bag filter. one of the following techniques given below. (based on Section 6.3.1.3.1)
Technique (1)
a
b
Bag filter
Venturi Wet scrubber
(1) Descriptions of the techniques are given in Section .11.10
Applicability
In the event of high organic carbon content in the concentrates (e.g. around 10% w/w), bag
filters might not be applicable due to the blinding of the bags and other techniques (e.g. wet
scrubber) might be used.
BAT-associated emission levels
See Table 11.50.
Table 11.50: BAT-associated emission levels for dust emissions to air other than those that are sent
to the sulphuric acid plant from pyrometallurgical zinc production
Parameter
Dust
BAT-AEL (1) (2)
2 – 5 ≤ 5 – 10
Unit
mg/Nm3
(1) As a daily average or as an average over the sampling period. (periodic measurements of at least half an hour).
(2) When a bag filter is not applicable, the upper end of the BAT-AEL is up to 10 mg/Nm3. The lower end of the
range is associated with the use of a bag filter. The upper end of the range is associated with the use of a venturiwet
scrubber.
The associated monitoring is in BAT 119.
BAT 134. In order to reduce SO2 emissions to air other than those that are sent to the
sulphuric acid plant in off-gases with a low SO2 content (< 1% v/v SO2) from
pyrometallurgical zinc production, BAT is to use a wet desulphurisation technique. semidry scrubber.wet scrubber with lime injection. (based on Section 6.3.1.3.2)
BAT-associated emission levels
See.Table 11.51
Table 11.51: BAT-associated emission levels for SO2 emissions to air other than those that are sent
to the sulphuric acid plant in off-gases with a low SO2 content ( < 1 % v/v SO2) from
pyrometallurgical zinc production
Parameter
SO2
Unit
mg/Nm3
BAT-AEL (1)
≤ 500
(1) As a hourly daily average. for continuous measurements.
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1151
Chapter 11
The associated monitoring is in BAT 119.
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11.5.3
Secondary zinc production
11.5.3.1
Air emissions
11.5.3.1.1
Channelled dust emissions
BAT 135. In order to reduce dust and metal emissions to air from pelletising and slag
processing, BAT is to use a bag filter. (based on Sections 6.3.2.1, 6.3.2.1.1 and 6.3.2.2.2)
BAT-associated emission levels
See Table 11.52.
Table 11.52: BAT-associated emission levels for dust emissions to air from pelletising and slag
processing
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
≤5
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119.
BAT 136. In order to reduce dust and metal emissions to air from the melting of metallic
and mixed metallic/oxidic streams, and from the slag fuming furnaces and the Waelz kilns,
BAT is to use a bag filter. one or both a combination of the following techniques given
below. (based on Sections 6.3.2.1, 6.3.2.2.1 and 6.3.2.2.3.2)
Technique (1)
a
b
Bag filter
ESP
(1) Descriptions of the techniques are given in Section .11.10
Applicability
A bag filter may not be applicable for a clinker operation (where chlorides need to be abated
instead of metal oxides).
BAT-associated emission levels
SeeTable 11.53.
Table 11.53: BAT-associated emission levels for dust emissions to air from the melting of metallic
and mixed metallic/oxidic streams, and from the slag fuming furnaces and the Waelz
kilns
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1) (2) (3)
2–5
(1) As a daily average or as an average over the sampling period. (periodic measurements of at least half an hour).
(2) When a bag filter is not applicable, the upper end of the BAT-AEL may be higher, up to 15 mg/Nm3.
(3) Dust emissions are expected to be towards the lower end of the range when e.g. emissions of arsenic and cadmium
are above 0.05 mg/Nm3.
The associated monitoring is in BAT 119.
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1153
Chapter 11
11.5.3.1.2
Organic compounds emissions
BAT 137. In order to reduce TVOC and PCDD/F emissions to air from the melting of
metallic and mixed metallic/oxidic streams, and from the slag fuming furnaces and the
Waelz kilns, BAT is to use one or a combination of the following techniques given below.
(based on Sections 6.3.2.1, 6.3.2.2.1 and 6.3.2.2.3.2)
b
Technique (1)
Injection of adsorbent (activated carbon or lignite coke) followed
by a bag filter and/or ESP
Thermal oxidiser
c
Regenerative thermal oxidiser
a
Applicability
Generally applicable
Generally applicable
May not be applicable due to
safety reasons
1
( ) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.54
Table 11.54: BAT-associated emission levels for TVOC and PCDD/F emissions to air from the
melting of metallic and mixed metallic/oxidic streams, and from the slag fuming
furnaces and the Waelz kilns
Parameter
TVOC as C
PCDD/F
Unit
mg/Nm3
ng I-TEQ/Nm3
BAT-AEL
2 –20 10 (1)
≤ 0.1 (2)
(1) As a daily average or as an average over the sampling period. (periodic measurements of at least half an hour).
(2) As an average over a sampling period of at least six hours. the sampling period (periodic measurements of at least
six hours).
The associated monitoring is in BAT 119.
11.5.3.1.3
Acidic emissions
BAT 138. In order to reduce acid emissions to air from the melting of metallic and
mixed metallic/oxidic streams, and from the slag fuming furnaces and the Waelz kilns,
BAT is to use one of the following techniques given below. (based on Sections 6.3.2.1
,6.3.2.2.1 and 6.3.2.2.3.2)
Technique (1)
a
Injection of adsorbent (activated carbon or lignite coke) followed by
a bag filter
b
Wet scrubber
Applicability
Generally applicable
Applicable to slag fuming
furnaces
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.55.
Table 11.55: BAT-associated emission levels for acid emissions to air from the melting of metallic
and mixed metallic/oxidic streams, and from the slag fuming furnaces and the Waelz
kilns
Parameter
HCl
HF
Unit
mg/Nm3
mg/Nm3
BAT-AELs (1)
≤ 1.5
≤ 0.3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119.
11.5.3.2
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Waste water generation and treatment
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BAT 139. In order to reduce the consumption of water in the Waelz kiln process, BAT is
to use multiple-stage counter-current washing. (based on Section 6.3.2.2.3.4)
Description
Water coming from a previous washing stage is filtered and reused in the following washing
stage. Two or three stages can be used, allowing up to three times less water consumption in
comparison with a single stage counter-current washing.
Applicability
Generally applicable to Waelz kilns.
BAT 140. In order to prevent or reduce halides emissions to water the avoid the
discharge of waste reduce water emissions to water from the washing stage in the Waelz
kiln process, BAT is to use crystallisation. one or both a combination of the following
techniques given below. (based on Section 6.3.2.2.3.5)
a
b
Technique
Crystallisation
Chemical precipitation, followed by filtration and a neutralisation step
Description
BAT 140(a): Crystallisation is a solid-liquid separation technique, in which a mass transfer of a
solute from the liquid solution to a solid crystalline phase occurs, allowing in this case the
production of a salt residue, and an alkali-free condensate from the waste water generated by the
washing of the Waelz oxides. In the crystallisation step, the total amount of halogens is
removed, avoiding waste water discharges.
(b) Sulphur containing additions, coagulants and flocculants are added in order to precipitate
dissolved metals. After a filtration and neutralisation step, the treated effluent is discharged.
BAT-associated emission levels
The BAT-associated emission levels for direct emissions to a receiving water body are given in
Table 11.56. These BAT-AELs apply at the point where the emission leaves the installation.
Table 11.56: BAT-associated emission levels for water direct emission to a receiving water body
from the washing stage in the Waelz kiln process
Parameter
Zn
Pb
Cd
As
Unit
mg/l
mg/l
mg/l
mg/l
BAT-AEL (1)
≤ 0.5
≤ 0.1
≤ 0.05
≤ 0.2
(1) As a daily average. based on 24-hours flow-proportional composite samples.
The associated monitoring is in BAT 120.
11.5.4
Melting, alloying and casting of zinc ingots and zinc powder
production
11.5.4.1
Air emissions
11.5.4.1.1
Diffuse dust emissions
BAT 141. In order to reduce diffuse dust emissions to air from the melting, alloying and
casting of zinc ingots, BAT is to use equipment under negative pressure. (based on Section
6.3.3.1)
11.5.4.1.2
Channelled dust emissions
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Chapter 11
BAT 142. In order to reduce dust and metal emissions to air from the melting, alloying
and casting of zinc ingots and zinc powder production, BAT is to use a bag filter. (based
on Sections 6.3.1.1, 6.3.1.2.1 and 6.3.1.2.2)
BAT-associated emission levels
See Table 11.57.
Table 11.57: BAT-associated emission levels for dust emissions to air from the melting, alloying
and casting of zinc ingots and zinc powder production
Parameter
Dust
BAT-AEL (1)
≤5
Unit
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119.
11.5.4.2
Waste water
BAT 143. In order to prevent the generation of waste water from the melting and
casting of zinc ingots, BAT is to reuse the cooling water after extracting the heat with
either cooling towers or heat exchangers connected to a secondary circuit.process water in
the cooling towers. (based on Section 6.3.3.3)
11.5.4.3
Waste
BAT 144. In order to reduce the quantities of waste sent for disposal from the melting of
zinc ingots, BAT is to organise operations on the site so as to facilitate process residues
waste reuse or, failing that, process residues waste recycling, including one or both a
combination of the following techniques given below. (based on Section 6.3.3.2)
Technique
a
Use, of the zinc dross and the zinc bearing dust from the melting furnaces, in the roasting furnace or
in the zinc chemicals production process of the oxidised fraction
b
Use, of the metallic fraction of the zinc dross and the metallic dross from cathode casting, in the
melting furnace or recovery as zinc dust or zinc oxide in a zinc refining plant
11.5.5
BAT conclusions for cadmium production
11.5.5.1
Air emissions
11.5.5.1.1
Diffuse emissions
BAT 145. In order to reduce diffuse emissions to air, BAT is to use one or both a
combination of the following techniques given below. (based on Sections 6.3.5.1.1, 6.3.5.2.3
, 6.3.5.2.4 and 6.3.5.3.1)
Technique
a
Central extraction
system connected with
an abatement system
b
Cover cells
1156
Applicability
Only applicable to leaching and solid/liquid separation in
hydrometallurgical production, to briquetting/pelletising, fuming in
pyrometallurgical production and to melting, alloying and casting
processes
Only applicable to the electrolysis stage in hydrometallurgical production
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11.5.5.1.2
Channelled dust emissions
BAT 146. In order to reduce dust and metal emissions to air from pyrometallurgical
cadmium production and the melting, alloying and casting of cadmium ingots, BAT is to
use one or a combination of the following techniques given below. (based on Sections
6.3.5.1.1, 6.3.5.2.3, 6.3.5.2.4 and 6.3.5.3.1)
a
b
Technique (1)
Bag filter
ESP
c
Wet scrubber
Applicability
Generally applicable
Generally applicable
Applicability of the wet scrubber may be limited in the following cases:
- very high off-gas flow rates: due to the cross-media effects (significant amounts
of waste and waste water);
- in arid areas by the large volume of water necessary and the need for waste
water treatment and the related cross-media effects
Applicable to new plants. For existing plants, applicability may be restricted
applicable if a suitable the waste water treatment plant is available cannot treat
the pollutant present in the scrubber´s effluent and the resulting water cannot be
recycled to the process or discharged
(1) Descriptions of the techniques are given in Section 11.10.
BAT-associated emission levels
See Table 11.58.
Table 11.58: BAT-associated emission levels for dust and cadmium from pyrometallurgical
cadmium production and the melting, alloying and casting of cadmium ingots
Parameter
Dust
Cd
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
2 –3 ≤ 5
≤ 0.1
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 119.
11.5.5.2
Waste
BAT 147. In order to reduce the quantities of waste sent for disposal from
hydrometallurgical cadmium production, BAT is to organise operations on the site so as to
facilitate process residues waste reuse or, failing that, process residues waste recycling,
including one of the following techniques given below. (based on Section 6.3.5.1.3)
a
b
Technique
Recover the cadmium-rich cementate extracted from the
purification section as marketable cadmium metal or cadmium
compounds
Precipitation of the cadmium-rich cementate
Applicability
Only applicable if an
economically viable demand
exists
Only applicable if suitable
landfill is available
Description
BAT 147(a): The technique consists in extracting the cadmium from the zinc process as a
cadmium-rich cementate in the purification section, further concentrate and refine it (by an
electrolysis or pyrometallurgical process) and finally transform it into marketable cadmium
metal or cadmium compounds.
BAT 147(b): The techniques consists in extracting the cadmium from the zinc process as a
cadmium-rich cement in the purification section, then applying a set of hydrometallurgical
operations in order to eventually transform the cadmium into a cadmium-rich precipitate (e.g.
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cement (Cd metal), Cd(OH)2) that is further landfilled. All other process flows are recycled in
the cadmium plant or in the zinc plant flow.
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11.6
BAT conclusions for precious metals production
11.6.1
Monitoring
BAT 4 and 5 do not apply to the precious metals sector.
11.6.1.1
Monitoring of emissions to air
BAT 148. BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
Standard(s)
EN 13284-2
a
Periodic (at least three
consecutive measurements
once per year)
156
EN 13211
EN 14385
Periodic (at least once per
year)
156
Dust ( )
Other metals, if
relevant (3)
c
SOX expressed
as SO2
d
NOX, expressed
as NO2
e
NH3
f
All gaseous
chlorides,
expressed as
HCl
g
Chlorine,
expressed as Cl2
h
PCDD/F
Monitoring associated
with BAT
156
EN 13284-1
2
b
Minimum monitoring
frequency (1)
Continuous
EN 14791
EN 14792
No EN or ISO
standard
available
Continuous
Periodic (at least three
consecutive measurements
once per year)
Continuous
Periodic (at least three
consecutive measurements
once per year)
Periodic (at least three
consecutive measurements
once per year)
EN 1911
Periodic (at least three
consecutive measurements
once per year)
No EN or ISO
standard
available
EN 1948 part 1,
2, 3and 5
Periodic (at least three
consecutive measurements
once per year)
Periodic (at least one
measurement once per year)
9, 10, 158, 158 bis
158, 158 bis
157
157
160
159
159
161
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed. More frequent monitoring (including the choice
between continuous or periodic measurement) should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used.
11.6.1.2
Monitoring of emissions to water
BAT 149. BAT is to monitor the emissions to water at the point where the emission
leaves the installation, before the discharge of the waste water into the receiving water, of
the parameters mentioned in the following table with at least the minimum frequency
given below and in accordance with EN standards. If EN standards are not available, BAT
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is to use ISO, national or other international standards that ensure the provision of data of
an equivalent scientific quality.
Parameter
a
b
c
d
e
f
g
h
Ag
As
Cd
Cu
Fe
Ni
Pb
Zn
i
Hg
j
SO42-
Minimum monitoring
frequency (1)
Standard(s)
Monitoring associated
with
EN ISO 11885
EN ISO 17294-2
At least once a month
BAT 14
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
EN ISO 10304-1
No EN or ISO standard
available
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media, the load of metals present in the waste
water.
11.6.2
11.6.2.1
Air emissions
Diffuse emissions
BAT 150. In order to reduce diffuse emissions to air from a pretreatment operations
(such as crushing, sieving and mixing), BAT is to use one or a combination all of the
following techniques given below. (based on Section 7.3.1)
Technique
a
Enclose pretreatment areas and transfer systems
Connect pretreatment and handling operations to dust collectors or extractors
via hoods and a duct work system
Electrically interlock pretreatment and handling equipment with their dust
collector or extractor, in order to assure that no equipment may be operated
unless the dust collector and filtering system are in operation
b
c
Applicability
Only applicable to
dusty materials
Only applicable to
dusty materials
Generally
applicable
BAT 151. In order to reduce diffuse emissions to air from smelting and melting (both a
Doré and non-Doré operations), BAT is to use all of the following techniques given below.
(based on Sections 7.3.2 and 7.3.3).
a
b
c
d
Technique
Enclose buildings and/or smelting furnace areas
Perform operations under negative pressure
Connect furnace operations to dust collectors or extractors via hoods and a duct-work system
Electrically interlock furnace equipment with their dust collector or extractor, in order to assure that
no equipment may be operated unless the dust collector and filtering system are in operation
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BAT 152. In order to reduce diffuse emissions to air from leaching and gold electrolysis,
BAT is to use one or a combination of the following techniques given below. (based on
Section 7.3.4)
a
b
c
Technique
Closed tanks/vessels and closed pipes for transfer solutions
Hoods and extraction systems for electrolytic cells
Water curtain
Applicability
Generally applicable
Only applicable to gold electrolysis
Only applicable to gold production
Description
BAT 152(c): This consists of a water wall that can be used to prevent chlorine gas emissions
during the leaching of anode slimes with hydrochloric acid or other solvents.
BAT 153. In order to reduce diffuse emissions from a hydrometallurgical operations,
BAT is to use all of the following techniques given below. (based on Section 7.3.5)
a
b
Technique
Containment measures, such as sealed or enclosed reaction vessels, storage tanks, solvent extraction
equipment and filters, vessels and tanks fitted with level control, closed pipes, sealed drainage
systems, and planned maintenance programmes
Reaction vessels and tanks connected to a common duct work system with off-gas extraction
(automatic stand-by/back-up unit available in case of failure)
BAT 154. In order to reduce diffuse emissions to air from incineration, calcining and
drying operations, BAT is to use all of the following techniques given below. (based on
Section 7.3.6
Technique
a
Connecting all calcining furnaces, incinerators and drying ovens to a duct-work system extracting
process exhaust off-gases
b
Applying electronic control systems, such as having the entire scrubber plant on a priority electricity
circuit which is served by a back-up generator in the event of power failure and operating start-up and
shut-down, spent acid disposal, and fresh acid make-up of scrubbers via an automated control system
BAT 155. In order to reduce diffuse emissions to air from the melting of final metal
products during refining, BAT is to use all of the following techniques given below. (based
on Section 7.3.8)
a
b
Technique
Enclosed furnace with negative pressure
Appropriate housing, enclosures and capture hoods with efficient extraction/ventilation
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11.6.2.2
Channelled dust emissions
BAT 156. In order to reduce dust and metal emissions to air from all dusty operations,
such as crushing, sieving, mixing, melting, smelting, incineration, calcining, drying and
refining, BAT is to use one of the following techniques given below. (based on Sections
7.3.1, 7.3.2, 7.3.3, 7.3.6 and 7.3.8)
Technique (1)
a
Bag filter
b
Wet scrubber in combination with an ESP dedusting
systems (e.g. venturi scrubbers followed by wet ESP)
ESP and wet scrubber
Applicability
May not be applicable for off-gases
containing a high level of volatised selenium
Generally applicable
Only applicable to off-gases containing
volatised selenium Se (e.g. Doré metal
production)
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 156(b): This allows the recovery of selenium.
BAT-associated emission levels
See Table 11.59.
Table 11.59: BAT-associated emission levels for dust emissions to air from all dusty operations,
such as crushing, sieving, mixing, melting, smelting, incineration, calcining, drying
and refining
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
2 –5
(1) As a daily average or as an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 148.
11.6.2.3
NOX emissions
BAT 157. In order to reduce NOX emissions to air from agold electrolysis and
hydrometallurgical operations involving dissolving/leaching with nitric acid, BAT is to use
one or a combinationboth of the following techniques given below. (based on Sections 7.3.4
and 7.3.5)
Technique (1)
Applicability
Applicable
to
gold
electrolysis
hydrometallurgical operations
a
Alkaline scrubber with caustic soda
b
Scrubber with oxidation agents (e.g. oxygen,
hydrogen peroxide) and reducing agents (e.g.
nitric acid, urea) oxygen injection or
hydrogen peroxide and nitric acid or urea
Scrubber containing hydrogen peroxide and
nitric acid
and
Applicable to those specific vessels in
hydrometallurgical operations with the potential to
generate high localised concentrations of NOx. This
technique is always applied in combination with an
alkaline scrubber with caustic soda
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 157(b): This technique is usually applied in those specific vessels in hydrometallurgical
operations with the potential to generate high, localised concentrations of NOX. It is often
applied in combination with an alkaline scrubber with caustic soda.
BAT-associated emissions levels
See Table 11.60.
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Table 11.60: BAT-associated emission level for NOX emissions to air from a hydrometallurgical
operation involving dissolving/leaching with nitric acid
Parameter
NOx
Unit
mg/Nm3
BAT-AEL (1)
70 – 150
(1) As an hourly average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
The associated monitoring is in .BAT 148.
11.6.2.4
SO2 emissions
BAT 158. In order to reduce SO2 emissions to air other than those that are sent to the
sulphuric acid plant from a melting and smelting operations relevant for the production of
Doré metal, hydrometallurgical operations and including the associated incineration,
calcining and drying operations, BAT is to use one or a combination of the following
techniques given below. (based on Section 7.3.3)
Technique (1)
Applicability
Generally applicable. Generally Applicable to new plants. For existing
plants, lime injection cannot be applied without retrofitting the existing
abatement system when temperature, moisture content and contact time
are not sufficient and the existing filter capacity cannot take the additional
dust load
a
Lime injection in
combination with a bag
filter
b
Alkaline scrubber with
caustic soda
Generally applicable
Peroxide Wet scrubber
Applicability of the wet scrubber may be limited in the following cases:
- very high off-gas flow rates: due to the cross-media effects (significant
amounts of waste and waste water);
- in arid areas by the large volume of water necessary and the need for
waste water treatment and the related cross-media effects
Applicable to new plants. For existing plants, applicability may be
restricted if the waste water treatment plant cannot treat the pollutant
present in the scrubber´s effluent and the resulting water cannot be
recycled to the process or discharged
b
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emissions levels
See Table 11.61.
Table 11.61: BAT-associated emission levels for SO2 emissions to air other than those that are sent
to the sulphuric acid plant from a melting and smelting operations relevant for the
production of Doré metal, hydrometallurgical operations and including the associated
incineration, calcining and drying operations
Parameter
SO2
BAT-AEL (1)
50 – 480 ≤100 – 500 (2)200
Unit
mg/Nm3
(1) As a dailyhourly average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a peroxide scrubber.
The associated monitoring is in BAT 148.
BAT 158bis. In order to reduce SO2 emissions to air from a hydrometallurgical
operation, including the associated incineration, calcining and drying operation, BAT is to
use a wet scrubber. an alkaline scrubber with caustic soda. (based on Section 7.3.5)
BAT-associated emissions levels
See Table 14.61bis.
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Table 14.61bis. BAT-associated emission levels for SO2 emissions to air from a hydrometallurgical
operation, including the associated incineration, calcining and drying operation
Parameter
SO2
Unit
mg/Nm3
BAT-AEL (1)
50 – 100
(1) As a daily average or as an average over the sampling period.
The associated monitoring is in BAT 148.
11.6.2.5
HCl and Cl2 emissions
BAT 159. In order to reduce HCl and Cl2 emissions to air from a hydrometallurgical
operations, including the associated incineration, calcining and drying operation, BAT is
to use an alkaline scrubber with caustic soda. (based on Section 7.3.5)
BAT-associated emissions levels
See Table 11.62.
Table 11.62: BAT-associated emission levels for HCl and Cl2 emissions to air from a
hydrometallurgical operations, including the associated incineration, calcining and
drying operation
Parameter
HCl
Cl2
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
≤ 5 – 10 1.5
0.5 – 2 ≤ 3 1.5
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 148.
11.6.2.6
NH3 emissions
BAT 160. In order to reduce NH3 emissions to air from a hydrometallurgical
operationsusing ammonia or ammonium chloride, BAT is to use a wet scrubber with
sulphuric acid. (based on Section 7.3.5)
BAT-associated emissions levels
See Table 11.63
Table 11.63: BAT-associated emission levels for NH3 emissions to air from a hydrometallurgical
operations using ammonia or ammonium chloride
Parameter
NH3
Unit
mg/Nm3
BAT-AEL (1)
1 – 3 ≤ 1.0
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 148.
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11.6.2.7
PCDD/F emissions
BAT 161. In order to reduce PCDD/F emissions to air from a drying operation where
the raw materials contain organic compounds, halogens or other PCDD/F precursors,
from an incineration operation, and from a calcining operationand drying operations,
BAT is to use one or a combination both of the following techniques given below. (based
on Section 7.3.6)
Technique (1)
a
b
c
d
e
f
g
h
1
Afterburner or regenerative afterburner ( )
Injection of absorption agent in combination with efficient dust collection system ( 1)Injection of
activated carbon followed by a bag filter
Optimise combustion or process conditions for the abatement of emissions of organic compounds
Avoid exhaust system with high dust coating for temperatures > 250 ºC
Rapid quenching (1)
Thermal destruction of PCDD/F in the furnace at high temperatures (> 850 ºC)
Use of oxygen injection in the upper zone of the furnace
Internal burner system
(1) Descriptions of the techniques are given in Section 11.10
Description
BAT 161(b): PCDD/F may be absorbed onto dust and hence emissions can be reduced using an
efficient dust filtration system. The use of a specific absorbing agents promotes this process and
reduces the emission of PCDD/F.
BAT 161(c): good mixing between air or oxygen and carbon content, control of the temperature
of the gases and resident time to oxidise the organic carbon comprising PCDD/F.
BAT 161(d): The presence of dust at temperature above 250 °C promotes the de novo PCDD/F
synthesis and should therefore be avoided.
BAT-associated emissions levels
See Table 11.64
Table 11.64: BAT-associated emission levels for PCDD/F emissions to air from a drying operation
where the raw materials contain organic compounds, halogens or other PCDD/F
precursors, from an incineration operation, and from a calcining operationand drying
operations
Parameter
PCDD/F
Unit
ng I-TEQ/Nm3
BAT-AEL (1)
≤ 0.1
(1) As an average over a sampling period of at least six hours. the sampling period (periodic measurements of at least
six hours).
The associated monitoring is in BAT 148.
11.6.3
Soil and groundwater protection
BAT 161bis. In order to prevent soil and groundwater contamination, BAT is to use a
combination of the techniques given below. (based on Section 7.3.5)
a
b
c
d
Technique
Use of sealed drainage systems
Use of double-walled tanks or placement in resistant bunds
Use of impermeable and acid-resistant floors
Automatic level control of reaction vessels
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11.6.4
Waste water generation
BAT 161ter. In order to prevent the generation of waste water, BAT is to use one or
both of the techniques given below. (based on Sections 7.3.4, 7.3.5 and 7.3.7)
Technique
Recycling of spent/recovered scrubber liquors and other hydrometallurgical reagents in leaching and
other refining operations
Recycling of solutions from leaching, extraction and precipitation operations
a
b
11.6.5
Waste
BAT 161cuat. In order to reduce the quantities of waste sent for disposal, BAT is to
organise operations on site so as to facilitate process residues waste reuse or, failing that,
process residues waste recycling, including one or a combination of the techniques given
below. (based on Section 7.3.3, 7.3.4 and 7.3.5)
a
b
c
d
e
f
g
1166
Technique
Recovery of the metal content from slags, filter dust
and residues of the wet dedusting system
Recovery of the selenium collected in the wet
dedusting systems of off-gases containing volatilised
selenium
Recovery of silver from spent electrolyte and spent
slime washing solutions
Recovery of metals from residues from electrolyte
purification (e.g. silver cement, copper carbonatebased residue)
Recovery of gold from electrolyte, slimes and
solutions from the gold leaching processes
Recovery of metals from spent anodes
Recovery of platinum-group metals from platinumgroup metal enriched solutions
Recovery of metals from the treatment of processend liquors
July 2014
Applicability
Only applicable to Doré production
Only applicable to Doré production
Only applicable to silver electrolytic
refining
Only applicable to silver electrolytic
refining
Only applicable to gold electrolytic
refining
Only applicable to silver or gold
electrolytic refining
Only applicable to silver or gold
electrolytic refining
Generally applicable
MR/GC/EIPPCB/NFM_Draft_3
11.7
BAT conclusions for ferro-alloys production
11.7.1
Monitoring
BAT 4 and 5 do not apply to the ferro-alloys sector.
11.7.1.1
Monitoring of emissions to air
BAT 162. BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
a
c
ChromiumVI
d
Lead and its
compounds,
expressed as Pb
e
Mercury and its
compounds,
expressed as Hg
g
Thallium and its
compounds,
expressed as Tl
Other metals, if
relevant (3)
Monitoring
associated with
BAT
169, 170, 171, 172,
173, 174
Continuous
EN 13284-1
or Periodic (at least three
consecutive measurements once
per year)
168, 169, 170, 171,
172, 173, 174
EN 14385
Periodic (at least once per year)
170
No EN or ISO
standard available
EN 14385
Periodic (at least once per year)
170
EN 14385
Periodic (at least once per year)
170
11
EN 13211
Continuous
Periodic
(at
least
three
consecutive measurements once
per year)
EN 14385
Periodic (at least once per year)
170
EN 14385
Periodic (at least once per year)
168, 169, 170, 171,
172, 173, 174
Dust ( )
Cadmium and its
compounds,
expressed as Cd
Minimum monitoring
frequency (1)
EN 13284-2
2
b
f
Standard(s)
c
SOX expressed as
SO2
EN 14791
h
NOX, expressed
as NO2 (4)
EN 14792
i
Benzo-[a]-pyrene
j
V TVOC
EN 12619
EN 13526
k
PCDD/F
EN 1948 part 1, 2,
3 and 5
g
SO3
ISO 11338:1
ISO 11338:2
MR/GC/EIPPCB/NFM_Draft_3
Continuous or periodic (at least
three consecutive measurements
once per year)
Continuous
Periodic (at least once per year)
Periodic
(at
least
three
consecutive measurements once
per year)
Periodic
(at
least
three
consecutive measurements once
per year)
Periodic
(at
least
one
measurement once per year)
Periodic
(at
least
three
consecutive measurements once
per year)
July 2014
11
9, 10
12
12
177
177
176
175
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(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed.More frequent monitoring (including the selection
between continuous or periodic measurements) should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emission from the storage and handling of raw materials, monitoring
could be based onthe measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used.
(4) Only applicable to FeSi and Si production.
11.7.1.2
Monitoring of emissions to water
BAT 163. BAT is to monitor the emissions to water at the point where the emission
leaves the installation, before the discharge of the waste water into the receiving water, of
the parameters mentioned in the following table with at least the minimum 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
a
b
c
d
e
f
g
h
i
As
Cd
Cr total
Cu
Fe
Ni
Pb
Zn
Other metals,
relevant (2)
j
Cr (VI)
k
Hg
Standard(s)
Minimum monitoring
frequency (1)
Monitoring
associated with
EN ISO 11885
EN ISO 17294-2
At least once a month
BAT 14
if
EN ISO 10304-3
EN ISO 23913
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media, the load of metals present in the waste
water.
(2) The metals monitored depend on the composition of the raw materials used.
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11.7.2
Energy
BAT 164. In order to use energy efficiently, BAT is to recover energy from the CO-rich
exhaust off-gas generated in a closed submerged arc furnaces or in a closed plasma dust
process by using one or a combination of the following techniques given below. (based on
Section 8.3.8.2)
Technique
Applicability
Applicability may be restricted depending on
local conditions such as energy prices and the
energy policy of the Member State Generally
applicable
a
Use of a steam boiler and turbines to recover the
energy content of the exhaust off-gas and
produce electricity
b
Direct use of the exhaust off-gas as fuel within
the process (e.g. for drying of raw materials,
preheating of charging materials, sintering,
heating of ladles, etc.)
Only applicable if a demand for process heat
exists Generally applicable
c
Use of the exhaust
neighbouring plants
Only applicable if an economically viable
demand for this type of fuel exists
off-gas
as
fuel
in
BAT 165. In order to use energy efficiently, BAT is to recover energy from the hot
exhaust off-gas generated in a semi-closed submerged arc furnaces by using one or both a
combination of the following techniques given below. (based on Section 8.3.8.1)
a
b
Technique
Use of a waste heat boiler and turbines to recover
the energy content of the exhaust off-gas and
produce electricity
Use of a waste heat boiler to produce hot water
Applicability
Applicable Applicability may be restricted
depending on local conditions such as energy
prices
Only applicable if an economically viable
demand exists
BAT 166. In order to use energy efficiently, BAT is to recover energy from the exhaust
off-gas generated in an open submerged arc furnaces via the production of hot water.
(based on Section 8.3.8.3)
Applicability
Only applicable if an economically viable demand for hot water exists.
11.7.3
11.7.3.1
Air emissions
Diffuse dust emissions
BAT 167. In order to prevent or reduce, and collect diffuse emissions to air from tapping
and casting, BAT is to use a hooding systemone or both of the techniques given below.
(based on Sections 8.3.3.2 and 8.3.4.1)
Technique
a
Use of a hooding system
b
Avoid casting by using ferro-alloys in the liquid
state
MR/GC/EIPPCB/NFM_Draft_3
Applicability
Applicable to new plants. For existing plants,
applicable depending on the configuration of
the plant
Only applicable when the consumer (e.g. steel
producer) is integrated with the ferro-alloy
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producer
11.7.3.2
Channelled dust emissions
BAT 168. In order to reduce dust and metal emissions to air from the storage, handling
and transport of solid materials,a pretreatment operations such as metering, mixing,
blending and degreasing, and from tapping, casting and packaging, BAT is to use a bag
filter. one of the following techniques given below. (based on Sections , 8.3.2.1 ,8.3.2.2,
8.3.2.6, 8.3.4.1, 8.3.4.2, 8.3.5.1, 8.3.5.2 and 8.3.5.3)
a
b
Technique (1)
Bag filter
Ceramic filter
Applicability
Generally applicable
Only applicable to the degreasing of titanium swarf in rotary kilns
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.65.
Table 11.65: BAT-associated emission levels for dust emissions to air from the storage, handling
and transport of solid materials, a pretreatment operations such as metering, mixing,
blending and degreasing, and from tapping, casting and packaging
Parameter
Dust
BAT-AEL (1)
2–5
Unit
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 162.
BAT 169. In order to reduce dust and metal emissions to air from crushing, briquetting,
pelletising and sintering, BAT is to use a bag filter or a bag filter in combination with
other techniques. one of the following techniques given below. (based on Sections 8.3.2.1,
8.3.2.3 and 8.3.5.1)
a
b
c
Technique (1)
Bag filter
ESP and bag filter
with
or
without
injection of specific
clays
Wet scrubber
Applicability
Generally applicable
Generally applicable
Applicable to new plants. For existing plants, applicability may be restricted
applicable if a suitable the waste water treatment plant is available cannot
treat the pollutant present in the scrubber´s effluent and the resulting water
cannot be recycled to the process or discharged
(1) Descriptions of the techniques are given in Section 11.10.
Applicability
The applicability of a bag filter may be limited in case of low ambient temperatures (-20 –
-40 ºC) and high humidity of the off-gases, as well as for the crushing of CaSi due to safety
concerns (i.e. explosivity).
BAT-associated emission levels
See Table 11.66.
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Table 11.66: BAT-associated emission levels for dust emissions to air from crushing, briquetting,
pelletising and sintering
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1) (2)
2 – 5 ≤ 5 -10
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) The upper end of the BAT-AEL range can be up to 10 mg/Nm3 for cases where a bag filter cannot be used.The
lower end of the range is associated either with the use of a bag filter or with the use of an ESP in combination with a
bag filter. The upper end of the range is associated with the use of a wet scrubber.
The associated monitoring is in BAT 162.
BAT 170. In order to reduce dust and metal emissions to air from an open or a semiclosed submerged arc furnaces, BAT is to use a bag filter. with or without the injection of
adsorbents. (based on Sections 8.3.3.1.1 and 8.3.3.1.2)
Applicability
Generally applicable. The injection of adsorbents (activated carbon or lignite coke) is applicable
if mercury and PCDD/F needs to be reduced.
BAT-associated emission levels
See Table 11.67.
Table 11.67: BAT-associated emission levels for dust emissions to air from an open or a semi-closed
submerged arc furnaces
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1) (2) (3)
2 – 5 ≤ 5 – 10
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) The upper end of the range may be up to 15 mg/Nm3 for the production of FeMn, SiMn, CaSi due to the sticky
nature of the dust (caused e.g. by its hygroscopic capacity or chemical characteristics) affecting the efficiency of the
bag filter.
(3) Dust emissions are expected to be towards the lower end ot the range when e.g. emissions of cadmium, chromium,
thallium and lead are above the following values: 1 mg/Nm3 for Pb and 0.05 mg/Nm3 for Cd, CrVI, Tl.
The associated monitoring is in BAT 162.
BAT 171. In order to reduce dust and metal emissions to air from a closed submerged
arc furnaces or a closed plasma dust process, BAT is to use one of the following
techniques given below. (based on Section 8.3.3.1.3 and 8.3.3.1.4)
Technique (1)
Applicability
Only applicable to gases that are not oxidised when extracted from the
furnace (i.e. gases with high CO content) For existing plants, applicable
if the waste water treatment plant could treat the pollutant present into
the scrubber´s effluent and the resulting water can be discharged
a
Wet scrubber
a
Wet
scrubber
in
combination with an ESP
followed by Hg abatement
techniques
Generally applicable Only applicable when further reduction of Hg
emissions is needed
Bag filter
Generally applicable unless safety concerns exist related to the CO and
H2 content in the exhaust off-gases. Generally applicable Applicable to
new plants. For existing plants, applicable to gases that are oxidised
when extracted from the furnace (i.e. gases with low CO content)
b
(1) Descriptions of the techniques are given in Section 11.10.
BAT-associated emission levels
See Table 11.68.
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Table 11.68: BAT-associated emission levels for dust emissions to air from a closed submerged arc
furnaces or a closed plasma dust process
Parameter
Dust
BAT-AEL (1)
2 – 5 ≤ 5 – 20 (2) 10
Unit
mg/Nm3
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
(2) The lower end of the range is associated either with the use of a wet scrubber followed by Hg abatement
techniques or with the use of a bag filter. The higher end of the range is associated with the use of a wet scrubber as a
stand-alone technique.
The associated monitoring is in BAT 162.
BAT 172. In order to reduce dust and metal emissions to air from the a closed plasma
dust process, BAT is to use a wet venturi scrubber in combination with a wet ESP and a
mercury filter unit (selenium filter). adsorbent injection. (based on Section 8.3.3.1.4)
Applicability
Only applicable to the processing of steel mill residues.
BAT-associated emission levels
See Table 11.69
Table 11.69: BAT-associated emission levels for dust emissions to air from the a closed plasma dust
process
Parameter
Dust
BAT-AEL (1)
≤35
Unit
mg/Nm3
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 162.
BAT 173. In order to reduce dust emissions from multiple hearth furnaces, BAT is to
use all of the following techniques: (based on Section 8.3.3.1.5)
Technique (1)
a
b
c
Cyclone
ESP
Wet scrubber
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
Table 11.70: BAT-associated emission levels for dust from mulptile hearth furnaces
Parameter
Dust
BAT-AEL (1)
≤5
Unit
mg/Nm3
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
BAT 174. In order to reduce dust and metal emissions to air from a refractory lined
crucibles for the production of ferro-molybdenum and ferro-vanadium, BAT is to use a
bag filter with or without a cyclone as a pre-filter. all of the following techniques: (based
on Section 8.3.3.1.6)
Technique (1)
a
b
Cyclone
Bag filter
(1) Descriptions of the techniques are given in Section11.10
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BAT-associated emission levels
See Table 11.71.
Table 11.71: BAT-associated emission levels for dust emissions to air from a refractory lined
crucibles for the production of ferro-molybdenum and ferro-vanadium
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
2 –5
(1) As a daily average for continuous measurements or as an average over the sampling period. (periodic
measurements of at least half an hour).
The associated monitoring is in BAT 162.
11.7.3.3
Mist emissions
BAT 175. In order to reduce SO3 mist emissions from molybdenite roasting, BAT is to
use one of the following techniques: (based on Section 8.3.3.1.5)
Technique (1)
Ceramic filter
Wet ESP
a
b
Applicability
Generally applicable
Generally applicable
(1) Description of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.72
Table 11.72: BAT-associated emission levels for SO3 mist from molybdenite roasting
Parameter
SO3
Unit
mg/Nm3
BAT-AEL (1)
≤ 5 – 20
(1) As an average over the sampling period (periodic measurements of at least half an hour).
11.7.3.4
PCDD/F
BAT 176. In order to reduce PCDD/F emissions to air from a furnaces producing ferroalloys, BAT is to use injection of adsorbents followed by an ESP and/or a bag filter. one of
the following techniques: (based on Sections 8.3.3.1.1, 8.3.3.1.2, 8.3.3.1.3, 8.3.3.1.4 and
8.3.3.1.5)
a
b
Technique (1)
ESP and/or bag filter with injection of adsorbents
Three-stage venturi scrubber, wet ESP and mercury filter unit (selenium filter)
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.73.
Table 11.73: BAT-associated emission levels for PCDD/F emissions to air from a furnaces
producing ferro-alloys
Parameter
PCDD/F
Unit
ng I-TEQ/Nm3
BAT-AEL
≤ 0.05 (1)
(1) As an average over a sampling period of at least six hours. the sampling period (periodic measurements of at least
six hours).
The associated monitoring is in BAT 162.
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11.7.3.5
PAHs and TOC VOCs
BAT 177. In order to reduce PAHs and TOCVOCs emissions to air from the degreasing
of titanium swarf in rotary kilns, BAT is to use a thermal oxidiser. (based on Sections
8.3.2.6, 8.3.3.1.1, 8.3.3.1.2 and 8.3.3.1.3)
Applicability
Only applicable to the degreasing of titanium swarf in rotary kilns. and furnaces using
Soderberg technology.
11.7.4
Waste
BAT 178. In order to reduce the quantities of slag sent for disposal, BAT is to organise
operations on the site so as to facilitate slag waste reuse or, failing that, slag waste
recycling, including one or a combination of the following techniques given below. (based
on Section 8.3.7.1)
Technique
a
b
c
d
e
Use of slag in construction
applications
Use of slag as sandblasting grit
Use of slag for refractory castables
Use of slag in the smelting process
Use of slag as raw material for the
production of silico-manganese or
other metallurgical applications
Applicability
Only applicable to slags from high-carbon FeCr and SiMn
production, slags from alloy recovery from steel mill residues
and standard exhaust slag from FeMn and FeMo production
Only applicable to slags from high-carbon FeCr production
Only applicable to slags from high-carbon FeCr production
Only applicable to slags from calcium-silicon production
Only applicable to rich slag (high content of MnO) from FeMn
production
BAT 179. In order to reduce the quantities of filter dust and sludge sent for disposal,
BAT is to organise operations on the site so as to facilitate filter dust and sludge waste
reuse or, failing that, filter dust and sludge waste recycling, including one or a
combination of the following techniques given below. (based on Section 8.3.7.1)
a
b
c
d
e
f
Technique
Use of filter dust in the smelting
process
Use of filter dust in stainless steel
production
Use of filter dust and sludge as a
concentrate feed
Use of filter dust in other
industries
Use of micro-silica as additive in
the cement industry
Use of filter dust and sludge in the
zinc industry
Applicability (1)
Only applicable to filter dust from FeCr and FeMo production
Only applicable to filter dust from crushing and screening
operations in high-carbon FeCr production
Only applicable to filter dust and sludge from the off-gas
cleaning in Mo roasting
Only applicable to FeMn, SiMn, FeNi, FeMo and FeV
production
Only applicable to micro-silica from FeSi and Si production
Only applicable to furnace dust and wet scrubber´s sludge from
the alloy recovery from steel mill residues
(1) Highly contaminated dusts and sludges cannot be reused or recycled. Reusing and recycling might also be limited
by accumulation problems (e.g. reusing dust from FeCr production might lead to Zn accumulation in the furnace).
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11.8
BAT conclusions for nickel and cobalt production
11.8.1
Monitoring
BAT 4 and 5 do not apply to the nickel sector.
11.8.1.1
Monitoring of emissions to air
BAT 180. BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
Standard(s)
EN 13284-2
a
2
Dust ( )
EN 13284-1
b
c
d
Mercury and its
compounds,
expressed as Hg
Nickel and its
compounds,
expressed as Ni
Other metals, if
relevant (3)
EN 13211
EN 14385
EN 14385
e
SOX expressed as
SO2
f
NH3
No EN or ISO
standard available
g
Chlorine,
expressed as Cl2
No EN or ISO
standard available
EN 14791
Minimum monitoring
frequency (1)
Continuous
Periodic (at least three
consecutive measurements once
per year)
Continuous
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Monitoring
associated with
BAT
189bis 190, 191, 192,
193, 196
189bis 190, 191, 192,
193, 196
11
11
194, 195
Periodic (at least once per year)
189 bis
Continuous
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
Periodic (at least three
consecutive measurements once
per year)
9, 10, 197
197
198
194
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed.More frequent monitoring (including the selection
between continuous or periodic measurements) should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used.
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11.8.1.2
Monitoring of emissions to water
BAT 181. BAT is to monitor the emissions to water at the point where the emission
leaves the installation, before the discharge of the waste water into the receiving water, of
the parameters mentioned in the following table with at least the minimum 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
a
b
c
d
e
f
g
h
As
Cd
Co
Cu
Fe
Ni
Pb
Zn
i
Hg
Standard(s)
Minimum monitoring
frequency (1)
Monitoring
associated with
EN ISO 11885
EN ISO 17294-2
At least once a month
BAT 14
EN ISO 17852
EN ISO 172941
EN ISO 12846
EN ISO 10304-1
No EN or ISO standard
available
j
SO421
( ) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While
respecting this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen
taking into account local environmental conditions such as the type of receiving media, the load of metals
present in the waste water.
11.8.2
Energy
BAT 182. In order to use energy efficiently, BAT is to use one or a combination of the
following techniques given below. (based on Section 9.3.1.7)
a
b
c
d
11.8.3
11.8.3.1
Technique
Use of oxygen-enriched air in smelting furnaces and oxygen converters
Use of heat recovery boilers
Use of the flue-gas off-gas generated in the furnace within the process (e.g. drying)
Use of heat exchangers
Air emissions
Diffuse emissions
BAT 183. In order to reduce diffuse dust emissions to air from the charging of a furnace,
BAT is to use enclosed conveying systems. (based on Section 9.3.1.3.1)
BAT 184. In order to reduce diffuse dust emissions to air from thesmelting DON process
and electric arc furnaces, BAT is to use covered and hooded launders connected with an
abatement system. (based on Sections 9.3.1.3.2 and 9.3.1.3.3)
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BAT 185. In order to reduce diffuse dust emissions from converting processes, BAT is to
use all of the following techniques given below. (based on Section 9.3.1.3.4)
a
b
Technique
Operation under negative pressure
Capture hoods connected to an abatement system
BAT 186. In order to reduce diffuse emissions from atmospheric and pressure leaching
processes, BAT is to use all of the following techniques given below. (based on Section
9.3.1.4.1)
a
b
Technique
Sealed or closed reactors, settlers and pressure autoclaves/vessels
Use of oxygen or chlorine instead of air in leaching stages
BAT 187. In order to reduce diffuse emissions from solvent extraction refining (via
sulphate route), BAT is to use one of the following techniques given below. (based on
Section 9.3.1.4.2)
a
b
c
Technique
Use of a low or a high shear mixer for the solvent/aqueous mixture
Use of covers for the mixer and separator
Use of completely sealed tanks connected to an abatement system
BAT 188. In order to reduce diffuse emissions from electrowinning, BAT is to use a
combination of the following techniques given below. (based on Section 9.3.1.4.4)
Technique
Use of dimensional stable anodes to
Collection and reuse of chlorine gas
Applicability
Only applicable to chloride-based electrowinning if an
economically viable demand exists for chlorine gas
b
Use of styropor polystyrene beads to
cover cells
Generally applicable
c
Use of foaming agents to cover the cells
with a stable layer of foam
Only applicable to
Generally applicable
a
sulphate-based
electrowinning
BAT 189. In order to reduce diffuse emissions from the hydrogen reduction processes
when producing nickel powder and nickel briquettes (pressure processes), BAT is to use a
sealed or closed reactors, a settlers and a pressure autoclaves/vessels, a powder conveyors
and a product silo. (based on Section 9.3.1.4.4)
11.8.3.2
Channelled dust emissions
BAT 189bis. When processing sulphidic ores, in order to reduce dust and metal
emissions to air from handling and storage of raw materials, a material pretreatment
process (such as ore preparation and ore/concentrate drying), the charging of a furnace,
smelting, converting, thermal refining and nickel powder and briquettes production, BAT
is to use a bag filter or a combination of a hot ESP and a bag filter. (based on Section
9.3.1.1.1, 9.3.1.2.1, 9.3.1.2.2, 9.3.1.3.3 and 9.3.1.4.5)
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BAT-associated emissions levels
See Table 14.73bis.
Table 14.73bis:
BAT-associated emission levels for dust emissions to air from
handling and storage of raw materials, a material pretreatment process (such as ore
preparation and ore/concentrate drying), the charging of a furnace, smelting, converting,
thermal refining and nickel powder and briquettes production when processing sulphidic
ores
Parameter
Dust
BAT-AEL (1) (2)
2–5
Unit
mg/Nm3
(1) As a daily average or as an average over the sampling period.
(2) In an ore/concentrate drying process, the BAT-AEL is associated with the use of a bag filter in combination with a
hot ESP.
The associated monitoring is in BAT 180.
BAT 190. In order to reduce dust emissions from handling, storage, material
pretreatment processes (such as ore preparation and ore/concentrate drying) and
charging of furnaces, BAT is to use one or a combination of the following techniques:
(based on Sections 9.3.1.1.1, 9.3.1.2.1 and 9.3.1.2.2)
Technique (1)
a
b
Bag filter
Hot ESP
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.74
Table 11.74: BAT-associated emission levels for dust from handling, storage, material
pretreatment processes (such as ore preparation and ore/concentrate drying) and
charging of furnaces
Parameter
Dust
BAT-AEL (1) (2)
≤5
Unit
mg/Nm3
(1) As a daily average for continuous measurements.
BAT 191. In order to reduce dust emissions from the DON process, BAT is to use a
combination of the following techniques: (based on Section 9.3.1.3.2)
Technique (1)
a
b
c
d
Hot ESP
Wet ESP
Lime injection followed by a bag filter
Wet scrubber
Applicability
Applicable to primary emissions
Applicable to primary emissions
Applicable to secondary emissions
Applicable to secondary emissions
(1) Descriptions of the techniques are given in Section 11.10.
BAT-associated emission levels
See Table 11.75
Table 11.75: BAT-associated emission levels for dust from the DON process
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
≤5
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
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measurements of at least half an hour).
BAT 192. In order to reduce dust emissions from electric arc furnaces, BAT is to use a
combination of the following techniques: (based on Section 9.3.1.3.3)
a
b
c
Technique (1)
Thermal oxidiser
Lime injection followed by bag
filter
Wet scrubber
Applicability
Applicable to primary emissions
Applicable to primary emissions, and secondary emissions from
the slag taphole
Applicable to primary emissions, and secondary emissions from
the slag taphole
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.76
Table 11.76: BAT-associated emission levels for dust from electric arc furnaces
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
≤5
(1) As a daily average for continuous measurements or as an average over the sampling period (periodic
measurements of at least half an hour).
BAT 193. In order to reduce dust emissions from the carbonyl process, BAT is to use a
bag filter. (based on Section 9.3.1.4.4)
BAT-associated emission levels
SeeTable 11.77
Table 11.77: BAT-associated emission levels for dust from the carbonyl process
Parameter
Dust
Unit
mg/Nm3
BAT-AEL (1)
≤5
(1) As a daily average for continuous measurements.
11.8.3.3
Nickel and chlorine emissions
BAT 194. In order to reduce nickel and chlorine emissions to air from atmospheric and
pressure leaching processes, BAT is to use a wet scrubber. (based on Section 9.3.1.4.1)
BAT-associated emission levels
See Table 11.78.
Table 11.78: BAT-associated emission levels for nickel and chlorine emissions to air from
atmospheric and pressure leaching processes
Parameter
Nickel
Chlorine
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
≤1
≤1
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 180.
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BAT 195. In order to reduce nickel emissions to air from the nickel matte refining
process using ferric chloride with chlorine, BAT is to use a bag filter (based on Section
9.3.1.4.3)
BAT-associated emission levels
See Table 11.79
Table 11.79: BAT-associated emission levels for nickel emissions to air from the nickel matte
refining process using ferric chloride with chlorine
Parameter
Nickel
BAT-AEL (1)
≤1
Unit
mg/Nm3
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 180.
BAT 196. In order to reduce dust emissions from nickel powder and briquettes
production, BAT is to use a bag filter. (based on Section 9.3.1.4.4)
BAT-associated emission levels
See Table 11.80
Table 11.80: BAT-associated emission levels for dust from nickel powder and briquettes
production
Parameter
Unit
BAT-AEL (1)
3
Dust
mg/Nm
≤5
(1) As an average over the sampling period (periodic measurements of at least half an hour).
11.8.3.4
SO2 emissions
BAT 197. When processing sulphidic ores, in order to reduce SO2 emissions to air other
than those that are sent to the sulphuric acid plant from smelting and convertingthe DON
process, BAT is to use a hot cyclone venturi scrubber with sodium hydroxide solution one
of the techniques given below. (based on Section 9.3.1.3.2)
a
b
Technique (1)
Lime injection followed by a bag filter
Wet scrubber
(1) Descriptions of the techniques are given in Section 14.10.
BAT-associated emission levels
See Table 11.81
Table 11.81: BAT-associated emission levels for SO2 emissions to air other than those that are sent
to the sulphuric acid plant from smelting and converting the DON process
Parameter
SO2
Unit
mg/Nm3
BAT-AEL (1)
≤ 300
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 180.
11.8.3.5
NH3 emissions
BAT 198. In order to reduce NH3 emissions to air from nickel powder and briquettes
production, BAT is to use a wet scrubber. (based on Section 9.3.1.4.6)
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BAT-associated emission levels
See Table 11.82
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Table 11.82: BAT-associated emission levels for NH3 from nickel powder and briquettes
production
Parameter
NH3
BAT-AEL (1)
≤3
Unit
mg/Nm3
(1) As an average over the sampling period (periodic measurements of at least half an hour).
11.8.4
Waste
BAT 199. In order to reduce the quantities of waste sent for disposal, BAT is to organise
operations on the site so as to facilitate process residues waste reuse or, failing that,
process residues waste recycling, including one or a combination of the following
techniques given below. (based on Section 9.3.1.6.1)
a
b
c
d
e
f
g
Technique
Use of the granulated slag, generated in the electric arc furnace used
in smeltingthe DON process, as an abrasive or construction material
Use of the off-gas dust, recovered from the electric arc furnace used
in smeltingthe DON process, as a raw material for zinc production
Use of the matte granulation off-gas dust, recovered from the
electric arc furnace used in smeltingthe DON process, as a raw
material for the nickel refinery/re-smelting
Use of the sulphur residue, obtained after matte filtration in the
chlorine based leaching, as a raw material for sulphuric acid
production
Use of the iron residue, obtained after sulphate based leaching, as a
feed to the nickel smelter
Use of the zinc carbonate residue, obtained from the solvent
extraction refining, as a raw material for zinc production
Use of the copper residues, obtained after leaching from the
sulphate and chlorine based leaching, as a raw material for copper
production
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Applicability
Only applicable depending on
the metal content of the slag
Generally applicable
Generally applicable
Generally applicable
Applicable depending on the
metals content of the waste
Applicable depending on the
metals content of the waste
Generally applicable
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11.9
BAT conclusions for carbon and graphite production
11.9.1
Monitoring
BAT 4 and 5 do not apply to the carbon and graphite sector.
11.9.1.1
Monitoring of emissions to air
BAT 200. BAT is to monitor the stack emissions to air mentioned in the following table
with at least the minimum 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
Standard(s)
Minimum monitoring
frequency (1)
Periodic (at least three
consecutive
measurements
once per year)
Periodic (at least three
consecutive
measurements
once per year)
Periodic (at least once per
year)
Periodic (at least three
consecutive
measurements
once per year)
Monitoring
associated with
BAT
202, 203, 204,
205
a
Dust (2)
b
SOX expressed
as SO2
EN 14791
c
NOX, expressed
as NO2
EN 14792
d
Benzo-[a]pyrene
ISO 11338–1
ISO 11338–2
e
VOCPhenol
f
Formaldehyde
No EN or ISO standard
available
EN 12619
EN 13526
Periodic (at least three
consecutive
measurements
once per year)
208
g
TVOC
EN 12619
EN 13526
Periodic (at least three
consecutive
measurements
once per year)
207
EN 13284-1
206
202, 203, 204,
205
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed.While respecting this minimum monitoring
frequency, the More frequent monitoring frequency should may be chosen taking into account based on local
environmental conditions and plant specificities such as capacity, mass flow of the pollutant, type of raw materials
used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of coke and pitchraw
materials, monitoring could be based on the measurement of surrogate parameters (such as the pressure drop).
11.9.2
11.9.2.1
Air emissions
Diffuse emissions
BAT 201. In order to reduce diffuse PAH emissions to air from the storage, handling
and transport of liquid pitch, BAT is to use one or a combination of the following
techniques given below. (based on Section 10.3.1.2)
a
b
c
Technique
Back-venting of the liquid pitch storage tank
Condensation by external and/or internal cooling with air and/or water systems (e.g.
conditioning towers), followed by filtration techniques (adsorption scrubbers or ESP)
Collection and transfer of collected off-gases to abatement techniques (dry scrubber or thermal
oxidiser/regenerative thermal oxidiser) available at other stages of the process (e.g. mixing and
shaping or baking)
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Chapter 11
11.9.2.2
Dust and PAH emissions
BAT 202. In order to reduce dust emissions to air from the storage, handling and
transportation of coke and pitchsolid materials, and mechanical processes (such as
grinding) and operations like graphitising and machining, BAT is to use a bag filter.
(based on Sections 10.3.1.1, 10.3.2.2, 10.3.3.4, 10.3.3.5)
BAT-associated emission levels
See Table 11.83.
Table 11.83: BAT-associated emission levels for dust and BaP particles emissions to air from the
storage, handling and transportation of coke and pitch solid materials, and
mechanical processes (such as grinding) and operations like graphitising and
machining
Parameter
Dust
BaP particles
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
2 – 5 ≤ 5-10 (2)
≤ 0.01 (2)
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
(2) The upper range may increase to up to 30 mg/Nm3 during silo filling and truck loading.
(2) BaP particles are only expected if processing solid pitch.
The associated monitoring is in BAT 200.
BAT 203. In order to reduce dust and PAH emissions to air from the production of
green paste and green shapes, BAT is to use one or a combination of the following
techniques given below. (based on Section 10.3.3.1)
Technique (1)
Applicability
a
Dry scrubber using coke as the adsorbent agent
and with or without pre-cooling, followed by a
bag filter
Generally applicable Only applicable to plants
producing a sufficient quantity of material to
be used as a scrubbing agent
b
ActivatedBed coke filter
Generally applicable Only applicable to plants
producing a sufficient quantity of material to
be used as a scrubbing agent
c
d
Regenerative thermal oxidiser
Thermal oxidiser
Generally applicable
Generally applicable
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.84.
Table 11.84: BAT-associated emission levels for dust and BaP (as an indicator of PAH) emissions to
air from the production of green paste and green shapes
Parameter
Dust
BaP
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
2 – 10 (2) ≤5 – 15 10
0.001 – 0.01
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a dry coke scrubbers using coke as the adsorbent agent
followed by a bag filter. The upper end of the range is associated with the use of a thermal oxidiser or a regenerative
thermal oxidiser.
The associated monitoring is in BAT 200.
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BAT 204. In order to reduce dust and PAH emissions to air from baking and rebaking,
BAT is to use one or a combination of the following techniques given below. (based on
Section 10.3.3.2)
Technique (1)
a
ESP
b
Regenerative thermal
oxidiser
c
Thermal oxidiser
Applicability
Generally applicable Applicable to off-gases not having high SO2
concentrations. When high volatile components are expected, a kind of
combustion is usually added (e.g. regenerative thermal oxidiser)
Generally applicable Applicable to off-gases not having high SO2
concentrations. In cases of high off-gas load, a pretreatment is needed (e.g.
ESP)
Not applicable to continuous ring furnaces
(1) Descriptions of the techniques are given in Section 11.10.
Description
BAT 204(a): When highly volatile components are expected, a thermal oxidation step is usually
added (e.g. regenerative thermal oxidiser).
BAT 204(b): In cases of high dust content in the exhaust off-gas load, a pretreatment is needed
(e.g. ESP).
BAT-associated emission levels
See Table 11.85.
Table 11.85: BAT-associated emission levels for dust and BaP (as an indicator of PAH) emissions to
air from baking and rebaking
Parameter
Dust
BaP
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
2 – 10 (2) ≤ 5 – 20
0.005 – 0.015 (3) (4)
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
(2) The lower end of the range is associated with the use of a combination of an ESP and a regenerative thermal
oxidiser. The higher end of the range is associated with the use of a thermal oxidiser.
(3) The lower end of the range is associated with the use of a thermal oxidiser. The upper end of the range is
associated with the use of a combination of an ESP and a regenerative thermal oxidiser.
(4) In case of cathode production, the upper end of the BAT-AEL is 0.05 mg/Nm3.
The associated monitoring is in BAT 200.
BAT 205. In order to reduce dust and PAH emissions to air from impregnation, BAT is
to use one or a combination of the following techniques given below. (based on Section
10.3.3.3)
a
Technique (1)
Dry scrubber followed
by a bag filter
b
ActivatedBed coke filter
c
Thermal oxidiser
Applicability
Generally applicable Only applicable to plants producing a sufficient
quantity of material to be used as a scrubbing agent
Generally applicable Only applicable to plants producing a sufficient
quantity of material to be used as a scrubbing agent
Generally applicable Generally applicable to impregnation processes
(1) Descriptions of the techniques are given in Section Section 11.10.
BAT-associated emission levels
See Table 11.86.
Table 11.86: BAT-associated emission levels for dust and BaP (as an indicator of PAH) emissions to
air from impregnation
Parameter
Dust
BaP
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
2 – 10 ≤ 5 – 10
0.001 – 0.01
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
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The associated monitoring is in BAT 200.
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11.9.2.3
SO2 emissions
BAT 206. In order to reduce sulphur dioxide emissions to air when there is a sulphur
addition in the process, BAT is to use one or both a combination of the following
techniques given below. (based on Section 10.3.3.2)
Technique (1)
a
b
Dry scrubber
Wet scrubber
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.87
.
Table 11.87: BAT-associated emission levels for SO2 emissions to air from processes with sulphur
addition
Parameter
SO2
Unit
mg/Nm3
BAT-AEL (1)
≤ 200
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
The associated monitoring is in BAT 200.
11.9.2.4
Organic compounds emissions
BAT 207. In order to reduce emissions of organic compounds to air, BAT is to use one of
the following techniques given below. (based on Sections 10.3.3.2 and 10.3.3.3)
a
b
Technique (1)
Regenerative thermal oxidiser
in combination with an ESP
Biofilter and bioscrubber
Applicability
Applicable to mixing, baking and impregnation stages
Applicable to the impregnation stage in speciality graphite
production, where special impregnation agents likesuch as resins
and biodegradable solvents are used
(1) Descriptions of the techniques are given in Section 11.10
BAT-associated emission levels
See Table 11.88.
Table 11.88: BAT-associated emission levels for TVOC emissions to air from mixing, baking and
impregnation
Parameter
TVOC as C
Unit
mg/Nm3
BAT-AEL (1) (2)
≤ 10 – 40
(1) As an average over the sampling period. (periodic measurements of at least half an hour).
(2) The lower end of the range is associated with the use of an ESP in combination with a regenerative thermal
oxidiser. The upper end of the range is associated with the use of a biofilter and a bioscrubber.
The associated monitoring is in BAT 200.
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Chapter 11
BAT 208. In order to reduce phenol and formaldehyde emissions to air from a special
production processes where special impregnation agents such as resins and biodegradable
solvents are used, BAT is to use a biofilter or a bioscrubber. one of the following
techniques given below. (based on Section 10.3.3.3)
Technique
(1)
a
Biofilter
b
Bioscrubber
Applicability
Applicable to the impregnation stage in speciality graphite production, where
special impregnation agents like resins and biodegradable solvents are used
(1) Description of the technique is given in Section 11.10
BAT-associated emission levels
See Table 11.89
Table 11.89: BAT-associated emission levels for phenol and formaldehyde emissions to air from a
special production processes where special impregnation agents such as resins and
biodegradable solvents are used
Parameter
Phenol
Formaldehyde
Unit
mg/Nm3
mg/Nm3
BAT-AEL (1)
≤ 1.0
≤ 0.2
(1) As an average over the sampling period. (periodic measurements of at least half an hour)
The associated monitoring is in BAT 200.
11.9.3
Waste
BAT 209. In order to reduce the quantities of waste sent for disposal, BAT is to organise
operations on the site so as to facilitate process residues waste reuse or, failing that,
process residues waste recycling, including use or recycle carbon and other residues from
the production processes within the process or in other external processes. (based on
Section 10.3.5)
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11.9 bis BAT conclusions for other non-ferrous metals' production
BAT 209bis. BAT is to monitor the stack emissions to air mentioned in the following
table and to use the indicated monitoring techniques with at least the minimum 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 (1)
Standard(s)
EN 13284-1
and 2
a
Dust (2)
b
Mercury and its
compounds,
expressed as Hg
c
Other relevant metals,
if relevant (e.g.
cadmium, lead) (3)
EN 14385
d
NOX, expressed as
NO2 (4)
EN 14792
e
SO2
EN 14791
e
EN 13211
VOC
f
TVOC
g
PCDD/F (4)
EN 12619
EN 13526
EN 1948 part 1, 2,
3 and 5
Minimum monitoring
frequency (1) (3)
Continuous or periodic
(at least three consecutive
measurements once per
year)
Continuous or periodic
(at least three consecutive
measurements once per
year)
Periodic (at least three
consecutive
measurements once per
year)
Continuous or periodic
(at least three consecutive
measurements once per
year)
Continuous or periodic
(at least once per year)
Periodic (at least three
consecutive
measurements once per
year)
Continuous or periodic
(at least three consecutive
measurements once per
year)
Periodic (at least one
measurement once per
year)
Monitoring associated
with
Emissions from nonferrous metals'
production stages such
as raw material
pretreatment, charging,
smelting, melting and
tapping
BAT 11
Where relevant in view
of the metal content of
the raw materials used
BAT 12
Relevant when there is
a sulphur concentration
in the raw materials
Where relevant in view
of the organic
compounds content of
the raw materials used
Where relevant in view
of factors such as the
halogenated organic
compounds content of
the raw materials used,
the temperature profile,
etc.
(1) The monitoring of these parameters apply to the production of non-ferrous metals not included in Sections 14.2 to
14.9.
(1) For sources of high emissions, continuous measurement is the preferred option. Where continuous measurement is
not applicable, more frequent periodic monitoring is performed.More frequent monitoring (including the choice
between continuous or periodic measurement) may should be chosen taking into account local environmental
conditions and plant specificities such as capacity, mass flow of the pollutant and type of raw materials used.
(2) For small sources (< 10 000 Nm3/h) of dust emissions from the storage and handling of raw materials, monitoring
could be based on the measurement of surrogate parameters (such as the pressure drop).
(3) The metals monitored depend on the composition of the raw materials used.
(4) Monitoring of SO2, NOX and PCDD/F may not be relevant for hydrometallurgical processes.
(5) For furnaces using oxygen enriched burners, the emissions are expressed in terms of grams of NOx emitted per
tonne of melted metal produced, as an average over the sampling period for the continuous smelter/melter process.
For the batch smelter/melter process, the emissions are expressed as an average of all the batch process operations.
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Chapter 11
BAT 209ter. BAT is to monitor the emissions to water at the point where the emission
leaves the installation before the discharge of the waste water into the receiving water, of
the parameters mentioned in the following table with at least the minium 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
Standard(s)
Hg
EN ISO 17852
EN ISO 17294-1
EN ISO 12846
c
Other relevant metals, if
relevant (2)
Fe
EN ISO 11885
EN ISO 17294-2
d
SO42-
EN ISO 10304-1
No EN or ISO
standard available
a
b
Minimum monitoring
frequency (1)
Monitoring
associated with
At least once a month
BAT 14
(1) The monitoring of these parameters apply to the production of non-ferrous metals not included in Sections 14.2 to
14.9.
(1) Monitoring frequencies may be adapted if the data series clearly demonstrate sufficient stability.While respecting
this minimum monitoring frequency, the More frequent monitoring frequency should may be chosen taking into
account local environmental conditions such as the type of receiving media and the load of metals present in the
waste water.
(²) The metals to be monitored depend to a large extent on the composition of the raw materials used.
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11.10 Description of Techniques
11.10.1
Air Emissions
The techniques described below are listed according with the main pollutant they are aimed to
abate, which does not prevent them from having a positive impact in the reduction of other
pollutants.
11.10.1.1
Dust emissions
Technique
Bag or fabric filter
Cyclone
Electrostatic
precipitator (ESP)
Wet
electrostatic
precipitator (Wet ESP)
Hot
electrostatic
precipitator (Hot ESP)
Settling
chamber/gravitational
separator
Ceramic and
mesh filter
Wet dust scrubber
metal
Description
Bag filters are constructed from porous woven or felted fabric through
which gases flow through and particles are removed by use of a sieve or
other mechanism. Use of a fabric filter requires a fabric material selection
suited to the characteristics of the waste off-gases and the maximum
operating temperature. Cartridge filters are a variation of fabric filter that
uses cartridges instead of bags
Cyclones use inertia in order to remove particulate matter from waste offgas streams, by imparting centrifugal forces, usually within a conical
chamber
Electrostatic precipitators operate such that particles are charged and
separated under the influence of an electrical field. They are capable of
operating over a wide range of conditions
The technique consists of an electrostatic precipitator in which the collected
material is removed from the plates of the collectors by flushing with a
suitable liquid, usually water. Some mechanism is usually installed to
remove water droplets before discharge of the waste gas (e.g. a demister or a
last dry field)
Hot electrostatic precipitators are electrostatic precipitators specially
designed to operate with high-temperature off-gases (> 300 ºC)
Settling chamber/gravitational separators are used to separate particulate
matter from waste off-gas streams by use of gravity/mass inertia. The
separating effect is increased by reducing the waste off-gas velocity (e.g. by
baffles, lamellae or metal gauze)
Low density ceramic filters operate in a similar manner to fabric filters as far
as operating principles, general arrangement and cleaning operations are
concerned. Instead of cloth bags and their metal supports, rigid elements that
resemble candle filters are used
Wet dust scrubbing is a variation of wet gas scrubbing, which can
additionally recover/abate particulate matter. Wet dust scrubbing entails
separating the dust by intensively mixing the incoming gas with water,
mostly combined with a removal of the coarse particles through the use of
centrifugal force. In order to achieve this, the gas is released inside
tangentially. The removed solid dust is collected at the bottom of the dust
scrubber. Aside from the dust, inorganic chemicals such as SO2, NH3,
NH4Cl, VOC and heavy metals that may be attached to the dust are removed
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Chapter 11
11.10.1.2
Mist emissions
Technique
Demister
Centrifugal system
11.10.1.3
NOX emissions
Technique
Low-NOX burner
Oxy-fuel burner
Flue-gas recirculation
1192
Description
Demisters are filter devices that remove entrained liquid droplets from a gas
stream. They consist of a woven structure of metal or plastic wires, with a
high specific surface. Through their momentum, small droplets present in
the gas stream impinge against the wires and coalesce into bigger drops
Centrifugal systems use inertia in order to remove droplets from off-gas
streams by imparting centrifugal forces
Description
Low-NOX burners reduce the formation of NOX by controlling peak flame
temperature, the availability of oxygen and the residence time in the
combustion zone through the staged addition of combustion air and/or fuel
and they may also include partial flue-gas recirculation
The technique involves the replacement of the combustion air with oxygen,
with consequent elimination/reduction of thermal NOX formation from
nitrogen entering the furnace. The residual nitrogen content in the furnace
depends on the purity of the oxygen supplied, on the quality of the fuel and
on the potential air inlet
Implies the reinjection of waste flue-gas from the furnace into the flame to
reduce the oxygen content and therefore the temperature of the flame. The
use of special burners is based on internal recirculation of combustion gases
which cool the root of the flames and reduce the oxygen content in the
hottest part of the flames
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11.10.1.4
SO2 emissions
Technique
Dry
and
scrubber
semi-dry
Wet scrubber
Sulphuric acid plant
Liquid SO2 plant
Wet sulphuric
process (WSA)
acid
Use of low sulphur
content fuels
Use of polyether-based
adsorption/desorption
system
Description
Dry powder or a suspension/solution of alkaline reagent (e.g. lime or sodium
bicarbonate) are introduced and dispersed in the waste off-gas stream. The
material reacts with the sulphur gaseous species to form a solid which has to
be removed by filtration (bag filter or electrostatic precipitator). The use of a
reaction tower improves the removal efficiency of the scrubbing system.
Adsorption can also be achieved by the use of packed towers (e.g. activated
bed coke filter).
For existing plants, the performance is linked to process parameters such as
temperature (min 60 ºC), moisture content, contact time, gas fluctuations and
to the capability of the dust filtration system (e.g. bag filter) to take the
additional dust load.
In the wet scrubbing process, gaseous compounds are dissolved in an
alkaline solution (e.g. lime, NaOH, H2O2). Downstream of the wet scrubber,
the off-gases flue-gases are saturated with water and a separation of the
droplets is required before discharging the off-gases flue-gases. The
resulting liquid has to be treated by a waste water process and the insoluble
matter is collected by sedimentation or filtration.
For existing plant the applicability of the technique may require significant
space availability
In this process, the sulphur dioxide in the gas is converted to sulphur trioxide
in a contact process when the gases are passed through a vanadium
pentoxide catalyst bed. Sometimes the catalyst is doped with caesium oxide,
which improves performance particularly when the SO 2 concentration is low
and variable or when the temperature is low. Single and double contact
plants are used, being the latter the most commonly applied
Sulphur dioxide is absorbed in cold water (e.g. cold seawater) followed by
vacuum stripping and recovery as liquid sulphur dioxide
It is an alternative process to the sulphuric acid plant, aimed to handle wet
gases, and in which after the converter the acid vapour is not absorbed in an
absorption tower, but it is condensed in a special type of heat exchanger
The use of natural gas or low sulphur fuel oil is applied to reduce the amount
of SOX emissions deriving from the oxidation of sulphur contained in the
fuel during combustion
Polyether-based solvent is used to absorb selectively the SO2 from the
exhaust flue-gases. Then the absorbed SO2 is stripped in another column and
the solvent is fully regenerate. The SO2 stripped is used to produce liquid
SO2 ore sulphuric acid.
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11.10.1.5
Hg emissions
Technique
Boliden-Norzink
process
Bolchem process and
filtering off mercury
sulphide
Outotec process
Sodium
process
thiocyanate
Use of an activated
carbon filter
Tynfos-Miltec
application
Lurgi process
Boliden/Contec process
DOWA
adsorption
process
Description
This process is based on a wet scrubber using the reaction between mercuric
chloride and mercury to form mercurous chloride (calomel), which
precipitates from the liquor. The process is placed after the washing and
cooling step in the acid plant
This process is based on the use of sulphuric acid (from the absorption part
of the acid plant) to oxidise mercury at ambient temperature. The resulting
acid that contains mercury is diluted to 80 % and the mercury is precipitated
as sulphide with thiosulphate
In this process the mercury is removed before the washing step in the acid
plant. The gas at about 350 °C, is led through a packed bed tower where it is
washed countercurrently with 90 % sulphuric acid at about 190 °C. The acid
is formed in situ from the SO3 in the gas. The mercury is precipitated as a
selenium chloride compound. The mercury sludge is removed from the
cooled acid, filtered and washed and sent to the production of metallic
mercury. Part of the acid is then recycled to the scrubbing step. In a revision
to this process, mercury is removed from the gases by washing with a
solution of selenium ions when selenium metal is produced along with
mercury selenide
In this process, the SO2 gas is washed with a solution of sodium thiocyanate
and the mercury is removed as sulphide
This process is based on the adsorption of mercury molecules in the
activated carbon. When the surface has adsorbed as much as it can, the
adsorbed content is desorbed as part of the regeneration of the adsorbent
This process is based on the oxidation of mercury in the off-gas using
sodium hypochlorite
This process consists of an electrostatic precipitator to remove residual dust
and tars, a gas heater, a packed bed absorber, a fan-damper system to control
the gas flow through the unit and extensive gas analysis nitrogen purge
equipment to maintain low oxygen levels in the gas
This process is based on the use of selenium-coated spheres in a packed bed
This process is based on the adsorption onto pumice stones coated with lead
sulphide
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11.10.1.6
VOC and PAH emissions
Technique
Afterburner or thermal
oxidiser
Regenerative
oxidiser
thermal
Catalytic
oxidiser
thermal
Biofilter
Bioscrubber
11.10.1.7
PCDD/F emissions
Technique
Use of an activated
carbon filter
Thermal oxidiser
Regenerative
oxidiser
11.10.2
thermal
Description
This process is based on the adsorption of PCDD/F molecules in the
activated carbon. When the surface has adsorbed as much as it can, the
adsorbed content is desorbed as part of the regeneration of the adsorbent
Combustion system in which the pollutant within the exhaust gas stream
reacts with oxygen in a temperature controlled environment to create an
oxidation reaction. It is also known as afterburner
Combustion system that employs a regenerative process to utilise the
thermal energy in the gas and carbon compounds by using refractory support
beds. A manifold system is needed to change the direction of the gas flow to
clean the bed. It is also known as regenerative afterburner
Water emissions
Techniques
Chemical precipitation
Sedimentation
Flotation
Filtration
Ultrafiltration
Activated
filtration
Reverse osmosis
1196
Description
Combustion system in which the pollutant within the exhaust gas stream
reacts with oxygen in a temperature controlled environment to create an
oxidation reaction
Combustion system that employs a regenerative process to utilise the
thermal energy in the gas and carbon compounds by using refractory support
beds. A manifold system is needed to change the direction of the gas flow to
clean the bed. It is also known as regenerative afterburner
Combustion system where the decomposition is carried out on a metal
catalyst surface at lower temperatures, typically from 350 to 400 °C. It is
also known as catalytic afterburner
It consists of a bed of organic material, where pollutants from waste off-gas
streams are biologically oxidised by naturally occurring micro-organisms
It combines wet gas scrubbing (absorption) and biodegradation, the
scrubbing water containing a population of microorganisms suitable to
oxidise the noxious gas components
carbon
Descriptions
This consists of adding a reagent such as lime, sodium hydroxide, sodium
sulphide or a combination of reagents, to adjust the pH value and promote
the precipitation of soluble metals
Sedimentation is a solid-liquid separation technique that utilises gravity to
separate the insoluble metal complexes and solid particles from the liquid
effluent
Flotation techniques are used to separate large flocs or floating particles like
plastic parts from the effluent by bringing them to the surface of the
suspension
It is the separation of solid from waste water effluent passing through a
porous medium. Sand is the most commonly used filtering media
It is a filtration process in which membranes are used to increase the
removal efficiency
It is a filtration process in which activated carbon is used as filtering media
It is a membrane process in which a pressure difference applied between the
compartments separated by the membrane causes water to flow from the
stronger solution to the weaker
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Chapter 11
11.10.3
Other descriptions
Techniques
Boosted suction system
Descriptions
Boosted suction systems are designed to modify the extraction fan capacity
based on the sources of the fumes that change over the charging, melting
and tapping cycles. Automated control of the burner rate during charging is
also applied to ensure a minimum gas flow during operations with the door
opened
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