Outotec and Environment

Kalle Hrkki President, Pori Research Center CMD Seville May 15, 2008

Outotec Oyj

CMD 2008 Seville, Spain

Content
General Ferroalloy technologies Flash Smelting and Converting technologies Acid plant technologies Mineral Processing - Hydrometallurgy

Outotec Oyj

CMD 2008 Seville, Spain

Award-winning clean technologies

Flash Smelting - Flash Converting technology for sulfidic copper ores
ASM Historical Landmark award in 2001; The cleanest copper smelting technology in the world

Ferrochrome process
Winner of the 2007 Cleantech Finland competition Qualified for the European Business Awards for the Environment 2008 competition; Because of its cleanness and energyefficiency.

A new copper production method

Quality Innovation of the Year 2007 by Excellence Finland Because of low investment, low operating cost and environmental sustainability.

Outotec Oyj

CMD 2008 Seville, Spain

Clean technologies as a booster for competitiveness and economic growth

Our customers want to produce metals competitively. Only those producers survive in the long run who use sustainable technologies. Profitability and environmentally sound technologies can and must go hand in hand.

Copper smelter, refinery, precious metals and sulfuric acid plant in Yanggu, China

Outotec Oyj

CMD 2008 Seville, Spain

Environmentally sound technologies

Technology development is the key to
effective use of raw materials lower energy consumption lower water consumption less emissions better working environment

In improving the environmental conditions of a metallurgical plant, it is important to evaluate the whole production chain, from ore to metal.

Outotec Ferroalloy Technology Economical and Environmental Benefits

Outotec Oyj

CMD 2008 Seville, Spain

Ferrochrome Process

Outotec Oyj

CMD 2008 Seville, Spain

Advantages of SBSTM technology

Lower investment and operation costs. Furnace gas rich in CO from the electric furnace. used as fuel. High efficient use of cooling gases of the sintered pellets. Low exhaust gas temperatures. Profitable and high grade pellets for smelting.

Outotec Oyj

CMD 2008 Seville, Spain

Profitable pellets
Spherical, equally sized, hard and porous pellets. Constant chemical and physical properties. High refractoriness under load. High reducibility.

Ideal charging material for smelting.

10

Outotec Oyj

CMD 2008 Seville, Spain

Benefits of using high quality pellets

Better submerged electric arc furnace operation. Average load and power factor are higher. Energy consumption is significantly lower. Electrode paste consumption is lower. Continuous and even operation. High furnace availability.

11

Outotec Oyj

CMD 2008 Seville, Spain

Outotec FeCr smelting process

Automatic batching system. Preheating in a stationary shaft kiln. Smelting furnace is closed and sealed. Patented power contol system. Cleaning of CO-gas. Slag is granulated.

12

Outotec Oyj

CMD 2008 Seville, Spain

Electric power consumption in smelting depending on chromite quality

RUN-OF-MINES, BRIQUETTES, FINES

Power consumption kWh/t

5 000

LUMPY ORE 4 000

PELLETS

3 000

Preheated

CHROMITE QUALITY

13

Outotec Oyj

CMD 2008 Seville, Spain

Without Technology Development the CO2 emissions would have been almost 5 fold compared to the actual amounts
CO2 emissions in FeCr production in Tornio With and without technology development
600 000 CO2 EMISSIONS, ACTUAL 500 000 CO2 EMISSIONS, tpa CO2 EMISSIONS WITHOUT IMPROVEMENTS

400 000

300 000

200 000

100 000

0 1970

1975

1980

1985

1990 YEAR

1995

2000

2005

2010

Flash Smelting & Flash Converting

15

Outotec Oyj

CMD 2008 Seville, Spain

Outotec Copper Flash Smelting / Converting Technology

16

Outotec Oyj

CMD 2008 Seville, Spain

Flash Smelting Technology Flexible Solution

Flash Smelting has been applied for smelting of
copper concentrates (matte and blister production), copper matte (i.e. Flash Converting), nickel concentrates,

Copper Flash Smelters have been designed, built and operated for smelting of copper concentrates containing as low as 14 % copper and as high as 55 % copper; Flash Smelting can use any kind of additional fuel like natural gas, fuel oil, recycled oil, coal or coke; with the benefit of being able to utilize high-sulphur fuels, too.

17

Outotec Oyj

CMD 2008 Seville, Spain

Advantages of Flash Converting

Closed process
low gas and dust emissions good working conditions

Continuous low-volume process gas flow, rich in SO2

less gas cooling and cleaning capacity required low CAPEX/OPEX possibility for liquid SO2 production

Continuous process
high automation degree, good process control

Smelting and Converting separated

high on-line availability

High capacity with one small-sized converting furnace

no converter aisle, no cranes less maintenance, low CAPEX

Proven Flash Smelting technology

18

Outotec Oyj

CMD 2008 Seville, Spain

Sulphur capture development in copper smelting

Sulfur capture in Cu Smelting Brook Hunt database 2005
100 90 80 SULFUR CAPTURE, % 70 60 50 40 30 20 10 0 S capture Outokumpu Flash Smelters S capture by other smelters

Most economic way to close the gap is to change smelting technology to Flash Smelting and Flash Converting
S capture average

19 92 19 93 19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 20 04 05 ( 20 F) 06 ( 20 F) 07 ( 20 F) 08 ( 20 F) 09 ( 20 F) 10 (F )
YEAR

19

Outotec Oyj

CMD 2008 Seville, Spain

Energy consumption in copper smelters

(based on Brook Hunt data)
60 Total net energy concumption,GJ/t Cu Outokumpu Flash Other Smelters Power (Other Smelters)

50

40

30

20

10

0 0 100 000 200 000 300 000 400 000 500 000 Total Cu-Production, tpa

20

Outotec Oyj

CMD 2008 Seville, Spain

KOKKOLA RNNSKR (SWEDEN) GLOGOW HAMBURG (GERMANY) SALT LAKE CITY SAN MANUEL HIDALGO (USA) PIRDOP (BULGARIA) BAIA MARE (ROMANIA) SAMSUN HUELVA (SPAIN) KHATOON-ABAD (IRAN) (TURKEY) KOSAKA HITACHI ASHIO TAMANO PASAR DAHEJ KHETRI GHATSILA (INDIA) CAMACARI (BRAZIL) CHUQUICAMATA CHAGRES (CHILE) FORTALEZA (BRAZIL) KALGOORLIE TENNANT CREEK OLYMPIC DAM MOUNT MORGAN (AUSTRALIA) KONKOLA (ZAMBIA) SELEBI-PHIKWE (BOTSWANA) JINCHANG YANGGU TONGLING GUIXI (CHINA) (PHILIPPINES) TOYO SAGANOSEKI (JAPAN) (POLAND) HARJAVALTA (FINLAND) NORILSK (RUSSIA)

ONSAN (SOUTH KOREA)

LA CARIDAD (MEXICO)

Flash Smelters around the world

Cu SMELTING Cu CONVERTING DIRECT TO BLISTER Ni SMELTING NOT IN OPERATION

Acid Plant Technologies

22

Outotec Oyj

CMD 2008 Seville, Spain

Sulphuric Acid Plants from Smelter Off-gas

1. Feed material: Off gas from metallurgical processes (melting, roasting, etc.) (SO2 content 2%-60% vol) 2. Products: Sulphuric acid ( 94,0 - 98,5% H2SO4) 3. Applications: Cleaning of metallurgical off gas (ore roasting, metal smelting and converting, etc.) 4. Capacity range: 50 5.000 tpd (product H2So4) 5. Investment costs: 5 - 200 Mio USD

23

Outotec Oyj

CMD 2008 Seville, Spain

Our experience in sulphuric acid plants

More than 80 Years in H2SO4 technology Over 600 acid plants built world wide Smelting, roasting, off-gas cleaning, acid plants single supplier Worlds largest metallurgical acid plant: 4,200 mtpd (1.5 MM t/a) Worlds largest sulphur burning plant 4,800 mtpd (1.7 MM t/a) Super project Maaden 3 x 4,500 mtpd (de-bottlenecked 5,000 t/d)

24

Outotec Oyj

CMD 2008 Seville, Spain

LURECTM @ Yanggu Xiangguang Copper Co (capacity 2,300 mtpd)

Conventional acid plant: 12 vol% => high gas volume => high invetment cost

LURECTM operates at 1618%-vol. SO2 5 Bed Converter with 3 integrated Heat Exchangers High Pressure Steam Production

Mineral Processing - Hydrometallurgy

26

Outotec Oyj

CMD 2008 Seville, Spain

Mineral Processing - Hydrometallurgy

ORE

CRUSHING

GRINDING

FLOTATION

FLOTATION TAILINGS

BIO
HEAP LEACHING OF ORE ORE LEACHING

CONCENTRATE

CONCENTRATE LEACHING

LEACH RESIDUE
SOLUTION PURIFICATION

REDUCTION

METAL

27

Outotec Oyj

CMD 2008 Seville, Spain

Energy-efficient grinding technology

Efficiency in the grinding circuit improves the overall performance of the concentrator. Outotec provides Advanced Control Tools (ACT) for grinding circuits:
Desired particle size distribution is achieved and maintained. Throughput of the mil is optimized.

This ensures cost-effective, troublefree and efficient operation of grinding circuit.

28

Outotec Oyj

CMD 2008 Seville, Spain

Advanced Flotation technology

Outotec sets new standards for Superior flotation performance: aeration, mixing and froth removing. Low operating and maintenance costs and high equipment reliability. The wide range of available cell sizes, including the world largest operating flotation cell (TC- 300) permits plant design to be compact, economical and efficient.

29

Outotec Oyj

CMD 2008 Seville, Spain

Leading Thickener Technology

The revolutionary SUPAFLO High Rate Thickener concept has pioneered and redefined the methods of clarification and thickening around the world over the past decade.

30

Outotec Oyj

CMD 2008 Seville, Spain

Paste thickening
Outotec leads the industry with thickening technologies for base metals and minerals slurries, using:
High rate, High Compression, Paste Thickeners.

Why use Paste Thickeners?

To efficiently use water (water shortage in mine-sites). Underflow (paste/solids) does not require filtration. De-watering a slurry to a paste will lead to environmentally sustainable tailings management. Paste might be used for refilling degraded mine-areas (rehabilitation of mine-sites).

31

Outotec Oyj

CMD 2008 Seville, Spain

Outotec hydrometallurgical processes

Standard HydroCopper Zn hydrometallurgy (direct zinc concentrate leach technology) SX technology Customer specific tailored Different unit processes (known performance) Equipment selection

32

Outotec Oyj

CMD 2008 Seville, Spain

The HydroCopper - process

HydroCopper is a chloride media based leaching process:

Copper concentrates. Secondary Copper raw materials.

Operating at athmospheric pressure and T = 80 -100 C. Final product copper rod. No concentrate transportation!!

33

Outotec Oyj

CMD 2008 Seville, Spain

Customized process solution

What is a customized process solution?
Utilization of existing knowledge and references. Adaptation of the knowledge for a customer specific case.

Customized process to treat customer specific raw material

Leaching Impurity control Residue control Product control.

Environmental aspects taken into account.

34

Outotec Oyj

CMD 2008 Seville, Spain

Mine to metal concept

MINE CONCENTRATOR HydroCopper END PRODUCT

No concentrate transportation. Local sosio-economic impacts.

35

Outotec Oyj

CMD 2008 Seville, Spain

Mine to Metal Longer lifetime for mine

36

Outotec Oyj

CMD 2008 Seville, Spain

Summary
Our customers want to produce metals competitively. Only those producers survive in the long run who use sustainable technologies. Profitability and environmentally sound technologies can and must go hand in hand. Technology development is the key. It is important to evaluate the whole production chain, from ore to metal.

37

Outotec Oyj

CMD 2008 Seville, Spain

More out of ore!