December 2014
Toxic Reduction Plan
Summaries
Copper Cliff Smelter
Complex
Carbon monoxide
Sulphur dioxide
Particulate Matter (TSP, PM10, PM2.5)
Nitrogen oxides
VOCs
Hexachlorobenzene
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
Toxic Substance Reduction Plan Summaries for Toxic Substances at the Copper Cliff Smelter
Complex
1. Facility information
NPRI identification number: 444
NAICS identification number: 33-14-10
NAICS Canada code: 33
Legal and trade name of company:
Vale Canada Limited
Facility Street Address:
Copper Cliff Smelter
18 Rink Street,
Copper Cliff, Ontario
P0M 1N0
Facility Mailing Address:
Copper Cliff Smelter,
18 Rink Street,
Copper Cliff, Ontario
P0M 1N0
Number of full time employee equivalents (2012): 492
UTM x: 493502
UTM y: 5143518
Public Contact:
Frank Javor,
Manager – Environment (Air)
705-682-6736
Central Engineering Building,
18 Rink Street,
Copper Cliff, Ontario
P0M 1N0
Prepared Plan:
Mary Dubel
Superintendent – Environment (Air)
705-682-5563
Central Engineering Building,
18 Rink Street,
Copper Cliff, Ontario,
P0M 1N0
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
Highest ranking official:
Mike McCann,
General Manager – Smelter Complex
705-682-7065
Copper Cliff Smelter,
18 Rink Street,
Copper Cliff, Ontario
P0M 1N0
Toxic Reduction Planner and certifier:
Mary Dubel
Licence number: TSRP0118
Company information:
Vale Canada Limited
Business Number: 102475084
DUNS number: 200429306
Street Address:
200 Bay Street,
Suite 200, South Tower, P.O. Box 70
Toronto, Ontario
M5J 2K2
Parent Company:
Companhia Vale Do Rio Doce (Vale)
Business Number: 102475084
DUNS Number: 200429306
26 Graça Aranha Avenue,
Rio de Janeiro, Brazil
2. List of Toxic Substances used and created at the Copper Cliff Smelter Complex and CAS # of
Substance
Carbon monoxide, 630-08-0
Sulphur dioxide, 7446-09-5
Particulate matter (TSP, PM10, PM2.5), NA-M08, NA-M09, NA-M10
Nitrogen oxides, 11104-93-1
VOCs NA – M16
3. Toxic Reduction Policy Statement of Intent
At Vale’s Sudbury Operations, we are committed to sustainable development – meeting the needs of
the present without compromising the ability of future generations to meet their own needs. Vale
believes in zero harm, to our people, to our workplaces, to the communities in which we operate and to
the natural environment. Vale Canada Sudbury Operation’s is committed to playing a leadership role in
protecting the environment. While, for milling, smelting and refining, this primarily means reducing toxic
substances end-of-pipe emissions, wherever feasible, Vale will adopt safer alternatives and
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
technologies to reduce the use and release of toxic substances. Toxic substance reduction will be a
continuing effort in our company and new technologically and economically feasible reduction options
will be considered if opportunities become available in the future and are in compliance with all federal
and provincial regulations.
4. Objectives
4.1. Carbon monoxide
At this time, Vale’s Sudbury Operation does not intend to reduce the creation of carbon monoxide at the
Copper Cliff Smelter Complex. Reduction options were identified, however, at this time all options were
not technically or economically feasible for the facility. In 2013, Vale’s Sudbury Operation decided to
move to a one flash furnace operation at the Copper Cliff Bulk Smelter. With the move to a one furnace
operation, some of the facilities within the Copper Cliff Smelter Complex will be shut-down and the
equipment decommissioned. The removal of these circuits is anticipated to reduce the consumption of
natural gas at the Smelter Complex, in turn, reducing the creation of carbon monoxide.
Vale’s Sudbury Operations have committed to and completed projects that resulted in the reduction of
carbon monoxide creation at the Smelter Complex. Projects starting in 2010 were implemented to
reduce the natural gas usage in the Super Stack burners. The flue system at the Bulk Smelter is
designed so that flue gases leaving the process through the Super Stack are at a temperature of
130oC. This temperature is achieved through the use of natural gas burners that heat the gas before
exiting the Super Stack. One project, completed in 2012, decreased the low firing rate of the flue
burners by 50%, reducing the amount of natural gas consumed. This reduction in natural gas
consumption reduced the creation of carbon monoxide from this source.
4.2. Sulphur dioxide
At this time, Vale’s Sudbury Operations does not intend to reduce the creation of sulphur dioxide at the
Copper Cliff Smelter complex. Vale’s Sudbury Operations were not able to identify options to reduce
the creation of sulphur dioxide at the facility. The current process flow at the Copper Cliff Smelter
Complex is designed to process the nickel sulphide (bulk) concentrate at the Flash Furnaces. The
exothermic reaction produced by the combustion of iron and sulphur maintains the heat balance
needed for the smelting process. Sulphur dioxide capture and abatement continue to be the focus of
Vale’s Sudbury Operations for the reduction of sulphur dioxide emissions from the facility.
Part of Vale’s continued initiatives to reduce sulphur dioxide emissions and to comply with Ontario
Regulations 194/05 and Ontario Regulation 419/05, Vale’s Sudbury Operations have begun
construction on the Clean AER (Atmospheric Emission Reduction) project. With the implementation of
the Clean AER project in conjunction with the move to a one flash furnace operation, sulphur dioxide
emissions from the Smelter will be reduce by over 70% from current levels. The Clean AER project is
designed primarily to capture sulphur bearing gases from the Smelter’s converter aisle that currently
report to the Super stack and convert these emissions into sulphuric acid. In 2013, Vale’s Sudbury
Operation decided to move to a one flash furnace operation at the Copper Cliff Bulk Smelter. With the
move to a one furnace operation, a reduction in SO2 creation from the flash furnace is expected.
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
4.3. Particulate matter
At this time, Vale’s Sudbury Operations does not intend to reduce the creation of particulate matter
emissions at the Copper Cliff Smelter complex. Reduction options were identified, however, at this time
all options were not technically or economically feasible for the facility. Abatement of particulate matter
emissions has been a long standing objective at the Copper Cliff Smelter. Part of Vale’s continued
initiatives to reduce metals and particulate matter emissions, Vale’s Sudbury Operations have begun
construction on the Clean AER (Atmospheric Emission Reduction) project. With the implementation of
the Clean AER project, in conjunction with the move to a one flash furnace operation, particulate matter
emissions for the Smelter will be reduced to meet the Federal Pollution Prevention Planning emissions
targets. Engineering and procurement for Smelter upgrade work is currently underway at the facility.
4.4. Nitrogen oxides
Vale’s Sudbury Operations does not intend to reduce the creation of nitrogen oxide at the Copper Cliff
Smelter Complex. Reduction options were identified, however, at this time all options were not
technically or economically feasible for the facility. In 2013, Vale’s Sudbury Operation decided to move
to a one flash furnace operation at the Copper Cliff Bulk Smelter. With the move to a one furnace
operation, some of the facilities within the Copper Cliff Smelter Complex will be shut-down and the
equipment decommissioned. The removal of these circuits is anticipated to reduce the consumption of
natural gas at the Smelter Complex, in turn, reducing the creation of nitrogen oxides.
Vale’s Sudbury Operations have committed to and completed projects that resulted in the reduction of
nitrogen oxides creation at the Smelter Complex. Projects starting in 2010 were implemented to reduce
the natural gas usage in the Super Stack burners. The flue system at the Bulk Smelter is designed so
that flue gases leaving the process through the Super Stack are at a temperature of 130oC. This
temperature is achieved through the use of natural gas burners that heat the gas before exiting the
Super Stack. One project, completed in 2012, decreased the low firing rate of the flue burners by 50%,
reducing the amount of natural gas consumed. This reduction in natural gas consumption reduced the
creation of nitrogen oxides from this source.
As part of Vale’s policy of zero harm, all new and replacement natural gas heaters/burners at the
Smelter Complex must meet a low NOx specification as part of Vale’s engineering standards.
4.5. VOCs
At this time, Vale’s Sudbury Operations does not intend to reduce the creation of VOCs. Vale’s Copper
Cliff Smelter Complex was not able to identify new options to reduce the creation and release of VOCs.
Vale’s Sudbury Operations have committed to and started to deploy projects that will reduce the
creation of VOCs. The Clean AER (Atmospheric Emissions Reduction) project will make several
significant changes to the consumption of natural gas at the Smelter Complex, the source for the
creation of VOCs.
4.6 Hexachlorobenzene
At this time, Vale’s Sudbury Operations does not intend to reduce the creation of Hexachlorobenzene.
Vale’s Copper Cliff Smelter Complex was not able to identify new options to reduce the creation and
release of Hexachlorobenzene. Vale’s Sudbury Operations have committed to and started to deploy
projects that will reduce the creation of Hexachlorobenzene. The Clean AER (Atmospheric Emissions
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
Reduction) project will make several significant changes at the Smelter Complex which should reduce
the amount of Hexachlorobenzene generated.
1. Description of Substances
1.1. Carbon monoxide
Carbon monoxide is created from the incomplete combustion of natural gas in heaters and burners
used throughout the Smelter complex. Natural gas is used in burners/heaters for supplementary heat
in the process, heating of process gas and equipment and, in some areas, provide heat for the
workroom environment.
1.2. Sulphur dioxide
The ore, which is processed at Clarabelle Mill, naturally contains many elements, including nickel,
copper, cobalt, precious metals and sulphur. Sulphur is a component of the feed materials processed at
the Smelter with bulk (nickel) concentrate from the Mill being the primary source. It is the goal of the
smelting and refining process to remove the undesirable impurities to produce a pure base metal
product. In the presence of heat and oxygen, the sulphur found within the feed is converted into sulphur
dioxide. Sulphur is a necessary component in the feed material for the flash furnaces. The exothermic
reaction caused by the creation of sulphur dioxide is needed in order for the feed material to flash smelt
and turn into a molten material. To reduce the emissions of sulphur dioxide to the atmosphere, the
process gases from the Smelter Complex are captured and the sulphur recovered into the form of
sulphuric acid.
1.3. Particulate matter
Particulate matter is created during the processing of the metals concentrate through high temperature
chemical processes to recover metals. Volatile metal oxides and sulphides are produced during the
metallurgical processes and enter the off-gas stream, collected and sent to pollution control equipment.
Fugitive particulate matter emissions can occur during charging of materials and by the movement of
materials. Particulate matter is defined as microscopic solid and liquid particles that remain suspended
in the air. Total particulate matter is any airborne particulate matter with a diameter less than 100
microns. PM10 and PM2.5 are particle size fractions of the total particulate matter produced and emitted.
PM10 dust particles are approximately 10 micrometers in size or less and PM2.5 are particle size of
approximately 2.5 micrometers or less.
1.4. Nitrogen oxides
Nitrogen oxides are produced from the combustion of natural gas in heaters and burners used for
supplementary heat in the process, heating of process gas and equipment and, in some areas, provide
heat for the workroom environment throughout the Smelter Complex. NO x is created through the
thermal dissociation and subsequent reaction of nitrogen (N2) and oxygen (O2) molecules in the
combustion air.
1.5. VOCs
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
VOCs are created from natural gas combustion at the Smelter Complex. Natural gas is used for
supplementary heat in the process, heating of process gas and equipment, and, in some cases, to
provide heat for the workroom environment.
1.6. Hexachlorobenzene
Hexachlorobenzenes are created from organic material, mainly natural gas and petroleum coke.
Natural gas is used for supplementary heat in the process, heating of process gas and equipment, and,
in some cases, to provide heat for the workroom environment. Petroleum coke is used as both a
reducing agent and fuel in the process.
2. Rationale as to Why No Reduction Options Were Selected
2.1. Carbon monoxide
Even though several reduction options were identified for carbon monoxide, at this time, these options
were not selected for implementation. At the moment it is impossible to provide an absolute reduction
estimate for the creation of carbon monoxide at the Smelter Complex, as the process flow for the move
to a one furnace operation is still being developed. Until the process flow is finalized, the anticipated
reduction of natural gas usage and establishing a definitive timeline cannot be made at this time.
2.2. Nitrogen oxides
Even though several reduction options were identified for nitrogen oxides, at this time, these options
were not selected for implementation. At the moment it is impossible to provide an absolute reduction
estimate for the creation of nitrogen oxides at the Smelter Complex, as the process flow for the move to
a one furnace operation is still being developed. Until the process flow is finalized, the anticipated
reduction of natural gas usage and establishing a definitive timeline cannot be made at this time.
2.3. Particulate matter
Even though several reduction options were identified for particulate matter, at this time, these options
were not selected for implementation. The options presented did not meet the technical or economic
feasibility criteria established by the facility. Abatement of particulate matter emissions has been a long
standing objective at the Copper Cliff Smelter. Part of Vale’s continued initiatives to reduce metals and
particulate matter emissions. Vale’s Sudbury Operations have begun construction on the Clean AER
(Atmospheric Emission Reduction) project. With the implementation of the Clean AER project, in
conjunction with the move to a one flash furnace operation, particulate matter emissions for the Smelter
will be reduced to meet the Federal Pollution Prevention Planning emissions targets. Engineering and
procurement for Smelter upgrade work is currently underway at the facility.
2.4. Sulphur dioxide
Vale’s Sudbury Operations were not able to identify options to reduce the creation of sulphur dioxide at
the facility. The current process flow at the Copper Cliff Smelter Complex is designed to process nickel
sulphide (bulk) concentrate at the Flash Furnaces. The exothermic reaction produced by the
combustion of iron and sulphur maintains the heat balance needed for the smelting process. Sulphur
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
dioxide capture and abatement continue to be the focus of Vale’s Sudbury Operations for the reduction
of sulphur dioxide emissions from the facility.
Abatement of SO2 emissions has been a long standing objective at the Copper Cliff Smelter.
Historically, Vale has met improved annual emission targets and has achieved significant SO 2
reductions since the late 1970s. With decreasing SO2 emission allowances in Ontario, in the early
1990s the Copper Cliff Smelter examined many alternative SO 2 abatement technologies and
flowsheets before adopting the current process flow. This strategy for SO2 abatement consists of
optimizing the use of the chemical energy that is generated by oxidation of the iron sulphide species
found in the bulk concentrate. Using the available oxygen technology, a new flash furnace was
designed and constructed at the Copper Cliff Bulk Smelter leading to high SO2 off-gas streams
amenable to economic fixation through utilizing a Sulphuric Acid Plant and Liquid SO 2 Plant. The main
fuel for the Flash Furnace is pyrrhotite (FeS) found in the bulk concentrate, which contains the highest
amount of iron and sulphur. The combustion of the iron and sulphur is an exothermic reaction within the
Flash Furnace free board. When the sulphur flashes in the furnace the reaction with oxygen converts
the sulphur into sulphur dioxide and heat. Within the bulk converters, the reaction of pyrrhotite (FeS)
and oxygen also provides the necessary heat for the converting process. The conversion of sulphur
dioxide from the off-gas to sulphur products at the Sulphuric Acid Plant is a necessary stage in the
smelting process providing pollution control required to operate the facility with current environmental
regulations and targets. Mid-2013, the Liquid SO2 plant was shut-down, stopping the creation of liquid
SO2 on property.
2.5. VOCs
Even though a reduction option was identified for creation of VOCs, at this time, this option was not
selected for implementation. The option presented in the plan did not meet the economic feasibility
criteria established by the facility. Due to possible construction and cash-flow restrictions associated
with the construction and commissioning of the Clean AER (Atmospheric Emissions Reduction) project,
the reduction of natural gas combustion at the Smelter Complex due to the Clean AER will only be
considered for implementation once the Clean AER project is undergoing the commissioning phase of
the project.
2.6. Hexachlorobenzene
No reduction option was identified for creation or release of Hexachlorobenzenes, at this time.
Additional Information
Vale has incorporated the concept of sustainability into the mining, milling, smelting and refining
practices in Ontario, endeavoring to achieve zero harm to our people, to our workplaces and to the
natural environment. For the Base Metals Industry, this is primarily accomplished through pollution
control of end-of-pipe emissions. For the Sudbury Operations, past pollution control projects have
reduced property source fugitive air emissions and reduced process air emissions, which included the
construction of new storage handling facilities for feed material, re-vegetation of property boundary
areas, and the installation of new baghouses and electrostatic precipitators to capture dust emissions.
Vale is undertaking its Clean AER (Atmospheric Emissions Reduction) project to reduce sulphur
dioxide emissions by a further 70%, to significantly reduce particulate and metal emissions and improve
Vale Copper Cliff Smelter Complex
Toxic Reduction Plan Summaries
local air quality. As part of the Clean AER (Atmospheric Emissions Reduction) project, the current
outdoors Feed and Material Handling area, located at the Copper Cliff Smelter Complex, will be moved
into vented buildings with dust capture. By enclosing the dry feed material, environmental forces, such
as wind erosion, will no longer act on the material reducing the material loss to the environment. These
projects will ensure Vale’s Sudbury Operations will continue to contribute decades of employment,
economic growth and community support.
8. Plan Summary Statement
This plan summary is an accurate synopsis of the content of the toxic substance reduction plan for
carbon monoxide, nitrogen oxides, particulate matter, sulphur dioxide, VOCs and Hexachlorobenzene
creation at the Copper Cliff Smelter Complex, Sudbury Operations, prepared for Vale Canada Limited,
dated December 2013 and amended December 2014 with the addition of Hexachlorobenzene. The
content of the summary is up to date and reflects the current version of the toxic substance reduction
plan.