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Acid Plant
Database September 1, 2010
| Owner |
Vale |

|
| Location |
337
Power Street
Copper Cliff, Ontario
Canada P0M 1N0 |
| Background |
Formerly
- INCO Limited
2007 - Companhia Vale do Rio Doce (CVRD) acquires INCO
- CVRD changes name to Vale
2010 - Inco dropped from name |
| Website |
www.vale.com
www.cvrd.com.br
www.inco.com |
| Plant |
- |
| Coordinates |
46º
28' 36" N, 81º 3' 8" W |
| Type of Plant |
Metallurgical
INCO Flash Furnace |
| Gas
Source |
Nickel
and Copper |
| (2)
INCO Flash Furnace |
MK Reactor |
Fluid
Bed Reactor (FBR) |
| Hot Gas Cleaning |
- |
Evaporative
Chamber - Hot ESP |
- |
| Wet Gas Cleaning |
Separate
gas cleaning system for each flash furnace (MECS/Lurgi) Quench Chamber - Primary Reverse Jet - Froth Column - Final
Reverse Jet - Primary WESP - Secondary WESP - Wet Gas Fans |
- |
Lurgi
Bischoff Quench - Venturi -
Packed Gas Cooling Tower - Primary WESP - Secondary WESP - Wet Gas Fan |
| Plant Capacity |
Original:
2900 MTPD
2007: 3200 MTPD |
| SA/DA |
3/1
DA
Ontario-Operations-Flowsheet-2007.pdf |
| Status |
Operating |
| Year Built |
1991 |
| Technology |
MECS |
| Contractor |
Simon-Carves
FENCO, Now SNC-Lavalin |
| Equipment |
Blower
Supplier: Allis-Chalmers
Delivery Year: 1990
Model: D42JR
Quantity: 2
Flow Rate: 106961 CFM (each)
Pressure Rise: 10.11 psi (280" WC)
Driver: 5300 Hp, Electric Motor |
| Remarks |
Plant
debottlenecked and expanded in 2006
Liquid SO2 is also produced from high strength flash furnace gasesNOx
Candle drainings collected and treated in a NOx stripper. NOx discharged to acid
plant stack.
Bulk acid treated with sulfamic acid and hydrogen peroxide as per US Patent 5955050 |
| Pictures |

|
| General |
- |
| References |
- |
| News |
July 6, 2010
- It could be several days before the series of events that unfolded during Thursday's
sulphuric acid cloud at Vale's Copper Cliff Smelting Complex are known and steps are put
in place to deal with another such incident. "We are still investigating,"
said Steve Ball, manager of corporate affairs for Vale's Ontario operations, said Monday.
"We don't even have a debrief scheduled until (Tuesday)." The leak
occurred about 8:15 a.m. July 1, when a railcar being filled with oleum (sulphur trioxide
in sulphuric acid) overflowed. The pumping of oleum into rail cars was immediately
stopped when an operator noticed the spill. According to Vale, the leak was
contained and the situation was downgraded by 8:40 a.m. A "noticeable
plume" of sulphuric acid leaked into the air, Vale said. It left the property and
then dissipated over the Kelly Lake area. Oleum, also known as fuming sulfuric acid,
is a solution of various compositions of sulfur trioxide in sulfuric acid or disulfuric
acid (also known as pyrosulfuric acid). It is a liquid that turns into a mist when
released into the atmosphere. While air horns sounded during the leak, it took about
three hours to let the rest of the community know through the media, as well as police and
fire officials, due to a loss of power in the general office at the smelting complex.
"It's (loss of power) part of our debrief," said Ball. "What didn't,
what did work. We need to make sure the (computer) server doesn't shut down in Copper
Cliff again." Tim Beadman, the City of Greater Sudbury's chief of emergency
services, said the events are still being examined. "Yes, there is a review
underway to determine what worked well, what didn't work well," he said Monday.
"I don't have any more information to share at this this point in time. I need
to meet with the other service providers. That's being scheduled as we speak."
On Friday, protesters, who held a short demonstration, said they were furious with
statements from Ball that the spill posed no threat to public health. They are
demanding answers from the Ministry of the Environment about how and why the spill
occurred while liquid oleum was being pumped into rail cars at the acid plant at the
smelter complex. Brian Cameron, district manager of the MOE in Sudbury, said
ministry officials visited Vale property after the spill was reported to make sure the
liquid portion was cleaned up. The matter has been referred to the ministry's
investigations and enforcement branch and it will decide if charges will be laid against
the company. Protesters, many of them members of CANARYS (Community Activists Need
Answers Regarding Your Safety), were also angry Vale did not issue a news release about
the spill until three hours after it occurred. July
4, 2010 - The end
to a long-running and bitter strike in Ontario is in sight as mining giant Vale announced
it reached a tentative agreement with production and maintenance workers on Sunday. The metals miner says the agreement involves a new
five-year contract with United Steel Workers Locals 6500 and 6200, which represent
production and maintenance employees in Sudbury and Port Colborne. It's been a long strike and I think that
both sides worked hard, said Cory McPhee, vice-president of corporate affairs. Both sides wanted a deal and that
ultimately was the driving force to this outcome.
Comprehensive memorandums of agreement are to be signed between Vale and the
USW in Sudbury and Port Colborne on Monday. The
deal contains a return-to-work protocol, but Vale says it is still unclear when the
employees will be returning to work. I
can't comment on timing, Mr. McPhee said. Once the vote process is sorted out,
we'll begin bringing people back to work. The
union will now present the deal to the membership and ratification votes will be
scheduled. Suffice to say, we're very
happy to have a deal done, Mr. McPhee said. The
announcement comes just days after Ontario Labour Minister Peter Fonseca said the two
sides had agreed to resume bargaining. Before
reaching an impasse, the two sides had agreed on all issues except one the firing
of eight workers during the strike and whether they were entitled to arbitration. A statement from Mr. Fonseca had said the impasse
on the issue was not acceptable to the communities involved nor to the government. Mr. McPhee wouldn't say how the issue was dealt
with but confirmed that it had been resolved. We
were able to come together and get over that hurdle. Vale
says the settlements were reached with the help of mediators Kevin Burkett and Reg
Pearson. More than 3,000 production and
maintenance workers at Vale's Ontario operations in Sudbury and Port Colborne have been on
strike since July 13. Key issues included a
nickel bonus, job transfers, contracting out and pensions.
Vale's nickel business employs more than 11,000 people worldwide and had net
sales of $3.26-billion last year, accounting for 13.6 per cent of Vale's overall revenue.
July 1, 2010 - A hazardous material leak
alert at a Sudbury, Ont., chemical plant Thursday morning was the result of a plume of
sulphuric acid that was accidentally released into the air during a transfer, according to
a press release from Vale Sudbury. The "noticeable" cloud of sulphuric
acid "was released into the environment and escaped off property before dissipating
over the Kelly Lake area," the press release said. The spill was due to
overfilling a rail car, the company said. The alert was issued at 11:19 a.m.
about three hours after the leak happened. The leak itself was contained and
downgraded at 8:40 a.m. "No injuries have been reported as a result of this
incident," the release states. "The cause for this incident is currently under
investigation." Steve Ball, a spokesperson for Vale, said there was no risk to
the public. Ball apologized for the "late issuance" of the
information. He said residents in the area have received letters and information in
the past about how to respond when the hazardous material leak alert happens, and that
information is released to the public as soon as it is possible.
May 28, 2010 - Just like that, an iconic
name with more than 100 years of history in Canadian business is gone. Thursday,
Brazilian mining giant Vale SA announced it is removing the name "Inco" from its
nickel business, less than four years after it paid nearly $20-billion for the Canadian
miner. It comes as Vale's relations with the former Inco employees in Canada are
poor. In a statement, Vale said that scrapping the Inco name is a "natural
evolution" of the company and aligns it more fully with Vale's other mining
operations around the world. It marks the official end to a name that dates back to 1902
and has been synonymous with Canada's leadership role in the global nickel business, a
role that some economic nationalists believe it has lost. When Vale acquired Inco in
2006, it decided to keep the Inco brand as it made a major commitment to Canada.
"There were a lot of good reasons to keep the name," said Vale spokesman Cory
McPhee. "One was a nod to the heritage of the company, which had more than a hundred
years of existence. The other was from a marketing standpoint. The Inco nickel carried a
premium in the market because of its quality." Mr. McPhee added the connection
between Vale and Inco has become well-known over time, and the company wanted the entire
organization to be brought under the "Vale" brand. That has been the goal since
it rebranded itself as Vale in late 2007. (It was previously known as CVRD.) Vale's
acquisition of Inco was the biggest takeover to date by a Latin American company. At the
time, Vale chief executive Roger Agnelli said the transaction was "good for Inco and
good for Canada."
July 13, 2009 Vale S.A. (Vale)
informs that the unionized maintenance and production employees at its operations in
Sudbury and Port Colborne, province of Ontario, Canada, went on strike today after
rejecting the companys settlement offer for a new three-year collective bargaining
agreement. Our proposal aims to provide the right incentives to labor productivity
growth and to enhance the foundations of our long-term competitiveness and capacity to
continue to generate value. The strike affects 3,073 employees at our integrated
mining, milling, smelting and refining operations in Sudbury, and 116 employees at our
Port Colborne refinery. In 2008, finished nickel production originated from the
Sudbury operations reached 85,300 metric tons, 31% of Vales total output. Our Port
Colborne facility produces platinum group metals, gold and silver intermediate
products. As previously disclosed, the Sudbury and Port Colborne operations began an
eight-week shutdown on June 1, 2009, and were scheduled to resume operations on July 27,
2009.
July 13, 2009 - Chemtrade Logistics Income
Fund announced that Chemtrade's supply of sulphuric acid and liquid sulphur dioxide to its
customers will not be affected by the labour disruption at Vale Inco's nickel mining and
processing facilities at Sudbury. Mark Davis, President and CEO of Chemtrade, said,
"Prior to Vale Inco's announcement in April of an extended shutdown we began building
inventory to ensure that supply to our customers was protected. While Chemtrade's product
supply of acid from Vale Inco ceased on May 9 and will not resume until the smelter is
restarted, we will continue to supply our customers from inventory, our own sulphuric acid
manufacturing facilities as well as sourcing from other suppliers. We will continue to
review the situation but currently anticipate that we will be able to keep our customers
supplied until Vale Inco resumes production."
April 16, 2009 - Major nickel mining
operations in Sudbury, Ont., will come to a standstill for the first time in more than a
century this summer after Brazil's Vale Inco announced plans to shutter its Sudbury mines
and smelters for two months. Blaming the devastating downturn in nickel prices and
plunging demand for the metal used to make stainless steel, Vale Inco parent Companhia Vale do Rio Doce [RIO-N] said late Thursday it will close its five operating
Sudbury mines and its entire suite of nickel processing operations in June and July.
Vale Inco spokesman Cory McPhee said there is no longer sufficient demand for all
the nickel the company produces from its Sudbury operations. The pipeline is
full. We are not selling all the nickel we produce in Ontario and so this allows us to
clear the pipeline.
When we return to work we are going to be in a much better
position, Mr. McPhee said. About 5,000 Vale Inco employees will be affected.
Mr. McPhee said the company will mandate employees to use their vacation time during the
shutdown, but will likely have to issue temporary layoff notices. The planned
shutdowns follow Xstrata Nickel's recent decision to shutter its mining operations in
Sudbury, save for a development mine that won't reach full production until 2010.
Xstrata laid off 686 workers at its Sudbury operations in February when it put its two
operating mines on care and maintenance. It continues to construct the Nickel Rim
South mine in the Northern Ontario city that has been the world's largest nickel mining
centre since the early 1900's. In December, Vale Inco closed its Copper Cliff South
mine in Sudbury. It recently said it is cutting 900 jobs including 350 in Canada.
Vale and Xstrata were the respective victors in a heated takeover battle for Canadian
mining stalwarts Inco and Falconbridge in 2006 and 2007. The foreign mining giants paid
more than $40-billion combined for the Canadian companies. In order to win Ottawa's
approval for the takeovers, both Vale and Xstrata promised not to lay off workers for
three years. The price of nickel reached record highs above $23 (U.S.) a pound
shortly after the buyouts. It has since fallen to about $5.50 a pound.
June 27, 2006 - INCO announced
construction on a new $115 million facility that will reduce sulphur dioxide emissions
from its Sudbury operation. The facility is expected to reduce emissions by 34 per
cent using unique fluid bed roaster (FBR) off-gas scrubbing technology. The FBR SO2
Abatement project will include construction of a gas-cleaning facility adjacent to the
existing FBR plant at the smelter; expansion of the existing acid plant; and construction
of a Weak Acid Treatment plant at the Copper Cliff Mill Filter Plant. The project is
scheduled for completion by the end of December 2006 with a potential operational date in
early fall. |
MTPD - Metric Tonne per
Day STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption
* Coordinates can be used to locate
plant on Google Earth
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