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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Sulphuric Acid on the Web

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Handbook of Sulphuric Acid Manufacturing
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Process Engineering Data Sheets - PEDS
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Preface
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Sulphuric Acid Plant Specifications
 

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Acid Plant Database December 27, 2010

Owner Xstrata Nickel

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Location Longyear Drive
Falconbridge, Ontario
Canada P0M 1S0
Background Formerly Falconbridge Limited
Formerly Falconbridge Nickel Mines Limited
Website www.xstrata.com
Plant Sudbury Smelter
Coordinates 46º 34' 43" N, 80º 48' 7" W
Type of Plant Metallurgical
Gas Source Nickel
(2) Roaster, Electric Furnace
Hot Gas Cleaning -
Wet Gas Cleaning Peabody Scrubber - (4) Primary WESP - 2 Secondary WESP
Contact Section Drying Tower - Blower - Cold HX (SS) - Inter HX (SS) - Hot HX (SS) - Bed 1 - Hot HX (TS) - Bed 2 - Inter HX (TS) - Bed 3 - 3/4 HX (SS) (air cooled) - Bed 4 - Cold HX (TS) - Tailgas HX (TS) - Absorber - Tailgas HX (SS) - Smelter Stack
Plant Capacity 1168 MTPD
SA/DA Original: 3 SA
2008 - 4 SA (with installation of an interbed heat exchanger)
Status Operating
Year Built 1978
Technology MECS
Contractor Simon-Carves FENCO
Equipment Blower
Supplier: Allis Chalmers
Delivery Year:
Model: D48JR
Quantity: 1
Flow Rate: 131334 CFM
Pressure Rise: 7.587 psi (210" WC)
Driver: Electric Motor
Remarks 2010 - Drying Tower replaced with an Outotec designed tower.  Wardrop provided engineering.
Pictures  
General The processing facilities operated by the Sudbury Smelter include a smelter and a sulphuric acid plant. The Sudbury Smelter smelts nickel-copper concentrate from the Sudbury and Raglan mines and processes custom feed materials. It is capable of producing 130,000 tonnes of nickel-copper matte annually. The smelter's electric furnace converts the mineral concentrate into a high-grade matte containing nickel, copper, cobalt and platinum group metals. The smelted and granulated matte is sent by rail to Quebec City, then shipped overseas to Falconbridge Nikkelverk in Norway for refining into pure metals.
References -
News

November 24, 2010 - Greater Sudbury citizens are invited to attend a Nov. 25 meeting focusing on Xstrata Nickel’s application to have longer to meet the province’s new air emissions guidelines for sulphur dioxide.   The meeting will be held between 2 and 8 p.m. at the Falconbridge Community Centre.  Marc Butler, director of regulatory affairs with Xstrata’s Sudbury operations, said the company has asked to have until 2015 to meet the province’s current standard of 0.25 parts per million of sulphur dioxide.  The company is currently emitting 0.34 parts per million of sulphur dioxide.  He said he hopes the Ministry of the Environment will make a ruling on Xstrata’s request within the first half of 2011.  Xstrata Nickel is planning investments in its Sudbury operations to meet the new environmental guidelines. Butler said he doesn’t know how much these investments will cost, but they could easily get up to hundreds of millions of dollars.  Vale announced recently that it will spend $1.5 to $2 billion on an atmospheric emissions reduction project.  It takes time to implement technology because it needs to be tested first on the ground, Butler said.

January 22, 2010 - Xstrata Nickel cut production at its Falconbridge smelter Thursday afternoon because the weather was causing an inversion effect, where the plume is closer to the ground, said a spokesperson from the Ministry of the Environment.  Kate Jordan said the ministry received three complaints from the public about a sulphur haze over the Ramsey Lake area starting at about 3 p.m.  "Once we received complaints, we followed up first with Inco to ensure that it wasn't anything that was happening at the smelter in Copper Cliff," Jordan said.  Inco's plume, however, was travelling away from the city, she said.  "Then our environmental officer followed up with Xstrata and they were already aware of the situation and had cut back operations," Jordan said.   Jordan said the weather conditions were causing an "inversion" where the plume is lower than it would be normally.  "They do monitor for it. They know when they see that that condition is going to be present, they cut back operation," Jordan said.  Dominique Dionne, vice-president of corporate affairs at Xstrata in Toronto, said the smelter was brought down when the problem occurred.  "We have systems that tell us when there is an exceedance (in emissions) and we haven't had any of that so far," she said.  Jordan said the ministry was in contact with Xstrata Thursday afternoon.  "Based on all the information that was provided by the company in our discussions with them, we don't have any immediate concerns for impacts to the environment or to public health," Jordan said.

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