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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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Acid Plant Database  September 13, 2019

 

Owner Teck Metals Limited

Teck-Logo.gif (1990 bytes)

Location P.O. Box 1000
25 Aldridge Avenue
Trail, British Columbia
Canada V1R 4L8
Background Formerly
The Consolidated Mining and Smelting Company of Canada
1996 - Company name changed to Cominco Limited
2001 - Teck and Cominco merge
- Teck Cominco Limited
Teck-Cominco-Logo.gif (5975 bytes)
Website www.teck.com
Plant No. 7 Acid Plant No. 8 Acid Plant No. 9 Acid Plant
Coordinates* 49º 6' 7" N, 117º 43' 14" W 49º 6' 4" N, 117º 43' 11" W 49º 6' 5" N, 117º 43' 13" W
Type of Plant Metallurgical Metallurgical Metallurgical
Gas Source Zinc - Roasters (2)
Lead - Kivcet
Plant Capacity 350 MTPD 460 MTPD 581 MTPD
SA/DA 3 SA 3 SA 3 SA
Status Shutdown 2014 Shutdown 2014 Operating
Year Built - - 1972
Technology MECS MECS MECS
Contractor - - -
Equipment

Blower
Supplier: Allis-Chalmers
Delivery Year:
Model: D30LR
Quantity: 1
Flow Rate: 46000 CFM
Pressure Rise: 3.58 psi (99" WC)
Driver: 865 Hp, Electric Motor

Blower
Supplier: Roots
Delivery Year:
Model: 42" OIB
Quantity: 1
Flow Rate: 53500 CFM
Pressure Rise: 4.505 psi (125" WC)
Driver: 1270 Hp, Electric Motor

Blower
Supplier: Allis-Chalmers
Delivery Year:
Model: D24JR
Quantity: 1
Flow Rate: 40000 CFM
Pressure Rise: 6.386 psi (177" WC)
Driver: 1315 Hp, Electric Motor

Remarks -

2006 - Original converter replaced with a SS converter designed and supplied by Chemetics

-
Gas cleaning system with a Boliden mercury removal system is common to all acid plants.  Acid plant tailgas is treated in an ammonia scrubber.  Liquid SO2 is produced by acidulation of the scrubber bleed.

NOx
Bulk acid treated with sulfamic acid and hydrogen peroxide as per US Patent
5955050

Pictures
  Teck-Cominco-AP8b.JPG (64256 bytes) -
Plant No. 1 Acid Plant No. 2 Acid Plant
Coordinates* 49° 6' 6" N, 117° 43' 15" W -
Type of Plant Metallurgical Metallurgical
Gas Source Zinc - Roasters (2)
Lead - Kivcet
Zinc - Roasters (2)
Lead - Kivcet
Plant Capacity 1040 MTPD 1040 MTPD
SA/DA 3/1 DA 3/1 DA
Status Operating Operating
Year Built 2014 2019
Technology Chemetics/Jacobs Chemetics/Jacobs
Contractor - -
Equipment Bed 4: 100% Cesium Catalyst
Two internal gas-gas heat exchangers
DeNOx reactor
-
Remarks Acid plants 7 and 8 shutdown -
Pictures  
General In smelting and refining, Teck Cominco Metals owns and operates the integrated smelting and refining complex at Trail, British Columbia. The complex’s major products are refined zinc and lead. It also produces silver, gold, germanium dioxide, indium, cadmium and copper compounds as metal co-products, along with a variety of sulphur products and ammonium sulphate fertilizers.

Cominco started in 1906 as The Consolidated Mining and Smelting Company of Canada, formed by the amalgamation of several units controlled by the Canadian Pacific Railway. The company changed its name to Cominco in 1966. Cominco's core Sullivan mine, which began production in 1909, would operate for more than 90 years until its ore reserves were exhausted in 2001.
Teck began as The Teck-Hughes Gold Mines Limited in 1913, to develop a gold discovery by prospectors Sandy McIntyre and James Hughes at Kirkland Lake. The Teck-Hughes mine was in production for 50 years until 1965. Teck purchased the Beaverdell mine in 1969. This silver mine was first explored in 1898 and was in production until 1991.
The association between Teck and Cominco began in 1986, when Teck and two industry partners acquired a shareholding from CP Limited. Teck and Cominco merged in July 2001.
The company’s legal name will remain “Teck Cominco Limited” until the next Annual General Meeting in April 2009. At that AGM, subject to the approval of shareholders, the company proposes to change the legal name to “Teck Resources Limited”. However, effective immediately, the brand of the company will be simply “Teck”.

References -
News September 13, 2019 - After two years of construction valued at $174 million, the No. 2 Acid Plant is now in service at the Trail smelter.  Teck Trail Operations officially announced the plant’s completion on Thursday, though the new facility has been fully operational since Q2 (second quarter), or late spring.  “This investment supports our ongoing focus on sustainability and the long-term viability of our operation,” Thompson Hickey, General Manager, Trail Operations, said in the Sept. 12 media release.  “Using the best available technology, the new plant will enhance productivity and operational efficiency here at Trail Operations.”  The new structure is a state-of-the-art replica of the No. 1 Acid Plant, which was completed in 2014.  Attributes of both facilities is “to significantly improve operating reliability and flexibility, reducing downtime and maintenance costs.”  The new plants replace 1970s technology and are expected to have a lifespan of over 40 years.  Ground broke on the second site in early 2017. Over the course of the build, the No. 2 Acid Plant created the equivalent of roughly 160 jobs, with local hires as the majority of contractors.  “Our employees and contractor partners have exemplified safety as a core value on the project, which was completed with zero lost time injuries,” said Hickey.  Local and provincial leaders were taken on a tour of the worksite in May 2018, when the build was at the half-way point.  “The No. 2 Acid Plant is the latest major investment to further strengthen Trail’s position as a world-class metallurgical facility and an important part of our business,” Shehzad Bharmal, Vice President, North America Operations, Base Metals, said at the May 22 event.  “Teck, as a company, is committed to the future of Trail Operations. That is why we have worked hard over the years to strengthen the operational and environmental performance of every aspect of the smelter.”  The acid plants are part of zinc production processes and convert SO2 (sulphur dioxide) gas into sulphuric acid.  Sulphuric acid is sent to Warfield Operations for use in fertilizer production and it is sold in the open market for other industrial applications.  Technology used in the new builds will further reduce SO2 emissions.  Teck Trail Operations houses one of the world’s largest smelting and refining complexes, which produces refined zinc and lead and a variety of precious and specialty metals, chemicals, and fertilizer products. The smelter employs approximately 1,400 people and has been in operation for over a century.

July 26, 2019
- Trucking sulphuric acid out of Teck Trail has been temporarily suspended after condensation was detected on a valve at the back end of a carrier last weekend.
  “This is not a long cessation, it’s a voluntary cessation,” said Tip O’Neill, president of International Raw Materials (IRM), the American company that purchases sulphuric acid from the Trail plant.  “We are just really making sure we have identified what the issue is (through) a forensic investigation. We want to make sure that we have that nailed and that we’ve checked all other valves in our fleet because we just absolutely do not want to put the community at risk,” he told the Trail Times.  “And there was never any danger to the public or the environment.”  Recounting what happened to the Times, O’Neill said when a truck carrying sulphuric acid arrived at Teck’s Waneta train centre late Saturday night (July 20), the driver noted dampness on one valve at the rear of the vehicle.  “The truck driver and the unloader do a 360 inspection, twice, on all of the trucks,” he explained. “And they saw this valve with some moisture, so they immediately put a pan underneath it to catch any drops, but there were never any drops.”  Early the following morning, he says a spot was noticed at the acid loading site in the centre of Teck Trail operations.  “That was contained and washed,” O’Neill said. “And we immediately reacted, so in the abundance of caution, we had multiple sets of eyes going over the entire route for the truck, to identify any mark on the road that could have been a drip of acid, and tested it,” he emphasized.  “There were no positive tests.”  The company, however, immediately suspended transporting acid via highway from the smelter to Waneta, which extends 10 kilometres (km) on Highway 3B through Trail and approximately six km on Highway 22 to the train.  IRM averages about 100 railcars of acid shipments per month from the Waneta Reload Facility, equating to roughly 10,000 metric tons.


June 5, 2018
- After 80 litres of sulphuric acid was recently spilled on the highway through Trail by Westcan Bulk Transport, the 
Times contacted Teck to ask if transportation changes have been made to better ensure public safety.  To clarify, 80 litres of sulphuric acid is the approximate total of two spills.  The first happened the morning of April 10 and extended the 16-km run from the Trail plant to the Waneta re-load station. The second acid leak occurred around 6 p.m. May 23 and stretched from the smelter through the city to Shavers Bench.  Immediately following the second spill, Teck Trail confirmed that Westcan Bulk Transport had been suspended.  Communications Leader Catherine Adair stated that, given the recent incidents, the company would be working closely with IRM, the owner of the product, to review its transport arrangements.  Since that time, IRM (International Raw Materials Ltd.) has made changes to both carrier and mode of transport.  “IRM has contracted an alternative trucking company, Trimac Transportation, to conduct trucking of sulphuric acid from the production point,” IRM Vice President Tim Mahoney told the Times.  “We have also positioned our own staff to supervise these operations directly to coordinate the transition and ensure the highest safety standards are met.”  Historically, the company loaded 15 to 20 trucks per day from the production site.  “We have reduced this by approximately 50 per cent,” Mahoney said. “And are shipping higher volumes via railcar from the Trail production site for the time being.”  IRM is committed to ensuring a safe and sustainable operation, he added.  “We are working with all stakeholders to ensure the safe and proper handling and distribution of the sulphuric acid produced in Trail.”  Immediately following second incident and Westcan suspension, Adair said production was unaffected as Trail operations had storage and IRM had alternate shipping options.  She clarified, “IRM takes care of transport and sale of sulphuric acid from Trail Operations.”  Westcan issued a statement following the first sulphuric acid “release.”  The company stated, “The release was quickly identified and our incident response team secured the area to assess the incident and begin the clean up process, with the assistance of the Teck Emergency Response Team.”  Westcan said, “We can confirm that there was no waterway or ground water contamination as a result of the release and do not expect there to be any long-term health, safety or environmental impacts.”  On Wednesday May 23, three firefighters from Station 374 Trail were called to assist Teck emergency response at a HAZMAT (hazardous material) scene, which started at Highway 3B and Rossland Avenue and continued to the west entrance of Glenmerry.  In both instances, Mahoney says the drivers visually identified the leaks.  www.trailtimes.ca


May 24, 2018
- After a second sulphuric acid spill in Trail in the past six weeks, Westcan Bulk Transport has been suspended as a carrier for Teck Trail Operations, the company confirmed Thursday.  “IRM is the owner of the product (sulphuric acid) and is responsible for safe transport once it leaves Trail Operations,” Teck’s Catherine Adair told the Times. “Westcan is one of the carriers that IRM retains to ship product.”  Teck is working closely with IRM to review their transportation arrangements given these recent incidents, Adair said. “A full investigation is underway, and the transportation of the product using Westcan as a carrier is suspended until Teck is satisfied it can be transported safely.”  Three firefighters from Station 374 Trail were called to a Hazmat scene near Shavers Bench Wednesday night.  A truck hauling sulphuric acid had “some spills” along Highway 3B, Captain Grant Tyson reported.  “Starting at Highway 3B and Rossland Avenue and continuing to the west entrance of Glenmerry where the truck came to a stop,” he explained.  “Teck’s Emergency Response team along with the Teck Fire Department were on scene and dealt with the spilled acid.”  Tyson’s crew arrived to the site at 6 p.m. He reported the incident under control by about 8:30 p.m.  Zoe LeParque, communications manager for RTL-Westcan Group of Companies in Edmonton, replied to questions from the Trail Times.  “Initial findings indicate that the cause of the incident was a gasket failure on the trailer unit and was unrelated to the release that occurred on April 10. As the incident is still under investigation, we will not be speculating or providing any additional comment at this time.”


May 23, 2018 - Teck Trail’s new state-of-the-art acid plant hit the halfway mark of construction this week.  Local and provincial leaders met with Teck representatives at the site on Tuesday to hear an update on the $174-million build, which is slated to be fully operational by next summer.  “Today is all about celebrating an important milestone in a major project here at Trail Operations – 50 per cent completion of the No. 2 Acid Plant, ” General Manager Thompson Hickey began. “And celebrating the achievements of our project’s team as well as the many contractors, including CIMS, West Kootenay Mechanical, A-Plus Electric and AMEC Foster Wheeler, who worked so hard to reach this milestone.”  The new facility is a replica of the No. 1 Acid Plant which was completed in 2014. Together the new technology will replace three acid plants, which were constructed in the 1960s and ‘70s, that have now reached the end of their lifespan.  “The No. 2 Acid Plant is the latest major investment to further strengthen Trail’s position as a world-class metallurgical facility and an important part of our business,” noted Shehzad Bharmal, Vice President, North America Operations, Base Metals, Teck. “Teck, as a company, is committed to the future of Trail Operations. That is why we have worked hard over the years to strengthen the operational and environmental performance of every aspect of the smelter.”  The acid plants are part of zinc production processes, and convert SO2 gas into sulphuric acid. The sulphuric acid is sent to Warfield Operations for use in fertilizer production and it is sold in the open market for other industrial applications.  The new plant will further reduce SO2 (sulphur dioxide) emissions.  “It’s so great to see this continuing investment made in Trail Operations,” Mayor Mike Martin said.  “This is new acid plant is going to be replacing two old units, and as was indicated today, it will have a 40-year asset life,” Martin told the Times. “So it will help, in part, to secure Trail Operations for the future.”  As far as the City of Trail goes, any environmental improvement that is made by Teck, is a benefit, he added.  “This is just another example of that, replacing an old unit with one that will be operating with higher efficiency in removing sulphur dioxide, so again, we’ll see improvement for the community.”  Investments such as the KIVCET Smelter and the Nov. 1 Acid Plant have reduced emissions from the Trail plant by 95 per cent, and the No. 2 Acid Plant will further reduce emissions while enhancing the efficiency of operations, Hickey noted.  “This investment is good for our operation and for the community, helping to ensure that Trail Operations continues to be an economic drive in the region for decades to come,” Hickey said. “At Teck, nothing is more important than everyone going home safe and healthy every day, so I’m very pleased to say we’ve also reached this important milestone with zero Lost Time Injuries.”  Trail Operations houses one of the world’s largest smelting and refining complexes, which produces refined zinc and lead and a variety of precious and specialty metals, chemicals, and fertilizer products. The site employs approximately 1,400 people and has been in operation for over a century.


April 11, 2018
- Westcan Bulk Transport issued an April 11 statement regarding a sulphuric acid release the previous morning in the Trail area.  “Shortly after 8:00 a.m. PST, there was a release of sulphuric acid from a Westcan Bulk Transport truck during the 16-km drive from Teck’s Trail Operations to the Quark Siding reload station in Waneta,” said the release.  The statement added, “The release was quickly identified and our incident response team secured the area to assess the incident and begin the clean up process, with the assistance of the Teck Emergency Response Team.  “The cleanup was completed at approximately 2:00 p.m. PST today (Tuesday). We can confirm that there was no waterway or ground water contamination as a result of the release and do not expect there to be any long-term health, safety or environmental impacts.”  The company did offer some precautionary actions for anyone concerned.  “Anyone who feels they may have come in contact with the product should avoid inhalation, digestion, and skin contact and wash any surface or item that may have come in contact with the product as a precaution.  “Anyone who was traveling in the vicinity at the time of the release and is concerned that their vehicle may have come in contact with the product should run their vehicle through an automatic car wash as a precaution to safely dilute and remove any residue.  “Our safety team is currently investigating to determine the cause of the release and the equipment involved has been taken out of service until a cause can be determined.”

March 23, 2017
- Structural element of the new $174 million acid plant at Teck Trail Operations are expected to start taking shape in a few weeks.  Three buildings from the 1960’s and ‘70s have been torn down to make way for the No. 2 acid plant, a carbon copy of the first emissions reducing plant Teck constructed in 2014.  “The project is progressing on schedule”, says Community Relations Leader Catherine Adair.  “We have completed demolition and the majority of excavation.  Foundation work is expected to begin in early April.”  HilTech Contracting and CIMS were awarded the contracts for demolition and site prep, the primary equipment supplier is the same company used for the previous build.  “The main equipment supplier for the project will be the same supplier as the No. 1 acid plant completed in July 2014”, Adair confirmed.  “as the new plant will be a replica of the previously constructed plant”.  Teck estimates approximately 650,000 hours of construction labour will be required to complete the build, which equates to about 160 jobs during construction.  “Contractor selection for foundation work, mechanical, structural and electrical work is currently underway”, Adair sadi.  “And other smaller contracts will be selected throughout the construction.  “The No. 2 acid plant is scheduled to become operational in the summer of 2019.  Over the last 20 years Teck has made significant investments to improve environmental performance at the Trail smelter, which is one of the largest zinc and lead smelting and refining operations in the world.  Notably, the company’s latest air quality summary to the Trail Health and Environment Committee showed that 2016 had the lowest annual average for lead and arsenic ever recorded in community air.  “The new acid plant represents an important investment in the ongoing sustainability and long-term future of Trail Operations”, Adair added.  “The new acid plant will significantly improve operating reliability and flexibility, reducing downtime and maintenance costs”.  SO2 (sulphur dioxide) emissions are projected to reduce a further five percent in addition to the 15 percent reduction in emissions realized from the 2014 installation of the No. 1 acid plant.  The acid plants are part of the process that converts sulphur from feed materials into useful products such as fertilizer.

March 20, 2012 - Jacobs Engineering Group Inc. announced today it received a contract from Teck Metals Ltd. to design and supply a new sulfuric acid plant for its Trail operation located in British Columbia, Canada.  Officials estimate the contract value to be approximately $50 million.  The new acid plant is replacing two aging plants at the site and is expected to improve operating reliability and flexibility, reduce downtime and maintenance costs, and improve environmental performance. The contract includes the design of the complete sulfuric acid plant contact section, including catalytic DeNO(x) system, as well as supply of all equipment and the majority of materials. The plant includes Jacobs' proprietary Chemetics® equipment throughout, including stainless steel converter (with dual internal exchangers), radial flow gas-gas exchangers, acid coolers and SARAMET® distributors and piping. The bulk of the proprietary equipment is being fabricated at Jacobs' facility in Pickering, Ontario.  Jacobs Group Vice President Andy Kremer stated, "We have been working together with Teck Trail Operations for many years on a variety of projects, and we are delighted that Teck has selected our technology for its new acid plant. We look forward to expanding our relationship with Trail Operations as the project is executed."  Trail Operations include one of the world's largest fully integrated zinc and lead smelting and refining complexes, a two-thirds interest in the Waneta hydroelectric dam and ownership of the dam's transmission system. The metallurgical operations produce refined zinc and lead, as well as a variety of precious and specialty metals, chemicals and fertilizer products.

March 16, 2010 - The Insurance Corporation of B.C. will destroy 18 vehicles belonging to employees of Teck Resources at the company's operations in Trail, B.C., after damage resulted from a sulphuric acid spill in January.  The acid spilled from a line that runs between the Trail and Warfield plants on Jan. 8 and emptied into a staff parking lot.   ``We couldn't predict the long-term effects so we can't guarantee safety,'' said ICBC spokeswoman Michelle Hargrave.   The leak affected 22 vehicles, each of which received new tires from Teck Resources. But ICBC has determined that's not enough for 18 of the vehicles.  “Customers were advised the vehicles would be crushed so that no affected parts from the vehicles could later enter the used parts market or end up in a repaired or rebuilt vehicle,” Hargrave said in an email.  The 18 clients are being compensated by ICBC, which is seeking to recover its costs from Teck Resources.   Hargrave could not say how much money is being awarded or the compensation amount ICBC is seeking, but said the corporation is in negotiations with the company.  The Teck employees' insurance premiums will not be affected.  A car that had the least contact with the acid is being returned to an employee who owned it because the vehicle was determined to be safe to operate.  The three additional damaged vehicles did not have comprehensive coverage with ICBC and their owners are not being compensated by the public insurer. Comprehensive coverage is optional and open to private competition in B.C.   Teck public affairs manager Richard Deane said he can't speak about individual employees' insurance arrangements but the company is continuing to work with those who've been affected by the spill.

October 19, 2009 - A contract employee was burnt with acid from a sulfuric acid drain line during a routine shutdown of the roaster acid area of Teck’s Trail operation on Oct. 19.  The contractor was treated for burns and released the same day at the Kootenay Boundary Regional Hospital (KBRH).  “We were in the midst of a planned shutdown of this area that began Oct. 17 and will run until Oct. 29,” said Carol Vanelli-Worosz, public relations for Teck’s Trail operation.  “We know he was discharged from the KBRH on the same day, but because he wasn’t our employee I have no further detailed information.”  Vanelli-Worosz said the shutdown isn’t anything out of the ordinary for Teck and about 120 contract employees would be coming and going on site during the maintenance.  She says an investigation is underway involving Teck, Work safe B.C. and Trail’s Local 480 United Steel-Workers Union.   “We are committed to everyone leaving our worksite safely everyday and we take these incidents very seriously,” said Vanelli-Worosz.  “There is now an investigation into the route causes of the incident to ensure it does not happen again.”

July 30, 2009 - Teck Resources Ltd. said it will resume full production at its Trail, B.C., zinc smelter due to recovering demand for the metal.   The company, Canada's largest base metals miner and a top producer of coal used in the steelmaking process, also said it has reached agreement with most of its coal customers on 2009 deliveries at $128 (U.S.) a tonne.  This brings its average realized coal price for the 2009 calendar year to between $155 and $160 a tonne, when factoring in coal sold early in the year at higher 2008 prices.  Teck slashed output at Trail by 20 per cent last fall as a result of plunging demand. It said it will raise output to 25,000 tonnes a month effective Sept. 1. The smelter had been operating at a rate of 20,000 tonnes a month. Mined zinc production will not be affected.  Teck said a strengthening in customer demand over the past several months has depleted refined metal inventories.

October 1, 2008 - Teck Cominco Limited (Teck) is pleased to announce the launch of its simplified name and brand, Teck, and the formation of five new strategic business units specializing in copper, metallurgical coal, zinc, gold and energy.  “Seven years ago when Teck Cominco was formed, two strong Canadian companies with a tradition of excellence in mining and metal refining were brought together. Since then, we’ve grown stronger through the acquisition and development of a diversified range of commodities,” said Don Lindsay, President and CEO. “Today, under one simplified name and a new strategic business unit structure, Teck is well positioned to build on our strength as a diversified resource leader.”  The new structure is designed to improve the company’s competitiveness by increasing Teck’s ability to analyze and act on available opportunities in each commodity segment. Each business unit is led by a senior executive with full responsibility for the unit’s performance including establishing a growth strategy, project identification and development, the safe and sustainable operation of the unit’s assets, delivering quality products to customers, and overall profit and loss accountability.

April 30, 2001 - The Boards of Directors of Teck Corporation and Cominco Ltd. are pleased to announce today that the two companies have entered into a merger agreement.  The ongoing company will be named Teck Cominco Limited, preserving the two most historic names in Canadian mining, with over 180 years of operating history between them.  Under the merger agreement, implementation of which is subject to regulatory, court and Cominco shareholder approvals and other customary conditions, Cominco shareholders will receive 1.8 Class B subordinate voting shares of Teck plus $6 in cash for each Cominco common share held. This represents a premium to Cominco shareholders of 21% over the average closing prices of the two companies in the 20 trading days prior to this announcement.  Dr. Norman B. Keevil, Chairman and CEO of Teck and Chairman of Cominco, stated: "The merger will result in a substantial, diversified, mining company with a larger market capitalization and much greater liquidity than either of the predecessors. The new Teck Cominco will have strong cash flow from world-class assets. The combined company's exceptional pipeline of expansion and development projects will fuel its ongoing growth. Chief among these projects are: the current expansion of capacity at the Red Dog zinc mine; the nearly-completed Antamina copper, zinc mine; the planned expansions of the Cajamarquilla zinc refinery and the Elkview coal mine; and the Pogo gold and San Nicolas copper, zinc projects currently at the feasibility study stage."  Dr. Keevil pointed to the trend towards consolidation in the mining industry to create stronger, more competitive companies, with the recently announced merger of BHP and Billiton being just the latest example.  He said: "With consolidation occurring across country borders around the world, it is only logical that two related companies based in the same city, with a number of joint operations and a significant proportion of common shareholders, join forces to become more competitive in the world mining industry."

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