1. Development of an Operational Plan for Environmental Protection from Industrial Dusts in Russia and other NIS Contract Number: INCO-CT-2006-518693 Starting Date: 01.09.2006 Ending Date: 31.08.2008 A Specific Support Action project funded by the European Commission SIXTH FRAMEWORK PROGRAMME

2. Project Partners Rheinisch - Westfaelische Technische Hochschule Aachen IME Process Metallurgy and Metal Recycling Ukraine research and Development Institute of Industrial and Sanitary Purification of Gases Laboratory of Wastes Recycling Moscow State Institute of Steel and Alloys - Technological University Department of Ore Preparation and Iron-making The K.I. Satpaev Kazakh National Technical University Department of Metallurgical Processes and Technology of Special Materials National Technical University of Athens School of Mining and Metallurgical Engineering Laboratory of Metallurgy

3. Project Main Objective The development of an Operational Plan aiming to: 1. Propose appropriate and viable technologies for the confrontation of the environmental problems related with the metallurgical dusts generated in Ukraine, Russia and Kazakhstan Target related with the sustainable development of metals industry 2. Compose a framework for the development of new and innovative technologies for the environmental management of the metallurgical dusts Pure Scientific Target 3. Enable the EC Authorities to define the future RTD strategic objectives and policies in the field of metallurgy in the geographical area of Russia and other NIS Strategic Target

4. Project Workplan WP1: Data collection and Environmental Problem Assessment WP2: Technology Assessment WP3: Operational Plan Development WP4: Dissemination of Knowledge WP5: Project Management The Workplan of the project comprises five Workpackages:  Inventory including all the mentioned information per metal industry  Qualitative Risk Assessment study Framework for potential and feasible technological improvements facing the environmental problems related to metallurgical dusts  Proposals for production technologies that could substantially decrease the problem of dusts emissions in the regional metallurgical industry  Proposals for the management of the generated dusts that could significantly reduce the resulting environmental impacts  Guidelines for the EC’s future strategic plan and policy related to RTD in the field of metallurgy in the geographic area of Russia and other NIS  Construction of a specific website: http://www.labmet.ntua.gr/enprodus/  Organization of local Workshops:  Ukraine (Zaporozhye) – 13 and 14 of May, 2008  Kazakhstan (Almaty) – 28 and 29 of August, 2008

5. Production Technologies – Short overview The production processes currently followed in the Kazakh metallurgical plants are more or less in accordance with the BAT. The metallurgical equipment used in the different production stages are also considered as BAT. In general …  The Reverberatory furnaces used in the copper smelting process are not included in the BAT.  The Open-hearth furnaces used in steelmaking are not included in the BAT. In this stage, the Basic Oxygen Furnace is considered as BAT. The deviations …

6. Dust abatement techniques – Short overview In almost all the production stages, dust abatement systems are used. These systems are considered as BAT. There is a quite low percentage of dusts that are not collected and finally released into the atmosphere.  Primary copper production: 1,35 % and 3,70 %  Iron and Steel production: 6,85 %  Zinc production: 12,09 % In general …  The lack of dust abatement systems, mainly in the stages of smelting (Cu); converting and blast furnace (Fe).  The low efficiency of certain abatement techniques used for dusts collection, in particular in iron and steel metallurgy. The release of dusts in environment is attributed to …

7. Dust management technologies–Short overview There is a quite high percentage of the collected dusts that are recycled, re-used or utilized.  Primary copper production: 98,93 % and 86,29 %  Iron and steel production: 26,15 %  Zinc production: 75,42 % In general …  Copper production: 1,07 % and 13,71 % of the collected dust is lanfilled; Charge preparation and Smelting process (Cu, Pb, As, Si; particle size: 2 - 7 μm)  Iron production: 73,85 % of the collected dusts is lanfilled; 75 % from the Agglomeration – Sintering process (Si; particle size > 10 μm) 15 % from the Blast furnace plant (Si, Fe; particle size > 10 μm) 5 % from the limestone roasting process (Si, Ca; particle size > 20 μm)  Zinc production: 24,58 % of the collected dusts is landfilled; Concentrates preparation and Pressure leaching process (Cu, Pb, Zn; size: 2 - 4 μm) The non-recycled dusts …

8. Proposals – Production Technologies Companies know very well what they ought to do and the only it is needed is the willing to do the investment mobilizing the necessary amount of money

9. Proposals – Efficient dust abatement Recommended BATs to increase the efficiency of abatement systems: Choice and design of a suitable abatement technique, or combination of techniques, that takes into account the characteristics of each dust.  Fabric or Bag Filters  Hot Electrostatic Precipitators  Wet Electrostatic Precipitators  Ceramic Filters  Wet scrubbers  Cyclones Group of cyclones in series Cyclones in combination with Bag filter or EP

10. Proposals – Management of dusts Recommended BATs: Recycling, re-use and utilization of dusts with an economic interest. If there is not any economic interest for the collected dusts, safe discharge into a landfill, according to the environmental requirements and standards.

11. Emerging Research Priorities  The Research and Technological Development of new technologies related to the utilization of metallurgical dusts is necessary and urgent.  European Commission ought to direct its RTD policy priorities in this field in order for the metallurgical industry to face the challenges for Sustainable Development.