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The cleaner production system is an integrated technology group, which is
expected to be composed of a series of individual techniques. Based on the
survey on 9 typical copper factories and questionnaires of related
experts/engineers/technicians, five groups of cleaner production technologies
were screened for designing the proposed CP options and then the integrated CP
system.

These five CP option are briefly described as follows:

a) Good operating practices/housekeeping: refers to efficiency improvements


and good management practices that can be employed to minimize wastes and
emissions, and are able to be implemented in most areas of a company at a
relatively low cost. For example, improvement of handling and inventory
practices can reduce the loss of input materials.

(b) Raw materials improvement: refers to reduction or elimination of hazardous


materials that enters the production process. For example, purification or
substitution can help to eliminate the generation of hazardous waste within the
production process.

(c) Technology modification: refers to changes in the process and/or equipment


to increase productivity and reduce waste and emissions. These modifications
can range from small, low-cost options to the replacement of processes
involving large capital investments. For example, the process conditions, such
as flow rates and/or temperature, could be optimized to save resources (raw
material and water) and energy consumption.

(d) Product changes: refers to changes in quality/quantity/variety of final


products through modifying quality standards, product composition, and
durability and/or substitute the partial/entire products to increase profits and
reduce wastes. For example, using waste slag to produce other metal as an extra
final product can obtain benefits from market sale and wastes disposal.

(e) Reuse/recycling: refers to the return of a waste material either to the


originating process as a substitute for an input material, or to another process as
an input material.

The most effective way to implement CP is to generate more feasible CP


options for each specific factory. A series of possible CP solutions will help
create a more integrated and effective CP system. After the screening procedure
based on consideration of environmental impacts and economic efficiency, four
integrated cleaner production options for promoting copper production, saving
water/energy resources, and reducing pollutants emission are suggested Mass
flow of copper process in JXCC

Option NO: Option 1 Option 2 Option 3 Option 4


Name Teniente ISA process treatment CIP system
technology plants for
dusts and
effluents
Effect improved eliminate the Reduce Reduce
through less starter effluents wastewater
down-time sheet, from and
and Improved sulfuric acid chemicals,
energy Cathode and save water
saving, Chemical smelter dusts and
High grade Quality, energy,
matte Increased reduce
operation, Refining clean time,
Improve Intensity, improve
copper Reduction Cathode
pure degree. of In-Process Chemical
Copper Quality
Inventory,
Increased
Productivity,
Improved
Electrode
Alignment
Type Technique Technique Technique Waste reusing
reformation reformation reformation
using the using the
existing existing
equipments equipments
Equipment Teniente stainless steel gas-handling CIP system
Converter and cathode, systems
Slag Cleaning Automated
Furnace Cathode
Stripping
Machine
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In CP option 1, the discharge of associate wastes is decreased by using Teniente
technology. For the elevation of the copper pure degree, the stuff copper ore of
per unit product is reduced. The consumption of coal is declined to 5.4 tons per
ton copper with areduction ratio of 18%. The discharge of Slag reaches 104
tons/d with a decrease of 25%.Thus, pollution problems caused by copper
production are well controlled.

Through CP option 2, the product quality is improved significantly and the


consumption of water, electrolyte and Electricity power for producing each unit
productis declined. The discharge of wastewater and waste copper is cut down.
The clean water is consumed at a lower level (21 tons/ton of copper), which is
30% less than that of using the existing technique. The environmental quality in
the ambient are will not be impaired by copper production in the JXCC.

During the process of reusing SO2 in option 3, the involved technologies belong
to close operations. Thus, there is almost no environmental concern during the
operation. Meanwhile, over 2000 tons of SO2, which is one of the most
important acid gas contributing to acid rain, can be reduced per year

By employing CP option 4, the discharge of wastewater and chemical is greatly


reduced during the CIP system. The reduction rate of chemical is up to 30%,
which markedly mitigates the associated pollution from cell clean process. the
quality of drained water can meet the corresponding standards and the pollution
could be voided in the ambient water bodies. Therefore, the implementation of
this option has attractive advantage for protecting water quality.

To improve the pollution reduction water saving and copper ore utilization for
copper industries in China, an integrated s ystem combined with a series of
advanced cleaner production technologies was proposed in this study. After the
consideration of environmental impacts and economic efficiency, four cleaner
production options integrated with various advanced technologies were
proposed.

To verify the proposed options, a case study was conducted in the Jiangxi
Copper Company (JXCC). After the production analysis and mass balance
calculation, the copper ore usage, water usage and waste discharge were
quantified during the copper production. The effects of four options were then
evaluated from the technical, environmental, and economic aspects,
respectively. After the assessment, the two-stage integrated cleaner production
system based on the proposed options was recommended to implement in the
factory. Through the two-year practices, significant results were obtained. The
productivity and quality of copper were improved. Meanwhile, the efficiency of
wastewater reduction, SO2 effluent reduction and water saving was increased
markedly. The goals of elevating economic benefits and improving
environmental quality were achieved through the integrated cleaner production
system.

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