
Environmental Encyclopedia 3
Smelter
metal particulates to the
environment
, and unless this is
prevented by
pollution control
devices, these emissions can
cause substantial environmental damages.
The earliest large industrial smelting technique in-
volved the oxidation of sulfide ores using roast beds, which
were heaps of ore piled upon wood. The heaps were ignited
in order to oxidize the sulfide-sulfur to sulfur dioxide,
thereby increasing the concentration of desired metals in the
residual product. The roast beds were allowed to smoulder
for several months, after which the crude-metal product was
collected for further processing at a refinery. The use of roast
beds produced intense, ground-level plumes filled with sulfur
dioxide, acidic mists, and metals, which could devastate local
ecosystems through direct toxicity and by causing
acidifi-
cation
.
More modern smelters emit pollutants to the
atmo-
sphere
through tall smokestacks. These can effectively dis-
perse emissions, so that local
air quality
is enhanced, and
damages are greatly reduced. However, the actual acreage
of land affected by the contamination is enlarged because
the tall smokestacks broadcast emissions over a greater dis-
tance and
acid rain
may be spread over a larger area as well.
Emissions of toxic
chemicals
can be reduced at the
source. Metal-containing particulates can be controlled
through the use of electrostatic precipitators or baghouses.
These devices can remove particulates from flue-gas streams,
so that they can be recovered and refined into pure metals,
instead of being emitted into the atmosphere. Electrostatic
precipitators and baghouses can often achieve particle-re-
moval efficiencies of 99% or better.
It is more difficult and expensive to reduce emissions
of gases such as sulfur dioxide. Existing technologies usually
rely on the reaction of sulfur dioxide with lime or limestone
to produce a
slurry
of gypsum (calcium sulfate) that can
be disposed into landfills or sometimes manufactured into
products such as wallboard. It is also possible to produce
sulfuric
acid
by some flue-gas desulfurization processes. At
best, removal efficiencies for sulfur dioxide are about 95%,
and often considerably less.
The types of smelters that do not treat sulfide metals,
such as iron ore smelters, logically do not emit sulfur dioxide.
They do, however, spew metal particulates into the atmo-
sphere. For example, a facility that has been operating for
centuries at Gusum, Sweden, has caused a significant local
pollution
with
copper
and
lead
, the toxic effects of which
have damaged vegetation. The surface organic matter of sites
close to the Gusum facility has been polluted with as much
as 2% each of zinc and copper. Secondary smelters also do
not generally emit toxic gases, but they can be important
sources of metal particulates. This has been especially well
documented for secondary lead smelters, many of which are
present in urban or suburban environments. The danger
1301
from these is that people can be affected by lead in their
environment, in addition to long-lasting ecological effects.
For example, lead concentrations in
soil
as large as less than
5% dry weight were found in the immediate vicinity of a
battery smelter in Toronto, Ontario. In this case, people
were living beside the smelter. Garden soils and vegetables,
house dust, and human tissues were all significantly contami-
nated with lead in the vicinity of that smelter. Similar obser-
vations have been made around other lead-battery smelters,
including many that are situated dangerously close to human
habitation.
One of the best-known case studies of environmental
damage caused by smelters concerns the effects of emissions
from the metal processing plants around
Sudbury, Ontario
.
This area has a long history as a mining community. For
many years, roast beds were the primary metal-processing
technology used at Sudbury. In fact, in its heyday, up to 30
roast beds were operating in Sudbury. Unforturnately, this
process saturated the air and soil with sulfur dioxide,
nickel
,
and copper. Local ecosystems were devastated by the direct
toxicity of sulfur dioxide and, to a lesser extent, the metals.
In addition,
dry deposition
of sulfur dioxide caused a severe
acidification of lakes and soil. This caused much of the plant
life to die, which in turn started soil
erosion
. Naked bedrock
was exposed, and then blackened and pitted by reaction with
the sulfurous plumes and acidic mists.
When the devastating consequences of the roast bed
method became clear, the government prohibited their use.
The processors turned to new technology in 1928 when they
began construction of three smelters with
tall stacks
. Since
these emitted pollutants high into the atmosphere, they
showed substantial improvements in local air quality. How-
ever, the damage to vegetation continued; lakes and soils
were still being acidified, and toxic contaminants were spread
over an increasingly large area.
Over time, well-defined patterns of ecological damage
developed around the Sudbury smelters. The problems that
had occurred in the roast beds were being repeated on a
large scale. The most devastated sites were close to the
smelters, and had concentrations of nickel and copper in
soil in the thousands of
parts per million
; they were very
acidic with resulting
aluminum
toxicity, and frequently fu-
migated by sulfur dioxide. Such toxic sites were barren, or
at most had very little plant cover. The few plants that were
present were usually specific ecotypes of a few widespread
species
that had evolved a tolerance to the toxic effects of
nickel, copper, and acidity. Aquatic lake habitats close to
the smelters were similarly affected. These waterbodies were
acidified by the dry deposition of sulfur dioxide, and had
large concentrations of soluble nickel, copper, aluminum,
and other toxic metals. Of course, the plant and animal life
of these lakes was highly impoverished and dominated by