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1 Introduction
It is not difficult to find evidence that human activities are beginning to overrun the resources of
the planet. The industrial processes that have benefited society are also among the sources of the
problems. It is clear that "business as usual" is not an option that industry can maintain for long.
(Jelinski et al.)
Industrial ecology is the multidisciplinary study of industrial and economic systems and their
linkages with fundamental natural systems. Natural ecosystems do not generate waste since the
wastes produced by one organism form the food source for another. Hypothetically, in a
completely efficient economy functioning in harmony with ecosystems, there would be no waste.
Finally, the pollution prevention and cleaner production approaches still think in terms of
preventing and reducing “wastes”, and thus, to a certain extent, share a perspective similar to the
end-of-pipe philosophy. By contrast, in certain cases, the industrial ecology approach would
even consider increasing the production of a particular "waste", in the absence of a cleaner
production viable alternative, if this would allow this "waste" to become a marketable by-
product. The point is, therefore, to integrate both end-of-pipe approaches and prevention
methods into a broader perspective, to which they should be subordinated. (Erkman 1997)
The first ever copper flash smelter went into operation in Harjavalta, Finland, in 1949. The
technology has since been applied to nickel concentrates. Flash smelting stands as Outokumpu’s
greatest technological achievement. Today, 46 licensees in all five continents evidence its
success. The technology is used to produce about 50 % of the world’s primary copper and 30 %
of the nickel. (Paatela 2002)
Copper and nickel flash smelters form the heart of the Harjavalta industrial ecopark consist of
thirteen different firms. Harjavalta Copper Oy, OMG Harjavalta Nickel Oy, Kemira GrowHow
Oy Harjavalta plants and Kemira Oyj Harjavalta, Porin Lämpövoima Oy, Oy AGA Ab, ABB,
Amica, Engel, SOL, Säkkiväline, Lassila & Tikanoja ja Valtasiirto. Table 1 presents the most
important milestones of the Harjavalta industarial area (Heino & Koskenkari s. 9)
The matte is further processed in a Peirce-Smith converter to obtain the metallic copper. The slag
is treated to recover its 2 % copper content. The off-gas contains about 10 - 75 percent by
volume SO2. Heating needed for smelting is obtained from the exothermic reaction of oxidizing
the Fe and S in the feed. The reaction is (Luomala 2002);
The SO2 is recovered and treated to make either SO2 or H2SO4. The recovery of by-products and
recycling of dust and wastewater have an important effect on the environment, because dusts and
wastewater contain quite a lot of heavy metals.
The Harjavalta Copper DON process eliminates the converting stage altogether and thus greatly
simplifies the nickel process. High-grade matte is produced using only the flash smelting furnace
and electric furnace – without Peirce-Smith converters. The SO2 is recovered and treated in the
same sulphuric acid plant as is the gas from copper smelter. The elimination of converters
reduces the investment, operating and maintenance costs significantly. The nickel flash smelting
flow sheet is shown in Figure 2.
Figure 3 The nickel production hydrometallurgical process flow sheet (Pääkkönen &
Mattelmäki 1996).
The most important advantages of the integration to the firms were environmental and recycling
advantages, image factors and marketing, and logistic advantages. The network and the better
co-operation has also been a very positive development factor. As well, safety actions improved
because of the co-operation (Heino & Koskenkari 2004, s. 25)
For the city of Harjavalta, the most important advantages of the industrial area are employment,
international dimension, intellectual capital and image because of the famous firms located there.
(Heino & Koskenkari 2004, s. 25)
The material and energy change between the firms is shown in Figure 4 (Heino & Koskenkari
2004, s. 31). Extra energy of the processes is utilized as electricity, high temperature steam or
heating energy by the process plants or by the city of Harjavalta, which utilizes the energy in
district heating.
When considering the Harjavalta industrial area as an industrial ecosystem, we take into
consideration the ecosystem principles roundput, diversity, locality and gradual change, which
are summarized in Table 2 (Korhonen 2001). Three of the four principles of Korhonen are
fullfilled in the Harjavalta Industrial Ecosystem. There are also plans and research work going on
to improve friendliness to the environment. (The grounds for this argumentation are better
expressed in the oral part of this presentation).
Article reference:
Heino J & Koskenkari T. (2004) Industrial Ecology and the metallurgy industry. The Harjavalta
industrial ecosystem. In: Pongrácz E. (ed.): Proceedings of the Waste Minimization and
Resources Use Optimization Conference. June 10th 2004, University of Oulu, Finland. Oulu
University Press: Oulu. p.143-151.