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Environmental protection at Pirdop

Aurubis Bulgaria is the largest copper producer in southeastern Europe and the second largest company in Bulgaria. Since the Pirdop site was officially opened in 1958, mainly copper anodes, copper cathodes, and sulfuric acid have been produced from primary raw materials.

Aurubis Bulgaria is the largest copper producer in southeastern Europe and the second largest company in Bulgaria. Since the Pirdop site was officially opened in 1958, mainly copper anodes, copper cathodes, and sulfuric acid have been produced from primary raw materials here.

In the last two decades, the plant has been converted into a highly modern, environmentally friendly operation. Since the acquisition by Aurubis in 2008, around € 165 million has been invested in modernizing the processes and improving the environmental performance of the site.

Because improving environmental protection remains a very important objective, about 20 % (~€ 75 million) of all investments at the site in the last five years have been allocated to environmental protection projects.

In the course of the extensive modernization, three significant, state-of-the-art environmental protection facilities have been built in the last several years. In November 2014, a new rainwater treatment plant was commissioned. The facility treats rain and drainage water from the 4 km² plant premises in order to continue reducing emissions to water.

A new additional treatment system for secondary hood off-gases has been in operation since March 2016. The new system utilizes a modern procedure known as Sulfacid technology, which is unique in Bulgaria and in the entire copper smelting industry.

In addition, a converter slag cooling optimization project (using pot cooling instead of pit cooling) went into regular operation in early 2020. This new facility further reduces the sulfur dioxide emissions and fugitive emissions from the smelting processes. The project will be expanded during the next several years to optimize cooling of the slags from the flash smelting furnace as well. The permit for the expansion was obtained in July 2024 and the construction started in September of the same year. More than 11,000 m² of green areas will also be rehabilitated as part of the project.

Aurubis assumes responsibility for environmental conservation. The plant is located near nature conservation areas. The closest are the Tsentralen Balkan buffer, about 1 km away, and Sregdna Gora about 2 km away. Protecting nature and biodiversity is one of our environmental targets, and Aurubis Bulgaria has defined measures to improve the habitat conditions of plants and animals. For example, we have taken the initiative to rehabilitate areas by planting grasses, bushes and trees. Defunct landfill areas on the premises are renatured in the course of their closing. Other environmental projects to reduce emissions likewise have a positive impact on the environment. For example, the reduction in metal emissions to water, which have been reduced by over 98 % since 2000, improves habitat conditions in rivers.

In 2006, Aurubis Bulgaria introduced an environmental management system in accordance with the ISO 14001 standard. The last recertification was successfully concluded in March 2024. The external audits carried out as part of the certification of the management system include a review of the environmental data, of the fulfillment of legal provisions, and of the effectiveness of the operating processes. During the second half of 2022, the energy management system pursuant to ISO 50001, the occupational health and safety management system pursuant to ISO 45001, and the quality management system were implemented at the Pirdop site.

Since 2011, an information center has been operating in Pirdop, which is used by the general public for information purposes. The environmental monitoring data can also be viewed by the public on monitors in the municipalities of Pirdop and Zlatitsa.

The results of the environmental monitoring are transmitted to the authorities. The reports prepared annually can be viewed on the homepage of the Bulgarian Executive Environment Agency.

The Pirdop site has been part of the EU emission trading scheme since 2008 and has continuously improved its energy efficiency over the years. Aurubis Bulgaria intends to make further investments in environmental measures and energy efficiency improvements in the future as well.

Environmental Protection Pirdop - facts & figures
Sulfur dioxide emissions
SO2 Pirdop EN

SO2 emissions [kg/t] per ton of copper output

SO2 emissions per ton of copper output have been reduced by 95 % since 2000.

Dust emissions
Dust Pirdop EN

Dust emissions [g/t] per ton of copper output

Dust emissions per ton of copper output have been reduced by 99.5 % since 2000.

Key factors in the reduction of dust and SO2 emissions include:

  • a number of modernizations in both lines of the Sulfuric Acid Plant (2001–2014)
  • the replacement of the heavy oil dryer with a steam dryer (2001–2002)
  • the first (conventional) off-gas cleaning system for secondary hood off-gases (2007)
  • the new additional (Sulfacid) off-gas cleaning system for secondary hood off-gases (2016)
  • the new facility for cooling converter slag in pots (2020)
Metal emissions
Metall Pirdop EN

Metal emissions in g/t of copper output and in g/t of copper equivalent

The specific metal emissions to water per ton of copper output have been reduced by 97 % since 2000.

Key factors in the reduction of metal emissions to water include:

  • the commissioning of the second and third stages of the treatment plant for industrial wastewater (2005-2006)
  • the modernization of the wastewater system for acidic wastewater (2006-2008)
  • the modernization of the wastewater systems for domestic sewage (2010-2011) and rainwater (2012-2013)
  • the commissioning of the rainwater treatment plant (2014)
  • the commissioning of a sand bed filter unit in the industrial wastewater treatment plant (2020)

Due to a new process of the planned upgrade of the wastewater treatment plant at Pirdop site, the amount of sludges for landfilling (generated during production processes in Pirdop) and the chemical consumption will be reduced. This will extend useful lifetime of the landfill for the sludges. Furthermore, the upgrade will increase the WWTP treatment volume capacity for a most efficient wastewater treatment. The construction started in September 2024 and the commissioning is planned in Q1 2026.

Environmental Protection Measures & Projects
Reducing fugitive emissions from converter slag cooling

Degree of implementation/date/next steps:

  • Constructing a new facility for cooling converter slag in pots.

    • Building permit received in Feb 2018
    • Commissioned in Q1 2020

Status:

  • Done
  • Extension of the project to further optimize the flash smelter furnace slag cooling process until Q3 2025 

Reducing emissions from undissolved substances from the treatment plant for industrial wastewater

Degree of implementation/date/next steps

  • Installing a new sand bed filter unit in the industrial wastewater treatment plant 

  • Building permit by October 2018

  • Commissioned in 2020  

Status:

  • Done
Reducing dust emissions by transporting concentrates via airlift

Degree of implementation/date/next steps

  • Investigation of optimization possibilities finished
  • Implementation done during the large-scale facility overhaul (Q2 2019)

Status:

  • Done 
  • Existing bag filters modified and additional filter boxes installed
Renaturing the current fayalite landfill after its closing until the end of 2018

Next steps:

  • Building permit received 
  • Landfill area renatured

Status:

  • Finished in Q3 2021
Solar park

Degree of implementation:

  • Signed agreement with CEZ ESCO Bulgaria for the construction of the photovoltaic power plant (10 MW) on a territory of historical remediated landfill
  • Detailed engineering for solar park number two and three finished

Status:

  • Done. The solar power plant was commissioned in March 2023

  • Construction started in Q1 2024

Certificates Aurubis Bulgaria
Your Contacts
Ange Kostov
Ange Kostov

Environmental Department Manager

Phone +359 728 62-203
Mobile +359 885 350 284
Send e-mail
Krasimir Slavov
Krasimir Slavov

Enviromental Department Operational Manager

Phone +359 728 62-514
Mobile +359 887 707 524
Send e-mail