United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 78-CUS-12
April 1979
Air
Arsenic
Non-Ferrous Smelter
Emission Test Report
ASARCO
Tacoma, Washington
-------
EMISSION TESTING OF ASARCO COPPER SMELTER
TACOMA, WASHINGTON
TO
U.S. ENVIRONMENTAL PROTECTION AGENCY
Contract •# 68-02-2812
Work Assignment # 25
January 18, 1980
TRW
ENVIRONMENTAL ENGINEERING DIVISION.
One Space Park, Redondo Beach, CA 90278
-------
CONTENTS
Page
Figures ii
Tables iii
1. Introduction ; 1
2. Summary and Discussion of Results 2
3. Process Description 16
4. Location of Sampling Points 17
5. Sampling and Analytical Procedures 30
Appendices
A. Field and Analytical Data 35
1. Traverse point locations 36
2. Field data sheets 46
3. Analytical data sheets 85
4. Meter box calibration data 151
B. Sample Calculations 162
C. Daily Activity Log 170
-------
FIGURES
Number Page
1 Roaster baghouse inlet duct 20
2 Roaster baghouse outlet duct 21
3 Reverberatory furnace electrostatic precipitator outlet 22
4 Matte tapping duct 23
5. Slag tapping duct 24
6 Calcine discharge duct 25
7 Arsenic kitchen inlet to arsenic baghouse 26
8 Metallic arsenic inlet to arsenic baghouse 27
9 Arsenic baghouse outlet duct 28
10 Converter slag return duct 29
11 Arsenic/sulfur dioxide sampling train 33
12 Modified EPA sampling train 34
11
-------
TABLES
Number Page
1 Roaster Baghouse Inlet Arsenic/S02 Results 4
2 Roaster Baghouse Outlet Arsenic/S02 Results 5
3 Reverberatory Furnace ESP Oulet Arsenic/SC^ Results 6
4 Matte Tapping Arsenic/SOg Results 7
5 Slag Tapping Arsenic/SOp Results: 8
6 Calcine Discharge Arsemc/S02 Results 9
7 Arsenic Kitchen Arsenic/S02 Results 10
8 Metallic Arsenic Asenic/S02 Results 11
9 Arsenic Baghouse Arsenic/S02 Results 12
10 Converter Slag Return Arsenic/S02 Results 13
11 Process Sample Analysis Results 14
12 Asarco Secondary Standard Analysis Results 15
m
-------
SECTION 1
INTRODUCTION
The Asarco Copper Smelter in Tacoma, Washington processes ores of high
arsenic content, and has the only arsenic production facility in the United
States. The hazardous nature of this material has caused Asarco to install
highly efficient control devices for processes emitting arsenic rich dusts.
From September 12 through September 25, 1978 a test team from TRW per-
formed emission testing on several control devices and fugitive emissions
gas streams. The control device sampling locations included the inlet and
outlet of the roaster baghouse, the inlets and outlet of the arsenic kitchen
baghouse, and the outlet of the reverberatory furnace electrostatic precipi-
tator. The fugitive emission system sampling locations included the matte
tapping, slag tapping, converter slag return and calcine emissions ducts.
The samples taken were analyzed for arsenic and sulfur dioxide. This
data will be used to support the EPA in establishing performance standards
for the copper industry.
This report presents the results of the sampling and analysis effort at
the Tacoma Copper Smelter. The following sections of the report contain a
summary of the results, descriptions of the sampling locations, descriptions
of the sampling and analysis procedures, and appendices containing field and
laboratory data and example calculations.
-------
SECTION 2
SUMMARY AND DISCUSSION OF RESULTS
The results of the sampling and analysis program are summarized in
Tables 1-10. Three sets of tests were performed at each sampling location.
The results of these tests and the average values for the three test are
given in the Tables.
Tables 1 and 2 give the results of the inlet and outlet tests at the
roaster baghouse. The inlet and outlet tests were done simultaneously during
normal operating periods of the roaster. The only difficulty encountered
during these tests was the plugging of the inlet location nozzle several
times during these runs. The material plugging the nozzle was recovered
into the probe rinse container and the test was continued.
Table 3 presents the results of the tests done at the outlet from the
reverberatory furnace electrostatic precipitator. This location required
vertical sampling with a 15 foot probe and a teflon flex line between the
probe and the filter (see diagram #2). The duct had a significant amount of
sediment in the bottom which precluded sampling at several traverse points.
Since the plant was on curtailed production due to meteorological conditions
some delay was encountered in completing these tests.
The data from tests done at the matte tapping, slag tapping, calcine
discharge, and converter slag return are given in Tables 4, 5, 6, and 10, re-
spectively. The activities feeding these fugitive systems occur for short
periods throughout the converter cycle, and consequently sampling had to be
timed to coincide with this intermittent schedule. Matte and slag tapping
fugitive emissions were sampled over 5 to 8 minute periods when either matte
or slag was being drawn from the reverberatory furnace. Sampling at these
locations was coordinated by EPA observers with transceluers who alerted the
sampling teams as to when to start and stop sampling trains.
During the Data Reduction, the meter volume was back calculated to
account for sulfur dioxide that was removed by the three 10% hydrogen peroxide
impingers. The back calculation f-r sulfur dioxide was accomplished in the
following order. First, parts per million sulfur dioxide at standard condi-
tions was calculated. Then parts per million was converted to a fraction by
dividing by 10&. This number was added to one and the result multiplied by
the volume of gas collected through the dry gas meter at standard conditions.
The result of multiplication yielded the true gas volume collected at stand-
ard conditions. Since S02 removal by the peroxide impingers does not reach
the dry gas meter, corrected values for dry gas meter volumes (at meter
conditions) found on the summary sheets will be slightly higher than those
obtained from the field data sheets.
-------
Although matte and slag are tapped from the same furnace, the fugitive
emissions from these processes were quite different. The amount of arsenic
and sulfur dioxide in the fugitive emissions from the matte tapping process
were considerably higher than the emissions of these constituents from the
slag tapping process. Arsenic emissions were 11.6 times higher and sulfur
dioxide emissions were 5.7 times higher (see tables 4 and 5).
Sampling of the calcine discharge ducts was done as the larry cars were
filled. The concentration of arsenic in these emissions was similar to that
of the roaster outlet, but volumetric flow of gas through the duct was much
smaller, and consequently so was the mass emission rate from this source.
The emissions from the ocnverter slag return were sampled during 1 to
3 minute intervals when slag was returned to the reverberatory furnace from
the converters. This procedure only occurred five to six times per day, so
that three days of testing were required to collect a large enough sample for
analysis.
At the matte tapping location, taps were of short duration and only one
point was sampled per tap, since the time for each tap varied, the sample
time for the points varied also.
Tables 7, 8 and 9 summarize the data from testing at the arsenic plant.
Tests at these locations were done simultaneously. Tables 7 and 8 give data
from the two inlets to the arsenic baghouse (arsenic kitchen and metallic
arsenic, respectively). This data indicates the very high concentrations of
arsenic, entering the baghouse (averaging 506 ppm from the arsenic kitchen,
and 649 ppm from the metallic arsenic area). The data from the second metal-
lic arsenic test on September 24, 1978 indicated that the process may not
have been operating during the test. This is based on the low arsenic level
found at the metallic arsenic inlet location and a correspondingly low ar-
senic concentration at the baghouse outlet for this test. Consequently, the
average concentration and mass emission rate for the metallic arsenic inlet
and baghouse outlet should be based on the first and third tests rather than
all three tests.
Table 11 and Table 12 presents the process data results. Table 11 is the
summary of all the process samples collected. Table 12 presents a compariscn
of the analytical results between Asarco Laboratory personnel and TRW lab- •
oratory personnel through the use of selected samples. These replicated
samples were prepared by Asarco personnel utilizing pulverizing equipment
and a sample splitter.
-------
TABLE 1 ROASTER BAGHOUSE INLET ARSENIC/S02 RESULTS
RUN NUMBER
1 DATE
I! STACK PARAMTERS
PST - STATIC PRESSURE, "He (MMHG)
PS - STACK GAS PRESSURE, "He ABSOLUTE (MM-HG)
I C02 - VOLUME T PRY
' $2 • VOLUME T, DRY
S&> - VOLUME I DRY
\ N-2 - VOLUME I DRV
Ts - AVERAGE STACK TEMPERATURE °F (°C)
t HiO - 5 MOISTURE IN STACK GAS, BY VOLUME
As - STACK AREA, FT" (M*)
MD - MOLECULAR HEIGHT OF STACK GAS, DRY BASIS
"s - foLECULAH WEIGHT OF STACK GAS, *ET BASIS
Vs - STACK fas VELOCITY, FT/SEC, (M/S:C)
JA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFM (NM*/Mig)
(:s - STACK CIAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSCFP (Nfr/niN)
% ' A - PERCENT EXCESS AIR
II! 'ESI CONriTIONS
Pfi - BAROMETRIC PRESSURE, "HG
-------
Table 2
Roaster Batghouse Outlet'
RUN NUMBER
1 DATE
II STACK PARAMETERS
PST - STATIC PRESSURE. "Ho (MMHG)
Ps - STACK GAS PRESSURE, "Ho ABSOLUTE (MNHG)
I C02 - VOLUME I DRY
I 0? - VOLUME X DRY
I CO - VOLUME I DRY
t !<2 - VOLUME I DRY
Ts - AVERAGE STACK TEMPERATURE °F (°C)
I H20 - I MOISTURE IN STACK GAS, BY VOLUME
As - STACK AREA. FTZ (M2)
MD - MOLECULAR WEIGHT OF STACK GAS, DRY BASIS
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK GAS VELOCITY, F'T/SEC, (M/SEC)
QA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFM (NMVMIN)
Os - STACK GAS VOLUMETRIC FLOH AT STANDARD CONDITIONS, I1SCFM (NMVMIN)
I EA - PERCENT EXCESS AIR
III TEST CONDITIONS
PB - BAROMETRIC PRESSURE, "Ho (MMHG)
DN - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (M3)
Np - NET SAMPLING POINTS
CP - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F (°C)
PM - AVERAGE ORIFICE PRESSURE DROP, "^0 (wHoO)
VLC - CoNOENSATE COLLECTED (IMPINGERS AND GEL), MLS
&F - STACK VcLOCir. HCAD "H .0 (r-MH-.O)
IV TEST CALCULATIONS
Vu - CONDENSED WATER VAPOR, SDCF (NM3) ,
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (Nn->)
1 H20 - PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
Z 1 - PERCENT ISOKINETIC •
V ANALYTICAL DATA
A) ARSENIC Fran HALF
PROBE (re)
CYCLONE (MG)
FILTER (HG)
ARSENIC FRONT HALF TOTAL (HG)
GRS/SDCF, (MG/M!)
ff/w, KG/HR)
B) ARSENIC BACK I«LF
(MG)
fi%(KS/HR)
ToTALARSENIC (Ms)
GRS/jlyv OlG/My
0 TOTAL SO? (MG)
PPM
0/HR, (KG/HR
1
ENGLISH
UNITS
9/15/78
•0.147
29.61
0.2
20.4
0.70
78.70
191
5.95
44.18
29.10
28.45
85.79
227002
171887
4.7
29.78
0.185
120
91.47
12
0.84
88
2.04
1.847
'
5.19
88.182
5.9
28.45
85.79
99.47
—
"".
...
0.268
0.396
0.014
0.021
0.282
0.416
7029.2
8158.7
12017.7
METRIC '
UNITS
9/15/78
-1.74
752.68
0.2
20.4
0.70
78.70
88
5.9
4. ID
29.10
28.45
26.15
6429
4866
4.7
756.41
4.10
120
2.59
12
0.84
11
51.82
120.1
46.914
0.15
2.50
5.9
28.45
26.15
99.47
0.960
...
0.575
1.515
0.6.15
O.IBO
o°6?f
0.009
1 615
0.647
0.189
46687.1
7029.2
18694.6
5460.2
2
ENGLISH
UNITS
9/15/78
-0.147
10.06
0.2
20.4
0.80
78.60
189
5.0
44.16
29.14
28.58
84.65
224518
174611
4.7
10.21
0.1875
120
95.98
12
0.84
95
2.195
1.847
4.62
92.651
5.0
28.58
84.65
100.1
...
...
...
...
0.268
0.401
0.017
0.026
—
0.265
0.428
7962.6
15850.6
11854.4
METRIC
UNITS
9/15/78
-1.74
761.60
0.2
20.4
0.80
78. 6D
87
5.0
4.10
29.14
28.56
25.66
6159
4946
4.7
767.11
4.76
120
2.72
12
0.64
15
55.75
106.8
46.914
0.14
2.624
5.0
28.56
25.86
100.1
0.985
0.625
1.610
0.614
0.182
0.105
0.040
' 0.012
1.715
0.654
0.194
55568.7
7962.6
21177.6
6284.4
3
ENGLISH
UNITS
9/16/78
-0.147
30.01
0.2
20.4
0.52
78.86
180
5.6
44.18
29.04
28.42
86.30
228148
176671
4.7
10.16
0.185
120
95.87
12
0.64
84
2.10
1.924
5.18
94.281
5.6
28.42
86.10
102.1
...
...
...
0.286
0.419
J. 361
0.554
...
0.647
0.991
5202.2
21901.5
9260.5
METRIC
UNITS
9/16/78
-1.74
762.64
0 .2
20.4
0.52
76.88
62
5.6
4.10
29.04
28.42
26.10
6467
5060
4.7
766.57
4.70
120
2.72
12
0.64
29
56.42
122.2
48.87
0.152
2.67
5.6
26.42
26.10
102.1
'.'7'
0.275
1.750
0.655
0.199
2.210
0.828
0.251
3.961
1.483
0.450
36943.07
5202.2
13815.6
4200.6
t
ENGLISH
UNITS
-0.147
29.91
0.2
20.4
0.67
78.7}
187
5.5
44.18
29.09
28.48
85.65
226622
175064
4.7
30.06
0.166
120
94.44
12
0.64
89
2.18
1.873
5.20
91.705
5.S
28.48
85.65
100.6
...
...
0.274
0.412
0.111
0.200
...
0.405
0.612
6711.4
15970.1
11717.5
METRIC
UNITS
•1.74
759.71
0.2
20.4
0.67
78.7}
86
5.5
4.10
29.09
28.46
16.10
6418
4958
4.7
761.44
4.72
120
2.68
12
0.84
12
55.11
116.4
4T.S7
0.14
2.60
5.5
28.48
26.10
100.6
1.14
...
0.492
1.612
0.628
0.187
0.798
0.100
0.011
2.41
0.928
0.278
46199.7
6711.4
17902.6
5115.0
-------
Table 3
ESP Outlet
RUN NUMBER
1 DATE
II STACK PARAMETERS
PST - STATIC PRESSURE, "He (MMHG)
Ps - STACK GAS PRESSURE, 'KG ABSOLUTE (MMHG)
I CO, - VOLUME J DRV
t 0, - VOLUME X DRV
X CO - VOLUME X DRV
X N2 - VOLUME X DRV
Ts - AVERAGE STACK TEMPERATURE °F (°C)
X H20 - X MOISTURE IN STACK GAS, Bv VOLUME
As - STACK AREA, FTZ
MD - MOLECULAR HEIGHT OF STACK GAS, DRY BASIS
Ms - MOLECULAR HEIGHT OF STACK GAS, UET BASIS
Vs - STACK GAS VELOCITY, FT/SEC, (M/SEC)'
OA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFM (NMVMIN)
Qs - STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSCFM (NMVMIN)
X EA - PERCENT EXCESS AIR
III TEST CONDITIONS
PB - BAROMETRIC PRESSURE, "Ho (MMHG)
DN - SAMPLING NOZZLE DIAMETER, in. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF
NP - NET SAMPI INO POINT?
Cp - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F (°C>
PM - AVERAGE ORIFICE PRESSURE DROP, "H20 (MnH20)
VLC - CONDENSATE COLLECTED ([MPINGERS AND GEL), MLS
&p - STACK VELOCITY HEAD 'H20 (MMH20)
IV TEST CALCULATIONS
V» - CONDENSED HATER VAPOR, SDCF (NM3) ,
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM*1)
X H20 - PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, HET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
X I - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) .VSENIC FRONT I'fiS
PROBE (MG)
CYCUKE (MG)
FILTER (MS)
ARSENIC FRONT HALF TOTAL (MG)
GRS/5DCF,
-------
TABLE 4. MATTE TAPPING ARSENIC/S02 RESULTS
RUN NUHRER
1 DATE
II STACK PARAFtURS
PST - STATIC PRESSURE, "Ho (MwHr,t
PS - STACK GAS PRESSURE. "He- ABS»LUII l.iMHr.)
I C02 - VOLUME Z PRY
Z 0? - VOLUME *, DRV
Stk, - VOLUME Z DRY
Z N2 - VOLUME Z DRV
Is - AVERAGE STACK TEMPERATURE °F (°( !
I H^n - 7, MOISTURE m STACK ^-AS, N Vom^t
As - STACK AREA, FT2 (M')
Ps - MOLECULAR WEIGHT OF STACK PAS, HIT PASIS
Vs - STACK GAS VELOCITV, FT/SEC, (M/S;C)
'JA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFr (NM'/HIN)
Qs - STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSfFv (NM'/MIN)
Z FA - PERCENT Exctss AIR
HI TFSI C ONPII IONS
PB - BAROMETRIC PRESSURE, "He (MMHG)
PN - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (M!)
HP - NET SAMPLING POINTS
CP - PITCT TUBE COEFFICIENT
TM - AVERAGE NETEH TEMPERATURE °F (°t)
PM - AVERAGE ORIFICE PRESSURE DROP, "h^O (MMHjO)
VLC - CONDENSATE COLLECTED UMPJNGERS AND GEL), MLS
QP - STACK VELOCITY HEAD "1^0 (wH^O)
IV IEST CALCULATIONS
Vw - CONDENSED VATER VAPOR, SJCF (NM'J»
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM3)
Z H20 - PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC WSEC)
Z 1 - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) ARSENIC FRONT HALF
PROBE (MG)
CYCLONE (MG)
FILTER (MO)
ARSENIC FRONT HALF TOTAL (MG)
ppfl/ (MG/M^)
»/««, (KO/KR)
B) ARSENIC - IMPINGLR COLLECTION
PPM, (MG/M^)
»/HR, (KG/HRl
PPM, MG/"5)
«/HB, I.O/HB)
C) ARSENIC - IMPINGER TOTAL (MG)
PPM, (MG/Mi)
«/MR, (KG/HR)
D) TOTAL ARSENIC (MG)
PPM, IMG/"')
«/HR. UG/HR)
Cl IOIM. SOj '"6i
PPM
'/M«, '-'/MR)
1
INfl ISH
HI] IS
Q/1Q/7R
.13
30.24
0.
20.
.18
79.82
134.
1.5
5.85
28.87
28.70
61.17
21470.7
18944.1
4.7
30.11
.250
78.
78.67
8.
.84
81.2
3.73
24.8
1.06
1.17
77.91
1.5
28.70
61.17
90.5
15.7605
3.4898
1 .0681
.2365
—
—
16.8287
3.7264
348.4429
nnp.ir
uciib
9/19/78
3.36
768.10
0.
20.
.18
79.82
56.7
1.5
.543
28.87
28.70
18.64
608.2
536.7
4.7
764.79
6.35
78.
2.23
8.
.84
27.3
94.74
24.8
26.92
.03
2.21
1.5
28.70
18.64
90.5
18.60
—
90.0
108.60
19.2052
1.5841
7.36
3.3347
.1074
*
-
115.96
52.5400
1.6915
10843.15
1844.073
4912.889
158.1675
2
rum ISH
in us
9/20/78
.13
30.21
0.
20.
.39
79.61
163
0.8
5.85
28.94
28.85
61.02
21418.0
18181.3
4.7
30.08
.250
75.
73.94
8.
.84
89.2
3.54
12.6
1.01
.593
72.05
0.8
28.85
61.02
91.0
78.0560
16.5879
.0636
.0135
-
-
78.1196
16.6014
705.7009
1IPK
UNITS
9/20/78,
3.36
767.33
0.
20.
.39
79.61
72.8
0.8
.543
28.94
28.85
18.60
606.7
515.1
4.7
764.03
6.35
75.
2.09
8.
.84
31.8
89.92
12.6
25.65
.02
2.04
0.8
28.85
18.60
91.0
22.40
__
475.0
497.40
243.6949
7.5297
.405
.1984
.0061
-
-
497.81
243.8934
7.5358
2)161.09
3891.526
10367.613
320.3390
LBWISII
UNITS
9/21/78
.13
30.14
0.
20.
.21
79.79
164.
0.9
5.85
28.87
28.77
61.82
21698.8
18329.1
4.7
30.01
.250
74.
72.27
8.
.84
84.1
3.45
13.1
1.03
.617
70.91
0.9
28.77
61.82
90.0
75.8189
16.2435
.0869
.0186
-
-
75.9056
lt.2621
3Kf .30-4
•UPK
iinir,
9/21/78
3.36
765.56
0.
.21
79.79
73.3
0.9
28.87
28.77
18.84
614.7
519.2
4.7
762.25
6.35
74.
2.05
8.
.84
28.9
87.63
13.1
26.16
.02
2.01
0.9
28.77
18.84
90.0
20.5
_
455.0
475.5
236.7106
7.1734
.545
.2713
.0085
-
-
476.0450
!3f.981S
/.3818
1)711.46
;n3.e;.i;
5<31.3Mf
i;5.4?'5
AWR
iii> i ISH
•'Illi
.13
30.20
o.
20.
.26
79.74
153.7
1.07
5.85
28.89
Z8.77
61.34
21529.2
18484.8
4.7
30.07
.250
75.7
74.96
8.
.84
84.8
3.57
16.8
1.03
.793
73.62
1.07
28.77
61.34
90.5
56.5452
12.1071
.4oez
.0895
-
-
C6 •"!-
I.M9K
1-..1-64
AM
*f "-'.
it.:'
3.36
767.0
0.
20.
79. 7«
67. t
1.07
.543
2r.;:
609.9
52!. 7
763.69
6.35
75.7
t.
29.3
9?. 7<
.71
2.39
).07
?t ..
1^.6?
v. ''
?0.50
__
J4C.7"
361". 5'
5.J-&
"w-s
-
-
.*-. .
•-.;:...••
.• '•;. i.-"
• ••:.' •
.•:... --
-------
TABLE 5 SLAG TAPPING ARSENIC/S02 RESULTS
RUN NUMBER
I DATE
II STAfk PARAVE«
PST - STATIC PRESSURE, "He <.-viHG>
°s - STACK GAS PRESSURE, "Ho ABSOLUTE KiKc-)
" Cni - VOLUME J TRY
" iV- VOLUME ' PRY
SOh" - VOLUME * ?RY
~ ^ - VOLUME * TRY
'* : AVERAGE STACK "EMPERATURE W (°P
* "O - " "lOISTURE JN SjACK '"-A?, FY VOLUME
As : STACK AREA, cr- L«-)
y: - VOLECULAR WEIGHT c* STACK .;is, "HY ?ASIS
'.; - STACK .:AS VEi.,-c:Tv, FT/SEC, (n/s;c)
^ - STACK C-AS VC"IJ^ET*;C FLOW AT STACK CONDITIONS, ACFP (NM'/MIN)
* :•'< - PERCENT EXCESS AIR
^F - "ARc-E":.1 "RESSURE, "Ho (MMHG)
TIN - SAILING 'IC::LE SIA^ETER, IN. (MM)
I - SAMPLING TIIE, UIN
V« - SAMPLE VOLUME, ACF («r)
VP - NET SAMPLING POINTS
i> - PITCT *UPE COEFFICIENT
VLC - CONOENSATE COLLECTED (IflPINGERS AND GEL), MLS
&p - STACK VELOCITY HEAD "H20 (MMtSP)
IV TEST CALCULATIONS
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM')
* fi^C - PERCENT P.OISTUSE, BY VOLUME
MS - "OLECULAR HEIGHT OF STACK ClAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
* I - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) AISENIC FRONT HALF
PROBE (MG)
CYCLONE (nc)
FILTER (MG)
ABSENIC FRONT HALF TOTAL (MG)
PPM, (MC/n3)
«», (KG/KR)
3) ARSENIC - IMPINGER COLLECTION
lw>iNfiER_?L 2 (MG)
PPM, (MG/M5)
»/MR, (KG/HR)
blPlNGER ^3^,5 (MG)
PPM, MG/M5)
IV/HR, (KG/HR)
C) ARSENIC - IMPINGER TOTAL (NG)
"M,
-------
TABLE 6 CALCINE DISCHARGE ARSENIC/SO, RESULTS
RUN NUMBER
1 DATE
II STACK PARAMETERS
PST - STATIC PRESSURE, "He »
y\ - VOLUME Z DRV
I H2 - VOLUME Z D»v
Is - AVERAGE STACK TEMPERATURE °F <°C)
X H20 - Z MOISTURE IN STACK GAS, Bv VOLUME
As - STACK AREA, FT* (MM
Mo - MOLECULAR WEIGHT OF STACK GAS, DRY BASIS
Ps - MOLECULAR HEIGHT OF STACK GAS, WET BASIS
Vs - STACK GAS VELOCITV, FT/SEC, (M/S:C)
OA • STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACPI* (NH /MIN)
Os - STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSCF" (NMVMIN)
Z EA - PERCENT EXCESS AIR
III TES1 CONDITIONS
PB • BAROMETRIC PRESSURE, "He (HHHG)
ON - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (M3)
Np - NET SAMPLING POINTS
CP - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F (°C>
PM - AVERAGE ORIFICE PRESSURE DROP, 'HjO (MMHoO)
VLC - CONOENSATE COLLECTED (IMPINGERS AND GEL), MLS
£F - STACK VELOCITY HEAD 'HjO (mHjO)
IV TEST CALCUUTIONS
v» - CONDENSED CATER VAPOR, SDCF (NM3>
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM5)
t HjO - PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR HEIGHT OF STACK GAS, HET BASIS
Vs - STACK VELOCITV, FT/SEC (M/SEC)
Z 1 - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) ARSENIC FRONT HALF
PROBE (MG)
CYCLONE
-------
TABLE 7 ARSENIC BAGHOUSE INLET (ARSENIC KITCHEN) ARSENIC/SOg RESULTS
RUN NUMBER
1 HATE
11 STACK PARAMETERS ,
Psr - STATIC PRESSURE, "HG (mHo)
Ps - STACK GAS PRESSURE, "He ABSOLUTE (HnHc)
Sk - VOLUME I DRV
10, - VOLUME ! DRV
I CO - VOLUME I DRV
1 N, - VOLUME I DRV
I I^O - I MOISTURE IN STACK GAS, Bv. VOLUME
As - STACK AREA, FT2 (M2)
KD - MOLECULAR WEIGHT OF STACK GAS, DRY BASIS
»s - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK GAS VELOCITY, FT/SEC, (M/S^C)
OA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACR" (NM^/MIN)
Os - STACK GAS VOLUMETRIC FLOM AT STANDARD CONDITIONS, DSCFM (NV/MIN)
X EA - PERCENT EXCESS AIR
II! TEST CONDITIONS
Ps - BAROMETRIC PRESSURE, "HG'(MMHG)
DN - SAMPLING NOZZLE DIAMETER, IN. (HM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (M3)
Np - NET SAMPLING POINTS
CP - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F (°O
PH - AVERAGE ORIFICE PRESSURE DROP, "H20 (nnHoO)
VLC - CONOENSATE COLLECTED (IMPINGERS AND GEL), MLS
Of • STACK VELOCITY HEAD "H20 (BMH20)
IV TEST CALCULATIONS
V» - CONDENSED MATER VAPOR, SDCF
-------
TABLE 8 ARSENIC BAGHOUSE INLET (METALLIC ARSENIC) ARSENIC/S02 RESULTS
RUN NINER
1 DATE
1 1 STACK PARArtTERS
PST - STATIC PRESSURE, "HG (MMHG)
Ps - STACK GAS PRESSURE, "HG ABSOLUTE (MMHG)
Z C02 - VOLUME Z TRY
Z Op - VOLUME ! DRY
SOj - VOLUME Z DRY
Z N2 - VOLUME Z DRY
Z H20 - 7, MOISTURE IN STACK GAS, BY VOLUME
As - STACK AREA, FT^ (MM
MD - MOLECULAR WEIGHT OF STACK GAS, DRY BASIS
.Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK GAS VELOCITY, FT/SEC, (M/S;C)
OA - SIACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFr1 (NM'/MIN)
l)s • STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSCFM (NM^/MIN)
t FA - PERCENT EXCESS AIR
II! TESI CONDI 1 IONS
PB - BAROMETRIC PRESSURE, "Ho (MHHG)
UN - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (H'>
Np - NET SAMPLING POINTS
CP - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F <°C)
PM - AVERAGE ORIFICE PRESSURE DROP, "H20 (MMH^O)
VLC - CONDENSATE COLLECTED (IMPINGERS AND GEL), MLS
OP - STACK VELOCITY HEAO "H20 (MnH20)
IV TEST CALCULATIONS
Vw - CONDENSED WATER VAPOR, SDCF <«*'>
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM5)
Z H20 - PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
Z 1 - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) ARSENIC FRONT HALF
PROBE (KG)
CYCLONE (MG)
FILTER (MG)
ARSENIC FRONT HALF TOTAL (MG)
FPH, (MO/M')
D/HR, (W/KR)
B) ARSENIC - IMPINGER COLLECTION
IMPINGER ffl. ? (MG)
PPM, (MG/M')
*/HR, (KG/HR)
IMPINGFR ^3,11,5 (MG)
PPM, MG/M3)
*/HR, (KG/HR)
C) ARSENIC - IMPINGER TOTAL (MG)
PPM, (MG/M3)
«/HB, (KG/HR)
D) TOTAL ARSENIC (MG)
PPM, (MG/M5)
tf/HR, (KG/HR)
E) lOIALSOj IMG)
PPM
(MG/M3)
VHR. (KG/HR)
1
ENGLISH
UNITS
9/24/78
.15
30.30
.1
20.
.24
79.66
242.
2.0
7.57
28.90
28.69
38.31
17400.4
12989.6
4.7
30.15
.308
94.
85.58
12.
.84
81.54
2.7
36.
.351
1.69
84.61
2.0
28.69
38.31
1W. 7
tt'lfisa
93.7907
.1123
.0170
617.8964
93.8078
316.1866
METRIC
UNITS
9/24/78
3.81
769.62
.1
20.
.24
79.66
116.7
2.0
.703
28.90
28.69
11.68
492.9
367.95
4.7
765.81
7.82
94.
2.42
12.
.84
27.52
68.58
36.
8.92
.05
2.40
2.0
28.69
11.68
100.7
4450.0
173.00
4623.00
1928.7543
42.5741
.84
.3505
.0077
4623.84
1929.1047
42.5818
15585.02
2440.6278
6502.2008
143. 52 si
2
ENGLISH
UNITS
9/24/78
.15
30.30
.1
20.
.17
79.73
231.2
1.1
7.57
28.87
28.51
44.60
20257.3
15141.3
4.7
30.15
.308
96.
96.87
12.
.84
89.79
3.40
63.
.48
2.97
94.48
3.1
28.53
44.60
94.5
.3076
.0544
.1520
.0269
.4595
.0813
260.3502
HETRIC
UNITS
9/24/78
3.81
769.62
.1
20.
.17
79.73
111.8
1.1
.703
28.87
28.53
13.59
573.9
428.9
4.7
765.81
7.82
96.
2.74
12.
.84
12.11
as. 36
63.
12.19
.08
2.68
3.1
28.53
13.59
94.5
2.04
.530
2.570
.9602
.0247
1.27
.4745
.0122
3.84
1.4347
.0169
12292.47
1723. 91 Jj
4592.7624
118.1798
3
ENGLISH
UNITS
9/25/78
.21
30.22
.1
20.
.22
79.68
207.
2.7
7.57
28.89
28.60
43.78
19884.9
15469.5
4.7
30.01
.250
96.
68.14
12.
.84
91.78
1.56
39.
.480
1.84
65.81
2.7
28.60
43.78
98.5
680.0486
122.9637
.0143
.0062
680.0829
122.9699
341.8159
"ETRIC
UNITS
9/25/78
5.23
767.59
.1
20.
.22
79.68
97.22
2.7
.701
28.89
28.60
11.34
563.3
438.2
4.7
762.25
6.35
96.
1.94
12.
.84
33.19
39.62
39.
12.19
.05
1.86
2.7
28.60
13.34
98.5
1880.0
80.00
3960.00
2123.1470
55.8165
.200
.1072
.0028
3960.200
2123.2543
55.9193
11004.0
2215.5144
5902.4647
155.1729
AVERAGE
ENGLISH
UNITS
.17
30.27
.1
20.
.21
79.69
227.4
2.6
7.57
28.89
28.61
42.23
19180.9
**t.7
30.10
.29
95.3
83.60
12.
.84
87.69
2.55
46.
.437
64.85
81.61
2.6
28.61
42.21
97.9
412.7134
72.2696
.099S
.0167
432.8130
72.2863
306.1275
METRIC
UNITS
4.28
768.94
.1
20.
.21
79.69
108.6
2.6
.703
28.89
28.61
12.87
543.4
411.7
4.7
764.62
7.31
95.1
2.17
12.
.84
30.94
64.83
46.
1.1 JO
.06
2.31
2.6
28.61
12.87
97.9
2777.35
84.51
2861.80
1350.9518
32.8051
.7700
.3107
.0076
~
2862.6267
1151.2646
12.8127
12960.491
2126.6848
5665.8091
138.9594
11
-------
Table 9
Arsenic Baghouse Outlet
RUN NUMBER
I DATE
II STACK PARAMETERS
PST - STATIC PRESSURE, "Ho (MnHc)
Ps - STACK GAS PRESSURE, "Ho ABSOLUTE (wwHc.) ;
I rn2 - VOLUME I DRY
', 0? - VOLUME ' DRY
T CO - VOLUME Z DRY
? N, - VOLUME J DRY
\ fyft - * MOISTURE IN STACK GAS, BY VOLUME
As - STACK AREA, FT2 (M2)
Mo - MOLECULAR WEIGHT OF STACK GAS, DRV RASIS
Ms - MOLECULAR WEIGHT OF STACK GAS,. WET BASIS
Vs - STACK GAS VELOCITY, FT/SEC, (M/SEC)
QA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFM (NM-/MIN)
(Is - STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, PSCFM (NM'/MIN)
111 TEST CONDITIONS
PB - BAROMETRIC PRESSURE, "He (MMHG)
DN - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF (M^)
Np - NET SAMPLING POINTS
CP - PITOT TUBE COEFFICIENT
TM - AVERAGE METER TEMPERATURE °F (°O
PM - AVERAGE ORIFICE PRESSURE PROF, "H^O (HHH^OI
VLC - CONDENSATE COLLECTED (iMPINGERS AND GEL), MLS
&p • STACK VELOCITY HEAD "H->0 (MMH-jfl)
IV TEST CALCULATIONS
Vw - CONDENSED WATER VAPOR, SDCF (Nn )
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NMJ)
7, H^O ~ PERCENT MOISTURE, BY VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
Z 1 - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) .ARSENIC PROMT I'ALF
PROBE to)
CYCLONE (us)
FILTER
-------
TABLE 10. CONVERTER SLAG RETURN ARSENIC/S00 RESULTS
RUN NUMBER
CmVERIFP ?LAG PF1MN
! DATE
II STACK PARAMETERS
Ps - STACK GAS PRESSURE. "He ABSOLUTE (MMHG)
1 C02 - VOLUME I D«r
X 0? - VOLUME ! DRY
I CO - VOLUKE I DRV
X N2 - VOLUME I DRV
Ts - AVERAGE STACK TEMPERATURE °F (°C)
1 820 - X MOISTURE IN STACK GAS, Bv VOLUME
As - STACK AREA, fr (tr)
Mo - MOLECULAR WEIGHT OF STACK GAS, DRV BASIS
PS - flOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK GAS VELOCITY, FIYSEC, (M/SCC)
OA - STACK GAS VOLUMETRIC FLOW AT STACK CONDITIONS, ACFP (NMVMIN)
Os - STACK GAS VOLUMETRIC FLOW AT STANDARD CONDITIONS, DSCFF" (NMVMIN)
X EA - PERCENT EXCESS AIR
III TESI CONDITIONS
PB - BAROMETRIC PRESSURE, "HG (MMHG)
DN - SAMPLING NOZZLE DIAMETER, IN. (MM)
T - SAMPLING TIME, MIN
VM - SAMPLE VOLUME, ACF
IV TEST CALCULATIONS
V» - CONDENSED WATER VAPOR, SDCF (Nn3)
VM - VOLUME OF GAS SAMPLED AT STANDARD CONDITIONS, DSCF (NM3)
X H20 - PERCENT MOISTURE, Bv VOLUME
Ms - MOLECULAR WEIGHT OF STACK GAS, WET BASIS
Vs - STACK VELOCITY, FT/SEC (M/SEC)
X 1 - PERCENT ISOKINETIC
V ANALYTICAL DATA
A) ARSENIC FRONT HALF
PROBE (no)
CYCLONE (MG)
FILTER (MG)
ARSENIC FRONT HALF TOTAL
IMJINGFR K.U.5 (MG)
PPM, MG/M?)
I/KB, (KG/HR)
C) ARSENIC - IMPINGER TOTAL (MG)
PPM, (MG/M3)
I/HR, (KG/HP.)
D) TOTAL ARSENIC (MG)
PPM, (MG/M')
I/HR, (KG/HR)
E) LoiAuSQj IMG)
PPM
(MG/M3)
C/MR, (KG/HR)
1
ENGLISH
UNITS
9/19-21/76
- .16
29.91
0.
20.
.07 •
79.93
95.3
.8
7.07
28.82
28.73
58.02
24612.1
23207.1
4.7
30.07
.187
22.6
13.40
18.
.84
83.8
.97
2.1
1.01
.099
13.10
.8
28.73
58.02
91.4
1.0185
.2763
.0734
.0199
•
1.0918
.29(2
164.0199
METRIC
UNITS
9/19-21/78
-4.02
759.71
0.
20.
.07
79.93
35.2
.8
.657
28.82
28.71
17.68
697.2
(57.4
4.7
763.78
4.75
22.6
.38
18.
.84
28.8
24.6
2.1
25.7
0.
.37
.8
28.73
17.68
91.4
.750
.430
3.1797
.1254
.085
.2290
.0090
~
1.265
3.4087
.1344
700.57
708.5918
1887.7955
74.4530
2
ENGLISH
UNITS
METRIC
UNITS
3
ENGLISH
UNITS
METRIC
UNITS
AVERAGE
ENGLISH
WITS
-.16
29.91
0.
20.
.07
79.93
95.3
.8
7.07
28.82
28.73
58.02
24612.1
23207.1
4.7
30.07
.187
n'.ta
IB.
.84
83.8
.97
2.1
1.01
.099
13.10
.8
28.73
58.02
91.4
1.0185
.27(3
.0734
.0199
1.0918
.2962
IM.OI99
METRIC
UNITS
-4.02
759.71
0.
20.
.07
79.93
35.2
.657
28.82
28.73
17. (8
(97.2
6S7.4
4.7
763.78
4.75
22.6
.38
18.
.84
28.8
24. (
2.1
25.7
0.
.37
.8
28.73
17. (8
91.4
.750
.430
1 .180
3.1797
.1254
.085
.2290
.0090
1.26S
3.1087
.1344
700.57
708.5918
1887.7955
74.4530
13
-------
TABLE 11
Process Sample Analysis Results
Sample Description
Date Sampled
Date Analyzed
Arsenic Concentration (*)
# 1 Plate Treater
Arsenic Baghouse Dust
# 1 Roaster Baghouse Dust
# 2 Reverb Matte
# 2 Reverb Matte
« 2 Reverb Matte
Roaster Calcine
Roaster Calcine
Roaster Calcine
Roaster Calcine
Roaster Calcine
Roaster Calcine
Roaster Calcine
Converter Slag
Converter Slag
Converter Slag
Roaster Charge
Roaster Charge
Roaster Charge
Roaster Charge
Roaster Charge
Roaster Charge
Roaster Charge
Godfry Calcine Charge
Godfry Calcine Charge
Godfry Calcine Charge
Godfry Calcine Charge
Mexican Arsenic
Reverb Slac, Slag Pot
#1
Reverb Slag, Slag Pot
#2
Reverb Slag, Slag Pot #1
Dump
Reverb Slag, Slag Pot #2
Dump
Reverb Slag, Slag Pot #3
Reverb Slag, Slag Pot #3
Top
Reverb Slag, Slag Pot #3
Dump
Reverb Slag, Slag Pot #4
Reverb Slag, Slag Pot #3
Bottom
Reverb Slag, Slag Pot #4
Dump
Reverb Slag #2
Reverb Slag #2
Reverb Slag #2
9/78
9/78
9/78
9/19/78
9/20/78
9/21/78
9/15/78
9/16/78
9/18/78
9/19/78
9/20/78
9/21/78
9/22/78
9/19/78
9/20/78
9/21/78
9/15/78
9/16/78
9/18/78
9/19/78
9/20/78
9/21/78
9/22/78
9/24/78
9/25/78
9/25/78
9/24/78
9/25/78
9/19/78
9/20/78
9/20/78
9/21/78
9/21/78
9/22/78
9/22
9/22/78
9/22/78
9/22/78
9/19/78
9/20/78
9/21/78
12/3/78
12/4/78
12/4/78
12/4/78
12/3/78
12/3/78
12/4/78
12/3/78
12/4/78
12/3/78
12/3/78
12/4/78
12/3/78
12/3/78
12/3/78
12/3/78
12/4/78
12/4/78
12/4/78
12/4/78
12/3/78
12/3/78
12/3/78
12/4/78
12/4/78
12/4/78
12/4/78
12/4/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
12/3/78
38.0
69.0
3.3
23.0
0.25
0.23
1.21
0.90
1.12
0.62
0.70
1.22
0.71
0.20
0.12
0.24
0.90
0.88
0.89
0.70
0.81
0.66
0.71
2:60
3.80
5.00
3.00
75.3
0.53
0.62
0.55
0.27
0.54
0.51
0.62
0.59
0.63
0.67
0.26
0.28
0.29
14
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Table 12 Asarco Secondary Standard Analysis Results
Sample
#1 Plate Treater
I
Anode Copper
Converter Blister
Reverberatory Slag
TRW Result UAs}
41.2
i
0.09
0.29
1.07
Asarco Result (%As)
40.12
0.10
0.30
1.02
15
-------
SECTION 3
PROCESS DESCRIPTION
16
-------
SECTION 4
LOCATION OF SAMPLING POINTS
1) Roaster baghouse inlet - The duct carrying emissions from the
roasting process is balloon shaped, measuring 11 feet high
and 8 feet wide at the widest point. Sampling was done through
four 4 inch sampling ports on top of the flue. The nearest
upstream disturbance was 50 feet (4 diameters) away, the near-
est downstream disturbance was a transition section into the
baghouse which was 10 feet away. Sampling was done at 20 tra-
verse points. Figure 1 is a diagram of the sampling location.
2) Roaster baghouse outlet - The treated gas leaving the roaster bag-
house was sampled approximately 1000 feet downstream from the
baghouse. The discharge duct was round, had an inside diameter
of 90 inches, and had sampling ports on the side and top. The
nearest upstream disturbance was 500 feet (13 diameters) and
the nearest downstream disturbance was 40 feet (4 1/2 diameters)
away. Sampling was done at 12 traverse points. Figure 2 is a
diagram of this sampling location.
3) Reverberatory furnace electrostatic precipitator - The outlet of
the electrostatic precipitator treating the emissions from the
reverberatory furnace has approximately 75 feet of straight
ducting before entering the main stack. There were ten sampl-
ing ports on the top of the rectangular brick flue, which were
20 feet from the transition section leaving the electrostatic
precipitator. Forty-eight traverse points were chosen for
sampling, but it was found that a significant amount of sedi-
ment in the duct precluded sampling at twelve of them. Figure
3 is a diagram of this location.
4) Matte tapping - Matte tapping emissions are captured by a moveable hood
over the matte tapping ladle, arid are ducted to an ESP. From the
ESP, a brick flu then transfers the gases to the main stack.
Matte tapping emissions were sampled in a vertical section of a
round duct approximately 100 feet above the hood. The nearest
upstream disturbance was 75 feet (22 diameters) away, and the
nearest downstream disturbance was 10 feet (3 diameters) away.
Normally, 12 traverse points would be used for a site of this
configuration, however, 8 points were chosen as explained below.
. Matte taps vary'in length and are relatively short. Due to the
short time period, one point was sampled per tap and a 12 point
sample, then would require 12 taps. If the smelter were operating
at full smelt (or full production) it would be a simple matter
to sample 12 points; however, production at the smelter was •
17
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curtailed from time to time. This was done by direction of the
ASARCO weather station that continually monitored local weather
conditions as well as ambient S02 levels provided by $03 monitors
located throughout the city. In the fall of the year, weather
conditions are generally favorable for smelting only at night, and
often-times then only at less than full productive capacity.
These were the conditions encountered during testing.
At times, only one converter was in operation throughout the night,
and one converter requires only 8-9 ladles of matte throughout
the cycle. If only one converter was on line, and only one point
was sampled per tap, then a 12 point sample would require over a
day to complete. Further-more, these samples would be difficult
to correlate with slag tap samples which were more easily obtained
due to longer slag tapping times. Analysis of the matte tapping
duct velocity traverse indicated that an 8 point sample would
provide adequate data as well as allowing a sample to be taken
in only one converter cycle. Samples were taken at 8 traverse
points during matte tapping operations, and Figure 4 is a diagram
of this sampling location.
5) Slag tapping - Slag tapping emissions are captured by a hood over the
slag trough and are ducted to the same GSD as are the matte
tapping emissions. Slag tapping emissions were sampled in a sec-
tion which angles down 20° from the horizontal. The sampling
ports are twenty feet downstream from a 20° bend (5 diameters),
and seven feet upstream from a 60° bend (21/2 diameters). Samples
were taken at twelve traverse points during slag tapping operations,
Figure 5 is a diagram of this location.
6) Calcine discharge - Dust emissions from loading larry cars from the
roasters are collected from slots in the loading apparatus.
These emissions in turn are routed to the main brick flue through
a 10 inch duct. The emissions were sampled 9 feet (11 diameters)
downstream from the blower, which was the nearest upstream dis-
turbance. Samples were taken at a single point due to the small
duct diameter. Sampling was done only shile larry cars were being
loaded. Figure 6 is a diagram of this location.
7) Arsenic kitchen - Arsenic trioxide is produced in the arsenic kitchen
area. The effluent gases from this process are routed through a
baghouse before being discharged through the main stack. The
sampling location was at a vertical round duct which is 26 1/2
inches in diameter. The nearest upstream disturbance was the
transition from the arsenic kitchen, a reducing section of duct-
ing, which was 6 feet (3 diameters) away. The nearest downstream
disturbance was a 90° bend 5 feet (2 diameters) away. Sampling
was done at 24 traverse points. Figure 7 is a diagram of this
location.
18
-------
8) Metallic arsenic - In the metallic arsenic area, arsenic trioxide is
converted to elemental arsenic. The effluent gases from this
process are routed to the same baghouse as are the arsenic kit-
chen discharges. The sampling location for this emission stream
was in a 37.25 inch round duct which slanted up at a 20° angle
from the horizontal. The nearest upstream flow disturbance was
50 feet (16 diameters) away, and the nearest down-stream flow
disturbance was 6 feet (2 diameters) away. Sampling was done at
twelve traverse points. Figure 8 is a diagram of this location.
9) Arsenic baghouse outlet - The discharge gases from the arsenic kit-
chen baghouse were sampled approximately 500 feet downstream
from the baghouse. Samples were taken from a round horizontal
duct with an inside diameter of 37.75 inches. The nearest up-
stream flow disturbance was 30 feet (9 1/2 diameters) away.
Samples were taken at twelve traverse points simultaneously with
tests at the two inlet locations. Figure 9 is a diagram of this
location.
10) Converter slag return - During the converter cycle, slag is periodi-
cally poured off the matte and this slag is returned to the re-
verberatory furnace. The fugitive emissions discharged during
this process are captured by a hooding system. These emissions
were sampled from a round horizontal duct 36 inches in diameter.
The nearest upstream flow disturbance was 100 feet (33 diameters)
and the nearest downstream flow disturbance was 25 feet (8 diameters)
away. Samples were taken at 12 traverse points. Figure 10 is a
diagram of this location.
19
-------
/^
X.
r
i
Traverse Point Distance from Wall
t
' \
\
, \
1
1
2
3
4
5
6
7
9
28
47
66
84
103
122
.4
.3
.1
.0
.9
.7
.6
11
3'
2' .L .V
•* From Crusher
Roaster Building
Top View
1
/
Roaster
Baghouse
Sampling Ports
Figure 1 - Roaster Baghouse Inlet Duct
20
-------
o
Horizontal Duct
ro
Traverse Point Location
Traverse Point Number % of Diameter
Distance from inside wall
1
2
3
4
5
6
4.4
14.6
29.6
70.4
85.4
95.6
4.0
13.1
26.6
63.4
76.9
86.0
Figure 2 - Roaster Baghouse Outlet Duct
-------
Sampling Ports
Reverberatory
ESP
Side View
Traverse Point Distances from top of Duct
20'
15'
1
2
3
4
5
6
7
8
9
10
9"
27"
45"
63"
81"
99"
117"
135"
153"
117"
Cross Section
Figure 3 - Reverberatory Furnace ESP Outlet Duct
22
-------
ro
CO
Traverse Point Location
Point Numhor °L nf Diamptpr
1
2
3
4
6.7
25.0
75.0
93.3
Distance from inside wal1
1.8
6.6
19.9
24.7
Plan View
Side View
Figure 4 - Matte Tapping Duct
-------
K—-27'1—H
Side View
t\»
Traverse Point Locations
Point. Number 1 nf ni
To Blower
i
1
2
3
4
5
6
4.4
14.6
29.6
70.4
85.4
95.6
1.2
3.9
8.0
19.0
23.1
25.8
Figure 5 - Slag Tapping Duct
-------
o
Side View
Figure 6 - Calcine Discharge Duct
Vertical Duct
Plan Vie\n
25
-------
Travpr<;p Pnint
ro
nf nuct Diamptpr
Distanrp frnm
1
2
3
4
5
6
7
8
9
10
11
12
2.1
6.7
11.8
17.7
25.0
35.6
64.4
75.0
82.3
88.2
93.3
97.9
1.0
1.8
3.1
4.7
6.6
9.4
17.1
19.9
21.8
23.4
24.7
25.4
Figure 7 - Arsenic Kitchen inlet to Arsenic Baghouse
Jl
c
o
Side View
26.5"
Plan View
-------
37.25"
o
Plan View
Traverse Point Locations
Point. Number % of Diameter
Side View
Distance from inside wall
1
2
3
4
5
6
4.4
14.6
29.6
70.4
85.4
95.6
1.6
5.4
11.0
26.2
31.8
35.6
Figure 8 - Metallic Arsenic inlet to Arsenic Baghouse
-------
37.75"
Pi
ro
CO
Traverse Point #
Side View
Traverse Point Location
of Diameter Inches from inside wall
1
2
3
4
5
6
4.4
14.6
29.6
70.4
85.4
95.6
1.7
5.5
11.2
26.6
32.2
36.1
Figure 9 - Arsenic Baghouse outlet Duct
-------
I*
36"
O
ro
us
Plan View
Trverse Point Number
% of Diameter
Ul
Side View
Distance from inside wall
1
2
3
4
5
6
4.4
14.6
29.6
70.4
85.4
95.6
1.6
5.3
10.7
25.3
30.7
34.4
Figure 10 - Converter Slag Return Duct
-------
SECTION 5
SAMPLING AND ANALYTICAL PROCEDURE
A) Arsenic/Sulfur Dioxide Sampling
The sampling train used for arsenic/sulfur dioxide collection consists of
an EPA Method 5 train modified by adding two additional impingers in series
to the four used in the Method 5 train. The first two impingers contained 150
mis of distilled water each; third, fourth and fifth impingers contained 150
mis of 10 hydrogen peroxide each. The sixth impinger contained 250 grams of
silica gel.
Before each test, a velocity traverse of the stack was done to determine
the average stack temperature and velocity pressure. The velocity traverse
was done according to EPA Methods 1 and 2. A grab sample of the stack gas was
taken and analyzed with an Orsat apparatus for C02 and Op. Before the first
test at each location, the moisture content of the gas stream was estimated by
either condensation in impingers as in EPA Method 4, or by wet and dry bulb
thermometer if the stack gas temperature was below 120°F.
The arsenic/sulfur dioxide samples were taken at traverse points at the
center of equal areas within the stack. The number of traverse points was
determined by the number of duct diameters upstream and downstream from the
nearest flow disturbances. The sampling rate was adjusted to isokinetic con-
ditions using a nomograph which had been set based on the preliminary velocity
traverse data, and moisture estimate.
The sampling time per traverse point was 3-9 minutes depending upon the
sampling location. Leak checks of the sampling train were done at the begin-
ning of each test, just before the sampling port change, and at the end of the
test. At the end of each test the sampling train was inspected for cracked or
broken glassware, and to assure that the filter remained intact.
s
Sampling and Analytical Procedures
At three of the sampling locations it was impractical to use the normal
sampling tain configuration. These three locations were the slag tapping,
metallic arsenic, and reverberatory furnace Cottrell locations. At the slag
tapping and metallic arsenic locations the angle of the duct made it diffi-
cult to support the heated box/impinger box/probe combination while travers-
ing. At the Aeverle Cottrell outlet, an overhanging roof caused a clearance
problem when suspending the equipment. In these locations a flexible teflon
line connecting the probe to the filter holder was used (see Figure 12).
This allowed the probe to be held in position by one man. The material cap-
tured in the heated line and cyclone (used to catch any condensate from the
flexible line) was recovered by rinsing with sodium hydroxide solution and
brushing with a flexible brush. The flexible line rinse was added to the
probe rinse. Condensate collected in the cyclone was measured and added to
the probe rinse.
30
-------
Sample Recovery
The sampling nozzle and probe liner were rinsed with 0.1N NaOH and
brushed out with a nylon bristle brush with a teflon tubing handle. The re-
mainder of the sampling train was removed to the mobile laboratory. The front
half of the filter and connecting glassware were rinsed with 0.1N NaOH and
this rinse was added to the nozzle and probe rinse. The filter was removed
from the filter holder and placed in a polyethylene container, which was
labeled and sealed. The first two impinger solutions were measured and placed
in a glass sample container along with a 0.1N NaOH rinse of the impingers.
The contents of the third, fourth and fifth impingers were measured and placed
in a separate glass sample container along with distilled water rinse of the
impingers. The silica gel in the sixth impinger was weighed to the nearest
gram and regenerated.
«
B) Analysis
Analysis-Sulfur Dioxide
The samples were analyzed for sulfur dioxide by taking an aliquot of the
hydrogen peroxide impinger solutions and titrating with barium perchlorate
solution and thorin indicator as described in EPA Method 6 (Determination of
Sulfur Dioxide Emissions from Stationary Sources).
!• Filter - Warm filter and loose particulate matter with 50 ml 0.1N
NaOH for about 15 minutes. Add 10 ml concentrated HMh and bring
to boil for 15 minutes. Filter solution through No. 41 Whatman paper
and wash with hot water. Evaporate filtrate, cool, redissolve in 5
ml of 1:1 HNOa transfer to a 40 ml volumetric flask and dilute.
2. Probe Wash and Impinger Solns - These should be combined and a 100
ml sample withdrawn. Add 10 ml concentrated HNOa and evaporate to a
few milllllters. Redissolve with 5 ml 1:1 HNOa and dilute to 50 mis.
A reagent blank should be carried through the same procedure. The
resulting blank solution should be used in the dilution of standards
to matrix match samples and standards.
3. All the samples prepared above should be screened by air/acetylene
flame. The filter samples may require dilution with 0.8N HNOj. Im-
pinger solutions containing more than 26 mg/1 of arsenic should be
diluted since linearity decreased dramatically above that level.
Since an entrained hydrogen flame provides about five times as much
sensitivity as the air/acetylene flame, a matrix check of a sample
in a hydrogen flame should be carried out by the method of standard
additions, and compared with a value obtained from matrix matched
standards in a hydrogen flame. If values are comparable (± 5/0 the
air entrained hydrogen flame.
Due to high concentrations of copper on the filter an air/acetylene
flame should always be used to dissociate any AsCu compounds stable
in the cooler hydrogen flame.
31
-------
For samples below the 1. mg/1 level, hydride generation is necessary.
An appropriate aliquot of digested sample in 0.8N HN(h containing
less than about lOyg of arsenic ts chosen (some screening may be
necessary). Five mis of concentrated H2S04 is added to the sample
which is then placed on a hot plate until $03 fumes rill the flask.
A reduction in volume to about 5 ml or less may be necessary. This
step removes HNOa which causes a violent reaction when the reducing
agent is added resulting in poor reproducibility and lowered sensi-
tivity by producing \2, N02 and possibly other species.
One ml of 30% KI and 1 ml of 30% SnClp are added to the sample, the
former to act as a catalyst in hydride formation and the latter to
reduce all the arsenic to As+3. The sample is then diluted to about
15 ml and 15 ml of concentrated HC1 is added. Powdered Zn (or NaBfy)
is then added, the reaction vessel is immediately closed and the ni-
trogen or argon carrier flow initiated. A peak should be produced
within a few seconds.
.32
-------
1.
2.
3.
4.
5.
6.
7.
12.
13.
12
13
Figure 11 Arsenic sulfur dioxide sampling train.
KEY
Calibrated Nozzle
Heated Probe
Reverse Type Pitot
Cyclone Assembly
Filter Holder
Heated Box
Ice Bath with Impingers
Thermometer
Check Valve
14. Vacuum Line
15. Vacuum Gauge
16. Main Valve
17. Air Tight Pump
18. By-Pass Valve
19. Dry Test Meter
20. Orifice
21. Pi tot Manometer
22. Thermometer
33
-------
GREENBURG-SMITH
IMPINGERS
© r
POTENTIOMETER
THERMOCOUPLE
NOZZLE
Figure 12 MODIFIED EPA SAMPLING TRAIN
------- |