United States
             Environmental Protection
             Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-CUS-14
September 1979
             Air
&EPA      Copper Smelters
            Emission Test Report
            Lead  Emissions

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         LEAD EMISSIONS  FROM
       PRIMARY COPPER SMELTERS
                   TO
    ENVIRONMENTAL  PROTECTION AGENCY

         Contract  #68-02-2812
         Work Assignment  #39
           February 5, 1980
                   BY
              D. Ringwald
                  and
               T. Rooney
                  TRW
        ENVIRONMENTAL ENGINEERING DIVISION
One Space Park, Redondo Beach,  CA    90278

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                                 CONTENTS

Figures	iii
Tables	    v
     1.  Introduction	    1
     2.  Summary and Discussion of Results 	    3
              ASARCO - El  Paso, Texas; TRW Test program	    3
              ASARCO - El  Paso, Texas; Monsanto Test program 	    8
              Phelps-Dodge - Douglas, Arizona; TRW Test program	   22
              Phelps-Dodge - Ajo, Arizona; TRW Test program	25
              Phelps-Dodge - Playas, New Mexico; TRW Test program.  ...   33
              ASARCO - Tacoma, Washington; TRW Test program	35
              Kennecott -  Magma, Utah; TRW Test program	51
              Anaconda - Butte, Montana; Monsanto Test program 	   58
              Process Samples	.'  .   62
              Lead Emission Factors	68
    3.  Location of Sampling Points	71
              ASARCO - El  Paso, Texas; TRW Test program	71
              ASARCO - El  Paso, Texas, Monsanto Test program 	   79
              Phelps-Dodge - Douglas, Arizona; TRW Test program	   86
              Phelps-Dodge - Ajo, Arizona; TRW Test program	89
              Phelps-Dodge - Playas, New Mexico; TRW Test program.  ...   99
              ASARCO - Tacoma, Washington; TRW Test program	101
              Kennecott -  Magma, Utah; TRW Test program	113
    4.  Sampling and Analytical Procedure	124
Appendices
                                     ii

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                                   FIGURES

Number            .                                                      Page
  1     Inlet to converter fugitive emissions  baghouse	    73
  2    Outlet from converter building fugitive emissions  baghouse.  .  .    74
  3    Roaster calcining fugitive emissions duct 	    75
  4    Outlet from the roaster/reverberatory  furnace ESP  	    76
  5    Outlet from roaster reverb spray chamber and electrostatic
           precipitator	    77
  6    Matte tapping reverberatory furnace outlet	    78
  7    Sampling location D 	    80
  8    Sampling location C	    82
  9    Sampling location B 	    83
 10    Sampling point A	    85
 11     Inlet to calcine/roaster baghouse 	    87
 12    Outlet from calcine/roaster baghouse	    88
 13    Converter fugitive emission duct	    90
 14    Converter fugitive emission system	    91
 15    Matte tapping emission duct 	    92
 16    Matte tapping fugitive emission system	    93
 17    ESP inlet sampling locations	    94
 18    Acid plant outlet location	    95
 19    ESP outlet/acid plant inlet sampling location  	    97
 20    Acid plant schematic - Phelps-Dodge Ajo, Arizona	    98
 21     Converter fugitive emission duct	100
 22    Roaster baghouse inlet	102
 23    Roaster baghouse outlet duct	103
 24    Reverberatory furnace electrostatic precipitator	104
 25    Matte tapping	105
 26    Slag tapping duct	106

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 27    Calcine discharge duct	108
 28    Arsenic kitchen inlet to arsenic baghouse 	  109
'29    Metallic arsenic inlet to arsenic baghouse. .	. .  110
 30    Arsenic baghouse outlet duct... .	  Ill
 3T    Converter  slag return duct	112
 32    Matte  tapping	115
 33    Slag tapping	.'	116
 34    Slag tapping fugitive emission duct traverse point
           location  procedure 	  117
 35    Plant  schematic - The matte tapping and slag tapping
           fugitive  emission system  	  118
 36    Acid plant inlet	119
 37    Converter  fugitive emission system	120
 38    Plant  schematic - Converter fugitive emission system	121
 39    Concentrate dryer stack 	  122
 40    Plant  schematic - Concentrate dryer fugitive
           emission  system	123
 41    EPA method 5 particulate sampling train 	  126
                                    1v

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                                   TABLES
Number                                                                 Page
  1    Baghouse Inlet Lead Results 	     4
  2   Baghouse Outlet Lead Results	     5
  3   Calcine Fugitive Lead Results	  .     6
  4   Matte Tapping Lead Results  	  .   7
  5   Summary.of Arsenic Results at  the Inlet of the Stack
      .  Point A	     9
  6   Summary of Lead Results at South Outlet of the
        Reverberatory Furnaces Point SB 	    11
  7   Summary of Lead Results at North Outlet of the
        Reverberatory Furnaces Point NB 	    13
  8   Summary of Lead Results at the Outlet of the
        Roasters Point C. .	    15
  9   Summary of Lead Results at the Inlet of the
        H2S04 Plant Point D	    17
 10   Summary of Lead Results at Outlet of the
        H2S04 Plant Point E	    19
 11    Inlet to Calcine/Roaster Baghouse Lead Results	    23
 12   Outlet from Calcine/Roaster Baghouse Lead Results 	    24
 13   Matte Tapping Fugitive Emission Results - Lead	    26
 14   Converter Fugitive Results - Lead	    27
 15   ESP Inlet #1  Lead Results.	    29
 16   ESP Inlet #2 Lead Results . .  . . \	 .  .  .    30
 17   ESP Outlet/Acid Plant Inlet Lead Results	    31
 18   Acid Plant Outlet Lead Results	    32
 19   Converter Fugitive Emissions Lead Results ,	,  .    34
 20   Roaster Baghouse Lead Results  	 ...........    36
 21   Roaster Baghouse Outlet Lead Results	  .    37

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             0
22   ESP Outlet Lead Results	J	 . .  .   38
23   Matte Tapping Lead Results	   39
24   Slag Tapping Lead Results . . . •	   40
25   Calcine Discharge Lead Results	   41
26   Arsenic Baghouse Inlet (Arsenic Kitchen)
       Lead Results	„   42
27   Arsenic Baghouse Inlet (Metallic Arsenic)
       Lead Results	   43
28   Arsenic Baghouse Outlet Lead Results	   44
29   Converter Slag Return Lead Results	  .   45
30   Converter Full Cycle Lead Results	   46
31   Converter Copper Blow Cycle Lead Results	   47
32   Converter Fugitive #1 (E) Lead Results	   48
33   Converter Fugitive #2 (M) Lead Results	   49
34   Converter Fugitive #3 (W) Lead Results	   50
35   Matte Tapping Lead Results. . . , .	   52
36   Slag Tapping Lead Results ,	   53
37   Acid Plant Inlet Lead Results	,.,.,.   54
38   Rollout Converter Fugitive Lead Results . , . , ,	   55
39   Full Cycle Converter Fugitive Lead Results. .... 	   56
40   Concentrate Drier Lead Results.	   57
41   Location 2A	 . . . . ,«...,.,   59
42   Location B	 . . ,	 . .  .   60
43   West Inlet	 . .  .   61
44   Process Samples	 . . .  .   62
45   Lead Emission Factors	   69
46   Lead Emission Factors for Primary Copper Smelters without
       controls.  .  .  0	   70
47   Lead Emission Factors for Primary Copper Smelters with controls   70
                                     vi

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                                INTRODUCTION


     Copper smelters are a significant source of airborne particulates.   The
fugitive dust emissions from various stages of the process are collected  by
hoods placed over equipment and ducting to control  devices.

     In conjunction with the Environmental Protection Agency's Program for
developing new source performance standards, TRW and  Monsanto  Research Cor-
poration performed fugitive emission tests at seven copper smelters  including
the Asarco smelters at El  Paso, Texas afnd Tacoma, Washington,  the Phelps-
Dodge smelters at Ajo and Douglas, Arizona and Playas, New Mexico, the
Kennecott smelter at Magma, Utah and the Anaconda smelter at Butte,  Montana.

     The scope of this testing program, designed to provide data  on  arsenic
and sulfur dioxide emissions, has been extended to lead by laboratory analysis
on the samples collected.

     The first two copper smelters tested in the program, the  Anaconda plant at
Butte, Montana and the Asarco plant at El Paso, Texas, were sampled  by Monsanto
Research Corporation.  At Asarco, El Paso, Monsanto tested the fugitive
emissions collected by hoods placed over the converter line at points before
and after the emissions entered the sulfuric acid plant.  Also tested by
Monsanto were the fugitive emissions collected in the roaster  building at
points before the emissions enter an electrostatic precipitator,  and at a
point in the ballon flue on the outlet of the electrostatic precipitator.

     In January of 1978 TRW sampled at the Asarco smelter in El  Paso.  Sites
tested by TRW included the converter building fugitive emissions  baghouse,
the calcining and matte tapping fugitive emissions ducts.

     The Phelps-Dodge copper smelters at Douglas and  Ajo, Arizona and Playas,
New Mexico were sampled by TRW in May, June and July  1978 respectively.

     At the Douglas, Arizona plant, TRW sampled the calcine/roaster  baghouse,
which collected fugitive emissions during the loading process  of the train
car.  The train car transported the concentrate to the reverberatory furnace
operation.  The fugitive emission system operated on  an intermittant basis.

     At the Phelps-Dodge Ajo smelter, TRW sampled the fugitive emission^
systems of the converter slag and copper blow cycle,  and the matte tapping
operation from the reverberatory furnace.  The sulfuric acid plant attached
to the copper smelter was also sampled at the inlet to the electrostatic
precipitator. the electrostatic precipitator outlet/acid plant  inlet, and the
acid plant outlet.  The acid plant converts sulfur dioxide to  sulfuric acid
with a contact catalyst.

                                      1

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     The converter slag and copper blow cycles were tested by TRW at the Phelps
Dodge Playas, New Mexico copper smelter.

     In September 1978 and May 1979, TRW tested the Asarco copper smelter in
Tacoma, Washington, which processes ores high in arsenic.   The TRW team per-
formed emission testing at the inlet and outlet of the roaster baghouse, the
inlet and outlet of the arsenic kitchen, the inlet and outlet of the rever-
beratory furnace electrostatic precipitator, the fugitive  emission systems of
the matte tapping, slag tapping, converter slag return, calcine, as well as the
converter during copper blow and full cycles and fugitive  emissions not
controlled by the hoods over the converter.

     TRW tested the Kennecott copper smelter at Magma, Utah in November 1978.
The matte tapping fugitive emission syst emotes ted was operated interim'ttantly
to control emissions from loading of coppe? matte from reactors to large
ladles.  The slag tapping futivive emission system works similarly during
loading of slag from reactors to the layer ladles.  Also tested by TRW were
the converter fugitive emission system, the acid plant inlet and the concen-
trate dryer emission system which removes water and fugitive dust from the
rotating concentrate dryers.

     This report presents the results of laboratory analysis for lead on the
samples collected during this test program.  Data is not complete for
some tests since some sample solutions required complete consumption in order
to accomplish the analysis for arsenic for the original test program.

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                      SUMMARY AND DISCUSSION OF RESULTS
ASARCO - El Paso, Texas; TRW Test program

     The results of the emission testing at the five test locations  are
summarized in Tables 1  - 4 of this report.   Three sets  of tests  were per-
formed at the inlet and outlet of the converter building fugitive emissions
baghouse, the calcining fugitive emissions  duct, and the matte tapping
fugitive duct.                        ^

     In addition, analyses were performed on composited process  samples
taken by plant personnel on the days that the fugitive  emission  testing was
being performed.  This  data is summarized in Table 44.

     Since some of the  samples from the converter baghouse outlet were
consumed in the previous analysis for arsenic the efficiency of  the  bag-
house for lead removal  can not be determined.  The converter baghouse inlet
averaged 6 Kg/hr of lead.  Fugitive lead emissions from the calcining and
matte tapping operations averaged 0.4 Kg/hr and 0.5 Kg/hr respectively.

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TABLE 1.  BAGHOUSE INLET  LEAD RESULTS.
RUN NUMBER
V ANALYTICAL DATA Pb
A) . Front Hilf '
Probe {mg) .
Cyclone (mg) .
Filter (mg) f .
Front Hilf TpUl (us)
grs/SDCF. (mg/m3)
Ihr, (kg/hr) .
6} MxMxrixMgxx Imp-r-1'. & 2
Ek_. . M '
gn/SOCF , (ng/ni3) '
l/hr, (kg/hr)
*" Pb . (ng) Imp 3- '..'.:'
grs/SDCF, (mg/m3)
*/hp, (kg/hr) . ;
0 Imp 4. 5. S 6 . . ..-.;.: * (M)
grs/SDCF, (mg/mj)
l/hr, (kg/hr)
nl Total Pb (M)
grs/SOCF ,(ng/in3) • '
»/hr. (kg/hr)
E) Tyt«»y»y (mg)
Pb'PP""
grs/SDCF, (mg/n3) .
*/hr , (ktfhr)
1
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-------
TABLE 2.  BAGHOUSE OUTLET LEAD  RESULTS.
,
RUN NUMBER
V ANALYTICAL DATA
A) . Front Half
Probe (ing) •-..'•


Filter (ing) t • .
rrnnt 11*1? Total final • '
jrt/SOCF, (rng/ro3)
Ihr. (kg/hr)

B) MfXttiiMXKXX Imp..l; & 2
Pb (mg) ' , .
gr*/SDCF . (mg/m*) '
l/hr, (kg/hr)
•*" Pb -. (rag) . Imp '3 .-••..
grs/SOCF, (mg/m3) ' '.;.'•
»/hr, (kg/hr)

c) Imp 4 5-& 6 . (JEt4-": •• t"u)
grs/SOCF, (irg/m1)
l/hr. (kg/hr)

gr$/SDCF ,(ng/w3)
l/hr, (kg/hr)
E) Total S0; (mg) " .
•PP«> .
gr$/SOCF, (rog/a3)
l/hr . (kgfhr)

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-------
TABLE 3.  CALCINE FUGITIVE LEAD RESULTS
9
RUN NUMBER
V ANALYTICAL DATA
A) . Front Half '
Probe (ing) . • .
Cyclone (rig) .
Filter (mg) f
Front Hilf ToUl (ng)
grs/SOCF, (mg/m3)
Ihr, (kg/hr)
I) NWWtW&x* imp.j. £ ^
Pb (mg)
gr»/SOCF, (mg/rn3) '
l/hr, (kg/hr)
01 Pb . . (ng) ..•'••
gr$/SDCF, (mg/m3) ' ' :'
l/hr, (kg/hr) ^ : . ;.
o Imp 4,.5.& fa. APpJ.-: ,{„)
grs/SOCF. (mg/inj) . . ..
l/hr, (kg/hr)
0) Total tnt.a] (w)
grs/SDCF ,(ng/m3) . • '
l/hr, (kg/hr)
E) T«t»t*9, (mg)
Pt>ppra
grj/SOCF, (mg/B3)
l/hr , (kg/hr)
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TABLE 4.  MATTE TAPPING LEAD RESULTS
RUN NUMBER
V ANALYTICAL DATA
A) . Front Half
Probe (1113)
Cyclone (mg)
Filter (tag) f .
Front tUH Total (ng)
grs/SDCF , (ng/n3)
Ihr. (kg/hr)
8} nwcwuuuwcx Imp1! & 2
Pb (ms)
grs/SOCF, (mg/m3)
«/hr, (kg/hr)
"J pb. . to) ImP 3
grs/SOCF. (mg/m3)
*/hr, (kg/hr)

c) imp ^,..4 & t> ...A^te,)
grs/SOCF. (mg/nj)
l/hr. (kg/hr)
D) Total total {Bg)
grs/SDCF ,(mg/m3)
*/hr. (kg/hr)
E) tMJJO«flg?(^
rD rr" -
grs/SOCF. (ng/nj)
l/hr . (kgyhr)

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76.5000
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-------
ASARCO - El Paso, Texas; Monsanto test program

     This program was separated into essentially two phases.  The first phase
was sampling of the effluent of the converter line.  These gases are collected
into ducts and directed to an induced draft fan.  The exhaust of this fan is
directed .through a short section of duct work into a long spray chamber.
This short section of duct work is sampling location D, inlet to the sulfuric
acid plant.  The gases leave the spray chamber and go to an electrostatic
precipitation particulate collection device.

     From here they are directed to the inlet of the sulfuric acid plant.  The
outlet of the sulfuric acid plant is an atmospherically vented stack.  This
outlet duct is sampling location E.  The second phase of this program was to
sample the outlets of the reverberatery furnace, the outlets of the multi-
hearth roasters, and the combination of these gases after passing through
the particulate removal system at the base of the main stack.  The gases
from .the multi-hearth roasters are directed to a large downtake at the side
of the roaster building and down into a large existing brick flue.  This
downtake is sampling location C.  The gases from the reverberatory furnace
pass through two waste heat boilers and then through two rectangular ducts
into the same existing flue.  These two flues are designated sampling
locations North B and South B.  The gases in this flue pass to a spray
chamber, leave the spray chamber and pass through an electrostatic precipita-
tor.  The gases leaving this electrostatic precipitator pass through a large
balloon flue and into the base of the main stack.  This balloon flue is
sampling location A.

     The lead concentration of fugitive emissions from the converter line,
which is summarized in Table 9, averages 2 Kg/hr.
                                      8

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      Table  5.    SUMMARY OF ARSENIC RESULTS AT THE INLET OF THE STACK (POINT A)
                                     Metric Units
Run Number
Date
Method Type
Volume of gas sampled-Nm3
Percent moisture by volume
Average stack temperature-°C
Stack volumetric flow rate-Nm3/min
Stack volumetric flow rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe, cyclone and filter catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg
     g/Nm3
     Kg/hr
Percent impinger catch
A-l
6/26/77
Arsenic
1.35
6.81
102
5693
8988
100.4
153
2.88
0.002
0.727
6.11
0.005
1.543
A-2
6/27/77
Arsenic
1.41
6.13
104
5944
9,398
100.4
153
9.89
0.007
2.496
13.30
0.009
3.357
A- 3
6/28/77
Arsenic
-1.42
1.39
105
6307
9478
95.4
153
4.72
0.003
1.252
5.80
0.004
1.539
53
26
19
 Normal cubic meters at 20°Cf 760 mm Hg
 'Actual cubic meters per minute

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TABLE 5. (continued)

RUN NUMBER
V ANALYTICAL DATA
A) . Front Half
Probe (mg) & cyclone (Test fl) (Probe Test #3)
fcrtwotaj} Front Filter
BackHlter (mg)
Front Half Total (mg)
grs/SOCF, (mg/m3)'
»hr. (kg/hr)
B) WHMtwxi&xx Imp-. 1 j & 2 & 3
Pb (mg)
grs/SDCF. (mg/m3)
l/hr. (kg/hr) ' •
Imp 4
° EL.».w
grs/SDCF. (mg/m3)
l/hr, (kg/hr)
c) Imp. 5 ..j - (Pb) ..... ••- dag)
grs/SDCF. (mg/m3}
*/hr, (kg/hr)
0) Total Imp Pb (mg)
grs/SDCF ,(ng/m3)
*/hr. (kg/hr) !
Pb
E) Total m. (rag)
ppra
grs/SDCF, (rog/ro3)
*/hr . (kgThr)
ppm Pb
1
ENGLISH UNITS

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1 .1800
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2.5730
1.9060
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3.229
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-------
      Table  6^     SUMMARY OF LEAD RESULTS-AT SOUTH OUTLET OF THE REVERBERATORY FURNACES (POINT SB)

                                      Metric Units
Run Number
Date
Method Type
Volume of gas  sampled-Nm3 a
Percent moisture  by volume
Average stack  temperature-°C
Stack volumetric  flow rate-Nm3/min
Stack volumetric  flow rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe,  cyclone and filter catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg
     g/Nm3
     Kg/hr
Percent impinger  catch
SB-1
6/26/77
Arsenic
0.44
14.19
420
560
1767
95.8
120
128.8
0.293
9.834
129.7
0.295
9.902
SB-2
6/27/77
Arsenic
0."67
13.36
408
&25
1928
97.7
120
901.8
1.803
67.55
912.0
1.824
68.31
SB-3
6/28/77
Arsenic
0.68
25.19
323
736
2292
113.4
120
954.6
1.395
61.56
1012.0
1.479
65.27
 Normal cubic meters  at 20°C,  760 mm Hg
 Actual cubic meters  per minute

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TABLE 6.  (continued)
RUN NUMBER
V ANALYTICAL DATA
A) . Front H»lf
Probe (ing) . •
Cyclone (ing) . ;
FUter (mg) f .
Front H«lf ToUl (09)
gr$/SDCF, (mg/m3)
Ihr, (kg/hr)
8) PtfatortWfefxx Bacle -Filter
Ek_ . to) '
grs/SOCF. (mg/m3) •
l/hr, (kg/hr)
~ P.b .tag) ImP' T» 2> & 3
grs/SDCF, (mg/rn3) ' '.;•'•
*/hr, (kg/hr) ; ..
C) Imp. 4 .. - . . .....i: •* (m)
grs/SOCF, (irg/nj)
«/hr, (kg/hr)
D) 3t««ak Imp 5 (n)
grs/SDCF ,(mg/m3) . • . '
'/hr, (kg/hr)
E) lotjL^ (mg) Irnpinqer total
'*W< total lead
grs/SOCF. (mg/n3)
«/hr , (kg/hr)
I
ENGLISH UNITS

-~
•
--



•
v_


--



—


__







METRIC UNITS

4.5000
1.7000
,5500
6.7500
15.3409
0.5155

.0610


.0100



.0130


.0290


0.1130
6.8630
1S.5977
0.5241
1.813
2
ENGLISH UNITS

—
-- '
—




_—


—



—


__
•





.
METRIC UNITS

.2100
iy/.uuiHj
.6100
197.8200
295.2537
11 ,072u

.4100


.0100



.UU3U


..0130


0.4360-
1^.256
^y^.yu^^
11.0964
46.023
3
ENGLISH UNITS

—

—




*


—



— —


__



.



METRIC UNITS

.U38U
I 1 .t>UUU
ii.^UUU
id.yj»u
20.4971
u.9u52

.0520


.2100



.028u


.3730


0.6630
14.6010
21 ;-472t
u.y^aiJ
2.477
AVERSE
ENGLISH UNITS

-_
—
—
-
METRIC UNIT

1.5827
^§5?
72-. 836 -
| 10. 36 39


—


—



~ —


--

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4.1642-

J743;
"

.0767



.0147


.1383

v, ....«-. -9^._»..-
0.4040
/3.Z4UU
1TO'.'9y~l4
4.1896
T6.77T.

-------
               Table 7.,    SUMMARY OF LEAD RESULTS AT NORTH OUTLET OF THE REVERBERATORY
                           FURNACES (POINT NB)
                                      Metric Units
Run Number
Date
Method Type
Volume of gas sampled-Nm3 a
Percent moisture by  volume
Average stack temperature-°C
Stack volumetric flow rate-Nm3/min
Stack volumetric flow rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe, cyclone  and filter catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg
     g/Nm3
     Kg/hr
Percent impinger catch
NB-1
6/26/77
Arsenic
0.91
6.86
500
1095
3555
103.8
120
98.85
0.108
7.083
255.70
0.279
18.32
NB-2
6/27/77
Arsenic
1.03
17.92
419
1198
3963
107.1
120
683.90
0.661
47.48
698.80
0.676
48.52
NB-3
6/28/77
Arsenic
1.05
19.00
401
1145
3721
112.7
120
691.00
0.664
45.62
756.20
0.727
49.92
61
 Normal cubic meters  at  20 °C,  760 mm Hg
 Actual cubic meters  per minute

-------
TABLE 7. (continued)
RUN NUMBER
V ANALYTICAL DATA
A) . Front Hilf
Probe (1119) . •
Cyclone (mg)
Filter (ng) f
Front Half Tgtal (mg)
grs/SDCF, (mg/m3) .
Ihr, (kg/hr)
6} WtttorttxKX* Back., f niter
PJb_ . {ng) •
1 grs/SOCF, (mg/m3) '
l/hr, (kg/hr)
£ Pb . (ng) Imp, 1, 2, & 3 :
grs/SOCF, (mg/m3)
l/hr, (kg/hr) . : ..
c) Jnip, 4. - . ..~-^; * (in)
grs/SOCF, (mg/n5) .
l/hr, (kg/hr)
D) Total I IIP ^ (ng) '
grs/SDCF .(ng/m3) • '
»/hr, (kg/hr)
E) XKMXXBU (ma) Impi nger total
•>^r Total lead
grs/SOCF, (mg/n3) .
l/hr . (kg/hr)
ppm Pb
i
ENGLISH UNITS

— r
—
—



•
__


; — •,



--










METRIC UNITS

5.150U
i .sluu
,6300
7.2900
8.0110
u.5263

.4600


.3600



• 0580


.0500


0.8700 '
"b.louu
8.9670
0.5891
1.033
2
ENGLISH UNITS

—
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—




__


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'••..' • • '
: ' *

--


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•




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.
METRIC UNITS

2.48UU
3.b2UU
.7260
6.7260
6.5301
u.4oy4

.0940


,0220



.0030


.0260


0.1450 .
fi.S7lO "
6.6708
Q.4795
0.771
3
ENGLISH UNITS

--
--.





•


—



--






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METRIC UNITS

2.o20u
10. 2000
.bZUU
13.44UU
22.3238
1.5336

.0350


.0020



.0170





0.0540
23.4940
22.375?
1.5372
2.623
AVERAGE
ENGLISH UNITS

--
--
--




—


—



—










METRIC UNI1

3.4lt)/
Fmoir
T^ssr
1 2". 4833-
1 2. 2883
O.«43l .

.1963 •
•

.1280



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0.3563^
CTI7"
12 fi?10!
iL.8686.
1 d7fi '

-------
en
         Table &."   SUMMARY OF LEAD RESULTS AT THE OUTLET OF THE ROASTERS (POINT C)
                                          Metric Units
Run Number
Date
Method Type
Volume of gas  sampled-Nm3  a
Percent moisture  by  volume
Average stack  temperature-°C
Stack volumetric  flow  rate-Nm3/min
Stack volumetric  flow  rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe,  cyclone and filter catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg
     g/Nm3
     Kg/hr
Percent impinger  catch
C-l
6/26/77
Arsenic
1.71
6.70
78
3991
5862
102.4
116
23.43
0.014
3.266
39.45
0.023
5.499
C-2
6/27/77
Arsenic
1.23
5.32
99
4241
-6502
66.8
120
22.67
•^ 0.018
4.680
29.03
0.024
5.993
C-3
6/28/77
Arsenic
0.75
9.41
111
1587
2629
109.2
120
53.78
0.071
6.800
65.47
0.087
8.278
                                                      41
22
18
     Normal cubic meters at 20°C» 760 mm Hg
     Actual cubic meters per minute

-------
TABLE 8,  (continued)
«
RUN NUMBER
V ANALYTICAL DATA
A) . Front Half '
Probe (ing) .-..•• .
Cyclone (mg)
niter (ing) (front) t .
Front Half Total (ng)
Srs/SOCF, (mg/m3)
Ihr, (kg/hr)
8) xiwiKHXstK&x Back. .Filter
Pb (mg)
grt/SDCF, (mg/n3) •
l/hr. (kg/hr)
* Pb. ..(H) ImP ls 2' & 3 '..'••' '
grs/SDCF, (mg/m3)
l/hr, (Icg/hr) ; : ;.
C) Imp 4 ..- . ". '....ii: * fail
grs/SDCF, (mg/m3)
l/hr. (kg/hr)
D) T^^f ImP 5 («)
grs/SOCF ,{ng/n3)
l/hr. (kj/hr)
0 J^y^^) Impinqer total
5W total lead (mq) .
grs/SDCF. (mg/m3)
l/hr.(kgyhr)
1
ENGLISH UNITS

_j.
—
_^.



•
v_






—


_ —







METRIC UNITS

3.3900
6.9300
.-Q400
n ?finn
6.5850
1.5768

.0390


.6200



.,0600


.4070


1.1260
12.2860
/ .33
2.4065
2.924 .
AVERAGE
ENGLISH UNITS

—
—
—




—


—



—


• --

• . . ....





METRIC UNIT
8TDTOD"
3T8500"
2.9467"
4."^QSO" "
4.3340
2.328"^ .

.0303 '


.6167
:


.U2//


.1473

- * „•• .1 <. ,,.- '
0.8220!'
•5.59G3 •
is^oaie;
2.4523
1.742

-------
                  Table  9.    SUMMARY OF LEAD RESULTS AT THE INLET OF THE H2S04 PLANT (POINT D)
                                      Metric Units
Run Number
Date
Method Type
Volume of gas sampled-Nm3  a
Percent moisture by volume
Average stack temperature-°C
Stack volumetric flow rate-Nm3/min
Stack volumetric flow rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe, cyclone and filter  catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg
     g/Nm3
     Kg/hr
Percent impinger catch
D-l
6/21/77
Arsenic
1.77
2.07
222
1653
3257
98.5
105
3923.00
2.210
219.0
4181.00
2.355
233.4
D-2
6/22/77
Arsenic
1.24
5.72
209
1563
J 3116
112.2
96
230.50
0.185
•^ 17.38
283.70
0.228
21.39
D-3
6/23/77
Arsenic
1.17
4.94
200
1553
3003
106.0
96
289.30
0.248
23.08
305.50
0.262
24.37
19
 Normal cubic meters at 20°C,  760 mm  Hg
 Actual cubic meters per minute

-------
TABLE 9.  (continued)
«
RUN NUMBER
V ANALYTICAL DATA
A) . Front Hilf '
Probe (ing) . . •
Cyclone (ing) . . .
Filter (mg) (front) f
Front Htlf Total (09)
grs/SOCF, (mg/m3)
Ihr, (kg/hr)
B) fcxWwtaKxx- Bacfc-Ftl ter
Ph . (mg)
gri/SOCF, (ing/oi3)
l/hr, (kg/hr)
oo Pbn .. (mg) Imp 1, 2, &3 N
grs/SOCF, (mg/m3)
l/hr, (kg/hr) .. .
C) Tmn 4 . . '....*'.•: •* (W)
grs/SOCF , (mg/oj)
l/hr, (kg/hr)
D) fttW ImP 5 (na)
grs/SDCF ,(mg/ra3)
l/hr, (kg/hr)
E) **x*»K (mg) Impinger total .
•^fc Total lead
gr»/SOCF. (mg/«i3)
»/hr , (kg/hr)
1
ENGLISH UNITS

—
--
^ ^



•



__



--


— ^







METRIC UNITS

45.9000
0.5700
8.4800
b4.ybUU
31.0452
j.u?yu

8.4500


.0050



. uouu


.0040


8.5390 '
6d.4HyLT
35.8695
3.5575
4.153
2
ENGLISH UNITS

—

—




w ••


' — •. •
/


- —


WM
•





.
METRIC UNITS

13.0000
3r/roo
3.1600
iy.j700
15.6210
1.4649

10.8000


2.2200



.04i:u


.3930


13.4550 .
^•8250
Zb.l/lo
2.4825
3.066
3
ENGLISH UNITS

—

—




- •


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--


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.



METRIC unns

8.5600
J . iOUU
2.3900
14.31
12.2308
1.1397

.0610


1.1600



.411)1)


.0010


1.6320
I5.y42
~T3TB2Tr
1.2696
T75B5"
AVERSGE
ENGLISH UNITS

—
—
--




-_


--



~™


--







METRIC UNIT

22.4857
-273800"
4.6767
29V5433 -
19.6323
1.8945 •

6.4370 '

1.1283



. I //3


.1327


7.8753
37.4187 '
2573223.
~2"."ZT3B5
2:935 .

-------
    Table  10.     SUMMARY OF LEAD RESULTS AT OUTLET OF THE H2S04 PLANT (POINT E)
                                     Metric Units
Run Number
Date
Method Type
Volume of gas sampled-Nm3 a
Percent moisture by volume
Average stack temperature-°C
Stack volumetric flow rate-Nm3/min
Stack volumetric flow rate-Am3/min
Percent Isokinetic
Duration of run - minutes
Arsenic - probe, cyclone and filter  catch
     mg
     g/Nm3
     Kg/hr
Arsenic - total catch
     mg  .
     g/Nm3
     Kg/hr
Percent impinger catch
E-l
6/21/77
Arsenic
1.64
0
64
1929
2542
73.0
132
0.27
0.0002
0.019
0.31
0.0002
0.022
E-2
6/22/77
Arsenic
1.52
0
64
1885
2485 '
76.2
132
2.75
0.0018
0.205 ^
4.77 ,
0.0031
0.355
E-3
6/23/77
Arsenic
1.91
0
66
1875
2475
96.4
132
2.06
0.0011
0.121
2.13
0.0011
0.126
E-4
6/24/77
Arsenic
1.88
0
69
1831
2441
97.4
132
0.39
0.0002
0.023
0.66
0.0004
0.038
13
42
41
 Normal cubic meters at 20°C,  760 mm  Hg
 Actual cubic meters per minute

-------
TABLE 10.   (continued)
*
RUN NUMBER
V ANALYTICAL DATA
A) . Front H«lf
Probe (ing) . .
Cyclone (mg)
Filter (ng) (front) f . .
Front Htlf Total (ng)
grs/SOCF , (ng/m3)
(hr, (kg/hr)

B> P*5&W*S- BaCk- filter
pb (ng)
gri/SDCF , (ng/m3) '
»/hr, (kg/hr)
o Pb. . (mq) Imp 1.' 2, &3 ;
grs/SOCF, (ng/m3)
*/hr, (kg/hr) ,

0 Imp . 4 ... . . Pb._...: ., (w)
grs/SOCF . (ms/inj)
l/hr, (kg/hr)
D) Ypxsdx TrnQ 5 fa9^
grs/SDCF ,(mg/ni3) • '
'/hr, (kg/hr)
E) Jat*3x$2« W Impinqer total
•«»x total lead
grs/SOCF, (rog/B3)
«/hr,(kgrhr)
ppm Pb
t
ENGLISH UNITS

_.*

_ —




—






—


_ —





-


METRIC UNITS

1.7700

.0080
1 .778(1
1.0841
0.1255

.0090


.0170



.0090


.0060


0.0410
1.8190
1.1091
0.1284
0.129
i
ENGLISH UNITS

__

__











—


__
•





.
.
METRIC UNITS

1.7600

.0060
1_7fifin
1.1618
0.1314




.0360



.0070


.0110


0.0540 •
1 ./BZU
1.1724
0.1326
0.136
•
3
ENGLISH UNITS

—

__




.






--


__



•




METRIC UNITS

3.0300

.0050
3.0350
1 . 5890
U.1788




.0500



.0050


.0040


0.0590
3 . Ub»4
T.^8W~
0.1788
inss"
#4
ENGLISH UNITS

-- '

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METRIC UN11

.4950

.0050-
O.^QQQ
0.2650
u.uzvz .

'•


.0250



.0260


.0060

- - -.-^..-'
0.0570
OT537IT
07Z963
O32T
n: 03-4-.

-------
TABLE 10.  (continued)
•
RUN NUMBER
V ANALYTICAL DATA
A) . Front Hilf '
Probe (ing) . • .
Cyclone (ing)
Filter (m$) f . . .
Front H«lf ToUl (ing)
grs/SOCF, (ng/m3)
Ihr. (kg/hr)
B) Participates -.-..;
(mg)
grt/SOCF, (mg/n3) •
»/hr, (kg/hr)
' ' ~ Pb ..M I™Pl.'2. &3
grs/SOCF, (mg/m3)
l/hr, (kg/hr) : .
c) Imp 4 .. - . . ...--•: * ta)
grs/SDCF, (irg/m3) . .
f/hr, (kg/hr)
• / •
0) totsclxx LlTlD_»_ 5f*9)
grs/SDCF ,(ng/m3)
»/hr, (kg/hr)
E) Total S0; (mg) . '.'.
-ppra .
grj/SOCF. (mg/»3)
»/hr , (kgThr)
1
ENGLISH UNITS

•
























METRIC UNITS















•










Z
ENGLISH UNITS










J








•





•
METRIC UNITS

























.
}
ENGLISH UNITS








-•













,



METRIC UNfTS





.















•

"


AVERAGE
ENGLISH UNITS

—

—







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--


—







METRIC UN11
TT638"

...OQ6P .

.

., 	

.0320



.uiyy


.0068

• --.,-.-•






-------
Phelps-Dodge - Douglas, Arizona; TRW Test Program

     Two main problems were encountered in the testing program at the Phelps-
Dodge copper smelter.  When the TRW personnel arrived at the site, the plant
was not operating due to mechanical malfunction.  This problem caused a one
and a half day delay in the testing program.

     The second problem was the intermittent process operation.  The emissions
being measured were during the loading of train cars that transported the
calcine.  The loading operation took two to five minutes and the process
occurred once every twenty-five to thirty minutes.  The testing necessitated
one traverse point per loading operation due to the variability in loading
times.  Stop watches were utilized to obtain accurate times.  All data was
time weighted to achieve the averages.  This was accomplished to account for
variability in loading times.

     The previous arsenic analysis on the samples collected required the
complete use of some fractions.  This precludes calculation of total lead
concentrations.  Results are summarized in Table 11 and 12.

     During the data reduction, the meter volume was back calculated to account
for sulfur dioxide that was removed by the impingers containing 10% hydrogen
peroxide.  The back calculation for 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 106.  This number was added to one and the result multiplied by
volume of gas collected through the dry meter at standard conditions.  The
result of multiplication yielded the actual gas volume collected at atandard
conditions.  Since SOg removal by the peroxide impingers does not reach the
dry gas meter, corrected values for dry gas meter volumes (at meter condi-
tions) found on the summary sheets will be slightly higher than those ob-
tained from the field data  sheets.
                                      22

-------
TABLE 11.  INLET TO CALCINE/ROASTER BAGHOUSE  LEAD RESULTS
»
RUN NUMBER
V ANALYTICAL DATA
A) pb • Front Half '
Probe (ing) . • .
Cyclone (rig) .
Filter (mg) f
Front Htlf Tot«l (mg)
grs/SDCF , (mg/m3)
Ihr, (kg/hr)
B) M«»e»««fcxx Imp..l-e 2, & 3
Pb (mg)
grs/SDCF, (mg/n3)
»/hr, (kg/hr)
. no . .
co . (mg) . • •
grs/SDCF, (mg/m3) ' ;
l/hr, (kg/hr) : : ...'..
Cl .. - . . ...i:.: M («9)
grs/SOCF , {mg/m3)
*/hr, (kg/hr)
nl Tnf al (on)
grs/SDCF .(ng/ra3) . • .'
l/hr. (kj/hr)
E) Total 50; (ng) . ..
'PC™ , -'.•••
grs/SOCF. (mg/o3)
l/hr . (kg/hr)
1
ENGLISH UNITS

7 —






—

















METRIC UNITS

.IWJU






.0030






•










2
ENGLISH UNITS

— -






—










•




•
•
METRIC UNITS

• 94BU























•
3
ENGLISH UNITS

--






*













.



METRIC UNITS

.1620



.


.0020












•




AVERAGE
ENGLISH UNITS

—
























METRIC UNI1

.3860

•-- 	 -

.

'•











- . -J., ...... •
••*





-------
TABLE 12.  OUTLET FROM CALCINE/ROASTER  BAGHOUSE  LEAD RESULTS
RUN NUMBER
V ANALYTICAL DATA pb
A) . Front Hilf
Probe (mg) . •
Cyclone (ng) • .
Filter (mg) f
Front Half Total (ng)
grs/SOCF , (mg/m3)
Ihr, (kg/hr)
B) >«*W
-------
Phelps-Dodge - Ajo, Arizona; TRW Test Program

     During the program one additional  test was run at the converter fugitive
emission system.  The test was performed because of a possible error in rinsing
a U connector which was believed rinsed with acetone instead of .IN NaOH.   To
compare results, the test, (Table 14) was included with other tests.

     The sampling required coordination with plant officials to assure that
the testing was performed during the process operation.

     The testing at the matte tapping fugitive emission system required inter-
mittent testing only when the copper matte was removed from the Reverb furnace.
The sampling at the converter fugitive^emission system required testing only
during the slag and copper blow cycles.

     Due to high ambient temperature (116°F) and high sulfur dioxide concen-
tration at the acid plant testing locations, sampling was performed under
adverse conditions.

     Test no. 2 at the north acid plant inlet was aborted because TRW
personnel inadvertently pointed the nozzle downstream.  Because of the
ensuing mechanical problems at the plant, the TRW crew could not repeat
test no. 2.  Results of the acid plant tests are summarized in Tables
15 - 18.

     The fugitive lead emission from the converter averaged 0.24 Kg/hr,
and from the matte tapping, 0.11 Kg/hr (see Table 13).  Because some samples
were consumed in the previous arsenic analysis the lead concentrations can
not be calculated.

     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 for sulfur dioxide was accom-
plished in the following order.  First, parts per million sulfur dioxide
at standard conditions was calculated.  Then parts per million was con*.
verted to a fraction by dividing by 10°.  This number was added to one
and the result multiplied by volume of gas collected through the dry gas
meter at standard conditions.  The result of multiplication yielded the
actual gas volume collected at standard conditions.  Since S02 removed
by the peroxide impingers does not reach the dry gas meter corrected values
for dry gas meter volume (at meter conditions) found on the summary sheets
will be slightly higher than those obtained from the field data sheets.
                                      25

-------
TABLE 13.  MATTE TAPPING FUGITIVE EMISSION RESULTS - LEAD
*
RUN NUMBER
V ANALYTICAL DATA Pb
A) . Front H«lf '
Probe (m Pb . (mg) total' . '
grs/SDCF, (mg/m3) ' ::
f/hr, (kg/hr)
ppm Pb . .
c) .. - . 	 ..: * (»s)
grs/SDCF, (irg/w'j
l/hr, (kg/hr)
D) Total (119)
grs/SDCF ,{ng/m3) • '
*/hr, (kg/hr)
1) Total SO, (mg)
%PP™ ' '
grs/SOCF. (rng/m3)
l/hr . (kgThr)
1
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-------
TABLE 14.  CONVERTER FUGITIVE RESULTS - LEAD
•
RUN NUMBER
ANALYTICAL DATA •
' A) . Front IUU ' . .
Probe (mg) . ' ••-. . ' • . .' • . .
Cyclone (nig) . . • . , '•.'••• . '
Filter (mg) f • ..' ..."••"• '•:'
Front Htlf ToUl (tag) • ' '
JM/SDCF, (mg/a3) . . . . •
Ihr, (kg/hr) ...

8} XWXJ859XWKKX Imp.f-.lj 2, & 3 .
Pb M '
gr»/SOCF, (mg/sr) . '
l/hr, (kg/hr)
^j Ek— • H) total ' . . ''''.
grj/SOCF, (mg/m3) ' ''•'.: . ; •'. .' • ''•' J •';''•". "'•
»/hr, (kg/hr) . . •';.-.•. .: '.'• : :.-.-..,
ppm Pb . • .. .", . • ••.
c) .. - . •.....;.: •- (TO)
grs/SOCF, (irg/raJJ ...... '
l/hr. (kg/hr)
nl Total (no)
grs/SDCF ,(ng/ra3J .. ' •''•..'
»/hr, (kg/hr) ' '
E) TotalSQj (mg) .'..•'• •' '.' .]
%PP"> ' ••'.-'.'•••• " ' •'
grj/SDCF, (mg/n3) . •
l/hr , (kgThr)

1
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-------
TABLE 14.  (continued)
RUN NUMBER
V ANALYTICAL DATA
A) . Front Hilf
Probe (HKJ) .
Cyclone (ng)
Filter (ing) f
Front Hilf Total (mg)
grs/SDCF, (mg/m3)
Ihr, (kg/hr)
B) fcc*fcxfc*9«x* Impvl-, 2, & 3
(mg)
gri/SDCF, (mg/m3)
l/hr, (kg/hr)
°° Pb . (mg) total
grs/SDCF, (mg/m3) ' .
*/hr, (kg/hr)
c) . ....... •-. («s)
grs/SOCF, (mg/mj)
»/hr. (kg/hr)
0) Total (DO)
grs/SDCF ,(ng/m3) • '
'/hr, (kg/hr)
E) Total 50, (ng) . .
•ppra
gr$/SDCF, (mg/ui3)
»/hr . (kgThr)
t
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-------
TABLE 15.  ESP INLET #1 LEAD RESULTS
RUN NUMBER
ANALYTICAL DATA •
' A) Rb • Front Half ' . '.
Probe (mg) . • •'•••> . • . / • .
Cyclone (ing) . . • • 1- , . . . " .
Filter (mg) f '•'..-'.•:' '' ' ;. •.
Front H*lf Total (ng)
. grs/SDCF, (mg/n3) . . . • . • ' . ;
Ihr, (kg/hr) . . '
Pb (mg)
grt/SOCF, (mg/i»}) . • " '•
|/hr, (Vg/hr)
grs/SOCF, (mg/m3) ' :' • '. . ;.^ .'.'..''•..'
*/hr, (kg/hr) .. '. ; ' \. ' ;.-". /.: '.'- '•• :.'••,.
C) .. - . ....ii-: •- (MB)
grs/SDCF, (ir.g/iaS) .-.-... ' . . .
l/hr. (kg/hr) . ' . :
D) Total (09)
grs/SDCF , (mg/m3) .. ' •. ' : ..' ....
l/hr, (kg/hr) ' '"' • ' '' .'' / ,- ,• ' ' '
E) Total SO, (mg) '..;••'. V. •'.
•ppra • .••' • ' . ••..-.
grs/SOCF, (ng/mj) . . •
»/hr , (kg/hr)
1
ENGLISH UNITS







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-------
TABLE 16.  ESP INLET #2  LEAD RESULTS
*
RUN NUMBER
ANALYTICAL DATA •
A) Pb . • front Hilf ' .: . .
Probe {mg) . • ... .' •
Cyclone (mg) . • ' , .
Filter (ng) f . .. . ' • '
Front H»lf TpUl (09)
.. grs/SOCF, (mg/in3) , . .
Ihr. (kg/hr) . . . '
B) NWWlriW- In»A 1 & *
Pb fag) '
grt/SOCF , (mg/B}) . ' '
l/hr, Ug/hr)
co ' ' -. •'•'..•'..'•
0 -.^—.N) . .' ; , •• .;..- •-.. • / ;.
gri/SOCF, (ng/m3) ' v : . ; !_;' - . V. ' ' . .'
l/hr, (kg/hr) . ; . '.'• V :. •: .
C) .. - . 	 :•: * («*)
grs/SOCF, (irg/raj) . .'•.'.-..• ' . .
«/hr. (kg/hr)
nl Total (no)
grs/SDCF ,(mg/m3) . f •'.'..
*/hr, (kg/hr) '" ' " '
E) Total SO, (mg) " .
•ppn •' ,-: ' • •.. .• ' .'
grs/SDCF, (mg/m3) . •
l/hr , (kg/hr)
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-------
TABLE 17.  ESP OUTLET/ACID PLANT INLET LEAD RESULTS.
.
RUN NUMBER
ANALYTICAL DATA
A) Pb - Front Hilf "...
Probe (mg) • ••-... • . .' • . •
Cyclone (ng) . • • , .;- ' ' .
Filter (mg) f ••'..' .•'•'' '•'.''.' '•
Front Hilf TeUl (rag) •'• '• ' • '

Jhr, (kg/hr) . . .

6) toXMXftWK&X* Imp.'. 1 & 2'
Pb (ng)
gr*/SDCF . (mg/nj) . ' .
l/hr, (kg/hr)
Cfc> • -. • - ' ' . .' ' * .-
grs/SOCF, (mg/m3) ' ': V '.;.-.,; ' ' -'::,'- '..'."••."•:'

-------
TABLE 18.   ACID PLANT OUTLET LEAD RESULTS
•
RUN NUMBER
ANALYTICAL DATA : •
A) Pb . Front Hilf ' . ,
Probe (mj) ' • . .; • .
Cyclone (mg) . . • '•:.'• , '
Filter (mg) f , .. : .' - ;
Front H»lf ToUl (og) . . .
grs/SDCF, (mg/n3) . . .' .....
Ihr, (kg/hr) .. . .. '
8) Pjn**W**XXX Imp-^- & 2 •
Eh 	 . N)
grt/SOCF, (ng/ni3) . .
l/hr, (lg/hr)
w . ', •• .'. • • '. .• • ; . '
10 _-_- -j.i tm9J . . • •'-.'' • '
grs/SOCF, (mg/m3) ' ': . ; ..'. .-' ''• .'
»/hr, {kg/hr) • . '. ' ' ';.:. '.: '.'-•' ;. ••:..'
C) - - . .-.»: •- («)
grs/SOCF, (irg/m1) ....... ' ..
*/hr, (kg/hr)
• •
D) Total (no)
grs/SDCF ,{mg/ra3) .. ' •'.'..
*/hr, (kg/hr) '"' . " .'
E) Total S0; (mg) ' .... •'. .' ; ' ':
•ppra •' .••'••. •'••...• .• . .'
gr$/SOCF, (mg/B3) .
*/hr,{kgrhr)
1
ENGLISH UNITS

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-------
Phelps-Dodge - Playas, New Mexico; TRW Test Program

     The process tested was a converter hooding system which removed fugi-
tive emissions from the converter during the copper blow cycle.

     The testing consisted of three arsenic/sulfur dioxide tests and three
particle sizing tests which were performed during the copper blow cycles.
The testing location was a seven foot duct located between the hooding sys-
tem and the stack.  These tests were coordinated with a process  engineer
from the Environmental Protection Agency.

     During the testing program the following observations and problems
were noted.

     For the first test, twenty-five minutes per sampling point  were used
to assure that sampling was done through a complete production cycle.  For
the second and the third test, twenty minutes per sampling point and a
smaller nozzle size was utilized.  After 155 minutes of the third test,
TRW personnel noticed that the AP readings were abnormally low.   After
checking equipment, the process engineer discovered that the plant opera-
tors inadvertently left the dampers on the system in the open position. When
the problem was corrected, the AP reading increased to the appropriate reading.
Thus, during 80 minutes of the sampling period of the third test, dilution
air entered the duct which resulted in a non-respresentative sample.

     Because of the previous arsenic analysis some sample fractions were
consumed, precluding the calculation of lead emission rates.  Results are
summarized in Table 19.

     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 for sulfur dioxide was accom-
plished in the following order.  First, parts per million sulfur dioxide
at standard consitions were calculated.  Then parts per million  were 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 standard 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.
                                      33

-------
TABLE.19.  CONVERTER FUGITIVE EMISSIONS LEAD RESULTS
*
RUN NUMBER
ANALYTICAL DATA •
' A) pb . Front Hilf ' .'...
Probe (mg) . • • . .' •
Cyclone (ing) . . • , '.'•••
Filter (mg) ?.....'•.; .
Front H»lf ToU) (mg)
. grs/SOCF, (mg/m3) /. • • ' .
Ihr, (kg/hr) . '
B) «*!&j«l*fcKx Imp*-^,5 2, & 3 •
^b_. . (mg) f . •
gr»/SOCF, (mg/ra3) . .'•"'•
l/hr, (Ig/hr)
0) . '. : '.•'•'•'.
•^ .. • . (ng) . .•'.'.•• • •
grs/SDCF, (mg/m) ' ' . ... ' , :. .'.
*/hr, (kg/hr) ..;•.'• ;; ';.'•'•. ;; > .'-. :. .'..
e) .. - . . ..-;.;•: •- (WB)
grs/SDCF, (irg/in1) . . •'.-..- • . .'
'/hr. (kg/hr)
nl Total (m)
grs/SDCF ,(ng/m3) • .'
l/hr, (kg/hr) '"' ' ' ,'
E) Total 50j (mg) " . ; .. '
•ppn •' ••'.-..•
grs/SOCF. (mg/m3) . •
*/hr . (ksThr)
1
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5.990






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3.530



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-------
ASARCO - Tacoma, Washington; TRW Test Program

     Tables 20.and 21 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 test 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 22 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 23, 24, 25 and 29,
respectively.  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 intermittant schedule.  Matte and slag tapping
fugitive emissions were sampled over 5 to 8 minute periods when matte or slag
were being drawn from the reverberatory furnace.  Sampling was coordinated
by EPA observers at the matte tapping and slag tapping areas who alerted the
sampling teams by transceiver as to when to start and stop sampling.

     The emissions from the converter 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.

     Results of the tests on the arsenic baghouse are summarized in Tables 26,
27 and 28.

     Data collected from tests done on the converter fugitive emissions
collected by hooding during the copper blow and full cycles are summarized
in Tables 30 and 31.  Fugitive emissions not collected by the hooding system
were also sampled using anemometer to continuously record flow past the
sampling point.  Results of these tests are summarized in Tables 32, 33 and
34.
                                      35

-------
TABLE 20 ROASTER BAGHOUSE LEAD RESULTS
,
RUN NUHBER
V ANALYTICAL DATA
A) . Front H»1f '
Probe (mg) (NaOhO

(>clana_u>9J- Probe (.HN03)
Filter (mg) f . .
Front H*lf Teul (eg) '
gr«/SDCF , (mg/n3)
Ihr, (kg/hr)

eu § es - imp'*"| '& 2 (NaOH)
jrs/SOCr t vinQ/B /
l/hr, (kg/hr)
** ,...t . .-j fm9)
grs/SDCF, (nj/n ) .
l/hr, (kg/hr) ; .

Cl ..... ....~: , (M)
gr»/SOCF, (ug/n1) .
«/hr. (kg/hr)
01 Total (M)
grt/SOCF ,(ng/n3) • "
l/hr, (kg/hr)
E) Total SOj (mg) ' . .
grs/SDCF. (mg/n3)
l/hr . (ksfhr)

1
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-------
TABLE 21 ROASTER BAGHOUSE OUTLET LEAD  RESULTS
•
RUN NUMBER
V ANALYTICAL DATA •
A) b Front Half -'•'•.'..
Probe (mg) (NaOH)
Cuiosa-d"^ Probe (HN03)
Filter (ing) f .
Front H»lf ToUl (rog)
grs/SOCF , (mg/m3) . .
Ihr, (kg/hr)
6) P«rt1cul«tes - IMP-.l ;& 2(NaOH)
. {mg) Irtip 1 & 2(HN03)
grs/SOCF, (mg/n3)
«/hr, (kg/hr)
itJ ... (ng)
grs/SDCF, (mg/m3)
»/hr, (kg/hr) : : . ..
C) .... ..—..: •* (W)
grs/SOCF , (irg/m3)
»/hr. (kg/hr)
ni Tntfli (M)
grs/SOCF ,(ng/m3) • ,'
»/hr, (kg/hr) ' ...
E) Total 50; (mg) ..
•ppra
grs/SOCF, (rog/B3)
l/hr , (kg/hr)
'
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-------
TABLE 22 ESP OUTLET LEAD RESULTS
*
RUN NUMBER
V ANALYTICAL DATA
A) Pb Front Half '
Probe (mg) (NaOH)
-cye4«,Hj-ta).probe (HNOs)
Filter (mg) f
Front H»lf ToUl (mg)
grj/SDCF , (mg/m3)
Ihr, (kg/hr)
8) «W«W1*fc*x. Imp k& -.2 (NaOH) .
(„,) Imp -142 (HNO^) .
grs/SOCF, (mg/n3)
»/hr, (kg/hr)
w . •'
00 . (mg)
grs/SDCF, (rng/m3) .
»/hr, (kg/hr) ;
C) - - . .--: •- («)
grs/SOCF . (irg/inj)
l/hr, (kg/hr)
0) Total (M)
grs/SDCF ,(ng/m3) • '
f/hr, (kg/hr)
C) Total SOj (mg) " .
•ppm
grs/SOCF. (mg/m3)
»/hr . (kgfhr)
1
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1.1000





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-------
TABLE 23 MATTE TAPPING LEAD RESULTS
RUN NUMBER
V ANALYTICAL DATA
A) Pv • Front Half '
Probe H) (NaOHRMSe) •
-Cj.64«Rc-{
l/hr, (kg/hr)
c^ .. . _t (ng) ' .
10 grt/SOCF, (mg/m3)
»/hr, (kg/hr) . . : . .. . .. .
C) .. - . . ......-: * (««)
grs/SOCF. (mg/roj) . .
l/hr, (kg/hr)
nl Total (ml
grs/SDCF ,{ng/(n3) .. • .'
l/hr, (kg/hr)
E) Total S0; (mg) . :
•ppm .
grs/SDCF. (mg/m3)
l/hr . (kgfhr)
1
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4.4727
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-------
TABLF ?4 SI Afi TAPPTNfi LEA
t
RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half ' .
Probe (m,) (NaQH) •
i*«J««-(roLprobe (HMO*).
Filter (mg) ° r . . .
Front Hilf ToUl (ing)
grs/SDCF, (mg/ffl3)
Ihr, (kg/hr)
B) Partieulates - Imp K& :2 (NaOH) •
(,„, .,-.,





. . -..*-_..'
- • ' " .•"*:'


'


-------
TABLE 25 CALCINE DISCHARGE LEAD RESULTS
RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half '
Probe (mj) . • •
Cyclone (ng)
Filter (mg) f .
Front H«1f ToUl (mg)
grs/SDCF, (mg/n3)
Ihr, (kg/hr)
« gX^^JS? Imp 1 -*-2;
P6 (mg) '
gn/SOCF, (mg/m3) •
l/hr, (kg/hr)
* .. _ ,. ta)
grs/SDCF, (mg/m3)
»/hr, (kg/hr) . ; -. ,
Cl .. - . ...-.: < (W)
grs/SDCF , (ng/mj) . . .
l/hr. (kg/hr)
ni Tntsi (OQ)
grs/SDCF ,(ng/m3) . • .'
»/hr, (kg/hr) ,
E) Total 5Q; (mg) . ..
•ppra
grs/SDCF, (mg/n3)
l/hr . (kg/hr)

1
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-------
TABLE 26 ARSENIC BAGHOUSE INLET (ARSENIC KITCHEN)  LEAD RESULTS
4
RUN NUMBER
V ANALYTICAL DATA
A) . Front Hilf
Probe (mg) (NaQH)
Filter M f ...
Front Hilf Total (ng)
grs/SDCF , (mg/m3)
Ihr, (kg/hr)
6) Part1orl«rt** - Imp.rl, &2
Pb (mg)
grs/SDCF, (mg/mj) '
«/hr, (kg/hr)
ro .
grs/SOCF, (mg/m3) ' : '...'•
l/hr, (kg/hr) ;.-. ..."..
C) , '. ...«.: •* (ng)
grs/SDCF, (mg/mj) .
l/hr. (kg/hr)
grs/SDCF ,{ng/m3) .
l/hr, (kg/hr)
E) Total 50; (mg)
grs/SDCF, (mg/m3)
l/hr . (kgThr)
I
ENGLISH UNITS

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_























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*
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1.5800
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3_3833_.
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-------
TABLE 27 ARSENIC BAGHOUSE INLET (MFTAI 1 TT ARS
#
RUN NUMBER
V ANALYTICAL DATA
A) . Front Half '
Probe H) (NaOH) ••••'•
-CyetoM-to) Probe (HMOs)
Filter (ng) f
Front H«1f ToUl (ing)
grs/SDCF. (ng/m3)
Ihr, (kg/hr)
' B) Wmmmw Imp,.l & 2 (NaOH)
-«»•• •l"') J% Imp 1 & 2 (HNO'3)
9r*/SDCF, (
-------
TABLE 28 ARSENIC BAGHOUSE OUTLET LEAD RESULTS
RUN NUMBER
V ANALYTICAL DATA
' A) pb - Front H«1f '
Probe (mg) (NaQH)
Cyclone. Iraalprobe (HMO*).
Filter (mg) ° f
Front Half ToUl (ng)
grs/SDCF , (ng/m3) .
Ihr, (kg/hr)
1 8} wxMxototes - Imp:-! & 2 (NaOH)
. W Irrtp 1 & 2 (HNOa)
grs/SOCF, (mg/m3) • " ' •
»/hr, (kg/hr)
£ _^ 	 - fag)
grs/SDCF, (ng/m3)
»/hr, (kg/hr) : ..
C) ..... .......: -, (M)
grs/SDCF . (mg/oi5)
l/hr, (kg/hr)
0) Total (n)
grs/SOCF .(mg/ro3) • . '
'/hr, (kg/hr)
E) Total S0; (mg)
•ppra : .
grs/SDCF, (mg/n3)
l/hr , (kgThr)
1
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-------
TABLE 29 CONVERTER SLAG RETURN LEAD RESULTS
*
RUN NUMBER
V ANALYTICAL DATA •
' A) pk . Front Half '
Probe (mg) . .
Cyclone (mg)
Filter (mg) f
Front Hilf ToUl (mg)
grs/SDCF, (mg/m3)
Ihr, (kg/hr)
B) R4rt4cuUU*.r- ftnp '-I & 2
Ph . (mg) '
grs/SOCF . (mg/m3)
l/hr, (kg/hr)
£ .. _ _- (mg)
grs/SOCF, (mg/m3)
l/hr, (kg/hr) . •
C) . - . '....ii: * (»«)
grs/SOCF. (mg/m3)
l/hr. (kg/hr)
grs/SDCF ,(ng/m3) . • "
l/hr, (kg/hr) ,
E) Total S0; (mg) . .
"PP" . .
grs/SDCF, (mg/m3)
l/hr , (kg/hr)
1
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-------
FABLE 30.
Converter Full Cycle Lead Results
.
RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half '
Probe (ing) .
Cyclone (ng)
filter (mg) f
front Half Tofcl (mg)
grs/SDCF, (ng/m3)
Ihr, (kg/hr)
8)xfcr*fcxfc*9?r Imp-V-&;2
(mg)
gr*/SOCF, (ng/m3)
»/hr, (kg/hr)
-f» . ' ' .• . •
en .
PJ^L . (ng) Total ' .
grs/SOCF, (mg/m3) ' . ;
*/hr. (kg/hr) .. .
t) . . ...--: « (B9)
grs/SDCF . (mg/mj)
l/hr. (kg/hr)
0) Tnfal (m)
grs/SDCF ,(mg/m3J . .. • ."
f/hr, (kg/hr)
E) Total 50; (mg)
•ppra
grs/SDCF. (mg/B3)
l/hr.(kgThr)
1
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-
-


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16.9100
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0.5800
17.4900



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25.7367
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-------
TABLE 31 CONVERTER COPPER Rl nw nvr.l F LEAD RESL
*
RUN NUMBER
V ANALYTICAL DATA
A) Pb • Front Hilf '
Probe (mg) . .' •
Cyclone (ng)
filter (mg) f . . .
Front Hilf ToUl (ng)
grs/SOCF, (mg/m3)
Ihr, (kg/hr)
B) !«****&**- imp j-'S 2
. (ng)
grs/SOCF, (ng/o3) .
l/hr. (kg/hr)
-^ ••'':•
*** -Pb . {mg) Total
grs/SDCF. (mg/m3) ' ...
»/hr, (kg/hr) . . - , . .. ..
el . ......: * (ng)
grs/SDCF, (mg/mj)
»/hr. (kg/hr)
n\ Tnf A! (BO)
grs/SOCF .(mg/ra3) • ' .
*/hr, (kg/hr)
E) Total 50; (mg)
"PP"
grs/SOCF. (mg/n3)
*/hr . (kg/hr)
t
ENGLISH UNITS

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48.8000 -
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49.8600



0.9300


50.7900
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3lJl333_.
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-------
TABLE 32.
CONVERTER FUGITIVE # 1  (E)  LEAD RESULTS
4
RUN NUMBER
V ANALYTICAL DATA
A) Pb • Front Hilf ' .
Probe (ing) . •
Cyclone (ng) . .
Filter (ng) ' . :
Front H«lf ToUl (rag)
grs/SDCF, (mg/m3)
Ihr. (kg/hr)
8) $««***&* - Imp.-1 ••& 2
. . . I"1''
grs/SDCF, (mg/m3)
»/hr, (kg/hr)
co P.b. .. (ng) Total '
grs/SOCF, (mg/ra3)
*/hr, (kg/hr) , ,
C) .. - . ....^:,* (no)
grs/SOCF , (irg/m3}
*/hr. (kg/hr)
D) Total (no)
grs/SDCF ,{ng/m3J • '
*/hr, (kg/hr)
£) Total S0; (mg) .
•ppra
grs/SDCF. (mg/m3)
*/hr , (kg/hr)
1
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_



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^



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-












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• -





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] 3 3000
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•

-------
CONVERTER FUGITIVE #2 (M
RUN NUMBER
V ANALYTICAL DATA
A) Pb - Front H«lf '
Probe (mg) . • .
Cyclone (mg)
Filter (ing) '..;..
Front Hilf ToUT (mg)
grs/SDCF, (ng/m3)
Ihr. (kg/hr)
B) #WXM«K!Xs - Imj>-. -, 1 & 2 .
-Pb- - ^ 3 ' ...
grs/SDCF. (mg/m4)
f/hr, (kg/hr)
•£» . •'••.'
*° Pb. ^ (mg) Total
grs/SOCF, (rng/m3)
»/hr, (kg/hr)
C) .. - . 	 .-: •* (BO)
grs/SOCF, (i?g/oij)
l/hr, 
-------
CONVERTER FUGITIVE # 3 (W
.
RUN NUMBER
V ANALYTICAL DATA
A) Pb - Front Half '
Probe (mg) . : • .
Cyclone (ng) .
Filter (ng) t .
Front Half Total (ng)
grs/SDCF , (mg/m3)
Ihr, (kg/hr)
B) fsiJTcimtn - Imp.r.l •& 2
Pb (mg) * .
grs/SOCF, (mg/rn3) •
l/hr, (kg/hr)
en '••'.'•
0 ..Pi) . (mg)
grs/SDCF, (mg/m3)
l/hr, (kg/hr) , •• '. ; - • :.
0 ... '...--I , (M)
grs/SDCF, (mg/mj) ... • . . ' •
l/hr, (kg/hr)
0) Total {«)
grs/SDCF ,(ng/m3)
l/hr, (kg/hr)
E) Total 50.. (mg)
grs/SDCF, (mg/m3)
«/hr.(kgrhr)
TABLE 34. LEAD RESULTS
i
ENGLISH UNITS

-
-
-
-






- ' - •
~
-












METRIC UNITS

1.3000
-
5.5000
6.8000



o.nsnn


6.8500
o nnfi
0.0395

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_






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. -
• _





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.
METRIC UNITS

2.5000
-
6.6000
9.1000



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9.2700
n.4QQ?
0.0709











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3
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_ .
_
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METRIC UNITS

3.1000
_
9.4000
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12.5300
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AVERAGE
i.
ENGLISH UNITS

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' ' V


*


METRIC UNIT

2.3000
_
7JL6.67:..
9^4667—
.

0 0833
"

3,5500
3,547_6,
).0749






. •-..•-.-..,...-,.•




•

-------
Kennecott - Magma, Utah; TRW Test Program

     The field sampling program encountered the following minor problems
which are outlined below with respect to the individual  sampling locations.

     During the field sampling at the matte tapping fugitive emission system
and the slag tapping fugitive emission system, the sampling program required
long days due to the intermittent process operation and  days of reduced op-
eration.  At the slag tapping fugitive emission duct there were two modifi-
cations in the sampling procedure required.  Only one port was located on
the duct which required that both traverses be performed through the same
port utilizing the pythagoream calculations.  The sampling train was modified
to allow for the two traverses through the single sampling port.  A teflon
flex line was inserted between the probe and heater box  to assist in maneu-
vering the probe into the proper placement.  After the testing the flex line
was cleaned with a probe brush and .IN NaOH.  The solution was placed in the
probe rinse bottle and saved for analysis.

     Testing the converter fugitive emission system and  the acid plant inlet
required TRW personnel to adjust the working schedule to fit the cyclic pro-
cess operation of the converter unit.  Due to lack of space at the converter
fugitive emission duct sampling position, TRW was required to utilize the
flex lines between the probes and heater boxes on each of the tests.  After
each test the flex line was cleaned with .IN NaOH and a  probe brush.  The
solution was placed in the probe rinse bottle and saved  for analysis.

     Weather forced TRW personnel to curtail the field sampling on Friday,
November 10, 1978.  TRW personnel returned on Monday, November 12, 1978 to
complete the field sampling on the concentrate dryer fugitive emission system.

     Testing the concentrate dryer fugitive emission system required the
test ports to be placed in the fiberglass stack.  Due to the working space
and the fiberglass stack, TRW utilized the flex line inserted between the
probe and the heater box to assist in performing the sampling traverses.
Testing at the concentrate dryer fugitive emission system was performed under
low ambient temperature which ranged from 20°F to 30°F.

     The average lead emission rate of the concentrate dryer fugitive emission
system (Table 40) was 0.1 Kg/hr.  The fugitive emissions of lead from the
matte tapping and slag tapping, summarized in Tables 35  and 36, averaged
0.7 Kg/hr and 0.04 Kg/hr, respectively.  Fugitive lead emissions from the
full cycle converter and rollout converter cycle both averaged about 0.4
Kg/hr and are summarized in Tables 38 and 39.  The acid  plant inlet (see
Table 37) had a lead concentration of 2.5 Kg/hr.

     During the data reduction, the meter volume was back calculated to ac-
count for sulfur dioxide that was removed by the three 10% hydrogen peroxide
impingers.  The back calculation for sulfur dioxide was  accomplished in the
following order.  First, parts per million sulfur dioxide at standard con-
ditions was calculated.  Then parts per million was converted to a fraction
by dividing by 106.  This number was added to one and the result multiplied
by volume of gas collected through dry gas meter at standard conditions.
The result of multiplication yielded the actual gas volume at standard
conditions collected.
                                      51

-------
	 	 	 TflRIf 35 HATTF TAPPTNfi L

RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Hslf
Probe (rig)
Cyclone (mg)
Filter (ng)
Front Half Total (mg)
grs/SOCF. (mg/ra3)'
»hr, (kg/hr)
B> &KB***fi£=- Imp *&2J
fib- - (n8)
grs/SDCF, (mg/m3)
l/hr. (kg/hr) •
S . ..Pb .;,. (mg) Total
grs/SDCF, (mg/m3)
»/hr. (kg/hr)
C) ... .j - .'...' ..— - (ing)
grs/SDCF. (mg/m3)
*/hr, (kg/hr)
01 Total (no)
grs/SDCF .(ng/m3)
l/hr, (kg/hr) ;
E) Total SO, (mg)
ppn
grs/SDCF. (mg/ro3)
»/hr , (kgfhr)
HAD RESULTS
1
ENGLISH UNITS

—

^




—



• -
.-












METRIC UNITS

.finnn

1 fi . snnn




.0010


16.9010
9.0380
0.9805












2
ENGLISH UNITS

.

_




^




• -












METRIC UNITS

.filfin

fi ^ROOn




.0040


7.4700
5.1875
' 0.5445












3
ENGLISH UNITS

_



•


^



-





^^







METRIC UNITS

.6790

Q g500




.0020


10.5310
6.8383
0.6473













AVERAGE
ENGLISH UNITS

^






^




-'












METRIC UNITS

.6983
• M.9333



.0023-


11.6340
7.0213
0.7241













-------
TABLE 36 SLAG TAPPING LEAD RESULTS

RUN NUMBER
V ANALYTICAL DATA
A) Pb • Front Half
Probe (mg)
Cyclone (mg)
Filter {mg)
Front Half Total fag)
grs/SDCF . (rng/m3)'
»hr, (kg/hr)
B) KMUUWK-Imp !.,&. 2
(mg)
gr$/SDCF. (ng/m3)
l/hr, (kg/hr) '
en . ..Pb..- (mg) Total
" grs/SDCF. (mg/m3) . . .
f/hr. (kg/hr)
C) .j -.'...' ...-- - ("S)
grs/SDCF, (mg/m3)
*/hr, (kg/hr)
grs/SDCF , (ng/m3)
*/hr, (kg/hr)
E) Total SO; (mg) •
ppra
grs/SDCF, (rog/m3)
*/hr , (kgThr)
1
ENGLISH UNITS

-
-
-
-






_
—
-












METRIC UNITS

.1110
-
.2750
.03860



nnsn


0.3940
U.34bb.
n n?qq












2
ENGLISH UNITS

-
-
-
_






_
-
_












METRIC UNITS

.2220
-
2.0800
2.3020



. nnfin


2.3080
0.6768
n . n.RRQ












3
ENGLISH UNITS

-
-
-
_
.


-


.
-
_

n


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METRIC UNnS

.1630
_
1.7900
i ,QR^n



.0030


1.9560
0.5753
0.0447













AVERAGE
ENGLISH UNITS

-
_
_ .
_





.. n

-
_•












MHRIC UNITS

.1953
_
U38J7
1 5460



.0057'


1.5527
0.5326
0 0438













-------
TABLE 37 ACID PLANT INLET LEAD RESULTS

PUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half
Probe (mg)
Cyclone (mg) .
Filter (mg)
Front Half Jot«l (rag)
grs/SDCF , (mg/m3)'
Ihr, (kg/hr)
?) XN*fcXJ0W?X- ItnpT & 2
- (m9' a
grs/SDCF, (mg/m-)
l/hr, (kg/hr)
en
*" . .. Pb;, (mg) Total
grs/SOCF, (mg/m3)
l/hr, (kg/hr)
C) 	 j - .... ..— •-, (mg)
grs/SDCF, (mg/in3)
*/»ir, (kg/hr)
D) Total (m)
grj/SDCF ,(ing/m3) . .
»/hr, (kg/hr)
E) Total SO, (mg)
ppra • .
grs/SOCF, (mg/n3)
«/l>r , (kgThr)
1
ENGLISH UNITS

-
_
_




•



' • - • •
-












METRIC UNITS
27.2000
-
2.9000
30.1000




0.0040


30.1040
21.0517
1 71fiR












2
ENGLISH UNITS

-
_
_




• -



-
-












METRIC UNITS
46.6000
-
1.6000
48.2000




.0020'


48.2020
35.1839
2.R747












:••••?
ENGLISH UNITS

-
^
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•' •


0



. -
-




..'







METBIf UHHS
54.4000
-
1.35000
55.7500

•


.1030


55.8530
32.8950
3_f)?73












AVERAGE
ENGLISH UNITS

-
_
_




_

• •• •

-













METRIC UNITS
33.6680
"TT9500
.4JL&a3.3



9.1017


44.7197
32.0435
2 4fi9fi






• •• .
?•



— . :

-------
TABLE 38 ROLLOUT CONVERTER FUGITIVE LEAD RESULTS

RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half
Probe (mg)
Cyclone (mg)
Filter (rag)
Front Half Total (mg)
grs/SDCF. (mg/m3)'
»hr. (kg/hr)
B) jraKHKfliJm Imp -i-&:2
pja 	 . (mg) .
grs/SDCF. (rng/m3)
l/hr. (kg/hr)
*" ...Pb ., (mg) Total
grs/SDCF, (ng/m3) ' • '. ."
*/hr. (kg/hr)
C) - - . ..—- - ("«)
grs/SDCF, (mg/n3}
f/hr, (kg/hr)
nl Tntal (no)
grs/SDCF ,(mg/m3)
*/hr, (kg/hr)
E) Total 50, (mg) •
ppm
grs/SDCF. (mg/ra3)
l/hr . (kgThr)
1
ENGLISH UNITS

_
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3 7710



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3.7760
2.521
0.2906












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i.nn

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6.2630
4.8177
0.6696












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5403

-4,2050.
5 0155



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5.0195
3.4349
0.4801






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-------
TABLE 39 FULL CYCLE CONV
RUN NUMBER
V ANALYTICAL DATA
A) Pb . Front Half
Probe (nig)
Cyclone (mg)
Filter (tag)
Front Half Total (mg)
grs/SDCF. (mg/m3)'
fhr. (kg/hr)
B> X*KX9tt*m fmp.: 1 & 2
Pb . («s)
grs/SDCF. (mg/m3)
J/hr. (kg/hr) ' '
w P.b . .., (mg) Total
grs/SDCF, (mg/m3)
*/hr. (kg/hr)
C) ... .- - . . . ' ..--. -.. (ng)
grs/SOCF. (mg/ra3)
*/hr, (kg/hr)
0) Total las)
grs/SDCF .(ng/ra3)
*/hr, (kg/hr)
E) Total SO, (mg)
ppm .
grs/SDCF. (mg/m3)
«/hr . (kg/hr)
RTER FUGITIVE LEAD RESULTS
i
ENGLISH UNITS


_
_




-



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—












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1.7300
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1? 3300



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12.3330
2.8287
0.4552












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3.6000
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3.6797
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4.5600
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-------
TABLE 40 CONCENTRATE DRIER LEAD RESULTS
.
RUN NUMBER
V ANALYTICAL DATA
A) Rb • Front Half
Probe (mg)
-Cycleae-lmg). F6Xline
Filter (mg) '
Front Half Total (mg)
grs/SOCF . (mg/m3)
Ihr. (kg/hr)

B) $$$$**- Imp-T & 2
(mg)
grs/SDCF. (mg/m3)
l/hr. (kg/hr)
en
VJ' Ph : . (mg)
grs/SDCF. (mg/m3)
l/hr, (kg/hr)

c) .. - . ...... j (wg)
grs/SOCF, (mg/m3)
l/hr. (kg/hr)
n) Total (no)
grs/SDCF .(ng/ni3)
l/hr. (kg/hr)
E) Total SO, (mg)
ppm
grs/SDCF, (rag/m3)
l/hr , (kgflir)

t
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—


-



_



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-













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1 10Q
1 QKQn
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0.9172
0.1131

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.3210

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1 i2110
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1 .?130
0.6005
0.0726











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.5070
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1 4QfiQ
1 9310
0.9343
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1 .1390
0.9367
0.1124












AVE
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_










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_









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RAGE
METRIC UNI1

.5620

1.1300
1.6677
0.8164
n 0991

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1.6713
0.8181
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~— — • —



-------
Anaconda - Butte, Monsanto Test Program

     No report on this test effort was  available  in  time  to  be  included  in
this report.  However, the results of the lead analysis run  on  the  samples
available are in Tables 41, 42 and 43.
                                    58

-------
TABLE 41. LOCATION 2A..
0
RUN NUMBER
ANALYTICAL DATA : •
' A) . front Hilf ' .
Probe (ing) . ' . .. ; . .' • . .
Cyclone (mg) . • .• , .:
Filter {mg} f -. .. : . V . '..
Front Hilf ToUl (rag)
grs/SDCF, (mg/m3) . . : • . .
Ihr, (kg/hr) . . . '
8) fcKWKrtxPtx* Inip%..l;, 2, & 3 .
Rb 	 {"9) • •; •. .
flrt/SOCF, (mg/mj) '
«/hr, |kg/hr)
<-n . ' ' - . .''..-,.
10 pb. ..(m9) ImP- 4 • /: . /-''
grs/SOCF, (mg/m3) ' ': • '.;.".,'• 1;V';.'/;..'
l/hr, (kg/hr) . , '. •';/-. ~: '.'- : ;..-:.
O Imp. 5 . - . . '..».-: * (m)
grs/SDCF. (irg/mj) ,....• : . . .
l/hr, (kg/hr) ' : .
n\ Tnfal (no) '
grj/SDCF ,(ng/ra3) . • ' • ." . .
l/hr, (kg/hr) '" ; '."..'. '. , . '..• ';.
E) Total S0; (mg) . . ; •'. .. "
•PP"" -•'•'.''• .'. •' . •'
grs/SOCF, frog/or) •
»/hr.(kgrhr)
I
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2.3700

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2
ENGLISH UNITS

—






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.7400






.3200.


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•
3
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-------
TABLE 42.   LOCATION B.
«
RUN NUMBER
ANALYTICAL DATA •
A) - Front Hilf ' .
Probe {mg) . • • • . / • .
Cyclone (mg) . . • •' , ••
Filter (mg) f ••• .. ' - •' '
Front Hilf ToUl (no.) ;
. grs/SOCF, (mg/m3) ,......'
Ihr, (kg/hr) . . . '
8) fcxMxrtxwaxx Impv.l-., 2, & 3 .
Pb .(mg) * •
jrs/SOCF , (mg/m3) . .'•"'•
l/hr, (kg/hr)
SPb :.(mg) Imp 4 - - ' ; ,;. ' . . ;':••
grs/SOCF, (ng/m3) ' !; .-•".; ^.' ;. ':'.".'
*/hr, (kg/hr) ..'', ': ;; •'•;.:'-. ; > ; ;. .:-..
C) Imp. 5 .. . Pb....ii.: .^ (ng)
grs/SDCF, (irg/mj) . . ',...• ' . .
«/hr. (kg/hr)
nl Tnfsi fnoV • *
grs/SDCF ,{mg/m3) ... •/ • ' •." . .
»/hr, (kg/hr) ' '" ' " .' . .' , , ' '
E) Total SOj (mg) " . : •'. .. ' . .
•ppm • . ' - ••"'.. • . ' .'
grs/SDCF. (mg/n3)
l/hr . (kgThr)
I
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-------
TABLE 43.  HEST INLET
•
RUN NUHBER
ANALYTICAL DATA
A) . Front HiU ' . . .
Probe (mj) • ..-..- . • :
Cyclone (rig) • ; • •• - '-'•'' . . '
FtHer (ing) f .-..-• •:' '" ' .'. •. ,.
Front H»lf TpUl IDJ)
gr«/SDCF, (ws/m3)
Ihr, (ky/hr) ..."
B) NKMx»«)i)«x- Back.Rilter
£h_ Jng) _ ' ...
jrt/SOCF . (mg/»J) . ' '
«/hr, (kg/hr)
2 pt> ..(»g) Imp- .^ 2, & 3 •••/.; ; •'.•
jri/SBCF, (mg/m3) ' ': . . ;•'.:' - V..'':;. .'
*/hr, (kg/hr) . '. ' ;.-. -: .; :..-:.
'*• • ...".' :.-p :-, -
o Imp 4 . . . . ..„...: •. (w)
jrs/SDCF, {rg/roJJ . . •'.-..- : . ..
l/hr. (kg/hr) . ' : . .
gn/SDCF ,(ng/mj) ... ' • .' ...
•»/hr, (kg/hr) ' .- ' ' . . . . . . ' -
E) Total SOj (ng) ' . . .. -] .', ..
•ppra . ' • ''...- ' .'
jrs/SDCF, (ng/p3) .
l/hr . (kgThr)
(
ENGLISH UNITS

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3.4300






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1.7400









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-------
PROCESS SAMPLES:
     Process samples recieved from Monsanto Research Corporation were in
                                                                       o
solution with HMOs and HF.  The solutions were analyzed as recieved without
modification except for dilution where necessary.  No information was pro-
vided as to the digestion procedures used by Monsanto.

     Details of the digestion method for all TRW collected samples are in-
cluded in section 4 of this report.
                                        62

-------
   TABLE 44
PROCESS SAMPLES
PLANT PROCESS DATE %Pb
0 '
ASARCO
El Paso (Mons.)

























ASARCO

El Paso (TRW)



















Dross Rev. Matte
Reverb Slag
it
it
Wedge Roaster Calcine
n
ii
Conv. ?
R & R Spray
Zn Slag
Matte
ii
n
n
ii
n
n
Roaster Charge
n
M
M
n
Conv. Slag
n
n
n
Wedge Roaster Calcine
n
n
n
n
n
n
n
n
Raw Rev. Slag
n
n
n
n
n
n
H.F. Reverbs Slag
n
n
n
n
n

6/26/77
n
6/28/77
6/26/77
6/27/77
6/28/77
6/28/77
6/28/77
6/22/77
6/21/77
6/22/77
6/23/77
6/24/77
6/26/77
6/27/77
6/28/77
6/21/77
6/24/77
6/26/78
6/27/77
6/21/77
6/22/77
6/23/77
6/24/77
6/28/77
1/17/78
1/18/78
1/19/78
1/20/78
1/21/78
1/22/78
1/23/78
1/24/78
1/25/78
1/17/78
1/18/78
1/19/78
1/22/78
1/23/78
1/24/78
1/25/78
1/17/78
1/18/78
1/19/78
1/20/78
1/21/78
1/22/78

0.257%
0.160%
0.210% .
0.133%
0.283%
0.321%
0.345%
0.554%
0.936%
0.555%
0.216%
0.342%
0.388%
0.879%
0.242%
0.886%
0.796%
0.220%
0.473%
0.427%
0.215%
0.373%
1.21%
0.621%
0.576%
0.413%
0.110%
0.264%
0.213%
0.150%
0.178%
0.294%
0.376%
0.200%
0.296%
0.180%
0.330%
0.277%
0.164%
0.210%
0.119%
0.397%
0.136%
0.146%
0.147%
0.177%
0.224%
0.153%
63

-------
                          Table 44 Cont.
PLANT
PROCESS
DATE
%Pb
ANACONDA
Butte (Mons.)
















PHELPS-
DODGE
Ajo
















PHELPS-
DODGE
Playas




Elec. Furn. Matte
II
Elec. Furn. Slag
ladle
ii
11
Reactor Feed
ii
11
Baghouse Dust
ii
it
"
n
Elect. Furn.
n
n
Conv. Slag

Acid Plant H2S04
11
ii
Acid Plant Purge H20
n
n
Converter Precip.
n
n
Anode Cu
n
n
Converter Slag
11
n
Matte
n
M
Flash Furnace Feed
Flash Furn. Slag
Elec. Furn. Slag
Flash Furn Mattp
riuoM ruin, net i* i*c
Elec. "
Pnnv/ Rl ici"ov*
ItUIIV. Dl lover
Conv. Slag
4/20/77
4/21/77
4/20/77

4/21/77
4/22/77
4/20/77
4/21/77
4/22/77
4/22/77
4/22/77
4/23/77
4/25/77
4/26/77
4/21/77
II
4/22/77
4/20/77

6/13/78
6/14/78
6/15/78
6/13/78
6/14/78
6/15/78
6/13/78
6/14/78
6/15/78
6/14/78
6/15/78
6/16/78
6/13/78
6/14/78
6/15/78
6/13/78
6/14/78
6/15/78












0.308%
0.590%
0.644%

0.512%
0.481%
0.434%
0.290%
0.461%
0.662%
2.14%
2.86%
1.14%
0.768%
1.12%
0.678%
0.718%
3.47%

0.011 ppm
0.013 ppm
0.081 ppm
27.5 ppm
34.3 ppm
14.5 ppm
0.518%
0.503%
0.960%
0.0011%
0.0021%
0.0010%
0.0332%
0.0519%
0.0391%
0.0414%
0.0418%
0.447%
0.140%
0.052%
0.118%
n Mit
U . 1 / / to
0.185%
OOQ'tV
. U7O&

                                 64

-------
                           Table  44  Cont
PLANT
PROCESS
DATE
%Pb
ASARCO
Tacoma











































Charge 183



Reverb Slag
"
"
Slag Pot #1
11
Slag Pot #2
"
Slag Pot #3
Slag Pot #3 (Top)
Slag Pot #3 (dump)
Slag Pot #4
Slag Pot #3 (bottom)
Slag Pot #4 (dump)
MP Y iPAn Av*cpnip
1 Iw A 1 1>Q 1 1 rM 3d 1 1 l»
Godfrey Calcine Charge
"
"
"
Roaster Charge
"
"
"
"
"
"
Conv. Slag
"
"
Roaster Calcine
"
"
"
11
"
"
#2 Reverb Matte
"
n
$1 Pl^i*p TvPA't'PY*
7T i r i a uc i i cu uci
Ac Ranhniicp Hucf*
no ucz^iii/uoc LTUOU
Blister Copper
Cu Slag from conv.
#1 going into Conv. #2
•
Anode Slag #2 conv.
from Anode Charge #158
to charge 183
9/19/78
9/20/78
9/21/78
9/19/78
9/20/78
9/20/78
9/21/78
9/21/78
9/22/78
9/22/78
9/22/78
9/22/78
9/23/78


9/24/78
9/25/78
9/25/78
9/24/78
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
9/19/78
9/20/78
9/21/78



5/14/78

n




0.423%
0.270%
0.378%.
0.431%
0.435%
0.187%
0.266%
0.778%
0.705%
0.835%
0.479%
0.784%
0.483%
OH9CW
• \)C.\J/o
0.166%
0.830%
0.260%
0.220%
0.182%
0.283%
0.142%
0.142%
0.167%
0.182%
0.238%
0.846%
1.36%
0.211%
0.180%
0.108%
0.231%
0.368%
0.201%
0.279%
0.069%
0.282%
0.107%
0.220%
n £9i °/
n ?RI?
n ?i i°/
U • c 1 O /o
0.056%

6.62%



5.02%
                                65

-------
                               Table 44 Cont.
PLANT
PROCESS
                                           DATE
%Pb
ASARCO
Tacoma



Charge 183












,



Charge 185











Charge 190












^
















4











•







Finish Cu Slag from
conv. #2
Conv. flux
Conv. Slag
Roaster Charge
#2 conv. matte
cyclone dust #2 conv.
Roaster
Ballon Flue Dust
Crushed Reverts
Fine Metal From Cu
slag from #1 conv.
going into #2 conv.
metal from crushed re-
verts
B#2 conv. cyclone dust
#2 Anode pies
Ballon Flue dust
Roaster Calcine
#2 conv. finish slag
(Cu slag)
Charge 184 Cu slag to
conv. #2
Roaster feed 5/10/79
Roaster feed 5/9/79
conv. slag
conv. flux
J2 Conv. Matte .
'Crushed reverts
Roaster Calcine
#2 conv. Slag
Roaster calcine
#2 Conv. Finish Slag out
#2 conv. crushed reverts
#2 conv. Flux
#2 conv. Matte
#2 Conv. Finish Slag
going into charge 190
#2 Conv. cyclone dust
Roaster charge
#2 Conv. anode slag
#2 Conv. ballon flue
dust
»

5/14/79
4 .
II
II
II
II
II
II
II
II
II

II


5/15/80
H
n
n

it
n

n
n
n
5/16/79
n
n
n
n
n
n
n

n
n
n
n

n


4.33%
0.77%
6.50%
1 .01%
1*">lo/
.32%
3.16%
1f\f\nl
.02%
2.91%
5.18%


1 .29%
2.31%

3.58%
0.069%
2.93%
1.14%

7.47%
4.35%
1.16.%
1 ,05%
6.82%
1.01%
3.14%
6.33%
0.40%
.5.46%
1.13%
4.69%
2.72%
1.04%
1.71%

7.74%
3.90%
1.19%
3.69%

2.76%
                                      66

-------
                          Table 44 Cont.
PLANT
PROCESS
DATE
%Pb
KENNICOTT
Magma























Before Dryer
it
ii
After Dryer
II

. Conv. #1
II
II
Conv. #2
"
H
Furn. Matte #3
Furn. Slag #3
Furn. Matte
n
Furn. Slag
n
Furn. Cone. Feed
n
Finished Cu Anode
n
Cyclone Scrubber H20
II
M
11/9/78 1st
11/14/78 2nd
11/14/78
11/9/78 1st
11/14/78
11/14/78 2nd
11/6/78
11/7/78
11/8/78
11/6/78
11/7/78
11/8/78
11/2/78
11/2/78
11/3/78
11/1/78
11/3/78
11/1/78
11/3/78
11/2/78
11/7/78
11/8/78
11/9/78
11/14/78 1st
11/14/78 2nd
0.101%
0.084%
0.079%
0.076%
0.077%
0.082%
0.229%
0.808%
0.585%
0.365%
0.023%
0.362%
0.185%
0.045%
0.120%
0.105%
0.064%
0.154%
0.192%
0.108%
0.027%
0.018%
4.4 ug/mi
28.3 ug/mfc
10.6 ug/mfc
                                67

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Lead Emission Factors:
               (Kg Pb/hr) (2.204 Ibs/Kg) = Ibs Pb/ton
               	:—.	—	= Ibs Pb/ton
               ( tons of roaster charge/hr)
     Data used in the calculation of emission factors i's contained in table
45.  The average and range of emission factors are summarized for operations
without emission control devices in table 46, and for those with emission
control devices in table 47.
                                          68

-------
          CO
      «  eg
       UJ
       Q  U.
   Z  -J  O

   2  O  Z
   oo  z  o
   (/)•_)  l-l
in I-H     I—
•tj- s:  to  
-------
         TABLE 46
            LEAD
         EMISSION FACTORS FOR PRIMARY
         COPPER SMELTERS WITHOUT CONTROLS
Type of Operation
Roasting
Smelting
Converting
Refining (a)
D
Range
Low
Ib/ton kg/NT
0.004 0.002
0.002 0.001
0.015 0.008

High
Ib/ton Kg/MT
0.880 0.440
4.136 2.068
0.792 0.396

Average
Ib/ton Kg/MT
0.492 0.246
1.343 0.672
0.272 0.136

(a)  No  data available
        TABLE 47
          LEAD
        EMISSION FACTORS FOR PRIMARY
        COPPER SMELTERS WITH CONTROLS
Type of Operation
6
Roasting (a)
Smelting (b)
Converting
Refining (b)
Range
Low
Ib/ton kg/MT
-
-
0.022 0.011

High
ib/ton Kg/MT
-
-
2.112 1.056
0
Average
Ib/ton kg/MT
0.154 0.077
-
0.520 0.260

(j
 (a)   Only one data point available
 (b)   No data available               70

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                                 SECTION 3

                        LOCATION OF SAMPLING POINTS


Asarco - El Paso, Texas; TRW test program

1)  Inlet to the Converter Building Fugitive Emissions Baghouse

    Samples from the inlet to the converter building fugitive baghouse were
    taken from a 152" diameter horizontal  duct which is 50 feet above the
    ground.  Sampling ports on the top and side of the duct allowed for
    vertical and horizontal traverses of the duct during sampling.   The
    nearest upstream flow disturbance was a bend 90 feet (7 diameters) away
    from the sampling point.  The nearest downstream disturbance was a bend
    100 feet (8 diameters) downstream.  Forty traverse points were  chosen
    so that the sampling period would coincide with that at the outlet from
    the baghouse.  Figure 1 is a diagram of the sampling location.

2)  Outlet from the Converter Building Fugitive Emissions Baghouse

    Samples from the outlet of the converter building fugitive baghouse
    were taken from a 20' by 9' rectangular duct.  The duct was horizontal
    and the sampling point was 35 feet above the ground.  The nearest up-
    stream flow disturbance was 45 feet (3.5 equivalent diameters)  away.
    The nearest downstream disturbance was 12.5 feet (1 equivalent  duct
    diameter) away.  Ten traverse points were selected at each of the four
    sampling ports.  Figure 2 is a diagram of this location.

3)  Roaster Calcining Fugitive Emissions Duct

    The roaster calcining fugitive emissions were sampled from a 28.5 inch
    diameter circular duct which was 15 feet above the ground and at a 10
    degree angle to the horizontal.  The nearest upstream flow disturbance
    was 75 feet away (32 diameters); the nearest downstream disturbance was
    8 feet away (3.5 diameters).  Twenty traverse points were selected for
    sampling, ten on each of the two traverses.  Figure 3 is a diagram of
    this sampling location.

4)  Outlet from the Roaster/Reverberatory Furnace Electrostatic Precipitator

    The duct exiting the roaster/reverberatory furnace electrostatic precipi-
    tator is a ballon shaped duct twenty-two feet high and twelve feet wide
    at the top.  The nearest upstream disturbance was 50 feet (4 diameters)
    away; the nearest downstream disturbance was 20 feet (1.5 diameters)
                                     71

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    away.  Sampling was done at 50 traverse points.   Figure 4 is the plan
    view diagram of this sampling location.  Figure  5 illustrates the cross-
    sectioned view.

5)  Matte Tapping Reverbatory Furnace Outlet

    The fugitive emissions from the matte tapping reverbatory furnace were
    sampled from a 32.75" diameter horizontal  round  duct.   The nearest up-
    stream disturbance was 20 feet (6 diameters)  away; the nearest down-
    stream disturbance was 12 feet (4 diameters)  away.  Sampling was done
    at 24 traverse points on two traverses.  Figure  6 is a diagram of this
    sampling location.
                                     72

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                                             TRAVERSE POINT LOCATIONS
           152"
Tra-
verse
Point
Loca-
tions
1
2
3
4
5
6
7
8
9
10
Fraction of
Stack I. D.
0.026
0.082
0.146
0.226
0.342
0.658
0.774
0.854
0.918
0.974
Distance
From Inside
Wall (in)
4.0
12.5
22.2
34.4
52.0
100.0
117.6
129.8
139.5
148.0
    TO
BAGHOUSEl
                              FIGURE 1.
           INLET TO CONVERTER FUGITIVE  EMISSIONS BAGHOUSE
                                                              FROM
                                                            CONVERTER
                                 73

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                                 DISTANCE OF SAMPLING POINT

                                         FROM PORT
                                              DISTANCE
                                                FROM
                                    TRAVERSE  INSIDE
                                      POINT  WALL  (IN)
      CROSS SECTION
                SAMPLING  POINT
                 A
                 o
                 o
1
2
3
4
5
6
7
8
9
10
12
36
60
84
108
132
156
180
204
228
                                         FROM BAG HOUSE
                         PLAN VIEW




FIGURE 2.  OUTLET FROM CONVERTER BUILDING FUGITIVE EMISSIONS BAGHOUSE

                                 \
                                 /

                             74

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                                                                 TRAVERSE POINT LOCATION
                           28,5*
en
TRAVERSE POINT
NUMBERS
1
2
3
4
5
6
7
8
9
10
FRACTION OF
STACK I.D.
0,026
0,082
0,146
0,226
0,342
0,658
0,774
0,854 .
0,918
0,974
DISTANCE FROM 1
INSIDE WALL (IN*
1,0
2,25
4,25
6,5
9,75
-18,75
22,0
24,25
26,25
27,75
                                                                       FROM CALCINING
                                                        SIDE VIEW
                                       TO SPRAY CHAMBER
                                       AND ELECTROSTATIC PRECIPITATOR
                          FIGURE 3.  ROASTER CALCINING FUGITIVE EMISSIONS DUCT

-------
        TO  MAIN STACK
             t
          oo  o oo
                           SAMPLING
                            'POINT
        ELECTROSTATIC

        PRECIPITATOR
PLAN VIEW
 SPRAY
CHAMBER


\      f
             FROM ROASTER/REVERBERATORY  FURNACE
  FIGURE 4.  OUTLET FROM THE ROASTER/REVERBERATORY  FURNACE ESP


                            76

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                                   4"  0,D,  PORTS
               0

               •
       CROSS SECTION  VIEW
                                            T
                                            22
              •12' 	

              FIGURE 5.
OUTLET FROM ROASTER REVERB SPRAY CHAMBER
   AND ELECTROSTATIC PRECIPITATOR
                  77

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                                  TRAVERSE POINT LOCATIONS
Traverse
Point 1
1
2
3
4
5
6
7
8
9
10
11
12
Fraction of
Duct I.D,
0.021
0.067
0.118
0.177
0.250
0.356
0.644
0.750
0.823
0.882
0.933
0.979
Distance
Fnsn
Inside Wall
1.0
1.8
3.1
4.7
6.6
9.4
17.1
19.9
21.8
23.4
24.7
25.5
               I           PLAN VIEW
TO MATTE TAPPING BAGHOUSE
   FIGURE 6.  MATTE TAPPING REVERBERATORY FURNACE OUTLET
                        78

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Asarco - El Paso, Texas; Monsanto test proqram

    There are two distinct control  systems in the copper smelting facility.
The first controls the effluent from the converter line, and the second
controls the effluent from the multi-hearth roasters and the reyerberatory
furnace.  The effluent of the converter line passes through an  induced draft
fans a spray chamber, an electrostatic precipitator, and finally through
a sulfuric acid plant.  The gases from the multi-hearth roasters are joined
by the gases from the reverberatory furnace, pass through a spray chamber,
are then cleaned in an electrostatic precipitator, and then are directed to
the base of the main stack where they are emitted to the atmosphere.  The
first system we will discuss is the effluent of the converter line.

EFFLUENT OF THE CONVERTER LINE

Point D Effluent of Converters

    Gases are collected from the converters in a system of duct work and
directed out of the building, in two ducts, to the plenum chamber inlet
of an induced draft (I.D.) fan.  The outlet of this fan is sampling  point
D.  The gases leave the fan through a transition duct and into  an expansion
joint approximately 4-foot (1.22 m) long.  The gas then passes  through a
horizontal duct that is 75 inches (190.5 cm) inside diameter and 16  ft.
(4.88 m) long and into the inlet of the spray chamber.  This section of
line, including the expansion joint, constituted a 20 foot (6.10 m)  straight
length of duct work and was selected as site D, inlet to the converter line
control device.

    Two 4 inch (10.2 cm) diameter pipe ports were located 4 foot (1.22 m)
from the spray chamber and 16 ft. (4.88 m) from the outlet of the fan,
giving 0.64 diameters downstream and 2.56 diameters upstream from the ports.
the ports were located on the top and side of the horizontal  duct 90° apart.
A 44 point total traverse was required, however, the first and  last  points
on each 22 point traverse were less than 1 inch (2.54 cm) from  the duct wall.
A 48 point total traverse was used and the first and last points were dropped
from each 24 point single traverse.

    It was discovered on the initial velocity traverse that the bottom of
the duct had an accumulation of material in it.  Only the first 13 points of
the vertical traverse were used to sample the duct.  All 22 points of the
horizontal traverse were used.  A sketch of this location is shown in Figure
70

Point E
    Sampling point E is the outlet of the sulfuric acid plant.   It is a
vertical stack with an atmospheric outlet.  There is a straight section of
stack from the last disturbance (a tee section) to the outlet of about 35
to 40 ft. (10.67 to 12.19 m) and the inside diameter of the stack is 66
inches (167.6 cm).  The ports were located approximately 12 feet (3.66 m)
from the disturbance to the ports and 4 or 5 diameters from the ports to the

                                     79

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  .SUPPORT BEAMS
SUPPORT HANGERS
Figure 7.    Sampling location D
                            o
                                           O

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outlet.  The ports were 4 inch (10.16 cm)  flanged pipe and were located 90°
from each other on the circumference of the stack.   A 48 point total  tra-
verse was laid out, however, the first and last points of each single tra-
verse were nearer than 1  inch (2.54 cm) from the stack wall  and were  not
used.  A 44 point total traverse was used.

EFFLUENT OF THE ROASTER AND REVERBERATORY  FURNACES

Point C - Effluent of the Roasters

    Sampling point C is the effluent of the multi-hearth roasters.  The out-
lets of the roasters are accumulated in a  system of duct work and directed
to a large rectangular downtake flue at the top of the roaster building.
This downtake, constructed of brick, runs  diagonally down the side of the
roaster building at approximately a 45° angle and joins the horizontal  flue
that takes the gases to the cleaning system.  This  downtake is sampling
point C.  Four 4 inch (10.16 cm) pipe sampling ports were installed in  a
horizontal line across the downtake at the second level of the building on
both the inside and outside of the duct and scaffolding was erected on  the
outside for access.  Since the duct was approximately 14.5 feet (4.42 m)
square inside, the ports were in the range of 2.21  to 2.75 equivalent
diameters from the nearest upstream disturbance and 0.55 to 2.07 equivalent
diameters from the nearest downstream disturbance.   A 40 point total
traverse was laid out to sample this duct.  This would have consisted of 5
traverse points per port.  The ports on both the inside and outside of  the
duct nearest the bottom was found to be under an accumulation of dust and
therefore were not sampled.  This left a 30 point traverse.   A sketch of
this location is shown in Figure 8.

Point B - Effluent of the Reverberatory Furnaces

    The gases leaving the reverberatory furnace first pass through a  waste
heat recovery boiler and then through two  I.D. fans.  The outlet of these
fans are sampling point B.  The two rectangular ducts from the fans,
designated South (SB) and North (NB), are  26 feet (7.92 m) long, 8 feet
(2.44 m) tall and 6 feet (1.83 m) wide giving an equivalent diameter  of
6.857 feet (2.09 m).  The ducts are about  12'feet (3.66 m) apart and  both
empty into the long horizontal flue that already contains the gases from the
roaster process.  Six 4 inch (10.16 cm) pipe ports  were located on each of
the ducts on the 8 foot (2.44 m) wall facing each other and were offset 1
foot (.30 m) from each other along the length to facilitate probe handling
during simultaneous sampling.  The South duct ports were located 15.5 ft.
(4.72 m) from the fan outlet and 10.5 ft.  (3.20 m)  from the flue giving
2.26 diameters upstream and 1.53 diameters downstream of unobstructed duct.
The North duct ports were located 14.5 ft. (4.42 m) from the fan and  11.5 ft.
(3.51 m) from the flue giving 2.11 diameters upstream and 1.68 diameters
downstream of unobstructed duct.  Each port was sampled using 4 traverse
point locations so that a 24 point overall traverse was obtained on each
duct.  A sketch of this location is shown  in Figure 9.
                                     81

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CLEAN OUT
 TRENCH
                 SUPPORT
                  BEAM
                                     2ND FLOOR
                                     1ST FLOOR
                                     GROUND FLOOR
VIEW FROM INSIDE BUILDING
    Figure 8.     Sampling  location C
                     82

-------
FAN
FAN
                             .26'
                  •14.5'
          DAMPER
           GRATING
          DAMPER
                         61
                      LADDER
                                       STAIRS
     r
PORT LOCATIONS
    SHOWN
                          TOP VIEW
                                               LADDER


^^



n
n
r— i
LJ
o
	 o
0




J

1
It


                         INSIDE VIEW
         Figure  9.    Sampling location B
                           83

-------
POINT A - OUTLET OF THE ESP

    Sampling point A is a large balloon flue that connects the ESP to the
base of the main stack.  The flue exits the ESP building and turns right
about 30°.  It then runs for a straight length of about 68 ft. (20.73 m)
where another bend occurs.  From this point it continues to the main stack.
The sampling points are located approximately 48 ft.  (14.63 m) from the
first bend and approximately 20 ft. from the second.

    There are no guidelines for calculating an equivalent diameter for a
balloon shaped flue.  The cross section of the flue has a semicircular top
of 6 ft. (1.83 m) radius, below this is a rectangular section 12 ft. (3.66
m) wide by 7.66 ft. (2.33 m) tall, and the bottom is  a V shaped triangle
with a 12 ft. (3.66 m) top and a depth of about 9 ft. (2.74 m).  This gives
a total area of approximately 200 ft2 (18.58 m2).  An equivalent circular
duct would have a diameter of about 16 ft. (4.88 m).   Using 16 ft. (4.88 m)
as an equivalent diameter the ports are located 3 diameters from the near-
est upstream bend and 1.25 diameters from the nearest downstream bend.  This
would normally require about 40 points to traverse.  Five 3 inch (7.62 cm)
ports were located on the top of the duct and were located on the top of the
top of the duct and were designated A through E across the duct.  Due to the
shape of the duct, various numbers of points were used on each port.

    Ports A and E were sampled using 7 points each, ports B and D with 11
points each and port C with 15 points.  This gave a total traverse of 51
points.  At each of the topmost points of each port traverse, no flow was
detected so the second point of each traverse was sampled twice as long.
This left a 46 point total traverse with the 5 uppermost points being
sampled at double the time of the others.  A sketch of this location is
shown in Figure 10.
                                    84

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TOP VIEW
                      3" PIPE PORTS w/CAPS
                           EXISTING
                            oo
                        CROSS SECTION
                            VIEW
w



7'
                                      9'
                                     i
 Figure 10.     Sampling point A
                85

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Phelps-Dodge - Douglas, Arizona; TRW test program

Inlet to Calcine/Roaster Baghouse

    Samples from the inlet to the calcine/roaster baghouse were taken from a
43" horizontal duct located approximately 25 feet above the ground.  Sampling
ports on the bottom and side allowed for vertical and horizontal  traverses.
The nearest upstream disturbance was 24 feet (8 diameters) away from the
sampling point.  The nearest downstream disturbance was the intake to the
baghouse located 7 feet (2 diameters) away from the sampling point.  Twelve
traverse points were selected for particulate and arsenic/sulfur dioxide
tests.  Figure 11 is a schematic of the sampling location.

Outlet from Calcine/Roaster Baghouse

    Samples from the outlet of the calcine/roaster baghouse were taken from a
42" horizontal duct located approximately 35 feet above the ground.  Sampling
ports on the bottom and side allowed for vertical and horizontal  traverses.
The nearest upstream disturbance was 42'feet (12 duct diameters)  away from
the sampling point.  The nearest downstream disturbance was a 90° bend
located 28 feet (8 duct diameters) from the sampling point.  Twelve traverse
points were utilized for particulate and arsenic/sulfur dioxide tests.
Figure 12 is a schematic of the sampling location.
                                    86

-------
                                         Tra-
                                        verse
                                        point
                                        loca-  Fraction of
                                        tions   stack I.D.
           43
                                          1
                                          2
                                          3
                                          4
                                          5
                                          6
.044
.146
.296
.704
.854
.956
 Distance
from inside
 wall (in)
    ;
    1.S7
    6.30
   12.72
   30.28
   36.70
   41.13
    TO
   m—
BAGHOUoi;
  CALCINZ/r.OASTER
  FUGITIVE EMISSION
  SYSTEM
           Figure  11.  Inlet to calcine/roaster baghouse.
                                 87

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                                          TRAVERSE POINT LOCATIONS
         42
                                      Tra-
                                      verse
                                      point
                                      loca-
                                      tions

                                         1
                                         2
                                         3
                                         4
                                         5
                                         6
Fraction of
 stack I.D.

    .044
    .146
    .296
    .704
    .854
    .956
 Distance
from inside
 wall (in)

   1.83
   6.15
  12.43
  29.57
  35.85
  40.17
  FROM
 	-H
CALCINE//
ROAGTER I
BAGHOUSE!
        V
   Figure 12.  Outlet from calcine/roaster baghouse.

-------
Phelps-Dodge - Ajos Arizona; TRW test program

Converter Fugitive Emission Duct

    Samples from the converter fugitive emission duct were taken through a
64" horizontal duct located approximately 75 feet above the ground.   The
sampling ports on the top and side of duct allowed for vertical  and  horizontal
traverses during sampling,,  The nearest upstream flow disturbance was a bend
43 feet (8 duct diameters) away from the sampling point.  The nearest down-
stream disturbance was a bend 11 feet (2 duct diameters) away.  Twelve tra-
verse points were selecteds six on each traverse.  Figures 13 and 14 are
schematics of the sampling location,,

Matte Tapping Fugitive Emission Duct

    Matte tapping fugitive emissions were sampled through a 73"  fiberglass
horizontal duct located approximately 25 feet above the ground.   Sampling
ports located on the side and bottom allowed for horizontal and  vertical
sampling,,  The nearest upstream disturbance flow is located 48 feet  (8 duct
diameters) away from the sampling.position.  Twelve traverse points  were
utilized for sampling;  six on each of two traverses.  Figures 15 and 16
are schematics of this sampling location.

Inlet to ESP

    Sampling was performed through a vertical rectangular duct which measured
94" x 85",  The sampling position was located approximately 80 feet  above
the ground.  Sampling ports consisted of six ports evenly distributed
across the west side of the duct.  Sampling ports enabled TRW personnel to
sample with horizontal traverses.  The nearest upstream disturbance  was
located 10 feet (1 1/2 duct diameters) from the sampling position.  The
flow disturbance occurs where the rectangular duct attaches to the circular
duct at a 90° angle to the flow of gases.  The nearest downstream distur-
bance is located 7 feet (1 duct diameter) from the sampling points where
the gases enter the acid plant.  Forty-eight sampling points were utilized
with eight points on each of six traverses.  Figure 17 is a schematic of
the sampling location.

Acid Plant Outlet

    Samples were taken from a 54" horizontal duct which was located  approxi-
mately 70 feet above the ground.  The sampling ports were located on the
side and top enabling horizontal and vertical traverses..  The nearest
upstream disturbance was located greater than 36 feet (8 duct diameters)
from the sampling points.  Figure 18 is a schematic of the sampling  location.

ESP Outlet/Acid Plant Inlet

    Sampling was performed through a horizontal circular duct that was
located approximately 25 feet above cthe ground.  Sampling ports  were
positioned on the bottom and side of the duct to allow vertical  and

                                     89

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64'
 Tra-
verse
point
loca-
tions
  1
  2
  3
  4
  5
  6
Fraction of
 stack I.D.
   .044
   .146
   .296
   .704
   .854
   .956
                                                     Distance
                                                    from inside
                                                     wall (in)

                                                        2.79
                                                        9.37
                                                       18.97
                                                       45.06
                                                       54.63
                                                       61.21
                                          JROM

                                         CONVERTER
       Figure 13.  Converter fugitive emission duct,

                          90 6

-------
                  PHELPS-DODGE, AJO
CONVERTERS WITH HOODS
  n—h     t->i
                                                   STACK
           DUCT
SAMPLING
 POINT
FAN
       Figure 14. Converter fugitive emission system

-------
73
                              Tra-
                              verse
                              point
                              loca-
                              tions
                                1
                                2
                                3
                                4
                                5
                                6
Fraction of
 stack I.D.

    .044
    .146
    ,296
    .704
    .854
    .956
 Distance
from inside
 wall (in)
    3.18
   10.69
   21.60
   51.40
   62.31
   69.82
                                           FROM
                                          t	
                                          MATTE TAPPING
                                             PkOCESS
       Figure 15.  Matte  tapping  emission duct
                         92

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vo
CO
                                           PHELPS-DODGE AJO
         SLAG TAPPING FUGITIVE EMISSION DUCTS
                       J_t
REVERE FURNACE
                        i       J  L
                                                                        FAN
                                                               SAMPLING

                                                                POINT
                MATTE TAPPING FUGITIVE EMISSION DUCTS
                            Figure 16.  Matte tapping fugitive emission system

-------
                   Figure 17.  ESP inlet sampling  locations.
           85'
85'
  94"
   I
                                                    Distance of  sampling point
                                                            from  port
                          ESP
                         Inlet
                         North
                ESP
               Inlet
               South
                    Traverse
                    point

                       1
                       2
                       3
                       4
                       5
                       6
                       7
                       8
 Distance
  trom
 inside
wall (in)

   5.88
  17.63
  29.38
  41.13
  52.88
  64.63
  76.38
  88.13
  From
converter
 building
                           t
                t
                                Add plant
                                  bypass
                     Sampling pointsSampling points   Damper
                                  Side view
                                     94

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                                    Traverse
                                     point
                                    locations
Fraction of
 stack I.D.
 Distance
from inside
 wall (in)
                                       1
                                       2
                                       3
                                       4
                                       5
                                       6
    .044
    .146
    .296
    .704
    .854
    .956
    2.35
    7.91
   15.98
   38.02
   46.09
   51.65
54"
                                                           From
                                                         acid plant
                Figure 18.  Acid plant outlet location.
                                  95

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horizontal sampling.  The nearest upstream disturbance was  located 12 feet
(2 duct diameters) from the sampling positions.   The nearest downstream flow
disturbance was at least 30 feet (5 duct diameters)  away from the sampling
position.  Thirty-six traverse points were selected  with eighteen points on
each traverse.  Figure 19 is a diagram of the sampling location.   Figure 20
depicts the acid plant sampling locations in relation to each other.
                                    96

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                                           Traverse
                                            point
                                           locations
                            Fraction of
                             stack I.D.
 Distance
from Inside
 wall  (in)
       72"
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0.014
0.044
0.075
0.109
0.146
0.188
0.236
0.246
0.382
0.618
0.704
0.764
0.812
0.854
0.891
0.925
0.956
0.986
1.01
3.14.
5.41
7.86
10.54
13.55
17.03
21.30
27.51
44.49
50.70
54.97
58.45
61.46
64.14
66.59
68.86
70.99
      Jo
add plant.
o
          Figure  19.  ESP outlet/acid plant inlet  sampling location.
                                     97

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STACK
               ACID PLANT OUTLET
                        ESP OUTLET
                       ESP
                                   ESP INLETS
ACID
PLANT
COMPLEX
              CONVERTER BUILDING
                     Figure 20.
               Acid plant schematic
             Phelps-Dodge Ajo, Arizona
                        98

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Phelps-Dodge - Playas, New Mexico; TRW test program

Outlet from Converter Hooding System

    Samples from converter hooding system were taken from a seven foot dia-
meter horizontal duct located approximately 50 feet above the ground.   The
sampling ports on the top and side of the duct allowed for vertical  and
horizontal traverses during sampling.  The nearest upstream flow disturbance
was 7 duct diameters from the sampling location.  The nearest downstream
flow disturbance was greater than ten duct diameters from the sampling
location, where there was a 90° bend.  Twelve traverse points, six on  each
traverse were used.  Sampling was done for twenty minutes per point to
provide sampling through a complete copper blow cycle.  Figure 21 illustrates
the cross-sectional view.
                                    99

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                                            Traverse point locations
Tra-
verse
Point
Loca-
f^ons
1
2
3
4
5
6
Fraction of
Stack I.D.
.044
.146
.296
.704
,854
.956
Distance
From Inside.
Wall (in)
3.66
12.30
24.85
59.15
71.70
80.34
Stack
  From
converter
  hoods
             Figure 21.  Converter fugitive emission duct.
                                 100

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Asarco - Tacoma, Washington; TRW test program

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 dia-
    meters) away, the nearest downstream disturbance was a transition section
    into the baghouse which was 10 feet away.  Sampling was done at 20 tra-
    verse points.  Figure 22 is a diagram of the sampling location.

2)  Roaster baghouse outlet - The treated gas leaving the roaster baghouse
    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 100 feet (13 diameters) and the nearest downstream disturbance was
    40 feet (4 1/2 diameters) away.  Sampling was done at 12 traverse points.
    Figure 23 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 sampling ports on the top of the rec-
    tangular 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
    sediment in the duct precluded sampling at twelve of them.  Figure 24
    is a diagram of this location.

4)  Matte tapping - Matte tapping emissions are captured by a moveable hood
    over the matte tapping ladle and are ducted to the brick flue which goes
    to the main stack after passing through an electrostatic precipitator.
    These emissions were sampled in a vertical section of the 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.  Samples were taken at eight traverse
    points during matte tapping operations.   Figure 25 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 brick flue as are the matte
    tapping emissions.  The emissions were sampled in a section which angles
    down 20° from the horizontal.  The sampling ports are twenty feet down-
    stream from a 20° bend (5 diameters), and seven feet upstream from a 60°
    bend (2 1/2 diameters).  Samples were taken at twelve traverse points
    during slag tapping operations.  Figure 26 is a diagram of this location,,

6)  Calcine discharge - Dust emissions from loaging lorry 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 disturbance.  Samples were

                                    101

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                                       Traverse Point
                            11
                                        Distance from Wall
1
2
3
4
5
6
9.4
28.3
47.1
66.0
84.9
103.7
7 | . 122.6
    3'
H-
3'
J
Roaster Building
                                                  *" From Crusher
                                                 Sampling Ports
                                    Roaster
                                    Baghouse
                  Figure 22.   Roaster Baghouse Inlet
                                 102

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                                                                             o
o
co
                                             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 23.  Roaster Baghouse Outlet Duct.

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                                       Sampling Ports
Reverberato'-y
     ESP
                           Side View
                                            Traverse Point  Distances *ror toe. c* Duct
          20'
                             Is'
                             (
                             i
1
2
3
4
5
• 6
7
£ .
9
1C
9"
27"
45"
63"
8V
99"
117'
135"
153'
171"
    Cross Section
Figure 24.   Reverberatory furnace  electrostatic precipitator.
                                 104

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                                                                                       I).
                             Traverse Point Location
                    Nnmhor   £ f>f
o
01
1
2
3
4
                                6.7
                               25.0
                               75.0
                               93.3
Distance, from insuh- wall
           I.H
           6.6
         19.9
         24.7
                                                             Figure 25.   Matte  tapping.

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o
at
                                                                   Traverse  Point Locations
                                                      Point. Nmnhpr   '". nf
frnm inciHo
1
?
;?
/I
s
6
4.4
14.6
29.6
70.4
85.4
9b.6
1.2
3.9
8.0
19.0
23.1
25.8
          To Blower
                                                      Figure 26.  Slag tapping duct.

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     taken at a single point due to  the  small  duct  diameter.   Sampling  was
     done only while lorry cars were being  loaded.   Figure  27  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 bag-
     house 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  ducting, which  was  6  feet  (3  diameters)
     away.  The nearest downstream disturbance was  a 90°  bend  5 feet (2 dia-
     meters) away.  Sampling was done at 24 traverse points.   Figure 28 is
     a diagram of this location.

 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 kitchen 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 near-
     est downstream flow disturbance was 6  feet (2  diameters)  away. Sampling
     was done at twelve traverse points. Figure  29 is  a  diagram  of this
     location.

 9)  Arsenic baghouse outlet - The discharge gases  from the arsenic kitchen
     baghouse were sampled approximately 500 feet downstream from the bag-
     house.  Samples were taken from a round horizontal duct with an inside
     diameter of 37.75 inches.  The  nearest upstream flow disturbance was 75
     feet (24 diameters) away, and the downstream 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  30 is a
     diagram of this location.

10)  Converter slag return - During  the  converter cycle slag is periodically
     poured off the matte.  This slag is returned to the  reverberatory
     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 31 is  a diagram  of  this location.
                                      107

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o
oo
                            o
                                  Figure 27.  Calcine discharge  duct.

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o
vo
Pninf
7. of  uct Diameter
                                                     Distanrp from
1
2
3
4
5
6
7
8
9
10
11
1?
2.1
6.7
11.8
17.7
25.0
35.6
64.4
75.0
K2 . 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.
                                                                                        c
                                                                o
                                 Figure 28.  Arsenic kitchen inlet to  arsenic  baghouse.
                                                                                                        26.5"

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37.25"!
         o
                                                  Traverse Point Locations



                                        Pnint 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
1.6
5.4
11.0
26.2
31.8
35.6
                                       Figure 29.   Metallic arsenic inlet to arsenic baghouse.

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37.75"
                                Traverse Point H
  Traverse Point Location
'.'. of Diameter   Inches from inside wall

•f
J
4
Cj
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  30.  Arsenic baghouse outlet duct.

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                  36'
rs>
                                                                              o
                         Lol
                           Trverse Point Number
7. of Diameter
                 Distance from inside wall
                                   1
                                   2
                                   3
                                   4
                                   5
                                   6
      4.4
     14.6
     29.6
     70.
     85.
.4
.4
                                                         95.6
 1.6
 5.3
10.
25.
30.
,7
.3
,7
                                34.4
                                        Figure  31.   Converter slag return duct.

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Kennecott - Magma, Utah; TRW test program

Matte Tapping Fugitive Emission Duct

     Samples from the matte tapping fugitive emission duct were taken from a
60" vertical duct located approximately 75 feet above the ground.   Two sampl-
ing ports located at a 90° to each other allowed for horizontal traverses
during sampling.  The nearest upstream flow disturbance was located 20 feet
(4 duct diameters) away from the sampling point.  The nearest downstream dis-
turbance was located 10 feet (2 duct diameters) from the sample location.
Twenty-four traverse points were selected with twelve points on each traverse.
Figure 32 is a schematic of the sampling location.

Slag Tapping Fugitive Emission Duct

     Slag tapping fugitive emission samples were taken through a 60" vertical
duct located approximately 75 feet above the ground.  One sampling port was
utilized for both horizontal traverses during sampling.  The nearest upstream
flow disturbance was located approximately 20 feet (4 duct diameters) away
from the sampling position.  The nearest downstream disturbance was a bend
located 10 feet (2 duct diameters) away from the sampling location.  Twenty-
four traverse points were selected with twelve points on each traverse.
Figure 33 is a diagram of this sampling location.

Acid Plant Inlet

     Acid plant inlet samples were taken through a 60" horizontal  duct loca-
ted approximately 8 feet above the ground.  The sampling ports on the top
and side of the duct allowed for vertical and horizontal traverses.  The
nearest upstream flow disturbance was a bend located approximately 20 feet
(4 duct diameters) away from the sampling position.  The nearest downstream
disturbance was located 10 feet (2 duct diameters) away from sampling posi-
tion.  Twenty-four traverse points were selected with twelve points on each
traverse.  Figure 36 is a schematic of the sampling location.

Converter Fugitive Emission Duct

     Converter fugitive emission samples were taken through a 38" x 84"
rectangular vertical duct located approximately 60 feet from the ground.
Six sampling ports were evenly spaced across the 84" face of the duct that
allowed for horizontal sampling.  The nearest upstream flow disturbance was
located approximately 4 feet (1 duct diameter equivalent) away from the
sampling position.  The nearest downstream disturbance was a bend located
approximately 8 feet (2 duct diameter equivalent) away from the sampling
points.  Figure 37 is a schematic of this sampling location.

Concentrate Dryer Stack

     Concentrate dryer  fugitive samples were taken through a 84" diameter
vertical fiberglass duct  located approximately  110 feet above  the ground.
Two sampling ports place  at  right angles allowed  for horizontal traverses


                                     113

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during sampling.  The nearest downstream disturbance was the stack exit
which was 40 feet (6 duct diameters) from the sampling points.  The nearest
upstream disturbance was two ducts entering the stack 56 feet (8 duct diame-
ters) away from the sampling position.  Figure 39 is a schematic of the con-
centrate dryer fugitive emission duct.
                                    114

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                                    TRAVERSE POINT LOCATIONS
60"
           I
TO STACK
                                TRA-
                                VERSE
                                POINT
                                LOCA-
                                TIONS
                           FRACTION OF
                           STACK I.D.
DISTANCE
FROM INSIDE
WALL (IN)
1
2
3
4
5
6
7
8
9
10
11
12
.021
.067
.118
.177
.250
.356
.644
.750
.823
.882
.933
.979
1.28
4.02
7.09
10.64
15.00
21.34
38.66
45.00
49.36
52.91
55.98
58.72
                                         MATTE TAPPING
               FROM MATTE TAPPING
                 EMISSION HOODS

                     Figure 32.   Matte  tapping.
                            115

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                                        TRAVERSE POINT LOCATIONS
60"
          STACK
           1
TRA-
VERSE
POINT
LOCA-
TIONS
1
2
3
4
5
6
7
8
9
10
11
12
FRACTION OF
STACK I.D.
.021
.067
.118
.177
.250
.356
.644
.750
.823
.882
.933
.979
                                                           DISTANCE
                                                           FROM INSIDE
                                                           WALL (IN)
 1.28
 4.02
 7.09
10.64
15.00
21.34
38.66
45.00
49.36
52.91
55.98
58.72
                                           SLAG TAPPING
               {FROM SLAG TAPPING
                EMISSION HOODS
                      Figure 33.  Slag tapping.
                             116

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                             Traverse 2
                                       WOOD PLATFORM
1.   Points are marked on the wood platform as illustrated above.  Note that
     30* distance from the line marked on the wood platform and sampling port
     is the same as the radius of the duct.
2.   Points marked on each line (AC)  and (AB) from the center point A.
               Point                            Distance "
               (AB)1                               8.66
               (AB)2                              15.00
               (AB)3                              19.36
               (AB}4                              22.92
               (AB)5                              25.98
               (AB)6                              28.74
                AC 1                               8.66
                AC 2                              15.00
                AC 3                              19.36
                AC 4                              22.92
                AC 5                              25.98
                AC 6                             .28.94
3.   During Sampling
            Point
              1
              2
              3
              4
              5
              6
              7
              8
              9
             10
             11
             12
Probe distance
   In Stack

    41.55
    36.69
    37.75
    35.72
    33.54
    31.22
    31.22
    33.54
    35.72
    37.75
    39.69
    41.55
Probe must Intersect
  the line at the
  following points
       AC 6
       AC 5
       AC 4
       AC 3
       AC 2
       AC1
       AB1
       AB 2
       AB 3
       AB4
       AB 5
       AB 6
 Figure 34.   Slag  tapping  fugitive  emission  duct
                 traverse point location procedure.
                               117

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          SLAG TAPPING FUGITIVE
          EMISSION SYSTEM
      SAMPLING POSITION
         !HOODS
REACTOR
      	I HOODS


       SAMPLING POSITION
         MATTE TAPPING FUGITIVE
         EMISSION SYSTEM
                                                      STACK
 Figure 35.  Plant schematic -  The matte  tapping and
             slag tapping fugitive emission system.
                        118

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                                       TRAVERSE POINT LOCATIONS
60"
TRA-
VERSE
POINT
LOCA-
TIONS
1
2
3
4
5
6
7
8
9
10
11
12
FRACTION OF
STACK I.6.
.021
.067
.118
.177
.250
.356
.644
.750
.823
.882
.933
.979
DISTANCE
FROM INSIDE
WALL (IN)
1.28
4.02
7.09
10.64
15.00
21.34
saee
45.00
49.36
52.91
55.98
58.72
                                                 FROM
                                                 CONVERTER HOODING
                                                 SYSTEM
            ACID PLANT INLET
              Figure 36.  Acid plant  inlet.
                           119

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TRAVERSE
POINT
1
2
3
4
5
6
FRACTION OF
DUCT I.D.
.044
.146
.296
.704
.854
.956
DISTANCE
FROM INSIDE
WALL (IN)
1.66
5.56
11.24
26.76
32.44
36.34
T
38"
1
• 4
• 4
• 4
• 4
• . <

.
» • 4
» • 4
» • 4
> 4> <
» • 4
....... R1" ..

» • •
» • •
> • •
» • •
> • •
» • •
1

                    t
                TO ACID PLANT
         O   no    OOP
SAMPLING PORTS
           FROM CONVERTER HOODING



                  SIDE VIEW

                Figure 37.  Converter fugitive emission system.
                                  120

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      CONVERTER FUGITIVE EMISSION DUCT
t
                            SAMPLING
                            POSITION
               ACID PLANT INLET DUCT
o
           HOODS
         CONVERTER
                                            TO
                                            STACK
                                                     ACID
                                                     PLANT
                                                     INLET
 Figure 38.   Plant schematic - converter fugitive
             emission system.
                      121

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88"
                                             TRAVERSE POINT LOCATIONS
      TOP OF STACK
           t
            T
                       TRA-
                       VERSE
                       POINT
                       LOCA-
                       TIONS

                         1
                         2
                         3
                         4
                         5
                         6
                                                 FRACTION OF
                                                 STACK I.D.
..044
 .146
 .296
 .704
 .854
 .956
               DISTANCE
               FROM INSIDE
               WALL (IN)
 3.75
12.59
25.45
60.55
73.41
82.25
                                           CONCENTRATE DRYER STACK
      FROM
CONCENTRATE DRYERS
                 Figure 39.  Concentrate dryer stack.
                                 122

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                                                    SAMPLING
                                                    POSITION
CONCENTRATE
DRYERS
                              CYCLONE
  WET

SCRUBBER
                                                             STACK
                  Figure  40.  Plant schematic - Concentrate
                             dryer fugitive emission system,
                                123

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                                 SECTION 4

                     SAMPLING AND ANALYTICAL PROCEDURE
SAMPLING
     The sampling train used in this testing program consists  of a  modified
EPA method 5 train (Figure 41).  The trains used consisted of  a seven
impinger system with 150 ml of deionzed water in each of the first  two
impingers, an empty third impinger to minimize carry over, and a forth,
fifth and sixth impinger with 150 ml of 10% hydrogen peroxide  in each.
The last impinger contained silica gel.

     The sampling procedure was identical  to that used in method 5, the
sample being collected isokinetically at the centers of equal  area  within
the duct.

SAMPLE RECOVERY

     The sampling nozzle and probe liner were rinsed with 0.1  N NaOH and
brushed with a nylon bristle brush.  The filter and impingers  were  then
removed to the mobile laboratory.  The front half of the glass filter holder
was also rinsed and brushed with 0.1 N NaOH and that rinse was combined with
that of the probe and nozzle.  The filter was then recovered from the holder
and placed in a polyethylene container, labeled and sealed. The contents  of
the first two impingers were placed in a graduated cylinder and the volume
recorded.  The impingers and connecting glassware were then rinsed  with
0.1 N NaOH and the rinse combined with the impinger contents in a glass
sample bottle.  During the test programs at Asarco in El  Paso  and Phelps-
Dodge in Ajo and Douglas, Arizona the third impinger was rinsed separately
and put in a glass sample bottle.  Subsequent analysis of this rinse for
arsenic showed no significant amount present and this part of  the recovery
was abandoned.  During the test program at Asarco in Tacoma, Washington, a
rinse of the probe and first and second impingers with 15% HNO^ was applied
to selected tests at the direction of the EPA project officer  in order to
determine the effectiveness of the 0.1 N NaOH rinse.  The contents  fourth,
fifth, and sixth impingers were measured and the contents combined  in glass
sample bottles for later S02 analysis.
ANALYSIS
         filter - The filter was placed in a 150 ml  beaker and 50 ml  of 0.1  N
         NaOH was added and allowed to warm for about 15 minutes.  Ten  ml  of
         concentrated HNO? was added and brought to  a boil  for 15 minutes.
         The mixture was then filtered through #41 Whatman paper, washed
         with hot water and the filtrate returned to the hot plate to evaporate.

                                    124

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    When the solution was evaporated the beaker was  removed from the hot
    plate and allowed to cool.   0.1  N HMOs was used  to redissolve the .
    residue and solution transfered  to a 50 ml volumetric flask and
    diluted to volume.  Many of the  filters collected only small  amounts
    of arsenic and the entire volume was needed in the previous analysis
    for arsenic by hydride evolution and were thus lost for purposes of
    lead analysis.

2.  Probe Wash and Impinger Solutions - Fifty ml  of  probe wash or impinger
    solution was placed in a 150 ml  beaker.  Two ml  of concentrated
    HNOs is added and the beaker was placed on the hot plate and
    allowed to evaporate,,  When evaporation was complete the beaker was
    allowed to cool  and the residue  redissolved with 0.1  N HN03 and
    transfered to a'50 ml volumetric flask and diluted to volume.

3.  Process Samples  - About 0.2 grams of sample was  weighed into a
    tarred 150 ml teflon beaker and  the weight recorded to the nearest
    0.1 mg.  Five ml  of concentrated HNOs and 5 ml of concentrated
    HF were added and the beaker placed on grating just above the hot
    plate to prevent overheating of  the teflon.  The solution was
    evaporated and the digestion was repeated until  a light-colored
    residue appeared.  The residue was redissolved in 0.1 N HMOs and
    transfered to a  50 ml volumetric flask and diluted to volume.

4.  Atomic Absorption - The analysis was performed with an Instrumen-
    tation Laboratories model 551 Atomic Absorption  Spectrophotometer
    equipped with a  model 555 graphite atomizer for  samples below 0.1
    ppm lead.  The analysis was performed at the 217 nm lead resonance
    using a 1 nm bandpass and a 5 milliamp current to the lead hollow
    cathode lamp.  Samples with a concentration above 0.1 ppm lead
    were analyzed using an air/acetylene flame.  Samples below 0.1 ppm
    lead were analyzed using the graphite furnace atomizer.
                               125

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                                                               12
                                                     17
              Figure 41.  EPA method 5 particulate sampling  train
 1.    Calibrated Nozzle
 2.    Heated Probe
 3.    Reverse Type Pi tot
 4.    Cyclone Assembly
 5.    Filter Holder
 6.    Heated Box
 7.    Ice Bath
 8.    Impinger - (Water)
 9.    Impinger - (Water)
10.    Impinger - (Water)
11.    Impinger - (Silica Gel)
KEY
 12.    Thermometer
 13.    Check Valve
 14.    Vacuum Line
 15.    Vacuum Gauge
 16.    Main Valve
 17.    Air Tight Pump
 18.    ByPass Valve
 19.    Dry Test Meter
 20.    Orifice
 21.    Pi tot Manometer
 22.    Thermometer
                                  126

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