SUMMARY OF TECHNICAL DATA
RELATED TO FUGITIVE EMISSIONS OF
LEAD, ARSENIC, COPPER AND SULFUR DIOXIDE
FROM THE 16 U.S. COPPER SMELTERS
by
Manuel Gomez
Richard Duffy
Vincent Trivelli
INFORM
25 Broad Street
New York, N.Y. 10004
Order # D0773NANT
Prepared for:
U.S. Environmental Protection Agency (D0773)
Research Triangle Park, N.C. 27711
Attn: Stanton Coerr
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CONTENTS
I. Introduction and Methodology
II. Fact Sheets
A. ARCO, Anaconda
B. ASARCO, El Paso
C. ASARCO, Hayden
D. ASARCO, Tacoma
E. Cities Service, Copperhill
F. Copper Range, White Pine
G. Inspiration Consolidated Copper, Inspiration
H. Kennecott Copper, Garfield
I. Kennecott Copper, Hayden
J. Kennecott Copper, Hurley
K. Kennecott Copper, McGill
L. Newmont Mining, San Manuel
M. Phelps Dodge, Ajo
N. Phelps Dodge, Douglas
O. Phelps Dodge, Morenci
P. Phelps Dodge, Hidalgo
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INTRODUCTION AND METHODOLOGY
This report presents a summary of the technical data which INFORM
has gathered and analyzed over the past three years related to fugitive
emissions from the sixteen domestic primary copper smelters.
Basic information on the nature of the process used at each smelter
was obtained primarily from published materials (company publications,
journal articles, EPA reports, papers presented at professional conferences,
etc.), from site visits by INFORM personnel, from inspection reports
prepared by the U.S. Occupational Safety and Health Administration on
file at the agency's area offices, from interviews with workers, and from
companies cooperating with the INFORM study (Anaconda, ASARCO and
Copper Range).
The data on the effectiveness of fugitive emission controls, in particular
in-plant monitoring and personnel sampling data, was gathered primarily
from the following sources:
(1) Regulatory agency inspection reports. These include reports
- obtained from U.S. Occupational Safety and Health Adminis-
tration Area Offices, from OSHA state plan designees, such
as the Washington Industrial Safety and Health Administration,
from other relevant state safety and health agencies, such as
the Arizona Office of the State Mine Inspector, and from the
U.S. Mining Enforcement and Safety Administration. (See
complete list of these agencies following this section.)
(2) Surveys sponsored by the National Institute for Occupational
Safety and Health.
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(3) Company data and expert testimony presented at
U.S. OSHA hearings on the agency's proposed
V
arsenic standard (held during 1975-76) and on the
proposed sulfur dioxide standard (held during 1977).
(4) Data supplied directly to INFORM by companies
cooperating with the INFORM study (Anaconda,
ASARCO, Copper Range).
Information on corporate programs and policies relating to these
hazards was gathered primarily through interviews with workers and
union officials, from the arsenic and sulfur dioxide hearings cited above,
and from company management in the companies cooperating with the
INFORM study.
The "Fact Sheets" on each smelter which follow were prepared at
various dates between January, 1978 and November, 1978. They
incorporated the most up-to-date information available from the above
sources, as of the date of their preparation.
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REGULATORY AGENCIES
FROM WHICH
SMELTER INSPECTION DATA WAS OBTAINED
Arizona
U.S. OSHA Phoenix Area Office
Office of the State Mine Inspector, Phoenix Office
New Mexico
U.S. OSHA, Albuquerque Area Office
Environmental Improvement Agency, Santa Fe
Nevada
U.S. OSHA, Carson City Area Office
Nevada Industrial Commission, Carson City
U.S. MESA (presently MSHA)
State Mine Inspector, Carson City
Montana
U.S. OSHA, Billings Area Office
Michigan
U.S. OSHA, Detroit Area Office
Michigan Department of Labor, Lansing
Michigan Department of Public Health, Lansing
Tennessee
Tennessee Department of Labor, Nashville
Tennessee Department of Public Health, Nashville
U.S. OSHA, Nashville Area Office
Utah
U.S. OSHA, Salt Lake City
Utah Industrial Commission, Salt Lake City
Washington
U.S. OSHA, Bellevue Area Office
Department of Labor and Industries, Olympia
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FACT SHEET
FACILITY: The Anaconda Reduction Works
COMPANY: ARCO, Inc.
INFORM
25 Broad Street
New York City
10004
(212) 425-3550
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page 1
GENERAL
Name: Anaconda Reduction Works
Location : Anconda, Montana
Description:
1)
2)
3)
4)
5)
6)
Combination of receiving facilities, fluo-solids reactor, electric
furnace, converters (3 operating), anode furnaces (4), casting
wheels (2), and supportive facilities.
Present feed structure is 60% Weed, 30% Twin Buttes, and 10%
precipitates. Yerington and Britania have been shut down.
Considerable future production from Carr Fork will reduce the
average arsenic content of the smelter feed. Arsenic content
estimated at 0.97% , lead content estimated at 0.28%.
Reserves are estimated at 800 million tons.
1,300 employees (approximately in-copper production). Payroll
approximately $28 million.
Plant is main source of tax revenue, and principal purchaser of fuel,
power, freight, and supplies in Anaconda area.
Production
1972
1973
1974
1975
1976
1977
Anode Copper
Sulfuric Acid
242,955
208,110
197,543
91,000
193,000
108,000
185,000
84,000
Comments:
PROCESS AND HAZARDS—SMELTER
NOTE: Throughout the following remarks, the phrase "poorly characterized"
or "uncharacterized" is used to indicate that we have found no evidence that
either the company or the regulatory agencies have sufficiently characterized
the exposures to permit proper evaluation and corrective action.
NOTE: All documented arsenic exposures are expressed in terms of OSHA's
new 10 yg/m3 standard. Copper dust exposures are expressed in terms of
OSHA's 1 mg/m3 standard. Lead exposures are expressed in terms of OSHA's
.1 mg/m3 standard (to be promulgated October 1978). Sulfur dioxide exposures
are expressed in terms of OSHA's proposed 2 ppm standard. Noise exposures
are expressed in terms of OSHA's 90 dBA standard.
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page
NOTE: In most areas of the plant, workers wear company-supplied and main-
tained respirators on a need basis. The following comments evaluate TWA
exposures independent of respirator usage.
A. Material Handling Areas ( workers)
1. Process materials—concentrate slurries, dry concentrates, and pre-
cipitates are received, weighed, sampled, blended and stored in the
smelter's material handling areas. Slurried concentrates are received
by rail, unloaded and pumped to thickening tanks. Dry concentrates
are received by rail, unloaded at one of two unloading facilities, and
transferred to roaster bins for storage. Additional dry concentrates
are stored in an outside storage area—Coal Pile—until needed. The
dry concentrates are then fed into a repulping system and mixed with
the slurried concentrates and additional water to form a pulp, which
is then pumped to surge tanks prior to transfer to the fluo-solids
reactor.
a. Dry Concentrate Unloading ( workers)— Car shaker find
air lance use create visible dust and high noise levels during
railroad car unloading. Arsenic exposures ranging from
slightly above to 20 times the standard. Potential copper and
lead dusts are poorly characterized. Noise levels exceeding
115 dBA reported during shaker operation; company requires
mandatory use of hearing protection. Operator booth for noise
control has been reported impractical during unloading opera-
tions .
- b. Roaster #2 (storage bins and transfer areas) (_2JL workers)--
Documented arsenic exposures ranging from the standard 1o
18 times the standard. Copper dust documented ranging from
slightly above to 11 times the standard. Lead dust exposures
slightly above the proposed standard. Company has reported
that engineering controls in this area—hoods on all bins and
belt transfer points, fresh air booth and rest station, and n
centralized vacuum system—have substantially reduced dust
exposures; however, intermittent exposures require mandatory
respirator use throughout this area.
c. Slurried Concentrate Unloading and Handling (jy__ workers)--
Exposures in this area uncharacterized. All materials are wot,
reducing potential dust exposures. However, spills can dry
on floors and eventually become airborne causing potential
worker exposure.
2. Flux materials—limestone and silica rock—are also used in the smelting
process. Crushed and sized limestone is purchased from a nearby
quarry, received by rail, and treated in the smelter's lime plant for
use in the smelting process and to produce milk of lime (calcium hy-
droxide) for use in the concentrating process and for pollution con
trol at various Anaconda operations. Silica rock—for use in the con-
verting process—is purchased from another quarry near the smelter
site. The company also purchases some concentrates with high silica
content, thus precluding the need for silica flux in the electric fur-
nace process.
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page 3
a. Potential exposures to lime dust, free silica, and calcium
hydroxide mist in the flux handling and treatment areas,
and during transfer, are uncharacterized. ( workers)
Comments:
B. Fluo-Solids Reactor Area (60 workers)
1. The blended slurried concentrates are pumped to a distributor tank
located at the top of the fluo-solids reactor. This feed is then dis-
tributed through air-aspirated feed guns into the reactor's roasting
zone. Fluxes are fed into the same area through a series of bins,
conveyors, and a sealed screw conveyor. Preheated air is introduced
under pressure through the reactor floor where it reacts with the feed
materials to produce calcine and sulfur dioxide. Most of the calcines
leave the reactor entrained in the offgas stream and are collected in
primary and secondary cyclones, from which they are removed by
screw conveyors which discharge into drag flight conveyors that feed
the electric furnace. Some of the, calcines are discharged from the
reactor through two bed overflow valves directly into the drag-flight
conveyors.
2. While the reactor operation is enclosed, the operation is under pres^
sure and seal leakage occurs intermittently. There have also been
problems with the cyclone seals which on occasion "blow out," releas-
ing dust and fumes into adjacent areas. Workers in this area are also
potentially exposed to fugitive emissions from the electric furnace,
since the reactor is located adjacent to the furnace and in the same
building.
3. Number of workers in this area and their respective duties are un-
known. Company reports average sulfur dioxide & arsenic exposures
above current standards.
Comments:
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page 4
C. Electric Furnace Area ( ^Q workers)
1. Upper Furnace Levels
a. Feed Levels (drag flight conveyor and slag launder/furnace roof
levels)— Calcines from the reactor, as well as recycled flue dust,
molten converter slag, and cold slag accretions from the converters
and ladles, serve as feed for the electric furnace. Calcines and
flue dust are fed to the furnace through multiple discharge points
along the length of two parallel drag-flight conveyors located /
above the furnace. Converter slag is introduced into the furnace
through two converter slag launders located at the converter aisle
end of the furnace. The revertable slag—converter accretions,
skulls, etc.—is loaded into portable hoppers, which are then
placed directly over chutes located along one side of the furnace.
b. Paste and Storage Levels— The uppermost level of the electric
furnace is used for storage—i.e., electrode paste. Just below the
storage level is the paste level, where paste is added to the six
electrodes—daily, usually during each afternoon shift.
c. Worker exposures in upper furnace levels:
1) Documented arsenic exposures ranging three to seven times
the standard. Copper dust exposures documented at slightly
above the standard to greater than eight times the standard.
Documented lead exposures twice the proposed standard.
2) The company reported that it has identified the sources that
were contributing to dust exposures in this area and is now
in the process of implementing engineering and administrative
controls to reduce these exposures. Extent and effectiveness
of controls are unknown.
3) Company reported sulfur dioxide levels ranging from greater
than twice to twenty times the proposed standard. Peak
levels up to 100 ppm.
4) Engineering attempts presently being implemented may reduce
some of the sulfur dioxide emission points and resulting
worker exposures; however, it has been reported that con-
verter aisle fugitive emissions drift into electric furnace
building and contribute to worker exposures in this area.
5) Potential aromatic hydrocarbon exposures, resulting from the
"baking" of the electrodes, and subsequent leakage around the
electrodes' seals.
2. Tapping Areas
a. Matte Tapping— Matte is tapped from the converter aisle end of
the furnace into ladles located underneath the tapping floor in a
semi-enclosure (short tunnel). After ladle is full, it is pulled out
of this area into the center of the converter aisle, where it is
picked up by an overhead bridge crane. Doghouse hoods cover
the matte tapping points for collecting the gaseous and particulate
fugitive emissions during tapping operations. The matte launders
are covered.
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page 5
1) Documented arsenic levels of 1,500 to 2,100 ug/m . Company
reoorts oersonal TWA arsenic exposures uncharacterized of 87
2) It has been noted that the matte tapper gets his head in heavy
smoke when checking the level of the ladles. Documented sul-
fur levels of 45 ppm. Personal TWA exposures are uncharacter-
ized.
3) Other potential exposures—i.e., lead—are uncharacterized.
Slag Tapping— Slag is tapped in one of two tapping bays located
on the opposite ends of the furnace. This operation utilizes rubber-
tired slag pot carriers which accept the slag directly from the
furnace. The slag is then transported to a disposal area. Similar
to the matte area, the tapping points are hooded by doghouses and
the launders are covered.
1) Personal TWA arsenic exposures are poorly characterized. One
three-hour level of 10 times the standard has been documented.
2) Sulfur dioxide and other potential exposures—i.e., lead—are
uncharacterized.
Comments:
D. Converter Area ( 59 workers)
1. Matte from the electric furnace is transferred to one of three Peirce-
Smith converters. Silica is added to the converters to form an iron
silicate slag which is returned to the electric furnace for additional
processing. The current practice is to have two converters operating
with the other one on hold. There are three additional converters in
the converter aisle; however, they are no longer used. All converters
have primary water-cooled hoods which capture the off gases and vent
them to the plant's baghouse. At the completion of the converter
cycle, blister copper is transferred to the anode area by overhead
crane.
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page 6
a. A consultant assisting Anaconda in a survey of potential arsenic
problem areas after the start-up of the electric furnace stated that
the arsenic and sulfur dioxide levels in the converter aisle would not
change after the elimination of the reverberatory furnaces. During
the OSHA Arsenic Hearings the company reported average arsenic
exposures in the converter area at almost five times the standard
with arsenic area levels of up to 2,194 pg/m^. The company recently
reported that converter1 employees' arsenic exposures ranged up to
twice the standard.
b. OSHA found high sulfur dioxide levels (35-40 ppm) that intermit-
tently occur and cause converter employee eye irritation. In 1978,
the company reported that converter employees' exposures ranged
up to 1£ times the proposed standard.
2. Crane cabs are under positive pressure and air conditioned. A worker
reported that the company wanted cranemen to work with respirators
when air conditioning failed. Complaints about crane cab conditions are
still heard during Joint Safety and Health Committee meetings.
3. Skimmer— Documented arsenic exposures of five to seven times the
standard and very high episodic levels of sulfur dioxide prior to the
insulating of the skimmer shacks and fitting them with positive-pressure
fans and duct heaters. Effectiveness of these controls is unknown.
4. Puncher— Documented noise exposures of 1^ times the standard with
intermittent noise levels exceeding 115 dBA prior to the installation of
insulated soundproof punching cabs on the active converters. Effec-
tiveness of these controls is unknown.
5. Potential exposures of arsenic, lead, and copper dusts, and sulfur
dioxide to converter aisle employees—ladle chasers, cat operator, etc.—
from converter aisle activities—skull breaking, cleaning of aisle with
bulldozer, ladle emissions, etc.—are poorly characterized.
Comments:
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page 7
E. Anode Casting Area (35 workers)
1. Overhead bridge cranes transfer the blister copper from the converters
to one of four anode furnaces, the refining cycle—oxidation and re-
duction (using natural gas)—usually takes- four hours, after which the
anode copper is cast on one of two casting wheels, each containing 26
anode molds. Gases emitted by the anode furnaces are not captured,
but are vented directly into the building. A fume exhaust system,
which encloses the new airless spray system—used to cool the anodes
on the casting wheels—collects gases, vapors, and particulate emis-
sions . These emissions are exhausted via a stack through the building
roof line to the atmosphere. After cooling,the anodes are placed into
rack cars and shipped to Anaconda's Great Falls Refinery for electro-
lytic refining.
a. Documented arsenic exposures ranging from slightly above to 10
times the standard.
b. The company recently reported sulfur dioxide exposures below the
proposed standard. During the 1977 OSHA Sulfur Dioxide hearings,
employee exposures were reported ranging from at to three times
the proposed standard.
c. After a 1975 OSHA noise citation, the company installed soundproof
pourer's booths equipped with electric heaters, ventilating fans,
and air conditioners. In addition, the open furnace burners were
converted to a closed type and the moldwash sprayers were con-
verted to an airless spray- Present noise exposures are reported
at the standard.
d. Poling generates "black smoke-"-unburned hydrocarbons—which is
released uncollected into the anode area. Worker exposures, if
any, are uncharacterized. It is unknown whether the company has
reduced the amount of unburned hydrocarbons by mixing air with
the reducing gas in the tuyeres.
e. Potential heat exposures are uncharacterized.
Comments:
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page
F. Baghouse (14 Workers)
1. A new particulate control facility that incorporates a baghouse was
installed to replace the plant's old Cottrell units. Major components of
this facility include two spray chambers to. cool the offgases, three
centrifugal fans, and an eighteen-chamber baghouse. After cleaning,
the gases are routed to the main stack or to the acid plant. Dust col-
lected in this facility is either returned to the electric furnace by screw
conveyor—to lower the furnace's roof temperature and to reduce the
rapidity of gasing in the furnace—or dumped. The dusts that are
dumped are first transferred to ventilated tanks where lime is added to
fixate the arsenic and then pumped to a retention pond where it is
stockpiled.
a. Arsenic exposures reported ranging from at to 47 times the stand-
ard. Area levels of up to 1,570 yg/m3 have been documented.*
b. Sulfur dioxide levels of up to 300 ppm have been reported, per-
sonal TWA exposures are poorly characterized.
c. Lead exposures have been reported from slightly above to seven
times the proposed standard.*
c. Cadmium exposures have been documented ranging from above to
twice the standard recommendec by the National Institute for Occu-
pational Safety and Health (NIOSH).*
Comments:
*Many exposures documented in the baghouse area were for employees who
carried out repair tasks in the area and only worked there intermittently-
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page 9
G. Acid Plant (16 Workers)
1. A single contact 660 ton per day sulfuric acid plant was enlarged to a
990 tons per day double contact plant in 1977. The company now in-
tends to add an additional plant to increase air pollution control.
a. Data on worker exposures in this area was not available to
INFORM. Hazardous exposures have been reported in acid plant
areas at other copper smelters.
Comments:
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page 10
COMPANY SAFETY AND HEALTH ACTIVITIES
A. History
1. Anaconda's Industrial Hygiene Department was first formed in 1943 and
remained at the smelter until 1958 when operations were switched to
the Butte Environmental Department. Industrial hygiene operations
were reorganized in 1969 under the Department of Environmental Af-
fairs. Since the ARCO takeover of Anaconda operations, industrial
hygiene activities were established at the corporate level under the
auspices of the Vice President of Environment, Health, and Technology.
At the smelter the program is overseen by the Director of Industrial
Health and Safety. In addition, the Industrial Health and Safety
Program is completely independent of the plant's environmental pro-
gram.
2. History of Anaconda's Safety Program not available to INFORM.
B. Staff (smelter)
1. Director of Industrial Health and Safety
a. Industrial Health Staff
1) Industrial Hygiene Engineer
2) Industrial Hygiene Technician
3) Respirator cleaning and maintenance (3)
b. Safety Staff
1) Safety Engineers (2)
C. Industrial Hygiene Activities
1. Environmental (inplant) Sampling
a. Until recently, personal sampling was performed on a "rule of
thumb" basis, basically in high risk areas such as the baghouse.
A routine sampling schedule has recently been implemented as a
result of regulatory actions—i.e. , new arsenic standard. The
company has recently completed a comprehensive sampling protocol
of all job categories at the smelter, even workers in outlying areas
where exposures were not thought to occur in the past. After
documentation of each job category's exposures, the company ex-
pects to adhere to the required sampling provisions as provided
for in the new arsenic standard. Air contaminants monitored for
include arsenic, sulfur dioxide, copper, lead, and cadmium.
b. Area sampling has been performed in many areas of the plant to
evaluate control approaches—i.e. , concentrate blending area and
electric furnace.
c. All area and personal samples collected at the plant are sent to
Anaconda's industrial hygiene lab in Tucson, Arizona. This
laboratory was certified by the American Industrial Hygiene Asso-
ciation in February, 1977.
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page 11
2. Noise Sampling
a. The company performs, on an annual basis, both area level (sound
level meters) and personal (dosimeters) noise sampling surveys.
3. Ventilation and engineering control systems are checked by the plant
engineering maintenance crews and environmental engineering techni-
cians on an "as needed" basis.
4. No formal reports or education are given to workers regarding the
need, objectives, and results of industrial hygiene activities.
Comments:
D. Respirator Program
1. Training, education, and supervision of respirator is the responsibility
of the Director of Health and Safety.
2. All workers are assigned and fitted with their own respirators accord-
ing to the hazards present in their work area. Respirators are worn
on an as needed basis, except in designated mandatory-use areas.
3. All workers at the plant have received extensive respirator training
which includes viewing of a film produced at the plant, and individual
fitting/leak testing of each respirator-
4. Workers in the smelting areas of the plant are furnished with a clean,
individually marked respirator at the beginning of each work shift.
Other workers are issued unmarked respirators which can be ex-
changed any time cleaning or maintenance is required.
E. Safety Activities
1. Plant safety engineers conduct routine inspections (monthly, bi-
monthly, annually) of the plant, in addition to those performed by the
Joint Safety and Health Committee. No specific checklists are used.
Results of inspections are prepared in memorandum format.
2. Accident investigations, for all compensated accidents, ambulance
calls, fatalities, and near misses with potential serious injury are con-
ducted jointly by the company and the union. In all cases, written re-
ports are prepared and a copy is forwarded to the union in memorandum
format.
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page 12
3. New employees are instructed as to the safety aspects, the associated
hazards, and the proper safety practices of their particular job
through an indoctrination orientation. After initial orientation, the
worker is assigned to work with an experienced worker. The length
of training period is dependent on the hazard of the job.
4. Formal safety refresher courses for all employees are not available.
5. Safety and health implications of new equipment and/or process
changes are first discussed with Joint Safety and Health Committee.
Safety training is then provided for those employees involved with the
change /addition.
6. Accident frequency rates are computed by prescribed MESA methods
(adopted from American National Standards Institute [ANSI] methods).
These rates were not available to INFORM.
7. OSHA 102 data is available for 1973 through 1976.
8. Identification of accident factors is a normal part of the plant's safety
program; however, these efforts have not resulted in any publicly
available findings.
9. Yearly estimated cost of the plant's safety program—labor and equip-
ment—was $360,000 in 1977.
10. Company reports that they are not engaged in any formal system of
safety information exchange outside the company.
Comments:
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page 13
F. Health Care
1. Smelter complex has its own onsite clinic which is staffed by four
Industrial Medics—enabling 24-hours-per-day availability.
2. All serious injuries and illnesses are treated at Anaconda Community
Hospital--a 60-bed facility—located two miles from smelter. Ambulance
is'avaHable at smelter site.
3. Emergency medical equipment—first aid/burn kits, stretchers—are
located at various locations throughout the smelter.
4. All employees receive pre-employment medical and audiometric exams
as required by Montana state law.
5. Annual audiometric exams are given all employees. Evaluation of
these tests is performed by a local otologist.
6. Until recently, company only provided annual physicals for baghouse
employees and those exposed to asbestos. While the company paid for
the examination—no company physicians at the plant—they were only
available to the employees on their own time. Company also provided
urine analyses (arsenic) for every person who is monitored for
arsenic exposure.
7. A new medical screening program--including chest x-ray, sputum
cytology, pulmonary function, and blood and urinary analysis for
heavy metals—was recently made available, on a voluntary basis, to
all plant employees. Results of the exams will only be available to the
individual worker; company officials will not receive the results of
these individual tests. These exams were performed by an independent
medical consulting firm—Tabershaw Occupational Medicine Associates.
After completion of and analysis of all the workers' examinations, the
consulting firm will report to the company any trends that management
should address. The company presently plans to make this screening
program available on an annual basis.
8, Until the above program was implimented, there was no evidence of a
formal education program regarding the need, objectives, and results
i of medical activities.
9. Epidemiological and medical research studies have been performed at
the Anaconda smelter. These studies have included the Lee and Frau-
meni study, a University of Utah study of Sputum cytology testing and
a study of smelter workers' urinary arsenic levels.
Comments:
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page 14
SAFETY AND HEALTH COMMITTEE I
i
A. The Joint Safety and Health Committee was established in compliance with
contract provisions in 1971. i,
B. Committee includes five management representatives and five union repre-
sentatives. One member from each group serves as a co-chairman for a
one-year period.
i
C. Committee meets once a month to discuss safety and health! conditions and
to make recommendations for corrective action. Inspection tours are con-
ducted if any member so requests. A written report ;(minutes) is prepared
at the conclusion of the meeting by the company and forwarded to all com-
mittee members and the union.
D. Other safety and health topics may be discussed, such as any new process
changes and/or additions. The union also uses the committee to air any
safety and health complaints. !
E. The safety and health provisions of the union contract address other
matters, such as : '
f
1. Right to refuse unsafe work. Specific procedures for handling dis-
puted cases have been incorporated into the contract.
2. Right of the International to enter areas of the plant if any dispute
arises over safety and health issues,
3. Right to retain wage rates if worker is forced to change jobs as a
result of toxic substance exposures.
F. There is no company policy which would allow the union to review the
results of the company's industrial hygiene monitoring.
Comments:
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page 15
REGULATORY HISTORY I
i
A. Pre-1970 jj
1. Safety
a. Industrial Accident Board
1) Smelters designated as hazardous workplace, 1961.
No inspection records available to INFORM. i
I
2. Health
a. Montana State Department of Health
i
1) 1943 established methods of determining ^nd monitoring air
contaminants. i
2) Periodic monitoring of Anaconda Reduction Works re:
arsenic, lead, zinc, sulfur dioxide, etc., beginning in 1943
—inspections on file at INFORM. <
3) Passed statutory inspection provision for Industrial Hygiene,
1967. {
B. Post-1970 ;
1. Safety
a. Bureau of Safety and Health, Division of Workers' Compensation
1) Drafted OSHA State Plan
2) State never passed enabling legislation; plan withdrawn
6/30/74.
3) No longer inspect.
2. Health
a. Department of Health and Environmental Sciences
1) 1971 passed comprehensive occupational health regulations
and standards.
2) Bureau of Occupational Health presently answers complaints
and requests.
C. OSHA Activities
1. Sole jurisdiction over state occupational safety and health activities
2. Inspections (see Table 3)
Comments:
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PROCESS EQUIPMENT—Anaconda
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Fluo-Solid Reactor
1975
1° + 2° Cyclones -> Spray Chamber
Baghouse ->- Acid Plant or Stack
Electric Furnace
1975
Balloon Flue ->• Spray Chamber
Baghouse -> Acid Plant or Stack
Matte and slag tap hoods (dog-
houses) . Semi-enclosed matte
ladle bay.
Converters
(6-- 3 active)
3 - 1941 Primary Hoods -> Balloon Flue ->
1 - 1968 Spray Chamber-Baghouse ->
2 - 1972 Acid Plant or Main Stack
Skimmer booths enclosed,
Punching cabs enclosed.
Refining Furnaces
(4)
2 - 1941 Furnace off gases not collected
2 - 1972 vented through roof monitor.
Closed-type burners.
Casting Wheels
(2)
Fume exhaust system which encloses
airless spray—cools anodes and
collects gases, vapors, and particulate
emissions
Enclosed pourers booths,
Baghouse
1976
Collected dusts returned to
furnace or mixed with lime and
-dumped.
Acid Plant
Enlarged
in 1976
No controls needed.
Presently controls 35% of total
sulfur input.
oq
to
-------
SUMMARY OF HEALTH HAZARDS—Anaconda
Number of-,
Employees
PLANT AREA in Area
Dry Concentrate
Receiving & Handling
Slurried Concentrate
Receiving & Handling
Fluo-Solids Roaster/
Electric Furnace Area
Converter Area
Refining & Casting
Baghouse
Acid Plant
35
9
64
102
53
16
.9
TWA Exposures *
(area levels)
Copper
(mg/m3)
.25-11.8
9
10-210
1.21-8.29
.05-. 22
.06-. 8
.05-. 20
9
Arsenic
(yg/m3)
10-450
9
10-210
[30-2,100]
46
[up to 2,199]
11-100
10-470
[770-1,570]
9
Lead
(mg/m^)
.01-. 13
9
.03-. 24
.01-. 02
.005-. 05
.01-. 74
..^.. . ^,
Sulfur Noise
dioxide Levels
(ppm) (dBA) NOTES
5-39.4
[20-100]
.04-3
[35-40]
.1-5.7
[16]
[up to 300]
f\
109-
117
9
92
115
90
9
9
High dust exposures occur
intermittently (e.g., large
spills) . Mandatory respi-
rator use area.
Potential exposures from
spills (drying on floors) ,
return side of belts. Ex-
posures, if any .unknown.
Re-engineering partly un-
derway: feeding opera-
tions, flues, draft.
High exposures occurring
intermittently during repair
Exposures unknown
independent of respirator usage
SOURCES: Arsenic OSHA hearings 1975. Company data
Sulfur dioxide OSHA hearings 1975.
OSHA inspections
NIOSH surveys
State Department of Health Inspections
Company data
Co
crq
-------
OSHA INSPECTIONS--Anaconda
DATE
5/26-27/71
12/26/72 -
4/17/73
case com-
pleted
2/4/74
6/26/73
7/2/73
3/4-7/75
case com-
pleted
9/15/75
3/7-11/75
9/9/75 -
2/13/76
case com-
pleted
1/24/77
TYPE
complaint -
health
general
schedule -
health
complaint -
health
Follow-up
general
schedule -
safety
complaint -
health:
gases §
dusts
general
schedule -
health
FINDINGS
PENALTIES
FOLLOW-UP
NO SPECIFIC STANDARDS IN EFFECT AT THE TIME
19 non-
serious
violations
1 serious
violation
In Compliance
21 non-
serious
violations
In Compliance
4 w i 1 f u 1
6 repeated
9 serious
16 non-
serious
$235
Contested - "controls
not feasible" for
dust § noise
$800
NONE
$535 - contested.
1 citation vacated
2 reduced by $15
Final penalty —-$47-5
NONE
$45,055 - contested.
Final penalty
$28,645. Repeated
violations reduced
to non-serious .
NONE
As per terms $
conditions set
forth in settle-
ment, abatement
dates were ex-
tended.
Violation
abated 7/2/73
NONE
Violations
abated 9/15/75
NONE
Interim inspec-
tions as per
terms & conditions
set forth in
settlement .
COMMENTS
Cu, Pb, As dusts sampling;
noise; asbestos storage,
handling, monitoring.
Guardrails in crane areas.
No violations pertaining to
complaints which were for
excessive noise, SO , dusts,
§ fume .
Follow-up on crane
guardrails.
Various safety violations -
guardrails, shields, etc.
Cited for Cu, Pb , As dusts
greater than unity; respi-
rator violations; asbestos
storage, handling, ti
monitoring; noise.
to
oq
CD
-------
DATE
12/06/76
12/14-14/76
3/2/77
3/29/77
4/8/77
TYPE
Accident
Fatality
Complaint
Health
Complaint
Safety
Follow-
up of
3/2/77
Complaint
[accident]
Safety
FINDINGS
1 other
violation
1 other
violation
1 serious
and 8 other
violations
3 other
violations
PENALTIES
$140
$0
$280
$0
rULjljWH-Lir
Company sub-
mitted abate-
ment .
Company sub-
mitted abate-
ment.
OSHA follow-up
inspection.
Company sub-
mitted abat"e=
•- ~" Tnent.
Cited for failure to complete
a written engineering survey
prior to starting demoloition
work. CSHO concluded that
accidental death was due to
employee insubordination.
Cited for not providing PPE
to prevent occasional eye
irritation from SC>2 . Company
enclosed and ventilated skimmer
shacks .
Serious violation for not having
access gates in place on one of
the conveter cranes. Other
violations for various crane
violations including lack of
load markings, guardrails &
electriacal violations.
OSHA found all violations of
3/2/77 have been abated.
Accident occurred during rebuilc
of converter.— --Injury sustained
was a fracture and dislocation
.QfLbones in hand. Complaintee
stated that noone accompanied
him to first aid, poor procedure
to take care of injuried. Citec
for three scaffold violations.
0>
-------
9/19/77
11/3/77
Follow-up
Health of
9/9/75 [#7]
2 other
violations
$60
Company sub-
mitted abate-
ment.
Copper exposures in the belt
areas of Ro. #2 and Serpentix
building ranging between
1.9 to 11.8 mg/m3.
11/1/77
3/20/78
Complaint
Health
4 other
violations
$0
Unless PMA is
granted, all
violations are
to abated by
09/27/78
Citations for copper and lead
exposures. Area sampling for
arsenic [up to 2,100 ug/m3]-4
sulfur dioxide [up to 45.5 ppm
All sampling performed in
electric furnace dept., after
worker complaint stating that
electric furnace workers are
exposured to dusty, hot, gaseous
conditions.
12/22/77
Complaint
Health
No
violations
Worker complaint in re to
asbestos exposures in converter,
boiler, and reverb shops, compl-
aint was informal since worker
would not release his name.
CSHO found that physicals were
given to exposured employees(44)
air sampling was performed (with
in limits), areas were posted.
asbestos maFeriats—labeled, and
asbestos materials properly ;
-s.to.red. -- no violations
observed.
Oq
0>
to
o
-------
FACT SHEET
FACILITY: El Paso Copper Smelter
COMPANY: ASARCO, Inc.
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
I. GENERAL
Name: El Paso Copper Smelter
Location: El Paso, Texas
Description:
1) Custom non-ferrous smelter complex producing lead, zinc, copper and
cadmium. Facilities to extract autimony from a complex copper ore
will soon go into operation. INFORM has researched! only the copper
circuit of the complex. Copper has been smelted since 1916.
2) Copper concentrates are mostly from Arizona. Company reported in
communications to INFORM in 1977 that the arsenic content of the
copper feed is 0.01%. In mid-1975, a consultant retained by ASARCO
presented testimony of the OSHA arsenic hearinjgs which placed the
arsenic content at 0.20%. Lead content is reported by the company
at 0.4%. !
3) Entire operation involves 900 to 1,000 employees. Copper circuit
production employees number approximately 150, excluding the yard
gang and the ore unloading departments which are shared by the
different smelter processes.
4) Plant is located in a relatively large metropolitan area (population
MOO,000) with diverse sources of employment. , Smelter is an impor-
tant area employer^ but not the predominant one.'
i
5) Production ;
a) Approximately 30% of ASARCO's total copper production.
bj 1972 1973 1974 1975 1976
Copper
78,000
98,000
78,479
88,706
83,793
Comments:
II. PROCESS AND HAZARDS
NOTE: In most areas of the plant, workmen wear company-supplied respirators
The following comments refer to exposures independent of respirator usage.
NOTE: The El Paso area is subject to strong winds several months during the
year. Since many of the areas of the smelter are semi-open, exposures can
be seriously influenced by the windy conditions.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
[page 2,
A) Receiving and Bedding Areas
1) Concentrates are received in bottom-drop railrdad cars or unloaded
with clamshell buckets into grate and undergroiifnd belt conveyor.
Occasional exposures to excessive noise (R.R. car vibrators) and
dust. Potential arsenic and lead exposures. A report by an ASARCO
consultant in 1975 estimated the percentage of arsenic in pavement
dust to be 0.9%.
2) Concerete ore bins. Materials distributed by automjatic tripper con-
veyor into appropriate bins. Both lead and copper (concentrates are
housed in same building. Potential lead and arsenic exposure haz-
ards. High dust exposures occur particularly when men use air
lances in bins to dislodge concentrate for delivery to hoppers
below. Company reports plans to remodel entirfe receiving and bed-
ding areas, automating and enclosing much of the operation. Plans
are a response to local and state pressures to- control fugitive
emissions of particulates.
B) Roasters
1) Four wedge roasters.
2) Operating decks
a) Arsenic exposures documented in a range ten. times the
proposed standard. Sulfur dioxide exposures are variable
but in a range between the present and! the proposed stan-
dard. Dust exposures, if any, are poorly characterized.
b) Exposures occur from "puffs" that exceed the draft in the
roaster, from the need to use access doors on all decks for
maintenance and repair, and from emissions during loading
of larry cars.
3) Unloading areas--larry car
a) Calcine is discharged at 1,000° F.
b) Company reports a "ventilation tunnel" for the loading area
is in operation.
c) Larry cars are not covered during rail transfer to top of
reverb, thus becoming an intermittent source of air contami-
nants .
d) Larry motorman has a very high documented exposure to sulfur
dioxide (four to five times the present standard). Excessive
arsenic exposures are almost certain, but they are not
available to INFORM. Dust and lead exposures are not char-
acterized.
e) Larry motorman exposures occur both in the roaster area and
above the reverbs while feeding calcine.
C) Reverb
1) One sprung-arch reverb furnace, charged with Wagstaff guns along the
sidewalks.
2) Slag is tapped into holding furnace, where residual copper settles
out. Tapping operation into slag cars from holding furnace is not
hooded.
-------
[page 3]
3) Matte tapping ports and launders are hooded and ventilated. Matte
ladle is exhausted with hinged hood while filling.
4) Compressed air is used for "blowing" the top of the furnace. No
vacuuming has been attempted. !•
5) Airborne arsenic levels in the entire area are eight to ten times
the proposed standard. Personal exposures for different job cate-
gories are probably characterized by the company, but not available
to INFORM. j
6) Sulfur dioxide levels in the charge deck area are 'reported variable
between 1 to 50 ppm. Personal exposures to sulfur dioxide in this
and other reverb areas are poorly characterized.
7) Copper dust and/or fume exposures are poorly characterized.
8) There are reported airborne lead levels in the| charge deck area in
the range of the proposed standard.
D) Converter Aisle
1) Three Pierce-Smith converters with primary water-cooled hoods.
2) Company presently building nearly complete enclosure around conver-
ter building. Together with roof fans and collection equipment,
however, these changes are in response to local and state pressures
to control fugitive emissions. Company statements indicate uncer-
tainty and some apprehension regarding the impjact of this enclosure
on workplace exposures. j
3) Zinc fuming furnace is in converter aisle area. It receives slag
from the lead circuit, containing zinc as well as lead. This fur-
nace is probably the main source of airborne lead in the converter
and reverb areas, although some copper matte from the lead blast
furnace is fed to the reverb and probably results in airborne lead
as well.
4) Arsenic exposures in the aisle average approximately ten times the
proposed standard. Personal exposures in different job categories
are probably characterized by company but not available to INFORM.
5) Sulfur dioxide exposures in the aisle and platforms are reported
close to the proposed standard. Exposures to cranemen are reported
in the same range.
6) Crane cabs are not enclosed and ventilated. Cranemen wear respira-
tors. Company reports plans to modify cabs.
7) Airborne lead levels reported to be around the proposed standard in
the platform area and around the present standard for cranemen.
8) Exposures to copper fumes are not characterized.
9) Converter punchers and skimmers are exposed to noise levels in
excess of the standard. Efforts to enclose the operator's cab were
made and abandoned. Company now reports steps to try out tuyere
mufflers.
-------
[page 4]
E) Anode Casting
1) Two anode furnaces, one casting wheel.
2) Company estimates arsenic levels to be two to iien times the proposed
standard. Personal exposures are not characterized.
3) Other potentially hazardous exposures are not characterized (e.g.,
heat, unburned hydrocarbons, burner noise).
F) Other Areas
1) Coarse and fine crushing areas. Very dusty conditions with ineffec-
tive engineering controls. I
2) Cadmium operation near the smelter, coupled with strong winds and
semi-open smelter areas may result in hazardous exposures to cadmium
in areas remote from actual handling. !
3) Dust handling from flues, baghouses and precipitators is in the
hands of outside crews, under contract, according to company hy-
gienist. Exposures are poorly characterized. : Company respirator
program requires supplied air for man entering baghouses during
operation. !
4) Exposures to other maintenance personnel have only recently begun to
be studied by the company. Details not availably to INFORM.
5) Exposures, if any, in the acid plant are not available to INFORM.
G) General
1) Potential engineering controls applicable to the El Paso smelter are
discussed in some detail in three documents which were introduced as
testimony at the arsenic and sulfur dioxide hearings. They are:
a) Testimony by Edwin S. Godsey of ASARCO at OSHA arsenic hear-
ings in 1975.
b) Feasibility and Cost Study prepared by Industrial Health
Engineering Associates, Inc., for ASARCO, and presented at
the OSHA arsenic hearings in 1975.
c) Feasibility and Cost Study prepared by Industrial Health
Engineering Associates, Inc., and presented at the OSHA
sulfur dioxide hearings in 1977.
INFORM may utilize these materials in its final smelter profile.
2) The El Paso smelter has been involved in a continuing controversy/
dialogue with city and state air pollution authorities in relation
to stack and fugitive emissions of heavy metals, sulfur dioxide, and
particulates. The record of the controversy (studies, legal deci
sions, articles, etc.) is voluminous and largely available to INFORM.
The matter is particularly important in relation to in-plant condi-
tions because many of the controls which have been installed in the
last few years, as well as those now being installed, have been the
result of enforcement of air pollution regulations, particularly
through a court case in the city of El Paso.
-------
[page 5]
3) A number of areas in the smelter have never be^n inspected by a reg-
ulatory agency. The sampling building, the receiving areas, the
bedding areas, and the crushing plant are reportedly under MESA1s
jurisdiction; yet MESA has never inspected them1, probably because
there is no mine at the site. OSHA did not toilich these areas during
its two inspections.
Comments:
I. COMPANY SAFETY AND HEALTH ACTIVITIES
A) Staff
1) Environmental and Industrial Hygiene
Since late 1976, El Paso has had a resident environmental scien-
tist who performs duties related to both occupational health and
air pollution.
2) Safety
a) Program is directed by a Personnel and Safety Director who
devotes approximately 40% of his time to safety matters.
b) In addition, the company reports another full-time employee
in the safety program. ("Safety Officer")
B) Respirator Program
1) Training, education and supervision is the responsibility of
smelter's environmental scientist.
2) Storage and facilities for daily cleaning are provided. Workmen
turn in their respirators at the end of each shift and a full-time
employee is in charge of daily maintenance.
C) Industrial Hygiene
1) Yearly sampling of some areas and work stations for S0~ and arsenic
since before OSHA. Extent of yearly monitoring increased signifi-
cantly in 1976, with more personal sampling carried out.
2) No monitoring conducted in areas under MESA jurisdiction.
3) Ventilation systems are checked "as needed" by department superin-
tendents .
4) No formal reports or education are given to the workmen regarding
the need, objectives and results of air monitoring.
-------
[page 6]
5) The company has provided a substantial amount of industrial hygiene-
related data to OSHA in the course of the arsenjic and sulfur dioxide
hearings. No data is routinely exchanged with/the union.
''\
D) Safety Activities j'
1) Plant safety staff conducts regular safety inspections. No check-
list is used but written reports are prepared.
2) Plant safety staff conducts investigations of accidents and near
misses with written reports. Labor is not invited jbo participate in
accident investigations.
3) Company reported to NIOSH in 1972 that corporate safety engineer
services were provided to the plant 8 hours/month. INFORM has not
determined whether this arrangement still exists.
4) There are no formal safety training procedures'for new employees.
Foremen and fellow employees introduce new employees to area haz-
ards . i
5) Initial safety training is provided to new foremen.
6) Refresher safety training is provided to supervisors.
7) Monthly departmental safety meetings take place under the direction
of foremen. i
8) Monthly safety meeting is conducted by the safety officer with two
representatives from each department.
9) Safety training for new equipment and changed processes is provided.
10) Company reports that certain "informal studies" have been conducted
to investigate the relationship of accidents to plant areas, worker
seniority, overtime, and different shifts. Written findings of
these studies are not available.
11) There has been no study of cost-benefit considerations in relation
to the safety program or related matters.
12) Safety statistics (frequency rates) are kept according to the tradi-
tional system of the National Safety Council. Data available to
INFORM for years 1972 to 1976.
13) Company reports that information exchange regarding safety issues
takes place in a formal way within the company.
14) OSHA 102 data available for 1973, 1975, and 1976.
15) INFORM has calculated incidence rates for 1973, 1975, and 1976,
according to OSHA methods.
E) Health Care
1) Smelter uses local health care facilities for major health services,
including emergency care.
2) Plant clinic is staffed by a full-time nurse and a practical nurse
as well as physicians on a part-time basis (12 hours/week).
3) In excess of 100 employees are trained in first aid, with the empha-
sis on foremen.
-------
[page 7]
4) There is a fairly comprehensive system of pre-p! lacement and periodic
health monitoring, including general exams, audiometric tests, blood
tests, x-rays, and pulmonary function tests. i|
5) Company estimates the cost of its medical prog'ram at $60,000 per
year (personnel, testing and equipment).
Comments:
:V. SAFETY COMMITTEE
I
A) According to the company questionnaire responses, nofjoint safety and
health committe exists at El Paso.
B) Contract language specifies a joint safety and health committee with
three employee representatives and specific functions (monthly meetings,
safety inspections, paid time).
Cl Union reports a joint safety committee with three union representatives.
Committee meets monthly to discuss safety matters. It also conducts
inspections of different departments each month with subsequent discus-
sion and write-up of recommendations for the supervisory personnel in
the area inspected. The committee does not address health issues, and
the smelter's environmental scientist does not take part in its activi
ties.
D) The Safety and Health provisions of the contract address other matters,
such as:
1) Right to refuse unsafe work. Reports to INFORM indicate that no
such instances have required arbitration.
2) Right of joint committee members to review monitoring records
"required by the Department of Labor." Individual workers do not
have the right to review their own monitoring results.
3) Right of international union representatives to enter the plant for
safety and health issues. The right to enter depends on the plant
manager's permission, and INFORM is not aware of any instances where
the union has requested entrance.
Comments:
-------
[page 8]
/. REGULATORY HISTORY
A) Pre-1970
As far as INFORM could determine, no state regulatory agency ever car-
ried out any inspection activity in the El Paso smelter. The State
Health Department, under the "Texas Occupational Safety Act" of 1967,
had safety and health jurisdiction.
B) Post-1970
1) Texas made relatively feeble attempts to develop a state OSHA plan.
Consequently, the state continued to play little or no role in rela-
tion to the smelter after 1970.
2)
3)
OSHA Activities
a)
Other
a)
Three inspections. One safety.
MESA reportedly has jurisdiction
ing, receiving and bedding areas.
been conducted by MESA.
Two hpalth. (See Table 3.
1
over the sampling, crush-
No inspection has ever
)
Comments :
-------
Table 1
PROCESS EQUIPMENT--E1 Paso, Texas
NAME
AGE
POLLUTION CONTROLS
Coarse and Fine Crushing
Bedding Bins
Wedge Roasters (4)
Some water sprays
None
Spray chamber -*• ESP
(joined, with reverb off gases) -*•
1921 stack
Reverb Furnace
Sprung Arch
Wagstaff gun feed on sides
1913
2 WHB + spray chamber
ESP -> s|tack
Reverb Holding Furnace
Converters
1 § 2
3
Two cranes in aisle
Anode Furnaces (2)
1970 ,
1916 2 WHB ->• spray chamber
1937 ->- ESP -> acid plant
1916
Casting Wheel (1)
-------
Table 2
SUMMARY OF HEALTH HAZARDS--E1 Paso, Texas
TWA
Number of
PLANT AREA Employees
Receiving and
Beading Areas
Roasters
Reverberatory Area
Converter Aisle
Anode Casting
-- 4-5 -
18
27
33
15-20
TWA Exposures in mg/M^
Copper
-
Arsenic
.06—-
.01-. 05
.10-. 15
.01-. 05
.01-. 05
Lead
.02<
.01-. 10
.10-. 18
.04
Sulfur
Dioxide
fppml NOTES
0.3-6
1-50*
0.3-8.4
*Area samples.
Average S02 exposure on charge deck is
9-10 ppm.
Larryman exposure to S09 is 23 ppm.
Converter punchers and skimmers are
exposed to noise in excess of standard.
SOURCES: 1) Company testimony at the OSHA arsenic and sulfur dioxide hearings
2) NIOSH industrial hygiene survey, April, 1972
-------
Table 3
OSHA INSPECTIONS--E1 Paso, Texas
DATE
TYPE
FINDINGS
PENALTIES FOLLOW UP
COMMENTS
1/14/74
General Schedule
Health
No violations
None
None
Sampling for Pb, Cd, S02. Mostly
in lead circuit. Many excessive
exposures found, but not cited
because protective equipment was
judged adequate protection by
OSHA.
1/24-27/77
General Schedule
Safety
2 Citations
one serious
one nonserious
63 items
4245 None yet Diverse safety items.
Contested. Settlement agreed upon.
1/25/77 -
4/20/77
General Schedule
Health
1 Citation
nonserious
5 items
None None yet Pb, Cd, As problems. Mostly in
lead circuit.
Noise in copper converter area
lunchroom facilities.
Citation in contest.
-------
FACT SHEET
FACILITY: Hayden Smelter
CCMPANY: ASARCO, Inc.
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
page 1
GENERAL
Name: ASARCO
Location: Hayden, Arizona
Description:
1) Custom smelter, no concentrator facilities.
2)
Smelter built 1912.
Ore comes from three ASARCO mines in Arizona, from independent Ari
zona mines, and Speiss from ASARCO--E1 Paso. Arsenic content esti
mated variously as 0.005% and 0.04 to 0.1%. Other trace metal
information on hand.
3) 450-500 production and maintenance employees. 65-70 administrative.
4) In 1974, $6.5 million in payroll and $1.98 million in taxes.
5) Production
Second only to Kennecott's
a) ASARCO's largest copper producer.
Garfield, Utah operation.
b)
1972
1973
1974
1975
1976
Blister Copper
Anode Copper
Sulfuric Acid
160,000
147,000
129,000
43,844
130,420
105,000
101,396
92,157
102,000
Comments:
[. .PROCESS AND HAZARDS--SMELTER
NOTE: In most areas of the plant, workmen wear company-supplied respirators
on a need basis. The following comments evaluate TWA exposures independent
of respirator use.
NOTE: Throughout the following remarks, the phrase "poorly characterised"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
A) Sample Building. Three men per shift. Dust exposures despite local
exhaust ventilation. Likely Arsenic exposures above proposed standard.
-------
page 2
Poorly characterized. Vacuum cleaning and wet housekeeping indicated
but not yet adopted.
B) Unloading of Ore. Likely exposure above proposed Arsenic standard.
Local exhaust and elimination of air lances indicated but not yet
adopted. Four men per shift.
C) Beds. Three men per shift. Varying dust exposures as well as general
area contamination. Arsenic exposures likely above proposed standard,
but poorly characterized. Local exhaust at the transfer point to the
bin-conveyor system leading to the roasters is indicated, as well as
better enclosure of entire bedding area to prevent wind-generated dust.
These measures not yet adopted.
D) Roasters
1) 22 men per shift. Arsenic exposures two to fifty times the proposed
standard. Copper dust exposures slightly above present standard.
Some lead exposure in the neighborhood of the proposed limits. SC^
exposures in the neighborhood of the present standard.
2) Dust-fume characteristics and respirability of airborne particulates
are not well studied.
3) Company considers all except one of the twelve roasters to be too
old to be repairable (for leaks).
4) Maintenance tasks generally in progress in one to four roasters.
Exposures to arsenic are likely to be very high. Poorly character-
ized.
5) Hot calcine discharge point is a source of heavy arsenic, S02, and
dust exposures to the workmen in that area, including clean-up
crews. Company reports improvement of local exhaust ventilation
system. Effectiveness unknown.
6) Larrymen traveling between calcine loading and reverb feeding areas
have the highest combined ^articulate and SO-? exposures. Arsenic
exposures have been reported as high as 20 times the proposed standards,
Company reports that more recent data indicates exposures ranging from
4 to 5 times the proposed arsenic standard.
7) Other sources of contamination are:
a) uncovered conveyor systems, transfer points, and bins at
the top level of the roaster
bj Lack of ventilation at roaster feed stations
c) Use of poles to help move the hot calcine during loading
d) Poor maintenance on calcine hopper - larry car seal
E) Reverberatory Furnaces
1) Four to five larry cars carrying calcine to the furnaces.
2) Charge floors of the reverbs have the highest SCL concentrations in
the smelter, 1974 peak above 140 ppm. 1975 peak concentration 23 ppm.
Larrymen and helpers (four per shift) are intermittently exposed.
Arsenic exposures 20 times the proposed limits. Larry car shakers
produce noise exposures twice the allowable limits.
-------
page 3
3) Two large., rooftop fans installed to provide dilution ventilation in
charge floor area. Effectiveness unknown.
4) Feeding of furnace with Wagstaff guns causes positive pressure
build-up and thus fugitive emissions.
5) Company reported to the State Mine Inspector in 1973 on efforts to
modify Wagstaff guns to stationary feed guns in order to avoid dust
generated while moving them from one feed hole to another. Success
of efforts not known.
6) Matte and slag tapping and launders are hooded. Arsenic exposures
exceed the proposed standard. Copper, lead, and total dust expo-
sures are within allowable limits. Sulfur Dioxide exposures are
poorly characterized. SC^ data suggests reduction since 1975, but
production was also substantially reduced from previous years; hence
cause-effect is difficult to ascertain.
7) Slag transfer in tunnel is a source of general contamination. Nega-
tive pressure in tunnel is indicated but not yet adopted.
8) Reverb arches are "blown" with compressed air. Source of general
contamination. Vacuuming tried slightly but failed.
9) Transfer of dust from the waste heat boilers, using payloaders, is a
source of high-arsenic contamination and exposure. Poorly charac-
terized. Enclosed conveyors indicated but not yet adopted.
10) Reverb maintenance tasks are likely to result in high dust and
arsenic exposures. They are poorly characterized.
F) Roaster and Reverb Dust Control Equipment
1) 7% of smelter's daily roaster input is recirculated flue dust. Its
arsenic content is 0.1 to 1.0%, much higher than the concentrate.
2) Dust exposures to the dustman and the pugmill operator, in the
precipitator, are comparable to those of the larryman. Since
arsenic and lead content are higher, the hazard is even more serious.
3) Little characterization exists for exposures of other workmen (i.e.,
precipitator operators and helpers)
4) Enclosed conveyor systems for dust handling are indicated but not
yet adopted.
G) Converter Aisle
1) Exposure to arsenic-laden dust for the personnel involved with the
dust-control equipment is variable but likely to be high. Poorly
characterized. Enclosed conveyor system is indicated but not yet
adopted. Company reports exposures below .5 mg/m .
2) Skimmers (4 per shift) and cranemen (3 per shift) are exposed to
arsenic concentrations two to four times the proposed standard.
3) Cranemen are likely exposed to SO,, concentrations in excess of pro-
posed limits Inside the crane cabs. TWA are poorly characterized.
4) Punchers are exposed to noise levels two to four times the allowable
limits. Ear muffs are worn. Company reports no efforts to silence
-------
page 4
the punching operation except "observation" of Anaconda's experi-
ments (cab enclosures).
5) A 1973 fatality resulted from a converter "blow-out." No satisfac-
tory explanation was ever found.
H) Anode Furnaces
1) Furnace burners create noise exposures one to four times the allow-
able limits to workmen involved in casting. Company has eliminated
the use of one burner per furnace to reduce noise.
2) Mold spraying position also results in excessive noise exposure.
3) Potential heat exposures in casting area. Not characterized.
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History--in corporate profile
B) Staff
Safety Director (responds to plant manager)
Environmental Scientist. Sent yearly (or as needed) from corporate
Salt Lake City Labs to perform personal sampling and/or air pollu-
tion tests. His role is advisory to plant management.
C) Yearly industrial hygiene sampling of some plant areas. -No reports or
education given to workmen.
D) Respirator Program: Full-time person devoted to maintenance and proper
instruction of employees. Satisfies OSHA requirements. Fairly rigid
enforcement of respirator-wear requirements.
E) Safety. Weekly meetings in all plant areas between foremen and workmen.
Begun as a result of 1973 fatality. Meetings of General Superintendent
with staff people take up safety and other matters. OSHA 102 reports
for 1972 through 1976 on hand.
F) Health Care
1) Clinic at Hayden. One doctor. One nurse. Closed weekends and
nights, when workers must go to Kennecott's Kearny hospital.
2) Contract gives workers right to see own doctor. Many take advantage
and see physicians in Tucson.
-------
page 5
3) Pre-employment physical and audiometric exams.
4) Yearly blood lead tests for all production workers.
5) Yearly audiometric tests for all noise-exposed Corkers. Referrals
if needed.
Comments:
V. SAFETY COMMITTEE
A) Description
1) Begun in 1971 contract.
2) Modified in 1974
3) Two USW representatives, 2 IBEW; and two company1.
4) Monthly tour and discussion. Written reports !to participants.
5) Mostly visible safety focus, but union has often brought up matters
of health concern.
Comments:
/. REGULATORY HISTORY
A) Pre-1970
1) Office of State Mine Inspector
B) Post-1970
1) State OSI1A Plan
a) Developmental. Headed by Arizona Industrial Commission.
Approved 10/74.
b) Jurisdiction over smelters still in hands of State Mine
Inspector.
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page 6
2) Office of State Mine Inspector
a) No contractual relationship exists with! Arizona In-
dustrial Commission.
b) Approximately two inspections per year in 1972; five
per year in 1976. See Table 3.
cj Limited industrial hygiene efforts.
C) OSHA Activities
1) Three inspections. None complete. See Table 3.
Comments:
-------
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Roasters 1-8 (McDouglas)
Roasters 9-11 (Herreshoff)
Roaster 12 (Bartlett-Snow-
Pacific)
1911-1969
Settling chamber and Cottrell
precipitator shared with
reverberatory furnace.
6 to 10 operating.
Reverb. #2
Reverb. #4
Converter
Converter
Converter
Converter
Converter
1942
1968
1949
1965
1968
1975
4 waste heat boilers.
Spray chamber.
Settling chamber and Cottrell
precipitator shared with
roasters .
Water-cooled hoods.
Cyclones, spray chambers,
scrubbing towers, mist
precipitator, ESP
2 Anode Furnaces
1974
2 Anode Casting Wheels
1974
Acid Plant
(single contact)
1968-1971
''Process flowsheet, Figures 2, 4; Design and Operating Parameters for Emission Control
Studies: ASARCO, Hayden, Copper Smelter.
OP
0>
-------
PLANT AREA
Unloading, Sampling,
Bedding
Roaster Department
Reverberatory
Furnace Department
Converter Department
Anode Casting
Plant
Acid Plant
Number of
Employees
10
36
54
42
34
12
Copper
2.9-7.0
0.25-7.82
0.24-3.87
0.02-0.68
Arsenic
0.01-0. 34
0.03-0. 36
0.003-O.Q2
-Lead
0.07-0.15
0.006-0.18
0.02-0.21
0.006-0.09
uioxxde
(ppm)
0-732
0-700
NOTES'
Noise exposures to
skimmers are up to 5
times the standard
* Independent of respirator usage.
Sources: Company Data.
OSHA Inspection records.
Office of State Mine Inspector. Inspection records.
Feasibility Document--David Burton Associates, 1975.
NIOSH Study, 1972.
fo
era
oo
-------
Inspections--ASARCO, Hayden
page 9
ME
13/73
10/75
16/75
TYPE
fatality
accident
complaint
FINDINGS
In Compliance
In Compliance
In Compliance
PENALTIES
NONE
NONE
NONE
FOLLOW-iUP
Recommended
i
Not Recommended
Not Recommended
COMMENTS
#3 converter blow
Waste heat boiler
pipe rupture
Alleged personal
harassment
zona State Mine Inspector--Inspections—ASARCO, Hayden
ATE
31/71
71/72
12/72
'26/73
79/73
'13/73
i/6/74
'17/74
1/4/75
2/4/75
TYPE
health
health
safety
health
safety
fatality
safety
safety
safety
health
FINDINGS
7 S02 samples
9 dust counts
7 S02 samples
9 dust counts
7 violations
9 S02 samples
9 dust counts
9 violations
In compliance
1 violation
8 violations
9 violations
8 S02 samples
9 dust counts
PENALTIES
FOLLOW-UP
NONE
NONE
Co. abatement
letter
Co. abatement
letter
Co. abatement
letter
NONE
NONE
8 notices
abated 2/4/75
NONE
NONE
COMMENTS
Grab area samples
Grab area samples
Grab area samples
#3 converter blow
acid plant
Grab area samples
(aj
-------
ona State Mine Inspector—cent'd)
page 10
•E
1/75
'/75
'76-
1/76
/76-
2/76
6/76
/76-
0/76
TYPE
safety
safety
safety
health
complaint
safety &
toxic gas
FINDINGS
19 violations
24 violations
11 violations
14 SC>2 samples
10 dust counts
4 SCL samples
30 safety
violations
PENALTIES
FOLLOW-UP
1
Abatement :
letter andi memo
i.
24 violations
abated 4/22/76
11 violations,
abated 6/1/76J
1
NONE
{
, 1
abatecl
I
NON'E
COMMENTS
Grab area samples
#4 crane cab
(b)
-------
FACT SHEET
Facility: Tacoma Smelter
Company: ASARCO, Inc.
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
I. GENERAL
Name: ASARCO, Tacoma, Copper Smelter
Location: Tacoma, Washington
Descripton:
1) Combination of concentrate receiving facilities, coarse ore and
concentrate handling and crushing facilities, roasters (10),
reverberatory furnaces (2), converters (4), anode furnaces (3),
and supportive facilities. The complex also has refinery
facilities for producing arsenic trioxide, dore, metallic arsenic,
nickel sulfate, and sodium selenite products, as well as electro-
lytically refined copper.
2) "Smelter began operation in 1890; purchased by ASARCO in 1905.
3) Employees: 822 (approximately 300 smelter production)
4) Tacoma is a custom smelter, where concentrates are treated under
contractual agreement. Concentrates from Philippines (Lepanto),
Vancouver, British Columbia (Similkameen), and Arizona (Sierrita
and Mineral Park).
5) ASARCO a major contributor to the economy of the surrounding area.
6) Production:
1974
1975
1976
Copper (tons)
Arsenic Trioxide (tons)
Nickel Sulfate (tons)
Sulfuric Acid (tons)
Sulfur Dioxide (tons)
Metallic Arsenic (Ibs.)
Gold (ozs.)
Silver (Ozs.)
117,381
9,646
863
47,657
20,360
96,562
120,484
776,289
119,670
10,518
943
52,895
42,290
320,616
127,385
786,789
87,699
9,835
695
46,509
47,2,81
508,000
N/A
N/A
Comments:
-------
rage
IT. PROCESS AND HAZARDS
NOTE: Respirators are company-supplied and worker maintained. They are
worn on a need basis. The following comments evaluate TWA
exposures independent of respirator usage.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the
company or the regulatory agencies have sufficiently characterized
the exposures to permit proper evaluation and corrective action.
A) Material Handling
1) Concentrates are received by ship at the South Dock where they are
are unloaded by crane. A crane hopper - conveyor belt system
transports these materials to the Martin Mill. Significant air-
borne dusts are generated during the unloading operations and by
the conveyor belt. Arsenic exposures above the proposed standard.
Other dust exposures are poorly characterized.
2) Martin Mill. Concentrates are received, split, and sampled prior
to roasting. Dusts are generated from the belts, transfer points,
sampling points, and the multiple bins. Arsenic exposures are above
the proposed standard. A wet collector dust control system is
presently in use, but is reported inadequate to reduce arsenic levels to
meet proposed standard. Other exposures, if any, are poorly characterized
3) Crushing Area. A jaw crusher is used to crush and screen concentrates
that are too large, so that they are ameneable to roasting. Arsenic
levels above the proposed standard. The crusher building is equipped
with dust control (rotoclone collectors) but system is reported inadequate
to reduce arsenic levels below .10 mg/m3. Other exposures, if any, are
poorly characterized.
4) Fine Ore Storage. The concentrates, along with other raw materials
(silica and lime fluxes) are stored in bunkers in the Fine Ore Shed.
The materials are mixed and moved by clamshell and crawler crane and
tripper belt, and finally transfered to the Roasters via a conveyor
system. Railroad cars, loaded with concentrates, are also unloaded
in this area. This building is wide open and a source of airborne
arsenic to other plant operations. The principles of exhaust
ventilation cannot be applied to this area without enclosing the
entire building. The two cranes and the two operator stations are
not presently enclosed. Arsenic levels are above the proposed
standard. Other exposures are poorly characterized.
5) South Dump. Silica and lime fluxes are received and stored in
this area prior to mixing with concentrates in the Fine Ore Shed.
These materials are transfered by the yard personnel. Exposures,
if any, are unknown.
B) Roaster Area
1) Ten Multi-hearth Roasters. There are usually four Roasters operating
at one time.
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Page 3
2) Roaster feed materials are transfered from the Fine Ore Shed via
an overhead conveyor system. The system consists of the conveyor,
tripper belts, and storage bins. The belt tripper, transfer points,
and the uncovered storage bins are major dust sources. Exposures
are uncharacterized.
3) Operating decks.
a) Exposures from dusts generated during feeding operations and
from intermittent "puffs" during roasting operations. Puffs
are due to draft reduction by the ESP operator to maximize dust
recovery or due to failure of the automatic draft control to
respond to changing requirements. S02 leaks through upper
hearth, refractory doors, and around doors.
b) Feedermen. Feeds the Roaster at the upper levels. Uses air
lance to blow hoppers, also shovels feed and performs other
cleaning tasks. Exposed to arsenic levels above the proposed
standard. S02 levels are poorly characterized.
c) Beltmen. 5-6 men make up a "belt crew" Crew brings feed to
hoppers during a belt run. Workers exposed to arsenic levels
above the proposed standard. S02 levels are poorly characterized.
4) Unloading areas.
a) Calcines are discharged at 900° F. into larry cars. The number of
loads vary. During normal operating conditions eight loads per hour
are collected and transfered to the Reverb.
b) During normal operations there are usually -2 larry car operators
and 1 relief man. Arsenic exposures documented in a range greater
than ten times the present standard. Copper dust exposures at
five times the standard. S02 levels eight times the proposed
standard. Lead levels at five times the proposed standard.
Total particulate levels documented at five times the nuisance
dust standard.
c) Larry cars presently covered during transit, however seals are not
adequate to stop leakage.
d) Larry car operator exposures occur both in the Roaster area and
above the Reverbs while feeding calcines.
e) Company proposes to enclose the larry car loading area to capture
fugitive emissions that escape during loading operations.
5) Firemen. Operator of the Roaster. Controls the gas burners during
roasting. Exposed to arsenic levels above the proposed standard.
Other exposures are poorly characterized.
6) Flue dust pullers. The roaster flue is cleaned out daily by emptying
the hoppers and loading the dusts into a dust car. Arsenic levels
five times the present standard. Total particulate levels exceed
the standard for nuisance dusts. Conditions and job will be eliminated
once the new baghouse is put on stream.
-------
rage
C) Reverberatory Area.
1) One suspended silica arch furnace and one suspended arch basic
brick furnace.
2) Reverb feed deck.
a) Larry car men. Exposures discussed in Roaster Area section.
b) Feed floor clean-up crew. Exposures similiar to larry car
operators. Clean-up performed on an "as needed" basis.
3) Furnacemen. Controls Reverb's burners. Arsenic levels above the
proposed standard. Noise levels exceed the present standard.
4) Tapper and Tapper Helper. The matte tap hole, the matte runner,
and the ladle charging station are presently hooded and exhausted.
Company reports that emissions (from this source) are normally
controlled, however, strong winds blowing through the building
cause S02 to escape from these ventilating systems. After ladles
of matte are poured, they are left smoking - also contributing to
background S02 levels. Company proposes placing ladles under a
hood, but such a practice has yet to be established. Arsenic levels
exceed the proposed standard. Noise levels exceed the present
standard.
5) Skimmer and Skimmer Helper. The slag tap hole and the slag runner is
hooded and exhausted. The effectiveness of this control equipment
diminishes as slag skimming operations continue. During the filling
of slag train cars, the filled cars continue to fume while the train
changes position to fill subsequent cars. Arsenic levels at the present
standard. Lead levels above the proposed standard.
6) Company reports that the skimmer, the tapper, and their respective
helpers are exposed to severe heat during skimming and tapping
operations.
7) Arch is blown once a week during the grave-yard shift. Company
unsuccessfully attempted vacuuming.
8) Waste Heat Boilers
a) Dusts entrained in the Reverb off-gases build up in the boiler
and must be frequently removed by air lancing. Dusts settle to
bottom and removed via screw conveyor system. Conveyor must be
cleaned out manually due to jams caused by fused chunks of ash.
b) The boiler lancer is exposed to arsenic levels above the present
standard. Lead levels above the present standard.
c) Exposures to other Waste Heat Boiler employees are poorly
characterized, however the company reports these employees are
exposed to area arsenic levels in the 1.0 - 2.0 mg/m3 range.
D) Converter Area
1) Four Fierce-Smith Converters with primary water cooled hoods. Three
are usually running at any one time with blowing limited to no more
than two at any one time.
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Page 5
2) Usual practice is to keep a Converter, not immediately required
for production, hot by use of a burner through the burner mouth.
This practice results in S02 release into the work environment
due to the oxidation of sulfur from the charge remaining in the
Converter.
3) Cranemen. Crane cabs (2) are not enclosed. Cranemen are exposed
to arsenic levels above the proposed standard. S02 levels are above
the present standard. Lead levels are above the present standard.
4) Skimmers. Skimmer shacks are not enclosed. The skimmers are
exposed to arsenic levels above the proposed standard. Lead levels
are above the present standard. Noise levels exceed the present
standard.
5) Punchers. Exposures to arsenic above the proposed standard. Lead
levels above the proposed standard. Noise levels exceed the present
standard. Company attempted to abate noise exposures by enclosing
and insulating punching platforms. Company presently studying
feasibility of of installing tuyere silencers.
a) Head puncher. Rolls converter and operate automatic punchers
on Converters #1, #2, and #4.
b) Tail puncher. Punches Converter #3 manually.
6) Exposures to other Converter workers are poorly characterized.
E) Anode Area.
1) Three Anode Furnaces and three Casting Wheels. #3 Anode is normally
in use.
2) Blister copper is transfered via converter crane to the Anode
Furnace where a final blow and subsequent deoxidation, using 20
foot logs, takes place. Anodes are'poured in the Casting Wheel
and after cooled with water sprays, are transported to the refinery.
3) Company states that many of the jobs in this area, notably the
wheelmen and anode tapper, are very hot, physically demanding, and
among the most hazardous in the smelter. Personal sampling results
for Anode workers were not available to INFORM. Background arsenic
levels reportedly ablove the proposed standard.
4) Noise levels have been reduce by burner and water spray alterations
after being cited by WISHA.
5) Company is also planning to capture Anode emissions and send
gases to the #2 ESP.
F) Cottrell Department.
1) Three ESP's are used for brick flues #1 and #2 to collect particulates
before the gases are emitted from the main stack. The two ESP's in
the #1 flue generally treat the Roaster off-gases and the single
ESP in the #2 flue treats the Reverberatory off-gases.
2) The dust puller is exposed to arsenic levels above the present
standard. Lead exposures above the proposed standard.
3) The treatermen are exposed to arsenic levels above the proposed
standard.
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Page 6
G) DMA (Liquid S02) Plant.
1) The DMA Plant processes a portion of the converter off-gases. The
system uses dimethylaniline to absorb the gaseous S02 which is
then regenerated by stripping with steam - producing 100% S02 as
a gas. The S02 is liquified by compression and stored under pressure.
2) Union complained to WISHA about conditions in the DMA Plant, resulting
in inspections. One inspection documented arsenic levels above the
present standard, lead levels above the present standard, and S02
levels five times the present standard. No violations were found
during the other inspection, however five repair-crew men became
ill from effects of unidentified chemical exposure.
3) Leaks from the poorly sealed DMA Plant cause high S02 levels in
other areas of the smelter complex.
H) Acid Plant
1) The single contact acid plant, originally designed in 1950 for
100 TPD production, was recently enlarged to a 200 TPD Plant.
2) Exposures and job descriptions for workers in this area were not
available to INFORM.
Comments:
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Page 7
I. COMPANY SAFETY AND HEALTH ACTIVITIES
A) History
1) Department of Industrial Hygiene was established in 1945 at the
corporate level. In 1966 this department combined with ASARCO's
Department of Agricultural Research to form the Department of
Environmental Sciences. In 1975 an industrial hygienist was
assigned to Tacoma on a full-time basis.
2) History of ASARCO's Safety Program not available tb INFORM.
B) Staff
1) Safety Director (50% of time devoted to safety matters)
2) Safety Superintendent
3) Safety Engineer
4) Industrial Hygienist
5) Environmental Scientist (operator of Intermittent Control System)
C) Respirator Program
1) Training, education, and supervision of respirator usage is the
responsibility of the industrial hygienist. j
2) All workers are assigned and fitted with their own respirators
according to the hazards present in their wor!k area. Respirators
worn on an "as needed" basis. Workers are responsible for cleaning
and maintenance.
D) Industrial Hygiene Activities
1) Annual sampling of areas and personnel by corporate personnel prior
to OSHA. Extent of monitoring increased with the assignment of
industrial hygienist.
2) Annual monitoring results are compiled in a final survey report. ASARCO
would not provide INFORM with copies of these materials.
3) Ventilation systems are checked by the mechanical superintendent
on an "as needed" basis.
4) No formal reports or education are given to workers regarding the
need, objectives, and results of industrial hygiene sampling. However,
during a pre-employment indoctrination, the company informs workers
of hazards they will possibly encounter while on the job.
5) The company has provided a substantial amount of industrial hygiene
related data to OSHA during the course of the arsenic and sulfur
dioxide hearings. The bulk of this material was related specifically
to Tacoma. The company provides the Union with monitoring results.
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Page 8
E) Safety Activities
1) Plant safety engineer conducts a monthly inspection of the
plant. No checklists are used except during Crane
inspections. In all cases, written reports are prepared
and a copy is forwarded to the Union. "
2) Accident investigations, for all lost-time accidents, compensated
accidents, and some near misses, are conducted jointly by the
Company and the Union. Written reports, which establish cause,
place responsibility, and make recommendations, arb prepared at
the conclusion of accident investigations. !
3) New employees are instructed as to the safety'aspects, the associated
hazards, and the proper safety practices of their particular job.
The indoctrination includes a tour of the smelter.
4) Formal safety refresher courses for all emplbyees are not available,
however, safety awareness is mainteined by way of safety committees.
a) Foremen Safety Committee includes a|ll formen and meets
weekly. :
b) Worker Safety Committee includes a representative from
each department and a management representative, meets
monthly. '
c) These committees' activities are independent of the Joint
Safety and Health Committee.
5) Safety training for new equipment and process; changes is provided.
6) OSHA 102 data is available for 1973, 1974, 1975, and 1976.
7] Accident frequency rates, computed according to the traditional
system of the National Safety Council, are available for 1972 -
1976.
8) Company reports that information exchange regarding safety issues
takes place in a formal way within the company.
9) Company reported that a study to determine the relationship of accidents
between new and old workers was performed at Tacoma. Written findings of
this study were not made available to INFORM.
10) Company reports that it has never conducted any studies to estimate
the indirect costs of smelter accidents.
F) Health Care
1) Smelter complex has its own on-site medical clinic with facilities
and staff to perform preventive testing and first aid care.
a) Staff: 1 part-time physician (3 days a week), 1 full-time
nurse, and 1 secretary.
b) Facilities: comprised of a waiting room, a dispensary and
a 2-bed ward and equipped with an EKG, oxygen
facilities, audiometry and eye-testing equipment,
and an X-ray machine (used only for accident
diagnosis,e.g. fractures).
-------
Page 9
2) All major injuries/illnesses .occurring in the smelter are referred
to one of three neighboring hospitals the closest being five
miles away.
l|
3) Smelter does not have an on-site ambulance, readily available
emergency transportation is provided by the Tacoma Fire Department.
4) There is a fairly comprehensive system of pre-placement and periodic
health monitoring, including: general exams, audiometric tests,
blood and urine analyses, and pulmonary function tests. Frequency
of blood analyses (lead) and urine analyses (arsenic) is determined
through industrial hygiene department's monitoring' results.
5) Epidemiological and research studies, through1contract or through
its own medical department, have been conducted and were available
to INFORM. '
Comments:
IV. SAFETY AND HEALTH COMMITTEE
A) The Joint Safety and Health Committee was established in 1971.
B) Committee includes three management representatives and three Union
representatives.
C) Meets once a month for a full day. Meetings begin with a tour, after-
which there is a discussion on the tour findings. A written report,
which includes documentation of the areas visited, subjects covered,
and recommendations made, is prepared by the company and forwarded
to each representative and the Union.
D) Other safety and health topics may be discussed, such as any new process
changes and/or additions. The Union also uses the committee to air any
safety and health complaints.
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Page 10
E) The Safety and Health provisions of the contract address other matters,
such as: !
i
1) Right to refuse unsafe work. A specific grieyance procedure
(arbitration) to handle disputed cases has been incorporated
into the contract.
2) Right of Union to review the results of the company's monitoring.
3) Right of the International to enter all areas of the plant for
safety and health issues and to review company-projduced materials
regarding safety and health. j
F) Workers do not retain wage rates if they are forced to change jobs
as a result of an occupational injury or illness.
Comments:
V. REGULATORY HISTORY
A) Pre-1970
1) Washington Department of Labor and Industries has juris over
safety matters since 1910. Pre-OSHA safety inspections of smelter
were not available to INFORM.
2) An Industrial Hygiene section was established in 1963. The smelter's
first health inspection was performed in 1970 - very limited due
to lack of equipment.
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Page 11
B) Post-1970
1) State OSHA Plan (WISHA)
a) Developmental plan approved in June 1973, Allowing the Department
of Labor and Industries to operate under 18(b).
bj Developmental steps completed by March 1976. Presently operating
under an operational status agreement with OSHA.
c) Inspections: See Table 2.
2) OSHA Activities.
a) One inspection safety.
Comments:
-------
PROCESS EQUIPMENT -- Tacoma
Table 1
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Roasters (10)
Herreshoff
(multi-hearth)
#1-6: 1915
#7-8: 1923
#9-10: 1929
ESP #1 (Pipe ESP ->• Plate ESP) -> Stack
Considerable leakage through
roaster and ductwork. Roaster
baghouse now under construction
Reverberatory (Silica)
Furnace #1
1915
#1 Waste heat boilers
#2 ESP -> stack
Not normally used.
Reverberatory (Basic)
Furnace #2
1929
#2 § #3 Waste heat boilers
#2 ESP -v stack
Reverb emissions will be
treated in #1 ESP when roaster
baghouse on-stream.
Converter
#1-3 Pierce-Smith
13 by 30
#4 Pierce-Smith
11 by 26
#1-2:
#3:
#4:
1916
1915
1968
Watercooled primary hooded -»•
multicyclone ->• ESP -*- acid plants
OR
multicyclone -*• ESP -»- liquid S02 (DMA) plant
Up to 3 used at one time.
Fan system to partially
capture fugitive emissions
during roll-out, venting
to ESPs.
Anode Furnace (3)
#1-2:
#3:
1915
1936
None
Proposed capture and treatment
of anode-emissions in #2 ESP
when roaster baghouse on-stream.
Acid Plant
1951
200 TPD
DMA Plant
1974
Arsenic Plant
Godfrey roasters (6)
#1-4:
#5-6:
1913
1938
Tail gases treated in baghouse.
Presently under variance from
arsenic emission standards
from the tall stack and low-
level sources.
-------
tions—Tacoma [WISHA], continued)
TYPE FINDINGS
EMPLOYEES
PENALTIES AFFECTED FOLLOW-UP COMMENTS
5
General
Schedule
Safety
2 None 4
non-serious
violations
1
Complied
i.
Test certificates
for Cranes not
displayed .
5 .Complaint
Health
None
14
non-serious
violations
S02 Plant cottrells
inspected for S02,
lead, and noise
exposures - cited for
failure to provide
engineering controls
to reduce S02 and
Lead exposures, and
for failure to provide
lockout system.
5
5
75
6
Complaint
Safety
General
Schedule
Safety
General
Schedule
Health
General
Schedule
Safety
2 serious, $400. 14
13 non-
serious, and
1 Deminimus
No 15
violations
No 1
violations
3 None 4
non-serious
violations
Complied S02 Plant - No resp-
i irator , program, No
SOP for material
handling, violations
| for brakes, derails,
i guards and sings.
Explosive magazine
i section.
Medical Clinic
None Ore Dock Cranes -
Warning signals and
rails needed , and
posting of dock's load
capacity.
-------
TABLE 2
ECTIONS — ASARCO, Tacoma Smelter
ington Industrial Safety and Health Administration
TYPE
FINDINGS
EMPLOYEES
PENALTIES AFFECTED FOLLOW-UP COMMENTS
General
Schedule
Safety
Accident
'73 General
Schedule
Safety
4 Accident
Asbestos
Survey
4 General
Schedule
Health
3 None 50
non-serious
violations
No
violations
1 None 4
non-serious
violation
1 serious $200. 1
violation
Consultation
5 $360. 927
non-serious
violations
None
I
I
Company
abatement
letter
1
None.
Company
abatement
letter^
|
Dock Area
Inspection.
Runaway in Anode //
No injuries.
No fire extinguisher
in Office.
Systemic blood
poisoning - AsH^
inhalation - Nickel
Plant employee.
Evaluation -of Asbestos
exposures
Failure to provide
engineering or
administrative con-
trol of exposures to:
1) LEAD
2) ARSENIC
3) SULFUR DIOXIDE
4) NOISE
Failure to provide and
use respirators for
protection from ex-
posure to LEAD.
General
Schedule
Safety
No
violations
10
Locomotive crane
inspection.
General
Schedule
Safety
No
violations
10
Crane inspection.
Complaint
Health
No
violations
Liquid Sulfur Dioxide
Plant inspection.
General
Schedule
Safety
None
20
None
non-serious
violations
Labeling and warning
devices needed for
Cranes.
-------
Table 3
SUMMARY OF HEALTH HAZARDS--Tacoma, Washington
PLANT AREA
Material
Handling
Roaster Area
Reverberator/ Area
Converter Area
Anode Area
Number of
Employees
60
48
53
38
37
TWA Exposures in mg/m3
Copper
.1-5.3
.8
<.2
Arsenic
.2-6.7
.02-. 5
.1-.3
Lead
.01-2.20
.05-. 46
.01-. 36
TWA
Sulfur
Dioxide
(ppm)
NOTES
Tappers and furnacemen are exposed
to noise in excess of standard.
Larrymen exposure to SOz is > 17 ppm.
Converter punchers and skimmers are
exposed to noise in excess of standard.
SOURCES: 1) Company testimony at the OSHA Arsenic and Sulfur Dioxide Hearings
2) WISHA health inspections
-------
FACT SHEET
Facility: Copperhill Operations (copper smelter)
Company: Cities Service Company
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
Name: Copperhill Operations, Cities Service Company
Location: Copperhill, Tennessee
Description:
1) Fully integrated chemical and metal producing complex including:
mine, mill, copper smelter, iron roasters, power plant, copper sul-
fate and fungicide plant, acid plants, organic chemical plant, pel-
letizing plant, recovery plant, ferri-floc plant ar(d liquid sulfur
dioxide facility. j
2) Mine begun 1850; smelter, early 1900s. ;
3) Employees approximately 2,000 with 250 to 300 in copper production.
i
4) Ore from the Ducktown converted underground mijne. Exect arsenic
content of concentrates unknown but likely nedr .003%. Other im-
purities if any are unknown.
5) Largest employer in Polk County. Annual per qapita income for
county--$2,642. ;
6) Production (figures in thousand tonsj
1976 1975 1974 ! 1973 1972
Sulfuric Acid
Other indus-
trial chemicals
Copper ('+)
985.4
201.4
86.6
865.3
155.8
46.9
849.6 ;
161.4
30.6
910.0
205.5
39.6
916.3
206.3
44.9
(+) possible inclusion of toll concentrates sold from company
complex in Miami, Arizona.
Comments:
PROCESS AND HAZARDS--SMELTER
NOTE: Workers in most areas are issued company-supplied respirators. Work-
ers are responsible for maintenance and storage; however, the company has
established a number of sanitary cleaning facilities.
NOTE: The following comments evaluate TWA exposures independent of respi-
rator use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
NOTE: The sole known evaluation by a regulatory agency of arsenic concen-
tration at the Copperhill complex was made by the Tennessee Division of
-------
Public Health in December of 1975. After initial release of the data in
terms of the present arsenic standard, the levels were(recalculated in light
of the proposed arsenic standard. All samples were reported well below the
proposed standard. The areas sampled were the electrif furnace and conver-
ter areas. '
A) Material Handling
1) Concentrates in a moist state are transferred from the nearby Lon-
don Mill by open railroad cars. Dust an intermittent problem due
to wind.
2) After storage in 450-ton open bins, flux is added to the concen-
trate. The mixture is conveyed uncovered to the repulping station.
The concentrates are then res lurried with weak, acid recycled from
the copper gas-cleaning circuit. Dust an intermittent problem due
to wind and spillage along conveyors, and air |lance use in bin area
clean-up. 16 workers.
B) Fluosolids Roaster
1) One 10-foot diameter slurry-fed roaster.
2) Slurry is gravity fed by injection nozzle in roaster dome. The
approximate 4/1 (concentrate to silica sand feed) ratio yields
calcines with a 38% to 40% copper content. The 'gases leaving the
vessel contain 84% to 85% of the calcines. The calcines collected
in the cyclones are combined with roaster bedicalcines, for pro-
cessing in the electric furnace. ;
3) INFORM has found no evidence of air monitoring by either the com-
pany or a regulatory agency in the copper roaster area. The union
reports an intermittent gas and dust problem throughout the system.
Additional problems include cyclone clean-up and repair. Actual
exposures are uncharacterized.
C) Electric Furnace
1) In 1972, the company built the first electric furnace in the U.S.
2) Calcines pass through "drop pipes" to one of two partially enclosed
pinless drag chain conveyors above electric furnace. The furnace
is fed through charge points near electrodes. Matte is tapped
through exhausted tap point onto unhooded launders and ladles.
Slag is tapped for an hour two to three times per shift and is
granulated for use and sale.
3) Arsenic and sulfur dioxide levels and exposures are poorly charac-
terized throughout the entire electric furnace area. Arsenic expo-
sures were reported below proposed standard throughout area in the
single state-conducted survey. Company reports that forty work-
ers in "smelter" are exposed to sulfur dioxide levels greater than
or equal to the proposed TWA standard.
4) Furnace operator helper—job station is on ceiling of furnace
measuring electrode paste and bath depth. Union reports gassy con-
ditions. Actual exposures are poorly characterized. 3 workers.
5) Slag tapper—job station is at unhooded slag launders beyond ex-
hausted tap points near granulation pump. Exposures, if any, in
-------
slag area are uncharacter!zed. Worker also assists in matte tap-
ping. Potential exposures during reportedly gassy tapping opera-
tion are uncharacterized. I
i
Matte tapper -- matte launders are unhooded past tapping points.
Union reports gassy conditions. Actual exposures are poorly char-
Rrt.ffri7.erl. 3 workers
6)
acterized. 3 workers.
7) Relief man--worker assists matte and slag tapping as well as feed
pipe clean-out. Union reports gassy conditions at jmatte tap and
feed pipe clean-out locations. Actual exposures are poorly charac-
terized. 7 workers.
D) Converter Aisle
1) Two Fierce-Smith primary hooded converters. Only one is in use at
a time, operating approximately ten hours per day. Slightly more
than 50% of the blister copper produced is used internally as cop-
per shot in the copper sulfate plant. The remainder is cast into
2,500-lb. bars and shipped to a refinery.
2) Arsenic and sulfur dioxide levels and exposures are poorly charac-
terized throughout the entire converter area. A'rsenic exposures
reported'below proposed standard in the single sftate-conducted
survey. Company reports forty workers in "smelter" exposed to
levels greater than proposed standard. Lack of positive seal be-
tween converter and hood makes fugitive sulfuy emissions likely.
3) Crane operator—continued problem with window'seals in crane cabs.
Company repairs often but problem persists. Actual exposures are
poorly characterized. 3 men.
4) Crane chaser—union reports gassy condition throughout converter
area. Actual exposures are poorly characterized.
5) Operator/foreman—job station is "all over the entire area," and at
converter control platform during pouring. Union reports gassy
conditions throughout converter area.
6) Puncher--documented noise violations prior to installation of auto-
matic punchers, effectiveness in reducing noise exposure unknown.
Union reports high noise levels continue. Exposures are poorly
characterized. 6 workers.
7) Flue duster—worker cleans out exhaust flues and works near open
conveyor belts. Union reports spillage and dust problem. Actual
exposures are poorly characterized. 2 workers.
8) Documented noise violation to puncher and workers near lunchroom
from #2 converter blower. Company studied possibility of enclosing
blower; effectiveness unknown.
E) Liquid S02 and Acid Plants
1) Company reports sixteen workers exposed to levels of 2ppm or
greater in the liquid sulfur dioxide and acid plants.
2) State documented sulfur dioxide levels above the existing standard
prior to installation of new ventilation. Company reports levels
in "compliance with 5 ppm TWA." Actual levels are uncharacterized.
-------
3) Reported possibility of V2o5 TWA violations duUng bed replacement
Actual exposures are uncharacterized.
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History—Details unavailable.
B) Staff (Safety Department)
Director—Industrial Hygiene (1)
Director—Safety Director (1)
Engineers (3)
Technical personnel (part-time)
C) Industrial Hygiene
1) Industrial hygiene functions are divided among the full-time indus-
trial hygienist and the safety personnel.
2) The company does "occasional" evaluatory sampling for hazards.
Exact frequency of sampling unknown.
D) Respirator Program
1) Respirators are issued on a need basis, based on evaluatory sam-
pling.
-------
2) Education for use and maintenance is administered by the worker's.
immediate supervisor.
3) Workers are responsible for storage and cleaning in most areas.
The company has established some sanitary cleaning facilities.
E) Safety
1) The company has no established pre-employment safety orientation
other than safety instruction administered by experienced employ-
ees .
2) Weekly departmental safety meetings were re-es'tablished in 1973.
3) Company issues free of charge most necessary slafety equipment in-
cluding: hard hats, safety shoes, fire-resistant clothes (where
needed) and safety glasses. '
F) Health Care
1) Cities Service Company has established a contractual-leasing rela-
tionship with Basin General Hospital.
l
2) Medical program is administered by one full-time and three part-
time physicians, as well as one nurse and several part-time techni-
cal personnel. j
3) First aid is administered through first-aid stations located
throughout the complex. !
4) Company reports that pre-employment test include: respirator com-
patibility, chest x-rays, blood and urine analysis, audiometric and
optometric testing, as well as history and physical.
5) The company in 1976 established a series of voluntary annual medi-
cal tests. Tests include chest x-rays and blood and urine analy-
sis, and audiometric and optometric testing.
Comments:
SAFETY COMMITTEE
A) Description
1) Monthly meetings are attended by the safety director, three safety
engineers, the company industrial hygienist, and one union repre-
sentative from each department.
-------
2) The committee is advisory in nature and has nojinspection powers.
3) The committee assists in all accident investigations.
Comments:
f. REGULATORY HISTORY
A) Pre-1970
1) Tennessee Industrial Hygiene Service--1937 to 1^70.
B) Post-1970
1) State OSHA Plan
a) State plan, approved June 29, 1973, after 15-month contract
period. ;
b) Originally divided between Tennessee Department of Public
Health and Tennessee Department of Labor; recently health
function (Division of Occupational and Radiological Health)
has been incorporated into Department of Labor.
2) OSHA activities
a) Never inspected Copperhill facilities.
b) Performs advisory and monitoring functions with inspection
jurisdiction over longshoring, shipbuilding and railroads.
Comments:
-------
PROCESS EQUIPMENT--Copperhill*
Table 1
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Fluosolids Roaster (1)
1972
15TettTrc - Furnace (1)
-— - 19-72-
Gas-es-from all furnaces are combined
and sent through a. Peabody Scrubber.
Gases are then added to iron roaster
gases and transported to the liquid
S02 and acid plants.
Converters (3)
(Pierce Smith)
Cylindrical mouth
shape prevents
tight hood seal.
Acid Plant #4, #5
Combined
1975
1,910 TPD
Acid Plant #6
1975
2,100 TPD
Liquid S02 Plant
Gases taken down stream of acid
plant #6.
On-stream factor of
90% to 95%.
* Copper smelter and related facilities.
SOURCES: Engineering Evaluation of Cities Service Smelter,
-------
Table 2
ctions--Copperhill
ssee Department of Labor
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
75
75
75
complaint/
safety
complaint/
safety
complaint/
safety
no violations
1 non-serious
violation
no violations
walk area
! #4 acid
$60 i plant
converter
; puncher
j- blow-back
ctions--Copperhill
ssee Department of Public Health
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
i/73
'4
/74
75
complaint/
health
follow-up/
health
general
schedule/
health
complaint/
health
1
15 violations $0 7/1/74
no violations
no violations
1 violation $0
liquid
S02 plant
arsenic
levels
noise/
converter
punchers
-------
Table 3
SUMMARY OF HEALTH HAZARDS--Copperhill
PLANT AREA
Material Handling —
Fluosolids
Roaster
Electric Furnace
Converters
Acid £ Dm plants
TWA Exposures*
Number of
Employees
16
50
27
100
Copper
mg/M3
Arsenic
mg/M3
-
.0001-. 0002
.0002-. 001
Lead
mg/M3
Sul fur
Dioxide
(PPM) NOTES
see noteA
see noteA
to
Roaster
see noteA
to
Roaster
see notet
AND known surveys for sulfur
dioxide by government regula-
tory agencies. Company re-
ports 40 workers in "smelter"
exposed to TWA levels of 2ppm
or greater.
Noise--documented violations
(>115 dBA) prior to installa-
tion of new punching system,
effectiveness unknown.
tDocumented levels S02 (6ppm)
prior to installation of new
ventilation in DMA plant.
Company reports 16 workers
exposed to TWA levels greater
than or equal to 2ppm.
SOURCES: Arsenic OSHA hearing, 1975. Company data.
Tennessee Department of Public Health inspections,
*Independent of respirator usage.
-------
FACT SHEET
Facility: White Pine Copper Smelter
Company: Copper Range Company
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
I. GENERAL
Name: Copper Range Company, White Pine Smelter
Location: White Pine, Michigan
Description:
1) Combination of concentrate receiving and mixing facilities, rotary
dryer, reverberatory furnaces (2), converters (2) ,, fire-refining
furnaces (2), holding furnace (1), semi-continuous! casting machines
(2), casting wheel (1), and supportive facilities.1
2) Smelter began operation in 1955. n !
Wf> 13n"
3) Employees: %%% smelter production. ~2-9-©0- at i the White Pine complex
4) Ores from White Pine underground mine (Nonesuph formation) are
concentrated in the White Pine Mill, adjacent to the smelter.
Arsenic content of the concentrates estimated' at .003%. Low sulfur
content requires the addition of pyrite to make feed amenable to
smelting. Other trace material information on hand.
5) White Pine is the second largest employer in Michigan's Upper
Peninsula. j,
6) Production ;
. 1973 1974 ' ;1975 1976
!
Copper (tons) 78,506 66,898 ; 70,776 46,053
Comments :
I. PROCESS AND HAZARDS
NOTE: Respirators are company-supplied and company-maintained. They are
worn on a need basis. The following comments evaluate TWA exposures
independent of respirator use.
NOTE: Throughout the following remarks, the phrase "Poorly characterized"
is used to indicate that we have found no evidence that either the company
or. the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
Page 2
A) Material Handling
1) The smelter feed, in the form of filter cake fa copper bearing concentrate
of -30-32% Cu and 18% H20), is received at thp Filter and Dryer Building.
*£feejr drying in the Rotary Dryer, fluxes (limestone, pyrite, and recycle
materials) are added to obtain good smelting characteristics. Exposures,
if any are uncharacterized for the Rotary Dryer Operator and the Operator's
Helper. Eight workers -- Company classifies these employees as Mill
workers.
2) If the reverberatory furnace is being charged the dried materials are
transfered directly to the reverberatory charge bins If not being
charged, the materials are transfered to the Smelter Feed and Bedding
Building. All concentrate transfer is by encjlosed conveyors. Documented
copper dust exposures for bedding plant employees. The company proposed
to implement certain engineering and administrative controls in this
building. Effectiveness of reducing hazards by this effort unknown.
Five workers.
3) Other material handling workers -- the conveyormen and the conveyor
attendants -- are potentially exposed to copper! dusts during the transfer
of concentrates. Documented copper dust exposures above the standard.
The company was to abate the dusty conditions during transfer by increasing
moisture of materials leaving the Rotary Dryer.! Effectiveness of reducing
dusts is unknown. Ten Workers.
B) Reverberatory Area
1) Two identical suspended arch reverberatory furnaces. At the present time
only one (#1) is presently in operation. The concentrate-flux mixture
is fed from the charge bins by a tripper belt - shuttle conveyor system
and is charged into the reverb through water cooled chutes. Approximately
50 workers.
2) Charge Floor
a) Tripperman. Operation consists of charging reverberatory furnace by
operating mechanized conveyor to load furnace hoppers with feed.
Loading operation takes about 2 hours, afterwhich worker spends about
1/2 hour cleaning hoppers. Documented S02 and Cu dust exposures above
standard. Arsenic levels above proposed standard.** Six workers.
b) Arch Attendant. Potential exposures similiar to tripperman. Reportedly
very high dust exposures during blowing of arch. Company attempted
vacuuming, however proven unsuccessful. Actual exposures are poorly
characterized. Four workers.
c) Brickmasons. Replacing refactory and maintaining furnace roof.
Documented Cu dust exposures of up to 13 times the standard. Arsenic
exposures above the proposed OSHA standard.** Potential S02 exposures
poorly characterized. Twelve workers.
-------
Page 3
3) Operating Floor
aj Furnaceman. Operator of the reverberator^ furnace. Documented Arsenic
exposures above the proposed standard.** ,'Potential Cu dust and S02
exposures are poorly characterized. Five,"workers .
b) Tapper and Tapper Helper. Matte and slag tap holes are ventilated
with hoods. The slag launder is reportedly uncovered. Slag and
matte is collected in a"tunnel located beneath! the operating floor.
Area S02 reported at >15 ppm. Arsenic exposures at the proposed
standard.** Eight workers.
4) Others
aj Locomotive Engineer and Carman. Transferj matte via electrical ladle
car to converter aisle and transfer slag via slag train to slag
dump (located adjacent to the smelter). 'Workers reportedly leave
tunnel during the filling of ladles. Potential S02 exposures are
poorly characterized. Other exposures, if any, unknown. Six workers.
b) Flue Dust Man and Flue Dust Helper. Emptying hoppers on ESP and
Waste Healt Boilers, among other dust handliing system tasks.
Documented Cu exposures above the standard.' Arsenic exposures above
the proposed standard.** S02 exposures, -if! any, are unknown.
Five workers.
c) Boiler (Waste Heat) Lancers. Performs lancing of boiler tubes. Cu
dust exposures above the standard. Other exposures, if any, are
poorly characterized. These employees are assigned to the Power
Plant -- number of boiler lancers unknown.
C) Converter Area
1) Matte from the reverberatory furnace is transfered in ladles to one of
the two Fierce-Smith converters by an enclosed and air conditioned over-
head crane. A siliceous flux is added to the converter bath to form
an iron oxide slag that is skimmed off and returned to the reverb. At
the completion of the converter cycle, blister copper is transfered to
a holding furnace or directly to the refining area for further processing.
2) Crane Man. Workers report conditions in the crane cabs to be good and
protective equipment (respirators) is not required. Three workers.
3) Crane Chaser. Directs crane-man on ladle movements and other converter
aisle tasks. One documented Arsenic exposure above the proposed
standard.** Other exposures, if any, poorly characterized. Six workers.
4) Skimmer. Operator of the converter. Some Arsenic exposures above
the proposed standard. S02 and Cu dust levels below the standards.
Three workers.
-------
GENERAL
Name: Copper Range Company, White Pine Smelter
Location: White Pine, Michigan
Description:
1) Combination of concentrate receiving and mixing facilities, rotary
dryer, reverberatory furnaces (2), converters (2), fire-refining
furnaces (2), holding furnace (1), semi-continuous casting machines
(2), casting wheel (1), and supportive facilities.
2) Smelter began operation in 1955.
3) Employees: 166 smelter production. 1279 at the White Pine complex.
4) Ores from White Pine underground mine (Nonesuch formation) are
concentrated in the White Pine Mill, adjacent to the smelter.
Arsenic content of the concentrates estimated at .003%. Low sulfur
content requires the addition of pyrite to make feed amenable to
smelting. Other trace material information on hand.
5) White Pine is the second largest employer in Michigan's Upper
Peninsula.
6) Production
1973 1974 1975 1976
Copper (tons) 78,506 66,898 70,776 46,053
Comments:
PROCESS AND HAZARDS
NOTE: Respirators are company-supplied and company-maintained. They are
worn on a need basis. The following comments evaluate TWA exposures
independent of respirator use.
NOTE: Throughout the following remarks, the phrase "Poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
Page 2
A) Material Handling
1) The smelter feed, in the form of filter cake (a copper bearing concentrate
of -30-32% Cu and 18% H20), is received at the Filter and Dryer Building.
Before drying in the Rotary Dryer, fluxes (limestone, pyrite, and recycle
materials) are added to obtain good smelting characteristics. Exposures,
if any are uncharacterized for the Rotary Dryer Operator and the Operator's
Helper. Eight workers -- Company classifies these employees as Mill
workers.
2) If the reverberatory furnace is being charged the dried materials are
transfered directly to the reverberatory charge bins If not being
charged, the materials are transfered to the Smelter Feed arid Bedding
Building. All concentrate transfer is by enclosed conveyors. Documented
copper dust exposures for bedding plant employees. The company proposed
to implement certain engineering and administrative controls in this
building. Effectiveness of reducing hazards by this effort unknown.
Five workers.
3) Other material handling workers -- the conveyormen and the conveyor
attendants -- are potentially exposed to copper dusts during the transfer
of concentrates. Documented copper dust exposures above the standard.
The company was to abate the dusty conditions during transfer by increasing
moisture of materials leaving the Rotary Dryer. Effectiveness of reducing
dusts is unknown. Ten Workers.
B) Reverberatory Area
1) Two identical suspended arch reverberatory furnaces. At the present time
only one (#1) is presently in operation. The concentrate-flux mixture
is fed from the charge bins by a tripper belt - shuttle conveyor system
and is charged into the reverb through water cooled chutes. Approximately
50 workers.
2) Charge Floor
a) Tripperman. Operation consists of charging reverberatory furnace by
operating mechanized conveyor to load furnace hoppers with feed.
Loading operation takes about 2 hours , afterwhich worker spends about
1/2 hour cleaning hoppers. Documented S02 and Cu dust exposures above
standard. Arsenic levels above proposed standard.** Six workers.
b) Arch Attendant. Potential exposures similiar to tripperman. Reportedly
very high dust exposures during blowing of arch. Company attempted
vacuuming, however proven unsuccessful. Actual exposures are poorly
characterized. Four workers.
c) Brickmasons. Replacing refactory and maintaining furnace roof.
Documented Cu dust exposures of up to 13 times the standard. Arsenic
exposures above the proposed OSHA standard.** Potential S02 exposures
poorly characterized. Twelve workers.
-------
Page 3
3) Operating Floor
a) Furnaceman. Operator of the reverberator/ furnace. Documented Arsenic
exposures above the proposed standard.** Potential Cu dust and S02
exposures are poorly characterized* Five workers.
b) Tapper and Tapper Helper. Matte and slag tap holes are ventilated
with hoods. The slag launder is reportedly uncovered. Slag and
matte is collected in a"tunnel"located beneath the operating floor.
Area S02 reported at >15 ppm. Arsenic exposures at the proposed
standard.** Eight workers.
4) Others
a) Locomotive Engineer and Carman. Transfer matte via electrical ladle
car to converter aisle and transfer slag via slag train to slag
dump (located adjacent to the smelter). Workers reportedly leave
tunnel during the filling of Ladles. Potential S02 exposures are
poorly characterized. Other exposures, if any, unknown. Six workers.
b) Flue Dust Man and Flue Dust Helper. Emptying hoppers on ESP and
Waste Healt Boilers, among other dust handling system tasks.
Documented Cu. exposures above the standard. Arsenic exposures above
the proposed standard.** S02 exposures, if any, are unknown.
Five workers.
c) Boiler (Waste Heat) Lancers. Performs lancing of boiler tubes. Cu
dust exposures above the standard. Other exposures, if any, are
poorly characterized. These employees are assigned to the Power
Plant -- number of boiler lancers unknown.
C) Converter Area
1) Matte from the reverberatory furnace is transfered in ladles to one of
the two Pierce-Smith converters by an enclosed and air conditioned over-
head crane. A siliceous flux is added to the converter ba^th to form
an iron oxide slag that is skimmed off and returned to the reverb. At
the completion of the converter cycle, blister copper is transfered to
a holding furnace or directly to the refining area for further processing.
2) Crane Man. Workers report conditions in the crane cabs to be good and
protective equipment (respirators) is not required. Three workers.
3) Crane Chaser. Directs crane man on ladle movements and other converter
aisle tasks. One documented Arsenic exposure above the proposed
standard.** Other exposures, if any, poorly characterized. Six workers.
4) Skimmer. Operator of the converter. Some Arsenic exposures above
the proposed standard. S02 and Cu dust levels below the standards.
Three workers.
-------
Page 4
5) Puncher. Punching the converters is performed manually by two workers
using six-foot steel rods.. Noise levels in punching area documented
as >105 dBA. Punching operations are intermitj'tent and 8-hour TWA's
are poorly characterized. Documented Arsenic 'exposures at the
proposed standard. S02 exposures below the proposed standard. Eleven
workers.
D) Refining and Casting Area.
1) Blister copper is fire-refined in one of two fire-refining furnaces
and cast into different shapes (copper ingots, wire bar, and copper
cakes) in the casting wheel or in one of two semi-continuous casting
machines. 35 employees.
2) S02 and Arsenic area samples throughout the Refining and Casting area
are documented below the proposed standards. 'However, actual 8-hour
TWA exposures for these employees are poorly characterized.
3) General dusty conditions prevailing in the Casting Area have been
reported due to the spraying of bone ash (a mold lubricant) and lamp-
black (a material that prevents re-oxidizing of I the fire-refined
copper). Actual exposures to these materials are uncharacterized.
4) NOTE--A uniqueness found at White Pine is that their final product,
the fire-refined copper, does not need electrplytic refining. While
the electrical conductivity (due to silver cohtent) is not equivalent
to electrolytic copper it carries the same classification.
E) Others.
1)
Due to the transient nature of a selected number of smelter jobs, INFORM
has created an "Others" cateogory. While many workers on this list are
permanently associated with on sub-department of the smelter -- i.e.
some of the surface laborers work full-time in the Reverb department --
we have been unable to differentiate these workers from their transient
counterparts. Hence they are included in this cateogory. These workers
are listed as follows:
Laborers
Maintenance Men
Technicians
Tool Room Man
Inspector
Janitors
69 workers,
27 workers.
3 workers,
1 worker.
1 worker.
2 workers,
2) Most exposures for these workers are poorly characterized.
**NOTE--Due to the low arsenic content in White Pine's ore, in-plant arsenic
levels have been documented as ranging between none detected and 20 yg/m .
However, many arsenic exposures, especially those of reverberatory workers,
are above the proposed action level. Therefore, these workers will be subjected
to the monitoring and medical surveillance requirements as set forth in the
standard.
-------
rage b
Comments:
I. Company Safety and Health Activities.
A) History
Details not available.
B) Staff
Safety Director (1)
Safety Engineer (2)
Director of Environmental Affairs (1)
Industrial Hygienist (2)
C) Industrial Hygiene
There is no regular schedule of sampling of in-plant levels of
gases and vapors in the smelter. However, since January of
1976, monitoring for copper dust levels has been performed
-------
Page b
monthly in the concentrate handling system, flue-dust handling,
and the waste heat boilers. This monitoring involves the personal
sampling of 16 to 20 workers.
D) Respirator Program
Respirators are company supplied and NIOSH approved. The respirators
are supplied on demand and worn on an "as needed" basis. Workers
are responsible for daily cleaning. Respirators are turned in weekly
to be replaced, torn down and rebuilt, and/or sterilized. The main-
tenance and rebuilding of respirators is performed by two Safety
Department technicians.
E) Safety
1) The company reports that a safety man is assigned to periodically (not
less than once a week) inspect the. smelter. If a substandard condi
tion is noted, "He will write it up."
2) Personal protective safety equipment—hard hats, safety glasses,
metatarsal guards — is issued to all smelter employees. Special pro-
tective equipment--aluminized clothing and gloves, face shields — is
issued where required.
3) General Safety Committee
Aside from the Joint Safety and Health Committee, a General Safety
Committee exists at this smelter. It consists of three management
and three union representatives. The committee reviews the general
safety policies of the company.
4) OSHA 100s for 1971-1976 and OSHA 102s for 1972-1974 on hand.
F) Health Care
1) White Pine owns and operates a 20-bed hospital located one mile from
the smelter.
2) Hospital staff of 34 (27 full -time, 7 part time), including 3 full-
time physicians.
3) All minor injuries, are treated at hospital. Preliminary treatment
only, for major injuries.
4) Supervisory personnel receive basic first aid training.
5) All employees, receive a pre-employment physical. Extent of annual
physicals, if any, is unknown.
Comments:
-------
Page 7
\l. Safety and Health Committee
A) Description
1) Joint Safety and Health Committees(both underground and surface) have
been in existence since the beginning of operations.
2) Committee consists of three management representatives and three union
representatives.
3) A once-a-month joint inspection of the plant is:made "to detect and
record violations of applicable OSHA standards and to detect and
record instances of non-compliance to other recommended safety prac-
tices."
4) At the tour's conclusion, a written report, consisting of union/man-
agement recommendations for corrections of conditions found to be
hazardous, and tentative abatement dates, is prepared by the company
and forwarded to the union.
B) The safety and health provisions of the contract address other matters,
s uch as:
1) Right to refuse unsafe work. A specific grievance procedure (third
party review) has been incorporated to handle disputed cases.
2) Exposure levels are made available to union.
3) International has access right to the plant for safety and health
meeting and inspections upon advance notification of management.
4) After a physical examination by the company physician, each employee
is furnished with the results.
Comments:
-------
rage »
V. REGULATORY HISTORY
A) Pre-OSHA
1) Safety—Passage of first state safety law an4 the creation of the
state's Department of Labor occurred in 1909.: A comprehensive safety
law—Occupational Safety Standards Act (Act 282)--was passed in 1967.
MIDOL records show that the White Pine smeltdr was never inspected
under this Act.
2) Health—Division of Occupational Health, Michigan Department of Public
Health, formed in 1937. INFORM has on file health inspections per-
formed at White Pine dating back to 1959.
B) Post-OSHA
1) State OSHA Plan
a) Developmental plan approved in October, 1973. The enabling
legislation became effective on January 1, 1975.
bj The Michigan Department of Labor has full authority to
endorse and administer the laws pertaining to occupational
safety.
c) The Michigan Department of Health is responsible for admin-
istering and enforcing laws concerning occupational health.
d) Inspections —See Table 2.
2) OSHA activities
a) Inspections —See Table 2.
-------
PROCESS EQUIPMENT -- White Pine
Table 1
NAME
Rotary Dryer
Reverberatory Furnaces (2)
Converters (Fierce-Smith)
Holding Furnace (1)
Fire Refining Furnace (2)
Casting Wheel (1)
Semi-Continuous Casting
Machine
SOURCES: Design and
White Pine
AGE
1970
1955
(2) 1955
1955
1974
1955
1955
POLLUTION CONTROLS COMMENTS
Two Stage Wet Scrubber -> Stack Particulate emissions are
also controlled by main-
taining a 9% moisture content
in the mixed charge.
Waste Heat Boilers -> ESP [Flat Plate ESP installed in 1961.
Type] -> 500' Main Stack Coal fired.
Baloon Flue •> 500' Main Stack No S02 control at this smelter.
Gases vented to 92' Stack
Gases vented to Separate 125 '
Stacks
Operating Parameters for Emission Control Studies:
Copper Smelter.
Field Study of The White Pine Copper Company NIOSH Study.
-------
Table 2
iections--White Pine
dgan Department of Labor
Page 10
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
1/75 general 5 citations $52
schedule (14 violations)
company
abatement
letter
guards, warning
devices, barriers
£ other safety
violations
775
follow-up
Involved whether
or not to issue a
variance from a
standard cited in
5/20/75 inspec-
tion. Variance
granted.
>/76
general
schedule
14 citations
(32 violations)
guards, electri-
cal, personal
protective equip-
ment, other
safety violations
7/76- general 7 citations $33
!2/76 schedule (21 violations)
company
abatement
letter
guards, electri-
cal, maintenance
records, other
safety violations
ligan Department of Health
: TYPE FINDINGS
PENALTIES FOLLOW-UP
referral no violations
inspection
COMMENTS
j/75-
L8/75
general 1 violation
schedule
$30 company
abatement
progress
reports
copper dust
violations
MIDOL calling for
inspection of
flux building
-------
iections--White Pine
Page 11
TYPE
1/72 accident
fatality
1/72 health
general
schedule
'75- health
>/75 general
schedule
(THHP)
FINDINGS
14 non-serious
violations
1 non-serious
violation
0
PENALTIES FOLLOW-UP
$180 company
abatement
letter
i
i
0 company
abatement
letter
1
i
I
i
COMMENTS
Death resulting
from fall from
roof during rest
period.
Cited for S02
exposures above
the reverb.
sampling for
As, Cu, and S02
-------
Table 3
SUMMARY OF HEALTH HAZARDS--White Pine
TWA Exposures'
Number of
PLANT AREA Employees
Material Handling
Reverberatory
Furnace area
Converter area
Refining
and Casting
Other
24
46
23
36
107
Copper
mg/M3
.7-4.7
<.1-13.
Arsenic
mg/M3
<.0002-.02
<.001-.011
Lead
mg/M3
Dioxide
(PPM) NOTES
S02 levels above
reverb range
between 4-10
ppm.
Tapping area
>15 ppm.
-- —
One copper dust measure-
ment of 245.5 mg/M3
All S02 sampling by
either state or federal
OSHA shows exposures
below proposed S02
standard.
Noise levels 105 dBA --
punching area.
insnections
*Inder>endent of resnirator
-------
FACT SHEET
Facility: Inspiration Smelter
Company: Inspiration Consolidated Copper Co.
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
Name: Inspiration Smelter (Inspiration Consolidated Copper Co.)
Location: Inspiration, Arizona
Description:
1) Part of an integrated copper producing operation wh|ch also includes
three open pit mines, vat and heap leaching, a concentrator, an
electrolytic refinery, and a continuous casting and!rolling plant.
2) Smelting has been carried out since 1915. Purchased by Inspiration
in 1960, the plant was modernized considerably.] In 1974, a brand
new smelter with an electric furnace and Hobok^n converters was put
in operation. I
I
3) Entire complex employs approximately 2,000 people. Some 450 are
employed in the smelter, including administrative and maintenance
employees.
4) Smelter is located in the Globe-Miami area of Arizona, with a popu-
lation of 17,500 people. Inspiration is the largest employer in the
area.
5) Arsenic content of the concentrates is unknown).
6X Production
a) Approximately 45-70% of the ore treated is on a custom basis.
b) 1972 1973 1974 1975 1976 1977
Copper (tons)
Sulfuric Acid
(tons)
94,000
175,000
127,000
237,000
Comments:
-------
[page 2]
PROCESS' AND HAZARDS
NOTE: In some areas of the plant, workmen wear company-isupplied respirators
on a need basis. The following comments refer to exposures independent of
respirator usage. ,
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
A) Material Handling-Receiving, Bedding Areas, and Dryer
1) Concentrates and precipitates are received mostly by rail car (some
by truck), unloaded to hopper with car shaker, find finally moved on
conveyor belt to bedding area.
2) Foreman and operator (3 shifts) in unloading area are exposed to
intermittent dust and noise from car shaking anii unloading. Actual
exposures are poorly characterized. :
3) Sampling area has been reported in need of ventilation. Actual
exposures were poorly characterized. SMI reported in late 1976 that
area would be replaced. Actual status is unknown
4) Bedding area is an enclosed building, with 2 doori and some windows.
It was built with the new smelter. Materials a|re bedded by means -of
an overhead tripper conveyor system, then placejd onto another con-
veyor by means.of a payloader with an open cab. Intermittent dust
exposures are poorly characterized.
5) Concentrates are conveyed to a 150 ton wet charge storage bin ahead
of the dryer. Fuller rotary dryer is designed to reduce the moisture
content from about 10% to less than 0.3%. The exit gases are cleaned
by cyclones and a baghouse before being vented into the atmosphere.
Dry material is fed directly to two 700-bins above the electric
furnace. The bins are "totally enclosed structures vented into the
dryer dust collection system." Dust exposures to the single operator,
if any, are poorly characterized.
6) Cleaning of the baghouse--carried out infrequently—is reported to be
"very dusty."
B) Electric Furnace
!)• Began operations in 1974. Largest in the world.
2) Feed is drawn from storage bins by screw feeders which deliver the
materials to two drag conveyors. Conveyor operation is reported
dusty.
3) Potential exposures to sulfur dioxide, metal dust and fumes on all
floors above the furnace roof are poorly characterized. A few grab
samples of S02 on record indicate levels of 2-28 ppm at the smelter
control room. The heat on the sixth floor of the furnace is reported
"terrible." Actual levels are not characterized.
-------
[page 3)
4) Matte is tapped from four holes on the converter aisle end of the
furnace. Only one is ventilated. The launders(converge onto two
ladle-filling spots. There is no ventilation at these spots. The
launders are reported to be partly covered, but^exact extent is un-
known. Potential exposures in these areas are poorly characterized.
5) Slag is skimmed from two tap holes in end wall of the furnace.
Tapping is done with machine. There is no hooding or ventilation
on tap holes, launders or slag pots. Slag is taken to dump by
rubber-wheeled vehicles. Potential exposures in thiis area are
poorly characterized. '
C) Converter Aisle
1) Five Hoboken-Overpelt converters. Off gases ar|b drawn from the
"siphon" units on the side rather than traditional primary hoods.
t
2) Emissions into the converter aisle through converter mouths are
reported frequent. These occur particularly wh|en there are diffi-
culties with the gas cleaning system downstream of the converters.
Labor walkouts have occurred in protest of conditions in aisle when
acid plant is down.
3) Potential exposures to sulfur dioxide and metal fumes, if any, in
the converter aisle are poorly characterized.
4) Usually one converter is down for repairs, particularly in the
"smoke box" section. Repair work by masons and others inside these
is reported to be extremely dusty. Actual exposures are poorly
characterized.
5) Crane cabs (2) are enclosed and supplied with fresh air. Maintenance
of seals and fresh air equipment is reported adequate. Sulfur di-
oxide levels inside the crane cabs are reported near zero.
6) Noise levels in converter aisle reported around 95-96 dBA. Actual
exposures are poorly characterized. No measures to reduce noise
levels from converters have been taken.
D) Refining and Casting Area
1) Blister copper is either cast into 6000-pound cakes directly or
refined in an anode furnace and cast into anodes in the 10-mould
anode casting wheel.
2) There is no hooding or ventilation at the anode furnace.
3) Potential exposures in these areas are poorly characterized.
E) Other Areas
1J Transfer of revert dust from dust control devices (e.g. cyclones,
flues, precipitators) is reportedly by enclosed systems (screw con-
veyors) back to mixing areas before rotary dryer. Potential dust
exposures, if any, are poorly characterized.
-------
("page 4]
2) Crushing plant handles silica and smelter reverts. Scant information
available to INFORM suggests that wetting systems are inoperative and
that there is no exhaust ventilation. Potential dust exposures are
poorly characterized.
3) Exposures, if any, in the acid plant are poorly, characterized.
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History--Not Available
B) Staff
l
1) Safety Department: Safety Director and two safety engineers working
under the director of industrial relations. Activities encompass
entire complex, not only smelter.
2) Industrial Hygiene: Former safety director now holds the position of
Director of Industrial Hygiene.
C) Respirator Program
1) There is no specific training, education or supervision of respirator
usage.
2) Respirators are cleaned and disinfected and repaired by the company
on a monthly or weekly basis, according to areas of use. Some work-
men are dissatisfied because respirators are returned at random.
Comments:
-------
[page 5]
D) Industrial Hygiene
1) Company performs some monitoring of personal exposures. Details of
monitoring program are unavailable.
2) Ventilation systems are not inspected according, to written plan or
schedule.
3) There is no exchange of information with the union regarding the
goals or results of air sampling.
4) Company presented no substantive testimony regarding hazards or
controls during the OSHA hearings for the proposed sulfur dioxide
and arsenic standards. INFORM found no evidence of any systematic
exchange of industrial hygiene data with government, unions, or
other companies.
Comments:
E) Safety
1) Company safety inspections are the same as those conducted by the
joint safety committee.
2) Details of accident investigation procedures are not available.
3) Safety training for new employees consists of
a) one-hour lecture
b) safety movie
c) instructions on protective equipment.
4) INFORM found no evidence of any refresher safety education.
5) Union reports that workmen were not trained in the safety aspects of
the new equipment put in operation in 1974.
6) INFORM has available OSHA 102 data for the years 1972, 1973, 1974,
and 1975.
-------
[page 6]
Comments:
F) Health Care
1) Health care for employees and dependents is provided by private
clinic set up by the company. Staff includes 7 physicians as well
as other personnel.
i
2) Clinic is approximately one mile from the smelter.
JOINT SAFETY COMMITTEE
1) A joint safety committee exists, with representatives from each of
the nine unions, as well as 3-4 management representatives. There
is no contract language outlining the existence, make-up, or
functions of this committee.
2) Committee meets monthly, when it selects one area of the smelter to
inspect. Committee has no specific authority; it can only make
recommendations.
3) There is no specific procedure for joint accident investigations
and union committee members are seldom included.
4) Other activities of the safety committee, if any, are unknown.
Comments:
-------
[page 7]
REGULATORY HISTORY
A) Pre-1970
Office of State Mine Inspector
B) Post-1970
1) State OSHA Plan
a) Developmental plan approved October 1974. Headed by Arizona
Industrial Commission.
b) Jurisdiction: Still in hands of state mine inspector.
2) State Mine Inspector
a) Inspections: see table.
b) Limited industrial hygiene efforts.
3) OSHA (Federal) Activities
Four inspections. Two accidents. Two complaints.
Comments:
-------
Table 1
PROCESS EQUIPMENT--Inspiration
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Fuller Rotary Dry~ex
1974 Two Dracco cyclones in series
followed by a baghouse
Elkem Electric Furnace
1974 Gas coolers (with some heat recovery)
-> 2 Dracco dust cyclones
-> electrostatic precipitator (ESP)
-> join the converter gases on the
way to the acid plant
Largest electric
furnace in the world.
Furnace fed by 2 drag
chain conveyors.
Hoboken-Overpelt Converters (5) 1974
Gas coolers -+• one Duccon cyclone per
converter -> mixing chamber -> 3
electrostatic precipitators -»• join
furnace gases on way to acid plant
Anode Furnace (1)
1915
Anode Casting Wheel (1)
1915
Acid Plant
1974
-------
Table 2
SUMMARY OF HEALTH HAZARDS--Inspiration
TWA Exposures in
Number of
PLANT AREA Employees
Material Handling
-Receiving Area . -.
--Bedding Area
--Dryer
Electric Furnace
Converter Aisle
Refining and Casting Area
Other
--Crushing Plant
--Acid Plant
-- ..
Copper
dust
-
Arsenic
OUJ. J. UX
Dioxide
(PPM) NOTES
Levels from 2-28 ppm reported.
TWA exposures not available.
Noise levels 95-96 dBA in
aisle. Details unavailable.
-------
HA INSPECTIONS--Inspiration
TF,
18/73
TYPE
Accident
Death
FINDINGS
l--non-serious. Failed
provide derail or bumper
to
: blocks
PENALTIES
$90.00
FOLLOW-
UP
No
on railroad spur track which
would have prevented car from
entering building and contacting
another car.
6/74
/18/74
llll
Accident
Death
Complaint
Complaint
In compliance. (Fall from crane
while changing lights. )
6--non-serious. t ?
No violation. Complaint re use of
--
No
—
wood brake handles at sampling and
unloading area.
-------
DATE
TYPE
FINDINGS
FOLLOW-UP
COMMENTS
10/21/74
Safety--smelter 19 violations
Co. abatement letter
11/25/74
Guards, clean-up, covers, etc.
Oil spill problem £ electrode
control tower.
Co. abatement letter
for acid plant in-
spection. No report.
5/1/75
Safety--smelter 18 violations
Co. abatement letter
5/28/75
9/18/75
Health $ safety
--smelter
9 noise readings
>90dbA
43 safety
violations
Signs requiring hearing protec-
tion need to be posted
Co. abatement letter
requesting 6 delays.
Others abated
3/8/76
Health--smelter
Dust.
S02--4 samples
>5 ppm.
2 >25 ppm.
3/16-17/76
Safety--acid
plant, smelter,
shops
33 violations
Housekeeping
5/7/76
Safety—use of
explosive
3 violations
5/10-11 spot check.
Co. in compliance.
1) No instruction on explosive
2). Not directed by authorized
personnel.
3) Area to be fired, not
guarded.
[Blasting the spill copper at
the dust box at converter.]
-------
DATE
9/21/76
9/21/76
TYPE
Health
Health--cranes
FINDINGS FOLLOW-UP
2 violations
4 dusts--
no violation
COMMENTS
1)
2)
Provide respirator program.
SOz violation at converters.
9/21-23/76 Health $ safety
40 sample plant
violations
3 acid plant
violations
3 3/16-17/76
violations abated;
1 3/16-17/76
extension
S02--5 above 5 ppm
[4 >20 ppm]
10/29/76 Abatement
Inspection of
above
(9/21-23/76)
-------
FACT SHEET
Facility: Utah Copper Division, Garfield Copper' Smelter
Company: Kennecott Copper Company
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
Name: Utah Copper Division, Garfield Copper Smelter
Location: Magna, Utah
Description:
1) Combination (within 15-mile radius) of open pit mine, three concen-
trators, copper smelter and refinery, silver refiner1/ and related
facilities.
2) 1,350 employees. Approximately 700 in production.
3) Ore received from Bingham Mine, largest open pi't mine in the world.
Concentrate arsenic content .135-. 15%. Other impurity data on hand
4) Kennecott, Utah Copper Division is Utah's largest taxpayer, with an
annual payroll of $100 million.
5) Production
1972
1973
1974
1975
1976
Copper
(net tons)
Silver
Molybdenum
258,037
254,965
1
229,330 !
171,482
188,917
Comments:
PROCESS AND HAZARDS
NOTE: Workers are issued company-supplied respirators. Use is not manda-
tory. Workers are responsible for maintenance, storage and clean-up.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
NOTE: The following outline attempts to define existing equipment, general
operating procedures and potential problem areas associated with the new
Noranda smelting system. The Garfield system is the first Noranda of its
-------
[page 2]
size and the first one used to produce 70% copper matte1, instead of blister
copper which the original continuous smelting process called for.
NOTE: Potential exposures to sulfur dioxide throughout!'the new system are
uncharacterized. Sulfur dioxide exposures in the reactor area will depend on
the percentage of sulfur that is removed at the reactor mouth, the extent of
the oxygen enrichment process and the effectiveness of ventilation and hood-
ing systems. Exposures in the remainder of the operation wi,ll be indirectly
affected by the Noranda system. Process and controls in the! converter area
remain virtually unchanged, making sulfur dioxide exposure l!ikely.
NOTE: Potential exposures to arsenic throughout the new system are uncharac-
terized. Experience with the old system and the high concentrate arsenic
percentage make exposures likely. Levels in the reverb'eratory furnace area
of arsenic ranged from .01 mg/m^ to .25 mg/m3. All oth'er areas were unchar-
acterized.
NOTE: Potential exposures to lead throughout the new system are uncharac-
terized. Scant sampling at the old reverberatory area indicates levels above
the OSHA proposed standard during some operations. Other( exposures, if any,
were uncharacterized.
A) Material Handling
1) Concentrates are received at the material handling building in a 15%
wet state, which is fairly effective at reducing dust, according to
the union. Despite original plans to construct new facilities as of
this writing, no new receiving areas exist. Concentrates are then
transferred through a new dryer on covered and underground conveyor
belts to bins above one of three Noranda reactors.
B) Reactors
1) There are three Noranda reactors at the Garfield smelter. Two of the
new reactors have been operating since December of 1977 with the
third beginning production in April, 1978. The company has reported
that it intends to operate two of the reactors during normal produc-
tion. The Norandas will be fed a mixture of concentrate, crushed
converter and reactor slag and flux by way of a slinger feed system.
Heat will be provided through a combination of burners, one on each
end, and oxygen enrichment by way of tuyeres. The mouth of the con-
verter shaped furnace is hooded and the 20% sulfur off-gases are sent
to one of four acid plants. Matte is tapped into ladles on the
south side of the reactors and transported by motorized transfer
cars underneath the reactor and out into the center of the con-
verter aisle. The tunnel under the reactors is under negative
pressure. The ladles are not covered during transfers. From the
center of the aisle the ladles are carried by overhead cranes to
one of four Fierce-Smith type converters. Slag is tapped into
hooded ladles and cools for 24 hours in the north portion of the
smelter building before it is carried by transfer haulers to the
new slag concentrating plant. All tapping points are hooded.
According to the company, the Noranda will be rolled out of its
hooding only in emergency situation.
-------
[page 3]
2) Crane Cabs-- The union reports that the new enclosed, charcoal-
filtered cabs are not as effective as those in the old smelter.
Actual exposures are uncharacterized. ;'
3) Ladles-- The union reports that ladles are left smoking (after
unloading) in the converter aisle. Other emissions from slag haulers
and matte ladles make conditions in the aisle "much the same" as in
the old reverberatory furnace building.
C) Converters
1) There are four converters in the new building. -One of the advantages
of the Noranda system when producing 70% copper, matte is the need of
fewer converter-hours per ton of copper. This Jin turn is reflected
in the fact that there are only four convertersi connected with the
new system versus nine in the old reverberatory building despite
comparable production rates. Kennecott has constructed two new
Fierce-Smith type converters and has retrofitted two old converters
and placed them in the new smelting building. The converters are
primary hooded, and gases are sent to the acid plant complex. Slag
is skimmed and transported to the new slag concentrator-floatation
facility before being charged into the reactors, f
2) Punching-- The union reports that the punchers are partially en-
closed and are used in conjunction with Norand^ silencers. INFORM
has been unable to determine if the company is ^experiencing any
difficulties with the silencers. The union indicated to INFORM that
there are intermittent noise exposures. Other exposures, to arsenic
and sulfur dioxide, if any, are uncharacterized.
3) Skimmer-- Skimmers are, as in most smelters, in the open for ex-
tended periods of time during the work day. Exposures, if any, are
uncharacterized and depend on the overall converter area levels.
D) Anode Area
Although construction on the new anode building is complete, the
company does not plan to construct new furnaces or casting wheels at
this time. Smelter operations continue to use the old anode fur-
naces. Exposures, if any, at the old anode area being used in con-
junction with the new system are uncharacterized.
E) Slag Concentrator
Reactor and converter slag are transported by ladle haulers to the
new slag floatation and concentrator. Slags are open-air-cooled and
then "crushed, ground, and treated by floatation for the recovery of
copper." The union reported early problems with workplace heat.
F) Other
1) The company is constructing a Zig Zag blender to treat ESP dust
prior to feeding into the reactors. All other revert dusts are
pneumatically conveyed to the reactor feed system.
-------
[page 4]
2) The company is constructing a boiler to supplement the power supply
at the smelter and will continue to operate oneiof the reverbs until
construction is completed.
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History-- Details unavailable.
B) Staff
Safety Director (1)
Senior Industrial Hygienist (1)
Technicians (3)
C) Industrial Hygiene
1) The smelter industrial hygienist performs some industrial hygiene
sampling. Exact frequency of sampling is unknown. The union
reports little sampling being performed in the new smelter areas.
2) The smelter has limited contact with the company environmental
division in Salt Lake City.
D) Respirator Program
1) Respirators are provided on a need basis, based on industrial hygiene
sampling and workers' requests.
2) Workers are responsible for maintenance, cleaning and storage of
respirators.
3) The union reports that the company provides little education for
respirator use and maintenance.
-------
[page 5]
E) Safety
1) Pre-employment safety orientation consists of the issuance of a
safety booklet and approximately one-half hour of instruction.
2) Refresher safety education is administered through monthly depart-
ment meetings. In many departments the meetings are held infre-
quently.
3) Company issues free of charge most necessary safety 'equipment.
F) Health Care
1) Most medical care is administered through the Wksatch Medical Clinic
located 20 miles from the smelter. |
2) The Clinic staff consists of two doctors and three registered nurses.
[
3) The company has also established emergency clinics on both the
smelter and refinery grounds, with a full-time staff of two nurses at
each and daily visits by one of the doctors. ;.
4) There are first aid trained guards and foremen in;all shifts.
5) The company performs pre-employment physicals o|n all employees.
Blood tests, hearing tests and lung function te;sts are administered
to appropriate employees.
Comments:
SAFETY COMMITTEE
A) Description
1) Joint Safety Council
aj Established in 1954 following a fatal accident.
b) The Council meets monthly with four representatives from the
union and four from the company. The Council acts on safety
suggestions and tours portions of the smelter.
2) Union representatives assist in accident investigations.
-------
[page 6]
Comments:
REGULATORY HISTORY
A) Pre-1970
1) Utah State Industrial Commission cooperating with the State Depart-
ment of Health and Welfare, Bureau of Occupational Health.
B) Post-1970
1) State OSHA Plan
a) Utah State Industrial Commission, Occupational Safety and Health
Division and the State of Utah Department of Social Services,
Division of Health.
b) The state has conducted eleven inspections :of the Garfield
smelter.
2) OSHA Activities
a) OSHA has inspected Garfield on four occasions, all between 1972
and 1973.
Comments:
-------
Table A
PROCESS EQUIPMENT--Garfielcr
NAME
AGE
POLLUTION CONTROLS COMMENTS
Noranda Reactor (3
1977
Electrostatic
precipitator (ESP)
->• acid plants
(2) 1977
Pierce-Smith Converters (4) (2) 1977 (retrofitted) ESP -*• acid plants
Anode Furnace (2) 1950
Anode Casting Wheel (2)
1950
none
none
Originally scheduled to
modify the anode area.
Acid Plant ,"S
#5,6,7
1977
1977 (retrofitted)
Reactor and converter gases
are combined prior to
acid plants.
*Sources: "Emission Control Effort at [\ennecott's Utah Smelter," September 21, 1974.
K. H. Matheson.
-------
SUMMARY OF HEALTH HAZARDS--Garfield
Table 2
TWA Exposures7
Number of
PLANT AREA Employees
Material Handling
Smelting Department
Reactors
Converters
Anode area
Acid Plants
Slag Concentrator
Other
41
120
(80)
(40)
117
Copper
mg/m3
Arsenic
mg/m3
Lead
mg/m3
auirur
Dioxide
(PPM) NOTES
•Independent of respirator usage
-------
tions--Garfield
Table 3
TYPE
FINDINGS
PENALTIES FOLLOWUUP
72
'3
'73
accident
fatality
complaint
safety
follow-up
to 4/2/73
accident
fatality
1 non-serious
violation $600 recommended
i
22 non-serious I
violations $220 6/11/73 !
all violations
abated
death natural
causes —
—
:tions--Garfield
OSHA
'5
i
75
75
75
75
:>
75
TYPE
general
schedule
health
complaint
safety
complaint
health
general
schedule
safety.
complaint
health
complaint
health
complaint
safety
complaint
health
FINDINGS PENALTIES FOLLOW-UP
in compliance
2 non-serious
violations $45
in compliance
25 non-serious
violations $290
in compliance 7/29/75
in compliance
3 non- serious
violations $45
in compliance
[to next page]
COMMENTS
1973 company
silica monitor-
ing data cited.
Item til
vacated 7/11/75
No samples
taken.
Six items
vacated 8/1/75
Roaster plate
treater bldg.
Roaster plate
treater bldg.
Anode area
Acid plant
-------
. 3--cont'd]
:tions--Garfield
OSHA
.nued]
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
general 1 serious ,
schedule 11 non-serious
i health violations $875
complaint
i health in compliance
complaint 3 non-serious
'6 health violations $90
1 serious and
7 non-serious
violations
abated 10/1/76
and 11/5/76.
Catenary
flue cleaning
Asbestos
-------
FACT SHEET
Facility: Ray Mines Division, Hayden Smelter
Company: Kennecott Copper Corporation
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
Page 1
GENERAL
Name: Kennecott Copper Corporation, Hayden Smelter
Location: Hayden, Arizona
Description:
1) Combination of concentrate receiving facilities^ fluo-solids
roaster, reverberatory furnace, converters (3),'anode casting
facilities, and supportive facilities.
2) Smelter built 1958; mill, 1909.
3) Employees: 194 smelter production.
4) Ore from Ray mines. Concentrates from Kennecott Hayden concentra-
tor. Arsenic content of concentrate estimated at .016%; other trace
material information on hand.
5) Area's (Hayden-Kearny) economic base largely derived from mining,
milling, and reduction of copper ores. '
6) Production
1973
1974
,'l975
1976
Copper* (tons)
H?S04 (tons)
Molybdenum (Ibs)
Gold (ozs)
Silver (ozs)
98,908
611,307
1,213
234,994
74,764
682,514
1,468
244,864
'• — r
42,036
175,000
^330,032
1,188
153,872
88,089
743,037
1,016**
107,855**
*Includes copper hydrometallurgically produced from silicate
ores as follows: 1973, 24,714; 1974, 18,065; 1975, 7,336;
1976, 25,213.
**1976 gold and silver production based on refinery figures.
Comments:
PROCESS AND HAZARDS
NOTE: Respirators are company-supplied and worker-maintained. They are
worn on a need basis. The following comments evaluate TWA exposures
independent of respirator use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
Page 2
A) Material Handling
1) Sulfide and Leach-Precipitation-Flotation (LPFjj concentrates are
received, as a slurry, at the Filter Plant whefe they are "de-
watered." Materials are then transferr d via open conveyors to a
screw conveyor/dryer. A final sent of conveyors transfer the
material to storage areas. Potential dust exposures to filter plant
and dryer operators and their helpers from open conveyors and trans-
fer points. Poorly characterized.
2) Storage building provides storage and removal facilities. Removal
consists of overhead cranes equipped with hoppers. Once charged,
the hopper then feeds the materials via open conveyor system to
the concentrate feed hopper above the fluid-bed roaster. Potential
dust exposures to the craneman, binmen, secondary materials
operators, and laborers. Poorly characterized1.
3) Outside storage area. Removal by front end loader. Loader dumps
materials on grizzly above a conveyor belt. Qpen conveyor belt
system transfers materials to storage above roaster. Yard covered
with 4 to 6 inches dust, which is constantly stirred by loader,
general activity, and the wind. Area cited by State Mine Inspector
after worker complaint. f
4) Lime Plant. Five employees. State inspection shows Si02 levels
below;TLVs. Noise levels above present standards.
B) Fluo-Solids Reactor !
1) Blended materials (concentrate, lime, silica, and precipitates) are
fed into reactor via a screw feeder which controls feed rate and
seals reactor vessel.
2) The "roasted" fine solids leave the reactor via the gas stream and
are recovered in primary and secondary cyclone banks above the
reverbs. Oversized materials (M5%) are removed from the reactor
via a cone type valve located in the reactor floor. This material
is transferred to the calcine bins above the reverb by drag chain
conveyor.
3) Exposures to the reactor operators(6) and reactor utilitymen (3) are
poorly characterized.
4) Cyclone utilitymen (3) must enter cyclones from time to time when
they become plugged. Exposed to high S02 and dust levels due to
nature and location of job. Poorly characterized.
5) Roaster feed ports must be cleaned out once a month. The operation
takes fourteen hours and involves entering the reactor and drilling
over 2,000 holes. To decrease exposures, the reactor is first
heated to VL,8000F to "burn it out." The reactor is then cooled
with sonic (fog) sprays. Unions wanted a 48-hour cooling time
before the reactor could be entered. However, a "sufficient cooling
period" was enacted, which leaves the cooling time up to the com-
pany's discretion. (Arizona Mining Code R-ll-1 1632) Workers enter
in teams (substituting in and out). One worker reported entering
reactor with a thermometer, and recording 300°F. Workers report
entering reactor and coming out two minutes later, not being able to
work for the rest of the day. Others report exiting from reactor
vomiting after five minutes.
-------
Page 3
C) Reverberator/ Furnace !
I
1) One suspended arch furnace. f
'i
2) Charge bins above the reverb receive the calcines from the reactor.
The calcines are intermittently fed to the reverb via Wagstaff
feeders.
3) The cyclone man and other working in the bin area above the reverb
are exposed to sizable S02 and arsenic levels. Employees complain
that "the company does not correct the dust and fumje problem [in
this area] at the source, they [company] just add on safety equip-
ment." I
4) Furnaceman. Workers report extreme noise levels—due to air and
steam blowing from the burner. They are supplied with ear plugs;
however, the furnaceman cannot wear them since1 he "relies on his
ears to notice changes in what's going on." OSHA determined noise
levels within standard.
i
5) Tapper. 25-30 ladles of matte are removed from reverb per day--
taking 10-20 minutes to fill a ladle. During tapping there is
considerable exposure to S02 and fume. The tapping area is hooded.
S02 and arsenic exposures above the present standard.
6) Slag Motorman. Slag is removed at an average rate of 650 TPD and
transferred to the slag dump via slag cars. The launders are
hooded; however., the cars themselves become fugitive emission
sources. Exposures to motormen poorly characterized.
7) Arch Blower. One man per day in afternoon shift. Arch blown from
catwalk 15-20 feet above the reverb. Company tried vacuuming;
proved unsuccessful, however. Arch blower works above reverb for
six out of every eight hours. Temperature exposures range from
130°to 200°F. He is equipped with safety glasses, safety shoes,
overalls, respirator, and rags to keep out irritating dusts. Nature
and location of job cause extreme S02 and dust exposures. Poorly
characterized.
8) Waste Heat Boilers. Dusts entrained in gas stream are collected in
hoppers. They are removed and transferred to converters via front
end loaders. Due to nature and location of job, dust and S02 expo-
sures are likely. Poorly characterized.
D) Converter Area
1) Matte transfer via matte ladle/cars to converter aisle. Matte then
fed to converter via crane/ladle operation. , Empty ladle returns to
reverb.
2) Crane cabs (2) are under positive pressure, filtered, and air condi-
tioned. The cranes are located 80 feet above the converters. Crane-
men intermittently exposed to S02 levels as high as 12 times the
present standard.
3) Three Fierce-Smith converters equipped with water cooled hoods and
gas cleaning spray chamber. The spray chamber nozzles (water and
air pipes join at nozzle to create spray) have to be changed, two
times per shift, with the resulting exposures poorly characterized.
-------
Page 4
Workers report that the hoods leak excessively!. There are no
secondary hoods . ',
4) Skimmer. Skimmer has a shelter where he governs the converter
operation by flame color. S02 exposures are Likely, but poorly
characterized. Due to nearby punching operation, the skimmer is
intermittently exposed to excessive noise levels. Area cited by
OSHA for noise.
5) Puncher. Noise levels of up to 16 times the standard. Cited by
OSHA. Company plans to implement muffler devices as a result of
this citation. Converter equipped with spark .shield which provides
puncher with ventilation and necessary protection from sparks.
6) Slag Haulage Operator. Slag is continuously "iskimmed" until all
iron sulfides have been removed. Slag then cqoled in cooling pits,
crushed, and sent to flotation mill to recover1 copper. The concen-
trate is "dewatered" and sent to roaster. Exposures poorly char-
acterized. I
7) Silica Flux Operation. Converter hoods are equipped with openings
through which silica flux is added. Silica transferred from
storage bins behind converters via an open belt .system, terminating
at hood. Material is discharged directly into a, chute, feeding
converter. Probable dust and S02 exposures. Poorly characterized.
E) Refining Area \
1) Two 250-ton anode furnaces surround one common anode casting wheel.
2) Poling, to rid the blister copper of oxides and other impurities, is
accomplished by reduction/oxidation with natural gas/compressed air.
The usual practice is to 'blow' these furnaces during the night
shift.
3) Casting furnacemen (2) control the furnaces, the pouring spoon, and
the casting wheel from one of the two enclosed, air conditioned
control booths. Exposures poorly characterized.
4) Furnace Helpers (8). Tending burners on the furnaces, among other
responsibilities. Area was cited by OSHA for burner noise. Company
was to have abated noise hazard by making change in burner system.
Extent of correction unknown.
5) After anodes are cast and cooled, they are removed via a Bosh-crane
and placed for further cooling in the two water filled Bosh-tanks.
After cooling, anodes are removed by an overhead crane to a storage
area. Anodes are shipped to refinery for additional processing.
6) Health hazards poorly characterized for anode casting area.
F) Auxiliary Equipment
1) Gas cleaning and acid plant. Fourteen employees. Job descriptions
and exposures are poorly characterized. A welder was severely
burned (sulfuric acid burns) at the acid plant loading station.
Comments:
-------
Page 5
COMPANY SAFETY AND HEALTH ACTIVITIES I
A) History ,
Details not available. I
B) Staff
Safety Director (1)
Safety Engineer (1)
Industrial Hygienist (1)
I
C) Industrial Hygiene ;
Company reports "Monitoring throughout plant at least once annually.
--Sampling for sulfur dioxide, lead, arsenic, cadmium, mercury.
Main contaminant sulfur dioxide--due to fact Ray ores are very low
in concentrations of other elements." Conflicting data on hand as
to actual extent of monitoring.
D) Respirator Program
No specific company details available. All workers issued
respirators. "Some use them. Some do not."
Workers responsible for maintenance. Respirator program cited by
OSHA 4/75--Extent of abatement unknown--No OSHA follow up.
E) Safety
1) Company details not available.
2) The number of lost workdays in 1974, as reported to State Mine
Inspector by company, is three times the number that appears on
1974 OSHA 102.
F) Health Care
1) Kennecott owns and staffs a 20-bed hospital seven miles from
smelter. Ambulance at smelter.
2) Hospital staff of 37, including five full-time physicians. Smelter
staff consists of licensed practical nurse [1) and emergency medical
technician (1) Supervisory personnel receive first aid training.
-------
Page 6
3) Pre-employment physical. Audiometric tests gijen annually to start
with. Hearing conservation program for workers in high risk areas.
4) Discrepancy exits between availability and extent of annual medical
testing that company reports giving and that workers report
receiving.
Comments:
SAFETY COMMITTEE
I
A) Description r
1) Established 1958. :
2) Two management representatives(safety director, and safety engineer);
two United Steelworkers representatives; one Representative each
from other unions.
3) Meets once a month on company time. They decide what areas to
inspect and write down what improvements should be made. Company
then decides either to reject or abate.
Comments:
REGULATORY HISTORY
A) Pre-1970
1) Office of State Mine Inspector
B) Post 1970
1) State OSHA Plan
a) Developmental pi an--Approved October 1974--Headed by
Arizona Industrial Commission.
b) Jurisdiction over smelter still in hands of State Mine
Inspector. No contractual agreement exists between SMI
and Arizona Industrial Commission.
-------
Page 7
2) State Mine Inspector j
a) Inspections: see table. i(
b) Limited industrial hygiene efforts.
3) OSHA Activities
a) Two inspections — one safety; one health.
Comments:
-------
NAME
AGE
CONTROLS
COMMENTS
Filter Plant
1958
Cyclone Scrubber
Storage Area
1958
DNA
Inside and
outside areas
Fluid Bed Roaster
1969
1° and 2° Cyclone Banks, Venturi
Scrubber, Peabody Scrubber, Mist
Precipitator, Drying Tower, Mist
Eliminator, Acid Plant
Reverb fed
pneumatically
Reverb (Detrick-type suspended arch)
Converters (3)
(Pierce-Smith 13' x 30 ' )
Casting Furnaces (2)
Casting Wheel
Acid Plant
(Double contact)
Lime Plant
and Silica Crushing Facilities
1958
1958
1958
1958
1969
Rebuilt 1974
1958
Waste Heat Boilers, ESP, 600' Stack
ESP, Peabody Scrubber , Mist Precip-
itator, Drying Tower, Mist Elimi-
nator, Acid 'Plant
None
None
Tail gases uncontrolled—leave via
100' Stack 950 TPD
DNA
SOURCES: Design and Operating Parameters for Emission Control Studies:
Kennecott, Hayden, Copper Smelter
"The New Hayden Smelter," Journal of Metals, June 1959
T3
V>
(TO
-------
Number of
AREA Employees
Material Handling
Roaster and
Reverb area
Converter Aisle
Anode Refining.,
and Casting
Acid Plant and
Gas Cleaning
Equipment
78
45
38
15
15
Copper
mg/M-S
.003-. 013
Arsenic
mg/M-5
.002-. 009
Lead
mg/M^
suirur
Dioxide
ppm NOTES
Reactor
10-29.5
Reverb
.9-6
0-60
Primary crusher and lime kilns
noise levels exceed standard.
Hazardous dust concentration at
outside feed area.
Content of dust poorly characterized.
Arch blower subject to temperature
range of 130°-200°F.
Severe dust exposure--likely arsenic
hazards .
Reactor cleanout crew exposed to
temperature exceeding 300°F.
Due to nature of job, high dust
exposure likely, but poorly
characterized
Mechanical puncher exposed to 16
times allowable noise.
Furnace man subject to noise
exceeding standard.
Most exposures poorly characterized.
SOURCES: OSHA data
State Mine Inspector reports
Union data
* Inspection reports consistently
state "poor housekeeping"
throughout plant.
-a
vo
-------
tions-.-Kennecott Hayden
Page 10
75
75
TYPE
general
schedule
safety
general
schedule
health
FINDINGS
15
non-serious
violations
2
non-serious
violations
PENALTIES
None
$90
Reduced
to $45
FOLLOW-UP ' COMMENTS
' All violations but one
;' abated before inspection
None team left premises.
S02 --cyclone man
wearing non-approved
rejspirator.
Noise-- #2 § #3 conver-
ter, anode furnace and
Recommended casting wheel.
tions--Kennecott Hayden
of Arizona, State Mine Inspector
TYPE
FINDINGS
PENALTIES FOLLOW-UP
I1
COMMENTS
72*
safety--
smelter
spot
safety--
concentrator
22
violations **
No
violations
]
Spot inspection of
reagent handling area.
accident
Insufficient
water pres-
sure for
deluge
shower and
eye wash; no
instructions
for safe
loading
operations.
Welder burned over 1/3
of body due to acid
plant § loading accident.
safety--
74 smelter
47
violations
1/2/75 SMI
letter--
granting
extension
for 11
violations.
Handrai1s, guards, etc.
safety--
smelter
violations
All
violations
of 10/22/74
abated.
Keep after housekeeping
*1972-1974 State Mine Inspection not available to INFORM.
**State Mine Inspector issues no $ penalties.
-------
:tions--Hayden [SMI], continued)
Page 11
TYPE FINDINGS PENALTIES FOLLOW-UP COMMENTS
safety--
prep 67
plant violations
7
noise-- violations
crusher, (above
'5 lime kiln 90 dBA)
health--
i flux
health- -
76 smelter
spot
health--
'6 lime plant
safety-- 30 safety
6 smelter violations
compliance
inspection
complaint--
flux 2 dust
division violations
health--
6 lime plant
1
6 complaint violation
1
complaint violation
8, health--
smelter;
S02, dust.
76 complaint
,' Toe boards, guard rails,
' machinery guards.
Housekeeping must be
improved.
i
Sajmples below TLV for
Si'02.
Dust samples.
j All samples (7) below
TLV for dusts containing
• Si02.
1
' All samples (6) below
TLV forSi02 dusts.
i
i'
21 i
violations ; '
abated, of I
4/20/76 i
smelter
safety in-
spection.
5
extensions
granted.
Outside feed area--clust
stirred by front end
loader.
All samples (5) below
TLV for Si02.
Crane Cab repairs—by
September 2.
Same cab, different
complaint --abate
immediately.
No cited violations, but
one area sample above
5 TLV for Si02 (14 samples
extensions taken) , and five out of
of 4/20 eight S02 samples above
abated. 5 ppm TLV--one for 60 ppm.
Complaint re accident on
slag train. Inspector
recommendation: take up
slack on hand brake.
-------
FACT SHEET
FACILITY: Hurley Reduction Works
COMPANY: Kennecott Copper Company
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
page 1
GENERAL
I
Name: Hurley Reduction Works j
Location: Hurley, New Mexico 'i
Description:
1) Combination of concentrator, "green-feed" smelter, fire refining
and supportive facilities.
2) Mine begun in 1909. Smelter built 1939-1942. i
3) 1,300 employees (total including mine): 196 (smelter production)
4) Ore from Chino Mine, reserves more than 50 years. Arsenic content
variously estimated as smaller than 0.005%; greater than 0.025°6.
Other trace metal information on hand. j
5) Largest employer in Grant County, N.M.; payrol'l $20 million.
6) Production '
a) Approximately 1/6 of Kennecott's total !
b) 1972 1973 1974
1975
1976
Copper (tons)
Molybdenum (Ibs)
Gold (ozs)
Silver (ozs)
Sulfuric Acid
73,403
396,671
587
12,650
67,836
608,098
228
5,428
60,557,
274,563'
1,990
39 , 7;76
?
53,193
421,596
1,911
55,604
?
57,202
190,200
1,929
?
Comments:
PROCESS AND HAZARDS--SMELTER
NOTE: In most areas of the plant, workmen wear company-supplied respirators
on a need basis. The following comments evaluate TWA exposures independent
of resporator use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
page 2
A) Material Handling
1) Open conveyor from mill to open pile storage i| yard. Wind some-
times results in dust exposure to yard personnel and even smelter
workers. Poorly characterized. 'i
2) Dryer. Potential dust and arsenic exposures to operator, clean-up
man, and heavy-equipment operator. No local exhaust at feed
station. Poorly characterized. Approximately 3 men per shift.
B) Reverberatory Furnace Area |
1) Two furnaces, only one operated at a time. '
2) "Down" furnace. Refurbishing may mean excessive noise and dust
exposures to jackhammerman, 'rebrickers, and others. Poorly charac-
terized. "Special smelter laborer" cleans outj the inside of waste
heat boilers and flues when furnace is down, i Likely very high
exposures to arsenic, other dust. Poorly characterized.
3) Tripper conveyor system, though automatic, requires frequent inter-
vention by operator. Intermittent but sizable S02 and dust expo-
sures. Arsenic in excess of proposed standard likely. Poorly
characterized. One man per shift. I
4) Feedermen. Wear full-face air-supplied respirat'ors while feeding,
as a result of OSHA citation. Sizable dust exposures. S02 expo-
sures above present standard with peaks above 100 ppm. Arsenic
exposures above proposed standard. Sizable contribution to all
exposures from "blowing of the arch." 2 to 4 times per shift. Two
to four men per shift.
5) Matte and Slag tapping. Exposures to S02 above recommended stan-
dard, but below present. Arsenic exposures above proposed standard.
Tap points and launders are not hooded or ventilated. Three men per
shift.
6) Waste heat boilers. Three men per shift with S02 exposures above
proposed standard, but below present. Arsenic exposures above pro-
posed standard. Heat exposure likely but not characterized.
7) Reverb--General
a) Others in reverb area (furnaceman, slag train motorman,
furnace brick repairman) probably have exposures similar to
tappers. Poorly characterized, Three to five men per shift.
b) Reverb "explosions" while feeding are commonplace source of
contamination. Cause and prevention of such unknown.
C) Converter Aisle
1) Four converters with water-cooled hoods. Secondary converter hood-
ing was outlined in fugitive emission control plans submitted to New
Mexico authorities in or around early 1974, but plans were never
implemented.
2) Skimmers and crane chasers with S02 exposures below proposed stan-
dards. Arsenic above proposed standard. Four to six men per
shift. Skimmers sometimes exposed to excessive noise as a result of
nearby punching.
-------
page 3
3) Crane seals and ventilation allow excessive S02 levels (above 2 ppm)
in crane cabs. Cranemen must often wear respirators. Three men per
shift. Arsenic poorly characterized but likeliy because of location
above converter aisle. .'
i|
4) The hood(s) to cover ladles while filling are hot routinely
used.
5) Maintenance of cranes (regarding safety) has been a source of some
labor-management conflict.
I
6) Converter punchers. Noise levels up to 6 times standard; also
exceeding 115 dBA. Men wear ear plugs. Cited by OSHA in 1974 for lack
of engineering controls. Modifications to one converter brought
noise down from 115 dBA to 100 dBA. Other converters not yet
modified. Arsenic exposures above proposed standard. Three men
per shift. '
r I
7) Converter repair likely to involve serious dust exposures, as for
jackhammerman and others in reverb rebuilding. Poorly character-
ized. • !
8) Silica flux handling tasks reported by union to be very dusty.
Poorly characterized. One man per shift. |
f
D) Refinery Area
1) Molten blister copper by ladle to holding furnade(s) or refinery
furnace. Reduction by "poling'' with natural gas. Metal covered
with coke. "Black smoke" (unburned hydrocarbons) emitted. Canopy
type hood above furnace. Effectiveness unknown. Hazardous expo-
sures, if any, poorly characterized.
2) Refinery tapper and helper exposed to "irritating smoke." Not
characterized. Two men per shift.
3) Potential heat hazard during long casting runs. Not characterized.
Two to three men per shift.
E) Auxiliary Operations
1) Lime plant crusher. No local exhaust. Dust exposures. Free silica
12%. One man per day. Poorly characterized.
2) Lime kiln operator. Dust from lime transfer. One man per day.
Poorly characterized
3) Lime slaker. Irritating calcium hydroxide mist exposure. No local
exhaust ventilation. One man per day. Poorly characterized.
4) Flux crushing. Siliceous dust exposure in crushing (ap'prox. 6 hours
per day) and transfer (approx. 2 hours per day). One man per shift.
Wetting but no ventilation. Poorly characterized.
5) Acid plant. Laborer's job description hints at potential dust and
arsenic hazards during cleaning of gas-cleaning equipment.
-------
page 4
6) ESP operator and helper. Precipitate drier operator. Poorly char-
acterized. Job descriptions suggest intermitteht high exposures to
arsenic. i
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History. Details unavailable
B) Staff--for entire complex
Director of Safety and Environmental Control
Safety Engineer (1)
Industrial Hygiene Technician (1)
Respirator Maintenance Person (1)
Supervisor of Environmental Control (1)
}m;
i;
mainly air-pollution
Environmental Control Engineer (1} _) issues
NOTE: Staff has grown by 3-4 since early 1970s.
C) Industrial Hygiene
1) Yearly sampling of some areas and work stations since 1973.
2) No reports or education given to workmen.
3) Results of monitoring are reportedly made available to the Inspec-
tor of Mines since 1976. That agency uses such to evaluate hazards.
D) Respirator Program. No details available
E) Safety
1) No accident investigations except those conducted through joint
safety committee.
2) 1973 OSHA 102 data on hand. Other years not available.
F) Health Care
1) Bayard clinic (under contract) or Silver City hospital (more serious
cases)
-------
page 5
2) No nurse on premises. Some first-aid training
3) Pre-employment physical. Hearing tests availably yearly but not
frequently taken by workers. No clearly define^ hearing conserva-
tion program. 'i
G) Corporate activities are essentially educational and advisory to plant
management. Local activities are fairly independent (except investment
decisions).
I
Comments: i
SAFETY COMMITTEE j,
A) Description :
1) More than a decade old I
2) Two-management representatives, two from each o'f four unions
3) 1974 contract stipulates general characteristics, i.e., inspection
tours, accident investigations, written records, etc.
4) No occupational health concerns addressed by committee.
5) Records indicate that inspection tours focus on visible safety
hazards.
Comments:
REGULATORY HISTORY
A) Pre-1970
1) State Inspector of Mines
-------
page 6
B) Post-1970
1) State Inspector of Mines (
i
a) Almost exclusively a safety focus until-'1973, when limited
health activities were implemented. '
b) Approximately two inspections per year. ' No union partici-
pation.
c) Agency still active. Jurisdiction question vis a vis New
Mexico State OSHA plan (see below) still unclear.
!
2) State OSHA plan '
a) Administered by New Mexico Environmntal Improvement Agency.
b) Approved 12/75. No smelter inspections\yet conducted.
C) OSHA Activities |
1) First two inspections: Safety.
2) Third inspection: Industrial Hygiene. Citations for noise and
personal protective equipment.
3) Fourth inspection: Brief follow-up of (2) above.)
r
D) MESA Activities
For the period October 1973 through April 1976 MESA conducted
6 safety inspections, 4 of which included among other areas the acid
plant, lime kiln and the receiving area.
Comments:
-------
NAME
Rotary Dryer (for ppt . )
5-Hearth Dryer? (old roaster?)
Flux crushing plant
Rotary Lime Kiln
Reverb #1
Reverb #2
Converter (Pierce Smith)
Converter "
Converter "
Converter "
Holding Furnace
Holding Furnace
Holding Furnace
Refining Furnace
Acid Plant (double contact)
*Process flowsheet, Figures
AGE
1965
1962
N.A.
1941
1937
1950
1938
1938
1940
1972
1942
1943
1951
1940
1974-1975
2,3; Design
POLLUTION CONTROLS
Cyclone § baffle spray
N.A.
Cyclone
2 waste heat boilers;
it ii it • H
Tight fittings; water-
Gas to acid plant
None
Canopy-type hood while
(scrubber)
flue; ESP (40%
capacity) ; stack
cooled hoods .
poling only
Gas conditioning, ppts; scrubbers; drop-
out chambers; heat exchangers.
and Operating Parameters
for Emission Control
Studies: Kennecott, Hurley, Copper Smelter.
OQ
CD
-------
Number of
Employees
MATERIAL HANDLING
REVERBERATORY
FURNACE AREA
CONVERTER AISLE
REFINERY,
CASTING £ LOADING
ACID PLANT
43
43
37
44
6
Copper
mg/M3
0.20-2.3
.01-. 42
Arsenic
mg/M3
<^.03-0.9
^.003-. 09
Lead
mg/M3
.002-. 01
.003-. 006
Sulfur
Dioxide (PPM)
2.5-22
0-18
NOTES
Most exposures poorly characterized
Some likely Arsenic hazards. Some
estimates possible through job
descriptions, interviews, other
indirect sources .
Punchers exposed to up to six times
the allowable noise
Most exposures poorly characterized.
Some estimates possible through job
descriptions, interviews, other
indirect sources.
* Independent of respirator usage.
Sources: OSHA Inspection records.
State Inspector of Mines records.
re
00
-------
Inspections--Hurley
page 9
E •
m
'74
'74
'74
TYPE
general
schedule
safety
general
schedule
health
general
schedule
safety
follow-up
to
4/22/74
FINDINGS PENALTIES FOLLOW'J-UP COMMENTS
15 non-serious
violations
3 non-serious
violations
16 non-serious
violations
3 non-serious
violations
$330.--
$130.--
$300.--
$80.--
i'
NONE
I
i
6/11/74 !
NONE
1
I
NONE
S02 : #2 reverber-
atory furnaces
Noise: #] -
3 converters
Respirator program
:tions: State of New Mexico, Inspector of Mines Dept.
TYPE
FINDINGS
PENALTIES FOLLOiy-UP
-
72
72
72
72-
72
n
13
safety
check-up
spot £
check-up
safety
safety
safety §
check-up
7 improvements
abated during
inspection
12 recommendations
smelter, refinery,
lime plant
3 recommendations
general
12 recommendations
mill-shops
1 notice
20 notices
16 notices
29 notices
4/20/72
9 notices
abated
3 notices
unabated
3 notices
abated
17 notices
abated 3/1/73
14 notices
abated
10/9/73
Mill
Shops
Smelter
Refinery
Lime Plant
Quarry
Smelter
Shop
Refinery
Smelter
Shop
Refinery
Smelter
Shop
Refinery
Smelter
Shop
Refinery
Smelter
Shop
Refinery
COMMENTS*
INFORM was unable to obtain records of inspections
for the years 1974-1975.
-------
;ions: State of New Mexico, Inspector of Mines Dept. --cont'd)
page 10
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
6
6
6
6
7
7
safety $
check-up
safety £
check-up
i
dust
safety $
check-up
electrical
Noise
safety $
check-up
22 notices
17 notices
mill-shops
2 notices
power plant
3 notices
acid plant
3 notices
14 free silica
samples
5 S02 samples
24 dust samples
23 notices
37 notices:
other
3 notices:
acid plant
3 recommendations
9 notices
16 notices
1
i
''\
19 notices ,
abated !
9/30/76 !
1
1
22 notices
abated
3/24/77 !
F
1
Smelter
Shop
Refinery
Mill-Shops
Power Plant
Acid Plant
Mill
Mill-Shops
Power Plant
Acid Plant
Mill-Shops
Power Plant
Acid Plant
Mines
Plant
*This column lists the areas covered by the inspection.
-------
FACT SHEET
Facility: Nevada Mines Division, McGill Smelter
Company: Kennecott Copper Company
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
Name: Nevada Mines Division, Kennecott Copper Corporation
i'
Location: McGill, Nevada
Description:
1) Combination of McGill concentrator, green feed smelter and support-
ive facilities. j
i
2) Mine begun in 1907; smelter, 1908.
3) 300 employees (170 concentrator, 130 smelter).
4) Ore from Ruth Pit. Arsenic content .12%. Othjer impurities unknown.
5) Largest employer in White Pine County. |
6) Production (figures in tons)* !
1972 1973 1974 ! 1975 1976
Copper
39,962
50,012
37,562
21,393
12,219
* Includes copper produced from precipitates ;obtained by leaching
waste dumps. '
Comments:
PROCESS AND HAZARDS
NOTE: The following comments evaluate TWA exposures independent of respira-
tor use.
NOTE: Following an OSHA citation of 8/13/74, the company has supplied res-
pirators to most areas of the plant. However, workers remain responsible
for maintenance, clean-up and storage.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
A) Material Handling
1) Copper concentrates are received from the nearby McGill concentrator
on open railroad cars, and unloaded into hoppers at the central
dumping area. After storage the concentrates are transferred by
open conveyor belts to charge bins above one of the two reverbera-
tory furnaces. Arsenic and copper dust exposures throughout the
area are poorly characterized.
2) Central dumper—documented violation for respirable silica exposures
to laborer and tripperman, as well as documented housekeeping prob-
lems, indicate potential exposures to copper and arsenic dust.
Seven workers.
-------
3) Coal ball mill —OSIIA reports potential noise hazard. Actual noise
and other exposures are uncharacterized. 1
4) Conveyor belts — documented spillage from uncovered conveyors.
Actual levels of arsenic, copper and silica!.dust are uncharacter-
ized.
B) Reverberatory Furnaces
1) Concentrates and flux are fed into one of two reveijberatory furnaces
by way of tripper bin / shuttle conveyor system. Ccjal is fed to
reverb \\2 by a similar tripper bin system. Matte is tapped into
hooded ladles and transferred to the converters by overhead crane.
Slag is tapped into a 200-yard "slag tunnel" which transports it to
the tailings pond where it is granulated and plumped to the slag
dump. I
2) Feederrnan--documented TWA sulfur dioxide exposures above the exist-
ing standard prior to installation of "fume collection equipment."
Effectiveness in reducing hazard levels is unknown. Excursions of
S02 as high as 20 times the existing standard during "puffs."
Arsenic levels are uncharacteri zed. General dus,ty conditions re-
ported in the area. Eight workers. i
3) Skimmers--documented S02 excursion levels to eighty times the exist-
ing standard. Actual TWA SC>2 and arsenic exposures are uncharacterized
Five workers. I
4) Tappers —documented sulfur dioxide levels well above existing stan-
dard. Actual TWA sulfur dioxide and arsenic exposures are unchar-
a-cterized. Five workers.
5) Tripper—cited by OS HA for sulfur dioxide TWA violations. Docu-
mented excursion levels of sulfur dioxide to twenty times existing
standard during puffs, prior to company-reported enclosure of trip-
per floor. Effectiveness of enclosure in reducing'hazard levels
unknown. Potential arsenic exposures are uncharacterized. One
worker.
6) Reverb helper—actual exposures to sulfur dioxide and arsenic are
uncharacterized; however, job description places workers in areas
of documented high sulfur dioxide levels. OSHA citation for high
noise levels during jackhammering procedure. Thirteen workers.
7) Flue dust handler-- OS HA indicates similiar operation and personnel as
converter dust conveyor operator. Total dust TWA violations docu-
mented by OSHA for converter flue cleaning. Company reports the use
of specially equipped respirators during operation. Other exposures,
if any, are uncharacterized. One worker.
8) Other workers —documented dusty and gassy conditions in area.
Actual exposures, if any; to additional workers are uncharacterized.
Nine workers.
9) Slag tunnel — documented "safety problem" in slag tunnel in 1974.
Problems included sulfur dioxide, erosion, lack of access, sub-
standard guard rails and structural weaknesses. Union reports no
major changes made since that time. Number of workers varies.
-------
C) Converter Aisle
1) Matte is transferred by overhead crane to charge four Pine-Smith
converters (two of which are normally in operation). The converters
are primary hooded; however, mouth design problems have led to fugi
tive emissions at hood-mouth seal. Blister copper is then molded
into cakes and transported for electrolytic refining. 23-27 workers.
2) Central platform—documented sulfur dioxide levels average at or
slightly above existing standard for platforms on converters 112, 3
and 4. However, most severe exposures appear to be related to cop-
per pouring and cooling schedules. Excursions up to nine times
existing SO^ standard during these operations. Arsenic levels are
uncharacterized.
3) Skimmer—documented sulfur dioxide levels in "general room" between
converters #2 and 3 varied from below proposed standard to three
times existing standard. Excursions during other smelter activity
are^documented. Actual S02 and arsenic TWA exposures are uncharac-
terized. Nine workers.
4) Crane chaser—documented sulfur dioxide area levels above existing
standard in converter aisle. Job description places worker in area
"all the time." Actual sulfur dioxide and arsenic TWA exposures are
uncharacterized. Four to five workers.
5) Dust coitveyor operator--OSHA citation for total dust TWA violations
during cleaning and belt operations. Company reports use of spe-
cially equipped respirators during operation. Other exposures, if
any, are uncharacterized. One worker.
6) Converter helper—documented dusty conditions during "clean-up" pro-
cedures. Other exposures, if any. are uncharacterized. Three
workers.
7) Converter punching—punching is accomplished with Kennecott type
punchers. Workers report maintenance problems similar to those at
Kennecott's Hayden smelter^
8) Crane operators are represented by the IBEW. The union reports that
the company samples for potential hazards and repairs cabs if neces-
sary upon request. Actual exposures, if any, are uncharacterized.
D) Auxiliary Operations
1) Silica-bentonite mixing area—documented violations for silica to
the mixer and sacker prior to the design of mechanical system.
Extent and effectiveness of system in reducing exposures is unknown.
2) Foundry—documented high noise levels to operator for short duration
of time (79-108 dBA). Potential problem of "gas and fume" rising
from furnace to crane cabs. Actual exposures, if any, are poorly
characterized. 27 workers.
3) Areas of uncharacterized potential hazards include cake-casting
(five workers), waste heat boiler clean-up and repair, and ESP
clean-up and dust handling.
-------
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History—Details unavailable
B) Staff
Safety and security director (1)
Senior industrial hygienist (2)
Safety inspectors (2)
C) Industrial Hygiene
1) There are full-time industrial hygienists at the division and com-
pany levels.
2) The company performs some evaluatory sampling. Exact frequency of
sampling is unknown.
D) Respirator Program
1) Respirators are supplied on a need basis, based on evaluatory sam-
pling.
2) Education for respirator use and maintenance is supplied by the com-
pany following a 1974 OSHA citation.
3) Workers are responsible for maintenance, cleaning and storage of
respirators.
-------
E) Safety (
1) The company has established pre-employment safety orientation con-
sisting of a safety booklet and instruction by!, immediate super-
visors, j,
2) Refresher safety education is administered through monthly safety
meetings.
3) Company issues free of charge most necessary safety equipment.
|
F) Health Care I
1) Most medical care is administered through the public hospital in
Ely, Nevada. There is an emergency transportation system from
McGill to Ely. j
2) The company has established an "emergency hospital" in McGill.
Staffing consists of a registered nurse. ,
3) There are first-aid trained foremen and guard^ on all shifts.
4) The company performs pre-employment physicals and "occasional" hear-
ing tests.
Comments: '
SAFETY COMMITTEE
A) Description
1) Department Safety Committee
a) Monthly meetings attended by a company representative, plant
safety engineer, one union representative per department,
and the Steelworkers' general plant safety man.
b) The committe discusses safety suggestions and inspects each
department.
2) General Plant Safety Committee
a) Quarterly meetings attended by the plant superintendent, the
company safety director, and one union representative from
each plant.
b) The committee acts on safety suggestions originating from
the Department Safety Committee.
3) The committees assist in most accident investigations.
-------
Comments:
REGULATORY HISTORY
!
A) Pre-1970 I
1) State Inspector of Mines :
B) Post-1970
1) State OS HA Plan
1 I
a) Nevada Industrial Commission \
b) pre-empted from the enforcement of health regulations.
c) The Industrial Commission has not inspected the McGill
facility. i
C) MESA Activities
'^
-
1) MESA ha^ retained -j-u-ris diet ion over the central dumpei>f and has per-
formed both safety and health inspections of the area.
Comments :
-------
PROCESS EQUIPMENT--McGill
Table 1
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Reverberatory Furnace (2)
Converters (4)
(Pierce Smith)
Foundry
1903
Waste heat boiler -»•
ESP •+ stack
4 multi-cyclone
units -*- brick flue -»•
stack
Gas rises to roof
and passes through
vents to atmosphere.
There is presently no S02
control at the McGill
smelter.
SOURCES: Design and Operating Parameters for Emission Control Studies
Kennecott, McGill Smelter
OSHA inspections
-------
tions--McGill
Table 2
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
4
4
4
74
D-
75
accident/
fatality
complaint/
health
complaint/
safety
follow-up/
safety
follow- up/
safety
follow-up/
health
1 serious $600
violation
6 non-serious $215
violations
41 non-serious $1,030
violations
6 non-serious $240
violations amended
to $40
1 non-serious $80
violation
no new
violations
!
last
progress
report
August| 4,
1976 I
10/7/7,4
3/6/75 |
1
completed
5/14/75
contestment
was withdrawn
sulfur
dioxide,
silica, §
noise
violations
item #3
deleted;
contestment
withdrawn
1/75
levels of S02
similar to
8/13/74
-------
Table 3
SUMMARY OF HEALTH HAZARDS--MeGill
TWA Exposures'
Number of
PLANT AREA Employees
Material Handling
Reverberator/
Furnace area
Converter area
Others
34
39 - 41
35
45
Copper
mg/M3
Arsenic
mg/M3
Lead
mg/M3
_.
OUO. -LUJ.
Dioxide
(PPM) NOTES
15 ppm TWAt
excursions
to 400 ppm
average
level ap-
proximately
10 ppm;
excursions
to 45 ppm
Respirable silica dust
violations in central
dumper.
fPrior to installation of
controls. Effectiveness
reducing levels is
unknown.
Documented noise viola-
tions for reverb helper
125%.
Total dust violation to
dust conveyor operator.
Includes maintenance and
-• -foundry workers,- _=-.
SOURCES: OSHA inspections
MESA inspections
* Independent of respirator usage
-------
FACT SHEET
Facility: Magma Copper Company, San Manuel Smeltei
Company: Newmont Mining Corporation
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
Page 1
I. GENERAL !
i
Name: Magma Copper Company, San Manuel Smelter l|
Location: San Manuel, Arizona ;'
Description:
1) Combination of concentrate receiving facilities, reverberator/
furnaces (3) , converters (6) , refining furnacejs (4) , casting
wheels (2), and supportive facilities. I
2) Smelter began operation in 1956. Magma became a wholly owned
subsidiary of Newmont Mining Corporation in 1969.
3) Employees: 398 smelter production. !
4) Ore from the San Manuel mine (containing approximately 1 billion
tons of ore - making it the largest underground copper mine in the
world) and the underground Superior mine.. Old smelter slag has
also been processed to yield approximately the same recoverable
copper content as the San Manuel ore, making a substantial contrib-
ution to total production. I
5) Area's economic base largely derived from mining,- milling, and
reduction of copper ores. !
6) Production*:
1973
Copper (tons) 158,300
Sulfuric Acid (tons)
*Figurcs for other San Manuel pr
1974
149!,600
-- -
oducts go
1975
139,000
;;o3,ooo
Id , si Iver ,
urn
145,000
DNA
and
molybdenum sulfide - were not available to INFORM.
Comments:
II. PROCESS AND HAZARDS
NOTE: Respirators are company supplied and worn on a need basis. The
following comments evaluate TWA exposures independent of respirator use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
Page 2
NOTE-: All documented arsenic exposures are expressed i|i terms of the new
10 yg/m standard. May worker exposures, while below tljie standard, are
above the action level (5 ug/m3). Therefore these workers will be re-sub-
jected to the monitoring and medical surveillance requirements as set forth
in the standard.
A) Material Handling (feed preparation area)
1) Ores from the San Manuel mine are concentrated in thle San Manuel
mill prior to transfer to 500-ton concentrate storage bins located
adjacent to the smelting complex. Concentrates from other sources
(i.e., the Superior concentrator) are received by railroad car and
transferred to the bin storage area. Fluxes (silica and limestone)
are crushed and prepared in the Lime Plant and jalso transferred to
storage bins prior to transfer to the smelting 'circuit. The feed
materials are transferred to the reverberatory Building by a series
of overhead covered conveyors. Poor housekeeping conditions docu-
mented at the walkways along the conveyors leading to the reverb
building.
2) Charge Operator and Sub-charge Operator-- Supervises the loading and
unloading of the storage bins. Also performs air' lancing tasks when
laborer's crew not available. Exposures to potential arsenic, cop-
per, and silica dusts presently uncharacterized. ' (4 workers)
I
3) Laborers-- Principal job duties entail the unlcjading of the bins by
using air lances to blow the materials down the sides of the bins
and general clean-up duties such as shoveling up spills of materials
around the bins. Potential exposures to arsenic, copper and silica
dusts are presently uncharacterized. Potential noise exposures,
especially during air lance use, are presently poorly characterized.
4) Standard safety equipment-- Safety lines and belts are provided to
employees while working above these storage bins.
B) Reverberatory Furnace Area (81 workers)
1) Three suspended-arch furances. All three furnaces are usually oper-
ating at full capacity at all times. A five-year campaign conducted
on the furnaces before rebuilding is required. The #2 reverb was
recently rebuilt, and the #1 furnace is presently shut down for
rebuild.
2) Reverb Charge Deck-- Feed materials enter the reverberatory furnace
building proper where tripper belts distribute it to charge bins.
Employees work over the reverberatory furnace on platforms elevated
approximately 75 feet from the floor. Jobs in this area entail
managing the distribution of concentrate and flux into the charge
bins. Specific tasks include shoveling up spills of material around
the bins and cleaning the bins with air lances.
a) Charge and Sub-charge Operators: Documented sulfur dioxide
exposures above the present standard. Potential exposures
to arsenic and copper dusts during air lance use and loading
operations are poorly characterized. Potential noise expo-
-------
Page 3
sures during air lance use are also poorly characterized.
(4 workers) I
b) Departmental Laborers: These workers perform clean-up tasks
throughout the reverberator/ department:, Their exposures
vary, depending on the conditions in the'area where the em-
ployee is working. They are presently uncharacterized.
c) Since a 1975 citation by OSHA, the company has attempted to
abate the excessive levels of sulfur dioxidej in the upper
reaches of the reverberatory building by the,1 installation
and the improvement of various engineering controls. These
controls and improvements include: i
--Water cooled charge hoppers were [installed. However,
the company has stated that the hoppers continue to be
a source of sulfur dioxide leakag'e. The company in-
formed OSHA that they are presently studying the
feasibility of implementing a different method of
feeding the reverbs "as yet untrr'ed in the industry."
--Roof fans: In order to enhance/improve the "chimney
effect" and improve the flow of makte-up air through
the building, the company has increajsed the number of
roof fans and altered the configuration of various
walls throughout the smelter. , '•
d) Upon OSHA's return in late 1977 for ajfollow-up inspection,
the Industrial Hygienist noted that the; employees' exposures
(sub-charge operators) had not changed, even after the im-
plementation of various controls. The company's response in
the latest progress report was that they are presently plan-
ning to install a control cab on the tripper.
3) Feed Deck-- The reverberatory charge is fed to one of the three
reverbs by way of a belt tripper that moves along the furnace side-
wall unloading the materials into water-cooled hoppers which feed
the down chutes leading into the furnace.
a) Feederman: Manages the distribution of the feed into the
furnaces. OSHA documented sulfur dioxide levels of up to
35 ppm. The most recently available company figures show
feederman exposures ranging between 2 and 13 ppm--all above
the proposed OSHA standard. Documented arsenic exposures
above the new arsenic standard. Noise levels were found to
be below the standard. (15 workers)
b) Helper: This job category includes the spoutman and the
arch-blowers. The spoutmen work in the converter slag re-
turn area where they clean the slag from the spouts that
load into the furnace. Potential exposures to sulfur diox-
ide, during the return of slag and from leakage through the
spout, are poorly characterized. Other exposures, if any,
are poorly characterized. The arch-blower's job is to blow
the reverberatory roofs clear of dust by using compressed
air lances. Documented exposures to arsenic at the stand-
ard, and documented exposurs to sulfur dioxide above the
present standard. OSHA documented noise levels at greater
-------
Page 4
than 115 dBA with the equivalent 8-hour (TWA at 110 dBA. The
company submitted plans to OSHA in regard to eliminating the
blowing of the arch by replacing air lan,ce use with a vacuum
system. The company stated that they have repeatedly tried
vacuuming; however, the roofs are still 'blown. (13 workers)
c) Aside from dust, gas, and noise exposures, another hazard
experienced in this area of the reverbs (feed deck) is blow
backs from the furnace. In 1976, a worker w^s severely
burned after such an event. A blow back occjirs when the
furnace experiences a build-up of gases that occasionally
flair up and vent out the feed chutes or other openings in
the reverberatory roof such as the slag spout. The State
Mine Inspector cited the company for not providing adequate
protective clothing. Reverb workers arp now required to
wear flame-proof jackets.
i
d) The company installed a White-Cap System for use by all em-
ployees working above the reverbs. The! company experienced
"considerable difficulty" maintaining this respiratory pro-
tective equipment when first installed in 1976. In 1977,
the company reported that the system is "flow effective and
probably more significant in SC^ protection than it was at
the time of installation." The Union reports that the
system is no longer used (1978). i
!
4) Matte and Slag Tapping Areas-- Once tapped, the; matte flows through
a matte drop hole to a ladle car. This ladle car is located in a
tunnel that travels the length of the furnace to the converter
aisle. Several ladles are filled before being brought out to the
aisle by a cable system that pulls the cars back and forth. Two of
the reverbs are equipped with operating exhaust enclosures--dog-
houses--that cover the tap hole, the launder, and the drop point to
the tunnels. The company is currently planning to redesign the dog-
houses to allow for the use of new tapping equipment that they plan
to install. This new design will be the company's fifth attempt at
capturing sulfur dioxide at the tapping points and exhausting it ^awa
from areas where employees are working. The slag tapping is neither
enclosed nor ventilated. The slag is tapped and loaded into cars
loaded into cars located in the slag tunnel beneath the reverb.
a) Tapper and Tapper Helper: Worker opens and closes tap hole
and manages the flow of matte into the ladle cars. The
company reports that the tapper is exposed to S02 levels
ranging from 1 to 16.8 ppm. OSHA documented arsenic expo-
sures above the standard. Other exposures, if any, are
poorly characterized. (19 workers)
b) Slag Motorman: Opens and closes the slag tap hole, manages
the flow of slag into the slag train ladles, and drives the
slag train to the slag dump. The company reports that
sulfur dioxide exposures are below the standard. Other ex-
posures, if any, are poorly characterized. (18 workers)
-------
Page 5
c) Some employees must work intermittentlyjin the matte and
slag tunnels. These include maintenance men, electricians,
and equipment operators. Exposures, if'i any., while working'
in these tunnels are poorly characterized. Union filed
complaint in regard to operating a D-8 loader in the tunnel
without adequate "headache" protection. These loaders are
occasionally brought into the tunnels for clean-up purposes.
The State Mine Inspector issued an order prohibiting use of
the loader in the tunnel until protection is! provided for
the operator. '
5) Reverb Man-- This job category is a combination of two jobs: con-
trol room operator and furnace operator. The jbb includes checking
the furnace for adequate feed, determines when 'the matte and the
slag should be tapped, checks to ensure that adequate draft is main-
tained, and other duties relating to the overall! operation of the
furnace. The reverb man does not remain at one; job station since
his duties require him to be at different stations throughout the
reverberatory furnace department. The company reports sulfur diox-
ide exposures above the proposed standard. Other) exposures are
poorly characterized and dependent on the area inj. which he is work-
ing. (12 workers)
C) Converter Area (45 workers)
1) Watte from the reverberatory furnaces is transferred in ladles to
one of the six Fierce-Smith converters by an overhead crane. A
siliceous flux is added to the converters. Gases from the converter
process enter water cooled primary hoods over each converter and are
then ducted to the acid plant. At the completion of the converter
cycle, blister copper is transferred to the anode casting area.
2) Crane man-- There are four overhead "hot metal" cranes--three in
operation. After an OSHA citation for sulfur dioxide exposures to
crane men, the company began experimenting with new air purifying
devices on one of the cabs. Company abatement data submitted to
OSHA indicated that sulfur dioxide levels have been reduced to
below the proposed standard. However, the company submitted expo-
sure data, during the 1977 S02 hearings that indicated craneman expo-
sure levels were above proposed standard. The company later re-
ported that it was having problems with the durability of the unit
and was experiencing a shorter than expected lifetime of the filter-
ing media. As a result, such units have not as yet been installed
in the other crane cabs. Union reports that respirators are at
times needed in the crane cabs. OSHA documented arsenic exposures
above the standard. (9 workers)
3) Skimmer-- Operator of the converter. OSHA documented SO? levels
above the present standard. Company industrial hygiene data from
early 1977 indicated SO,-, exposures for skimmer platform as being
below the proposed standard. Personal exposures are reported as
variable with some exposures above the proposed standard. The union
reports that the skimmer platforms at the #5 and #6 converters are
-------
Page 6
high S02 areas. Arsenic levels were found to bi at or below the
arsenic standard. Company was cited for excessive noise exposures
in this area. Noise sources affecting the skimmers are the tuyere
punching operation (see Punchers) and the reverb,eratory furnace
burners. The company installed an acoustical wall at the burner
end of the reverb; however, it was destroyed by swinging crane
hoods before any evaluation of its noise level abatement capabili-
ties could be made. Since the company is presently converting the
reverberatory furnaces' fuel supply from natural gasj to coal, a hold
has been put on any additional construction of sound barriers in
this area. The company's research has indicated that coal firing
burners may be much quieter. A partial enclosure is, however, being
designed and built to reduce skimmer exposure from the tuyere noise
and other background noise sources, such as the] reverb burners.
I
4) Puncher-- Punching performed mechanically by pneumatically operated
tuyere punchers. The puncher operator sits on a moving cart and
operates this mechanism. Company industrial hygiene data shows that
sulfur dioxide levels in the punching area are above the present
standard. Trace metal exposures are presently poorly characterized.
Company was cited for excessive noise to the puncher--often exceed-
ing 115 dBA. The company abatement program included the installa-
tion of Noranda Tuyere Silencers on all the converters. Leaks in
the air lines to the tuyeres were also found to be problematic. To
eliminate this noise source, the company has bqgun replacing the
lines with "a new, longer, and more durable flex-line." The company
reported to an OSHA hygienist that they were thinking of punching
the converters remotely from an enclosed booth by using a laser as
the aiming, device. The company's latest quarterly report, however,
does not discuss this concept. Instead, they are partially enclos-
ing the punch car cab and presently evaluating its effectiveness.
5) Silica Belt Tender (sub-charge'operator)-- These workers spend a few
hours every other shift managing the distribution of silica fluxes
into the converter flux storage bins. The flux belt gallery is not
enclosed—subjecting these workers to high levels of sulfur dioxide.
Other exposures--arsenic, silica dusts, etc.--are at present poorly
characterized.
6) Converter Laborer-- Performs various tasks in the converter aisle
and around the adjacent converters. Potential exposures to arsenic,
sulfur dioxide and noise are poorly characterized. (3 workers)
7) Converter Aisle Equipment Operator-- Cabs are not enclosed. Expo-
sures are poorly characterized. (3 workers)
D) Anode Area (81 workers)
1) Four anode furnaces and two casting wheels
2) Blister copper from the converters is transferred by overhead crane
to an anode furnace where a final blow and subsequent deoxidation,
using reformed gas, takes place. Anodes are poured in the casting
wheel and after being cooled, are transported to the neighboring San
Manuel Refinery for electrolytic refining.
-------
Page 7
3) After a worker complaint in 1976 (regarding high sulfur dioxide
levels "in all of the smelter"), an OSHA hygienist found S02 concen-
trates on the Anode Floor at the present standard. During the in-
spection one interviewed worker stated that the;.gas (S02) comes when
the wind "sets up" the valley and is only bad when several of the
converters are out of the stack at the same time. TWA exposures in
the anode area are poorly characterized.
4) Trace metal, noise, and heat exposures, if any are uincharacterized.
E) Acid Plant Area (19 workers)
1) The 2,400 TPD single contact was completed and placed on-stream in
December of 1975. If the total amount of acid produced cannot be
sold or it it exceeds the avialable storage capacity, it is neutral-
ized in an adjacent acid neutralization plant. ,
2) Exposures to workers (acid plant men, helpers, 'and departmental
laborers), if any, are poorly characterized.
F) Electrostatic Precipitator Area
1) Dusts from the reverberatory precipitator are combined with lime and
processed in a pug mill before being returned to the reverberatory
furnace feed in the materials handling area. Dusts from the conver-
ter precipitator are taken by truck to the reverberatory furnaces or
loaded into ladles and fed to the converters.
2) Potential exposures to copper and arsenic dusts are poorly charac-
terized. Other exposures unknown.
G) Others (158 workers)
1) Due to the transient nature of a selected number of jobs, INFORM has
created an "Others" category. While many of the workers on this
list may be permanently associated with one sub-department of the
smelter--i.e. , some of the laborers work full-time in the material
handling areas—we have been unable to differentiate these workers
from their transient counterparts. Hence they are included in this
category. These workers are listed as follows:
Laborers-- 102 workers
Utilitymen— 28 workers
Brick Masons-- 14 workers
Equipment Operators-- 11 workers
Tool Tender-- 1 worker
Mechanical Sweeperman-- 1 worker
Janitor-- 1 worker
2) Most exposures for these employees are poorly characterized.
-------
Page
Comments :
-------
Page 9
COMPANY SAFETY AND HEALTH ACTIVITIES I
i
A) History /
'i
1) Industrial Hygiene Program. In June of 1975, an Industrial Hygien-
ist-in-training was added to Magma's staff. Other historical
details were not available to INFORM.
2) Safety Program. History of Magma's safety program nlot available to
INFORM. j
B) Staff :
1) Safety Director I
2) Safety Engineers (2) I
3) Director of Environmental Affairs !
4) Industrial Hygienist (in training] '
5) Safety Aide (respirator man)
l
C) Respirator Program i:
1) Administration of program is the responsibility of the Division
safety department. Training, education, and supervision of respira-
tor usage is the responsibility of plant managers, superintendents,
and--department heads.
2) All workers are assigned and fitted to a respirator according to the
hazard present in their work areas. They are responsible for daily
cleaning and maintenance of respirators.
3) A permanent employee (safety aide) was hired to service the respira-
tors. Each week respirators are exchanged for ones that have been
repaired and sanitized.
D) Safety Equipment
1) All required safety equipment is loaned to employees, except safety
shoes with metatarsal guards which must be bought outright by the
worker.
E) Industrial Hygiene Activities
1) Area and personal sampling for sulfur dioxide and noise performed by
hygienist. No evidence that the company samples for other in-plant
hazards.
2) INFORM was unable to determine the extent and frequency of the in-
plant sampling program.
3) No formal reports or education are given to workers regarding the
need, objective, and results of industrial hygiene sampling.
-------
Page 10
4) The company provided limited industrial hygiene;related data during
the course of the OSHA sulfur dioxide hearing, /Magma did not parti-
cipate in the arsenic hearings. 'i
F) Safety Program
1) Smelter safety program as well as the safety programs throughout the
San Manuel complex are under the direction of the Safety Director.
Safety acitivities are carried out by two safety engineers.
2) Extent and frequency of safety inspections unknown to INFORM.
3) Accident investigations are conducted by companjy; however, workers
are not allowed to participate. Written report's prepared at the
conclusion of the accident investigations are not available to the
union. >
4) New employees are instructed on the general safety aspects of their
jobs prior to employment in the smelter.
I
5) Formal safety refresher courses for all workers ajre not available.
6) Safety training for new equipment and process changes is provided on
a limited basis.
7) OSHA 102 data is available for 1974, 1975, and'1976.
G) Health Care
1) Smelter complex has a first aid station staffed by a nurse. Aside
from general first aid, nurse performs yearly pulmonary function
exams.
2) Company owns and operates its own hospital in San Manuel, with phy-
sicians on call 24 hours a day. Union reports, however, that
while "on call," physicians are not always available.
3) Emergency transportation is available at the plant. The ambulance
is operated by a plant guard, who, the union reports, is not readily
available.
4) All employees receive a physical examination prior to employment.
Periodic health monitoring—excepting pulmonary function exams and
audiograms--are not provided to workers. Salaried employees receive
yearly physicals.
5) Hearing program
a) The company performed a plant-wide noise survey to determine
areas where noise levels exceed 85 dBA. Areas found to be
above this level were designated in writing and posted.
b) All workers in designed areas were given an audiogram. _In
1976 the second year of this program, the company initiated
an annual resereening audiogram program of the exposed work-
-------
Page 11
force. More frequent testing—in some (pases quarterly—for
those workers showing "a shift in hearing acuity and for
those with an apparent, large-, absoluteness."
'i
c) If a further loss of hearing is noted, the worker is moved
out of the designated area or occupation. Workers do not
retain wage rates if they are forced to change jobs as a re-
sult of an occupational injury or illness.
d) It is the company's position that hearing protection can
prevent "deterioration of hearing acuity if (the employee
will use it without fail." If worker audiogr'am results show
a shift in hearing acuity, the company assumes that the
worker failed to wear hearing protection properly and as a
consequence he is removed from the exposure.
e) INFORM has not found any evidence that the company performed,
either through contract or through its medical department,
any epidemiological or medical research, studies.
Comments:
SAFETY AND HEALTH COMMITTEE
A) There is no joint safety and health committee at the San Manuel complex.
B) The union appoints a safety man from each division of the complex — mine,
mill, smelter, refinery. Each representative is then allowed to accom-
pany the company's safety engineer on an inspection of his respective
division every six weeks during which time "he shall cooperate in making
recommendations with respect to safety." The areas entered for the pur-
pose of inspection are at the discretion of the company's engineers.
C) At the conclusion of the inspection tour, a report is prepared and for-
warded to the union.
D) There is no contractual right to refuse unsafe or unhealthy work.
E) The union does not have the right to review the results of the company's
industrial hygiene monitoring.
F) The International does not have the right to enter the plant for safety
and health issues,nor is it allowed to review company-produced materials
regarding safety and health.
G) Workers do not retain wage rates if they are forced to change jobs as a
result of an occupational injury or illness.
-------
Page 12
Comments:
REGULATORY HISTORY
A) Pre-1970 ,
I
Office of State Mine Inspector |
B) Post-1970
1) State OSHA Plan
a) Developmental. Headed by Arizona Industrial Committion.
Approved October, 1974. I1
b) Jurisdiction over smelters still in hands: of State Mine
Inspector
j
2) Office of State Mine Inspector !
a] No contractual relationship exists with Arizona Industrial
Commission.
b) Two to three inspections per year, 1972-1976.
c) Limited industrial hygiene efforts.
3) OSHA Activities
a) OSHA has inspected smelter ten times. All were due to
worker complaints.
Comments:
-------
NAME
Reverberator/ Furnaces (3)
[Suspended arch]
Converters (6)
3 - 13'x35'
2 - 15'x35'
1 -
Anode Furnaces (4]
Casting Wheels (2)
Acid Plant
Acid Neutralization Plant
AGE
1956
1956
1956
1975
1956
1956
1975
1975
POLLUTION CONTROLS
Waste Heat Boilers -> ESP + 515'
Stack
Radiation/Conductive cooling ducts -> ESP
Scrubber Cooler -> Acid Plant -> Stacks
Tail gases vented through (2) 200' stacks
COMMENTS
Green feed operation.
Gases that by-pass Acid Plant «
are vented through 550' Stack,;
2400 TPD with two parallel
single contact sections.
SOURCES: Design and Operating Parameters for Emission Control Studies
Magma, San Manuel, Copper Smelter
An Industrial Hygiene Study of the Magma Copper-Company
Smelter [NIOSH Study~ — —
-0
P
-------
Number of
PLANT AREA Employees
Material Handling
Reverberatory Furnace
Converter
Anode
Other
(including acid plant]
14
81
45
81
177
TWA Exposures*
Copper
mg/M3
L >2
Arsenic
pg/fm3
i
<10-60
<10-40
<40
Lead
mg/M3
Sulfur
Dioxide
(PPM) NOTES
35
l.S->30
10
Worker exposures in material
handling (bins to reverb)
are uncharacterized.
S02 excursions greater than
200 ppm. Arch blower exposed
to noise levels .> 115 dBA.
Skimmer and puncher noise
exposures > standard.
Most exposures poorly charac-
terized.
* Independent of respirator usage
SOURCES: Sulfur dioxide OSHA hearings, 1975. Company data,
OSHA inspections
OSHA/company abatement correspondence
Arizona State Mine Inspector inspections
NIOSH data
00
CO
-------
Table 3
'ECTIONS -- MAGMA, San Manuel Smelter
;c of Arizona, State Mine Inspector
Page 15
''
,8/71
1/72
16/72
/701
/701
/711
/73
73
/73
3/74
TYPE
Safety
Dust
Survey
Safety
Dust
Survey
Safety
Dust and
Toxic Gas
Survey
Dust
Survey
Special
Inspection
Safety
Safety
FINDINGS PENALTIES FOLLOW-UP , COMMENTS
4 -0- Company Machinery guards , fire
violations abatement extinguishers, gratings.
letter ,
No --.- S02 levels in tripper
violations : belt area 14-18 ppm (not
cited) . Poor housekeeping
tripper floor.
20 -0- All viola- • Poor housekeeping -
violations tions abated excessive dust build-up
within 60 t on steel beams.
days .
No l NO counts above limit.
violations j,
2 -0- All viola- ; S02 above limit. House-
violations tions were keeping exceptionally
subsequently good.
abated.
No Two S02 counts above
violations limit.
No Si02 measurement above
violations standard not cited.
S02 "fairly high" in some
areas .
No Special inspection investi
violations gating State Sen. Ulm's
24 complaints describing
unsafe or unhealthy condi-
tions in the smelter.
? ? Inspection results not
available to INFORM.
9 _0- Violations concerned guards
violations covers, safety chains, etc.
1/74 Safety - No
Acid Plant violations
Good housekeeping and drain-
age in the Acid Plant.
-------
pections--San Manuel [SMI], continued)
Page 16
TYPE
FINDINGS PENALTIES FOLLOW-UP I COMMENTS
/75 Complaint
'75 Safety
'75 Abatement
inspection
'5 Safety
'6 Complaint
76 Complaint
6 Accident
investigation
Toxic Gas
76 Inspection
'i
1 -0- Variance !' Complaint re use of Dozer
violation granted in matte tunnel without
"headache bar".
6 (smelter) -0- Dipt conditions must be
violations improved in smelter.
--- , Violations of 2/15/75
abated.
5 -0- Investigate the engineering
violations • solution to the precipitator
dust handling system.
i
1 -0- Abated : #4 converter crane not in
violation immediately compliance steel plate
1 over "deadman" switch.
No < Complaint re solitary
violations ; employment, high temper-
encountered atures, and no ventilation
' at sub-charge operator's
station.
1 -0- Employee severly burned
violation during smelter "blow-
back".
5 -0- All S02 samples above TLV's
violations Levels range from 22 ppm
125 ppm.
-------
Table 4
ACTIONS -- MAGMA, San Manuel Smelter
Page 17
TYPE
FINDINGS
PENALTIES
FOLLOW-UP
COMMENTS
'72 Complaint In
Compliance
Found complaint to be in-
valid. Management-Labor
issue.
'73 Complaint In
Compliance
Employee discharges because
refused unsafe work. CSHO
found that "facts as stated
in complaint were not entire!-
the same as observed at the
actual scene. Employee
reinstated.
Complaint In
Compliance
Employee complaint re heat
stress in tank house.
'/74 Complaint 2 citations
75 (5 non-serious
items)
$45. abatement I'Cited 1. noise reverbs
plan sub- 'for: 2. noise - converters
mitted : 3. S02 - reverbs,
I cranes
4. no emergency eye §
body flushing
facilities
5. noise - rod plant
/74 Complaint 1 citation $35.
(7 non-serious
items)
recommended
by CSHO
Complaintant listed 24 hazard:
that he believed existed.
Union rep was "somewhat
disturbed over way which
complaintant had acted...they
[Union] had a safety committee
that took care of [such]
problems ....
Complaint 1 non-serious $35
75 violation
recommended
by CSHO
complaint re inadequate
respirators. Company abated
by initiating new respirator
program.[S02-Sub-charge area
Complaint In
Compliance
Complaint re lack of lunch
room for smelter repair crew.
Lunch room available in
general vicinity.
75
Complaint In
Compliance
Reverb worker complained abou
elimination of White Cap
protective equipment. OSHA
only requires approved
respirators which were
issued.
-------
iCTIONS -- MAGMA, San Manuel Smelter
(continued)
Page 18
TYPE
FINDINGS
PENALTIES
FOLLOW-UP
COMMENTS
/75 Complaint 1 non-serious $0
[Health] violation
none
Complaint re condition of
holding vessels. Company now
under a repair schedule to
correct this condition. Othei
areas of complaint not cited
since company under an
abatement plan.
/75 Complaint no violations
[Safety]
Safety inspection for 12/10/7!
complaint inspection. CSHO
noted that "there appears to
be a lack of communications
between employees and super-
vision to inform them
I(employees) of maintenance £
j,repair schedules".
76 Complaint In
Compliance
Complaint re S02 levels no
'violations found that were
not already cited and under
an abatement schedule.
76
Complaint 3 non-serious
violations
company Complaint re unsanitary
abatement conditions in lunch room
-------
FACT SHEET
Facility: New Cornelia Branch, Ajo Smelter
Company: Phelps Dodge Corporation
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
I
Name: New Cornelia Branch, Ajo Smelter i
Location: Ajo, Arizona ;i
Description:
1) Combination of open pit mine, concentrator, green feed smelter,
anode casting, and supportive facilities.
2) Smelter built in 1950; mill in 1922. j
3) Employees: 176--concentrator; 129--smelter; 1,400-!-mine.
4) Ore from New Cornelia open pit mine, as well as some custom work.
Arsenic content of concentrate "less than .005%" as reported by
James E. Foard, Phelps Dodge metallurgist. j
5) Largest employer in Pima County '
6) Production
j
a) Approximately 1/6 of Phelps Dodge's total
b)
1972
1973
1974
1975
1976
Copper
(short tons)
Acid
57,876
53,799
1
43,501,
33,025
Comments:
PROCESS AND HAZARDS--SMELTER
NOTE: Workers are issued company-supplied respirators; however, use is not
mandatory. Workers are responsible for maintenance and storage. OSHA
inspection of 2/24-26/76 indicated use but lack of clean-up program for USBM-
and NIOSH-approved respirators. Level of recorded exposures precluded
establishment of comprehensive program.
NOTE: The following comments evaluate TWA exposures independent of respira-
tor use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
A) Material Handling
1) Concentrates are transferred from the Cornelia Mine by uncovered
conveyer belts. Exposures are uncharacterized but dusty conditions
prevail.
-------
2) Concentrate passes through filter and drying bililding; open conveyer
to charge can filling area. New swivel conveyejr hood of unknown
effectiveness. Background exposures to arsenic ijand S02. Six men.
B) Reverberatory Furnace
1) One sprung arch type furnace situated parallel to converter aisle.
2) Arch last rebuilt June 1976. Workers compalined of excessive heat
and dust. OSHA found allegations to be unfounded, jforeman appar-
ently relieved of duties. Approximately 22 workers to rebuild.
Exposures are uncharacterized.
3) Charge cans are tranferred by overhead cranes to three charge
points on each side (north and south) of reverberatory furnace.
Crane cabs are enclosed but not pressurized. Exposure levels are a
source of union/management friction. Three men.
4) Reverb is fed by high speed slinger system. Operator is exposed to
levels of arsenic above the proposed standard.! Sulfur dioxide expo-
sures are poorly characterized.
5) Reverberatory arch cleaning is the responsibility of reverberatory
laborer #2. Cleaning actually occurs no more than once a week.
Vacuum system all but discontinued, arch is air lance blown. S02
exposure above the proposed standard. Arsenic exposures are poorly
characterized.
6) Also present in the reverb area at various times is the refractory
department. Hot patching is accomplished at least three
times during each day. Reverberatory furnace area monitoring
indicates arsenic levels above the proposed standard. Personal
samples are poorly characterized, but likely to be high. Five men
per shift.
7) Matte tap launders are uncovered but short. Launders transfer matte
from reverberatory furnace into enclosed matte ladle area. Workers
complain of inoperable exhaust and matte tap hole punching systems.
Exposures above the proposed arsenic and S02 standards.
8) Slag drops to waiting cars below the reverb floor and is transferred
to the slag dumping area. Exposures above the proposed arsenic
standard have been reported. Slag launders are unhooded.
9) Reverb waste heat boilers reportedly leak and need replacing. There
is a staff of nine, divided between the two reverb and three pres-
surized waste heat boiler areas. Arsenic levels of .062 mg/M^ are
reported. Hand-lancing (soot-blowing) several times per day
involves an unknown quantity of workers. Exposures during this
mechanical operation are uncharacterized.
10) Crane repair bay (north end of reverberatory crane aisle) area ex-
posures of S02 are as high as 6 times the proposed standard.
Arsenic exposures are uncharacterized. Number of men and length of
exposure are undetermined but likely to be varied.
-------
C) Converter Aisle
I
1) Three Fierce-Smith converters with movable radiation cooled rib
steel primary and secondary hoods. Due to production cutback, only
one or two operate at a time.
2) Crane cabs are enclosed and air conditioned (1573, 1975 respec-
tively) . Exposures are poorly characterized. Cabs reportedly
ride "roughly."
3) Converter punching stations cited for noise by OSHAJ. "Quietaire"
and auto mufflers on pneumatic cylinder exhausts ha've reduced levels
considerably. However, tuyere silencers have proved ineffective
over time. Therefore, baffling of puncher platform reportedly was
to be installed in January, 1977. As of July,, 1977, no progress in
installation. Cooling system reported to be ineffective, even when
functioning. Supply air system never fully developed.
4) Silica is discharged into the converters by wa;y of a Garr gun
attached to portable silica hoppers above the jskimming platform.
Arsenic exposures above proposed standard. SQ2 exposures are poorly
characterized. Three workers.
5) Converter operator (skimmer) is unsheltered from exposure. Expo-
sures above proposed arsenic standard are reportfed. S02 and noise
exposures are uncharacterized. Three workers. '
6) Exposures during soot-blowing of waste heat boilers uncharacterized.
7) Converter repair bay S02 exposures average above proposed standard.
Excursions as high as 22.28 ppm. Other exposures are poorly charac-
terized. Number of men unknown.
D) Oxidizing Furnace
1) Formerly used for copper blowing. Due to production cutback, pres-
ently used as holding furnace.
2) Copper is tranferred from the converters by overhead crane to an
unhooded Great Falls Oxidizing Furnace. There are four 2-inch
tuyeres. Exposures to arsenic, S02, and noise are uncharacterized.
Possible high S02 and arsenic levels due to its proximity to the
converter and reverb areas.
E) Anode Area
1) One anode furnace and one anode casting wheel. Area S02 exposures
are generally low, while arsenic exposures above proposed standard
are reported. Pedestal fans are reportedly situated throughout the
area. Twelve workers.
2) Blowing of unhooded anode furnace is with reformed natural gas.
Exposures during procedure are uncharacterized.
3) Two to four men per shift work on the anode casting wheel removing
anodes, placing them in water and spraying silica solution in the
anode molds. Exposures are poorly characterized.
-------
F) Auxiliary Operations |
1) Silica Crushing and Handling
a) Silica circuit consists of junction house, smelter crushing
building, uncovered conveyer belts, a ball mill, and por-
table hoppers. Exposures to silica likely. Number of men
unknown.
b) Crushed silica is transferred by converter pverhead cranes.
Crusher exposures to arsenic documented above the proposed
standard. Other exposures are poorly characterized.
2) Acid Plant
a) Acid Plant designed to handle the off-gases from one con-
verter blow. Problems have included insufficient mist
precipitator capacity and extensive corrosions. Exposures
to the six men are poorly characterized.
3) DMA Plant !
a) 1972 plant designed to handle overflow converter gases,
redirected to handle lower-sulfur-dioxide-concentration
reverberatory furnace off-gases. Longest continuous run
ten days. Exposures are uncharacterized, S02 exposures
possible during malfunctions. |
4) Electrostatic Precipitators I
I
a) Electrostatic precipitators are cleaned at undetermined
intervals, by hand. Workers are equipped only with halfmask
respirators.
b) Revert is reportedly stored in open piles at various loca-
tions throughout the smelter building. Blowing dust is
problem prior to recharging in converters. Possible expo-
sures unknown.
Comments:
-------
COMPANY SAFETY AND HEALTH ACTIVITIES ,
I
A) History--Details Unavailable.
'i
B) Staff '•
Safety Director (1)
Environmental Engineer (1)
Safety technical personnel (part-time) !
i
C) Industrial Hygiene
1) There is no full-time staff at local level. Company technicians
from Tuscon on premises part-time. i
D) Respirator Programs
1) Respirators are available in most areas of the smelter, but use is
not mandatory- ;
2) Workers are responsible for training, maintenance and storage.
3) Levels of recorded exposure during 2/24-26/76 OSHA inspection pre-
cluded establishment of comprehensive program.
4) 1977 union contract demands included establishment of a respirator
program. I
E) Safety '
1) There is no extensive pre-employment safety instruction.
2) Monthly departmental safety meetings are held infrequently if at
all.
3) 1974, 1975 OSHA 102 Data on hand.
F) Health Care
1) New Cornelia hospital built and staffed by the Phelps Dodge Corpora-
tion.
2) Staff includes six doctors, twelve registered nurses, on full-time
staff. Undetermined number of part-time technical personnel.
3) Adequate 24-hour emergency facilities,as well as pre-arranged
referral capabilities to Phoenix and Tuscon medical centers.
4) Pre-employment physical includes x-ray, audiometric, and pulmonary
function tests.
5) Conflicting information as to existence and/or extent of company-
sponsored annual medical testing offered.
Comments:
-------
SAFETY COMMITTEE
A) Description '
1) Established following the 1974 contract negotiations.
2) Management and labor (I/union) represented
3) Committee acts on suggestions received from departmental meetings.
The committee has no investigatory or inspection powers.
Comments:
REGULATORY HISTORY
A) Pre-1970
1) Office of State Mine Inspector
B) Post-1970
1) State OSHA Plan
a) Developmental. Headed by Arizona Industrial Commission.
Approved October, 1974.
b) Jurisdiction over smelters still in hands of State Mine
Inspector.
2) Office of State Mine Inspector
a) No contractual relationship exists with Arizona Industrial
Commission.
b) Two to three inspections per year, 1972 - 1976.
c) Limited industrial hygiene efforts.
-------
3) OSHA Activities I
1) Initial inspection: fatality investigation
ii
2) 2nd inspection: general schedule safety ,
3) 3rd inspection: general schedule health. ' Citation for noise
while punching converters.
4) 4th inspection: complaint,reverberatory arch building. In
compliance. j
Comments:
-------
PROCESS EQUIPMENT*--Ajo
Table I
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Reverb (1)
Converter (Pierce Smith]
Converter "
Converter "
Oxidizing Furnace (Great Falls)
Anode Furnace
Casting Wheel
Acid Plant (Single Contact)
DMA Plant
Waste Heat Boilers (5)
1950
1950
1950
1971
1950
1950
1972
1972
ESP
DMA plant or stack
Primary and secondary hoods,
ESP,
acid plant
None
None
None
3--Converter (pressurized)
2--Reverb
high speed slinger feed
Used primarily as holding furnace
600 TPD
50 TPD--handles reverb off-gases
Longest continuous run- -10 days
*Figures 2,3,4,5; Design and Operating Parameters for Emission Control Studies:
Phelps Dodge, Ajo, Copper Smelter
-------
ictions--Ajo
Table 2
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
'72
,/75
76
'6
fatality
general
schedule
safety
general
schedule
health
complaint
hazard not covered
by standard None
17 non-serious
violations $185
1 non-serious
violation None
in compliance
None
company
letters
company
letters £ memos
through 1/3/77
converter
#2,3--noise
reverb arch
rebuilding
:Ctions--Ajo
of Arizona, State Mine Inspector
72
72
72
73
m
4
/74
75
/75
76
76
5
TYPE
fatality .
dust j
safety
dust
safety
spot
safety
!
1
safety
dust
safety
safety
safety
FINDINGS PENALTIES FOLLOW-UP
i
4 recommendations 10/5/72
5 S02 samples
13 dust counts
COMMENTS
#3 converter
rollback
•spill
grab area
samples
6 violations
'9-dust counts
1 11 violations
i 3 recommendations
' 1 violation
2 recommendations
6 violations
11 violations
abated
11 violations 10/20/75
6 S02 samples
,,' 13 dust counts
!| 10 violations
i 10 violations abated 5/18/76
i
8 violations
3 violations
grab area
samples
smelter
acid plant
acid plant
grab area
samples
smelter
acid plant
rebuilding
reverb arch
-------
SUMMARY OF HEALTH HAZARDS--Ajo
Table 3
Number of
PLANT AREA Employees
Material Handling
Reverberator/ Furnace
Converter
Anode
Other
43
25
13
12
66
TWA Exposures*
Copper
mg/M3
Arsenic
mg/M3
000-.317
000-.026
000-.012
Lead
mg/M3
Sulfur
Dioxide
(PPM) NOTES
0-48
0-22
Noise levels 1.59 times the
standard for
converter puncher.
independent of respirator usage
SOURCES: Arsenic OSHA hearings, 1975. Company data.
OSHA inspections
Arizona State Mine Inspector inspections
-------
FACT SHEET
Facility: Douglas Reduction Works
Company: Phelps Dodge Corporation
INFORM
25 Broad Street
New York, N.Y.
10004
(212) 425-3550
-------
GENERAL
Name: Douglas Reduction Works, Phelps Dodge Corporation
Location: Douglas, Arizona
Description:
1) Combination of custom smelter and supportive facilities.
2) Smelter built in 1903.
3) Employees: 565
4) Ore is received as toll from nearby open pit mines. Arsenic content
of concentrate reported by the company to be between .1 and .3 per-
cent.
5) The Douglas smelter employs 42% of Cochise County's manufacturing
workforce, and is responsible for 50% of the County's manufacturing
payroll, with an annual payroll of $8,000,000.
6) Production:
Prior to the closing of the Bisbee Mine in 1974-1975, the Douglas
smelter received the majority of its concentrate from there, with a
small percentage from the developing Tyrone mines. Currently, the
smelter processes Tyrone and toll concentrates and scrap purchased
by the company, and revert dust from the company's Morenci smelter.
Comments:
PROCESS AND HAZARDS--SMELTER
NOTE: Respirators are available in most areas of the plant; however, use is
not mandatory. Workers are responsible for training, maintenance, clean-up
and storage of respirators.
NOTE: The following comments evaluate TWA exposures independent of respira-
tor use.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action.
-------
A) Material Handling
1) Concentrates are received at the preparation plant in open railroad
cars which are dumped into bins. Dust generated by air lance use is
reported. Documented respirable nuisance and 'silica dust violations
as well as noise violations at concentrate unloading dock and bins.
Five workers.
2) Concentrates are crushed, screened, and mixed, prior to open con-
veyor transportation to 100-ton feed bins above the! multi-hearth
roasters. Documented silica violations to feeder c!ar man, screen
operator and bedding plant operator, with near, violations to several
other workers. Documented noise violation to feeder car man, slag
screen operator and rolls operator, with potential exposures to sev-
eral other workers. Use of hearing protection' is intermittent
throughout preparation plant. Forty workers. !
3) Potential exposure to arsenic dust is uncharac^terized throughout the
preparation plant. '•
B) Multi-Hearth Roasters (
1) There are 24 Herreschoff multi-hearth roasters, with 16 to 20 nor-
mally in operation. Off-gases from the two parallel rows of 12
roasters pass into an electrostatic precipitator, are combined with
reverb off-gases, and sent out through the stack. Concentrates are
fed by vaned drum feeders into roasters. Company reports average area
sulfur dioxide levels to be two times the existing standard.
2) Operating Decks
a) Tripper floor sulfur dioxide exposures vary from below pro-
posed standard to four times existing standard. Arsenic
exposures are poorly characterized.
b) Company reports charge floor average sulfur dioxide level
at proposed standard. Excursions during malfunctions docu-
mented to 220 ppm. Company also reports feeder station TWA
arsenic levels slightly above proposed standard, with oper-
ator exposure averaging well above proposed standard.
Twelve workers.
3) Unloading Areas
a) Calcines are discharged into larry cars below roasters.
Larry car trains of two cars each make approximately fif-
teen trips to reverb per shift.
b) Larry cars are filled from hoppers through pneumatically
activated gates by remote control. Discharge points are
draft hooded. Operator station is approximately 30 feet
from hoppers; however, company reports sulfur dioxide ex-
posures as high as 11.30 ppm, due to gap between larry car
-------
and hoppers, and unhooded areas betweeiji hoppers. Company
states gap is "necessary for clearance;and is a source of
gas spillage." Operator arsenic exposures are poorly char-
acterized. ''•'
c) Larry cars during transit are presently uncovered. Expo-
sures to motor man reported by company to be as high as
19.53 ppm. Company reports that it has bee|n unable to
"put together a workable system" of closed jcontainers or
cars. Arsenic exposures are poorly characterized; however,
limited company data indicates a level of four times pro-
posed standard for 2-hour period.
i
4) Company reports that structure and design of bjuilding allow for
"S02 and dust from this source (calcine cars) drift upward and per-
meate other working areas in the roaster building."
I
5) Other areas of potential exposure to hazards include the center
aisle,where the company reports sulfur dioxide levels averaging ap-
proximately six times the existing standard, andl the roaster flue
test station, where limited company data indicates arsenic levels
slightly above the proposed standard. Actual exposure and exact
number of workers affected are unknown. :
C) Reverberatory Furnace
1) Three reverberatory furnaces: two silica sprung arch, one suspended
basic roof. Company reports area average sulfur dioxide level to be
slightly above proposed standard.
2) After traveling approximately 200 yards, the larry cars are emptied
through "close fitting linkages" on underside of car. There is no
attempt to capture dust and gases at this area. Company reports
calcine motor man exposed to levels of sulfur dioxide averaging two
and one-half times the existing standard in reverberatory furnace
area. Potential arsenic exposures in this area are uncharacterized.
3) Charge floor: Sprung arch furnaces #9 and #10 are fed through grav-
ity (Wagstaff feeders), while #8 is fed by drag chain conveyor.
Company reports leakage at both types and average sulfur dioxide ex-
posure to area workmen slightly above proposed standard, with excur-
sions higher than existing standard.
a) Reverb #8-- Company reports charge floor area arsenic levels
average three times proposed standard. Company reports
charge helper personal exposure to be nine times proposed
standard for 2-hour period. Actual TWA exposures are un-
characterized. Documented sulfur dioxide levels of six
times existing standard during charging.
b) Reverbs #9 and #10-- Company reports spoutman personal ex-
posures to arsenic ranging from the proposed action level to
thirteen times the proposed standard. Documented sulfur di
-------
I
oxide levels as high as four times theiexisting standard
during car unloading. I
4) Matte tap areas: Company reports vented launder covers have become
"distorted and ill-fitting," and ladle hoods are damaged, rendering
them "ineffectual." Company sulfur dioxide data indicates an aver-
age area level below proposed standard, while working station con-
centration near vented launders is above proposed sjtandard and two
times existing standard at unvented launders. I
a) Reverb #10-- Company reports average arsenic level at the
west side of matte launder to be greater than two times the
proposed standard. j
j
b) Reverb #9-- Company reports personal arsenic exposures to
tapper to range between two and twenty times the proposed
standard. i
5) Slag skimming areas: Slag holes are locally exhausted and vented.
Company reports that sulfur dioxide exposure rarely exceed existing
standard. Arsenic exposures are uncharacteri zed1.
6) Reverberatory furnace man: Company reports that;arsenic exposures
range from three to thirty times the proposed (standard for short
periods of time. Actual time-weighted-average exposures are poorly
characterized. Sulfur dioxide levels are uncharacterized.
D) Converter Aisle
1) Five Fierce-Smith converters with three running during normal opera-
tion. The converters are primary-hooded. Secondary hoods are con-
sidered "infeasible" by company. Company reports average area S02
level to be below the proposed standard; however, company also re-
ports "SC>2 in work areas adjacent to the Douglas converter has been
measured at 4.26 ppm." Arsenic exposure in entire converter area is
poorly characterized.
2) Matte is transported across the converter aisle by overhead cranes.
Cranes are enclosed and ventilated. Sulfur dioxide levels inside
cabs are reported near or above the proposed standard. Arsenic ex-
posures, if any, are uncharacterized.
3) Skimmer: Controls blowing schedule as well as silica flux input.
Sulfur dioxide levels reported at present standard. Arsenic levels
are poorly characterized.
4) Potential converter punching hazards--arsenic, sulfur dioxide, and
noise--are poorly characterized.
5) Company reports extensive sulfur dioxide problem in upper galleys of
converter area. Sulfur dioxide levels range from 60 to 170 ppm.
Company is considering-enclosing the most heavily exposed walkways
(galleys). Arsenic exposures are poorly characterized.
-------
E) Anode Area
1) Two furnaces and one casting wheel
2) Company data indicates sulfur dioxide levels below proposed stan-
dard. Arsenic exposures, if any, are uncharacterized.
F) Auxiliary Operations
1) Company reports potential arsenic problem in roaster gas cleaning
bag house. Company data places arsenic exposure to inspector
at greater than three times the proposed standard during inspection.
Potential additional problem for repair and clean-up workers. Other
exposures, if any, are uncharacterized.
2) Waste heat boilers: Company data indicates average sulfur dioxide
level to be above proposed standard. Company also reports arsenic
levels at #10 waste heat boiler to average above the proposed stan-
dard and personal exposure to #10 boiler fireman to average twice
the proposed standard.
3) Electrostatic precipitators: Company reports arsenic levels above
the proposed standard at converter precipitate dust bin. Other ex-
posures, if any, are uncharacterized.
4) Documented exposure to dust in sample mill and bucking room. Actual
current exposures are uncharacterized.
Comments:
-------
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History — Details unavailable.
B) Staff
1) Labor Department Head / Safety Director (1)
2) The Labor Department Head is assisted by the department heads, the
master mechanic and one safety inspector. I
C) Industrial Hygiene
There is no full-time staff at the local leveli. Company technicians
from Tuscon on premises part time. i
D) Respirator Program
I
1) The company provides respirators in most areas of the plant, but use
is not mandatory-
I
2) Workers are responsible for training, maintenance, clean-up and
storage of respirators.
E) Safety I
1) Pre-employment safety orientation was developed in 1972.
2) New or transferred employees receive seven days of supervision at
new job.
3) The company provides protective equipment in most areas of the plant.
F) Health Care
1) All employees are required to learn basic first aid. The Company
annually reviews each employee's competence in the skill.
2) There are first aid stations located throughout the plant.
3) The extent of annual medical examinations is unknown at this time.
4) All extensive care is administered through the Cochise County Hospi-
tal in Douglas.
Comments:
-------
SAFETY COMMITTEE
A) Description
1) Established in 1971.
2) The quarterly meetings of the Committee are attended by three com-
pany representatives and one representative from each union in the
^Tnp I T f*.T . i
3) The Committee is advisory in nature and has no inspection or inves-
tigatory powers. :
Comments:
REGULATORY HISTORY
A) Pre-1970
Office of State Mine Inspector
B) Post-1970
1) State OSHA Plan
a) Developmental. Headed by Arizona Industrial Commission.
Approved October, 1974.
b) Jurisdiction over smelters still in hands of State Mine In-
spector.
2) Office of State Mine Inspector
a) No contractual relationship exists with Arizona Industrial
Commission.
b) Two to three inspections per year, 1972-1976.
cj Limited industrial hygiene efforts.
3) OSHA Activities
a) There has only been one OSHA inspection. A fatal accident
on December 27, 1973, brought two non-serious violations.
-------
4) MESA Activities
a) MESA has jurisdiction over the Douglas: Preparation Plant
b) There have been ten inspections of the! Preparation Plant
since October of 1974.
c) Citations have included safety violations, housekeeping,
silica dust violations and noise violations'.
Comments:
-------
PROCESS EQUIPMENT--Douglas
Table 1
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Roasters (24)
multi-hearth
Reverberator/ Furnaces
#8--suspended arch
#9 and #10--silica
spray arch
Converters (5)
Anode Furnace (2)
1903
1903
1903
flue -»- 4 parallel
ESPs ->- stack
flue ->• 3 parallel
ESPs •+ stack
Balloon flue -*• 4
parallel
ESPs ->- stack
Side-charge-fed furnace.
There is no S02 control at Doug-
las. Acid plant was destroyed in
1945.
SOURCES: Design and Operating Parameters for Emission Control Studies:
Phelps Dodge, Douglas , Copper Smelter
OSHA inspections
-------
Table 2
:tions--Douglas
of Arizona, State Mine Inspector
'2
'2
'3
'73
74
74
5
S
6
6
TYPE
dust
safety
dust
safety
safety
complaint
--dust
follow-up
safety
safety
safety
complaint
FINDINGS
6 S02 samples
18 dust counts
23 violations
60 SC>2 samples
14 dust counts
31 violations
18 violations
20 dust counts
15 violations
abated
26 violations
25 abatements
1 extension
7 violations
1 violation
PENALTIES FOLLOWfUP
i.
i
!
i
company
letter:
2/19/75
1
)
1
1 company !
letters : :
1/24/7J4.
5/21/74
company
letter:
11/26/74
company
letter
11/26/74;
3/28/75
inspection
_.__ 2/5/76
inspection
8/31/76
4/13/76
COMMENTS
3 dust samples
above allowable
limit .
4 S02 samples
20 ppm or above.
1 dust count
above allowable
limit .
S02 as high as
220 ppm.
"potential dust
problem" at
concentrate
loading bin.
preparation
plant
dust, heat 5 gas
-------
3 2—continued)
76
76
76
76
76
'6
'76
TYPE FINDINGS PENALTIES FOLLOW-UP
accident 4 violations 4/13/76
safety 9 violations 8/31/76
follow-up
accident |
i
dust 5 S02 samples
12 dust counts j
general 4 safety ,
inspection violations;
15 dust counts '
!
i
complaint/ 4 violations --.-- ;
accident: :
safety ,
;tions--Douglas
TYPE FINDINGS PENALTIES FOLLOW-UP
'73
accident/ 2 violations $75 none
fatality
COMMENTS
reverb #9: roof
slag train
1 S02 sample at
25 ppm.
Preparation
department--
no dust counts
above allowable
limit.
reverb repair
COMMENTS
dock area
-------
Table 3
SUMMARY OF HEALTH HAZARDS--Douglas
Number of
PLANT AREA Employees
Preparation
Department
Roasters
Reverberator/ Furnace
Converter
Anode
Other
40
TWA Exposures*
Copper
mg/M3
Arsenic
mg/M^
.004
average
charge floor
average
.0135t
tapping aver-
age .out
see note
Lead
mg/M^
Sulfur
Dioxide
(PPM) NOTES
10.59 ppm
average
area general
average
2.38 tt
calcine
motorman :
10.59tt
~"" ~47 ppm
0-.46 ppm
TWA as high as .007 reported.
Company data—Excursions re-
ported to 100 ppm. SMI indi-
cates excursions to 200 ppm.
tCompany data indicates levels
of .054, .121 for 2-hour time
periods .
ttCompany data. SMI indicates
reverb floor levels of 24 ppm.
Company data for dust handling
only. Data indicates TWA at
—..006, with excursions,. to_ JD69 .
Company data. SMI indicates
skimmer-platform levels at
5 ppm. Company indicates gal-
ley levels to be as high as
170 ppm.
-------
FACT SHEET
Facility: Morenci Smelter
Company: Phelps Dodge Corporation
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL
Name: Phelps Dodge Corporation, Morenci Branch
Location: Morenci, Arizona
Description:
1) Combination of crushing plant, concentrator, smelter, and supportive
facilities in operation since 1942.
2) Smelter division had 374 employees in 1977. Entirejoperation (includ-
ing mines) had 2800 employees.
3) Ore from Morenci open pit mine (70%) and the Metcalf open pit mine
(30%). Arsenic content in the concentrate reported between .001% and
.02%. j
4) Largest employer in the county, with a payroll of approximately $50
million. !
5) Production I
a) Approximately 45% of Phelps Dodge's total copper
b) 1972 1973 1974 *1975 1976
-j_ _
Copper
(short tons) 119,700 119,500 101,400 118,100 157,200
Sulfuric Acid (tons) | 327,026
Comments:
PROCESS AND HAZARDS
NOTE: In many areas of the plant, workmen wear company supplied respirators
on a need basis. The following comments evaluate TWA exposures independent
of respirator usage.
NOTE: A number of the areas discussed below have been cited by OSHA. The
details are all available to INFORM but not generally included in the interest
of brevity.
NOTE: A.significant amount of information concerning the issue of engineering
controls is available in the record of the OSHA arsenic and sulfur dioxide
hearings. Such information is not, on the whole, included below.
-------
2.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence that either the company
or the regulatory agencies have sufficiently characterized the exposures to
permit proper evaluation and corrective action. ;
A) Fluid bed roaster
1) Feeds 2 reverbs. About 35% of total feed.
2) Feed is very fine. Calcine is moved by screw conveyor.
3) Union has filed grievances for "dusty and gassy conditions."
4) Area samples in the control room indicate exposures 2 times the
proposed arsenic standard. ;
5) Sulfur dioxide exposures in control room reported with a TWA of
10 ppm. Reportedly exposures occur as a result of emissions from
nearby acid plant.
6) Personal exposures are poorly characterized.
I
B) Reverbs
1) Two furnaces with sprung silica arch. Three witty suspended arches.
Usually four in operation at once. f
2) Four of the furnaces have "doghouse" ventilation on tap holes and
covered launders. Newest furnace (#5) has the matte tap hole in an
enclosed room with an automatic punching machine. Ladle car is with-
drawn from room after filling.
3)- Arsenic exposures range from undetectable to 40 times the proposed
standard. Personal exposures are poorly characterized.
4) Sulfur dioxide exposures range from 3 to 78 ppm. TWA personal expo-
sures are poorly characterized.
5) Furnacemen and chargers were exposed to excessive noise. Enclosure
and maintenance lubrication of drag chain conveyors corrected the
problem after it was cited by OSHA in 1974.
6) Copper exposures among feeders range from 1 to 9 times the dust stan-
dard. Use of vibrators, air lances and blow pipes to dislodge jammed
concentrate from bins is source of dust in area above reverbs.
7) Waste heat boilers and uptakes reportedly leaky.
8) Flue cleaners lance waste heat boilers during day shift. Exposures
uncharacterized. Reported "gassy and hot" by union.
9) Several burn and flashback incidents around the furnaces in 1974
exemplify a serious safety concern in the area.
10) Two acute exposures to sulfur dioxide have occurred in conveyor areas
above the reverbs. Both cases have required hospitalization and the
union has filed grievances.
11) Tops of furnaces are "blown" with compressed air causing general area
contamination. No vacuuming has been tried, even on the 2 suspended
arch furnaces.
-------
3.
C) Converter Aisle
1) Nine Fierce-Smith converters. About 7 operating at once. All are
equipped with primary and secondary hoods. ;'
2) 4 cranes are sealed and air-conditioned, but maintenance and/or
design are poor and leaks cause exposure to sulfur dioxide above the
present standard. Arsenic exposures are poorly characterized but
likely high. 17 men.
3) Arsenic exposure range from 0.0 to 0.209 in the arei. Personal expo-
sures are poorly characterized. i
4) Sulfur dioxide exposures in the lower levels of the aisle (skimmer
platforms, aisle floor) are reported in excess of the proposed stan-
dard but are generally poorly characterized. i
5) Punchers' noise exposure has been eliminated by enclosing the punchers'
cabs after an OSHA citation. No safety concerns have been voiced by
employees regarding the enclosures.
6) Conveyor galleries above the aisle result in excessive exposures to
sulfur dioxide and metal fumes for workmen who must enter the area.
Exposures are poorly characterized. I
D) Refinery and Casting
1) Four anode furnaces and two casting wheels. Mouths of furnaces are
not exhausted. I
2) Some reports indicate occasional exposures to sulfur dioxide in excess
of the proposed standard due to proximity to converters.
3) Some excessive exposures to noise (1-3 times the standard) occur near
the refining furnaces. Personal exposures are poorly characterized.
E) Other
1) Exposures to air contaminants in the acid plants, if any, are poorly
characterized.
2) Exposures arising from handling of dust from flues, precipitators, pug
mills, etc., are poorly characterized.
3) A significant number of repairmen work in the different areas of the
plant. Potentially high exposures may exist in areas such as the crane
bay repair section. Repairmen are affiliated with the Machinists Union.
Exposures are poorly characterized.
4) Men in refractory department are likely exposed to levels existing in
reverb areas. 13 men. Poorly characterized.
5) Crushing plant. Silica dust exposures three times the limit, documented
by MESA samples. Wetting system inoperative or nearly so. No local
exhaust ventilation. 4 men.
6) Lime plant. Excessive silica exposures in crushing were documented by
MESA in early 1976. Union reports that local exhaust was installed,
with notable improvement. Lime slaking has no local exhaust ventila-
tion, resulting in exposures to irritating calcium hydroxide mist.
-------
7) Bedding areas. Documented high copper exposures for laborers
suggest arsenic exposures as well most likely Resulting from their
duties in conveyor lines above the reverb. Poqrly characterized.
Transfer of silica flux in and around bins is Reported dusty-
Potential silica exposures are poorly characterized. (Four dust
collectors were being installed in this area as of mid-1976.J
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A) History—Details Unavailable.
B) Staff
Safety Director (1)
Safety Engineer (1)
Smelter Safety Superintendent or Inspector (1)
Dust Engineer (1)
Other
C) Industrial Hygiene
1) Testimony during arsenic and sulfur dioxide hearings strongly suggests
that little evaluation of air contaminants took place before 1974-1975.
Since that time, the company has conducted some area sampling, but
little or no personal sampling.
2) Dust Engineer, who performs air sampling, does not work under the super-
vision of a corporate industrial hygiene or similarly competent person.
3) Company statements strongly suggest that there is little industrial
hygiene or occupational health expertise at the corporate level.
-------
5.
D) Respirator Program
1) Cited by OSHA in mid-1976. No corrections yet (implemented.
E) Safety ''
ii
1) Company conducts accident investigations utilizing a written format
and report form.
2) Monthly safety inspections. Labor does not participate.
i
3) Monthly safety meetings and discussion for each work crew.
i
4) Company computes injury frequency and severity rates routinely,
using ANSI method. [
5) Frequency rates in 1974, 1975, and 1976 for total cases, lost workday
cases and lost workdays are above the industry!average for SIC 3333.
I
F) Health Care ,
1) 100-bed hospital in Morenci with 6 doctors andl other staff. 24-hour
emergency room. :
2) Pre-placement exam. t
3) No periodic health exams or medical monitoring, with the following
exceptions: 1
a) Yearly audiometric exams.
b) Yearly medical exams for cranemen. !
4) First aid equipment and trained personnel at the plant. Ambulance
service is available.
5) Referral system pre-arranged with medical institutions in Tucson
and Phoenix.
6) No company rehabilitation program. Workers rely on state efforts.
Comments:
-------
SAFETY COMMITTEE
i
A) Description '
i|
1) Begun in 1971 contract. ,,
2) Two company, two union representatives.
3) Few specific functions except to review suggestions. No regularly
scheduled joint inspection tours. No written record provided to
union participants. No monthly meetings. i
4) Union judges it to be of little effectiveness. !
Comments:
REGULATORY HISTORY
A) Pre-1970
1) Office of State Mine Inspector
B) Post-1970
1) State OSHA Plan
a) Approved 10/74.
b) Developmental.
c) Headed by Arizona Industrial Commission.
2) State Mine Inspector
a) Still retains jurisdiction over smelters.
b) No contractual relationship exists with the Industrial Commission.
c) Approximately 2-3 inspections per year between 1972 and 1976.
d) Limited industrial hygiene efforts. Essentially spot sampling.
3) OSHA Activities
a) Four inspections, all as a result of complaints. Two were safety
only, one health only, and one combined. Last inspection was
completely contested.
4) MESA Activities
MESA has traditionally inspected the lime plant, the silica plant
and even sections of the bedding area. The jurisdiction which is
exercised over the acid plants (i.e., MESA or OSHA) is unclear to
INFORM.
-------
PROCESS EQUIPMENT*--Morenci
Table I
NAME
AGE
POLLUTION CONTROLS
COMMENTS
Bedding Plant
Crushing Plant
Lime Kiln
wet scrubber
baghouse
Roaster
Fluid Bed
series of cyclones •>
.scrubber -> acid plant
A.P. produces 100% ti2SOk
150 TPD used
in plant, remainder sold
operates 21 hrs. a day
Reverbs
#1---,
£2__jsprung silica arch
#3--,
#. /suspended arch
#5--l new reverb; suspended
roof with tripper belt
sidewall feed
gases pass through waste heat boiler ->
1942-43 ESP ->• some dilution ->• 605' stack
(reverb)
*A new ESP installed to control #5
particulates
Converters
9 Pierce Smith (7 usually
active) (x~3.37 blowing
when 7 converters active)
close fitting hoods on all converters •>
gas coolers ->• 4 ESP -> gas cleaning
(i.e. scrubber) -> single contact acid
plant ->- tail gases out 60S' stack (con-
verter) secondary hoods on all now operating
1500 TPD H2SOk produced
Anode Furnace
4
None
Reducing gas through
tuyeres (at one time
practiced poling)
Casting Wheels (2)
None
750 tons per day
2500 tons per day
Acid Plants (2) (single contact)
tFigures 2,3; Design and Operating Parameters for Emission Control Studies:
Phelps Dodge, Morenci, Copper Smelter
-------
ections--Morenci
Table 2
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
/73
74
n
(7/76
complaint
safety
complaint
health
complaint
safety
complaint
safety $
health
1 non-serious
10 non-serious
41 non-serious
29 items
8 lumped as
serious
1
$40 None I
$120 None ,
!
i
$995 None !
1
$700 None
f
crane issues
7 noise
2 S02
1 respirator
program
in contest
;ctions--Morenci
; of Arizona, State Mine Inspector
TYPE
FINDINGS
PENALTIES FOLLOW-UP
COMMENTS
•14/72
health
noise £ SOa some
high spot samples
None
2 health
4 of 18 grab dust
samples exceeded
standards
compliance
None letter from co.
772
3
73
74
/74
74
safety
health
safety
safety
safety
safety
22 violations
1 of 9 grab dust
samples exceeded
standards
16 violations
9 violations
25 violations
32 violations
None
None
None
None
None
None
None
None
compliance
letter from co.
compliance
letter from co.
compliance
letter from co.
compliance jointly with
letter from co. MESA
-------
Table 2 (cont.)
ections--Morenci
e of Arizona, State Mine Inspector
TYPE FINDINGS PENALTIES FOLLOW-UP | COMMENTS
I
compliance
/75 safety 15 violations None letter from co.
f
compliance
^75 safety 28 violations None letter from co.
recommended
health high SOa exposure ' respirators and
•15/76 complaints in crane None None I.H. testing
!,13, safety and "No dust •
'76 health problems" None None '
-------
Table 3
SUMMARY OF HEALTH HAZARDS--Phelps Dodge, Morenci, Arizona
Number of
PLANT AREA Employees
Preparation Dept.
Fluid Bed Roaster
and Acid Plant
+ Converter Acid Plant
Reverberator/ Dept.
Converter Aisle
Refining and Casting
23
27
83
87
34
TWA Exposures*
^ Copper
mg/M3
1.03-9.07
(among la-
borers ;
other expo-
sures
unknown)
22
(Feeders
only, not
entire dept)
Arsenic
mg/M3
.001-. 030
(around
Junction
House and
some
conveyors)
.002-. 007
<.001-.169
0 - .209
Sulfur
Dioxide (ppm) NOTES
0.85-10.86
0 - 131
0-23
Some hazardous exposure to
siliceous dust in lime and
silica plants .
Area samples.
Highest exposures to arsenic and
sulfur dioxide occur in Feed floor.
Worst sulfur dioxide exposures are
in upper reaches of converter aisle
No hard data-available to INFORM.
Some excessive noise exposures
reported near the refining furnaces
•'Independent of respirator usage.
SOURCES: OSHA Inspections
-------
Table 3 (cont.)
SUMMARY OF HEALTH HAZARDS--Phelps Dodge, Morenci, Arizona
TWA Exposures
Number of
PLANT AREA Employees
Refractory Dept.
Other
13
141
rCopper
mg/M
Arsenic
mg/M
Sulfur
Dioxide (ppm) NOTES
No details available to INFORM.
Exposures likely similar to those
in reverb areas .
Some of the job categories strongly
suggest hazardous exposures (eg. >
flue cleaners, sweepermen, clean-up
laborers, etc.). No details
available to INFORM.
independent of respirator usage.
SOURCES: OSHA Inspections
State Mine Inspector Inspections
Company testimony in arsenic and sulfur dioxide hearings.
-------
FACT SHEET
FACILITY: Hidalgo Smelter
COMPANY: Phelps Dodge Corporation
INFORM
25 Broad Street
New York, New York
10004
(212) 425-3550
-------
GENERAL ,
i
Name: Hidalgo Smelter, Phelps Dodge Corporation;
Location: Playas, New Mexico ['
Description:
1. Copper smelter and supportive facilities. Production equipment
includes flash furnace, electric furnace, three converters, two
anode furnaces, casting wheel, elemental sulfur plant and two
acid plants.
2. 460 employees.
i
3. Concentrates are received from the Tyrone mine and concentrator.
Arsenic content of concentrate is .002%. Other impurity data on
hand. In the future the smelter will also handle concentrates
from the company's Arizona Bagdad mine.
4. Annual payroll at the smelter is $6 million.
5. Production: !
1977 1976 f
Comments:
Copper (tons)
82,500
37,900
PROCESS AND HAZARDS
NOTE: Respirators and replacement parts are issued to all smelter employees.
Employees are responsible for care, maintenance, and storage. Following a
1976 OSHA citation, the company installed respirator storage and cleaning
stations.
NOTE: Throughout the following remarks, the phrase "poorly characterized"
is used to indicate that we have found no evidence to indicate that either the
company or the regulatory agencies have sufficiently characterized the expo-
sures to permit proper evaluation and corrective action.
NOTE: The Outokumpa type flash furnace at Hidalgo is the first application of
this technology in the United States.
-------
A. Material Handling
Concentrates are received at the smelter by rail and ^re transported by
conveyor to the 24,000-ton covered storage area. Fripm there conveyors
transfer the concentrates to storage bins near the roitary drier. Concen-
trates and flux are transported, as needed, through•• the rotary drier
on a single conveyor belt.
1. Exposures in the smelter's material handling areas are, poorly charac-
terized. The company has spent three years developing a dust-sup-
pression wetting system to increase the moisture content of the con-
centrates received.
B . Flash Furnace I
Concentrates and silica flux are pneumatically conveyed to bins above the
flash furnace. The mixture is fed by a drag-chain conveyor into the
furnace's reactor chamber where four concentrate burners preheat it.
The feed rate (the speed of the feed belt) is established after a chemical
analysis of the copper content of the furnace slag. A chemical analysis of
the matte grade and temperature determines the air inflow and the concen-
trate burner combustion rates. Matte is tapped througih hooded and ex-
hausted tap holes and transported by overhead cranesj
-------
have been documented at other smelters with similar arsenic content
in their concentrate. The company has reported! average sulfur diox-
ide exposures to be 8.17 ppm and average area levels to be 4.67ppm.
2. OSHA has documented sulfur dioxide levels as high as 25 ppm near
the charge floor conveyors. OSHA has documented exposures for the
operator helper to be 9 ppm.
3. The company has reported average sulfur dioxide levels on the west
side of the slag skimming area to range between 0 anal 138.5 ppm and
average 28 ppm.
I
D. Converter Aisle
i
The Hidalgo smelter has three Peirce-Smith converters. Matte from the
flash and electric furnaces is transported to the converters by overhead
cranes whose cabs are enclosed. Slag from the converters is returned to
the electric furnace. Blister copper from the converters is carried by
crane to the anode area.
1. Arsenic exposures are poorly characterized. Potentially hazardous
exposures due to fugitive emissions during converter roll-out and
matte transportation have been documented in smelters with similar
arsenic content in the concentrate. In 1977, the company reported
average exposures to sulfur dioxide at 2.45 ppm and average area
levels to be 5.58 ppm. OSHA has documented sttlfur dioxide levels
on the converter operating floors to range between 2 and 11 ppm.
However, exposures are uncharacterized.
2. The company is currently operating under an extended variance
for high noise levels during converter punching (110 dBA). OSKA
documented high to very high exposures to the converter puncher
and utility man (2 to 2.5 times the allowable exposure limit). The
company is currently testing Noranda tuyere silencers to control
noise levels. In requesting the extended variance the company
stated, "Our preliminary investigaions to date [June, 1977] suggest
that the success of the tuyere silencers in regard to satisfying the
OSHA regulation is marginal." Exposures are uncharacterized.
E. Anode Area
The Hidalgo smelter has two anode furnaces and one casting wheel. The
blister copper in the anode furnaces is "poled" with a reformed propane/
air mixture to drive off the oxygen in it, and then cast into anodes on
the casting wheel. The casting wheel is equipped with an automatic
"take off" device which removes the anodes.
1. Following an August, 1977 inspection, OSHA issued serious citations
for high noise levels in the anode area (utility man's exposures
ranged from 2 to more than 3 times the allowable exposure limit).In
March, 1978, the company reported to OSHA that conversion from
high-pressure air propane burners to low-pressure kerosene burners
was reducing exposures and area levels which had ranged from 86
to 93 dBA. However, Phelps Dodge added, "We are not in compliance
with the regulation at all times due to the proximity of the anode
area to the converter tuyere punchers." Current exposures are
unknown.
-------
2. Arsenic exposures, if any, are poorly characterised. Although by
this time most arsenic has been driven off from the blister copper,
and the arsenic content of the concentrates at the Hidalgo smelter is
low, this area has sometimes been the scene of potentially hazardous
arsenic exposures at other smelters. ['
F. Other Areas
1. The company has reported an average sulfur dioxide Jevel on the
fourth floor of the Alhstrom Boiler to be 6.96 ppm. EjXposures and
number of workers affected are uncharacterized.
2. The company has reported that the average personal exposure to
sulfur dioxide at the drier is 3 ppm. Individual jexposures are un-
characterized. j
Comments:
COMPANY SAFETY AND HEALTH ACTIVITIES
A. Staff
Industrial hygiene technician - 1
Safety Supervisors - 1
Safety Engineers - 2
Labor Department Director - 1
B. Industrial Hygiene
1. There is no industrial hygienist on staff at the smelter.
2. All industrial hygiene activities are co-ordinated by the Safety
Supervisor and the industrial hygiene technician.
3 The company performs some industrial hygiene sampling for noise,
sulfur dioxide, and hydrogen sulfide. Extent and exact frequency
of sampling for these and other hazards is unknown.
-------
C. Respirator Program I
Respirators are issued to all employees. Employees are responsible
for maintenance and storage. Following a 1976 OSHA citation, the
company installed respirator cleaning stations. '•
D. Safety
1. Pre-employment safety orientation is conducted by the Safety Super-
visor, i
i
2. Refresher safety education is administered through department-level
meetings every six weeks.
i
3. The company issues free of charge most necessary safety equipment.
F. Health Care
I
1. Most medical care is administered through the company clinic in
Playas, New Mexico, ten miles from the smelter.
i
2. Clinic staff includes registered nurses, and paraprofessional per-
sonnel. Closed circuit TV monitor connects clinic with hospital in
Silver City during emergencies. An M.D. visits the clinic twice a
week.
3. Facilities for emergency and out-patient care only. All other treat-
ment is handled in the Silver City Hospital, sixty miles to the north.
4. There are supervisors and workers trained in first aid on all shifts.
5. The company performs pre-employment physicals.
Comments:
SAFETY COMMITTEE
There is no Joint Safety and Health Committee at the Hidalgo smelter-
-------
REGULATORY HISTORY (
i
A. Pre-1970 i(
1. State Inspector of Mines
B. Post-1970
1. State Inspector of Mines j
I
a. Almost exclusively a safety focus until 1973, when limited health
activities were implemented. ;
b. Approximately two inspections per year. No union participation.
c. Agency still active. Jurisdiction question vis a vis New Mexico
State OSHA plant (see below) still unclear -
i
2. State OSHA plan ,
a. Administered by New Mexico Environmental Improvement Agency
b. Approved 12/75. No smelter inspections yet cpnducted.
I1
C. OSHA Activities
Seven inspections: 3 health, 3 safety and one fatality.
-------
PROCESS EQUIPMENT—Hidalgo
TABLE 1
NAME
Flash Furnace ( 1)
Electric Furnace ( 1)
Peirce-Smith Converters (3)
Anode Furnace (2)
Anode Casting- Wheel (1)
Acid Plant (2)
Elemental Sulfur Plant
AGE
1977
1977
1977
1977
1977
1977
1977
POLLUTION CONTROLS COMMENTS
Waste Heat Boiler ->
Electrostatic Precipitator
-> Acid Plants
Scrubber -> Stack
WHB + ESP -> Acid Plants
none
none
-------
TABLE 2
SUMMARY OF HEALTH HAZARDS—Hidalgo
TWA Exposures A
Number of
PLANT AREA Employees
Material Handling-
Smelting Furnaces
Flash Furnace
Electric Furnace
Converters
Anode Area
Acid Plants
Ahlstrom Boiler
Copper
mg/m^
Arsenic
mg/m3
Lead
Dioxide
(PPM) NOTES
3.00 personal*t
4. 35 personal*
6.39 area*
8. 17 personal*
4.67 area
2.45 personal*
5. 58 area*
. 16 personal*
1.05 personal*
6.96 area*
tDryer
excursions to 64 ppm
of sulfur dioxide
excursions to 138 ppm
of SO2.
Noise exposures to
248 percent of standard
• Silica exposure to
cast sprayer approxi-
mately one-half permis-
sible level.
•Noise exposures to
316% of standard
- •- ^-
A Independent of respirator usage
Sources: OSHA inspections
*Company reported average figures
-------
TABLE 3
SHA Inspections
idalgo, Phelps Dodge
FOLLOW-]'
------- |