EPA-600/2-76-036a
February 1976
Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
White Pine Copper Smelter
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
EPA RE VIEW NOTICE
This report has been reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Approval
does not signify that the contents necessarily reflect the
views and policy of the Agency, nor does mention of trade
names or commercial products constitute endorsement or
recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-76-036a
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
WHITE PINE COPPER SMELTER
by
I. J. Weisenberg and J. C. Serne
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, California 90404
Contract No. 68-02-1405, Task 5
ROAP No. 21ADC-061
Program Element No. 1AB013
EPA Project Officer: R. D. Rovang
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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TABLE OF CONTENTS
A. INTRODUCTION AND SUMMARY 1
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT 1
C. PROCESS DESCRIPTION . 4
D. EQUIPMENT. . 6
a. Reverberatory Furnaces 6
b. Converters 6
c. Dryer . 6
d. Other Emitting Equipment ]0
E. EXISTING CONTROL EQUIPMENT 11
F. GAS SYSTEM DUCTWORK 11
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT 12
H. GAS CHARACTERISTIC VARIATION 15
I. STACK DESCRIPTION 15
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING . . 16
K. FOOTING REQUIREMENTS AND STRUCTURAL CRITERIA „ 16
L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES 17
M. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION AREAS AND PROBLEMS. . . 17
REFERENCES 19
APPENDIX A SMELTER OPERATION
APPENDIX B PLANT DESIGN CRITERIA
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LIST OF FIGURES
FIGURE 1. TOPOGRAPHICAL MAP OF SMELTER AREA . . . . .
FIGURE 2. OVERALL PLANT GENERAL ARRANGEMENT ....
FIGURE 3. SMELTER FLOW SHEET ....
FIGURE 4. PLAN VIEW CONVERTERS AND REVEFBERATORY FURNACES
FIGURE 5 REVERBERATORY FURNACE ELEVATION
FIGURE 6 CONVERTER AND HOOD ELEVATION
FIGURE 7 CONVERTER BALLOON FLUE
FIGURE 8 POSSIBLE CONTROL SYSTEM LOCATIONS ....
2
3
5
7
8
9
13
18
ii
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A. INTRODUCTION AND SUMMARY
The purpose of this report is to present background design data on
the White Pine Copper Company smelter operation at White Pine, Michigan
in sufficient detail to allow air pollution control system engineering
studies to be conducted. These studies will be primarily concerned with
lean SCL streams that are currently not being captured.
Physical layout of the smelter and surrounding area along with
existing smelter and control equipment is presented. Ductwork that would
be considered for future system tie-in is defined. Emissions from operating
equipment, gas flow rates, temperatures, sulfur balance and process flow
sheet are included. Utilities, stack dimensions, footing requirements, and
solid waste handling are defined. Available area for new control equipment,
gas characteristic variation and potential new control equipment installation
problems are discussed.
There is presently no SCL control at this smelter. The major un-
controlled sources of SO- and particulate being the reverberatory furnaces
and the converters. Approximately 78,500 tons per year of SO and 2500 tons
per year of particulate are emitted. There appears to be sufficient space
and utility availability to install additional control equipment. The ore '
used has a much lower sulfur content than the ore processed at Western
smelters. Due to the lower sulfur input SO emission, fugitive losses in
particular, are less than normally encountered.
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT
The White Pine Copper Company smelter is located adjacent to the town
of White Pine, Michigan about 5 miles from Lake Superior. Figure 1, reproduced
from a USGS map, shows the topography of the immediate area. The plant site
elevation is 880 feet MSL. The plant site coordinates are latitude 46°-46' N
and longitude 89°-36' W.
The overall plant site is shown in Figure 2. The smelter portion of
the plant consists of the initial ore handling and mixing equipment, a rotary
dryer, two reverberatory furnaces, two converters, two fire refining fur-
naces, two continuous casting machines, and a casting wheel.
-1-
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(BERGLAND NE)
3077 II NE
SCALE 1:24000
o
1 MILL
1000 0
FH U^nTH-
1000 2000 3000
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FIGURE 2.
OVERALL PLANT GENERAL ARRANGEMENT
(.LOCATED IN ENVELOPE INSIDE BACK COVER.)
-3-
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The pollution control equipment consists of a two-stage wet scrubber
to remove particulate matter from the rotary dryer flue gas, and an electro-
static precipitator to clean the reverberatory furnace effluent. There is no
sulfur dioxide control equipment at the smelter. Converter and reverberatory
flue gases are emitted to the atmosphere from a 504-foot stack. A separate
90-foot stack handles the refining furnace flue gas.
As seen in Figure 2, available space for new control equipment could be
found south of the Smelter Building or west of the Reverberatory Furnace
Building No. 2.
C. PROCESS DESCRIPTION
The smelter flow sheet diagram is shown in Figure 3. The feed in the
form of mill concentrate or filter cake (approximately 30-32% copper and
18-22% moisture) is mixed with limestone, pyrite, and recycle material. The
ore is mined underground in the vicinity of the smelter. It is considerably
lower in sulfur content than Western ores. Additional sulfur must be added
in the form of pyrite for metallurgical and handling control because of the
low availability of sulfur in the ore. On a dry basis, the mixed charge
contains 68% mill concentrate, 19% limestone, 8% pyrite, and 4% recycle
material, by volume.
A large rotary dryer reduces the mixed charge moisture content to the
range of 9 to 10% HO. A network of conveyors transport the dryer fluxed
charge to two reverberatory furnaces. The reverberatory furnaces are fired
with a fuel mixture of pulverized coal and preheated air. The matte produced
in the reverberatory operation is transported in large ladles to one of two
converters. Blister copper (99% copper) produced in the converters is trans-
ferred to one of two fire refining furnaces. The refining furnaces are
charged with 240 tons of blister copper and approximately 8,000 pounds of
soda ash. To lower the oxygen content of the copper, green hardwood poles
are inserted into the molten material. Copper with 99.95% purity is produced
for casting. Wheel casting and semi-continuous casting machines are operated
at the smelter.
Gases from the rotary dryer pass through a two-stage wet scrubber
with 99.5% particulate matter collection efficiency, then out the stack.
Gases from the reverberatory furnaces pass through waste heat boilers and
-4-
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300 GPM Wate
Inputs: 108.2TPD-S
MI 1.1 Concentrate
Limestone i
Pyrites
Reverts & Flue DUE
Gas
Two-Stage
Wet
Scrubber
(99.5 % Eff.)
30,000 SCFM
203,000 SCFM
to
33,000 SCFM
430°F
107.5 TPD-S
9 to 10Z HO
Reverberatory
Furnaces
(2)
Inputs:
Soda Ash
Silica Sand
Green Wooden Pole*
Casting Wheel
Copper
Shapes
99.95 % Cu
Casting Machine
(2)
Copper
Shapes
PROCESS FLOW & SULFUR BALANCE
WHITE FINE SMELTER.W.P Michigan Prepared August 1975 I
PACIFIC ENVIRONMENTAL SERVICES
-5-
Figure 3
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are transported by a balloon flue to an electrostatic precipitator
where 95.4% (rated efficiency) of the particulate matter is removed.
The cleaned gas is discharged from a 504 foot stack. Converter gases
pass through a balloon flue directly to the 504 foot stack.
Temperatures, volumetric gas flows, and SO- percentages are shown
on the process flow sheet. Appendix A is a detailed process description
provided by the smelter.
D. EQUIPMENT
a. Reverberatory Furnaces
Two reverberatory furnaces are installed at the White Pine Smelter
Operation. Dimensions are 120 feet long by 40 feet wide by 27 feet high.
A top charge tripper system in each furnace building feeds the furnaces
which take a side-wall charge. Figure 4 shows the furnaces in plan view
and Figure 5 furnace elevation with uptake to the waste heat boilers.
As seen in Figure 4, one reverberatory furnace is equipped with a
single waste heat boiler, while the other furnace is equipped with a
paif of waste heat boilers. The single waste heat boiler has a design
rating of 68,000 Ib/hr of steam and normally operates at about 80,000
Ib/hr of steam. The pair of waste heat boilers are each rated at 77,000
Ib/hr and normally operate at 80,000 Ib/hr of steam.
b. Converters
There are two Peirce-Smith converters 13 feet in diameter by 30 feet
long. Figure 4 shows plan view location of the converters and Figure 6
shows elevation with offgas hood arrangement.
c. Dryer
One Koppers direct fired rotary dryer 10 feet diameter by 70 feet long
is used to prepare the furnace charge. Natural gas consumption averages
-6-
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Figure 4,
-7-
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ER
L\
fgD HOPPER
FURNACE ROOF
SPRN2 NE
1/0-0
HEARTH II NE
FUSED HEARTH
N C
SELECT
A C C R E GA TE
REVERBERATORY FURNACE
-8-
Flgure 5
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-9-
Figure 6.
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27 MCFH. The dryer general specifications are as follows:
CONCENTRATE DRYER
General Specifications
Combustion Equipment - Hauck Mfg. Co.
Model - No. PRN 10442
Type - Direct Fired
Range - 7,500,000 to 36,000,000 BTU/HR
Burner Blower HP - 40
Dryer - Hardinge Division of Koppers
Model - Class XH-24
Size - 70' long x 10' dia., 316 ss construction
Drying Eff. - 70% Based on maximum throughput.
Drive HP - 125
Dust Collector - Krebs Elbair two stage wet scrubber
Inlet Load - 3 grs/ACF at 150° to 200°F and 14.44 Psia
Guaranteed Collecting Eff. - 99.5% by weight
Pressure Drop - 2 inches water gauge
Water Consumption - 300 gpm
Discharge Temp. - 120°F saturated
Exhaust Fan HP - 50
Volume - 30,000 SCFM
Scrubber Pump HP - 20
Auxiliary Material Handling
Feed System - 24 screw feeder, 15 HP
Discharge Conveyor - 24" belt, 175 fpm, 7% HP
d. Other Emitting Equipment
Material handling, mixing and drying in the rotary dryer can produce
particulate emissions but these are controlled by maintaining 9% moisture
-10-
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in the mixed charge and scrubbing the dryer offgases.
Refining furnace (2) offgases are vented to a separate 90 foot tall
stack. The refining furnaces generate small quantities of SCL, NO , and
^ X
particulate.
Leaks in ducts and at; other pieces of equipment can generate S00
and particulate.
Ladles holding matte and slag (175 cu. ft. and 225 cu. ft.) will
produce visible fugitive emissions.
E. EXISTING CONTROL EQUIPMENT
An electrostatic precipitator, flat plate type, was installed in 1971
to control particulate emissions from the reverberatory furnaces. The
precipitator consists of two parallel chambers each two sections in series.
The guaranteed collection efficiency was 95.4% but the actual efficiency is
reported to be 90%. Source testing conducted in May, 1975, indicated that
at an inlet dust loading of 2.817 gr/SCF, the outlet grain loading was
0.213 gr/SCF (Ref. 3). The precipitator was designed by Joy Manufacturing,
Western Precipitation Division to handle 130,000 ACFM at 500°F and located
between the Reverberatory Furnace Building No. 1 and the Reverberatory
Balloon Flue (see Figure 4).
A two stage wet scrubber (Krebs Elbair) with guaranteed collection
efficiency of 99.5% provides particulate control for the rotary dryer. A
50 HP exhaust fan is needed to transport the gas to the stack. The wet
scrubber, installed in 1969, employs the so-called rebound principle.
Water is sprayed in the direction of the gas flow against a rod screen.
A rebound zone of atomized liquid droplets is established at the rod screen
surface. A high collection efficiency is achieved at relatively low pressure
drops, typically 2 to 3 inches w.c.
F. GAS SYSTEM DUCTWORK
The gas system ductwork for the reverberatory furnaces and converters
is shown in plan view in Figure 4. The reverberatory furnace gases after
-11-
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passing through waste heat boilers are collected in a balloon flue.
The flue gases are treated in the electrostatic precipitators and
then pass through a second leg of the balloon flue to the 500 foot
main stack. A dimensioned cross section view of the balloon flue
is shown in Figure 7. The reverberatory balloon flue between the
"turn point tower" and the stack is approximately 275 feet long.
The flue centerline is about 50 feet above grade. A bypass is
available in case the precipitators are down.
The converter flue gases are collected in hoods and travel
through a 188 foot balloon flue directly to the main stack. The
converter balloon flue centerline is about 50 feet above grade.
A cross section view of the converter balloon is also shown in
Figure 7.
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT
Typical Sulfur Balance Data
Based on Data from Reference 1
Sulfur in TPD
Reverberatory 108.2
Secondaries 4.9
Total 113.1
Sulfur Fixed
Reverberatory slag 3.4
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REVERBERATORY BALLOON FLUE
CONVERTER BALLOON FLUE
48'
ABOVE
GRADE
J_
'/ABOVE
GRADE
J_
FLUE DIMENSIONS
WHITE PINESMELTEFPWHITE PfNE
PREPR'D
AUGJ9-75
PACIFIC ENVIRONMENTAL SERVICES
-13-
FIGURE 7
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Sulfur emitted to the stack TPD
Reverberatory offgas 19.2
Converter offgas 88.3
Total 107.5
Fugitive sulfur emitted to
Atmosphere 2.2
When the converters are not operating (13.5 hours/day) the stack gas
conditions at the 250-foot level are 269,000 ACFM (160,000 SCFM) at 370°F.
The S09 concentration in the reverberatory furnace offgas range from about
0.1 to 0.2% S0_. With the reverberatory furnaces and converters operating
(10.5 hours per day) there are 366,000 ACFM (203,000 SCFM) at 430°F.
Converter offgases are estimated to contain an average of 4% S0_.
Recent test data obtained by the smelter indicate the following values:
REVERBERATORY AND CONVERTER FLUES MATERIAL BALANCE
Reverberatory Furnaces (2) (Precipitator Output)
Gas Volume Flow Rate 166,900 SCFM @ 498°F (Avg.)
Particulates 307 Ibs/hr
SO 2,822 Ibs/hr (0.16% b.v.)
S03 181 Ibs/hr ( 81 ppm )
H20 3.7% b.v.
0 11.9% b.v.
C02 7.3% b.v.
Converters(s)
Gas Volume Flow Rate 106,855 SCFM (3 487°F (Avg.)
(Average of the three normal operating blow periods)
Particulates 338 Ibs/hr
S02 48,222 Ibs/hr (4.2% b.v.)
S03 224 Ibs/hr (157 ppm)
HO 2.6% b.v.
02 17% b.v.
C02 1.8% b.v.
-14-
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1st slag blow = 98,783 SCFM (@ 464 F.. Ave. Operating)
2nd slag blow = 142,217 SCFM (@ 450°F. Ave. Operating)
Copper Blow = 106,383 SCFM (@ 546°F. Ave. Operating)
Reference 2
H. GAS CHARACTERISTIC VARIATION
It can be expected that SO. concentration in the offgas from the re-
verberatory furnace will vary significantly with time. This results from
the variation in time required for decomposition or reaction of the various
sulfide ores charged to the furnace. The S02 concentration has
been known to vary as much as 10 to 1 within a given charging time cycle.
While no data are yet available from this smelter concerning this point,
it should be considered for control system design. The furnaces are charged
one side every 1/2 hour for a period of 18 hours each day. Thus each side
receives a charge every 2 hours.
The SO,, concentration in the converter offgas will also vary considerably
for an entirely different reason. The operation of a converter includes two
slag blows and one copper blow. Between these blows the converter may be
rolled out for slag pouring or material charging. The attempt is always
made to maintain at least one converter blowing at any given time. Usually
a converter will be provided with 18,000 to 20,000 SCFM to the tuyeres. An
additional 100 to 120% of dilution air is generally estimated to be added
to this gas flow resulting in a total gas flow from each converter in the
range of 35,000 to 40,000 SCFM.
As can be seen from the above data in Section G, the average converter
gas flow has been measured to be 106,855 SCFM. This would imply a considera-
ble increase in dilution air which may result from a large gap at the con-
verter hood or duct leakage.
I. STACK DESCRIPTION
Height
Diameter
Draft
Main Stack
504 feet
15 feet @ top, 40 feet @ base
2.75" w.c.
-15-
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Main Stack (continued)
Construction Acid proof brick lining, fiberglass
insulation, reinforced concrete
exterior
Temperature limitations 300° to 600°F
Dew point 170°F to 230°F
Two Refining Furnace Stacks
Height 90 feet each
Diameter 2'-6" and 3'-0"
Draft 0.8 to 1.0" w.c.
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING
Slag from the reverberatory furnace is taken to the slag dump. Slag
from the converters is recycled to the reverberatory furnaces. Flue dust
captured in hoppers is recycled.
K. FOOTING REQUIREMENTS AND STRUCTURAL CRITERIA
If construction is to be carried out in some areas, footing tests
would be required. A major portion of the area adjacent to the smelter
is coal storage areas and slag dumps. It will be necessary to conduct
footing tests to determine detailed footing requirements. However, if
slag is assumed for determining requirements then each position would
have to be dug out and footings placed on undisturbed soil with design
loading of 3000 PSF. No local codes apply. The White Pine smelter is
located in seismic zone 0. The Uniform Building Code (UBC) specifies
the following design criteria:
Wind load 30 PSF at 30 feet above grade
Snow load 40 PSF reduced by 1 Ib PSF for
each degree of roof slope over 20
A more complete list of design criteria, prepared by Bechtel Corporation
during the smelter design, are included as Appendix B.
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L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES
Electrical: All smelter substations are loaded to design capacity
except for S3A which could handle about 200 additional KVA. Any
additional capacity could be very costly, depending on just what
is required.
Water: Present facilities are loaded to maximum.
Gas; Present firm gas contract expires early in 1978. Availability
of gas beyond that date is at present unknown. White Pine Planning
anticipates greatly reduced gas after January, 1978.
Steam; Steam available in smelter is used for electric power generation,
building heat, and the heating of reverberatory furnace combusion air.
There is no surplus steam available and little or no space available
in present buildings for an orderly engineering boiler installation.
M. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION AREAS AND PROBLEMS
Sludge or water containing dissolved metals and solids disposal will
be a potential problem at this smelter. Waste material that may result
from the operation of a control system will be discharged to the tailings
pond processed and, eventually, the cleared water will enter the local creek,
river and lake system. The present fluid waste handling system is operating
at near maximum capacity and additional facilities will probably be required.
Figure 8 shows suggested areas for control systems as well as rever-
beratory furnace, converter and power plant expansions. Sufficient space
appears to be available.
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POTABLE WATER
LINE TO TOWNSITE
t V*
PUMP HOUSE
H£MY OIL. TANKS
-18-
Figure 8.
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REFERENCES
1. "Typical Smelter Data" White Pine Smelter, 1974
2. Letter from J.W. Maksyn, Environmental Control Engineer to I.J. Weisenberg
dated July 24, 1975.
3. Personal Communication with J.W. Maksyn, Environmental Control Engineer;
October 6, 1975.
-19-
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APPENDIX A
WHITE PINE COPPER COMPANY - SMELTER OPERATION
At the end of the mill process, a copper bearing concentrate (filter
cake) of approximately 30-32% copper and 18-22% moisture is produced. The
next step in the process is to flux this material to obtain good smelting
characteristics. Lime is added to enhance the fluidity of the slag in
smelting and to lower the smelting temperature of the mixed charge.
Currently, tests are being conducted to eliminate the need for pyrite
fluxing. By volume, a dry mixed charge contains 69% mill concentrate, 19%
limestone, 8% pyrite, and 4% recycle material.
Once the addition of fluxes has been made to the filter cake from
the mill, the material is directed thru a large rotary type dryer. Here,
the moisture content is reduced to 9%. Removing the moisture at this
point rather than at the furnace has significantly increased the furnace
smelting capacity. The 9% moisture left in the mixed charge gives us a
material which is suitable for handling in that the relative small quantity
of moisture remaining prevents dusting. Another important function of the
rotary type dryer is the blending of the fluxes uniformly in the mixed
charge which provides a more uniform feed for smelting.
Through a network of conveyors, the dry fluxed concentrate (mixed
charge) is transported to a level above the two large reverberatory furnaces.
(See following flow sheet). A shuttle conveyor operates above the furnaces
introducing the mixed charge into the furnace through a series of water
cooled charge chutes on either side of the furnace. The mixed charge forms
charge banks along the internal walls of the furnace. This charge bank
extends approximately 2/3rds the length of the furnace. Simultaneously,
the reverb furnace is fired with a fuel mixture of pulverized coal and
preheated air. Furnace arch temperature is maintained at approximately 2600
degrees and melting of the charge banks is a continuous process. Once in
the liquid form, two definite molten materials are recognized; slag which
is the lesser viscous material, and matte which is the heavier copper
bearing material. The molten combinations flow into a settling zone near
A-l
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the uptake end of the furnace and a distinct separation takes place. You
will note the difference of elevation of the tap holes on the side of the
furnace wall. The upper elevation hole permits the "tapping" of slag .wastes,
while the two lower holes are used for extracting matte.
The matte produced in the reverberatory operation is transported in
large ladles to one of two converters. The converter operation can be
thought of as a means of promoting further separation of copper from the
gangue material. The converter is a cylindrical holding vessel laid on it's
side and employing a means of rotation. The opening into the converter is
referred to as the mouth. Opposite the mouth of the converter, on the
opposite wall, the converter is fitted with a series of air pipes called
"tuyeres". In the converting process, these tuyeres are rolled beneath the
bath and air is forced into the liquid charge. The oxygen reacts with the
iron and forms an iron oxide slag which is removed in the skimming process.
The oxygen also reacts with the sulphur to form a sulphur gas which is
carried off in the exhaust air stream. The converter charge is slagged off
in the skimming process and the resulting charge is 80 tons of "blister"
copper ready for transfer to one of two refining furnaces.
The refining method used at White Pine is one of the very few "fire
refining" processes in existance today. Due to impurities and the presence
of other minerals in other copper producers ores, they have been forced
into a more costly method of electrolytic refining. Refining begins after
three (3) converter charges, or 240 tons of copper have been transferred from
the converters. Approximately 8000 // of soda ash is blown into the bath
using compressed air and pipe lances. A soda slag cover is formed over
the bath and the bath is "rabbled" (stirred) using a series of 3/4" air
pipes.
A-2
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FLOW SHEET
WHTTE PINE COPPER CO-
CHARGE: MILL CONCENTRATE
+ LIU ESTONE t PY RITE
ALSO REVETS A. FLUE DUST
REV. V-75 R-A-A
PULVERIZED
COAL
SLAG
STEAH TO POWER PLAWT
HOT
GASES
HEAT
BOILER
REVERBERATORY
MATTE 63 XCU- FURNACE
1»
ELECTROSTATIC
PRECIPITATOR
TOSLAC
DUMP
SLAG
RABBLING
rSODA ASH
SILICA SAND
WHEEL SHAPES TO
MARKET
55^ 6
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APPENDIX B
PLANT DESIGN CRITERIA
A. GENERAL
These data, related to the physical design of the plant, were
established by studies, conferences and correspondence between
White Pine Company representatives and Bechtel Corporation.
Installations will be designed and constructed as permanent and
having an estimated 20-year life. Provisions will be incorporated
in the design and considered in the selection of equipment for sub-
zero operation where required. Full consideration will he given
to the protection and comfort of operating personnel.
The plant design will be in compliance with existing codes,
governmental regulations, Factory Insurance Association and
White Pine Copper Company Safety Rules and Regulations dated 1962.
B. CLIMATIC DATA
Composite average of U.S. Weather Bureau Station records at
Ontonogan, Bergland, Marquette and Duluth.
1. Temperature
a. Highest Recorded Temp. °F 102°F
b. Lowest Recorded Temp. °F -33°F
- c. Mean yearly temp. . 42 F
d. Mean daily max. temp. 52 F
e. Mean daily min. temp. 31 F
f. Mean no. of days temp.above 90 F 4 days
g. Mean no. of days temp, below 32 F 186 days
2. Precipitation
a. Yearly average total (in.) 32"
b. Snowfall (in.) 173"
c. Percent precipitation in form of snow 35%
d. No. of days precipitation over 0.10" 83 days
e. No. of days precipitation over 0.50" 18 days
f. Max. snowfall in 24 hr. 25"
3. Winds
a. Daily Average 9 MPH
b. Max. Winds once in 20 years 75 MPH
c. Max. Monthly range 50 MPH
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C. CIVIL
1. Plant Datum
To convert USC & GS topographic elevations to plant datum,
add 4396.44 feet.
2. Fire Protection System
Materials and arrangement details of the fire protection
facilities set forth herein will conform with the require-
ments of the Factory Insurance Association (FIA). Under-
ground fire lines will be cast iron pipe with mechanical.
joints with ductile iron retainer glands at all fittings,
thereby eliminating the need for thrust blocks. Section-
alizing valves with post indicators will be provided to
isolate various sections of the system for maintenance or
repair. Hydrants will be dry barrel type with one pumper
connection and two hose outlets.
3. Utility Systems
Utility piping between the various facilities will be
generally run underground. Water lines subject to freezing
will have a minimum cover of 6 feet in areas not normally
cleared of snow and 10 feet at roadways. All underground
lines will be sloped to low points with provisions for
draining.
4. Clearing
Brush and trees will be removed from the graded plant area
to a line 20 feet beyond the top of cuts and toe of fills
and 100 feet from structures. Stumps will be grubbed from
areas to receive fills for structures, roads, railroads and
parking areas. All organic material removed as part of the
clearing and grubbing operations will be disposed of in
waste areas or burned.
5. Earthwork
a. Excavation
Cut slopes in excavated areas to be left exposed will be
no steeper than 1-3/2:1 in overburden and 1/2:1 in rock.
Structural excavation in rock will be performed in a
manner to prevent the fracture of rock on which structures
will be founded. For future expansion, if required, rock
will be drilled and blasted to foundation elevation for all
future structures within 100 feet of initial construction.
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b. Embankments
Fills for roads and parking areas except as filled by
mine waste will be obtained from excavated areas,
placed in successive layers and compacted to 95% of
maximum density as determined by ASTM Designation
D-1557-64 T. Fills on which structures will be placed
will be select granular material obtained from the
site or imported as required and compacted to 100% of
maximum density. Fill slopes will be no steeper than
1-1/2:1.
6. Roads and Parking Areas
a. Access Roads
The facility access roads will have a Surfaced width
of 24 feet with 4-foot stabilized aggregate shoulders.
Surfacing will consist of bituminous plant mix having
a compacted thickness of 2 inches placed on an 8-inch
stabilized aggregate base course.
b. Plant Roads
Secondary roads at the facility will have the same sur-
face and base as the access roads, but will be only 20
feet wide with 4' stabilized aggregate shoulders.
c. Parking Areas
Parking areas wi]l have a 2-inch bituminous plant mix
surface placed on a 6-inch stabilized aggregate base
course and will slope to drain by sheet runoff to the
east.
7. Storm Drain System
Culvert and ditch capacities will be based on anticipated
run off from a storm having a frequency of occurrence of ten
years. Runoff from storms of greater intensity will cause
localized ponding for a few minutes; however, such ponding
will be controlled to prevent flooding of structures or
roads.
a. Erosion Control
Runoff from above the top of excavated slopes will be
intercepted by ditches and conveyed down the slope in
ditches or conduits to natural drainage channels.
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b. Surface Drainage
Runoff from graded areas will be conveyed in a system
of open ditches discharging to natural drainage channels.
Culverts with a minimum diameter of 12 inches will be
placed where required under roads and railroad. Head-
walls or prefabricated end sections will be provided at
culvert inlets and outlets. Riprap will be used where
required to control scour.
c. Subsurface Drainage
Subsurface drains consisting of perforated pipe with
gravel encasement will be provided where necessary to
relieve hydrostatic pressure against subsurface structures.
Subsurface drains will discharge to natural drainage chan-
nels or to pump sumps within the structure.
D. STRUCTURAL CRITERIA
1. Codes
The general design of all building structures will be in com-
pliance with the 1964 edition of the Uniform Building Code
(UBC) of the Pacific Coast Building Officials Conference.
Structural steel will be in accordance with the American
Institute of Steel Construction Specification for the Design,
Fabrication and Erection of Structural Steel for Buildings,
1963 edition.
Reinforced concrete will be in accordance with the American
Concrete Institute Specification 318-63.
Light gauge cold-formed steel structural members will be in
accordance with the American Iron & Steel Institute Specifi-
cation.
Welding procedure will be in accordance with the Standard
Code for Arc and Gas Welding in Building Construction,
AWS-D1.0.
2. Live Loads
Office area floors 50 PSF
Floors for walkways 75 PSF
Conveyor walkways 50 PSF
Stairs and Landings 100 PSF
Laydown areas and truck aisles 200 PSF*
To be checked against equipment operating wt + 75 PSF on uncovered floor
used as walkway.
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Service Platforms 250 PSF
Roof-UBC Section 2305-40 PSF reduced by 1 Ib PSF for each
degree of roof slope over 20 .
Wind-UBC Section 2308-30 PSF at 30 ft above grade.
Ore Bins - Angle of repose of ore 38
Ratio of lateral to
vertical pressure 0.3
Wt. per cu ft of ore 100 Ibs.
Seismic - UBC Section 2314 Zone 0
Major equipment foundations will have a minimum weight
2-1/2 to 3 times the revolving combined weight of the
equipment, charge and ore.
Highway truck loading AASHO H20-S16-44
3. Allowable Bearing Values Assumed
Owner will furnish soil bearing pressure recommendations
upon completion of its soil testing program. A soil pres-
sure of 4500 PSF for miscellaneous structures and a one-
third increase in stress for combinations including wind
or seismic loads will be assumed. Footings subjected to
overturning forces will be designed so the resultant falls
within the middle third of the footing.
Frost Line is established at 5.5 feet below finished grade.
4. Concrete
Concrete will he designed for 3000 PSI at 28 days.
Lean concrete fill will be designed for 1500 PSI at 28 days.
5. Structural Steel
Structural steel exposed to atmospheric temperatures or
for use in unheated areas will conform to ASTM serial
designation A 131 Grade B for material to 1 inch thickness
and A 13] Grade C for material over 1 inch thickness. In
other areas ASTM serial designation A36 will be used.
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6. Miscellaneous Steel
Minimum requirements for miscellaneous steel will conform
to ASTM serial designation A7.
E. ARCHITECTURAL
In general the National Building Code and National Fire Under-
writers Code will be used in the development of the building
designs for this project where it does not conflict with FIA
requirements. The remainder of the design criteria will be as
supplied by the Owner and as dictated by economy consistent
with the requirement of site conditions, climate, process and
20 year life of the project.
The architectural materials and details not specified by the
Owner, will be chosen for their durability, their maintenance-
free qualities and economy. Because of the subzero temperatures
and heavy snow fall, the walls of heated buildings will be in-
sulated and protected at their bases by concrete sill walls.
Exterior doorways will be furnished with canopies for protection
from falling ice.
Structural steel framing will be fabricated to allow for future
expansion.
Provisions will be made for relocating wind columns and girts.
All buildings will be of rigid frame prefabricated construction
with insulated steel roofing and siding panels, set on a
reinforced concrete foundation and floor slab on grade and will
be designed in accordance with structural criteria listed above.
Manufacturer and model numbers are shown to indicate quality.
Equal materials of other manufacturers may be substituted when
approved by Owner.
1. Materials
The materials described herein apply to all new structures
and additions to existing structures, in so far as applicable.
Prefabricated Building - Building manufacturers standard
prefabricated rigid frame steel building, gable roof type,
with insulated prefinished formed metal roofing and siding,
with metal doors and windows, and with all necessary fram-
ing, hardware and accessories.
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Acoustical Ceilings - Acoustical Tile, 3/4 inch thick, with
a Noise Reduction Coefficient of .75 and a flame spread of
less than 25, supported on an exposed aluminum tee grid
suspension system, to form a completely accessible and
demountable ceiling system.
Ceramic Tile - Unglazed ceramic mosaic floor tile and glazed
ceramic wall tile, with coved base and wainscot cap.
Concrete Block - Hollow load bearing masonry units, made
with light weight aggregate, laid in running bond.
Drywall Construction - 5/8 inch thick, fire rated, gypsum
wallboard, on metal studs, with wallboard joints taped
and corners reinforced.
Metal Doors - 1-3/4 inch thick., hollow core, flush steel
doors in pressed steel frames, complete with hardware. Doors
in movable metal partitions will be the manufacturer's stan-
dard flush steel doors, metal frames and hardware.
Movable Metal Partitions - Sound insulated, flush type parti-
tions. Partitions will be of the glazed and unglazed type,
extending from finish floor to finish ceiling, and will be
completely demountable and reuseable for maximum flexibility
of room rearrangement.
Painting - All exposed surfaces, except prefinished surfaces
will, in general, receive three coats of paint. Shop primed
surfaces will be touched-up as required, and be finish
painted. Concrete and masonry surfaces will be painted.
Resilient Flooring - 1/8 inch thick vinyl asbestos floor
tile with vinyl topset base for application on concrete floor
slabs.
Stairs - Metal pan, closed riser stairs with cement filled
treads and safety nosing, complete with stringers, handrails,
and landings.
F. MECHANICAL
1. General
Equipment proposed will be of the type as listed in Section
VI-Equipment List. Final selection of equipment will be
predicated on suitability of equipment offered, quality,
price and economy of operation and maintenance.
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2. Conveyors
All conveying equipment will be heavy duty and suitable for
operation at extremes of temperature expected. Belting will
be best grade for the specific conditions. Conveyor idlers
will be of heavy duty construction with 60,000 hour rated
sealed anti-friction bearings. Head and tail pulleys will
be welded steel heavy duty construction. Lagging will be
used where required. Take-up will be vertical gravity type
wherever possible. Pillow blocks will be heavy duty with
60,000 hour rated sealed anti-friction bearings. Speed re-
ducers will be of standard design and use sealed anti-friction
bearings. Holdbacks, where required, will be separate from
speed reducers. Wherever possible, components will be
standardized. All conveyors will include belt cleaners or
scrapers at the head pulley.
3. Dust Control
Dust control facilities when provided to minimize the escape
of dust to the atmosphere will be of the wet type.
4. Duct Work
Duct work upstream of collectors will be provided with rubber
lined fittings to minimize erosion and straight runs will be
constructed of 10-gauge mild steel sheet. Duct work down-
stream of collectors will be provided with 12-gauge fittings
and 14-gauge will be provided on straight runs. Cleanouts
will be provided at the beginning of horizontal runs.
Duct velocities wilJ be maintained between 3000 and 4000 FPM.
Dust collecting systems will he balanced insofar as possible
using the "duct sizing" method; that is, the system will be
in balance without depending upon blast gates or orifice
plates. However, blast gates (and not butterfly dampers) or
orifice platee (bottom eccentric) may be required in some
cases, particularly on relatively short runs where the veloc-
ity is at its prescribed maximum.
5.
In selecting pumps and motor drives, due consideration will
be given to surges and overloads which may be expected in the
systems. In general, pumps will be accessible by fork lift
for maintenance except in a few areas and in the case of
vertical pumps where this arrangement is not practical. For
such cases, provisions will be made for removal by overhead
hoist or crane.
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Sand pumps will be V-belt driven and in general will be
rubber lined. Where possible, motors will be mounted
directly over and above the pumps.
Water pumps will be of cast iron construction and gener-
ally will be direct connected to their motors through
flexible couplings.
Pump sumps in general will have a capacity equivalent to
1-1/2 minutes surge time with the exception of the mill
discharge and primary and secondary classifying cyclone
feed pump sumps which will have capacities in slight
excess of 1/2 minute each. The size of these sumps are
limited by layout considerations.
6. Piping Systems
Process piping will be in accordance with the ASA Code
for pressure piping.
Fuel oil and 150 psig steam will be all steel welded
systems with 150# flanges where required.
Water, compressed air and space heating steam will gener-
ally be as follows:
a. Weld end pipe and 125# CI flanged valves for 2-1/2"
and over.
b. Screwed pipe and 200// bronze valves for 2" and under.
Ore pulp systems will be standard weight carbon steel pipe
for all sizes, grooved for victaulic coupling where
required.
Tailings lines may be spiral weld pipe.
7. Insulation
Lines operating at temperatures in excess of 140 F will he
insulated for conservation of thermal energy, or personnel
protection, with the exception of the fuel oil system which
will be insulated and steam traced in its entirety. In
addition, due consideration will be given to insulating and/
or protecting lines exposed to weather to prevent freezing.
Inside lines requiring thermal insulation will be covered
with a single layer of sectional pipe insulation. Generally,
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equipment requiring insulating will be covered with insula-
tion in block form. The insulated items will be covered
with a loose weave fiberglass cloth thoroughly impregnated
with an adhesive material.
Outside lines requiring.thermal insulation and equipment
above ground will be covered with sectional or block insula-
tion to suit. The insulation will be fastened in place by
wire bands and covered with an application of a weather-
proof coating of black asbestos filled water soluble asphaltic
emulsion applied over hexagonal wire mesh fastened to the
insulation.
Buried lines requiring insulation will be embedded in
gilsonite and will require no other insulating covering.
G. ELECTRICAL
1. General
The existing electrical system will be modified and expanded
to include all additional material and equipment for power,
control, grounding, lighting, instrumentation and annunciation.
Simple radial electrical power distribution will be employed
and the system will be designed to keep the plant power factor
at 0.9 or above, using synchronous motor drives.
Medium voltage cable will be carried in conduit, duct or armor.
Conduit will be used extensively for low voltage systems
throughout the plant with some use of cable tray where condi-
tions are suitable.
Protective relaying and metering will he provided for all
voltage levels for both distribution systems and installed
equipment.
2. Voltage Levels
The voltage levels as established in the design of the
existing plant will be followed. A basic primary distribu-
tion voltage of 13.8 kv will be employed for distribution to
plant load centers. Utilization voltages will be 4160 volts
or 480 volts for power equipment 1/2 hp and over.
3. Equipment Enclosures
Electrical equipment located out-of-doors will be provided
with NEMA 3 weather protected or NEMA 4 water-tight enclosures.
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Electrical equipment located in operating areas will be
provided with NEMA 1.2 liquid and dust-tight gasketed
enclosures. NEMA 1 enclosures will be used for equipment
installed in electrical rooms and other locations where
freedom from dust is maintained by filtered air supplies
and moisture is not prevalent.
Electric motors will be open-dripproof type with premium
shielded insulation to minimize absorption of moisture
and attack from abrasive dust and chemical reagent vapors.
4. Lighting Levels
Average maintained lighting levels and assumed maintenance
factors for the expansion program will be as follows:
Location Illumination Factor
Operating Areas
Conveyor Ways
Yard & Roadways
Offices, control
& electrical rooms
Shops & Warehouses
30 foot candles
10 foot candles
1 foot candle
50 foot candles
40 foot candles
0.60
0.65
0.75
0.75
0.65
5. Codes and Standards
All equipment will conform to the latest applicable standards
of IEEE and NEMA for design, construction and tests. Elec-
trical system design and construction will conform to stan-
dards required by the National Electrical Code.
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TECHNICAL REPORT DATA
(Please read Instructions on t/ic reverse before completing)
1. REPORT NO.
EPA-600/2-76-03 6a
2.
3. RECIPIENT'S ACCESSIOI»NO.
4. TITLE AND SUBTITLE
Design and Operating Parameters for Emission
Control Studies: White Pine Copper Smelter
5. REPORT DATE
February 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHORIS)
8. PERFORMING ORGANIZATION REPORT NO.
I. J. Weisenberg and J. C.. Serne
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, CA 90404
10. PROGRAM ELEMENT NO.
1AB013; ROAP 21ADC-061
11. CONTRACT/GRANT NO.
68-02-1405, TaskS
12. SPONSORING AGENCY'NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 4-10/75 ._
14. SPONSORING AGENCY CODE
EPA-ORD
15. SUPPLEMENTARY NOTES
EPA Task Officer for this report is R.Rovang, 919/549-8411, Ext 2557.
16. ABSTRACT
rep0r^ gjves background design data for a specific copper smelter.
The data is sufficiently detailed to allow air pollution control system engineering
studies to be conducted. These studies will be concerned primarily with lean SO2
streams that currently are not being captured. Physical layout of the smelter and
the surrounding area is presented, along with existing control equipment. Ductwork
that would be considered for future system tie-in is defined. Emissions from
operating equipment, gas flow rates, temperatures, sulfur balance, and a process
flow sheet are included. Utilities , stack dimensions , footing requirements , and
solid waste handling are defined. Available area for new control equipment, gas
characteristic variation, and potential new control equipment installation
problems are discussed.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Air Pollution
Copper
Smelters
Design
Sulfur Dioxide
Utilities
Air Pollution Control
Stationary Sources
Emission Control
Operating Data
Solid Waste Handling
Wastes
13B
07B
11F
8. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
B. SECURITY CLASS (Thispage)
nclassified
22. PRICE
EPA Form 2220-1 (9-73)
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