EPA-600/2-76-036b
February 1976
Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
Kennecott, Hayden, 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-600/2-76-036b
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
KENNECOTT, HAYDEN, COPPER SMELTER
by
I. J. Welsenberg and J. C. Serne
Pacific Environmental Services, Inc.
T930 14th Street
Santa Monica, California 90404
Contract No. 68-02-1405, Task 5
ROAP No. 21ADC-06T
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 5
D. EMITTING EQUIPMENT 7
a. Fluo-solids Reactor 7
b. Reverberatory Furnace 10
c. Converters 11
d. Other Emitting Equipment 16
E. EXISTING CONTROL EQUIPMENT 17
a. Particulate Control Equipment 17
b. Acid Plant System 17
F. GAS SYSTEM DUCTWORK 25
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT .... 26
H. GAS CHARACTERISTIC VARIATION 29
I. STACK DESCRIPTION 30
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING 31
K. FOOTING AND STRUCTURAL REQUIREMENTS 31
L. EXISTING AND AVAILABLE UTILITIES 31
M. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS . . 32
REFERENCES 33
APPENDIX t 34
LIST OF FIGURES
FIGURE 1. PLANT LOCATION (USGS MAP) 2
FIGURE 2. PLANT LAYOUT AND FLOWSHEET REFERENCE 3
FIGURE 3. OVERALL PLANT AND GENERAL ARRANGEMENT
(Located in Pocket Inside Back Cover)
FIGURE 4. PROCESS FLOWSHEET AND SULFUR BALANCE 8
FIGURE 5. FLUOSOLIDS SYSTEM FLOWSHEET 9
FIGURE 6. REVERBERATORY, CONVERTER, & ANODE CASTING
FLOWSHEET 12
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TABLE OF CONTENTS (continued)
Page
FIGURE 7. ELEVATION VIEW OF WATER-COOLED HOODS AND
SPRAY COOLER ........ 14
FIGURE 8. ACID PLANT FLOWSHEET 19
LIST OF TABLES
TABLE 1. TYPICAL SULFUR BALANCE 27
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A, INTRODUCTION AND SUMMARY
The purpose of this report is to present background design
data on the Kennecott Copper Corporation, Ray Mines Division
smelter at Hayden, Arizona in sufficient detail to allow air pollu-
tion control system engineering studies to be conducted. These
studies will be primarily concerned with lean S0_ streams that are
currently not being captured.
Physical layout of the smelter and surrounding area along
with existing smelter and control equipment is presented. Duct-
work 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 charac-
teristic variation and potential new control equipment installation
^
problems are discussed.
The major uncontrolled source of SO at this smelter is the
reverberatory furnace with approximately 8,700 tons per year of
S0_ emitted. The primary particul;
crushing and screening operations.
S0_ emitted. The primary particulate emission sources are the
B, PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT
The Kennecott Copper Corporation smelter is located adjacent
to the town of Hayden, Arizona. An enlargement of the USGS map,
showing land contours of the immediate area, is presented in Figure
1. Design altitude for the plant is 2200 ft. with latitude 33° 00'
and longitude 110 47'. The plant layout is shown in Figure 2. The
smelter general arrangement is shown in Figure 3. As seen in the
general arrangement drawing, the smelter layout is relatively com-
pact, with most available space east of the main stack and smelter
building.
The information contained herein was obtained from a smelter visit in
1974 and from the State of Arizona. Kennecott/Hayden has taken the
position that they do not need additional control equipment and do not
feel obligated to supply the additional detailed information required to
complete this report.
1
-------
2000 3000 4000 5000 6000
-------
0D
Acid Plant OOO
FU/wshcct XI
Koppers
Electrostatic
Prccipltator
PLANT LAYOUT AND FLOWSHEET REFERENCE
oo
o
Smelter Hcverberatory
Converter ti Anode Casting
(Flowsheet K)
Smelter Fluosollda System
(Flowsheet X)
Reagent Storage
t Pilot Plant
LJ (See
Flowsheet I)
Jaw Crusher
\^-" (Flowsheet VIH)
Figure 2
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Figure 3. OVERALL PLANT AND GENERAL ARRANGEMENT
(Located in Pocket Inside Back Cover)
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The smelter portion of the plant consists of the initial ore
handling, crushing, grinding and mixing equipment, a fluo-solids
reactor, a reverberatory furnace with two waste heat boilers, three
converters, an anode furnace and anode casting wheel. Five vertical
lime kilns are also used.
The pollution control equipment consists of cyclones and
rotoclones for the crushing, grinding, screening and materials
handling operations and lime kilns. Reverberatory furnace gases
pass through two waste heat boilers, a balloon flue and a four
chamber electrostatic precipitator before exiting through a 600
foot stack. Fluo-solids reactor offgases pass through primary
and secondary cyclones and a gas cooler before entering the acid
plant system. Converter offgases are cooled and then pass through
a two chamber electrostatic precipitator before entering the acid
plant system. In the acid plant, fluo-solids reactor and converter
gases are treated in separate scrubbers, combined, and passed
through three parallel trains of two mist precipitators in series,
a drying tower, a mist eliminator, and into a double contact acid
plant. Acid plant tail gases are vented to a 100 foot stack.
C, PROCESS DESCRIPTION
The Kennecott Copper Corporation Smelter at Hayden was put
on stream in mid-1958 as a green-feed sidewall-charged reverbera-
tory furnace with Peirce-Smith converters. All gases, after dust
removal in electrostatic precipitators, were discharged through
a 600-ft. stack. In 1966 it was decided to convert the plant to a
calcine reverberatory using a fluo-solids roaster. Roaster gases
were to be cleaned and sent to a 750-ton per day acid plant. The
design was started in June 1967, and construction completed March
1969. The basis for the decision was to provide a source of acid
for mine leaching, increase capacity of the green-feed reverbera-
tory furnace, and reduce air pollution.
Concentrate, silica sand, lime flux, and precipitate copper
-------
in the following proportions are blended together prior to being
fed into the fluo-solids reactor. (Ref. 1).
Concentrate 88.68 %
Lime Flux 3.93 %
Silica Flux 3.93 %
Precipitate 3.46 %
100.00 %
The process weight varies from 1200 to 1400 TPD. The blended
material contains from 6 to 12 percent moisture and is fed into the
reactor through a screw feeder. This feeder both controls the feed
rate and seals the reactor vessel. Fluidizing air at approximately
3 psi is supplied to the reactor tuyeres in the floor of the reactor.
The bed which is about 4 feet deep is in a constant fluidized
state. The sulfide ore reacts with the fluidizing air and partially
oxidizes forming SO^ gas and calcine. Operating temperatures range
from 1,000 to 1,150 F. The process is controlled by limiting the
air volume (09). Approximately 50 percent of the total sulfur is
converted to S09. The reaction is exothermic and therefore natural
gas is not required except for cold startup. Gas and fine solids
leave the reactor by duct and pass through primary and secondary
cyclones. The calcine is collected and fed to the reverberatory
furnace via calcine bin and Wagstaff feeder. The oversize material
in the reactor is withdrawn by a cone type valve located in the
reactor floor and is conveyed by drag chain to the calcine bin. The
gas from the cyclones is cooled in the gas cooler (1,000 F to 800 F.)
The reactor gas is then combined with the converter gas and is
fed to the acid plant.
Calcine and precipitator dust are smelted in the reverberatory
furnace. Slag is skimmed from the bath and removed by slag train to
a dump. Copper matte is tapped near the bottom of the bath and
transferred by ladle to the converters.
-------
Combustion air for the reverberatory furnace is supplied at
700°F by a Lungstrom preheater. Both the preheater and reverberatory
furnace are natural gas fired. In addition, the reverberatory
furnace is equipped with diesel oil burners for stand-by service.
Combustion gases from the furnace pass through the uptakes into two
waste heat boilers. The gases then enter the reverberatory furnace
balloon flue and travel to an electrostatic precipitator and then
to the smelter stack. The dust collected is returned by screw
conveyors to the calcine bins. The dust loading in the smelter
stack averages 0.04 grains per SCF. The gas flow rate at the stack
exit is approximately 130,000 SCFM and the average stack gas
temperature is 360°F.
The process flow diagram with sulfur balance and typical gas
temperature and flow data is shown in Figure 4.
A set of process flow sheets prepared by Kennecott Copper
Corporation (Ref. 2) are reproduced in Appendix A for reference.
a. Fluo-solids Reactor
The fluo-solids reactor system is illustrated in Figure 5.
The system was designed by Dorr-Oliver in conjunction with Kennecott
engineering (Ref. 2). The original system included a preheater for
the fluidizing air, a fluo-solids roaster or reactor, dual flues to
banks of four primary and four secondary cyclones each equipped with
jug dampers, and calcine bins and feeders. Air preheater failures
led Kennecott to by-pass the preheater. Preheated air has not been
used for the past few years. To assist in starting the reactor
Kennecott now uses about a ton of 3/4 inch slack coal mixed with sand
and fired by two auxiliary burners through the sidewall. The reactor
is 13 feet 6 inches in diameter with 373 tuyeres. Fluidizing air at
approximately + 100 inch w.c. (water column) is supplied to the reactor
-------
' 12 TPD-S
359°F
Inputs
950--1050 TPD concentrate
100 TPD Flux
44 TPD Precipitate
345 TPD-S
Scrubber
Sludge To
Roaster
+ 100" w.c.
600' Stack
550°F
15,000 SCFM
Precipitator
Dust
f Rev
( 130,
Reverb Off Gas
000 SCFM
650°F
Fugitive
Emissions to
Atmosphere
L8 TPD-S
2 Waste Heat
Boilers
Silica Flux
135 TPD
Anode
Furnace
Blister
Copper
223 TPD
Anode
Copper
Fluo-Solids
Roaster
1,150°F
15%
f Roaster-Off-Gas
T-W 31,000 SCFM
^ V 13% SO,,
+o" w.c.
1100° F
Cyclones
2 Banks of
4 Primary
4 Secondary
Snray
Sonic Nozzle
Gas Cooler
Calcine + 40" w.c.
1172 TPD
Calcine
181 TPD-S
Reverb Furnace
2,800° F
I
Copper Matte
562 TPD
146 TPD-S
3 Converters
Converter Off-
Gas
50,000 SCFM
6-7% S00
1600°F
Spray Coolers
1100°F
85%
Calcine & Dust
Reverb
Slag
650 TPD
3 TPD-S
Converter
Slag
300 TPD
2 TPD-S
600°F
Calcine
Dust
Plant water
Dust
Overflow
Tailing Pond
Precipitator
|750°F
Venturi
Scrubber
Peabody
Scrubber
Mist
Precipitator
Peabody
Scrubber
Tail Gas
1 TPD-S
Double Contact
Acid Plant
950 TPD
I
323 TPD-S
Drying
Tower
100' Stack
;Gas to Acid
Plant
100,000 SCFM
6.6% S00
Mist
Eliminator
Plant Water
PROCESS FLOW & SULFUR BALANCE
Kennecott Copper Ca/Hayden Bfahch
prepared August, 19 75
PACIFIC ENVIRONMENTAL SERVICES
Figure 4.
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RAY SMELTER FLUOSOLIDS SYSTEM
FLOWSHEET
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DESCP.IFIICM
2V Conveyor Belt
21*" Conveyor Belt
Concentrate Feed Hcpper
Concentrate Screw Feeder
Flucsolida r.eactor
Air Filter
Fl'iidizirs -Sc -"n-wer
Preheater
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DSSCPIPTICN
Gas Cocler Upleg
Deleted
Screw Conveyors
Seactcr 12 Tar. Intermediate
Feactcr 13 Far. West
Converter Gas TLectrcstatlc Precipitatcr
Converter ^ss ID Fan
S?rev Cc /.•.•»• crs
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DSSCBIKTCH
Vibratory Feeders
Welzh IJe^l; Convevor
Calcine Feed Bin
Wa^staff Feeder
Figure 5
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through a distribution plate in the floor of the reactor. The
distribution plate contains 373 spuds each containing seven I/A
inch diameter holes (Ref. 3). A pressure drop of approximately 60
inches w.c.is experienced in the reactor. Downstream
of the cyclones the pressure is 0 inches w.c. and remains below atmos-
pheric pressure throughout the remainder of the duct system to the
acid plant. Approximately 25,000 SCFM of roaster gas is treated
at the acid plant. The roaster gas feed ports must be cleaned out
once a month. This operation requires 14 hours and is accomplished
by going into the roaster and drilling out the over 2000 holes.
t
The bed, in a constant fluidized state, is about 4 feet deep.
The sulfide ore reacts with the fluidizing air and partially
oxidizes forming SO. gas and calcines. About 50 percent of the
total sulfur is converted to SO- in the reactor. The process is
controlled by limiting the air volume (0-). The operating tempera-
ture ranges from 1000 to 1150 F. No fuel is required except for
cold startup because the reaction is exothermic. Approximately
15% of the roasted material (calcine) is removed as "underflow"
along two sides of the distribution plate. The rest of the roasted
material leaves in the gas stream and is recovered in the cyclones.
b. Reverberatory Furnace
A flowsheet showing the equipment and process steps associated
with the reverberatory furnace, converters, and anode casting opera-
tions appears as Figure 6. Calcines, approximately 1100 to 1200 TPD,
are fed into the reverberatory furnace through a pair of Wagstaff
feeders. The reverberatory furnace, a suspended arch design, 30
feet wide by 100 feet long, generates 120,000 to 130,000 SCFM of
offgas with an average sulfur dioxide concentration of about 0.5%.
The reverberatory furnace is natural gas fired and has a
natural gas fired Lungstrom air preheater. Approximately 202,527
MSCF of natural gas is burned monthly in the furnace and 16,490 MSCF
10
-------
is burned monthly in the preheater (Ref. 1). Gases from the furnace
pass through the reverberatory uptake and through a pair of waste heat
boilers. Dust collected in hoppers beneath the waste heat boilers
is carried by a front-end loader to the converters.
The reverberatory furnace operates at a slight negative
pressure, -0.06 inches w.c. It is fed intermittently by dropping
calcines through the Wagstaff feeders. Feeding takes place
two minutes in every fifteen minutes. The furnace operates at
about 0.6% CO. This is possible because a major portion of the
sulfur is removed in the fluo-solids roaster.
Slag is removed at an average rate of 650 TPD and transported
to a slag dump in slag cars. The reverberatory slag contains
approximately 0.2 to 7.5 TPD of sulfur.
Approximately 25 to 30 ladles of matte per day are handled
from the reverberatory furnace. It generally takes 10 to 20
minutes to fill a ladle. During matte tapping there is evidence
of considerable fuming and SO . Kennecott is planning to enclose
the matte tap. The matte is taken by car to the converters at a
typical rate of 562 TPD.
c. Converters
The equipment associated with operation of the converters is
designated on the process flow sheet, Figure 6. Eight 200 cubic foot
ladles feed the converters. There are presently three Peirce-Smith
converters, 13 feet in diameter by 30 feet long equipped with forty-
two 2 inch tuyeres. .The converter aisle is served by two P & H
cranes each with a 60-ton main hoist and two 20-ton auxiliary hoists.
The converters are natural gas fired and typically process 135 TPD
of silica flux and 526 TPD of copper matte. At this charge rate,
223 TPD of blister copper is produced and sent to two anode furnaces
and then to a casting wheel. Typically, 300 TPD of converter slag
containing an average of 3 to 5 TPD of sulfur is generated.
11
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RAY SMELTER REVERBERATORY, CONVERTER, & ANODE
CASTING FLOWSHEET K
DUST TO £ASr
i
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Wazstaff Feed Door
Reverteraton* Furnace
Bu mors
Matte L.iuner
Sl:i? Launder
Ma::e Transfer Cnrs
Slaz Cars
Prchoatcr Furnace
FortL-d Draft Fan
Rfclnuljting Air Fan
MS
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DESCrttPTION
Wasted Heat Boilers
Rcverberatorv Upuke
Dust Collecting Hoppers
Front Er.rt Loader
Slag Fume Exhaust
M.itte Fume Exhaust Fan
Matte Fume Exhaust Fan
Converter Slaic Return Launder
"OH fu- Ft. Lidlp
Cogpor Convertejrs
Converter Hoort
MK
23
24
J5
26
27
2S
29
30
31
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DESCRIPTION kverberatorv Flue Scireu- Convevori36
Electrostatic Precipitator 137
High Vetocitv Flues as
Converter ID Fan yy
Du.st Hopper 140
Precioitator Screw Cor.vevor \4l
f,fi T.-.n rrir.Lprt.-i- Alsl<» rr--.r.p '•*-
Casting Crane :-*;1
Track Scale i-li
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DESCRIPTION
Plilm:>r1 Hrtlr r^r
Fork Lift Truck
Pump Sump
Anode Cooling Water Pumpa
Anode Coollra Water Tower
Anode Cooli.-j; Recirculatinjz PUITVDS
Propane Ston-ce
iOO Cu. Ft. Ladle
Anoile Furnace
Anotle Wheel Pouring Spoon
Bosh Crane
IK
45
46
47
TsT
1
2
1
DESCRIPTION
Anode Casttne Wheel
Bosh Tank
soo1 Hiirh Stack
Figure 6
-------
The converters were originally equipped with a mild steel
hood with cast steel liners and a movable door to close at the
front (Ref. 2). Each hood had a sliding gate-type damper leading
into a common balloon flue. To meet air pollution regulations,
Kennecott installed water-cooled hoods and gas coolers that
enable operation with 50% (Reference 8) dilution of the gas.
The new hood design is shown in Figure 7. The hood jackets,
a plate type with T-bar dividers and stiffeners, are fabricated
of 3/8 inch steel plate.
The water cooled portion includes the hood, the movable door,
and the dust settling chamber extending up about 30 feet behind the
converter. A 66-inch stainless steel flue channels the gas up,
over, and down into the gas cooler where it flows concurrently
with an ultrasonically dispersed water spray. The gas flows out
of the bottom of the gas cooler, up out of the building and across
to the induced draft fan plenum. Three bullseye dampers at the
plenum entrance isolate converters from the draft fan. The fan
discharge flows through an electrostatic precipitator before pro-
ceeding to the acid plant.
Each hood has a water flow of 1200 gallons per minute traveling
from a 6 x 4 pump through the jackets to an air-to-water heat ex-
changer, and back to the pump. A condensate storage tank main-
tains a constant pressure at the pump suction. The water temperature
rise in the hoods is between 20° and 30°F. The inlet water temper-
ature is 140°F and outlet is between 160 and 170 F.
The gas cooler is an unlined stainless steel vessel with eight
Sonocore ultrasonic water sprays in the top. Inlet gas temperature is
1100° - 1250°F. The outlet gas is controlled at 700°F by controlling
the volume of water supplied to the sprays.
The draft control system is two-part. The ID fan plenum draft
setting automatically controls the fan speed to maintain the plenum
draft. Each converter also has a butterfly-trim damper down stream
13
-------
ELEVATION VIEW OF WATER COOLED HOODS AND SPRAY COOLER
Figure 7,
-------
of the gas cooler to maintain a draft setting at the top of the
hood. This trim damper is activated with an air cylinder.
The dust recovery system consists of screw seals below the
hood dust chamber and the gas cooler. These screws feed a gathering
screw which discharges into a dust bin. The gathering screw and
both converter screws are actuated by the converter blast air pres-
sure and only run while the converter is blowing.
Loading and operation of the converters consists of the following:
(Ref. 4).
Five ladles of matte
One hour blow
Fifteen tons of silica loaded through the hood
Three ladles of slag removed
Two ladles of matte removed (15 to 20 minutes)
Fifty minutes blow
Add 10 tons of silica
Remove one or two ladles of slag
Repeat to obtain 100 tons of copper per converter load.
The level of the converter is judged by the operator. Slag
is continuously taken off until it appears that all of the iron
sulfide has been removed by reaction with the slag. When the iron
sulfide has been eliminated the copper blow starts. The copper sul-
fide is converted to copper and S07 during the copper blow. During
the copper pour which takes approximately 30-40 minutes, the con-
verter is rolled out and the blister copper is poured into large
ladles which are picked up by a crane and poured into the holding
and refining furnaces.
The converter hoods are pulled back leaving a gap of about one
foot during slag tapping. The hood draft is curtailed by closing the
plug type bullseye damper. When the hood is pulled completely back
fuming can be seen from the mouth of the converter. A portable gas
15
-------
heater is used in the converter mouth when the matte production is
not keeping up with the converter production to maintain an accept-
able internal converter temperature.
During the operation of the converter hood and damper system
the following negative pressures have been measured at the converter
hood: (Ref. 4).
-4.5" w.c. - normal open-acid fan on, converter on, damper open
-5.5" w.c. - converter roll out-acid fan on, converter off,
damper closed
-S" w.c. - momentary when damper closes and converter continues
to roll
The converter hood system has a fan which provides additional suction
and is controlled by an automatic pressure sensor. The converter
fan works in conjunction with the acid fan to provide sufficient
suction to pull the gases into the collection system. All of the
gases go to the acid plant.
d. Other Emitting Equipment
Material handling in the feed preparation area during crushing
and screening operations generates particulate matter. Roto-clone
dust collectors and cyclones control these dust emissions. Ladles
holding matte and slag are sources of visible fugitive emissions.
The five vertical Ellerman type lime kilns used in the lime plant
produce particulates. Small quantities of SO , NO , and particulate
Z X
are generated in the anode furnaces. The holding furnaces are usually
blown during the night shift. According to plant operators, there is
no smoke observed when pouring these furnaces into the casting molds.
Water sprayed on the cast anodes once they have "frozen" to further
cool them produces large quantities of steam. Leakage in ducts and
at other pieces of equipment results in additional particulate and
SO emissions.
16
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E, EXISTING CONTROL EQUIPMENT
Fluo-solids reactor and converter gases are treated for both
particulate and SO- removal. Reverberatory furnace gases are treated
for particulate removal only. The general arrangement of the control
equipment is shown in Figure 3.
a. Particulate Control Equipment
Fluo-solids reactor gases pass through two parallel sets of
4 primary and 4 secondary Ducon cyclones with a reported dust collec-
tion efficiency of 96.6%. The gases are cooled from 1050 F to
about 800 F, then enter the acid plant system where S0_ removal and
additional particulate removal is accomplished. Gases from the three
converters are collected in close-fitting water cooled hoods and pass
through a gas cooler and three high velocity flues to an electro-
static precipitator. The precipitator, manufactured by Western Pre-
cipitation Division of Joy Manufacturing Company, is a two chamber
design with three fields in each chamber. At the precipitator the
gas temperature is about 600 F. Converter gases then enter the
acid plant system.
Reverberatory furnace gases after heat recovery in two waste
heat boilers travel through a balloon flue to a Koppers Corporation
electrostatic precipitator. The precipitator consists of four
chambers each with three fields. The overall dimensions are 35 feet
wide by 120 feet long by 11 feet-4 inches high. Each field is 7 feet
-6 inches long. The gas velocity through the precipitator is
approximately 5 feet per second. Following the precipitator, the re-
verberatory furnace gases are discharged from a 600 foot tall stack.
b. Acid Plant System
The original acid plant was built in 1967 - 1968. This plant
was designed to handle 75,000 standard cubic feet of gas per minute.
17
-------
The plant originally had a two-pass converter with a single absorbing
tower. In 1973 the plant was rebuilt to increase the capacity to
100,000 standard cubic feet per minute. A new three-pass converter
was installed with an interpass absorbing tower between the second and
third passes. This not only increased the capacity but also increased
the conversion efficiency from 96% to 99%.
The following description of the equipment and operation of the
present acid plant was taken from Reference 2. The acid plant
flow sheet is shown in Figure 8.
Gas Scrubbing and Cooling
The scrubbing and cooling is done in two Peabody Towers. The
smaller tower, designed to handle the fluo-solids roaster gas, is
preceded by a Venturi scrubber. The Venturi scrubber is necessary
because of the high dust loading of extremely fine dust. The
larger tower is used to clean and cool the gas from the copper con-
verters. The towers consist of two principal sections: One, a
lower humidifying section constructed of mild steel plate and lined
with brick and lead; two, an upper cooling section constructed of
Alloy 20.
Hot gas enters the humidifying section and passes upward through
a spray of weak acid from the spray nozzles in the top of the section.
This spray removes the coarser solids from the gas and at the same
time the heat in the gas evaporates water from the weak acid thus
cooling the gas nearly to its adiabatic saturation temperature.
On leaving the humidifying section the gas then enters the
cooling section which contains three Peabody impingement baffle grid
assemblies mounted on the plate in such a manner as to provide an
impact surface directly over each perforation. The gas flows up-
ward through the perforations and is cooled by weak acid flowing
across the perforated plates.
18
-------
RAY ACID PLANT
FLOW SHEET
t/14/71
Air
MK
?
1
4
I
6
!;pt Preoinitritor
?.*ist PrecipLUitor
Dn'ini; Tower
Ml."t Eliminator
93' .-Vrul Pjmp TarJt
.SO? Blower
No. 1 Colrf Heat Exchanger
No. 2 Cold Heat Exchanger
Hot Heat Exchanger
MK
24
in
•;B
27
2S
29
SO
:il
32
33
N-0
1
r~i
i
i
i
i
i
i
i
i
DEECrtrPTION
Hot Interr.-:'-! Meat Exchanger
Converter iCatalvst Chambers)
Interoass Absorbinc Tc'.ver
Final Absorhira Tower
Preheat Heat Exchanger
Combustion Chamber
Combustion Air Fan
Recvcle Fsn
Ir.'eroass Acid Purro Tank
Inrerpass AciU Cooler
MK
3S
f#
t!7
bs
33
l;o
41
42
l»3
44
NO
1
2
•>
4
a
DESCHrPTION
Final Absorbirs Acirf Piimo Tank
Fir.al A^^orbir^ Acid PUTT.D
Fir-iJ Abs'-rbtrjr AcW Coolers
Pro*c: Ac:a '.Vclen
Drv:re Tower Acid Coolers
Dn'irc To-Aer Acid Pvnr.o
Ac:ri ?'.orise TirJcs
Ac:ci I.^adins P-^mpa
Trjck Haulage to Ra%-
:til Kaulaze
MK
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4fi
47
4»
49
50
51
52
53
54
NO
1
t
1
2
1
1
1
1
1
i
DESCRIPTION
Coldweli Pump
Standby PumD
Hotwell Pujnos
Secondary Cooling Tower
Co!d-A-«*ll Pump
SMmlby Pumo
Hor.vell Pump
Siudze TVi-kenerSO' Dia.
Dlaotinucn Pumos
Figure 8
-------
The weak acid from the cooling section flows to a pump tank
and is then recirculated by a pump through coolers back to the top
of the cooling section.
All the make-up water is added to this pump tank to control
the concentration of chlorides, percent acid, and other impurities
in the weak acid circulating solutions. The overflow from the
cooling section pump tank goes to the pump tank of the humidifying
section.
Weak acid from the humidifying section sprays also flows to a
pump tank and is recirculated. Weak acid is purged from the
humidifying section by pump pressure through a level control valve
to the effluent stripper.
The effluent water from the stripper flows to a sludge settler,
where solids are removed and then overflows the settler with a por-
tion returning to the lower circuit pump tank and the remainder to
sewer. The settled solids are pumped from the bottom of the settler
to the filter plant for recovery of the contained copper.
The cooled gas leaves the two Peabody scrubbers in FRP ducts
which are combined before entering the mist precipitators.
Mist Precipitators
The mist precipitator consists of six units arranged so that
the gas passes through three parallel trains of two precipitators
in series. Each precipitator chamber consists of 170 ten-inch
lead pipes in each of which is suspended a wire covered with star-
shaped lead. The high voltage current is connected to the wires
while the lead pipes are grounded. The mist-laden gas enters the
bottom of the chamber and flows up through the lead pipes. The mist
and solids precipitate on the lead pipes where they are drained to
the bottom of the chamber. The gas then leaves the upper section of
the chamber substantially free of acid mist and solids. Each train
20
-------
has a safety seal constructed into the bottom of the mist precipi-
tator. The seal is so constructed that air is admitted to the gas
stream if the suction reaches 26 inches water gauge differential
and thereby protects the lead chambers from excessive suction. The
gas goes from the mist precipitators to the entrance of the drying
tower.
Drying and Absorbing Acid System
The drying tower removes water vapor from the S0_ gas stream
before it passes to the converter and absorbing systems. Drying
eliminates the corrosive action of wet SCL gas, reducing possible
damage to the catalyst.
The drying, interpass and final absorbing towers are nearly
identical in construction. Each is a vertical, cylindrical, brick-
lined chamber containing ceramic packing supported by brick grid bars
resting on brick piers. Each tower also has a Brink Mist Eliminator
located above the acid distributors in the tower top to remove any
acid mist particles in the gas stream. Cast iron troughs distribute
circulated acid uniformly into the packing. The gas flow is upward
through the towers countercurrent to the acid distributed over the
packing. Acid flows by gravity from each tower to a pump tank and is
recirculated through coolers to the distributor troughs. Inter-
connecting piping between the tower units for the transfer of acid from
one circulating system to the other and dilution water inlet lines
to the absorbing system are used to maintain the desired acid con-
centration for the towers.
The strength of the drying acid should be maintained at not
less than 93% H^SO, if possible. The acid strength in the absorbing
towers should be maintained between 98-99% H^SO,. The temperature
of the drying acid should be as low as practicable and never more
than 130 F. The absorbing acids are maintained at about 170 F for
best results.
21
-------
The gas goes from the drying tower to the main blowers.
Main Blowers
The purpose of the main blowers is to provide means for moving
the process gas through the plant.
There are three blowers installed for parallel operations.
Each blower is a single stage centrifugal type driven by a 2000
HP electric motor through a gear increaser. Each of the three
blowers is equipped with an inlet control butterfly valve which is
pneumatically operated from the main control panel. Depending on
the amount of process gas available, one, two, or three blowers
are operated.
The process gas goes from the main blowers into the converter
system.
Converter System
The function of the converter is to effect the chemical reaction
between sulfur dioxide and oxygen to form sulfur trioxide. The func-
tion of the catalyst is to accelerate the reaction, that is, to
shorten the time required for the reaction to reach equilibrium.
The catalyst is not itself affected or used up.
The converter system consists of an insulated, vertical, cylin-
drical vessel, known as a converter, five gas heat exchangers, and
inter-connecting ducts. The converter contains four layers of vana-
dium catalyst arranged in three passes. The first pass consists of
two layers, each remaining pass of one layer. The heat exchangers
are insulated, vertical shell and tube units.
In operation, the flow of cold S07 gas from the blowers is through
the shell side of two cold and one hot heat exchanger in series to
the converter. The S09 gas preheated to operating temperature by
utilizing the heat generated from the chemical reaction within the
22
-------
converter. The preheated gas enters the top of the converter. The
gas flow is downward through the catalyst layers with the gas leaving
the converter after each pass for cooling. The arrangement for
cooling is outlined as follows:
No. 1 pass (Upper 2 layers of catalyst), hot heat exchanger
(tube side).
No. 2 pass (3rd catalyst layer), cooled in No. 1 and No. 2 cold
heat exchangers (tube side) and reheated after the
interpass absorption in cold interpass and hot
interpass heat exchangers (shell side).
No. 3 pass (4th catalyst layer), cold interpass heat exchanger
(tube side) before entering final absorbing tower.
A system of bypass ducts, with control valves around the cold
and hot heat exchangers is provided for temperature control to the
first and second passes and around the cold and hot interpass ex-
changers for temperature control to the third pass. Control valves
at the tube side outlet of the hot and cold interpass exchangers are
provided to control the split of the hot gas from the first pass
through these exchangers.
Thermocouples are located in the inlet and outlet of each pass
of the converter. The converter is operated by controlling the inlet
temperature of each pass. Knowledge of the outlet temperature of each
pass is also important as a means of determining the temperature rise
and hence the amount of conversion done in each pass,
Pressure taps are provided at the inlet and outlet of each
catalyst layer for field measurement of the pressure drop across the
catalyst layer.
Direct Fired Preheater
The purpose of the preheater is to raise the temperature of the
catalyst in the converter to a point at which conversion of SO- to
S0» will occur. Operation of the preheater is required during
starting of the plant after a shutdown or during periods of low gas
23
-------
strength.
The preheater consists essentially of two parts: a brick-
lined combustion chamber, and a tubular steel heat exchanger. The
combustion chamber is fired with fuel to produce hot combustion gases
which pass through the tubes in the heat exchanger. Air or SO- gas
from the acid plant blowers passes around the tubes. Control dam-
pers in the duct system are used to vary the amount of process gas
through the preheater depending on the need of the plant. The pre-
heater is kept on the line at all times because of frequent periods
of low gas strength or volume.
Absorbing System
There are two absorbing towers in this plant — the interpass
absorber and the final absorber. The gas leaving the second pass
of the converter passes through two heat exchangers and then to the
interpass absorber. The S0_ is absorbed from the gas stream leaving
SO- to S0_ in equilibrium so nearly all the remaining S09 can be
converted in the final pass of the converter. The gas from the
third pass then goes to the final absorber where the last traces of
S0_ are absorbed. This plant with the interpass absorber will give
better than 99% conversion of SO- to SO-.
For maximum absorption of SO- the circulating acid has to be
between 98% and 99% in strength and the temperature between 160 and
180°F.
Acid Cooling
The absorption of water vapor in the drying tower and the con-
stant addition of 98%-99% acid to the drying acid pump tank materially
raises the temperature of the acid. Hence, this acid is pumped
through cast iron coolers before delivering it again to the top of
the drying tower because cool acid dries the process gas better than
hot acid.
24
-------
The absorption of SO. gas, the water or weaker acid added to
the absorbing acid pump tanks, and the heat in the process gas,
materially raises the temperature of the absorbing acids. Hence,
this acid is also pumped through cast iron cooling coils before
delivering it again to the top of the interpass and final absorbing
towers so that it will not be too hot for efficient absorption.
The addition of dilution water to the absorbing acid, the
absorption of SO,, in the acid, and the absorption of water vapor
by the drying acid constantly increases the volume of acid in the
pump tanks. Hence, the product acid from the drying tower system
must be pumped continuously to storage to maintain a constant level
in the pump tanks.
The product is pumped through cast iron cooling coils to any
of four 5000 ton storage tanks. The acid from the storage tanks
can be loaded into either tank trucks or railroad cars.
Water Cooling System
The heat exchangers in the gas cooling section and in the acid
cooling sections require a large volume of cooling water to maintain
the desired temperatures. This water, after having been pumped
through the heat exchangers and over the cooling coils, is then
pumped over cooling towers to get rid of the excess heat.
F, GAS SYSTEM DUCTWORK
The gas system ductwork is shown in Figure 3, the general
arrangement drawing. A few modifications in the ductwork have been
made as noted below in the text. Reverberatory furnace gases,
approximately 130,000 SCFM, enter the two waste heat boilers at
approximately 2300 F and exit at 650 F. The heat is recovered
by producing steam, 66,000 pounds per hour, at 450 psig and 750 F.
The furnace gases are then carried by balloon flue to the four chamber
Koppers precipitator. The dimensions of the balloon flue are
25
-------
13" - 0%" by 13' - Oh". The length of the balloon flue between
the waste heat boilers and the precipitator is approximately 180
feet. The gases travel through an additional 50 feet of ductwork
before entering the 600 foot stack.
Fluo-solids reactor gases are carried in one of two gas ducts
to the primary and secondary cyclones. It was necessary to blank
off one of the gas ducts, thereby doubling the gas velocity in the
other, to minimize dust buildup and plugging problems in the duct-
work preceding the cyclones. The cyclones collect approximately
85% of the calcines from the reactor for feed to the reverberatory
furnace. The reported overall efficiency of the cyclones is 96.6%
(Ref. 2). Following the cyclones, the gases pass through a duct to
a gas cooler, and then a bypass around the original calcine pre-
cipitator. The original calcine precipitator, shown in the general
arrangement, has been bypassed by a high velocity flue. The bypass
was installed because air infiltration into the precipitator caused
burning of the residual sulfur which resulted in plate warpage. A
Venturi scrubber was installed preceding the Peabody scrubber to
handle the high dust loading of extremely fine dust. The reactor
gases are then treated in the smaller of two Peabody scrubbers
before entering the acid plant.
Converter gases are collected in water-cooled hoods and travel
through approximately 180 to 200 feet of ductwork (4 feet inside
diameter) to the blower. From the blower the converter gas travels
through a 75 inch diameter duct to the two chamber Western Precipi-
tation Division, Joy Manufacturing Company precipitator. Following
the precipitator the gases are ducted to the larger Peabody scrubber
and then on to the acid plant.
G, SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT
Typical sulfur balance data are presented in Table 1. (Ref. 6).
Of the 361 TPD of sulfur entering the smelter approximately 33 TPD
(18 TPD fugitive and 15 TPD stack emissions) are emitted to the at-
26
-------
Sulfur
Input
TPD-S
361
Fluo-Solids
Roaster
%so2
13
TPD-S
180
Reverb
%so2
0.5
TPD-S
32
Converter
%so2
6-7
TPD-S
144
Slag and
Solid Waste
TPD-S
5
Fugitive
Emissions
TPD-S
18
Present
Sulfur
Captured
TPD-S
328
Stack
Emissions
TPD-S
15
NJ
•vl
Table 1. KENNECOTT COPPER COMPANY/HAYDEN SMELTER - TYPICAL SULFUR BALANCE SUMMARY
-------
mosphere. Presently 328 TPD of sulfur is captured (323 TPD
captured in the acid plant and 5 TPD contained in slag and solid
wastes). The "overall" sulfur removal efficiency of the smelter
is therefore;
x 100% = 90.9%
Most of the stack S0? emissions are generated in the reverberatory
furnace and are emitted from the 600 foot stack. At the main stack
exit the following gas characteristics are typically encountered:
Gas volumetric flow 130,000 SCFM
Gas temperature 359 F
SO concentration 0.4%
Dust loading 0.04 grains/SCF
The sulfur dioxide emission rate from the main stack varies from
0 to 8000 pounds per hour for periods of less than an hour. The
average emission rate based on 24 hourly emission measurements
per day for July 1974 was 1973 pounds per hour (23.7 TPD-S02) (Ref. 5)
Acid plant tail gas accounts for approximately 1 TPD of sulfur
emissions. At the exit of the 100 foot and plant stack the gas
temperature is typically 175 F.
The sulfur dioxide emission rate from the acid plant may vary
from 0 to 2,000 pounds per hour for brief periods during startup
when the catalyst beds are cold. However, these extremes occur only
during upset conditions. The average hourly emission rate based
on 24 hour average hourly emissions for 11 days in July 1974 was
237 pounds per hour (2.8 TPD-SO ). (Ref. 2).
Fugitive emissions cannot be accurately measured, but are
estimated to be 5% of the input sulfur. Sources of fugitive
emissions are the slag skim bay, matte runners, waste heat boilers,
and converter hood doors.
28
-------
Converter dust collected in the precipitator was analyzed, and
reported to contain the following:
Cu 16.2%
Pb 7.1%
Zn 4.0%
Cd 1.3%
Mo 1.0%
Fe 24.1%
S 11.4%
Insolubles 15.6%
H, GAS CHARACTERISTIC VARIATION
It can be expected that S0~ concentration in the offgas from
the reverberatory 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. This
variation in S09 content 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.
S07 concentration in the converter offgas will also vary con-
siderably for an entirely different reason. The operation of a con-
verter includes several, usually three, slag blows and one copper
blow. Between these blows the converter is not blowing the hood
above the converter is closed off by dampers so that the gases do
not pass through the collection system to the acid plant. The
attempt is always made to maintain at least one converter blowing
gases into the system at any given time. Usually a converter will
be provided with 20,000 SCFM to the tuyeres. An additional 50%
of dilution air is estimated to be added to this gas flow resulting
in a total gas flow from each converter in the range of 30,000 SCFM.
29
-------
f
When a converter is blowing there will usually be approximately
30,000 SCFM at an SO content in the range of 4.0 to 4.5%.
The fluo-solids reactor generates about 25,000 SCFM of gas with
an SO concentration of approximately 13%. Operation of the roaster/
reactor is relatively constant. After cooling and initial dust re-
moval, the reactor offgases are treated in the acid plant, Shutdown
for cleaning of the reactor air distribution plate can take up to 14
hours every month.
Because of the normal fluctuation in converter feed and opera-
tion, the SO. concentration can vary over a relatively wide range.
In addition, the gas volume flow from the converter line to the acid
plant can vary over a wide range from maximum to zero. Operation
of the control system must be conducted in a manner to compen.sate
for these fluctuations. Acid plant operation at this smelter appears
to be typical providing satisfactory control. The acid plant operates
at approximately 5 to 10% downtime,
I, STACK DESCRIPTION
*
Main Stack (Reverberatory Stack)
Height 600 feet
Diameter (ID) 39 feet, base
17 feet 2-3/8", top
Stack gas temperature (average) 359 F
Stack gas exit velocity
(calculated) 1050 fpm
Base elevation above MSL 2204 feet
Acid Plant Tail Gas Stack
Height 100 feet
Diameter (ID) 8 feet
Stack gas temperature (average) 175 F
Stack gas exit velocity
(calculated) 2000 fpm
Base elevation above MSL 2204 feet
Reference 7.
30
-------
J, PRESENT TECHNIQUE FOR SOLID WASTE HANDLING
Reverberatory furnace slag is hauled in slag cars to the slag
dump at an average rate of 650 TPD. Converter slag is not returned
to the reverberatory furnace, but is allowed to cool slowly, crushed,
and sent to a flotation mill to recover copper. The concentrate
is dewatered and sent back to the fluo-solids roaster. Waste
material from the sulfide flotation process is partially dewatered
in thickeners and then pumped to the tailings pond. Sludge from
the two Peabody scrubbers is returned to the fluo-solids roaster.
Overflow from the scrubbers is pumped to the tailings pond. Dust
collected in the reverberatory furnace waste heat boilers is
collected in hoppers and hauled by a front end loader to the
converter. Dusts from the reverberatory furnace which are
collected in the balloon flue and electrostatic precipitator are
transported by screw conveyor to the east calcine bin and then
back into the reverberatory furnace. Likewise, converter flue dust
collected in the electrostatic precipitator is returned to the
furnace.
K, FOOTING AND STRUCTURAL REQUIREMENTS
No local codes apply. Seismic zone 2, wind load 20 PSF
and snow load 20 PSF are used for design.
Soil testing should be assumed to determine footing require-
ments.
L, EXISTING AND AVAILABLE UTILITIES
Water is obtained from wells. It is expected that future gas
supplies be limited. Additional electricity beyond present capacity
will be available from public utility unless an electrical furnace
is considered.
31
-------
M, POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS
Except for available area to locate control equipment, no
additional installation problems are apparent at this time.
32
-------
REFERENCES
1. Kennecott Copper Corporation, Ray Mines Division, Permit IX
2. Kennecott Copper Corporation, Ray Mines Division, Hayden
Smelter and Acid Plant Gas Handling System. Stocker J.E.,
Nelson D.E., and Mulholland LE. Presented at the Annual
Meeting, AIME Tucson, Arizona, December 2, 1974.
3. Visit to Kennecott Copper Corporation, Hayden, Arizona,
July 24, 1975.
4. Visit to Kennecott Copper Corporation, Hayden, Arizona,
August 15, 1974.
5. August 29, 1974. Kennecott Copper Corporation memo to
U.S. Environmental Protection Agency, Region IX
6. Evaluation of Controllability of S0_ Emissions from Copper
Smelters in the State of Arizona, Weisenberg I.J. and G.E.
Umlauf, June 1975.
7. Kennecott Copper Corporation Correspondence with U.S. Environ-
mental Protection Agency, Region IX, August 29, 1974.
8. Letter K.H. Matheson to I.J. Weisenberg, October 9, 1975.
33
-------
APPENDIX
34
-------
o
CD ,
Add Plant OOO
Flowsheet XI QOO
00
Hoppers
Electrostatic
Precipi'jtor
PLANT LAYOUT AND FLOWSHEET REFERENCE
Smelter Revcrberatory
Converter & Aaode Casting
(Flowsheet K)
Smelter Fluosolids System
(Flowsheet X)
(Flowsheet VE1
vtt £M
Lime
Burr-ir.g._
Plarf
na &xro
"n
Silicate Plant
__Slag Storage Bin
U^
-^.
_^_
=^=>o<.Fine Lime
X^ Storage Bin
_ \-S48dt
S'.dg.
\
Reagent Storage
I Pilot Plaot
(See Flowsheet I)
Jaw Crusher
(Flowsheet VTII)
-------
RAY CONCENTRATOR-SECONDARY CRUSHING PLANT
FLOWSHEET I
REVISED 6/14/74
XX
J.
2
5
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^5" Pelt Ccnveyor «^IA. 3. C
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1*8" Belt Conveyor fi
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^2" 5elt Feeder - Variable Sr»e4_
G>'clone Dust Collector
Pu=p, Sliirry 3" x 3"
Sctc-clo.-.e Dust Collector
MK
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-------
RAY CONCENTRATOR
GRINDING
SECTIONS 1-4
FLOY/SHEET No. IT
REVISED 6/14/74
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-------
RAY CONCENTRATOR
GRINDING SEC 53:6
FLOWSHEET No.H
REVISED 6/14/74
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SULPHIDE FLOTATION-SEC. 1-6
^"---i x--f^l
-TO
FLOWSHEET TV
REVISED 6/14/74
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15
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DESCRIPTION
Section 5 rM*trihn*nr p.-iv
Section 6 Dlslribator Box
Socrion 1-4 Distributor Box
Wcmco I'M Mechanical Cells - Row 1
M>mco 120 Mechanical Colls - Ro-.v •*
*\>TT.CO 120 Mechanical Cells - Hr-*.v 3,4,5
Wen co 'ISO Mechanical Cells - Row 6
Rougher Concentrate Sump - Section 5
5" x 4" Centrifugal Pimps
Rougher Concentrate Sump - Section 8
RIK
11
1"
1,1
M
15
H
17
18
ia
U
KO
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1
5
1
nr=rRTpTrnv
j" x 4" Centr1h:'r
3
5
3
:l
4
3
•J
r)FsrniT>Tinv
S" Ce"tr!fiicil PMTrn«j
Final Cleaner Cnncentraw Sumo.
. S" Centrifueal Purnps
5«" Fag. 1st Cleaner - Sec. 3
44" Fag. 2nd Cleaner - Sec. 5
44" Faf. 3rd dinner - Sec. 5
•>H" Fn^ 1st CleinPp- - Sec- fi
44" Fag. 2nd Cleaner - Sec. 6
44" Fag. 3rd Cleaner - Sec. 6
56" Fan. 1st Cleaner - Sec. 1-4
VK
11
32
33
34
35
3fi
37
38
39
40
41
NT),
4
3
1
t
1
•j
6
1
3
6
1
DESCRIPTION
44" Fae. 2nd Cleaner - Sec. 1-4
44" Fag. 3rd Cleaner - Sec. 1-4
Final Concentrate Sump
6" Centrifugal Pumps
Sampling Oox
Agitator (Steadv Head) Tanks
6" x 6" Centrlfasil Pumps .
Hegrind Purno Surap
10" x 3" Centrifugal Puznps
Krebs D20B Cyclones
Test Regrtnd Circuit (two T'xlO' Ball Mills)
-------
SCALPER FLOTATION
FLOWSHEET 7
RETURN WATER
SULPHIDE PLOT. TAIiJ
F.3.17.MK.5,6.7 4-8
TOTAILIUGS POND
POND
TOSTTADY HEAD TANKS
FLOW5HE.ETJS" UK 27
MK
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2
3
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6
7
8
9
10
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1
1
5
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1
1
12
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1
1
1
;
DESCRIPTION
Sampler
Pump Sump
8" Centrifugal Pumps
D2O Krebs Cyclones
Distributer Bex
Rovs Callcv C-!lls 2-70'
Sampler
Pump S^zip
6" x 5" C r.trif-igal P>cnps
P>jgp Siuq)
6' C:ntrirJ(;al ?<^IBS
MK
13
1U
15
16
17
IB
19
20
21
22
23
2*<
!!0
1
6
1
1
2
1
2
1
It
3
I
3
D3SCRIPTTOH
Distributor Box
Fag. 1st Cleaner 56"
Pump Sump
6" Centrifugal Punn>3
10" Krebs Cyclone
PU3P SUHP
3" Centrifugll Pumps
7' x 10* Regrend Ball Mill
Fag 2nd Cleaner UU
Fag 3rd Cleaner Ult
Pump Sump
V Centrifugal Pumps
MK
25
26
27
?fl
29
V>
31
32
33
3U
31?
36
NO
It
3
1
?
1
1
3
1
2
1
b
1
DESCRIPTIOH
Fag Uth Cleaner UU
Fag 5th Cleaner W»
PunD Sump
^*" Centri fttfi^l P"-ufflDs
^•5- Thickun.r
Sampler
16" x I1*" Centrifugal Pumps
26* Surge Tank
10" Centrifugal Pumps
Uo' Storage Tank
S" x 6" Centrifugal Pumps
3" Centrifugal Pumpa
MK
37
38
39
ItO
1.1
Up
»3
lilt
"•5
U6
U7
ua
HO
1
1
1
1
1
1
1
1
1
I
1
1
DESCRIPTIOH
75' Thickener
Pump Sump
6" Centrifugal Pump
2" Centrifugal PunD
Bin 20
_Pln_£L
Bins 10 to 16
U" Centrifugal Pump
Pump Suorp
U" Centrifugal Pump
U" Centrifugal Punjp
6" Centrifugal Pump
-------
RAY CONCENTRATOR .MOLYBDENITE PLANT FLOWSHEET
a
A
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ICC'
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3
4
5
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7
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11
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DESCRIPTION
75' Thickener
100' Thickener
' Denver rxiolcx Pum»s
Ptiv.p Sump
4" x 6 ' Ccntrifusrt! Purcss
4" X »>" Cer.' r:?-5u! Pu^ips
Pump Sumo
Stcarr. Ta,-As iNi)l on I.ir«:l
Asrtntinn TnrJcs
Purr.p Sump
4" x 6" Centrlfu^aJ P>;r-.o»
MK
12
13
1-1
15
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19
20
21
22
NO.
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DESCRIPTION 'MK
Rcuehcr Conditioners -23
Distributor Do.x
Boucher Flotation Rows - Galighcr --i8
Scavenger Flotation Sows - Galtsher "48
Pump Surnp
3-C,.mrif-jM P-J--.5
Pumn SITTID
3" Cor.tr: fxiiial Pumps
1st clr-arsr rr-.w - GaSizher i-W
1st Cleaner Scalper Row
Punip Sump
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25
26
27
"«
29
:!0
31
3*>
33
SO.
o
1
1
10
1
1
1
•-.
1
1
1
DESCRIPTION
2" Centrifugal Pumps
Krebs DIOB Cvclone
Rcgrtnd Oall Mill
15S Denver Counter Current Cleaner
Hvdro - Separator
Rojrind Ball Mill
Pump Sump
2" x 2'* Certrifu^il Pumps
6' x 4' Disc Filter
Purr.o Sump
5" Vertical Purnp
MK
NO,
DESCRIPTION
-------
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RAY CONCENTRAlOR SMELTER DEWATERING PLANT FLOWSHEET 211
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4
5
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1
2
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3
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Cvoloic
• ICO' Kaircter Thickener
Pump 6x6
Puir.p
Crj^-p
Disc Flitcr i> x 1
9ump
Pump 6 x 6 - . '
80' DUmetcr Thickener
MV
10
11
12
13
14
15
16
17
13
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1
1
1
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1
1
1
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DF>CHn>TTON-
PumD 3x4
24" Cons-evor Belt. *'2i
24" Con\-evor Sell, -2C
Merrick Scale
Screw Con\-cvor and Drver
2 1" Convcvor Belt, ?2D
24" Convc\*or Belt, -30 '
24" Conveyor Sell, "'23
24" Conveyor Belt, -27
MK
19
20
21
•22
23
24
25
26
27
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A
6
1
2
4
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1
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1
DESCarPTSON
ficceivcr
Filtrate Pump
Seal Ta.-i
Vacmnr. Purr.p
Moisrure Separator
Sump
Pump (vertical) 4"
PUTT.P 2"
Suir.p
MK
28
90
.10
NO
1
I
1
nrcr-prorinv:
Cycions
ID Fan
Son.bb«r
-------
RAY CONCENTRATOR SMELTER DEWATERING PLANT
FLOWSHEET
ConCENTCATE
OYPais
"TO CorrCENTKATE
set FLOIU
MK
1
2
3
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5
6
7
8
9
NO
1
2
1
1
1
2
L
2
1
PffrTPipnoN
160' Diameter Thickener
Pinnr ^ v ^
Sunp
Disc Filter 6x8
Pmap 6 x o
80' Diameter Thickener
P-jap 5 x U
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MX
10
11
12
13
lU
15
J6_
17
18
BO
1
1
1
1
1
1
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1
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nracRrpTTnn
2lt" Conveyer Shuttle Belt #25
2fc° Conveyer Belt #3O
V.errick Scale
2U" Conveyor Belt #S6
2U" Conveyor Belt f28
Screw Feeder
Dryer
2U" Conveyor Belt *29
KK
19
20
21
22
?1
2lt
«
26
27
BO
1
1
1
1
1
6
6
3
2
DESCPTPTTQH
Cyclone
I D Fan
Scrubber
Sump
Receiver
Filtrate Puap 1-1/2"
Moisture Trap
Vacuum Pua^ -
ML
28
29
30
11
1?
190
fc
1
1
1
2
DESCP1PTIOK
Moisture Separator
Sump
faap (Vertical) It"
Seal Tank
Puaro 6x6
-------
RAY SMELTER REVERBERATORY, CONVERTER, & ANODE
CASTING FLOWSHEET K
DUST TO r-»r e*ic/v£
zm£T no. S.-KIT.
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rx. — ..-^
Matte Lviner
5!-.j !.3cr.-Vr
>t:;t:.? Tn»n.«for Tars
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Ir.ir". i Snift Fsr.
lie-. ;r: ul::ltrjj Air F-in
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DESCRIPTION
Wasted Heat Hollers
ncvcrhcmtot->- Vptike
DM.st roliectir.z Hoopers
Front End Loarter
Sla; Fume E.xhtiust
M:i!ti; Fume Exhaust Fan
M.ltte Fdmo F.shr.u^t Fan
rt!11 fl- ^» "I I--1V
Cornt'r C.mwrters
Convener !!ooti
MJ
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24
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2li
27
2-;
20
10
11
»•»
13
NC
1
1
1
3
1
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1
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1
1
DESCRIPTION'
Convertor C.^s.'Cooler
Rev-erber:»tor\' Ballon Flue
'
Revcrberitorv Flup Screw Convevor
Elecrrostcttc Precipitaror
High Volncin- Flues
Converter ID Fan
Oust Hcijpor
Precipilator Screw Cor.vc-vor
Ca.«t^r^ CrTflnP
Track Scale
:Hi
.14
M
3fi
37
;>.s
:(H
-10
41
42
43
H
NO
4.
1
3
1
3
o
•X
1
DF.SCRrPTTON
n-iiiwi,! p^%- r-n-
Fork Lift Tr-ck
Pur:p Sump
An»n!e Coolin? Uater Pumps
Am:!e Coolirj Wn:er To-.vcr
An--i.'e C-'-'-iir.^ !?ecirculatine Purrcs
ProDar.c Sror-ae
200 Cu. Ft. Ludlc
Anot!e Furnace
Anoile Wheel Pourine Spoon
Bosh Cnne
IK
43
46
47
xc
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DESCRIPTION
Anode Castine \V>.eeI
Bosh Tank
600' Hish Stick
-------
RAY SMELTER FLUOSOLIDS SYSTEM
FLOW SHEET Z
MK
1
2
3
u
^
7
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HC
1
1
1
2
1
1
1
DESCRimOH
2U" Cor.veyor Belt
2U" Conveyer Belt
Concentrate Feed Hopper
Concentrate Screw Feeder
Air MUer
rl-ilizir.z Air Blower
Pre'neater
MK
9
10
11
12
13
1U
15
16
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2
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U
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2
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DESCRIPTION
UnderfT ow
Underflow Seal Screw
Drag Chair. Cor.veyor
Secondary Oyclone
Primary Cyclone Seal Screw
Secondary Cyclone Seal Screws
Jas Cooler
-------
RAY ACID PLANT
FLOWSHEET
MK
1
?
^
u
5
6
7
R
9
10
NO
1
1
1
.1
2
U
1
2
T
1
DESCRIPTION
Peabody Gaa Scrubber
Lower Recycle Tank
Lower Recycle Pump
•Vpper r.ecycle Punq>
Carfcate Heat Exchangers
Weak Acid Thicker.er - 50' D
^rder^cw P-iTS Diapbraffii
Mist Precipitate r
Mat Precipitatcr
MX
11
12
13
Ik
15
16
17
ia
19
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NO
T
1
1
1
2
1
1
1
1
1
DBiCRIPTIOH
Wasbing Chambers
Drying Tower
934 Acid Punp Tank
S02 Blower
No. 1 Cold Heat Exchanger
Ko. 2 Cold Heat SKChar.£er
Hot Heat Exchanger
Converter (Catalyst Chamber)
AbsorSir.g Tower
MK
21
22
r>,
zk
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26
27
28
29
30
NO
I
1
1
1
1
1
2
2
DESCRIPTTOH
Brink Mist Slinlnator
90% Acid PUQP Tank
Combustion Air 'an
Combustion Chamber
Preheat Heat exchanger
Recycle Fan
93* Acid Circulating Punp
9fl< Acid Circulating Pump
Drying Torer Acid Coolers
Absorbing Tower Acid Ccolers
MIT
•n
IS
^^
T>
35
36
I7
13
19
ff°
1
1
1
5
1
U
3
T^STRTPTTON
Product Acid Cooler*
Acid Cooler Basin
Hotwell SUOD
Coldwell Slunp
Circulating'Vater Pa-ips
Cooling Tcver
50OO Ton Storage Tank
Acid Leading Puaps
Truck Havtlafge To Ray
-------
RAY SMELTER LIME PLANT
FLOWSHEET ZZT
-1
MK
1
2
1
It
5
6
7
8
TO
1
1
1
I
1
S
5
•5
DESCRIPTION
3' x 6' Double Deck Screen
Bucket ELevator
Welgbtometer
2U" Shuttle Belt Conveyor M1 - 0" Ig.
Vertical Kllna, nlerHan Type
Exh&ust Blower
MK
9
10
11
12
13
l"f
15
16
NO
•j
•j
5
5
1
]
1
?
DESCRIPTION
Circulating Blower
Conbustlon Air Bl^^wr
Discharge Rakes
H' Reversible Belt Cooreyor 155' - 3"
111" Bait romnwnr lid' - O" Ig
Bucket Elevator
Storage Bias. 25O Tons &ch
MK
17
18
19
20
21
32
23
2U
:ro
2
1
1
1
1
\
1
1
DESCRIPTION
2U" Feedoveight Conveyors 8* - 7* Ig.
2k" Belt Conveyor 5k' - 0 - 3/U" Ig.
16' - 0" Dla. Slaker
18" Belt Conveyor 16V - 1O" Ig.
Ptnm) ^ipp
r.f^o Pim^>
Cyclone
MK
25
?fi
71
SO
1
2
1
DECREPTIOH
Sum
T.lma PUQPS
7S1 Mi. Milk r,f Mii. Stn™™ Tiu,k
(At Concentrator Area)
-------
TECHNICAL REPORT DATA
(Please read lawuctions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-036b
2.
3. RECIPIENT'S ACCESSION-NO.
4.TITLE ANOSUBTITLE
Design and Operating Parameters for Emission
Control Studies: Kennecott, Hayden, Copper Smelter
5. REPORT DATE
February 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
I. J. Weisenberg and J. C. Serne
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORG \NIZATION 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
The report gives 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
flowsheet 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.lDENTIFIF.RS/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
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
51
?0. SECURITY CLASS (This pag?)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
------- |