EPA-600/2-76-036C
February 1976 Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
Kennecott, McGili, Copper Smelter
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, Nortfi 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 REVIEW 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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E PA-600/2-76-03 6c
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
KENNECOTT, McGILL, COPPER SMELTER
by
I. J. Welsenberg 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
SECTION PAGE
A. INTRODUCTION AND SUMMARY 1
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT . . 2
C. PROCESS DESCRIPTION 2
D. EMITTING EQUIPMENT 7
a. Reverberatory Furnaces ... 7
b. Converters 7
c. Other Emitting Equipment 11
E. EXISTING CONTROL EQUIPMENT 11
F. NEW ACID PLANT 13
G. GAS SYSTEM DUCTWORK 16
H. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT .... 16
I. GAS CHARACTERISTIC VARIATION 23
J. STACK DESCRIPTION 25
K. SOLID WASTE HANDLING 25
L. FOOTING AND CONSTRUCTION REQUIREMENTS 25
M. EXISTING AND POTENTIALLY AVAILABLE UTILITIES 26
N. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS . . 28
LIST OF TABLES
TABLE PAGE
1. PARTICULATE EMISSIONS ANALYSIS AT STACK OUTLET 19
2. SULFUR BALANCE 24
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LIST OF FIGURES
FIGURE PAGE
1. PLANT LOCATION (USGS MAP) 3
2. MAP OF MC GILL PLANT 4
(Located in Pocket Inside Back Cover)
3. PROCESS FLOW AND SULFUR BALANCE 5
4. REVERBERATORY FURNACE PLAN VIEW
(Located in Pocket Inside Back Cover)
5. REVERBERATORY FURNACE ELEVATION VIEW 9
6. CONVERTER ELEVATION VIEW 10
7. PRECIPITATOR GENERAL ARRANGEMENT 12
8. MULTICLONE GENERAL ARRANGEMENT . , 14
9. ACID PLANT GENERAL ARRANGEMENT ..... 15
(Located in Pocket Inside of Back Cover)
10. REVERBERATORY FURNACE PARTICULATE BALANCE 17
11. COPPER CONVERTERS PARTICULATE BALANCE 18
12. PARTICLE SIZE DISTRIBUTION - CONVERTER 20
13. PARTICLE SIZE DISTRIBTUION - REVERBERATORY FURNACE. ... 21
14. PARTICLE SIZE DISTRIBUTION - REVERBERATORY FURNACE. ... 22
15. STATISTICAL DATA FOR 750-FOOT SMELTER STACK 27
ii
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A, INTRODUCTION AND SUMMARY
The purpose of this report is to present background design data
on the Kennecott Corporation, Nevada Mines Division, McGill, Nevada
smelter in sufficient detail to allow air pollution control system
engineering studies to be conducted. These studies will be primarily
concerned with lean SO. 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 sheets 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.
The major uncontrolled sources of SO at this smelter are the
reverberatory furnaces and the converters. Plans have been completed
and work initiated on the installation of a 500 TPD sulfuric acid
plant to capture a major portion of the sulfur emitted by the converters.
This system also includes new water cooled converter hoods and flues
to minimize gas dilution. Work has been stopped on this installation,
which has progressed through site clearance and receipt of some
equipment, because of litigation with EPA.
Installation of new electrostatic precipitators to handle
reverberatory furnace and converter exhaust gases is planned.
Converter gases to be processed in the acid plant will be pretreated
in wet scrubbers.
The present control equipment includes multiclones to control
particulate from the converters and a precipitator to control
particulate from the reverberatory furnaces. Approximately 200,000
TPY of S09 are emitted at the old high production rate. This has
been reduced to 175,000 TPY to allow full converter offgas flow to
the new sulfuric acid plant which will control up to 61% of the S0.2
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at the lower production rate when it is completed. There is limited
space available to install additional control equipment near the
reverberatory furnaces.
B, PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT
The Kennecott Copper Corporation, Nevada Mines Division smelter
is located adjacent to the town of McGill, Nevada. A section of the
USGS map showing land contours in the immediate area is presented in
Figure 1. Design altitude of the plant is 6300 feet with a latitude
of 39°10' and longitude of 114°50'.
The smelter portion of the plant consists of a receiving central
dumper which dumps feed material such as converter flux, reverts,
coal, limerock, filter concentrates and miscellaneous into specific
hoppers for mixing by conveyor to feed the charge bins, two coal fired
reverberatory furnaces, four converters and a casting area producing
blister copper cakes. The pollution control equipment currently
consists of precipitators for handling the reverberatory furnace gases
and multiclones for handling the converter gases. There is presently
no S09 stream control. A single contact 500 TPD sulfuric acid plant
is currently planned for controlling 862 in the converter offgases.
Figure 2 shows the overall smelter plant layout. Space for new
control equipment may be found west of the converter building or to
the north of the acid plant installation.
C, PROCESS DESCRIPTION
The process flow sheet for the Kennecott McGill smelter is
shown in Figure 3. Input material is placed in bedding bins consisting
of converter flux, reverts, coal, lime (rock), miscellaneous and filter
concentrates. Material from these bins is placed on a conveyor belt
in proper proportions to make up the reverberatory furnace feed which
is sent to the charge bins. A belt conveyor system is used to feed
the coal fired reverberatory furnaces.
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CONTOUR INTERVAL 40 FEET
DOTTED LINES REPRESENT 20-FOOT CONTO
DATUM IS MEAN SEA LEVEL
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Figure 2.
MAP - MC GILL PLANT
(Located in Pocket Inside of Back Cover)
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coal To
Power Plant
Track
h-rp
Scales
Conveyor Be 1 t
I Gondola I
To Refinery __
PROCESS FLOW & SULFUR BALANCE
KENNECOTTCOPPERCORP/M£GILL
Prepared Sepl. 1975
PACIFIC ENVIRONMENTAL SERVICES , INC.
Figure 3.
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Matte from the reverberatory furnace is taken in ladles by
crane and charged to the converters. From the converters the blister
copper is poured into molds forming blister copper cakes. The cakes,
the major product from this smelter, are sent to the Kennecott
Refining Corporation, Baltimore, Maryland.
The smelter has a charge capacity of approximately 400,000 TPY
of concentrates. The daily charge rate generally varies from 750
to 1,300 TPD depending primarily upon availability of charge
materials.
Gases from the reverberatory furnaces pass through waste heat
boilers and precipitators for particulate cleaning then out the
new 750 ft. stack. Gases from the converters are picked up by hoods
and passed to. a multiclones plant for particulate control and then
out the new 750 ft. stack. The gases leave the reverberatory
furnace at 2200 F and enter the waste heat boilers where they are
reduced to a temperature of approximately 750 F. Gases from the
converters leave at 800 F,
Dust from the precipitators is processed in a pug mill and then
returned to the charging bins. Likewise, dust from the multiclone
plant and flues is transported by conveyor to the charge.bins. Slag
from the converters is returned to the reverberatory furnace. Slag
from the reverberatory furnace is sent to the slag dump.
Temperatures, flow rates, and S02 concentrations are shown on
the process flow sheet, Figure 3. It should be noted that there is
considerable dilution air entering the system from the large gap
in the converter hoods and other leakage points. The total volume of
gases leaving the reverberatory furnaces and converters is 380,000
SCFM and this is then diluted by sufficient air to reach a volume
as high as 580,000 SCFM leaving the stack.
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D. EMITTING EQUIPMENT
a. Reverberatory Furnaces
There are two coal fired reverberatory furnaces each with two
waste heat boilers shown in Figure 4 and Figure 5. Furnace #2 is
31' x 132' and furnace #3 is 32' x. 132'. The furnaces were built
and installed by Kennecott Copper.
Waste heat boilers #3 and #4 for the //2 furnace are rated at
40,000 Ibs/hr steam. Waste heat boilers #5 and #6 are rated at 70,000
Ibs/hr and are fed by gases from the //3 furnace. The two reverberatory
furnaces process an average of 46 tons per hour of concentrate, 3 tons
per hour residue, 14 tons per hour of coal, and 30 tons per hour converter
slag.
b. Converters
The following describes the four Peirce-Smith converters shown
in Figure 6:
No. Dimensions Blower Capacity
1 12'-0" x 30'-0" 25,000 CFM at 18 psi
2 13'-0" x 30'-0" 25,000 CFM at 18 psi
3 , 12'-0" x 30'-0" 50,000 CFM at 17 psi
4 15'-0" x 35'-0" 40,000 CFM at 18 psi
The charge to the four converters averages 34 tons per hour
of copper matte, 1 ton per hour of residue and 12 tons per hour of
flux.
As seen in Figure 6 the converter mouth design has a cylindrical
portion raised above the surface of the converter. This requires
that the hoods be considerably higher than conventional "tight"
fitting converter hoods resulting in increased amounts of dilution
air entering the system.
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Figure 4. REVERBERATORY FURNACE PLAN
(Located in Pocket Inside Back Cover)
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_ . 29'- I03A j I
EAST-W yr FLUt g
SECTICN A-
O-ES45
SECTION P-b
D-25.2S
MZi/riot-i'o A- -x s fs : :
•CALK '/IG =I-O DATE I-
KENNECOTT COPPER CORPORATION
NEVADA MINES DIVISION - MCGlIX, NEVADA
ENGINEERING DEPARTMENT
F I CURE 5
MAWm TRACED CHECKED SJOMEO APPROVED
M. j. i\i •
-------
o
EL-G35O-O -
.:1- i 7 . PI IT!
re)
•IB! ' 19
: v»vot'_u fj-Ktt."'c" i
~ r- - T i -'
I . ^ t ! •
/\N/i/\ /\M/I. -
10
'SECTION
SCALE
klOTE :
V.
r-.rr:
FIGURE 6
SMELTEP.
i ;-L A^eAf.
SECT1'.
•CALE . ; NOTED
F- F
KENNECOTT COPPER CORPORATION
NEVADA MINES DIVISION - MCGlLL, NEVADA
ENGINEERING DEPARTMENT
RAWM j TRACED T CHECKED I SIGNED I APPROVED
IED I API
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With two converters operating (handling matte from one
reverberatory furnace) typical converter offgas volume flows are:
Volumetric Gas Flow in SCFM (14.7 psia and 32°F)
Wet Dry
Maximum 103,000 100,000
Average 70,040 68,000
Minimum 30,900 30,000
These values were used to define the requirements for the
sulfuric acid plant. The gas temperature downstream of the
precipitator was assumed to be in the range of 450°F to 750°F. The
SO- concentration typically ranges from 3.0% to 3.9% with a maximum
range of 6% to zero percent. Zero percent may occur for 2 hour
durations requiring acid plant recycling.
c. Other Emitting Equipment
Material handling in the unloading and bin loading areas can
generate some particulate matter. Crushing and screening operations
are performed but are not considered major sources of particulates.
Ladles for handling slag and matte from the reverberatory furnaces
do produce visible fugitive emissions, however, while the ladles are
receiving molten material movable hoods, shown in Figure 4, are
placed on top and evacuated through a separate duct and fan system.
This minimizes fugitive emissions.
E, EXISTING CONTROL EQUIPMENT
An electrostatic precipitator is currently used to clean the
gases coming from the reverberatory furnaces. Figure 7 is a general
arrangement of the building and floor plan section of the precipitator
handling the gases from the reverberatory furnaces. The overall
11
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*., 4-UL.iii4C.«,£aaljr{.Z<"- _ , __?
_A_;°) ±t£.'-£e&e»r c»*^ca.< L J
•12
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dimensions of the multi-stage unit are 90' x 38'. Screw conveyors
transport the dust collected in the precipitator hoppers to a pug
mill. The precipitator inlet flue is also equipped with a hopper
and screw conveyor. Gases from the waste heat boilers enter the
inlet flue and are then passed through a 25' wide opening to the
precipitator sections. After cleaning, the gases are passed to
the new 750 ft. stack (not the one shown).
Figure 8 shows the multiclone arrangement for handling the
gases from the converters. Converter gases, collected in the
converter flue, are ducted to four 16 VD size 45-9 multiclone units.
Each unit has a butterfly damper upstream for isolation and a louver
damper downstream for control. In addition, a bypass damper is
provided to allow direct flow of the gases to the stack. A 273,000
SCFM 2" S.P., 362 RPM Buffalo Fan located downstream of the multiclone
units pulls the gases through the multiclone units. From the fan
the gases travel through a brick flue and then out the stack.
F, NEW ACID PLANT
Figure 9 shows the general arrangements of the presently
planned acid plant and gas handling facilities. This acid plant
has been designed and installation initiated. The site has been
graded and compacted and some equipment received. Because of
Kennecott litigation with EPA, work has been halted on this new
installation. The installation includes new precipitators for both
the reverberatory furnaces and the converters along with a 500 TPD
single contract sulfuric acid plant, and associated facilities.
The new 750 ft. stack has been installed and is currently being
used to handle all offgases from the smelter.
13
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OuSSalonn
* n (Special)
V&ria|b/e wvme Control
CONVERTER
PROPOSED MULTICLONE .
toM/£:R7£/?6/)5 4 UN/73 /£ VD5H£45-f\
KENNECOTT COPPER CORPORATION
NEVADA MINES DIVISION-MCGILL. NKVADA
ENGINEERING DEPARTMENT
5ou7H ELEVATION
WEST ELEVATION
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Figure 9. ACID PLANT GENERAL ARRANGEMENT
(Located in Pocket Inside Back Cover)
15
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G, GAS SYSTEM DUCTWORK
Ductwork details in plan view and elevations are shown in Figures
4, 5 and 6. Gases from each reverberatory furnace pass through an
uptake to a pair of waste heat boilers. Following the boilers, the
gases pass through a brick flue to the precipitator and are then
discharged from the new 750 ft. stack.
Gases from the converters are collected in the hoods, travel
through the converter balloon flue to the parallel multiclone plant,
and are then discharged to the stack. A bypass exhaust dust collection
flue from the converter flue aids in the distribution of the gases.
The converter flue and the exhaust dust collection flue meet at the
junction box and then the single balloon flue carries the gases from
this point.
H, SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT
Figure 10 and Figure 11 show the particulate balance throughout
the smelter.
Analysis of particulate emission from the combined reverberatory
furnace and converter gas systems is shown in Table 1. Listed are
constituents that could cause pollution problems. The data were taken
from stack dust lost test number 241 conducted on May 13, 1971.
Typical data for gases leaving the stack are as follows:
S02 0.89% (b.v.)
S03 0.027% (b.v.)
H20 0.20% (b.v.)
0_ not available
Pollutant gases such as Cl, NO - no data available.
Particle size distribution data measured upstream from the dust
collection devices by Research Cottrell personnel are shown in
Figures 12, 13, and 14.
16
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Concentrate
750 TPD
Coal
200 TPD
Other
46 TPD
Converter
Slag
405 TPD
Reverb
Furnace
i
Dust
26.0 TPD
1
Exhaust
26.5 TPD
Waste Heat
Boilers
Dust
4 TPD
Belt Conveyor
Flues
(existing)
i
Electrostatic.
Precipltator
i
Dust
5 TPD
1
Dust
16.5 TPD
Screw Conveyor
Loader
Emission
0.5 TPD
1
Flue and
750 Ft. Stack
Dust
0.5 TPD
Reverb Furnace Input
Other:
Lime Rock
Flux
Coal
Dust
Concentrate
Converter Slag
Total
Average
Allowable Partftu-
late
Emission
TPD
45
1
200
26
750
405
1,427
59.2 tons/hr
46.2 Ib/hr
Projected Particulate Emission
TPD
Reverb Exhaust 26.5
Collection:
Waste Heat Boilers 4
Flue 5
Precipitator (New) 16.5
Flue Extension &
Base of Stack 0.5
Subtotal
Projected Emission
Contingency
Particulate Emission
26.5
0.5 = 42 Ib/hr
_3
45 Ib/hr
Figure 10. REVERBERATORY FURNACE PARTICULATE BALANCE
750 TPD (one reverberatory furnace)
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Air
348 TPD
Reverb Matte
248 TPD
Emissions
0 TPD
Flux
63 TPD
One Converter
Converter Input
Flux
Air*
Dust
Reverb Matte
Total
Average
Allowable Particulate
Emission:
(One converter)
(Two converters)
TPD
f>3
13.3 tons/hr
23.2 Ib/hr
46.4 Ib/hr
*Process air excluded by definition
Dust Exhaust
9.0 TPD
Flues
'Dust
8.5 PTD
Electrostatic
Precipitator
Dust
6 TPD
Ladle Crane
Acid Plant
Dust
2.5 TPD
Screw
Conveyor
Sludge
0.5 TPD
Screw
Conveyor
Projected Particulate Emission
TPD
Converter Exhaust 9.0
Collection:
Flues 6
Electrostatic
Precipitator 2.5
Acid Plant Sludge 0.5
Subtotal 9.0
Projected Emission 0
Contingency
Particulate Emission:
(One converter)
(Two converters)
= 0 Ib/hr
5
5 Ib/hr
10 Ib/hr
Figure 11. COPPER CONVERTERS PARTICULATE BALANCE 730 TPD (two converters)
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Table 1. PARTICULATE EMISSIONS ANALYSIS AT STACK OUTLET
Metal
Arsenic
Cadmium
Copper
Selenium
Zinc
Chromium
Manganese
Nickel
Vanadium
Boron
Barium
Mercury
Lead
Total
0.038
0.008
5.6
0.014
1.1
0.006
0.023
0.0045
0.0023
0.12
0.03
0.0007
0.065
7.0115
Stack Dust Lost Test No. 241 (5/13/71)
19
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CONVERTER
N3
o
o
o
>-
CO
'.J
a:
UJ
CL
i.o 10.0
PARTICLE DIAMETER (MICRONS)
-------
REVERBERATORY FURNACE
00.3 r
93.8
93.5 H~
or
UJ
t-
o
Q
2:
O
CO
I—
z
UJ
OC
Ul
0.
0(1 J U'-L
1.0
p A R T i c i r
M'F
10.0
' C ". 0 N 5 )
Figure 13
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REVERBERATORY FURNACE
<
Q
CO
J/>
UJ
ro
N5
a:
UJ
ft.
-1
2
-3
10.0
-------
Typical sulfur balance data for two charge rates are shown in
Table 2. Fugitive emissions are reported as "Process Loss" in the
"Sulfur Emitted" column. The 1,300 TPD concentrate assumes an
average of the maximum feed to the reverberatory furnaces which has
been encountered in the past.. Currently operation is closer to the
750 TPD rate.
I, GAS CHARACTERISTIC VARIATION
There are no data available on gas characteristic variation
from the smelter, but it can be expected that S(>2 concentration in
the offgas from the reverberatory furnaces will vary significantly
with time. This results from the variation in time required for
decomposition reaction of the various sulfide ores charged. This
variation in SC>2 content has been known to vary as much as 10 to 1
within a given charging time cycle.
S02 concentration in the converter offgas will also vary con-
siderably for an entirely different reason. The operation of the
converter includes several, usually three, slag blows and one copper
blow. Between these blows the converter may be rolled out for slag
pouring or material charging. When 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. An attempt is always made
to maintain at least one converter blowing gases into the system
at any given time. The requirements for the acid plant design were set
to cover an S02 range from 3.5% to 10.0%. It is expected that an
average of 4.5% SC>2 will be encountered in the gases going to the acid
plant from the converters. Gas volume flow to the acid plant will vary
from 30,000 to 68,000 SCFM.
23
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Table 2. SULFUR BALANCE - 750 TPD(Concentrate)
(Illustration No. 1)
Percent of Sulfur in Feed Emitted
PERCENT
SULFUR
(%)
Sulfur Input
100 —
80 —
60 —
40 —
20 —
97%
39%
1 1 1 | 1 I 1 | 1 1 1 1 1 1 I 1 1 1 1
1972 1973 1974 1975 1976
YEARS
Sulfur Captured Sulfur Emitted
TPD (%) TPD (%) TPD (%)
Concentrates
750 tpd
@35% S
Slag 8 3 Reverb Furnace 83 32
Blister Copper 1 0 Emergency Bypass 0 0
263 100 Sulfuric Acid 146 56 New 750-Ft. Stack 83 32
Acid Plant Sludge 6 2_ Process Loss<£ugitive)i 1 4
263* 100% 161 61% Acid Plant Tail Gas 8 3
102 39%
SULFUR BALANCE - 1,300 TPD (Concentrate)
(Illustration No. 2)
Percent of Sulfur in Feed Emitted
PERCENT
SULFUR
(%)
Sulfur Input
100 — ,
80 —
60 —
40 —
20 —
o ...
97%
59%
I I I 1 I 1 1 1 I 1 1 1 I 1 1 1 1 1 I
1972 ' 1973 ' 1974 1975 1 1976 '
YEARS
Sulfur Captured Sulfur Emitted
TPD (%) TPD (%) TPD (%)
Concentrates
1, 300 tpd
@ 35% S
Slag 14 3 Reverb Furnaces 144 31
Blister Copper 1 0 Acid Plant (Bypass) 99 22
455 100 Sulfuric Acid 163 36 New 750-Ft. Stack 243 sT
455 100% Acid Plant Sludge 7 2 Process Los8(FuBltive)18 4
185 41% Acid Plant Tail Gas 9 2
24 270 59%
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J, STACK DESCRIPTION
Figure 15 contains data and a sketch of the new 750 ft. stack.
This figure also shows location of the new stack. Stack has a concrete
shell with a 1/4" carbon steel liner. Inlet temperature averages 410°F
with a range of 350°F to 700°F.
K, SOLID WASTE HANDLING
Slag is granulated as it leaves the reverberatory furnace by
passing it into a slag launder tailing pond which causes the slag to
granulate. The slurry thus formed is pumped to the slag dump.
Converter slag is returned by ladle to the reverberatory furnace with
a crane dumping into the return slag launder.
Reverberatory bottoms are sent to the mill for crushing and
returned directly to the reverberatory furnaces for charging. Flue
dust from the multiclone and precipitator plants is returned to the
charge bins by conveyor belt.
L, FOOTING AND CONSTRUCTION REQUIREMENTS
The original ground density for the acid plant foundation was
110 Ibs per cubic foot. To meet specifications the area was excavated,
backfilled and then compacted to give a density of 128 Ibs per cubic foot.
The following environmental conditions are used for design:
Temperature -28°F to +128°F
Design Wet Bulb Temperatures 58 F
Design Dry Bulb Temperature 85°F
Average annual rainfall 8.33 inches
Average wind velocity 11 miles per hour
Maximum wind velocity 100 miles per hour
Direction of wind 80% SSW to NNE
Average annual snow fall 56 inches
25
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Design snow load 20 inches
Frost line design 30 inches
Thunderstorms, number per year 9
Dust storms moderate
Earthquake Uniform Building Code Zone 2
M, EXISTING AND POTENTIALLY AVAILABLE UTILITIES
1. Electric
Existing 40,500 kva produced by Kennecott.
44,000 kva produced by Mount Wheeler Power Inc.
Potential: Operating with all available power now.
Additional transformer equipment required.
Pickup at power house, switch house or
transformer building.
2. Water
Existing 14,586 gallons per minute
Potential: Operating with all available water. Main lines ,
run approximately east-west direction and pass
between boiler room and cooling tower. Additional
lines feed reverberatory and converter buildings.
3. Steam
Existing 753,900 Ibs/hr maximum total
Potential: Operating with all available steam
In addition to the waste heat boilers, there are 4 coal fired
boilers used at the present time.
4. Gas
Usage is very limited throughout the general plant.
26
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to
srcii
(.(HI*
STATISTICAL DATA FOR 750-FOOT SMELTER STACK
The following figures are approximate and are provided for general information only:
SITI PLAN
Concrete in column
Concrete in foundation
Thickness of concrete column at
thickest point
Thickness of concrete column at
narrowest point
Octagonal foundation dimensions
Weight of reinforced concrete column
Diameter of column at base
Diameter of column at top
Diameter of steel liner at bottom
Diameter of steel liner at top
MUTT CMC-
4500 cubic yards L*°°"
1310 cubic yards
48 inches
8 inches
78 feet across f
8 feet thick
9,150 tOnS
54 feet 7 inches
23 feet 4 inches
30 feet
15 feet 6 inches
'""«" •*«*
rrt,«..ii,
SjCTMJNAL
Figure 15
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N, POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS
There are four basic installation problems which Nevada Mines
Division, Kennecott Copper Corporation considers existing for the
installation of new control equipment. They are as follows:
1. Lack of surplus energy - due to the isolated area in which
the plant is located the energy resources and potential are
very limited.
2. Confined plant area - the existing plant area has very little
capacity for expansion within, due to the limited area created
by the complexity of the processes now in use. (It is believed
that there is additional space available if ductwork is
extended - PES comment.)
3. Continued operation while installation is taking place -
the operations performed at Nevada Mines Division are all
linked to each other in producing a finished product. Any
loss of one of these steps produces a domino effect
throughout the plant.
4. Economics - The status of the copper economy combined with
the rise in the cost of material has produced economic hardship
on copper producers.
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-036c
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Design and Operating Parameters for Emission
Control Studies: Kennecott, McGill, Copper Smelter
5. REPORT DATE
February 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
I.J. Weisenberg and J. C. Seme
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, Task 5
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.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
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Re port I
Unclassified
21. NO. OF PAGES
32
B:
1. SECURITY CLASS (Thispage)
nclassified
22. PRICE
EPA Form 2220-1 (9-73)
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