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

-------
               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.

-------
                              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

-------
                          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

-------
                         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

-------
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

-------
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.

-------
     CONTOUR INTERVAL  40 FEET
DOTTED  LINES REPRESENT 20-FOOT CONTO
        DATUM  IS MEAN SEA LEVEL

-------
                Figure 2.
          MAP - MC GILL PLANT
(Located in Pocket Inside of Back Cover)

-------
                                     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.

-------
       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.

-------
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.

-------
Figure 4.  REVERBERATORY FURNACE PLAN




(Located in Pocket Inside Back Cover)

-------
                                                                                                                                   _  . 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

-------
      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

-------
                                                                                                                                           	*.,	4-UL.iii4C.«,£aaljr{.Z<"- _    , __?
                                                                                                                                             _A_;°)	±t£.'-£e&e»r c»*^ca.<		   L	  J
•12

-------
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

-------
                                                                                                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

-------
Figure 9.  ACID PLANT GENERAL ARRANGEMENT



(Located in Pocket Inside Back Cover)
                      15

-------
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

-------
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)

-------
         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)

-------
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

-------
                                                          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

-------
                                                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

-------
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%

-------
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

-------
    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

-------
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

-------
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.
                                   28

-------
                                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)
                                         29

-------