EPA-600/2-76-036d
February 1976
Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
Kennecott, Hurley, Copper Smelter
Industrial Environmental Research Laboratu..
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 "urther development and application of
environmental technology. Elimination OT 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 v V ;
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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EPA-600/2-76-036d
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
KENNECOTT, HURLEY, COPPER SMELTEfl
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
A. INTRODUCTION AND SUMMARY 1
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT . 1
C. PROCESS DESCRIPTION .... 5
D. EMITTING EQUIPMENT 7
a. Reverberatory Furnaces 7
b. Converters . 7
c. Other Emitting Equipment 9
E. EXISTING CONTROL EQUIPMENT 9
F. GAS SYSTEM DUCTWORK 10
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT ... 10
H. GAS CHARACTERISTIC VARIATION 19
I. STACK DESCRIPTION 20
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING 20
K. FOOTING AND STRUCTURAL REQUIREMENTS 20
L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES 21
M. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS. . 21
REFERENCES 22
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LIST OF FIGURES
Page
1. LAND CONTOUR MAP OF SMELTER AREA 2
2. OVERALL SMELTER GENERAL ARRANGEMENT 3
3. GENERAL SMELTER LAYOUT 4
4. PROCESS FLOW SHEET 6
5. REVERBERATORY FURNACE GAS SYSTEM DUCTWORK 11
6. FLUE NO. 3 12
7. CONVERTER GAS SYSTEM DUCTWORK 13
LIST OF TABLES
I. REVERBERATORY FURNACE DATA ..... 8
II. EMISSION SOURCE, CONTROL EQUIPMENT, CONTAMINANT
AND EMITTED QUANTITY 15
III. EMISSIONS 16
11
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A. INTRODUCTION AND SUMMARY
The purpose of this report is to present background design data on the
Kennecott Copper Corporation, Chino Mines Division Smelter at Hurley, New
Mexico in sufficient detail to allow air pollution control system engineering
studies to be conducted. These studies are 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 sheet are included.
Utilities, stack dimensions, footing requirements, and solid waste handling
are defined. Available area for new control equipment, gas characteristic
variation and potential new control equipment installation problems are
discussed.
The major uncontrolled source of SO- and particulate at this smelter is
the reverberatory furnace with approximately 88,330 tons per year of SO and
6,833 tons per year of particulate emitted (Ref.l). There appears to be
sufficient space and utility availability to install additional control equipment.
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT
The Kennecott Copper Corporation Smelter is located adjacent to the town
of Hurley, New Mexico. A portion of the USGS map, showing land contours of
the immediate area, is presented in Figure 1. Design altitude for the plan is
5,700 ft. with latitude 32°41' and longitude 108°07'
Overall plant and smelter general arrangement are shown in the drawings,
Figures 2 and 3. The primary particulate emission sources are the crushing
and screening operations and the reverberatory furnaces and converters. The
primary sources of sulfur dioxide are the reverberatory furnaces and the
converters. Ore source is from the local Kennecott open pit mine and is
primarily in sulfide form.
-1-
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b^ V*« SAFETY
3pTfrrr3:OFFicE
__.
rfjtSUSJssJl^
KCNNECOTT COPPER CORPORATION
T A L MINING. DIVISION
CHINO MINES DIVISION
HURUEY, NEW MEXICO a80*3
-------
. --- /
V "'vjs-"->«* ,'
'>--iW» v
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Figure 3
KENNECOtT COPPER CORP.
S DIVISION,1
*
GENERAL SMELTER L'AYOOt '
y v-' ' n y-y' ^--: r
-------
The smelter portion of the plant consists of the initial ore handling
and mixing equipment, rotary dryer, two reverberatory furnaces, four Peirce-
Smith converters, a fire refining furnace, a rotary lime kiln, and three
holding furnaces.
The pollution control equipment consists of multi-cyclones, rotoclones
and cyclones for the crushing and screening operations and the lime kiln.
Part (.40%) of the gases leaving the reverberatory furnace pass through a
precipitator for particulate control. The gases from the converters are
passed to a double contact sulfuric acid plant to control the SCL and are
conditioned before entering this plant by passing through precipitators
and scrubbers for particulate and temperature control.
Figure 2, showing overall plant site, indicates space for new control
equipment could be found adjacent to the acid plant on the slag dump.
Considerable additional area is available to the east of the smelter.
C. PROCESS DESCRIPTION
The smelter flow sheet diagram is shown in Figure 4. The feed in the
form of precipitates, concentrate, lime and flue dust is fed to a rotary
dryer which removes a major portion of the moisture to minimize excess
pressures in the reverberatory furnace. The partly dried material is then
passed to one of two reverberatory furnaces where it is processed to matte.
The reverberatory furnace uses preheated air, flux and fuel to produce slag
and matte.
The matte is then taken to the four converter lines where normally
three operate at any one time. The converters produce blister copper
which is then placed in a holding furnace and is further refined in the
refining furnace and cast into ingots. This is one of two smelters in the
United States that does not make copper anodes.
Gases from the rotary dryer pass through a cyclone and scrubber and
then out the stack. Gases from the reverberatory furnace pass through a
waste heat boiler, a precipitator and out the stack. Gases from the con-
verters pass to a gas cleaning system which consists of settling chambers, air to
-5-
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Inputs
300"F
Concentrates
Precipitates
Lime
Flue Dust
625'
Dryer off Gas
60,000 ACFM
350°F, 170°F D.P.
510'
200,000-260,000 SCFM
0.3-0.8% SO,
700F
JPrecipitatod
-JPrecipitatod
JPrecipitatoa
Air to Gas
Heat Exchanger
I
Settling
Chamber
Converter off GasS.
36,000 SCFM/ConverterN
108,000 SCFM Max. s
36,000 SCFM VA.-D../
4-4.5% SO.
PROCESS FLOW & SULFUR BALANCE
Kennecott Copper Co /Hurley Branch
prepared June ,1975
PACIFIC ENVIRONMENTAL SERVICES
Figure 4
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gas heat exchangers, precipitators, and scrubbers. The cleaned gases then
pass to a double contact sulfuric acid plant and then to the acid plant
stack.
Temperatures, volume flows, and SO- percentages are shown on the
flow sheet.
D. EMITTING EQUIPMENT
a. Reverberatory Furnaces
Two reverberatory furnaces are installed. Dimensions are 125 feet
long by 35 feet wide by 25 feet high. The draft for the furnace is generated
entirely by the stack. A top charge tripper system feeds the furnace which
takes a side^wall charge. Only one reverberatory furnace is operated at a
time. A suspended arch roof is used to facilitate repair during operation.
Oxygen quantities of 1 to 2 percent total gas volume are used for burner
combustion.
One reverberatory furnace is now down for refurbishing. This takes
approximately 8 months. If a long campaign is planned, the system must be
designed to handle maximum leakage on the last day of operation. Launders
will be covered completely with hooding in the new, reworked reverberatory
furnace.
Table I summarizes reverberatory furnace design data from Reference 3.
b. Converters
There are four Peirce-Smith converters 13 feet in diameter by 33 feet
long. Normally only three of these converters are active at one time with
the fourth being repaired. Each converter has a close-fitting water-cooled
hood with a sliding front door to aid in sealing when the converter is
rolled in. Only shut-off dampers are used for each hood system.
-7-
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TABLE I: REVERBURATOKY FURNACE DATA (Reference 3)
"'."-..I'.Ci; ar:E;:sio:cs
Length. Inside
Firing End
Flue End
Height Inside
Firine End '
Flue End
Side Wall Thickness
at Slag Line
Side Kail Thickness
above Slag Line
Roof Thickness
Area Gas Uptake
FIRING DATA
c
Amount of Fuel per Day
Fuel per Ton of Solid Charge
Fuel per Ton of Total Charge
Temp. Exit Gases
Per Cent Calories
Recovered in Steam
Is Automatic Draft Control used?
Type Waste Hoat Boilers
PP.Oil'JCT DATA
Depth Molten Charge
Tons Slag per 24 Hours
Method Slag Disposal
Tens Matte per 24 Hours
Vol. Gas per 24-Hour
Standard Condition
Per Cent Cu in Matte
121 Ft. 10 in.
28 ft. 8 in.
28 ft. 8 in.
11 ft. 5 in.
11 ft. 5 in.
4 ft. 3 in.
20 in.
20 in.
146 sq. ft. '
Natural gas
5,056,000
5,998
.
2408°F
51.54 .
No
Stirling, three pass and one pass
33 in.
539
Dumped hot
621
63,800,000 cu. ft.
34.85
"
I"-:":.'.I:TO-.:V DATA
Kind of uric!., I'.oof
Side Walls
Kcatth Material
Type and Location of Water
Cooling
CHARGE DATA PER 24 HOURS
Wt. Hot Calcine
Ut. Raw Concentrate
Av. Moisture in Raw Cone. Pet.
Kt. Crushed Ore
Wt. Flue Dust
Wt. and Nature of Flux
Wt. Liquid Converter Slag
V.tnere and How is Furnace Charged
Wt. and Nature of Fettling
Material
Silica
Silica
Crushed Quartzite slag cover
None
None
689 tons (dry)
8.74
None
9 tons
38 tons limerock
449 tons
77 tons copper precipitates
Vibrator conveyors
70 ft. along sidewalls
30 tons mine ore 70 pet. Si 0
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c. Other Emitting Equipment
Material handling in the feed preparation area during crushing and
screening operations generates particulate.
The refining furnace generates small quantities of SO , NO and
L X
particulate.
Leaks in ducts and at other pieces of equipment can release SO
and particulate.
Ladles holding matte and slag produce visible fugitive emissions.
The rotary dryer for processing the reverberatory furnace feed
produces particulate.
E. EXISTING CONTROL EQUIPMENT
The existing electrostatic precipitator installed to control the
particulate from the reverberatory furnace is considerably under capacity.
It was designed originally for 80,000 SCFM and there is over 200,000 SCFM
currently generated by the furnace. It is an American.Standard unit
(company not now in business).
Dimensions of the reverberatory furnace precipitator are 43 feet high,
50 feet in length, and 22 feet wide. It is stub-nosed against the reverbera-
tory furnace and connected with very little duct work. The inlet duct to
outlet duct dimension is 17 feet.
A Chemico 600-ton-per-day double contact sulfuric acid plant has been
installed and was started up in December 1974 to handle all of the gases
from the converter collection system. Gas conditioning before the acid
plant includes precipitators, scrubbers, drop-out chambers and heat exchangers.
The plant can handle a maximum short term load of 900 tons per day.
There were some problems with the preheater, however, the system seems to
be operating reasonably well at the present time.
Particulate control in the ore crushing and handling area is accom-
plished by multiple cyclones and rotoclones. The rotary dryer for reverb
feed uses a cyclone and scrubber.
-9-
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F. GAS SYSTEM DUCTWORK
A plan view of the reverberatory furnace gas system ductwork is shown
in Figure 5. Flue gases from the four waste heat boilers pass through
individual ducts into Flue No. 3. Sixty percent (by volume) of the gas flow
goes directly to Flue No. 5 and then to a 510 foot tall stack. The remaining
40% of the gas flow in Flue No. 3 passes through Flue No. 4 and into an electro-
static precipitator. Downstream of the precipitator, the cleaned gas rejoins
the bypassed gas in Flue No. 5 before entering the 510-foot stack. As seen
in Figure 6, an elevation view, Flue No. 3 is balloon-shaped, approximately
17.5 feet in diameter and 132 feet long. Flue No. 4 is 12 feet wide, 14.5
feet high, and 50 feet long.
Watercooled hoods collect the offgases from the four converters. The
converter offgas system ductwork is shown in Figure 7. Larger particles
are removed from the gases in a settling chamber. The gases then travel
through high velocity circular flues to air-cooled heat exchangers. The
cooled gases then pass through three parallel electrostatic precipitators.
The dust-free gases travel via round duct, 72 inches in diameter, to a
double contact acid plant. A manual bypass valve permits venting the dust-
free gases directly to a 625-foot tall stack in the event the acid plant
is down.
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT
Typical Sulfur Balance Data
Based on Data From Smelter Sulfur Balance Report:
Sulfur in TPD
Reverberatory 324.5
Secondaries 26.8
Total 351.3 (maximum estimated at 525 TPD)
Sulfur Fixed
Reverberatory slag 18.2
Sulfur that would
report to acid plant 196.5 Reference 4
Total 214.7
Sulfur emitted to atmosphere
Reverberatory offgas
plus fugitives 130.5
Acid plant emissions 6.1
Total 136.6
-10-
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No. 4
LI 11 H 71
No. 3
No. 2
No.l
Waste Heat Boilers
25' 32.5' 35' 32.5' 7'
50'
, 16'
N
132'
0 50'
SCALE
1" - 50'
PU\N
REVERBERATORS FURNACE GAS SYSTEM DUCIWRK
Kennecott/Hurley
June, 1975
PACIFIC ENVIIWEKTAL SERVICES
-ii-
Figure 5
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o '
53
0)
Waste Heat
Boiler Bldg.
§
O
cd ,
« I
El. 5723' &i
ri
^
L
Flue No. 4
X
14' 6'
ElfVATION (LOOKING Soum)
30'
SCALE
1" = 30'
FUENO, 3
Kennecott/Hurley
June, 1975
PACIFIC ENVHOierWL SERVICES
-12-
Flgure 6
-------
o
ss
M
0)
4J
M
0)
1
O
cS i 30-40' Elev. '
rfj
/
1
CM
O
M
0)
§1
«.
M
0)
§1
3
"CZJ
in
1
Bins
u
-
1
Flux Bii
r^
ConveyoO^
i
3 .
1
fl
m
i
7P
Coi
f\f
Settling
Chamber
High Velocity
Flue - Circular
80 Ft. Elev.
'' 3H2
' ^^ t1*^
\ 1
*'
L-
i
f- J
1
L
/*
D
X
ft
Cooling Air
T ^Blowers
Gas Coolers
Ele ctrostatic
Pre cipitators
Manual
Bypass
Valve
3 Blowers
Ground Level
Variable Speed
45,000 SCFM
6.5 - 7.0" W.C.
Acid
Plant
90 Ft. Elev.
fice
N
I ' i i ri * I t i I
0 50'
SCALE
1" - 50'
CONVERTER GAS SYSTEM DUCIWRK
Kennecott/Hurley
June, 1975
PACIFIC ENVIRMNTAL SERVICES
Figure 7
-13-
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Emissions stated in tons per year for the various pieces of equipment
studied are shown in Table II. Table III summaVizes stack test data. This
information taken from Reference 1 is somewhat contradictory to the data
obtained and accepted by the smelter; however, it appears to be typical
for water, SO., and oxygen content.
There is no evidence of chlorine, fluorine, arsenic, or other potentially
harmful constituents. Zinc, tin, iron, and copper particulates have been de-
tected and have been lumped into the particulate emission values shown in Table I.
The following is an estimate obtained from smelter personnel of the
gas and dust composition from the reverberatory furnace.
GAS DUST
CO 8.3% Cu 47.4%
S02 3.0% (High value) Fe 9.5%
H20 19.1% (High value) S 9.6%
N2 67.6% Si02 19.0%
02 2.0% A1203 2.1%
CaO 0.4%
Grain loading in the gases leaving one reverberatory furnace ranges
from 0.4 to 0.8 grains per ACF (0.9 to 1.7 gr/SCF). For short periods
(5-10 min.) 2.5-4.0 gr/SCF has been detected. Another estimate was noted
to be 0.97 gr/SCF maximum and 0.45 gr/SCF average. A puff situation
occurs which may generate from 0.3 to 1.5 gr/SCF.
-14-
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TABLE II. EMISSION SOURCE, CONTROL EQUIPMENT, CONTAMINANT A^D EMITTED QUANTITY
Type Unit
notary Dryer
Precipitate
Reverberatory
Furnace
Reverberatory
Furnace
Converter
Converter
Converter
Converter
Fire Refining
Furnace.
j Rotary
Line Kiln
| Hoi-din,;
Furnace
Holding
Furnace
Hold ing
. Furnace
Primary \
1 Crushing & \
-Screening )
Secondary \
Crushi:.s /
ar.j ?
Screening )
; Scr = e:-.ir.;;
S-ecr.ir.g
Screening
?,re,,,r.s
Type of Control
Equipment
Cyclone & Baffle Spray
Electrostatic Precipitator
Electrostatic
Precipitator
Settling Chamber
A/G Heat Exchanger Acid
Electrostatic Plant
Precipitators
Scrubbers
None
Cyclone
None
None
None
Mul tic lone
Mul tic lone
Rotoclone
Rotoclone
Rotoc lone
Rotcclone
Rotoclone
Plot ocioi-.e
Rot o*-. lone
xoco,:. .
Installation
Date
1965
1937
1950
1938
1938
1940
1972
1940
1941
1942
1943
1951
Type of Air
Contaminant
Particulate
Copper \
Zinc I
so2 >
Particulate '
Tin
Iron
so2 .
Particulate
Carbon, S02> N0x> Cu
SO
2
so2
so2
so.
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate .
Particulate
Particulate
Particulate
Particulace
Quantity E.*nittfed
Per Year (tons)
N/A
S02 - 102,000
Particulates - 275
SO. - 145,000 ) controlled by acid
. , , .. > plant uith 2,500 ppm
Particulates - 1,000 ( ^ <,-«.<-nI
f SO emissions
/ w"2 **>***
N/A
S/A
Estimated to be very low
S/A
N/A
S/A
107.9
1C.O
77.6
1.03
11.1
34.9
8.14
11.0
12.0
16.41
53.34
0.45
Ln
I
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TABLE III. EMISSIONS
REVERBERATORY FURNACE
Particulate
After Precipitator
so2
so3
NO
x
CO,,
Volume Flow
CONVERTERS
Particulate
After Precipitator
so2
so3
NO
x
co2
°2
Volume Flow
Volume Flow out stack
Dilution
25.6 TPD
18.72 TPD
242 TPD = 1.07%
4.5 TPD
3.38 ppm
5.5 % b.v.
2.0 % b.v.
17.2 % b.v.
176,000 SCFM «§ 70°F)
8.15 TPD
5.68 TPD
489 TPD
1.4 TPD
1.96 ppm
2.3
.5
19.7
% b.v.
% b.v.
% b.v.
130,860
200,000
SCFM (@ 70 F)
SCFM
69,000 SCFM
Reference 1.
-16-
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Later data than the above supplied by the smelter personnel Indicated
the following for the furnace emissions:
FURNACE EMISSIONS
Particulate 27 TPD
HO 4.0% to 7.0% b.v.
S02 7400-8700 PPM
SO 220 PPM
C02 2.0% b.v.
02 17.0%
NO 1.0-7.0 PPM
x
SO 550 Ibs/hr (sulfuric acid mist)
HO 5%-7% b.v.
Cl none
F_ none
NO none
x
Arsenic, Selenium, and Zinc mostly in
the form of Sulfides. Lead tied up
in the slag.
Particulate size range is currently being investigated and is not
available.
-17-
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PARTICULATE OUT OF REVERBERATORY FURNACE
Element
Cu
Fe
Mo
Pb
Si Approx.
Al
As
Ba
Hg
Mg
Mn
Ni
Sn
W
Zn
/« D . W .
1-25
2-20
.1 - .5
.2 - 2.0
60.0.
2.0
.01 - .15
.5
None
.2
.01
.001 - .02
.1 - 1.0
None
2.0 - 30
95% thru 200 mesh
SO
y
SO.
SO,
246 short tons
242 98.4%
4 1.6%
Reference 5
-18-
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H. GAS CHARACTERISTIC VARIATION
It can be expected that SO 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 SO 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.
SO concentration in the converter offgas will also vary considerably
for an entirely different reason. The operation of a converter usually
includes 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 to the
acid plant. An attempt is always made to maintain at least one converter
blowing gases into the system at any given time. Usually 18,000 to 20,000
SCFM will be introduced to the converter tuyeres. Additionally, 100 to 120%
dilution air is added to this gas flow resulting in a total gas flow from
each converter in the range of 35,000 to 40,000 SCFM. When a converter is
blowing there will usually be approximately 38,000 SCFM with an SO content
in the range of 4.0 to 4.5%
Because of the normal fluctuation in converter feed and operation,
the SO concentration can vary over a relatively wide range. In addition,
the gas volume flow from the converter line to the control system acid
plant can usually vary over a wide range from maximum to zero. Operation
of the control system must be conducted in a manner to compensate for
these fluctuations. Acid plant operation at this smelter appears to be
typical providing reasonably satisfactory control. Significant on-time
data have not yet been accumulated because of the relatively short time
the plant has been in operation.
-19-
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I. STACK DESCRIPTION
Reverberatory Stack
Height 510 feet
Diameter 26 feet
Draft 24.2" Hg Absolute
Acid brick lined
Converter Stack
Height 625 feet
Diameter 33 feet
Draft This stack presently not being used.
Acid brick lined
Acid Plant Stack
Height 200 feet
Diameter 10 feet
Draft (forced)
Steel
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING
Slag from the reverberatory furnace is taken to the slag dump. Dust
from the precipitator in the converter gas cleaning system is taken by
screw conveyor into a pug mill where it is processed to allow
handling for feeding to the reverberatory furnace via loaders.
K. FOOTING AND STRUCTURAL REQUIREMENTS
If construction is to be carried out in some areas, footing tests
would be required. A major portion of the area adjacent to the smelter is
old slag dumps. It will be necessary to conduct footing tests to determine
detailed footing requirements. However, if slag is assumed for determining
footings, then the most conservative (highest cost) estimate will result.
There is also a large amount of consolidated rock in the area.
-20-
-------
No local codes apply. Seismic zone 2, 20 PSF wind load and 20 PSF
snow load are used for design.
L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES
The smelter produces its own electricity. They have recently added
30 megawatt capacity. This leaves approximately 15 megawatts available
above that presently being used.
Water is obtained from wells. There does not appear to be a limitation
on availability of water. A new pumping system would be required if a
large quantity of additional water is used.
There is no additional gas available for fuel. If additional fuel is
required, oil must be used.
Steam generated by the smelter is used for electrical power generation.
M. POTENTIAL NEW CONTROL EQUIPMENT INSTALLATION PROBLEMS
The existing precipitator on the reverberatory furnaces is designed
for 80,000 SCFM. Since gas flow is currently in the range of 200,000 SCFM,
it will be necessary to add additional particulate collection capability.
This could be done by either removing the existing units and replacing with
one of larger capacity or adding to these units to match the total gas flow.
Since the precipitator is old, it would be advisable to replace it.
-21-
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REFERENCES
1. "Source Emissions Survey of Kennecott Copper Corporation Copper Smelter
Converter Stack Inlet and Outlet and Reverberatory
Electrostatic Precipitation Inlet and Outlet, Hurley,
New Mexico, April 1973," File Number EA 735-09,
Ecology Audits, Inc.
2. "Air Quality Source Sampling Report #44, Kennecott Copper Corporation
Hurley Smelter Reverberatory Furnace," March 27, 1974,
Environmental Improvement Agency.
3. "Outline of Metallurgical Practice," C. A. Haward, D. Von Nostrand
& Co., Third Edition, 1952.
4. Kennecott Copper Corp., Chino Mines Division "Average Tons
Su.lfer per Day" EC/MM/9 Jan 75
Kennecott Copper Corp., Chino Mines Division Data.
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TECHNICAL REPORT DATA
(Please read Inunctions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-036d
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Design and Operating Parameters for Emission
Control Studies :Kennecott, Hurley, 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. Serne
9. PERFORMING ORG -vNIZATION 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 rpjie repOr^ gjves background design data for a specific copper smelter.
The data is sufficiently detailed to allow air pollution control system engineering
studies to be conducted. These studies will be concerned primarily with lean SO2
streams that currently are not being captured. Physical layout of the smelter and
the surrounding area is presented, along with existing control equipment. Ductwork
that would be considered for future system tie-in is defined. Emissions from
operating equipment, gas flow rates, temperatures, sulfur balance, and a process
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 Report)
Unclassified
21. NO. OF PAGES
26
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
GPA Form 2220-1 (9-73)
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