EPA-600/2-76-036e
February 1976
Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
Magma, San Manuel, Copper Smelter
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Tiiangle 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
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-600/2-76-036e
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
MAGMA, SAN MANUEL, COPPER SMELTER
by
I. J. Weisenberg and J. C. Serne
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, California 90404
Contract No. 68-02-1405, Task 5
ROAP No. 21ADC-061
Program Element No. 1AB013
EPA Project Officer: R. D. Rovang
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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TABLE OF CONTENTS
Page
A. INTRODUCTION AND SUMMARY 1
B. PLANT LOCATION ACCESS AND OVERALL GENERAL ARRANGEMENT ... 1
C. PROCESS DESCRIPTION 4
D. EMITTING EQUIPMENT 7
a. Reverberatory Furnaces 7
b. Converters 7
c. Other Emitting Equipment 8
E. EXISTING CONTROL EQUIPMENT 8
F. GAS SYSTEM DUCTWORK 10
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT 10
H. GAS CHARACTERISTIC VARIATION 14
I. STACK DESCRIPTION 14
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING 15
K. FOOTING AND STRUCTURAL REQUIREMENTS 15
L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES 15
M. POTENTIAL NEW CONTROL EQUIPMENT PROBLEMS 15
REFERENCES 17
LIST OF FIGURES
FIGURE 1. GENERAL AREA MAP 2
FIGURE 2. OVERALL PLANT AND GENERAL ARRANGEMENT
(Located in Pocket Inside Back Cover)
FIGURE 3. SAN MANUEL DIVISION SMELTER FLOW SHEET 5
FIGURE 4. PROCESS FLOW & SULFUR BALANCE SHEET 6
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A, INTRODUCTION AND SUMMARY
The purpose of this report is to present background design data
on the Magma Copper Company Smelter, San Manuel Division at San Manuel
Arizona in sufficient detail to allow air pollution control system
engineering studies to be conducted. These studies are primarily
concerned with lean SCL streams that are currently not being captured.
Physical layout of the plant 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. Avail-
able area for new control equipment, gas characteristic variation
and potential new control equipment installation problems are dis-
cussed.
The major uncontrolled source of SO- at this smelter are the
three reverberatory furnaces with approximately 92,000 tons per year
of SO- and 570 tons per year of particulate. There appears to be some
additional space for new control equipment within the smelter area
but not necessarily adjacent to the emitting equipment.
B, PLANT LOCATION ACCESS AND OVERALL GENERAL ARRANGEMENT
The Magma Copper Company Smelter is located to the northeast
and adjacent to the town of San Manuel, Arizona. A portion of the
USGS map showing land contours of the immediate area is presented
in Figure 1. Design altitude for the plant is 3,200 feet with lati-
tude 32° 37' and longitude 110° 37'.
The overall plant and smelter general arrangement are shown
in Figure 2. 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
-1-
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IKW30*
540
1000 2000 3000 4000 5000 6000 7000 FEET
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Figure 2
OVERALL PLANT AND GENERAL ARRANGEMENT
(Located in Pocket Inside Back Cover)
-3 -
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reverberatory furnaces and converters. Ore source is from the local
San Manuel Mine, an underground mine. Additional concentrate feed is
obtained from outside sources.
The Magma San Manuel smelter consists of three reverberatory
furnaces with six converters. A seventh converter may be added at a later
date if the need is indicated. The output from the converters is
taken to the anode furnaces which supply the casting wheels for
casting the anodes. Figure 3 is a smelter flow sheet schematic. (Ref. 1)
The pollution control equipment consists of electrostatic pre-
cipitators for cleaning the offgases from the reverberatory furnaces
and additional electrostatic precipitators for cleaning the offgases
from the converters. No S0_ control of the reverberatory furnace
offgases is accomplished. A 2,400 ton per day single contact sulfuric
acid plant collecting SO,, from the converter offgases was recently
started up. In addition, a separate system has been established to
neutralize the liquid effluent from the scrubber and other acid plant
sources.
Figure 2 showing the overall plant site indicates space for new
control equipment could be found to the northwest of the smelter
building. The area southeast of the smelter building could be used if
an alternate area for emergency concentrate storage could be established.
C, PROCESS DESCRIPTION
The smelter flow sheet diagram is shown in Figure 4. The feed in
the form of precipitates, concentrate, lime, flux,and flue dust is fed
to one of the three reverberatory furnaces. Matte is produced in the
reverberatory furnaces and is passed to one of the six converters which
produce blister copper for further refining in the anode furnace. Copper
from the anode furnace is then used to cast anodes. Gases from the
reverberatory furnace pass through waste heat boilers, electrostatic
precipitators and then out the stack. Gases from the converters pass
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mAsrriA
San Manuel Division
Smelter Flow Sheet
SOLID FLOW
SAN MANUEL CONCENTRATE
OUTSIDE CONCENTRATE
FLUX
MOLTEN FLOW
GAS FLOW __«»»^. LIQUID FLOW
SILICA ROCK
AND SULFIDE ORE
CONCENTRATES
AND LIMEROCK
BINS
6 SAN MANUEL CONCENTRATE a 500 TONS
6 OUTSIDE CONCENTRATE 3 500 TONS
6 FLUX 3 375 TONS
RECYCLED DUST
PREHEATED AIR
NATURAL GAS
fcoNVERTER
SLAG
AIR
REVERBERATORY FURNACES
NO. 1: 32 FT. X 102 FT. INSIDE
NO. 2: 31 FT. X 102 FT. INSIDE
NO. 3: 36 FT. x 102 FT. INSIDE \
2 WASTE HEAT
BOILERS PER
FURNACE
ELECTROSTATIC
PRECIPITATOR
MATTE LADLE
300 CUBIC FEET
515 FT. STACK
SLAG POT
REVERBERATORY
SLAG TO DUMP
MATTE
ELECTROSTATIC
PRECIPITATOR
380 CUBIC FEET
SCRUBBER
2 STACKS
200 FEET
BLISTER
COPPER
3-13 FT. X 35 FT.
2-15 FT. x 35 FT.
DUST TO REVERBERATOR IES
NEUTRALIZATION
PLANT FOR
EXCESS ACID
AIR
REFORMED
GAS
REFINING VESSELS
2 - 13 FT. x 35 FT.
2 - 13 FT. x 30 FT.
CASTING WHEELS
1 - 45 FT, DIAMETER, 28 MOLDS
1 - 34 FT. DIAMETER, 22 MOLDS
SULFUR 1C ACID
TO MARKET
f— AIR
REFORMED
GAS
TO SAN MANUEL REFINERY
TO OUTSIDE REFINERY
Figure 3
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Process Flow & Sulfur Balance Sheet
Magma Copper Co./San Manuel Nov., 1975
3150 TPD Charge
30-32% S
950 TPD-S
Pacific Environmental Services. Inc.
/Reverb Off-Gas
J 350,000-450,000 SCFM
I 0.5-1.0% SO
Reverb Slag to Dump
2431 TPD
Flux - 616 TPD
4 IPD-S
Cold Dope & Refinery Scrap
125 TPD
(2 parallel S.C
Scrubber Effluent
1200 TPD Sol'n
19.8 TPD-S
Acid Plant Tall
Gas
187,000 SCFM
0.11% SO-
13.1 TPD^S
7300 SCF7-! .032 Sc-
0.13 TPD-S
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through water cooled hoods to electrostatic precipitators, then to
scrubbing towers, mist precipitators and finally a Monsanto single
contact acid plant.
Temperatures, volume flows, and S09 percentages are shown on
the flow sheet.
D, EMITTING EQUIPMENT
a. Reverberatory Furnaces
The initial copper concentrate containing approximately 28% copper
is fed to three natural gas or oil fired top charged reverberatory
furnaces all 102 feet long by 32 feet, 34 feet and 36 feet wide
respectively. The reverberatory furnaces have suspended roofs with
sealing materials such as ceramic fiber, mud or asbestos packed along
the joint. The roof is anchored with tie rods suspended from the
ceiling.
Magma normally operates three reverberatory furnaces at full
capacity at all times. The reverberatory furnaces are fed from the
top along the front 60% of the furnace side walls. Two air preheaters
capable of operating on either No. 2 fuel oil or natural gas are used to
preheat the air going to the reverberatory furnace burners. This allows
an increase in the gas temperature and also combustion efficiency. It
is necessary to have at least 60% fire to the reverberatory furnace to
maintain temperature. A five year campaign is presently being conducted
on the furnaces before reworking is required. The processes occurring
within the reverberatory furnace are controlled by adjusting draft, fuel
input, fuel air ratio, and feed scheduling.
b. Converters
The matte produced by the reverberatory furnace containing 32 to
35% copper is processed in three 13 foot by 35 foot and three 15 foot
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by 35 foot Peirce-Smith type converters. Converter slag is returned
to the reverberatory furnace and blister copper is delivered to four
anode holding furnaces.
The 15 foot by 35 foot converters use an air supply varying from
30,000 to 45,000 SCFM. Scheduling of the converters to maintain a
more or less constant flow of S0? to the acid plant is attempted. A
single charge will remain in the converter for a period of about twelve
hours. There are four or more slag blows of about 1% hours each and
one finish blow. Oxygen has been used at a rate of up to 30 TPD at
times in converter blowing air to increase the heat available allowing
cold dope addition.
c. Other Emitting Equipment
Material handling in the feed preparation area during crushing
and screening operations generates particulate. The anode/refining
furnace generates small quantities of S0? and particulate.
Leaks in ducts and at other pieces of equipment can release
SO. and particulate. Ladles holding matte and slag will produce
visible fugitive emissions.
The acid plant will also produce S02 emissions.
E, EXISTING CONTROL EQUIPMENT
Gases from the three reverberatory furnaces, after passing
through the waste heat boilers, are combined and enter an electro-
static precipitator. Gases from the precipitator then pass directly
to the 515 foot reverberatory furnace stack. Dust from the precipi-
tator is combined with lime and is processed in a pug mill and returned
to the reverberatory furnace feed.
Gases from the converters enter water cooled hoods over each
converter. The gases are then ducted together and enter a radiation/
conduction cooler which simply consists of a duct sized to provide
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7,000 FPM gas velocity. Total gas flow from the converters t,o the
acid plant varies from 154,000 to 200,000 SCFM. At this range of
flow the gases are cooled from an inlet temperature of 1200 F down
to 400°F to 500°F at the outlet of the cooler. They then pass into
a precipitator which removes a major portion of the particulate matter.
The converter gases then go to a 2,400 TPD sulfuric acid plant.
The gases average 5.5% SO-. The Monsanto single contact acid plant
was completed in January, 1975 and is currently in operation. It is
designed to be converted to double contact. The gases are further
cleaned, after going through the precipitator, by passing to one
unpacked and one packed cooling tower that have weak acid flowing
through to provide humidification and cooling. From the packed towers
the gas, which will be at a maximum temperature of 140 F and will
average 100 F, passes to six mist precipitators in a parallel series
circuit. From the mist precipitators, the gas is passed to the dryer
where the moisture is absorbed in concentrated acid. The gas is then
passed through demisters and on into the S09 to SO converter which has
four conventional stages with three inner stage heat exchangers that use
incoming gas to cool the outgoing gas.
One special feature of this plant is that there are two parallel
trains starting downstream of the packed cooling tower and following
through to the end of the acid plant. This design allows shut down
of one side for maintenance while the other side continues to operate.
In addition, each side has a preheater that is designed to "float"
on line. The preheater controls the gas temperature into the first pass
of the converter. If the concentration of SO.- in the gas stream is too
low, for example, for autogenous operation, the burner will immediately
and automatically turn up providing additional heat for efficient
conversion. The burner is semi-automatic and will stop and start on
the temperature signal from the converters.
Carbate heat exchangers are used for cooling the weak acid. In
addition, Teflon "spaghetti" coolers are used for cooling the strong
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product acid. An air cooled evaporation cooling tower is used to cool
all process cooling water.
Fiberglass reinforced plastic (FRP) is used for ductwork throughout
to handle the wet S0_ laden gases up to the dryer. There are three main
blowers for the process gas system with one being used as a standby unit.
Each blower has a 6,000 horsepower motor and individual pressurized
lubrication system.
A neutralization plant is available to neutralize excess acid produced.
This plant uses the concentrate tailings since they are basic and have a
major portion of the material necessary to neutralize the acid. When total
acid to be neutralized exceeds the quantity the basic mill tails can
neutralize, lime rock slurry must be added. The neutralization system is
used when the total amount of acid produced cannot be sold or exceeds
storage capacity. Up to 800 TPD has been neutralized.
F, GAS SYSTEM DUCTWORK
Sufficient information was not obtained from the smelter to define
ductwork.
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT
1. Maximum Sulfur Balance Data Based on Enlarged Capacity
Of 1,125,000 Tons of Concentrate Per Year Based on Data
From Smelter (Reference 2)
TPD
Sulfur Input 954
Sulfur Emitted by Reverberatory Furnaces 259
Sulfur Emitted by Converters 660.9
Sulfur Removed in Slag 34.0
Sulfur Removed in Blister Copper .15
Sulfur Fixed
Acid Plant 647.8
Slag and Solid Waste 34.0
681.8
Sulfur Fixed 71.5%
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2. Sulfur Balance Data For August 1973 Throuph July 1974
Based On Average Production Of 750,000 Tons Concentrate
Per Year (Reference 3)
32.07% sulfur in concentrate, average (660 TPD)
Sulfur lost:
In slag
In blister copper
In reverb gas
In converter gas
TPD
23.97
0.10
181.59
454.55
660.21 total
% of Total Sulfur
3.630%
0.015%
27.505%
68.850%
100.000% total
Sulfur lost in fugitive emissions: less than 2.5% of total sulfur,
or less than 16.5 TPD
Sulfur lost in acid plant sludge: not applicable
Sulfur converted to H~SO,: not applicable
Sulfur emitted from reverberatory furnaces: 181.59 TPD
Sulfur emitted from roasters: not applicable
Sulfur emitted from converters: 454.55 TPD
3. Reverberatory Flue Gas Analysis (Reference 4)
so
co
N
0.7 - 1.0%
8.3%
69.71%
19.24%
10-15%
4. Converter Flue Gas Analysis During Slag Blow (Reference 4)
so,
»2
2
9-10%
82.27%
10.65%
5. Converter Flue Gas Analysis During Finish Blow (Reference 4)
SO,
N,,
13-14%
79.14%
10.43%
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6. Range of Converter Gas Constituents
Constituent Percent Range
SO 5.0 to 14.0
SO .15 to .16
02 8.6 to 12.9
N2 78.75 to 82.27
HO 0 to 2.6
Traces of chlorine, fluorine, arsenic, antimony, bismuth
s lenium, chromium, zinc, and lead with maximum dust loading
of 0.5 grains per SCF.
Trace Element Range
Chlorides or Chlorine 10-30 ppm b.v.
Fluorine or Fluorides 25-50 ppm b.v.
7. Gas Reformer Gas (Reference 4)
Combustion Products - C0~, HO
Process Gas - H , CO, CO , N
Reformer gas is used to provide a reducing atmosphere for final
refining in anode furnace.
The anode furnace generates combustion products which go to
the atmosphere with a negligible SO concentration and primarily
CO- and HO. This is also true for the.air preheater.
8. Particulate Analysis
Copper (as CuO) 10-15% b.w.
Iron (mostly Fe (SO ) ) 10-20% b.w.
Arsenic .04 - 0.6% b.w.
Selenium .03 - 0.5% b.w.
Tellurium .005 - .01% b.w.
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9. Particulate Analysis (Reference 5)
Compound
Copper
Iron
Sulfur
sio2
CaO
A1203
Zn
Pb
Trace Elements
Average % b,w,
18.3%
11.2%
12.13%
. 4.9%
1.05%
0.39%
9.4%
2c *v
• J /o
L.T. 2%
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H, GAS CHARACTERISTIC VARIATION
The S07 concentrations in the offgas from the reverberatory
furnace will vary significantly depending upon the charge rate
and the various sulfide materials contained in the charge. The
normal or average charge rate into the furnace can vary as much as
4 to 1 over a period of time. This variation is a result of normal
smelter operation and can be controlled only to a limited extent.
S0_ concentration in the converter offgas also varies considerably
because of the batch nature of the operation. Also, the variation in
actual metallurgical operation between slag blows and copper blows will
cause a variation in percent S0_. (See Section G). Between blows
the converter may be rolled out for slag pouring or material charging.
The attempt is always made to maintain at least two converters
blowing gases into the system at any given time. Usually a converter
will be provided with 18,000 to 20,000 SCFM to the tuyeres. An
additional 100-120% of dilution air is generally estimated to be
added to this gas flow resulting in a total gas flow from each con-
verter in the range of 35,000 - 45,000 SCFM. Thus, the gas volume
from the converter line to the control system acid plant and liquid
SO- plant can vary over a wide range from maximum to zero.
STACK DESCRIPTION
Reverberatory Furnace Stack
Height 515 feet
Inside diameter 20.8 feet (top)
Inside diameter 30 feet (base)
Gas exit temperature 450 - 500° Fahrenheit
Acid brick lined
Draft at Base 2.6" w.c.
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Converter Stack
Stack height 550 feet
Inside diameter 20.0 feet (top)
Exit temperature 4'
Draft -2.5" W.C.
Exit temperature 450 - 500° Fahrenheit
Acid Plant Stacks (2)
Height 250 feet
Diameter 10 feet
Draft (forced) +10.0" W.C.
Steel
J, PRESENT TECHNIQUE FOR SOLID WASTE HANDLING
Slag from the reverberatory furnaces is taken by ladle car to
the dump. Dust from the reverberatory furnace gas precipitator is
treated in a pug mill and then recycled through the bedding plant
and added to furnace feed. Dust from the converter gas precipitator
is taken by truck to the bedding plant for recycle to the furnace.
K, FOOTING AND STRUCTURAL REQUIREMENTS
Seismic zone 2 and wind load 20 PSF are used for design.
Ambient temperature range is 110 F to -20 F.
L, EXISTING AND POTENTIALLY AVAILABLE UTILITIES
Water is supplied from wells. It can be expected that future
supplies of fuel gas in this area will be limited. Plans for handling
and burning coal are currently being formulated. Electricity should
be sufficiently abundant for most control requirements with the possible
exception of use of an electric furnace to replace the reverberatory
furnace.
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M. POTENTIAL NEW CONTROL EQUIPMENT PROBLEMS
The variation of emissions could limit control system
effectiveness. It appears that the area adjacent to the smelter
is sufficient to allow installation of new control systems.
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REFERENCES
1. Magma Copper Company
2. Magma Copper Company - San Manuel Smelter - Smelter Flow Sheet
3. Letter to Mr. P.M. Covington, EPA from Mr. W.L. Parks, Magma
Copper Co. dated September 11, 1974
4. Smelter material balance 4th Qtr. 1971
5. Letter from T.E. Hearon, Magma to I.J. Weisenberg PES,
October 8, 1975.
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-036e
2.
3. RECIPIENT'S ACCESSION>NO.
4. TITLE AND SUBTITLE
Design and Operating Parameters for Emission
Control Studies: Magma, San Manuel, Copper Smelter
5. REPORT DATE
February 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
B. PERFORMING ORGANIZATION REPORT NO.
I.J. Weisenberg and J. C. Seme
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, CA 90404
10. PROGRAM ELEMENT NO.
1AB013; ROAP 21ADC-061
11. CONTRACT/GRANT NO.
68-02-1405, TaskS
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 4-10/75
14. SPONSORING AGENCY CODE
EPA-ORD
16. SUPPLEMENTARY NOTES
EPA Task Officer for this report is R.Rovang, 919/549-8411, Ext 2557.
i6. ABSTRACT
rep01^ 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
flow sheet are included. Utilities , stack dimensions , footing requirements , and
solid waste handling are defined. Available area for new control equipment, gas
characteristic variation, and potential new control equipment installation
problems are discussed.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Copper
Smelters
Design
Sulfur Dioxide
Utilities
Air Pollution Control
Stationary Sources
Emission Control
Operating Data
Solid Waste Handling
Wastes
13B
07B
11F
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
20
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
18
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