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
                                 -4-

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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
                                 -7-

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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
                                 -8-

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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
                                 -9-

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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%
                                  -10-

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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%
                           -11-

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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.
                           -12-

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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%
                          -13-

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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.
                                -14-

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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.
                             -15-

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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.
                             -16-

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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.
                                -17-

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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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