ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
KENNECOTT
HAYDEN
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
EJBD DENVER. COLORADO
ARCHIVE
EPA ,
331- I
R- ?j
006
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E3BO
AftUWfi
32»l-
STATE IMPLEMENTATION PLAN
INSPECTION OF
KENNECOTT COPPER CORPORATION
RAY MINES DIVISION SMELTER
HAYDEN/ ARIZONA
C<1
§5
3
JULY 1976
US EPA
Headquarters and Chemical Libraries
EPA West Bldg Room 3340
Mailcode 3404T
1301 Constitution Ave NW
Washington DC 20004
202-566-0556
Repository Material
Jermanent Collection
ENVIRONMENTAL PROTECTION AGENCY
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Denver
OFFICE OF AIR QUALITY PLANNING AND STANDARDS
Durham
REGION IX
San Francisco
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CONTENTS
INTRODUCTION •. . . 1
PROCESS DESCRIPTION 2
EMISSION SOURCES AND RELATED
CONTROL EQUIPMENT 6
EMISSIONS DATA . . . 10
BIBLIOGRAPHY 14
TABLES
1 Smelter Process Equipment
and Operating Data 4
2 Smelter Air Pollution Control
Equipment and Operating Data .... 8
3 Particulate Matter Emissions Test
Results 13
FIGURES
1 Kennecott, Hayden Process Flow
Diagram 3
2 Kennecott, Hayden Plant Layout,
Process Exhaust Flow and Air
Pollution Control Systems 7
APPENDICES
A NEIC Information Request
Letter to Kennecott
B Kennecott Response to
NEIC Information Request
C SIP Regulation Applicable to
Kennecott
D Example Calculations of Gas Flow
Rates and Equivalent Duct
Diameters
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KENNECOTT COPPER COMPANY
RAY MINES DIVISIDN SMELTER
HAYDEN, ARIZONA
SUMMARY AND CONCLUSIONS
Kennecott Copper Corporation (KCC) operates a mine at Ray, Arizona
and a concentrator and smelter at Hayden, Arizona. An inspection to
acquire data with which to evaluate the operation of existing process
and particulate matter air pollution control equipment at the smelter
was conducted by EPA personnel on January 28, 1976. Substantial amounts
of process and control equipment information were requested of, and
received from, Kennecott.
The following conclusions are based on the inspection and a review
of the information obtained.
1. The Ray Mines Division smelter is one of the two Arizona
smelters which has a fluo-solids roaster. It is also the only
conventional smelter, excluding Inspiration, which demonstrates
compliance with the process weight regulation.
2. This smelter is the only Arizona smelter which has discontinued
returning converter slag to the reverberatory furnace and has
made a concerted effort to seal all holes and leaks in the
reverberatory furnace to minimize infiltration air. This
practice reduces the gas volume which must be handled by the
air pollution control system.
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3. The control systems are well operated such that the smelter Is
in compliance with the Arizona process weight regulation.
Both the Engineer Testing Laboratories (ETL) 1974 and the KCC
1975 source tests show compliance.
4. Both the ETL and KCC source tests should have used 16 traverse
points, 8 on each diameter, since a downstream flow disturbance
exists less than 8 stack diameters from the sampling station.
5. This Company is the only Arizona smelter company which has the
air pollution control activities explicitly vested in an
organizational unit separate from the production staff. The
Company's compliance achievement record demonstrates a recognition
of more than a single objective - copper production. An
organizational structure reflecting the duel objectives -
copper production and air pollution control - provides a
management mechanism to assure optimization of both objectives.
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INSPECTION OF
KENNECOTT COPPER COMPANY
RAY MINES DIVISION
Hayden, Arizona
January 28, 1976
602/356-7811
INTRODUCTION
The Ray Mines Division of Kennecott Copper Corporation operates a
mine at Ray, Arizona and a concentrator and smelter at Hayden, Arizona
to produce anode copper from concentrates and precipitates. Average
anode copper production during 1975 was 222 m. tons (255 tons)/day.
On December 17, 1975, the general manager of Kennecott was re-
quested by letter to provide process and air pollution control information
on the Ray Mines Division Smelter and informed of a planned plant
Inspection [Appendix A]. On January 28, 1976, the following EPA personnel
conducted a process inspection: Mr. Larry Bowerman, USEPA, Region IX;
Mr. Reid Iversen, USEPA, ESED; Mr. Gary D. Young, USEPA, NEIC; Mr. Jim
V. Rouse, USEPA, NEIC. The data requested were furnished the day
following the completion of the inspection [Appendix B].
The purpose of the inspection was to acquire data with which to
evaluate the design and operation of existing particulate matter air
pollution control equipment. The inspection team examined the process
equipment, the particulate matter emission sources, and the air pollution
control equipment, focusing primarily on the smelter.
Company personnel were cooperative throughout the inspection. All
the information requested was supplied at the completion of the inspection
or by subsequent letter or telephone call. Company personnel participating
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Included: Mr. K. H. Matheson, Jr., General Manager; Mr. J. S. Nebeker,
Reduction Plant Superintendent; Mr. J. E. Stocker, Smelter Superintendent;
Mr. J. T. Mortimer, Director of Safety and Environmental Control; and
Mr. Clint Fitch.
The applicable regulation contained in the Arizona State Implemen-
tation Plan (SIP) of specific interest for this inspection was the
process weight regulation [Appendix C]. This regulation was promulgated
as 40 CFR § 52.126 on May 14, 1973, to replace the State's process
weight regulation, which was determined by EPA to be not sufficiently
stringent. The regulation provides for an allowable emission rate for
each process unit based on the production feed rate to the unit.
PROCESS DESCRIPTION
Figure 1 is a simplified process flow diagram for the smelter.
Table 1 is a list of the smelter process equipment and operating data.
Concentrate and precipitates are delivered from the concentrator
and blended with silica flux. The blended materials are then fed to the
fluo-solids roaster by a screw feeder which controls the feed rate and
maintains a seal for the roaster. Air is supplied through tuyeres at
the bottom of the roaster to maintain the blended feed (solids) in a
fluidized state. The reaction is exothermic, and except for cold
startup, requires no auxiliary fuel.
As a result of the reaction between the fluidizing air and the
blended feed, sulfur is oxidized to S02 and the feed is reduced to
calcine. Approximately 50% of the total sulfur in the feed is converted
to S02. Most of the calcine produced (85%) leaves the reactor as dust
suspended in a gas stream. The gases pass through a series of primary
and secondary cyclones, an integral part of the process, from which an
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FLUOSOLIDS
REACTOR
ONVERTERS
(3)
SILICA FLUX
CASTING WHEEL
Figure I. K«nnecoff,
Hoyden
Process Flow Diagram
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Table 2
SHELTER PROCESS EQUIPMENT AND OPERATING DATA
KENNECOTT COPPER CORPORATION
Say den, Arizona
Parameter
No. of Units
Feed Constituents*
Feed Rate
Co
P
F.
TOTAL
Size of Unit
Hours of Operation/month
Gas Volume Generated
•
Exit Gas Temperature
i
Roaster
1
Co. P, F
m. ton/day ton/day
906 998
23 25
121 133
1.050 1.156
Not Reported
561
m /mln scfm
670 23.700
i
°C °F
566 1.050
Reverberatory
1
Ca.
m. ton/day
Ca 1 .046
F 40
1.086
meters
width 9
length 30
Furnace
F
ton/day
1.152
44
1.196
feet
30
100
624
m /min
3.440
°C
260
scfm
121.600
°F
500
Converters
3
M. CD. F
m. ton/day ton/day
M 652 718
CD 45 50
F 73 80
770 848
meters feet
diameter 4 13
length 9 30
650+t
m /mln scfm
2*140 75,400
°C °F
621 1 ,151
t Concentrate (Co), precipitates (P), flux (silica) (F), calcine (Ca), matte (M), cold dope (CD)
tt Time too converters are on bloa concurrently.
ttt Standard conditions are 29.92 in Sg (14.7 psia) and 21°C (70°F)
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estimated 95% of the solids (calcine) are collected and conveyed to the
calcine bin by a screw conveyor. The remainder of the calcine produced
(15%) is drawn off through an underflow valve and conveyed to the
calcine bin by a drag chain.
From the calcine bins, the calcine and flux are fed to the single
reverberatory furnace. The reverberatory furnace is 30 m (100 ft) long
and 9 m (30 ft) wide and is a suspended arch design. The furnace is fed
through two openings at the top by a pair of Wagstaff feeders. The
calcine drops from the calcine bins through the feeders which feed the
furnace for two minutes in every fifteen minutes. Since the furnace
operates under a slightly negative pressure when the Wagstaff feeders
are not in operation, the furnace openings are closed to prevent air
infiltration. The furnace is normally fired with natural gas, but if
natural gas delivery is interrupted, fuel oil is used. Slag is tapped
near one end of the reverberatory furnace into 14 m. ton (15 ton) capacity
steel pots mounted on rail cars that haul the slag to the slag dump.
Matte is tapped into 18 m. ton (20 ton) capacity steel ladles resting on
a pallet which is then moved into the converter aisle.
The matte ladles are picked up by overhead crane and charged to one
of three Fierce-Smith 4 x 9 m (13 x 30 ft) converters. Air is blown
through tuyeres into the charge, flux is added, and slag produced is
skimmed into a ladle. Present Kennecott practice is to have two converters
on charge concurrently, each on blow 50% of the time. Although Kennecott
used to operate like the other smelters in Arizona, converter slag is no
longer returned to the reverberatory furnace, but is truck hauled to a
special slag pit. After slow cooling, this slag is returned to the
concentrator and combined with raw ore. The Company has closed off the
converter slag return bays since they are no longer used to prevent air
infiltration to the reverberatory furnace.
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Additional matte is added to an active converter to produce a total
of approximately 91 m. tons (100 tons) of blister copper. The finished
blister copper is then poured into ladles and carried by overhead crane
to one of two anode furnaces. The blister copper is completely oxidized
with addition of air through tuyeres and then reduced by propane or
natural gas, as available. Finished anode copper is then poured into
anode molds on a single casting wheel. Anodes are cooled and loaded
onto rail cars for shipment to a refinery.
EMISSION SOURCES AND RELATED CONTROL EQUIPMENT
The primary particulate matter sources at the Kennecott smelter are
the fluo-solids roaster, reverberatory furnace, and the converters. The
majority of the exhaust gas volumes produced by these sources is treated
by control systems which are discussed below. However, fugitive emissions
from feeding concentrates or skimming converter slag are neither collected,
nor treated, but are exhausted directly to the atmosphere. Similarly,
converter "smoke" not collected by the primary hood system is exhausted
untreated. The anode furnaces also emit some untreated particulate
matter directly to the atmosphere above the converter aisle; however,
the concentrations are indeterminate.
Figure 2 is a diagram of the Kennecott smelter layout, the-air
pollution control systems, and the exhaust gas flow. Table 2 summarizes
certain design and operating data for the individual air pollution
control systems. Appendix B contains more specific information on each
control system.
Fluo-Solids Roaster Control System
The roaster off-gases pass through one of four primary cyclones and
then through a companion secondary cyclone. An estimated 95% of the
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ORVINO TOWER
MIST E8P
PEABODV
VENTURI SCRUBBER
WASTE HEAT BOILER
0
HEAT EXCHANOCRB .
r'^T )CATALV8T CHAMBER
^<-X
-jt.«ro*T
PEABODY
SCRUBBER
• ABSORBI
PLU080LI08 REACTOR
ESP
(2)
FINAL
ABSORBING TOWERS
ESP
»«v
EVERB STACK
CASTINO WHEEL
PROCESS PLOW
—— — — EXHAUST OASES
fl.
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Table 2
SMELTER AIR POLLUTION CONTROL EQUIPMENT AND OPERATING DATA
KENNECOTT COPPER CORPORATION
Hoyden, Arizona
Control
Device
Cyclones
Scrubber
Scrubber
Add Plant
ESP
Date of
Manufacturer Installation/ No. of
Modification Units
Ducon 1969 '8
Venturl NR 1
Peabody 12/73 1
(see description under Converters)
Koppers 1958 1
i
Gas Flow Operating Pressure Drop Collection Velocity
Rate Temperature • Area
m3/m1n scfm' °C °F cm H2° 1n mz ft2 m/sec ft/sec
Roaster
1980 70,000 649 1,200 44.5 17.5 NRb NR
NR NR NR NAC NA
670 23,700 204 400 61 24 NA' NA
Inlet
41 105
Outlet
Reverberatory Furnace
5,030 177,800 260 500 1.3 0.5 5,020 54,000 0.5 1.6
Retention
Time
sec
NR
NA
NA
14.1
ESP
Scrubber
Acid Plant
Western
PreclpHator
Peabody
Monsanto
NR
12/68
12/73
1
1
ld
Converters
NR 371 700 NR 3.692 39.744 1.2 3.9 9.2
-*•
2.140 75,400 232 450 30-33 12-13 NA NA NA
Inlet
38 100
Outlet
2,530 89.400° NR NR NA NA NA
' Standard conditions are 29.02 in Eg (14.7 psia) and 21°C (70°F)
^ NR = Not reported
NA = Not applicable
*• Double absorption
e Note that this reported value is not equal to the sum of the gas streams earning off both Peabody Sorubbers for unknoan reasons.
CO
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dust (calcine) is removed by this system. The roaster exhaust gases
o
[670 std m /min (23,700 scfm)] then enter a Venturi scrubber in which
most of the remaining extremely fine particulates are removed. The gas
stream then enters the smaller of two Peabody Scrubbing Towers. These
towers consist of a lower humidifying section and an upper cooling
section. The hot gas enters the humidifying section and passes upward
through a weak acid spray. The coarser^solids are removed and the heat
of the gas evaporates the water of the acid, hence cooling the gas
stream. The gas leaves the humidifying section, passes through three
perforated plates for flow distribution and acid bubble formation, and
is cooled by weak acid flowing across the plates. The clean roaster
exhaust gas stream then joins the clean converter exhaust gas stream,
which will be discussed later.
Reverberatory Furnace Control System
The principal reverberatory furnace exhaust gases pass through a
pair of waste heat boilers which partially cool the gases. The gases
then combine and travel through a balloon flue to (an^electrostatic
precipitator (ESP). The ESP was designed to handle 9,150 std m3/min
(323,000 scfm), the estimated gas volume is 5,030 std m3/min (177^800
scfm) [see Appendix D for calculations]. The ESP consists of^gjur bankj
(parallel units) of three stages each (units in series) with a total
collection area of 5,020 m2 (54,000 ft2). Gas retention time is estimated
to be 14 seconds with an average gas velocity of less than 0.6 m (2
ft)/sec. The pressure drop across the ESP is 1.3 cm (0.5 in) of water.
The exit gas stream is exhausted to and discharged from the 183 m (600
ft) stack.
Converter Control System
The converter exhaust gases become laden with particulate matter
when air is blown into a converter through tuyeres to oxidize the iron
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10
and copper sulfides. An estimated 100% dilution.air infiltrates around
the primary hoods which collect the off-gases. This entire gas stream
then exhausts through a gas cooler in which the gas stream is treated by
a concurrently flowing ultrasonically dispersed water spray. The cooled
[371°C (700°F)] gas stream flows through the induced draft fan plenum
and then into an ESP. The Company did not report the actual gas flow
rate capacity of, nor the pressure drop across, the ESP. The ESP has a
total collection area of nearly 3,700 m (40,000 ft2). Gas retention
time is about 9 seconds with an average gas velocity of just under 1.2 m
(4 ft)/sec. Following the ESP, the gas stream enters the larger Peabody
Scrubbing Tower in which the gas is treated identically as the roaster
exhaust.
• '
After the cleaned and cooled roaster and converter gases are combined,
the resultant gas stream enters three parallel trains of two mist precipitators
in series. The gas stream then enters the double-absorption acid plant
where it is dried, the S02 converted to SOg, and the SO. absorbed in
acid to form the final strength acid. Although designed to produce
1,770 m. tons (1,950 tons)/day, approximately 770 m. tons (850 tons)/day
of 93.5% strength sulfuric acid is actually produced. The exit gas from
the final absorber passes through a mist eliminator before being exhausted
from the 30 m (100 ft) stack.
EMISSIONS DATA
Several source tests were conducted at the Kennecott smelter during
March through May 1974 by Engineers Testing Laboratories (ETL), Phoenix.
The only ETL test of particular interest to this report was the one
particulate matter test conducted during late April 1974 at the reverbera-
tory furnace stack. Kennecott (KCC) conducted its own of tests on the
reverberatory furnace for particulate matter in April 1975. Both ETL
and KCC tested the acid plant for S02 emissions, but neither used a
filter to capture particulate matter.
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11
All the tests on the reverberatory furnace stack were conducted at
the 70 m (229 ft) level where the stack diameter-is 8.4 m (27 ft 7 in).
Each test was conducted as a compliance test following the prescribed
methods (Methods 1-5) in the regulation [Appendix C]. The stack has
four sampling ports at 90° angles and three sampling points were used at
each port.
For both the ETL and KCC tests, only 12 traverse points were
sampled. Using the minimum number of points (12) requires that the
sampling port location be a minimum of eight stack diameters downstream
from a flow disturbance. If the breeching enters the stack more than
£.4 m (8 ft) above the stack bottom, the eight-diameter requirement is
not met and more sampling points (16) are required. [See Appendix D for
calculation of equivalent stack diameters.]
The ETL test report does not indicate how the process weights were
determined. The Company determined the process weight by dividing the
tonnage feed to the reverberatory furnace by the number of furnace
operating hours during which the furnace was fed. The allowable process
weight rate was then determined by the formula contained in the applicable
regulation [Appendix C]. The sampling results were compared with the
allowable emissions.
Following is a summary of each of the two tests and comments
regarding the methods, procedures, and results of each test.
ETL: April 17-29. 1974
Several operating changes at the smelter were made as a result of
the preliminary test findings. Most of these changes have since been
adapted by the Company as normal operating procedures.
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12
The test report indicates a 5.5 m (18 ft) teflon-lined probe was
used during the test, although a 3 m (10 ft) probe should have been long
enough. The impinger case was identical to the one described in Method
5, with the exception that 10% hydrogen peroxide was used in place of
water to collect the gaseous sulfur compounds.
Since the stack velocity was on the order of 1.5 m (5 ft)/sec, a
tracer method, the accuracy of which was not determined, was used to
check the stack flow rate. The minimum sampling time of 2 hours and the
minimum sampling volume of 1.70 m (60 ft ) were both met [Appendix C].
The first two runs were within isokinetic tolerances (90 to 110%), but
the third run was at 111%. The results of the three runs are presented
in Table 3.
KCC: April 17-18, 1975
The Company test report contains no discussion of the methods or
procedures used in the conduct of their test. The document is basically
an assemblage of the raw and calculated data showing the results of the
test. However, the test report does indicate that a preliminary test
for moisture was conducted on April 15 and the results were used as a
correction to each of the subsequent runs. Each of the three runs was
within isokinetic tolerances and the minimum sampling volume and time
were both met. The results of the test are presented in Table 3.
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13
Table 3
PARTICULATE MATTER EMISSIONS TEST RESULTS
KENNECOTT COPPER CORPORATION
Hoyden, Arizona
Test
Run
18
20
21
1
2
3
Date
4-17-74
4-22-74
4-29-74
4-17-75
4-17-75
4-18-75
Stack
Temperature
op OQ
337
359
377
303
301
293
169
182
192
151
149
145
Gas
Vol ume
Moi sture
Content
7
acfm m /min %
215
194
186
163
177
179
,000
,000
,000
,022
,488
,044
ETL
6,090
5,490
5,270
KCC
4,620
5,030
5,070
7.0
8.2
8.2
7.5
7.5
7.5
Actual
Emissions
Ib/hr
28
22
27
24.0
22.3
22.0
kg/hr
13
10
12
10.9
10.1
10.0
Allowable
Emissions
Ib/hr
32
33
34
33.2
33.2
33.5
kg/hr
14.5
15.0
15.4
15.1
15.1
15.2
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BIBLIOGRAPHY
1. Kennecott Copper Corporation, Ray Mines Division Smelter Question-
naire, Hayden, Arizona. Undated.
2. Kennecott Copper Corporation, Ray Mines Division, Hayden Smelter
and Acid Plant Gas Handling System. J. E. Stocker, D. 0. Nelson,
L. E. Mulholland. Dec. 2, 1974.
3. Compilation and Analysis of Design and Operating Parameters of the
Kennecott Copper Corporation Smelter, Ray Mines Division, Hayden,
Arizona for Emission Control Studies. Pacific Environmental Services,
Inc.., Santa Monica, Oct. 1975.
4. Stack Emission Analysis, Copper Smelter, Hayden, Arizona, 12 March
through 1 May 1974. Engineers Testing Laboratories, Inc., Phoenix,
June 5, 1974.
5. 1975 Compliance Test for Arizona Operating Permit, Kennecott Copper
Corporation, Hayden, Arizona, May 8, 1975.
6. Letter from Joseph T. Mortimer, Director of Safety and Environ-
mental Control to Gary D. Young, EPA-NEIC, Denver, Mar. 4, 1976.
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APPENDICES
A NEIC Information Request Letter
to Kennecott
B Kennecott Response to NEIC Information
Request
C SIP Regulation Applicable to Kennecott
D Example Calculations of Gas Flow Rates
and Equivalent Duct Diameters
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Appendix A
NEIC Information Request Letter to Kennecott
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ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL FIELD INVESTIGATIONS CENTER-DENVER
BUILDING 53, BOX 25227. DENVER FEDERAL CENTER
DENVER, COLORADO 80225
December 17, 1975
Kenneth Matheson
General Manager
Ray Mines Division
Kennecott Copper Corporation
Hayden, Arizona 85235
Dear Mr. Matheson:
The Environmental Protection Agency has undertaken a program to
evaluate the performance characteristics of particulate control facilities
at the copper smelters in Arizona and Nevada. Representatives of EPA
will observe each smelter's process operations and air pollution control
facilities, review source test data, examine appropriate records, etc.,
during a site inspection of each smelter.
In anticipation of such a site inspection of your smelter, we have
prepared the attached list of detailed information needs which we intend
to use as a discussion outline during our inspection. We would appreciate
it if you could inform the appropriate company personnel about the
attached list and the forthcoming inspection of your facility so that
the necessary information will be readily available and the inspections
can be expedited.
We are conducting these inspections under the authority of Section
114(a)(ii) of the Clean Air Act, which authorizes representatives of EPA
to enter facilities for the purpose of determining whether the facility
is in violation of any requirement of a state implementation plan. At
your facility, we anticipate that EPA or a contractor hired by EPA will
be conducting an emissions source test for particulate matter within the
next few months. Therefore, EPA will make a source test pre-survey,
either separately or in conjunction with our site inspections, prior to
performing such a source test.
If you have any questions concerning the purpose of these site
inspections, please feel free to contact Mr. Gary D. Young of my staff
(303/234-4*658) or Mr. Larry Bowerman, EPA Region IX (415/556-6150). Mr.
Young will be in contact with you within the next few weeks concerning a
site inspecton of your smelter during January or early February.
Sincerely,
Thomas P. Gallagher
Attachment Director
cc: Richard O'Connell
Bruce Scott
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COPPER SMELTER INFORMATION NEEDS
A. GENERAL
1. Plant location
2. Person to contact regarding plant survey information needs, his
telephone number and address
3. Simple block flow diagram showing smelter process equipment, air
pollution control devices, and stack configuration
B. PROCESS
1. General
a. Detailed description of the process, including flow diagrams,
unique features, and how the process operates
b. Definition of normal operation
c. Actual production rate (Ibs blister copper/hr and percent Cu)
d. Type and quantity of fuel consumed
Oil - i. Heating value (BTU's/gal)
ii. Percent sulfur (by weight)
iii. Percent ash (by weight)
iv. Specific gravity
v. Consumption (gals or bbls/yr)
Gas - i. Type of gas (constituents in percent by weight)
ii. Density (Ibs/SCF)
iii. Heating value (BTU's/SCF)
iv. Percent sulfur (by volume and grains/SCF)
v. Consumption (SCF/yr)
Coal - i. Heating value (BTU's/T)
ii. Percent sulfur (by weight)
iii. Percent ash (by weight)
iv. Consumption (Ibs/unit/hr)
e. Ore composition, including a typical percent and range of
percentages for each chemical constituent
f. Flux composition, including a typical percent and range of
percentages for each chemical constituent
g. Standard conditions - pressure (psi) and temperature (°F)--
used to calculate SCFM
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2. Concentrators
a. Design process feed rate (Ibs raw ore/hr)
b. Actual process feed rate (Ibs raw ore/hr), including method
and estimated accuracy of measurement
c. Average number of hours of operation per month
d. Process instrumentation used, including data for a typical
reading and range of readings
e. Description of where and how samples of process material can
be collected
f. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results
g. Expected life of process equipment (years)
h. Plans to modify or expand process production rate
3. Roasters
a. Design process feed rate (Ibs concentrate/hr)
b. Actual process feed rate (Ibs concentrate/hr), including
method and estimated accuracy of measurement
c. Design process gas volumes (SCFM)
d. Actual process gas volumes (SCFM), including method of
determination, calculation, or measurement
e. Actual process temperature (°F)
f. Average number of hours of operation per month
g. Process instrumentation used, including data for a typical
reading and range of readings
h. Description of where and how samples of process material
can be collected
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results
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j. Expected life of process equipment (years)
k. Plans to modify or expand process production rate
4. Reverberatory furnaces
a. Design process feed rate (Ibs calcine/hr + Ibs flux/hr" +
Ibs converter slag/hr)
b. Actual process feed rate (Ibs calcine/hr + Ibs flux/hr +
Ibs converter slag/hr), including method and estimated
accuracy of measurement
c. Design process gas volumes (SCFM)
d. Actual process gas volumes (SCFM), including method of
determination, calculation, or measurement
e. Actual process temperature (°F)
f. Average number of hours of operation per month
g. Process instrumentation used, including data for a typical
reading and range of readings
h. Description of where and how samples of process material can
be collected
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results
J. Expected life of process equipment (years)
k. Plans to modify or expand process production rate
5. Converters
a. Design process feed rate (Ibs matte/hr + Ibs slag/hr +
Ibs flux/hr)
b. Actual process feed rate (Ibs matte/hr + Ibs slag/hr +
Ibs flux/hr), including method and estimated accuracy of
measurement
c. Design process gas volumes (SCFM)
d. Actual process gas volumes (SCFM), including method of
determination, calculation, or measurement
e. Actual process temperature (°F)
-------
f. Average number of hours of operation per month
g. Process instrumentation used, including data for a typical
reading and range of readings
h. Description of where and how samples of process material can
be collected
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results
j. Expected life of process equipment (years)
k. Plans to modify or expand process production rate
6. Refining Furnaces
a. Design process feed rate (Ibs blister copper/hr)
b. Actual process feed rate (Ibs blister copper/hr), including
method and estimated accuracy of measurement
c. Design process gas volumes (SCFM)
d. Actual process gas volumes (SCFM), including method of
determination, calculation, or measurement
e. Actual process temperature (°F)
f. Average number of hours of operation per month
g. Process instrumentation used, including data for a typical
reading and range of readings
h. Description of where and how samples of process material can
be collected
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results
j. Expected life of process equipment (years)
k. Plans to modify or expand process production rate
-------
C. EMISSIONS
1. List of sources of particulate emissions in the plant (including
fugitive emissions)
2. Level of uncontrolled particulate emissions by source (Ibs/hr or
T/yr)
3. Existing source test data employed for particulates by stack,
process unit, or control device, including:
a. Test method
b. Data acquired
c. Operating process weight rate
d. Calculations
e. Test results
4. Particle size and chemical composition of uncontrolled particulate
emissions, including method of determination
.5. Level of uncontrolled visible emissions by source (percent opacity)
and method of determination
6. Extent of and reason for variance of particulate emissions with:
a. Process design parameters
b. Process operating parameters
c. Raw material composition or type
d. Product specifications or composition
e. Production rate
f. Season or climate
g. Sulfur dioxide control
D. CONTROL SYSTEMS
1. Detailed description of the particulate and sulfur dioxide emissions
control systems, including:
a. Process treated
-------
b. Type of fuel consumed per unit
c. Quantity of fuel consumed per unit
d. Method of determination of design parameters
e. Engineering drawings or block flow diagrams
f. Expected life of control system
g. Plans to upgrade existing system
2. Electrostatic precipitators
a. Manufacturer, type, model number
b. Manufacturer's guarantees, if any
c. Date of installation or last modification and a detailed
description of the nature and extent of the modification
d. Description of cleaning and maintenance practices, including
frequency and method
e. Design and actual values for the following variables:
i. Current (amperes)
ii. Voltage
iii. Rapping frequency (times/hr)
iv. Number of banks
v. Number of stages
vi. Particulate resistivity (ohm-centimeters)
vii. Quantity of ammonia injected (Ibs/hr)
viii. Water injection flow fate (gals/min)
ix. Gas flow rate (SCFM)
x. Operating temperature (°F)
xi. Inlet particulate concentration (Ibs/hr or grains/SCFM)
xii. Outlet particulate concentration (Ibs/hr or grains/SCFM)
xiii. Pressure drop (inches of water)
3. Fabric filters
a. Manufacturer, type, model number
b. Manufacturer's guarantees, if any
i
c. Date of installation or last modification and a detailed
description of the nature and extent of the modification
-------
d. Description of cleaning and maintenance practices, including
frequency and method
e. Filter material
f. Filter weave
g. Bag replacement frequency
h. Forced or induced draft
1. Design and actual values for the following variables:
i. Bag area (ft2)
ii. Bag spacing (inches)
iii. Number of bags
iv. Gas flow rate (SCFM)
v. Operating temperature (°F)
^vi. Inlet particulate concentration (Ibs/hr or grains/SCF).
vii. Outlet particulate concentration (Ibs/hr or grains/SCF)
viii. Pressure drop (inches of water)
4. Scrubbers
a. Manufacturer, type, model number
b. Manufacturer's guarantees, if any
c. Date of installation of last modification and a detailed
description of the nature and extent of the modification
d. Description of cleaning and maintenance practices, including
frequency and method
e. Scrubbing media
f. Design and actual values for the following variables:
1. Scrubbing media flow rate (gals/min)
ii. Pressure of scrubbing media (psi)
iii. Gas flow rate (SCFM)
iv. Operating temperature (°F)
v. Inlet particulate concentration (Ibs/hr or grains/SCF)
vi. Outlet particulate concentration (Ibs/hr or grains/SCF)
vii. Pressure drop (inches of water)
5. Sulfuric acid plants
a. Manufacturer, type, model number
-------
b. Manufacturer's guarantees, if any
c. Date of Installation or last modification and a detailed
description of the nature and extent of the modification
d. Description of cleaning and maintenance practices, including
frequency and method
e. Frequency of catalyst screening
f. Type of demister
g. Design and actual values for the following variables:
i. Production (T of acid/day)
ii. Conversion rate (percent)
iii. Acid strength (percent t^SC^)
iv. Number of catalyst beds
v. Gas flow rate (SCFM)
vi. Operating temperature (°'F)
vii. Inlet S02 concentration (ppm)
vili. Outlet S02 concentration (ppm)
ix. Acid mist (Ibs t^SO^/T of acid)
x. Blower pressure (psi)
Liquid SC>2 plants
a. Manufacturer, type, model number
b. Manufacturer's guarantees, if any
c. Date of installation or last modification and a detailed
description of the nature and extent of the modification
d. Description of cleaning and maintenance practices, including
frequency and method
e. Absorbing media
f. Design and actual values for the following variables
i. Production (T of S02/day)
ii. Conversion rate (percent)
iii. Gas flow rate (SCFM)
iv. Operating temperature (°F)
v. Inlet S02 concentration (ppm)
vi. Outlet 562 concentration (ppm)
vii. Acid mist (Ibs H2S04/T of S02)
-------
7. Detailed description of how the particulate and sulfur dioxide
emission control systems operate
8. Description of instrumentation (flow meters, continuous monitors,
opacity meters, etc.) used, including manufacturer and model
number, data for typical and range of readings, and identification
of location by process unit, control system unit, or by stack
9. Description of typical types of control system malfunctions,
including frequency of occurrence and anticipated emission results
E. STACKS
1. Detailed description of stack configuration, including process
and/or control system units exhausted
2. Identification by stack of:
a. Heights (ft above terrain)
b. Elevation of discharge points (ft above sea level)
c. Inside diameters (ft)
d. Exit gas temperatures (°F)
e. Exit gas velocities (ft/sec)
-------
Appendix B
Kennecott Response to NEIC Information Request
-------
KENNECOTT COPPER CORPORATION
RAY MINES DIVISION SMELTER
QUESTIONNAIRE
A. General
1. Plant location:
Hayden, AZ 85237
2. Person to contact:
J. S. Nebeker
Reduction Plant Superintendent
Kennecott Copper Corporation
Hayden, Arizona 85235
Phone: (602) 356-7811
3. Simple flow diagram:
Attached
The time constraint for gathering
this information has not allowed
for in-depth review and some data
may be in slight error.
B. Process
1. General
a. Detailed description of the process, including flow diagrams, unique
features, and how the process operates.
b. Definition of normal operation:
1500T/day reactor feed
c. Actual production rate (Ibs. anode copper/hr. and % Cu)
244T/day (1975) 244T/day x 2000 Ibs/T = 20,333 Ibs/hr
24 hrs/day
97. 94% Cu
d. Type and quantity of fuel consumed
Oil #2 oil
Heating value (BTU's/gal)
% S (by weight)
% ash (by weight)
Specific gravity
Consumption (gals orbbls/yr)
137,830
32%
N/A
35.1 Ibs/ft3
2,111,081 gallons/yr.
19 Dec 74 - 19 Dec 75
-------
Gas Natural gas
I. Type of gas (constituents in % by weight)
CH4 Ethane Propane
Mol. % 90.28 6.31 1.09
II. Density (Ibs/SCF) .050
HI. Heating value (BTU's/SCF) 1059 BTU/SCF
IV. % sulfur .05 grains/100 ft.3 =
V. Consumption (SCF/yr) 1,657,245,000 SCF/yr. TOTAL SMELTER
e. Ore composition, including a typical percent and range of percentages for
each chemical constituent.
(Appendix A)
f. Flux composition, including a typical % and range of percentages for each
chemical constituent.
(Appendix B)
g. Standard conditions
1 mol. of gas at 32° F and 1 at m. 14.7 psi
2. Concentrators
a. Design process feed rate (Ibs raw ore/hr)
25,400 TPD or 2,116,667 Ibs/hr
b. Actual process feed rate (Ibs. raw ore/hr)
The average during 1975 was 20,432 TPD (1,702,667 Ibs/hr.). The
concentrator was operated below capacity during the 2nd, 3rd, and 4th
quarters. Presently, at 17,500 TPD (1.458.333K Normally at 24,000 TPD
(2 million Ibs/hr.). Measured on Merrick weightometers. Corrected
to dry weight.
c. Average number of operating hours
Present 549 hours/month (excluded June-September, 1975)
Normally 24 hours/day.
-------
d. Process instrumentation used, including data for a typical reading and
range of readings.
The process instrumentation installed in the concentrator is nominal.
Listed below are those items which are used to monitor or regulate
process conditions.
Work Center
Crusher
Standard
• Measurement Typical Reading Range of Readings
Amperage
Amperage
Ore feed rate
Shorthead
Grinding
Rod mill
Flotation
Copper sulfide circuit
pH rougher sections
Cell level control
(bubble tube back pressure)
Molybdenite circuit
pH Agitator tanks
pH Rougher cells
pH 1st cleaners
Agitator density
Agitator mass flow
Grinding Section 5 only
Rod mill HP
feed rate
H£O addition
Ball mill
HP
Cyclone feed H2O addition
density
massflow rate
Cyclone overflow
particle size
density
200 amp. 150-300 amps
150 amps 150-200 amps
5000 TPD
11.5
6.5
7.5
7.5
55%
1700 TPD
700 HP
5000 TPD
500 gpm
715 HP
700 gpm
60% solid
12,000 TPD
3000-7000 TPD
11.0-11.8
0-10"H20
6. 0-7. 0
7.0-8.0
7.0-8.0
30-70% solids
0-4000 TPD
600-800 HP
4000-7500 TPD
0-700 gpm
680-740 HP
0-1200 gpm
45-70% solids
0-24,000 TPD
25%+100 mesh 13-33%+100 mesh
40% solids 35-50% solids
-------
e. Description of where and how samples of process material can be collected.
Sample stations in the concentrator are located on the following process streams:
Section 1-4 heads
Section 5 heads
Section 6 heads
General Tails (all effluents)
Section 1-6 tails (flotation tails)
Section 5 tails
Section 6 tails
General concentrate
Molybdenite tails
All samples are taken as finely ground flotation products by a primary
traversing sample cutter. Where required a rotary secondary cutter is
employed to reduce the sample volume. Grab samples are taken of
molybdenite products and other process streams as required.
f. Description of typical types of process fluctuations and/or malfunctions,
including frequency of occurrence and anticipated emission results.
The typical concentrator fluctuations are changes in ore hardness and
mineral content which cause swings in the concentrator throughput rate
and concentrate production. The concentrator is designed to handle these
fluctuations without process upsets.
Due to the abrasive nature of the slurries treated, process equipment is
either provided with standby capacity or process bypass to permit the
continuation of normal operations when key pieces of process equipment
fail. Grinding and flotation are wet processes and the concentrator uses
a recycle water system which returns the process water to the concentrator
for reuse after the solids have settled out. No emissions occur when a
malfunction occurs within the concentrator.
There are nine Roto-clone dust collectors used on the dry ore handling
system. The down time on these units is approximately one unit down
-------
for two days each month. Failure of a Roto-nlone results in increased
dust in and around the area serviced by the down unit. The amount of dust
escaping will depend on the ore type, the moisture content, the size of the
material being handled, and the location of the failed dust collector.
g. Expected life of process equipment (years)
The service life of concentrator is indefinite. The equipment has replaceable
wear components which allow repairs as often as necessary without the
replacement of the equipment units.
h. Plans to modify or expand process production rate
The concentrator is presently operating at a reduced capacity on a
5 day week. There are no immediate plans to expand the design capacity
of the concentrator.
3. Roaster
a. Design process feed rate
Min. TPD Max. TPD
Copper concentrate (Ibs./hr.) 66,667 (800) 116,667 (1400)
Copper precipitates (Ibs./hr.) 1,667 (20) 2,917 (35)
Silica flux (Ibs./hr.) 8,917 (107) 15,583 (187)
TOTAL 77,251 (927) 135,167 (1622)
b'. Actual process feed rate and accuracy of measurement
Rate (Ibs./hr.) 96,334 (1156 TPD) concentrate
Determined by Ramsey weight rate meter belt scale which can't be
positive checked.
+ 10%
c. Design process gas volumes (SCFM)
22,030 SCFM (dry) - SC>2
- natural gas
d. Actual process gas volumes (SCFM), including method of determination,
calculation, or measurement.
OO f\t(\ GfTTft/T /rlrrA — TVTiJOB
-------
e. Actual process temperature (°F)
1000 - 1200° F
f. Average number of hours of operation per month
561 hrs. /month
g. Instrumentation
(See Appendix C)
h. Description of where and how samples of process material can be collected.
I. reactor feed - from #54 belt
II. reactor underflow - with effort to pot
III. cyclone underflow - not white running
IV. SO2 - sampled on discharge side of blowers by acid plant.
i. Description of typical types of process fluctuations and/or malfunctions,
including frequency of occurrence and anticipated emission results.
There are numerous fluctuations which can occur. The most significant
are plugging of reactor feeder, cyclone screw, calcine bin, and gas cooler.
Failures of reactor feed systems, underflow conveyor system, reactor
blower system, and off-gas handling system. Improper sizing and
composition of reactor feed. Failure of Venturi scrubber in the acid
plant and/or reverberatory furnace. All would cause shut down of reactor.
Start-up of reactor may give increased particulate and sulfur dioxide. It
causes an upset condition in the acid plant. See Appendix C.
j. Expected life of process equipment is estimated at 5 years.
k. Plans to modify or expand process production rate.
Possibly, if copper market improves.
-------
4. Reverberatoiy furnaces
a. Design process feed rate (Ibs. calcine/hr. + lbs. flux/hr. + lbs.
converter slag/hr.)
TPD
Ibs. calcine/hr. 136,834 1642
Ibs. flux/hr. 4,834 58
Ibs. converter slag/hr. none none
b. Actual process feed rate
TPD
Ibs. calcine/hr. 96,000 1152
Ibs. flux/hr. 3,667 44
Ibs. converter slag/hr. none none
c. Design process gas volumes (SCFM)
300,000 SCFM - 10"W. C. at 500° F (Knapp Eng. Book)
150,000 SCFM
d. Actual process volumes (SCFM), including method of measurement,
determination, and calculation.
112,899 SCFM (from Stack Emission Report)
e. Actual process temperature (°F)
Slag 2250
Matte 2075
f. Average number of hours of operation per month.
Down 2 days out of 14. On 30-day month, 624.
g. Instrumentation
(Appendix D)
h. Description of where and how samples of process material can be collected.
Matte and slag sampled at the tap'holes. Gas sampled from front end of
furnace chamber.
Sample gas at stack and other places along duct system.
I. Description of typical types of process fluctuations and/or malfunctions,
including frequency of occurrence and anticipated emission results.
All molfimntirmo r\f -rooff-nt* Twfj?orvtofir foilntv* •nin r»iifo fiiol
-------
failures, waste heat boiler failures, and precipitator failure.
5. * Converters
a. Design process feed rate (Ibs. matte/hr. +lbs. cold dope/hr. +lbs. flux/hr.)
Ibs. matte/hr. UNKNOWN -'
Ibs. cold dope/hr. CONVERTERS ARE DESIGNED
Ibs. flux/hr. ON AIR FLOW BASIS.
b. Actual process feed rate (Ibs. matte/hr. + lbs. cold dope/hr. + lbs. flux/hr.)
TPD
Ibs. matte/hr. 59,833 718
Ibs. cold dope/hr. 4,167 50
Ibs. flux/hr. 6,667 80
c. Design process gas volumes (SCFM)
72,070 SCFM (dry)
d. Actual process gas volumes (SCFM)
70,000 SCFM (dry)
e. Actual process temperature (° F)
1900 - 2250
f. Average number of hours operation per month (2 converters).
650 hrs. of blowing
g. Process instrumentation used, including data for a typical reading and
range of readings.
(See Appendix E)
h. Description of where and how samples of process material can be collected.
(1) Slag sample while skimming
(2) Matte when reverb is tapped
(3) Blister copper as poured from converter
(4) Dust from bin.
i. Description of typical types of process fluctuations and/or malfunctions,
Including frequency of occurrence and anticipated emission results.
(1) Loss of air
(2) Loss of draft - increases fugitives.
(3) Runaway - increases fugitives.
<4\ Acid nlnnt. nrnhlems
-------
j. Expected life of process equipment (years).
Converters 30 years
Ladles 10 years
Cranes 50 years
6. Refining furnaces (2)
a. Design process production rate (Ibs. anodes/hr.)
Batch process at 250 TPD (20,833 Ibs/hr.)
b. Actual process production rate, including method and estimated accuracy
of measurement.
244 TPD (20,333 Ibs/hr.). Based on anode copper weighed for shipment.
c. Design process gas volumes (SCFM)
None
d. Actual - See (JE
e. Actual process temperature.
2150 - 2350° F
f. Average number of hours operation per month.
400
g. Process instrumentation (See Appendix E).
h. Description of where and how samples of process material can be collected.
From mouth of furnace using 8" ladles.
i. Description of typical types of process fluctuations and/or malfunctions,
including frequency of occurrence and anticipated emission results.
(1) plugging of tuyeres
(2) cold copper
j. Expected life of process equipment (years).
30 years not including refractory replacement.
-------
C. Emissions (^)
1. List of sources of participate emissions in the plant.
Main stack, flux crusher roto-clone, concentrate dryer, and lime kiln.
Fugitives from converters, reverberatory furnace.
2. Level of uncontrolled particulate emissions by source (Ibs. /hr. or T/yr.)
Not available on property.
3. Existing source test data employed for particulates by stack, process unit,
or control device, including: (See Engineering Testing Laboratories report).
4. Particle size (not available)
Chemical composition of uncontrolled particulate emissions, including method
of determination (not available).
5. Level of uncontrolled visible emissions by source (% opacity) and method
of determination.
(See Arizona Dept. of Health Services, Bureau of Air Quality).
6. Extent of and reason for variance of particulate emission with:
a. Process design parameters.
b. Process operating parameters.
(1) Air infiltration oxidizing sulfur dioxide to 803.
c. Raw material composition or type.
?variance - none ?
d. Product specifications or composition.
No variance.
e. Production rate.
Undetermined.
f. Season and climate.
-------
g. See "b".
D. Control Systems
1. Detailed description of the particulate and sulfur dioxide emissions control
systems, including:
(assure acid plant is part of control system)
(a) Process treated
Reverb gas 22-28 Ibs/hr. '- Koppers precip.
Roaster )_ TQ acid
Converters) No particulate
(b) Type of fuel consumed per unit.
Natural gas or #2 oil at the acid plant.
(c) Quantity consumed.
15,000 cfm natural gas.
(d) Method of determination of design parameters.
Remove 90% of input sulfur.
(e) Engineering drawings or block flow diagrams.
(See charts)
(f) Expected life of control system - 20 years.
(g) Plans to upgrade system.
No
Electrostatic Precipitator
a. Manufacturer
Koppers, Electrostatic precipitator
b. Manufacturer's guarantees, if any.
1 year. Already ran out.
c. Date of installation or last modification and a detailed description of the
nature and extent of the modification.
-------
1958 - installation
The changes have involved new dust removal hoppers and new electronic
control systems.
d. Description of cleaning and maintenance practices, including frequency
and method.
(1) Dump electrostatic precipitator once per day.
(2) Frequency of cleaning depends on performance of precipitator.
e. Design and actual values for the following variables:
I. Current (amps)
II. Voltage
III. Rapping frequency (times/hr.)
IV. Number of banks
V. Number of stages
VI. Particulate resistivity (ohm-cin)
VII. Quantity of ammonia injected
VIII. Water injection flow rate (gpm)
IX. Gas flow rate (SCFM)
X. Operating temperature (°F)
XI. Inlet particulate cone, (grains/SCFM)
XII. Outlet particulate cone. (grains/SCFM)
XIII. Pressure drop (inches of water)
Fabric Filters
(None in use)
4. Scrubbers - Reactor
a. Manufacturer.? Peabody
b. Manufacturer's guarantees, if any? 1 yr. ,. 03 grains/SCFM
c. Date of installation or last modification and a detailed description
of the nature and extent of modification.
December 1973 (start-up)
d. Description of cleaning and maintenance practices, including frequency
and method.
(1) Clean one of three (3) plates every month.
e. Scrubbing media.
Design
40
250
3
4
3
none
none
300,000
500
0.5
0.48
0.5
Actual
40
250
3
4
3
none
none
165,000
500
unknown
.015
w. c. 0.5
-------
f. Design and actual values for the following variables:
I.
II.
III.
IV.
V.
VI.
VII.
Scrubbing media flow rate (gpm)
Inlet press, of sprays (psi)
Gas flow rate (SCFM)-dry
Operating temperature (° F)
Inlet particulate cone. (grans/SCF)
Outlet " " " "
Pressure drop (inches of H2O)
In
Out
Design
900
30-35
22,030
600°F
95°F
25
;>.os
30"
Actual
• 900
>15
22,030
400
105
25
>-.03
24"
Sc rubbe r-Converter
a.
b.
c.
d.
e.
f.
Manufacturer? Peabody
Manufacturer's guarantees, if any? None
Date of installation or last modification and a detailed description of
the nature and extent of the modification?
December 1968
Description of cleaning and maintenance practices, including frequency
and method.
Clean one (1) plate of four (4) twice a month.
Scrubbing media? Weak acid
Scrubbing media flow rate (gpm)
Inlet pressure of scrubbing media (psi)
Gas flow rate (SCFM)
I.
II.
III.
IV. Operating temperature (°F)
Design and actual values for the following variables:
Design Actual
2,500 2,500
30-35 30-35
72,070 70,000
Inlet 750 450
Outlet 95 100
V. Inlet particulate cone. (Ibs. /hr.) 833 .833
VI. Outlet particulate cone. (Ibs./hr.) none stated ^.05
VII. Pressure drop (inches of water) 10"w. c. 12-13
Sulfuric Acid Plants
a. Manufacturer? Monsanto Enviro-Chem Systems, Inc.
b. Manufacturer's guarantees, if any?
c. Date of installation or last modification and a detailed description of the
nature and extent of the modification.
_o{nrrla orvntoot
1 Q73— mnrlifiprl to drmhlfi contfict.
-------
Major modifications in December 1973 consisted of an additional scrubber
for reactor gas with associated weak acid pumps and coolers, a modified
drying tower, mist eliminator, additional cold and hot interpass h?at
exchangers, a new three pass converter with tight division plate between
third and fourth catalyst layers, additional catalyst (273,000 vs. aOS.OOO ),
a new interpass absorbing tower, pumps and acid coolers, a H. E. Brink Mist
Eliminator, a modified existing absorbing tower which becomes a final
absorbing absorbing tower with modified H. V. Brink Mist Eliminator,
modified gas ducts, an addition to the water cooling tower with additional
cooling water pumps, and additional instrumentation.
d. Description of cleaning and maintenance practices, including frequency and
method.
(1) Drain acid from heat exchanger - daily.
(2)
e. Frequency of catalyst screening? Twice/year.
f. Type of demister? Brink - H.V. which isaplate type
- H.E. which is a tubular (internal) type
g.- Design and actual values for the following variables:
Design Actual
I. Production (T of acid/day) 1,950 850
II. Conversion rate (%) 99.3 99.5
III. Acid strength (% H2SO4) 93 and 98 93.5
IV. Number of catalyst beds 4 ' 4
V. Gas How rate (SCFM)-dry 94,100 • 83,000
VI. Operating temperature ?? where ??
VII. Inlet SO2 cone. (%) - 10.66 4.6%
VIII. Outlet SO2 cone, (ppm) 939 230
IX. Acid mist (Ibs. H2SO4/T of acid) None 0.07
X. Blower pressure (psi) 5.5 5.5
E. Stacks
1. Detailed description - (See drawing)
-------
2. Identification by stack of:
Main Acid
a. Height (ft. above terrain) 600 100
b. Elevation (ft. above sea level) 2,804 2,304
c. Inside diameter (ft.)
Base 39'0" 8'
Top 17'2-3/8" 8'
d. Exit gas temperature (<>F) 337 152
e. Exit gas velocities (ft. /sec.) 5.2 35.8
-------
APPENDIX A
Ore Composition and Ranges (Based on 1975)
% Cu Fe MoS2 SLO2 A12O3 CaO S K2O MgO
VIin. .84 5.0 .013 57.6 6.0 .30 .80 3.38 1.25
Median 1.04 7.06 .026 61.4 11.85 1.67 2.3 3.92 1.75
Max. 1.25 8.75 .056 66.3 12.8 2.55 2.9 4.80 2.75
-------
APPENDIX B
Flux Compositions and Range of Percentages (Based on 1975)
Lime Flux:
Cu
Fe
A12O3
SiO2
CaCOS* K2O
(*) CaO
Min.
Median
Max.
XI. 783 =
0
.39
1.0
CaCOS
.50
.85
2.0
Assays
.47
.98
1.40
only cover
4.4 44.8 .13
7.5 48.5 .34
11.2 52.0 1.75
11 days during Jan-Feb. , 1975.
.75
1.95
3.50
Silica Flux (Fettling-Reverb):
%
Min.
Median
Max.
Cu
.53
5.18
13.3
Fe
1.88
8.43
18.3
A12Q3
2.35
4.83
8.80
SiO2
42.0
66.5
87.8
CaO S K2O
.45 .21 .60
1.47 6.44 1.66
3.75 14.4 2.50
MgO
.38
.73
1.50
Converter Flux:
%
Min.
Median
Max.
Cu
.35
1.08
3.53
Fe
1.70
9.0
11.0
A12Q3
2.2
5.2
9.0
SiO2 CaO S
60.4 .38 .10
79.9 .79 .34
86.6 3.3 .78
-------
APPENDIX C
Smelter Process Instrumentation
ROASTER
Reactor Fluidizing Air Control - Conoflow Corp.
0 - 100% (% of blower max. output 22,700 SCFM)
Normal operating range ( 30 - 50%)
Typical reading (50%) (Reactor down - 0%)
Reactor Fluidizing Air Recorder - Foxboro Model 40
0-25,000 SCFM
Normal operating range 13,000 - 15,000 SCFM
Typical reading 15,000 SCFM (Reactor down - 0 SCFM)
REACTOR
Hydraulic Feeder Speed Control - Conoflow Corp.
0 - 100% (% of feeder max. output 14 RPM)
Normal operating range 45 - 90%.
Typical reading 60% (Reactor down - 0%)
Reactor Bed Temperature Recorder - TE31-Foxboro Model 40
500°- 1500° F
Normal operating range 1050° - 1150° F
Typical reading 1100O F (Reactor down - temp, is constant at last operating
temp, except for gradual heat loss in system)
Reactor Bed Temperature Recqrder - Thermocouples 1, 2 & 3 - Bailey Meter
Type WM55A Model E101
0 - 1800° F
Normal operating range 1050 - 1150° F
Typical reading 1100° F (Reactor down - see previous)
Reactor Freeboard Temperature Indicator - Honeywell
0 - 2000° F
Normal operating range 950° - 1100° F
Typical reading 1000° F
Reactor Windbox Temperature Indicator - Honeywell
0 - 800° F
Normal operating range 180° - 220° F
Typical reading 200° F
-------
Cyclone Outlet Temperature and Bed Temperature Recorder - Esterline Angus
0 - 1500° F
Normal operating range 500 - 700° F
Typical reading 600° F (Reactor down - cyclones lose temp. ^
Gas Cooler Temperature Recorder and Controller - Foxboro Model 40
500 - 1000° F
Normal operating range 600 - 700° F
Typical reading 650° F (Reactor down - gas cooler temp, drops.)
Gas Cooler Outlet Pressure Indicator
0 to -15" H2O
Normal operating range -12 to -22" H2O
Typical reading -15+ (pegged out) (Reactor down & fans off - pressure to 0)
Cyclone Outlet- Pressure Indicator
0 to -15" H2O
Normal operating range -7. 5 to -14.0" H2O
Typical reading -12.5" H2O (Reactor down & fans off - pressure 0)
Reactor Freeboard Pressure Indicator
-15 to +50" H2O
Normal operating range +18. 0 to +24. 0" H2O
Typical reading +20" H2O (Reactor down & fans off - pressure 0)
Reactor Freeboard Pressure and Bed Depth Recorder - Bailey Type KM55A
Model E101
Pressure -15 to +50" H2O
Bed depth 0 to 125" (Actual chart scale set up 0 - 100'V
Normal operating range (pressure) 18 to 24" H2O
Typical reading (pressure) 20" H2O
(*) Normal operating range (depth) 68-72"
Typical reading (depth) 70"
Reactor Feed Bin Weight Recorder - Foxboro Model 40
Empty to full
Normal operating range - empty to full
Typical reading - half full
% SQ2 Recorder - Leeds & Northrup Speedomax
0 - 14.5% (% of total off gas volume)
Normal operating range 0 - 10%
Typical reading 7% (Reactor down - 0%)
-------
Booster I. D. Fan Control
0 - 100% (% of max. fan RPM)
Normal operating range - 100%
Typical reading 100% (Reactor down -
Westl.D. Fan Control
0 - 100% (% of max. fan RPM)
Normal operating range 100%
Typical reading 100% (Reactor down - 0 %)
Reactor Hot Gas Duct Bullseye Damper Control
Open/Closed
Normal operating range - closed
Typical reading - closed (Reactor down - open)
#1 and #2 Reactor Burner Preheater Control
On/Off switch
Normal operating conditions - off
Typical reading - off (Preheater burners used only when bedding reactor)
Reactor Water Addition Flowmeters (2)
Each flowmeter 0-30 gpm
Normal operating range - 10-25 gpm total
Typical reading 25 gpm (Water added to reactor only when conditions warrant it)
Reactor Feed Rate Recorder - Honeywell Model Y15201816 01-01-0-000-024-00
0 - 100 TPH
Normal operating range 40 - 85 TPH
Typical reading 80 TPH
Reactor Feed Totalizer Scale - Ramsey
Normal operating range 1,100 - 1,600 TPD (wet)
Typical reading 1500 TPD (wet)
(Instrument totals feed to reactor on a continuous basis)
-------
APPENDIX D
Instrumentation of Roverberatory Furnace
REVERB FURNACE
Reverb Gas Control
0-30 psi (instrument air range)
Reverb Gas Recorder and Combustion Air Recorder - Bailey Type KM55A Model E101
Gas flow - 0-300,000
Air How - 0-3,000,000
Normal operating range (gas flow) 0 - 250,000 CFM
Typical reading (gas flow) 200,000 CFM
Normal Operating range (airflow) 0 - 2,650,000 CFM
Typical reading (air flow) 2,120,000 CFM
Reverb Combustton Air Flow Control
p - 30 psi (instrument air pressure)
Normal operating range - 13 to 24 psi
Typical reading 15 psi
Reverb Draft Control
0-30 psi (instrument air pressure)
Reverb Draft Recorder - Bailey Type KM55A Model E 101
-3 to +3"H2O
Normal operating range 0 to -'. 3
Typical reading -.06
Reverb Oil Flow Meters (2) - Rockwell
0 - 30 gpm (each)
Normal operating range 26 - 28 gpm
Typical 28 gpm
Oxygen-Natural Gas Burners (2) (pressure guage only)
(0 - 30 Ibs oxygen), (0 - 60 Ibs. gas)
Normal operating range - gas 8 Ib.; air 10 Ib.
Typical reading - gas 8 Ib.; air 10 Ib.
Preheater Induced Draft Control
0-30 psi (instrument air pressure)
-------
Preheater Fuel (Gas)
0-30 psi (instrument air pressure)
Reverb Furnace Bath Temperature Recorder - Bailey Type WM55A Model El00
1500° - 3500° F
Normal operatini
Typical reading 2,500° F
Normal operating range 2,300 - 2,600° F
-------
APPENDIX E
Instrumentation for Converter and Refining Furnaces
CONVERTERS
Converter Air Flow and Bath Temperature Recorders - Bailey Type WM55A Model E101
Total (3) - one per converter
Air flow 0-30 (instrument air)
Normal operating range 20,000 - 22,000 SCFM
Typical reading 21,000 SCFM
Bath temperature 1500° - 3000° F
Normal operating range 1900° - 2250°
Typical reading 2250° F
Converter Air Pressure and Air Temperature Recorders- Bailey Type KM55A Model E101
Total (3) - one per converter
Air pressure 2.5-25.0psi
Normal operating range 13.0 - 18. 0 psi
Typical reading 15. 0 psi
Air temperature 0 - 400° F
Normal operating range 200 - 300° F
Typical reading 250° F
Converter Gas Flow (Mouth Burners*- Natural Gas)- Bailey Type KM55A Model El01
(One instrument monitors all gas)
Gas flow
Normal operating range
Typical reading
(*) Amount of gas used dependent upon availability of matte
% SO2 Recorder - Leeds & Northrup Speedomax
0 - 14. 5% (% of total off gas volume)
Normal operating range 0-8%
Typical reading 5%
Gas Cooler Temperature Recorder and Control - Bailey Type WM55A Model E101
Total (3) - one per converter
500° - 1000° F
Normal operating range 650 - 750° F
Typical reading 700° F
-------
Converter Hood Outlet Draft Recorder - Bailey Type KM55A Model El01
Total (3) - one per converter
0 to +5" H2O
Normal operating range +£- to -£" H2O
Typical reading 0" H2O
Plenum Draft Recorder and Control - Bailey Type KM55A Model El01
0 to -15" H2O
Normal operating range -4. 6 to -5.2" H2O
Typical reading -5.0" H2Q
ANODE FURNACES
Utility Gas Flow Recorder- Bailey Type KM55A Model El01
(in waste heat boiler office at reverb)
0 - 2,000 CFM
-------
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-------
KENNECOTT COPPER CORPORATION
RAY MINES DIVISION
HAYOEN, ARIZONA 65235
March k, 1976
Mr. Gary D. Young, Environmental Engineer
National Field Investigations Center
Environmental Protection Agency
Building 53, Box 25227
Denver Federal Center
Denver, Colorado 80225
Dear Mr. Young:
Attached is information requested by phone from you and
Mr. Reid Iversen. Information includes:
1. Paper on Acid Plant Gas Handling System,.
presented at December 2, 197^ AIME Meeting.
2. Photographs of Stack Sampling Stations.
3. Information on Reactor Cyclones.
k. Information on Electrostatic Precipitators.
Yours truly,
f.
Joseph T. Mortimer
Director of Safety and
Environmental Control
JTM/es
End.
cc: Mr. Reid Iversen
Mr.K. H. Matheson, Jr.
-------
Reactor Cyclones
a. Manufacturer: The Ducon Company
b. Manufacturer's guarantees, if any: expired.
c. Date of last modification and detailed description of the nature and
extent of the modification.
Total system redesigned to estimate plugging of second bank
of cyclones. (See attached drawings)
d. Description of cleaning and maintenance practices.
Reactor cyclones are cleaned when plugged.
e. Design and actual values for the following variables:
Design Actual
i
1. Number of banks 2 U
2. Number of stages 8 2
3. Gas flow rate/cyclone 3630 16250
h. Operating Temperature 1200°F 1200°F
5. Collection Efficiency 100$ 96.5
6. -Pressure drop 15.5 W.C. 1?.5 W.C.
-------
2/25/76
Electrostatic Precipitators
Collection^
Area - ft*
Reverb - Koppers
5^,000 ft2
Converters - Western Precip^.
39,7^ ft2
Gas Vel. -
ft/sec.
Original = U.8 ft/sec.
Original
Wow
1.6 ft/sec.
Design = 3.6 ft/sec.
Original
Now
= 3-9 ft/sec,
Treatment
Time - sec.
Original = if.69 sec.
Original
Now
= lU.l sec.
Design = 10 sec.
Design
Now = 9-2 sec.
-------
siiii
DATE!
1841 NORTH 1STM AVENUE • HO EN IX . A R I ZON A
•j- .'
-i—?:."
i, : . r i
Electrostatic
Preeipitator
Cooling
Vessel
...'.- F » .m ' . ' i • '.' ' ."} ' I' f. *' ''.*«'„.<
, :> Fan •--,.'' UD.^Fan •--!^>-^..-l^l;^:|™i._ ivi^^ij;:^^^.
•t»—:— : J -i ' • • -.1-* ''^'Liv^ :r'.L£"-:'.'.' ;* - •
. . ' ^\ -. ..'.'_'*TM: ,:.„•,...!• [ii J! ...'JV'.-1-^-'. .".-iSraelc K.
i_
Relocated
Fan
i" Peabody -~
Scrubber .
inr . ( .,.i . •••;.-.! -»-fc, •• if,, :: •- • • .' .••;
' - i - - -j ... i I-From, :,_r..ri..'From'-:-_. ^
• "j «^ . :!>• Conv«rtor riv*'iRevarbqtory
-'-• ; --,t--;;;ff;f.oe-----(.
TV -f ; ;
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KENNECOTrcqPPER trlill|5
HAYDEN,>RIZQNA . , l-.:j
"•''?^1 'i^VffiST'**^1' S^UWBT^ffW^
&iSA2?Mwfcs*£ > jiii3raiiiHsL4s?il3:kl''
-------
DATE.
.1841 NORTH 15TH AVENUE • (6O2) 277-726B • PHOENIX. ARIZONA 85015
t> M c. M
-------
Appendix C
SIP Regulation Applicable to Kennecott
-------
RULES AND REGULATIONS
Subpart D—Arizona
§52.124 [Revoked]
1. Section 52.124 is revoked.
2. Section 52.126 is amended by add-
ing paragraph (b) as follows:
§ 52.126 Control strategy and regula-
tions: Parliculate matter.
• • • * •
(b) Replacement regulation for Regu-
lation 7-1-3.6 of the Arizona Rules and
Regulations for Air Pollution Control,
Rule 31 (£) oj Regulation III of the Rfari-
copa County Air Pollution Control Rules
and Regulations, and Rule 2(B) of Reg-
ulation II of the Rules and Regulations
of Pima County Air Pollution Control
District (Phoenix-Tucson Intrastate Re-
gion) .—(1) No owner or operator of any
stationary process source in the Phoenix-
Tucson Intrastate Region (5 81 36 of this
chapter) shall discharge or cause the
discharge of participate matter into the
atmosphere in excess of the hourly rate
shown in the following table for the proc-
ess weight rate identified for such
source:
Process Fmmsion Process Emission
weight rate rate weight rate rate
(pounds (pounds (pound:, (pounds
per hour) per liour) per hour) per hour)
80
100
800
1,000
5,000
10,000
20,000 ...
0 38
0 55
1.53
2 25
6 34
9 73
14 99
60 000
80 QUO
120,000
ICO 000
VOO.OOO
400 000
1,000,000
29 60
31 19
33 28
34 85
38 11
40 35
46 72
(i) Interpolation of the data in the ta-
ble for process weight rates up to 60,000
Ibs/hr shall be accomplished by use of
the equation:
E=3 59 P"-" P< 30 tons/h
and Interpolation and extrapolation of
the -data for process weicht rates In ex-
cess of 60,000 Ibs/hr shall be accom-
plished by use of the equation:
P>30tons/b.
(It) Process weight is the total weight
of all materials and solid fuels introduced
Into any specific process. Liquid and
gaseous fuels and combustion air will
Dot be considered as part of the process
weight. For a cyclical or batch operation.
the process weight per hour will be de-
rived by dividing the total process weight
by the number of hours in one complete
operation from the beginning of the
given process to the completion thereof.
excluding any time during wluch the
equipment is idle. For a continuous op-
eration, the process weight per hour will
be derived by dividing the process weight
for a given period of time by the num-
ber of hours in that period.
(iii) For purposes of this regulation.
the total process weight from all similar
units employing a similar type process
shall be used in determining the maxi-
mum allowable emission of participate
matter.
(2) Paragraph (b)(l) of this section
shall not apply to incinerators, fuel
burning installations, or Portland cement
plants having a process weight rate in
excess of 250,000 Ib/h.
(3) No owner or operator of a Port-
land cement plant in the Phoenix-Tucson
Intrastate Region (§ 81.36 of this diop-
ter) with a process weight rate in excess
of 250.000 Ib/h shall discharge or cause
the discharge of participate matter into
the atmosphere in excess of the amount
specified in § 60 62 of this chapter
(4) Compliance with this paragraph
shall be in accordance with the provi-
sions of $ 52.134(a).
(5) The test methods and procedures
used to determine compliance with this
paragraph are set forth below The meth-
ods referenced are contained in the ap-
pendix to part 60 of this chapter. Equiv-
alent methods and procedures may be .
used if approved by the Administrator.
(i) For each sampling repetition, the
average concentration of participate
matter shall be determined by using
method 5. Traversing during sampling
by method 5 shall be according to meth-
od 1. The minimum sampling time shall
be 2 hours and the minimum sampling
volume shall be 60 ft3 (1.70 nT), cor-
rected to standard conditions on a dry
basis.
(ii) The volumetric now rate of the
total effluent shall be determined by us-
ing method 2 and traversing according to
method 1. Gas analysis shall be per-
formed using the integrated sample
technique of method 3, and moisture
content shall be determined by the con-
denser technique of method 4.
(in) All tests shall be conducted while
the source is operating at the maximum
production or combustion rate at which
such source will be operated. During the
tests, the source shall burn fuels or com-
binations of fuels, use raw materials, and
maintain process conditions representa-
tive of normal operation, and shall op-
erate under such other relevant condi-
tions as the Administrator shall specify.
Where: E= Emissions in pounds per hour
P= Process weight In tons per hour
FEDERAL REGISTER, VOL. 38. NO. 92—MONDAY, MAY 14, 1973
-------
Appendix D
Example Calculations of Gas Flow Rates
and Equivalent Duct Diameters
-------
Flowrate at Standard Conditions*
Ti
^ - v-^,^,.,
's ps 'i
where:
given pressure = 14.7 psi therefore P^ = Pc
given gas volume
given temperature in ° R = 492°R
pressure @ std condns (14.7 psi or 760 mm Hg)
gas volume @ std condns (in same units as V.)
temperature @ std condns (530 °R)
Roaster
22.030 (530)
492
= 23,730 scfm
Reverberatory Furnace
H2.899 (530) _
- ' - *-
Converters
<
Cyclones
Actual: V.
crfm
scfm
70,000 (530) 7, .nc ,
— qg2 = 75,406 scfm
16,250 x 4 (pairs of cyclones)(530)
492
= 70,020 scfm
Peabody Scrubber (Roaster)
J2.030J5301
's 492
Reverberatory Furnace ESP
Design: Vg =
Actual: V.. =
300,000 (530) •_
scfm
nnn cr,
,000 scfm
165,000(530) . 177>800 5cfm
* Reference 1 reports standard conditions as 760 mm Hg (14. 7 psi) and
0 °C (32°F). The calculations below are simple corrections of reported
values.
-------
Peabody Scrubber (Converters)
70.000^(530) .
Acid Plant
Vs = 83.00M530) = 89,400 scfm
Duct Diameters (Sampling Station to Stack Bottom)
n ^amQ*Q^ - 229 ft (height of sampling station)
u idiameters; - 27 ft 7 in (diameter of stack @ sampling station)
D = 8.3 diameters
8 diameters = 8 x 27' 7" = 220' 8"
229 ft - 220 ft 8 in = 8 ft 4 in
------- |