ENVIRONMENTAL PROTECTION AGENCY
OFFICE OE ENFORCEMENT
NSPIRATION
NSPIRATION
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
EJBD DENVER, COLORADO
ARC HIVE ^t0 ST/%
EPA *•
331- I
R- Q
76- \
007
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STATE IMPLEMENTATION PLAN
INSPECTION OF
INSPIRATION CONSOLIDATED COPPER COMPANY
INSPIRATION SMELTER
INSPIRATION/ ARIZONA
SEPTEMBER 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
'r)ermanent 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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INSPIRATION CONSOLIDATED COPPER COMPANY
Inspiration, Arizona
SUMMARY AND CONCLUSIONS
Inspiration Consolidated Copper Company operates an open pit mine,
concentrator, oxide ore leach plant, smelter, and tank house for the
production of cathode copper near Inspiration, Arizona. An inspection
to acquire data with which to evaluate the design and operation of
existing particulate matter air pollution control equipment at the
smelter and to survey the suitability of the smelter to be emission
tested was conducted by state and EPA personnel on January 26-27, 1976.
Substantial amounts of process, control equipment, and stack sampling
were requested of and received from the Company.
The following conclusions are based on the inspection and a review
of the information obtained:
1. The Inspiration Smelter is the newest Arizona smelter and the
only one which has an electric furnace instead of reverberatory
furnaces. It is also one of the two smelters which reports,
on the basis of stack testing results, that it is in compliance
with the process weight regulation. However, as will be
discussed below, those stack test results should be considered
invalid.
2. This smelter uses cyclones as a pretreatment device preceding
the electrostatic precipitators (ESP's). This arrangement
reduces by 80% the particulate matter concentrations to be
controlled by the ESP's. No test data are available with
which to draw conclusions as to the appropriateness of such a
control system.
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3. The measured gas volumes produced by the individual process
units are less than the design gas volume capacities of the
control systems. This allows the control systems to operate
at their design efficiencies.
4. The source tests conducted at the Inspiration Smelter did not
determine whether the smelter was in compliance with the
process weight regulation because both tests were performed at
an unsuitable location. Upstream and downstream flow disturbances
are in close proximity to the sampling station so that Method
1 criteria cannot be met. In addition, only one diameter
could be traversed and only 12 points, instead of 48, were
sampled. Isokinetic rates were not within tolerances.
5. The control system design of the entire smelter suggests the
smelter is capable of complying with the process weight regulation.
Continued performance of an acid plant requires a nearly
particulate free inlet gas stream. Thus, the cyclones, ESP's,
and cold gas cleaning system of scrubbers and mist ESP's must
perform adequately and continuously. If the inlet particulate
matter concentration to the acid plant is high, the catalyst
beds in the acid plant conversion towers will soon clog, the
plant will be shut down, and the bypass stack will have to be
used.
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INSPECTION OF
INSPIRATION CONSOLIDATED COPPER COMPANY
INSPIRATION SMELTER
Inspiration, Arizona
January 26-27, 1976
612/473-2411
INTRODUCTION
The Inspiration Consolidated Copper Company operates an open
pit mine, concentrator, oxide ore leach plant, smelter, and tank house
for the production of cathode copper near Inspiration, Arizona. Based
on September 1975 data, the daily production was 350 m. tons (385 tons)
of blister copper with an approximate assay of 98% copper.
On December 17, 1975, the Vice President and General Manager of the
Inspiration Consolidated Copper Company was requested by letter to pro-
vide process and air pollution control information on the Inspiration
Smelter, and informed of a planned plant inspection [Appendix A]. On
January 26 and 27, 1976, the following EPA and State personnel conducted
a process inspection: Mr. Meade Stirland, Arizona Department of
Health; Mr. Larry Bowerman, EPA, Region IX; Mr. Gary D. Young, EPA,
NEIC; Mr. Jim V. Rouse, EPA, NEIC. The data requested were furnished at
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 and to survey the suitability of the smelter
to be emission tested. The inspection focused primarily on the smelter,
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although the oxide ore leach plant and tank house were also inspected.
The process equipment, the particulate matter emission sources, and the
air pollution control equipment were also examined. The inspection team
surveyed the existing smelter source testing locations for accessibility
and capability to perform source testing.
Company personnel were cooperative throughout the inspection. Com-
pany personnel participating included: Mr. D. W. Middleton, Vice Presi-
dent and General Manager; Mr. W. Pattullo, Director of Environmental
Control; Mr. J. B. Holman, General Superintendent.
The applicable regulation contained in the Arizona State Implementa-
tion 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 allows certain emission rates for each process unit based
on the production feed rate.
PROCESS DESCRIPTION
Figure 1 is a simplified process flow diagram for the Inspiration
Smelter. Table 1 is a list of the smelter process equipment and
operating data.
Concentrates and precipitates are bedded in an enclosed building
near the smelter building. Limestone flux is added to the bedded material.
The mixture is reclaimed by front-end loaders which deliver it to a
charge belt to the dryer. In the dryer the moisture content of 9 to 12%
is reduced to less than 0.3%; a moisture-free condition in the furnace
feed is necessary to prevent explosions. The dried material is discharged
to a pair of 635 m. tons (700 tons) capacity furnace feed bins located
above the slag tapping endwall of the furnace.
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CASTING WHEE
CONCENTRATES
PRECIPITATES
REVERTS
SLAG
ELECTRIC
FURNACE
AIR
SILICA FLUX
CD
m
CONVERTERS (5)
REFORMED GAS
~TOLL CUSTOMERS
ANODE FURNACE
Figure I. Inspiration, Inspiration Process. Flow Diagram
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Table 1
SMELTER PROCESS EQUIPMENT AND OPERATING DATA
INSPIRATION CONSOLIDATED COPPER COMPANY
Inspiration, Arizona
Parameter
Electric Furnace
Converters
No. of Units
Feed Constituents1
Feed Rate
1
C/C, R, F, CS
(m. tons/day) (tons/day)
M, F, CD
(m. tons/day) (tons/day)
C/C
R
F
CS
1212
77
109
529
1335
85
120
583
M
F
CD
803
482
321
..
1"r
Size of Unit
Mrs. Operation/mo
Gas Volume Generated
Exit Gas Temperature
Total 1927
(meters)
Width 10
Length 36
2123 Total 1606
(feet) (meters)
34 Diam.
117 Length
720-744
o
(std m/min)
433-722
°C
650-760
>tttt
(scfm)
15,300-25,500
°F
1,200-1,400
12
(std m3/min)
578-663
°C
885
531
354
tf
1,200
1707
(feet)
14ttt
38m
720-744
(scfm)mt
20,400-23,400
°F
2,200
t Concentrates/cements (C/C)t Reverts (R)3 Flux (F)s Converter Slag (CS),
Cold Dope (CD)
tt Assume 0.6 ton flux/ton of matte
ttt Siphon converters are considered to be the equivalent of 4 x 10 m
(14 x 32 ft)^ Fierce-Smith converters
tttt Standard conditions are 760 mm Eg (29.92 in Eg or 14.7 psia) and 21°C (70°F)
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The El kern electric furnace is the largest copper matting furnace in
the world. The furnace's inside dimensions are 10 x 36 m (34 x 117 ft)
In width and length, respectively. The furnace is equipped with six
self-baking carbon electrodes, 180 cm (71 in) in diameter, that enter
the furnace along the center line of the sprung arch roof. The electrodes
can be raised or lowered, but when in operation dip into the molten slag
above the matte layer. Heat for smelting is generated by resistance of
the slag to the submerged arc between electrode pairs.
Dried feed is reclaimed from each feed bin by a variable speed
screw feeder which augers the charges to a drag conveyor extending
nearly the length of the electric furnace. Each bin features this
arrangement, one serving the east and the other the west side of the
electrode lines. Each totally enclosed drag conveyor delivers the
charge to a series of fifteen feed spouts on the furnace roof. Seven
spouts are near the line of electrodes; the other eight are near the
furnace sidewall. The charge in the spout enters the furnace first
through an arc gate and then through a weighted tilt gate, sequenced so
that a seal is maintained on the furnace. Most of the charge is introduced
nearest the electrodes; the remaining 10 to 20% enters through the
spouts near the furnace sidewalls.
The inverted, double arch bottom of the furnace and the end- and
sidewalls, to a point above the bath line, are of basic brick construc-
tion. Above the bath the upper side- and endwalls and the sprung arch
roof contain fire brick. The furnace is supported on concrete piers.
Vertical steel columns and tie rods clamp the sidewalls and provide ad-
ditional structural support.
The endwalls of the furnace are water cooled. The sidewalls and
bottom are air cooled from a set of three blowers rated at 3,340 std
m3/min (118,000 scfm) each, on each side of the furnace at ground level.
Two blowers on each side normally operate at one time, with the air
produced sweeping under the furnace, up the sidewalls and exhausting
through the roof, changing the atmosphere once each minute.
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The unit operates with 76 cm (30 in) of matte and a 152 cm (60 in)
slag layer. Slag is skimmed from either of two tap holes in the endwall
of the furnace into a launder. The launder delivers slag to 17 m (600
ft3) pots mounted on trucks which haul the slag to a dump. The matte
endwall faces the converter aisle and contains four holes for drawing
off matte into two pairs of launders. Two 8.5 m3 (300 ft ) ladles are
positioned on either side of a swivel spoon at the end of the matte
launder. As matte flows into the swivel spoon a ladle fills. Once it
is filled, the swivel spoon tilts to a reverse slope and matte flows
into the adjacent ladle.
Matte ladles are picked up by an overhead crane and matte is charged
to one of the five Hoboken-Overpelts converters. These siphon converters
are 4 x 12 m (14 x 38 ft) in diameter and length, respectively. Air is
blown into the charge through tuyeres, flux is added, and slag produced
is skimmed into a ladle. The converter slag is then returned to the
electric furnace by overhead crane. Additional matte is added to the
converter to produce finished blister copper. Of the five converters,
four will be in service while one is down for repairs. The converters
are cycled so that one hot converter is on standby and the other three
are in operation and blowing a large percentage of the time. The three
converters on blow are staggered so that one is on its "copper blow"
while the other two are at differing stages of the "slag blow."
Finished blister copper is poured into ladles and carried by over-
head crane to the one anode furnace or returned to toll customers. The
anode grade molten copper is cast into molds on the casting wheels. The
anodes are cooled, inspected, and transferred to the Inspiration tank
house for production of cathode copper.
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EMISSION SOURCES AND RELATED CONTROL EQUIPMENT
The primary participate matter sources at the Inspiration Smelter
are the electric furnace and the converters. The majority of the exhaust
gas volumes produced by these sources is treated by control systems
which are discussed below. Fugitive emissions from such sources as
skimming and returning converter slag are neither collected nor treated,
but are exhausted directly to the atmosphere through the smelter building
roof vents. The anode furnace emits some untreated particulate matter
directly to the atmosphere above the converter aisle; however, since
this gas stream is not collected, the concentrations are indeterminate.
Figure 2 is a diagram of the Inspiration Smelter plant layout, the
air pollution control system, and the exhaust gas flow. Table 2 summarizes
certain design and operating data for the individual air pollution con-
trol systems. Appendix B contains more specific information on each
control system.
Electric Furnace Control System
The principal electric furnace exhaust gases pass through a vertical
radiation-type gas cooler. Heat recovered from the 590°C (1,100°F) exit
gases is used for steam production. The gases then enter a convection
type gas cooler, flowing outside a bundle of tubes through which cooling
air is circulated by a fan. The furnace gas temperature has thus been
reduced to 510°C (950°F). The first stage of hot cleaning of the
electric furnace gases takes place in two parallel cyclones. The cyclones
o
are designed to handle a maximum gas volume of 870 std m /min (30,000
scfm), but usually handle between 430 and 720 std m3/min (15,300 and
25,500 scfm) [Appendix D]. Second stage hot cleaning of the furnace
gases is performed by an electrostatic precipitator (ESP) with an operating
temperature range between 315 and 400°C (600 and 750°F). With some air
infiltration into the system, an estimated design volume of 1100 std
m3/min (38,700 scfm) of gas is delivered to the acid plant.
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ELECTRIC
FURNACE
CONVECTION
COOLER
PROCESS PLOW
_____ EXHAUST OASES
-0
VCLONE8 (2)
EXHAUST
4
ESP
BYPASS STAC
CONVERTERS (B)
CYCLONES
(8)
ANODEFURNACE
CONVECTION
COOLER
ESP ^
««y-
, VENTURI
I SCRUBBERS (2) PACKED TOWERS (2)
MIST ESP (8)
RYING TOWER
INTERMEDIATE
ABSORBTION
TOWER
• • •
H—'
CATALYST
CHAMBER
HEAT EXCHANGERS
\
O FINAL
ABSORPTION
I
TOWER
IACID PLANT
STACK
Hguro 2. fnspfroflon, Intplrotlen Plant layout. Prec.n Cnha.if flow, and Air Pollution Control Sr»»«m«
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Table 2
SMELTER AIR POLLUTION CONTROL EQUIPMENT AND DATA
INSPIRATION CONSOLIDATED COPPER COMPANY
Inspiration, Arizona
Date of
Control Installation/ No. of Gas Flow Operating
Device Manufacturer Modification Units _. Rate Temp. Pressure
m°/min scfma °C
op HO
cm
Collection
Drop Area Velocity
n>2 ft 2 m/sec ft/sec
in
Retention
Time
sec
Electric Furnace
Cyclones Ducon NRb
ESP Research ri 1973
2 866 30,600 455
1 433- 15,300- 400
850 NR
750 ' NR
NAC NR
NR NR
NR
NR
Cottrell 722 25,500
Scrubbers and
Acid Plant (see description under Converters)
Converters
Cyclones
ESP
Scrubbers6
Acid Plant
Ducon
Research
Cottrell
Cyprus Skele
Lurgi
NR
1973
1973
19739
5
3
2
1
663
866
3030
3030
23,400
30,600
107,000
107,000f
480
400
290
105
900
750
550 5
NR
NR
2
NR
NA
NR
NA
NA
NR
NR
NR
NA
NR
NR
NR
NA
a Standard conditions are 760 mm Hg (29.92 in Eg or 14.7 psig) and 21°C (70°F)
NR = Not reported
c NA = Not applicable
d Reference 2 reports this unit is a Western Precipitation ESP
Venturi-type _
1 Design flow rate is 2770 std m /min (97*800 scfm) ^Appendix D"]
9 Double absorption
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10
Converter Control System
The converter exhaust gases become laden with participate matter
when air is blown into a converter through tuyeres to oxidize the iron
and copper sulfides. An estimated 660 std m3/min (23,400 scfm) of gas
is produced by one converter and is exhausted through a vertical waterwall
radiation and convection cooler to cool the gases from 1,200 °C (2200
°F) to approximately 480 °C (900 °F). The exhaust gas then enters a
cyclone (one per converter) and subsequently is delivered to a mixing
plenum chamber which serves three ESP's in parallel. The cyclones are
designed to remove 80% of the dust carried in the gas stream. The ESP's
are each designed to handle 980 std m3/min (34,700 scfm) of gas at a
maximum temperature of 400 °C (750 °F). The gases cleaned in the ESP's
are ducted to the acid plant.
The cleaned and cooled electric furnace and converter gases are
combined and ducted to the cold gas cleaning system preceding the acid
plant. Here the gas is split between a pair of venturi scrubbers,
flowing concurrently with 20% sulphuric acid solution down through the
units and then into the lower end of either of two packed washing and
cooling towers. Cooled gases from the packed towers are combined and
then split again before entering either of two pairs of mist ESP's.
Upon exiting the first two pairs, the gas is again recombined and then
split to pass through a second set of mist ESP pairs.
A gas volume of approximately 3720 std m /min (131,500 scfm) con-
taining 7% S02 then enters the double absorption acid plant where it is
dried, the S02 converted to S03> and the S03 absorbed in acid to form
the final strength acid. Although designed to produce 1210 m. tons
(1330 tons/day), approximately 910 m. tons (1000 tons)/day of 92 to 95%
strength sulphuric acid is actually produced. The exit gas from the
final absorption tower is exhausted from the 60 m (200 ft) acid plant
tail gas stack.
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11
EMISSIONS DATA
Three separate source tests were conducted at the Inspiration
smelter during 1975 by Engineers Testing Laboratories (ETL), Phoenix.
Only the two tests on the acid plant stack are of particular interest
for this report. Both tests were believed to be compliance tests following
the prescribed methods (Methods 1-5) in the EPA regulation [Appendix C].
The sampling location for both tests was the single horizontal port
located on the breeching to the acid plant tail gas stack. At this
location the duct is 2 m (6.4 ft) in diameter. Upstream of the port
less than one-half duct diameter,the gas stream enters the stack. Less
than one-half duct diameter downstream from the port is a flange in the
duct. Only twelve sampling points were used on one diameter during both
tests.
Individual hourly process weights were not determined for the first
test, but were determined for the second test. For that test, the
estimated charging rate to the electric furnace was summed with the
estimated charging rate of cold dope and silica to the converters. The
allowable process weight was then calculated by the formula contained in
the applicable regulation [Appendix C], and the test results compared
with the allowable results.
Following is a summary of both tests and comments regarding the
methods, procedures, and results of each test.
May 8-9. 1975
The sampling train used was a Method 5 front-half with a 10% solu-
tion of hydrogen peroxide in the impingers. Moisture was measured as
impinger weight gain corrected for sulfur compounds as SOg in the gas
stream.
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12
Only two runs were conducted. The minimum sampling time of 2 hours
and the minimum sampling volume of 1.70 m (60 ft ) [Appendix C], were
met for the first run but not the second; the second run was conducted
3 3
just over 80 minutes at only 8 traverse points and only 1.5 m (52 ft )
of gas was collected. The isokinetic flow rates were not reported. The
results of test runs 4 and 5 are presented in Table 3.
June 17. 1975
The sampling train arrangement was the same as that used in the May
test. However, only a 5% solution of hydrogen peroxide was used in the
impingers. Moisture content was assumed to be nil based on the results
of the May test. Only two runs were conducted. The sampling time was
2 hours for each run and the sampling volumes were 1.78 and 1.66 m
(63.3 and 58.5 ft3), respectively. The isokinetic rate was 111% for
both runs. The results of both runs are presented in Table 3.
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13
Table 3
PARTICULATE MATTER EMISSIONS TEST RESULTS
INSPIRATION CONSOLIDATED COPPER COMPANY
Inspiration, Arizona
Test
Run
4
5
1
2
Date
(1975)
5-8
5-9
6-17
6-17
Stack
Temperature
F
120
133
131
128
°C
49
56
55
53
Gas Moisture
Volume Content
acfm
98,100
93,400
83,500
78,900
mj/min %
2,780 <0.1
2,640 <0.1
2,360 <0.1ft
2,230 <0.1ft
Actual
Emissions
Ib/hr
5
7
11
11
kg/hr
2
3
5
5
Allowable
Emissions
Ib/hr kg/hr
NDf
ND
38 17
38 17
t ND = Not Determined
t+ Assumed values from previous test results
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14
BIBLIOGRAPHY
1. Copper Smelter Information Needs, Inspiration Consolidated Copper
Company, Inspiration, Arizona. Undated.
2. Inspiration's Copper Smelter Facilities. Richard C. Cole, Vice
President. Oct. 1974.
3. Particulate and Sulfur and Emissions Tests, Concentrate Dryer and
Acid Plant, May 6, 7, 8 and 9, 1975. Inspiration, Arizona.
Engineers Testing Laboratories, Inc., Phoenix. 1975.
4. Particulate Emissions Tests, Acid Plant, June 17, 1975. Inspiration,
Arizona. Engineers Testing Laboratories, Inc., Phoenix. June 30, 1975,
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APPENDIX A
NEIC INFORMATION REQUEST
LETTER TO INSPIRATION
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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
D. W. Middleton
Vice President and General Manager
Inspiration Consolidated Copper Company
Inspiration, Arizona 85537
Dear Mr. Middleton:
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
(303/234-4658) 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
.^ . . Director
Attachment
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 - pressur.e (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
1. 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. Flans 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)
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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
1. 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
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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
£. 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)
11. Bag spacing (inches)
ill. 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)
vlii. 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)
11. Pressure of scrubbing media (psi)
111. 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)
vli. 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:
t
i. Production (T of acid/day)
II. Conversion rate (percent)
iii. Acid strength (percent l^SO^)
iv. Number of catalyst beds
v. Gas flow rate (SCFM)
vi. Operating temperature (°'F)
vii. Inlet SO2 concentration (ppra)
viii. Outlet S02 concentration (ppm)
lx. Acid mist (Ibs H2S04/T of acid)
x. Blower pressure (psi)
6. Liquid S02 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
1. 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 S0~ 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)
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APPENDIX B
INSPIRATION RESPONSE TO NEIC
INFORMATION REQUEST
-------
COPPER SMELTER INFORMATION NEEDS
A. GENERAL
1. Plant Location - Inspiration, Arizona
2. Person to contact: D. W. Middleton, Vice President and
General Manager
Telephone: 612-473-2411, Ext. 201
Address: Inspiration, Arizona 85537
3. Block flow diagram, etc. - See attached page 1(A)
B. PROCESS
1. General
a. & b. Detailed description of process, flow diagrams,
unique features, how process operates:
The new plant will be operating about 40% on Inspiration
feed and 60% on toll-processed material. The electric matte
furnace is designed for a daily diet of 1,821 tons of feed
composed about as follows: 1,500 tpd of concentrate, 148 tpd
of cold dope, 123 tpd of silica flux, and 50 tpd of limestone.
Inspiration feed and toll concentrate (with copper precipi-
tates) are bedded in an eclosed building on a concrete slab in
two parallel 6,000-ton piles by means of an overhead tripper
conveyor system. Lime is needed for the electric furnace and
is added as minus 1/4-in. material in the bedding plant. The
bed mixture is reclaimed by front-end loaders which deliver it
to a 24-in. wet charge belt equipped with a continuous weighing
system. Wet concentrate with silica flux, as required, and
reverts are conveyed to a 550-ton wet charge bin.
A screening installation is used to provide the converters
with sized plus 1/4-in. minus 2-in. cold dope and silica. This
system also handles and sizes matte smelter reverts to minus
1/4-in. for the electric furnace. The feed preparation used for
the new plant varies somewhat from the mix blended for the reverb-
eratory system. Formerly, flux, concentrates, and precipitates were
interlayered in the bedding building, and the old furnace was fed
a wet charge. Reverts were recycled directly to the converters.
The mix delivered to the wet charge bin in the new system has
a moisture content of 9% to 127.. It must be taken to a bone-dry
condition, largely to prevent explosions that may range from a
mild bump to something of a damaging proportion. Experience else-
where has shown that serious eruptions can occur in an electric
-------
I
r.r
Overall view of smeller and pollution control faci ities described in following
illustration, photographs and text. (Photography by Dale R Henderson. Inspitati
dated Copper Company)
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-------
furnace when the charge contains free moisture. For efficient
operation, electric matte furnaces run best with the bath
completely covered with solid charge. If moist charge caves
or sloughs into the bath, an eruption may follows.
Considered only from the aspects of the material and
moisture load, Inspiration invested in a rather large 16-ft-
dia by 80-ft-long Fuller rotary dryer with a fully insulated,
but unlined, stainless 316L steel shell. It is designed to
reduce the moisture content to 0.1% to 0.3%. Fired by either
natural gas or heavy fuel oil, the dryer helps conserve power
consumption in the electric furnace. However, the main factor
considered in its sizing was relief from the dust load carryover.
Most materials handled by the smelter are finely divided and
become very dusty when dried. They are easily swept by a fast-
moving stream of gases. In order to hold the particulate load
of dryer gases within reasonable limits, the unit was designed
to keep gas velocities low while taking advantage of dryer
residence time. It has been calculated that 20%, or less, of
the solids will be entrained in the gas stream.
The dryer is concurrently fired from Peabody burners. The
exit gas is maintained above the dew point for a cleaning system
consisting of a pair of Dracco cyclones and a high-efficiency
baghouse before it is vented to the atmosphere. The dried
charge is a very abrasive mixture that can become aerated to
form a fluid, free-flowing mass. To minimize problems in handling
this difficult material, the dryer was elevated on a concrete pier
to bring the discharge point as close as possible to a pair of
700-ton-capacity furnace feed bins, located on the charging floor
above the slag tapping endwall of the furnace. Both are totally
enclosed structures vented into the dryer dust collection system.
The Elkem electric furnace is the largest copper matting
furnace in the world. Measuring 34 ft wide by 117 ft long (ID),
the furnace is equipped with six in-line, self-baking carbon
electrodes, 71 in. in dia, that enter the furnace along the
centerline of the sprung arch roof. They dip into the molten
slag layer. Heat for smelting is generated by resistance of the
slag to the submerged arc between electrode pairs.
On the charging floor, a twin system is employed. Dried feed
is reclaimed from each 700-ton bin by a 6-ft-long variable speed
screw feeder which augers the charge to a 22-in.-wide, four-speed
drag conveyor extending 114 ft, nearly the length of the furnace.
Each bin features this arrangement, one serving the east and the
other the west side of the electrode line. Each totally enclosed
drag conveyor delivers the charge to a series of 15 feed spouts
that enter the furnace roof. Seven of these spouts are near the
-2-
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line of electrodes, and the other eight are near the furnace
sidewall. The charge in the spout enters the furnace through
an arc gate and then a weighted tilt gate, sequenced so that
a seal is maintained on the furnace. The end spout is open at
all times. Most of the charge will be introduced in the line
of spouts nearest the electrodes; the remaining 10% to 207. will
enter the line near the furnace sidewalls.
The inverted, double-arch bottom of the furnace and the end
and sidewalls, to a point above the bath line, are of basic
brick construction. Above the bath, the upper-side and endwalls
and the sprung arch roof contain firebrick. The furnace is
supported on concrete piers. Vertical steel columns and tie
rods clamp the sidewalls and provide additional structural
support. The unit operates with 30 in. of matte and a 60-in.
slag layer.
The endwalls of the furnace are water cooled. The sidewalls
and bottom are air cooled from a set of three blowers, rated at
118,000 cfm each, on each side of the furnace at the ground level.
Normally, two operate on each side and one is on standby. Air
sweeps under the furnace, up the sidewalls and exhausts through
the roof, changing the atmosphere once a minute.
Electric power is delivered to Inspiration at 115 kv and
stepped down to 22.9 kv in a new substation rated at 56,000 kva.
The transformer vault, located on the furnace charging floor,
takes 22.9-kv power on the primary side of three single-phase
transformers with a total rating of 51,000 kva.
The electric furnace transformers reduce the voltage to the
operating level required for slag resistance operation. They
are connected to the furnace electrodes by means of a bus bar
and flexible cable arrangement leading to a copper contact shoe
below the electrode slip ring. The slip ring permits automatic
adjustment of the electrode position according to the desired
power input. A full range of operating voltages is available,
and the power input will not exceed 11.5 kw per sq. ft. of hearth
area. The bus bars are contained in an enclosed duct, which is
under pressure to maintain a dust free atmosphere. If the trans-
formers should develop a leak, the oil is drained out of the
building and away from the electrical atmosphere.
Electrode paste for the Soderberg self-baking electrodes is
delivered to the smelter in 1-ton blocks having the following
specifications: fixed carbon 75.4%, volatile matter 11-12%, and
ash 7.6%. The blocks have a density of approximately 1.6 gm per
cc, and become fluid at 80° to 100°C. The electrode clamps and
slipping mechanisms, which act on the steel casing housing the
carbon, are the reverse of the arrangement used elsewhere. At
-3-
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Inspiration, Che clamps arc spring loaded in a closed position
and can be opened only by Che applicaCion of hydraulic power Co
100-ton jacks for purposes ofpositioning. The slip rate, based
on power input requirements, is normally handled automatically,
but the system is equipped with a manual override from a remote
station.
The upper floor of the furnace building is arranged for
electrode paste handling and the assembly of steel casing for
the carbon blocks. The floor is serviced from an elevator for
delivery of carbon blocks and flat 12-gauge steel plates. New
casing is assembled in sections standing 5 ft 11 in. in height
by first punching the sides of 18 plates to shape fins pointing
inward, then rolling them to the proper radius. The shaped and
punched sections are then joined into a finished cylindrical
section by an automatic welding machine. As casing and carbon
are consumed, a new casing section is mounted and welded Co Che
shortened assembly. A hoist then loads the carbon blocks into
the empty casing.
Electric furnace matte smelting eliminates the dilution of
reaction gases by the large volume of combustion products associ-
ated with fuel-fired furnaces. This makes it possible to pull a
4-6% S02 gas stream from the furnace into the uptake positioned
in the furnace roof near the matte tap endwall—a marked contrast
to the weak 0.5-0.8% S02 coming off Che reverberaCory furnace.
The furnace endwall panels, two slag tap blocks, four matte
tap blocks, and six electrode contact clamps are water-cooled
from a 1,200-gpm pumping, distribution, and return system. The
six electrode compression rings are water cooled by a separate
300-gpm pumping and circulation network.
Slag is skimmed from one of two tap holes in the endwall of
the furnace. A pair of launders, sloped close to 19%, delivers
the slag to a set of 600-cu-ft pots, and at the rated capacity,
the slag handling will amount to about 980 tpd. The pots will
be hauled to Che dump by trucks of special design. The slag end
of the furnace is equipped with a Joy tapping machine with a mud
gun assembly for opening and replugging the slag skimming hole.
The matte endwall faces the converter aisle, parallel to Che
longitudinal axis of the latter. This endwall contains four holes
for drawing off matte into two pairs of launders that take a modi-
fied V-shape in plan.
At the two junctions, the matte flows into one of two .swivel
spoons. Four 300-cu-fC ladles are posicioned in a sand pit at
the matte end. As a ladle is filled, Che swivel spoon is Cilted
to a slight reverse slope, accumulating matte in the spoon. It is
then pivoted to a new position over an empty ladle and down-tilted.
Rotation and tile of the swivel spoon is handled by air-actuated
cylinders.
-4-
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The converter is equipped with two 75-ton, two-hook P&H
overhead bridge cranes. A clever leap-frog winch arrangement,
installed near the junction of the two buildings, allows the
position of the new cranes to be interchanged on the same track
connecting the two converter aisles. The converter aisleway
serving the revcrberatory furnace contains cranes with a 40-ton
main hoist and two 20-ton auxiliary hoists for the 175-cu-ft
ladles in use there.
At the nominal rated capacity of the new smelter, over
1,200 tpd of matte will be tapped through the endwall. Con-
verter slag is returned through the matte tap endwall from
ladles that empty into two launders entering the furnace on
10 ft 6 in. centers about 10 ft above the matte tap holes.
The siphon converters, 14 ft dia by 38 ft long, are considered
the equivalent of 14 x 32-ft Peirce Smith converters. The five
Hoboken-Overpelts are equipped with automatic draft control, 52
tuyeres on 6-in. centers, a tight converter flue and gas cleaning
system, and a charge mouth of 20 to 25 sq. ft. This opening is
small by comparison with standard converters. The reaction end
of the vessel, measuring 32 ft. long, is extended by the siphon
which is totally enclosed and damned from the reaction zone to
contain the bath. The casing for this extension contains a
raised roof to siphon off the gases. It is also e'quipped with a
counterweight to compensate for the asymmetry of the vessel.
A horizontal 9-ft-dia concentric cylinder taps the siphon on
the rotary centerline of the converter unit, conducting the
offgases to a dust settling chamber and the gas uptake. A pro-
prietary gas-tight seal and joint links the rotating portion of
the vessel assembly with a stationary section which enters the
dust chamber. The entire converter assembly from endwall to the
dust chamber and uptake measures about 75 ft. long.
It is anticipated that each siphon converter equipped with
1-1/2-in. tuyeres, will be unable to take an air blast in the bath
much in excess of 20,000 scfm without tending to plug the siphon.
The Hoboken-Overpelt converters are installed on 55-ft centers
in a unique "en echelon" pattern slanted at 37.5° from the con-
verter aisle craneway. This arrangement places each converter
mouth under the crane aisle for ladle servicing. The siphon end
and gas uptake system of each converter extends outside the crane-
way in a lateral extension of the building. By freeing the exit
gas handling system from the path of crane travel, it has been
possible to use a simpler and more desirable design for the gas
uptake and initial cooling system since it has unencumbered head-
room. The converter platforms are equipped with Gaspe-type Heath
& Sherwood tuyere punching machines.
-5-
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Individual dampers installed in the flue system behind
each converter are automatically controlled. Regulation of
the dampers maintains an approximate zero pressure across the
mouth of the converter. The Hobokens will, in fact, hardly
tend to puff at the mouth, thus preventing gas escape and
minimizing the intrusion of dilution air. The latter two
effects are among the big advantages claimed for the siphon
converter. Reduced gas escape will pbviously improve in-plant
working conditions, and SC>2, concentrated in a manageable gas
stream, is a more desirable acid plant feed.
Each Inspiration converter is equipped with separate 80-ton ^
capacity cold dope and silica bins. Both bins are equipped with
variable-speed feeder belts which deliver sized, plus 1/4-in., /
minus 2-in. products to an adjustable downspout. This system is C, /
able to feed flus or cold dope to the converter while the tuyeres ;
are submerged and the converter is blowing. Matte can also be \
ladled into the converter during a blow. Such flexibility assists, )
in achieving an optimum gas grade for delivery to the acid plant.
Since the converters must now be geared to efficient acid
making, as well as blister copper recovery, the operating strategy
of Inspiration's seasoned converter crews will require some
reorientation. A new objective is in effect at the operacion--
to maintain as smooth a gas flow as possible in a volume that has
a concentrated SO2 content for the acid plant. The latter will
run more efficiently if surging volumes and SO2 grades are reduced.
Of the five converters, four will be in service while one is
down for repairs. The converters will be cycled so that one hot
converter will be on standby, and the other three will be in
operation and blowing a large percentage of the time. The three
on blows are staggered so that one is on its copper or finishing
blow while the other two are at differing stages of slag blowing.
Matte is tapped from the electric furnace for the hot standby con-
verter as the unit on the copper blow nears its end point. The
fourth converter can then start a slag blow, and the finished con-
verter can be down-turned for pouring blister copper. The hot blister
can be transferred via the craneway to the existing anode refining
furnace at the near end of the old converter aisle. Alternatively,
the blister can be cast into 6,000-lb cakes.
The converters on slag blows are periodically turned down to
skim slag for return to the electric furnace. When the smelter
is at its nominal rated capacity, about 600 tpd of converter slag
will be returned to the electric furnace. A fan of 40,000-cfm
capacity ventilates the matte tap end of the furnace.
From a materials handling view, the converter aisleway, the
reaction vessels and their work platforms, the associated gas
-6-
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handling equipment, and the feed arrangements for fluxing and
reverts present a clean, uncluttered design which lends a feeling
of spaciousness to the interior. The ground floor of the aisle
is concreted, but contains appropriate gravel pits under splash
areas, such as the converter mouths and the matte tap and slag return
area of the electric furnace. The aisleway also contains a preheat
station that can accommodate three ladles along the wall to the west
of gravel pit at the matte tap section. Between the preheat and
matte tap its, a ladle crust breaker ram has been mounted.
Electric furnace and converter gases are processed in separate
hot cleaning systems designed for high-efficiency recovery of par-
ticulates. The final exhaust from the hot gas cleaning system is
drawn through a 90-in.-dia flue to the acid plant where the stream
enters a cold gas cleaning installation.
The electric furnace generates an approximate average of 30,000
scfm of gas at 1,300°F. It leaves the furnace through an uptake
hood serving an American Schack Co. model, 14 ft sq by 65 ft high,
vertical radiation and shot-cleaned convection cooler. The radiation
section features water-wall construction. On leaving the convection
cooler, the gas has a temperature of about 850°F. A coupled flue on
the furnace building roof delivers the gas to one of two Ducon dust
cyclones arranged in parallel. It is estimated that a peak of 6,700
Ib. per hr. of particulates can reach the cylones, which are designed
to drop 807. of the dust load. Cycloned gas enters a high-velocity
flue linked with a Research Cottrell electrostatic precipitator,
which has a design specification of 98% collection efficiency.
On entering the Cottrell, the gas has been cooled to about
7SO°F. With some air infiltration in the system up through the
electrostatic precipitator, an estimated volume of 38,000 scfm of
gas from the electric furnace hot gas cleaning system is delivered
through a 48-in. flue to the insulated duct leading to the acid plant.
Converter gases are handled in much the same way. At peak
volume, each converter will produce about 23,000 scfm of gas at
2,200°F, which is swept from the dust chamber to a vertical American
Schack water-wall radiation and shot-cleaned convection cooler. The
gas leaves the radiation section at about 1,200°F and exits the
convection cooler at about 900°F. It is then cleaned in a Ducon
cyclone (one per converter), and five 46-in. flues deliver the
cycloned converter gases to a mixing plenum chamber which serves
three Research Cottrell electrostatic precipitators in parallel.
The converter cyclones are also designed to separate 80% of the
dust carryover in the gas stream. The electrostatic precipitators
on the converter system are each designed tn handle 34,000 scfm of
gas with a maximum temperature of 750°F at 95% collection efficiency.
All electrostatic precipitators for the furnace and converters are
ganged on the roof of the furnace building. Electrostatic precipitator
-7-
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gases from Che converter system are ducted in 48-in. insulated
lines into the 90-in. main delivering gas to the acid plant.
Dust from the precipitators and plenum chamber is collected
by screw conveyors and transported to a bin at ground level next
to the furnace building or to the furnace feed bins.
The draft to pull electric furnace and converter gases through
the hot cleaning system is created by two 1,250-hp hot gas fans,
each rated for 70,000 scfm. A total of about 140,000 scfm of gas
will be drawn to the acid plant from the hot gas cleaning system
of the electric furnace and the three converters that are on-line.
All flues in the hot gas handling installation are high-velocity
ducts which convey gas at speeds of 4,000 to 7,000 fpm to minimize
the settling of dust in the flues. The gas delivered to cold gas
cleaning at the acid plant should be about 550°F.
The merged gas streams from the smelter are piped 430 ft. in
the 90-in. main to the cold gas cleaning system at the acid plant.
Here, the gas is split between a pair of venturi scrubbers, flowing
concurrently with 25% sulphuric acid solution down through the
units into the lower end of two packed washing and cooling towers.
A bleed stream from the acid wash solution goes through a set
of settling tanks to remove sludge so that the circulating acid
can be adjusted to about 0.57, solids content. Some of the acid LS
bled to SO2 strippers. Stripper gas joins the smelter gas stream
entering the packed towers. The 25% acid from the stripper is
recovered for use in an agitation leach and CCD circuit for slimes
at the Inspiration concentrator.
A 1% washing acid circulates through the packed towers
countercurrently to the gas flow. This solution passes through
graphite tube and shell coolers. The condensed water from the
gases is ducted from the washing tower overflow to the sump of the
venturi scrubber.
Cooled gases from the packed towers at about 104°F are combined
and enter eight electrostatic mist precipitators, furnished by
Plastic Design and Engineering. They are arranged in two stages,
with four units in parallel composing each stage. This final gas
cleaning renders an optically clear stream for the adjacent acid
plant.
To attain the desired degree of S02 recovery, a more expensive
double-absorption contact system, furnished by American Lurgi, was
selected for acid making. Clean gas from the cold cleaning system
contains about 7% SC^- It is pulled through a drying towe'r counter-
currently to a flow of 93-96% sulphuric acid by a pair of downstream,
5,000-hp Allis Chalmers blowers in parallel.
-8-
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From the blowers, the gas eaters the conversion and absorption
system. The Lurgi plant is equipped with a total of four V205
catalyst beds for converting S02 to 803. Four Cyclotherm heat
exchanger installations, two of~them containing two vessels in
series, maintain proper gas temperatures for conversion and
absorption. Top bed gases from the catalytic converter are
cooled in one heat exchanger. Gases leaving the second bed arc
cooled by two heat exchangers in series before going to the inter-
mediary double venturi type absorber. With over 80% of the SCb
converted to SO-i, the heat-exchanged, second-bed gases flow con-
currently with acid from the top of the intermediate absorber
down through the unit. This helps conserve heat required for the
catalytic reaction in the third state of conversion.
The weak offgas from the absorber returns to the catalytic
converter after it is further heated in the shell of the set of
exchangers handling second-bed gases. Containing less than 2%
S02i this weak gas passes through the third and fourth catalyst
beds, with a single heat exchange taking place between them. The
gas from the fourth bed enters two heat exchangers in series and
then the final absorption tower. Off-gas from the final absorption
tower goes to the 200-ft-high tail gas stack.
Nominal monohydrate acid production, without allowances for
losses, will be 1,330 tpd in the plant, which has the capability
of producing either 93% or 98% acid. The final product will be
delivered to a 10,000-ton sotrage system.
An ingenious sytem recovers waste heat from furnace and
converter gas cooling stages and utilizes it to generate steam
in a plant designed by Treadwell Corp. as part of its overall
engineering contract.
High pressure, high temperature water (500°F at 1,000 psi)
circulates in a closed loop system through the water jackets on
the American Schack radiation coolers handling electric furnace
and converter offgases. Heat is removed from this closed recircu-
lation system and converted to steam in steam generators. A peak
total of 126,000 Ib. per hr. of steam will be generated. The
steam is used to drive turbines supplying blast air to the con-
verters and to drive the pumps which recirculate the high pressure
water through the radiation coolers. Any excess steam can be fed
to the Inspiration power plant.
Maintaining the cooling water at 500°F will keep the offgases
above the dew point and out of the corrosion range. The system
includes water treatment facilities to supply treated water to
the steam plant.
The new smelter-acid installation is a highly sophisticated
system with two control centers. The nerve center for the smelter
-9-
-------
commands a sweeping view of the converters and furnace. This
control room houses the instruments which monitor and control
furnace and converter operating conditions. Temperature
indicator and recorder panels track sensitive points in the
system, including concentrate feed, hot gases, and cooling
water. Functioning of equipment, which is operated either
automatically or manually by local operators, is also monitored
in the smelter control room.
A DuPont 460 photometric analyzer monitors the S02 content of
effluent gases at seven locations. A paging system links the
smelter control center, the acid plant control center, and the
smelter cranemen for telephone communications.
Combustion chamber
ELECTRIC FURNACE AND DRYER
Cyclone—«^ , —, . —- 'Electrostatic precipitators
Gas plenum
Cvclone
^^/-•K^KP^^f^^^.K -^ r-l- ••,
••^rrrjiffi^u^^
LONGITUDINAL SECTION A-A FROM PLOT PLAN
Hoiqase.
Hot gas cleaning »I tnwller
GAS AND ACID PLANT
FLOWSHEET AT INSPIRATION
No- 1 heat No. 3 heat C0(
»xeh»r.ger
-10-
-------
c. Actual Production Rate - For operating days in month of
September 1975 was 385 tons/day of blister with approximate
assay of 98% copper.
d. Type and Quantity of Fuel Consumed:
Diesel Oil #2 #6
Heating Value (BTU's/Gal) 140,000 150,000
Percent Sulfur (by weight) 0.35 0.9
Percent Ash (by weight)
Specific Gravity 0.860 0.972
Consumption (Gals/yr) 1975 56,848 32,230
Natural Gas
Specific Gravity 0.625
Heating Value (BTU's/Scf) 1091
% Sulfur (By Vo. & Grains/Scf) 0
Consumption (Scf/yr) 1975 1.171 x 109
Constituents in '/, By Wt.
Methane CH4 87.04 f
Ethane C2Hg 8.49
Nitrogen NZ 2.47
Propane C,Ho 1.81
Carbon Dioxide C02 0.07
N Butane C4H10 0.05
Iso Butane C4H^Q 0.04
Helium HE 0.03
Coal (Not Used)
e. & f. Ore and Flux Composition Chemical Constituents
Composite (Sept.1975) Cu
1. Concentrate
2. Cement Copper
3. Limestone
4. Silica
g. Standard Conditions - Psi - 14.7, Temp. °F - 60, used to
calculate scfm.
-11-
-------
2. Concentrators - We felt this was not applicable due to the
fact that the smelter is a toll smelter receiving concentrates
from various companies and we do not have information on other
concentrators.
3. Roasters - N/A
4. Reverberatory furnaces - N/A We do not operate a reverberatory
furnace, however, we do operate an electric furnace and the
information received is as follows:
a. Design process feed rate -
Concentrates and cements - 1,500 TPO
flux - 173 TPD
reverts - 148 TPD
converter slag - original design
b. Actual process feed rate for September per operating day -
Concentrates and cements - 1335 TPD
flux - 120 TPD
reverts - 85 TPD
converter slag - 583 TPD
Method of determining is based on scale weights and
calculated volumes of ladles of converter slag.
c. Design gas volumes - 30,000 scfm
d. Actual process gas volumes - 15-25,000 scfm. Determined
by measurement with annubar.
e. Actual process temperature - between 12-1400°F
f. Average number of hours of operation per month - plant is
scheduled to operate every day throughout the month.
g. Process instrumentation used - controlling instrumentation
are flowmeters and thermocouples. The flowmeter measures
from 0 to 45,000 scfm with a typical reading of 15-25,000 scfm.
Thermocouples are recording various temperatures throughout
the off gas system and ranges from 200-2000°F.
h. Description of where and how samples of process material can
be collected - the samples are taken by sampling the matte
and slag molten streams leaving the furnace.
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anti-
cipated emission results - Will discuss.
j. Expected life of process equipment - Should be indefinite
if properly maintained .
k. Plans to modify or expand process production rate - Unknown
at this time.
-12-
-------
5. Converters
a. Design process feed rate - designed for electric furnace
feed rate of 1500 TPD.
b. Actual process feed rate - September 1975 -
matte grade - 43.5%
885 TFD of matte
flux - assume .6 tons silica flux/ton of matte = 885 x .6 =
531 TPD, cold dope approximately 354 TFD.
c. Design process gas volumes -
(1) slag blow - 21,000 scfm
(2) copper blow - 23,000 scfm
d. Actual process gas volumes - slag and copper blow - 20,000 scfm
measured by converter - annubar (pitot tube).
e. Actual process temperature - molten material 2300°F. 2jO& '
f. Average number of hours of operation per month - 24 hours,
seven days /week.
g. Process instrumentation used, including data for a typical
reading and range of readings - Process instrumentation
used is blast air rate with volume ranging from 10-22,000 scfm.
h. Description of where and how samples of process material
can be collected - Hand samples are taken by sampling the
molten stream of the slag during the converter cycle.
i. Description of typical types of process fluctuations
and/or malfunctions, including frequency of occurrence
and anticipated emission results - Will discuss
j. Expected life of process equipment - Unknown if properly
maintained.
k. Plans to modify or expand process production rate - unknown
at present.
6. Refining Furnaces
a. Design process feed rate - Not known
b. Actual process feed rate, including method and estimated
accuracy of measurement - Actual process feed rate approx.
250 TPD. Weigh anodes on railroad scales - process varies
more than accuracy of scales.
c. Design process gas volumes - Not known
d. Actual process gas volumes, including method of determination,
calculation, or measurement - Unknown
-13-
-------
e. Actual process temperature - 2100°F
£. Average number of hours of operation per month - 24 Mrs./Day
seven days per week.
g. Process instrumentation used, including data for a typical
reading and range of readings - Not known
h. Description of where and how samples of process material
can be collected - Samples of the molten copper are taken
from the pouring spout.
i. Description of typical types of process fluctuations,
malfunctions, frequency, and anticipated emission results -
Will discuss.
j. Expected life of process equipment - Indefinite if properly
maintained.
k. Flans to modify or expand process production rate - None
definite at this time.
C. EMISSIONS
1. List of sources of particulate emissions in the plant:
a. Rotary dryer baghouse
b. Acid plant tail gas stack.
2. Level of uncontrolled particulate emissions by source - Not known
3. Existing source test data employed for particulates by stack,
process unit, or control device, including:
a. Test Method #5
b. through e. - please refer to attachment
4. Particle size and chemical composition of uncontrolled
particulate emissions, including method of determination -
Unknown.
5. Level of uncontrolled visible emissions by source and method
of determination - Unknown.
6. Extent of and reason for variance of particulate emissions with:
a. through g. Unknown
D. CONTROL SYSTEMS
1. Detailed description of the particulate and sulfur dioxide
emissions control systems, including:
-14-
-------
s.;'<\ Inspiration
Cwpper
AiiAUL'iLNi
INSPIRATION. ARIZONA 63537
July 3, 1975
Bureau of Air Pollution Control
Division of Environmental Health Services
Arizona Department of Health Services
1740 West Adams Street
Phoenix, Arizona 8S007
I-.
Attention: Mr. Carl Billings
Dear Sir:
Please find enclosed our application for an Operating Permit
for our modified smeller facility.
Mass emission testing was performed at points in the process
selected by the Bureau of Air Quality Control. Actual compli-
ance testing was performed by Engineering Testing Laboratories,
Inc. of Phoenix and witnessed by representatives of the State
Bureau of Air Quality Control and EPA Region IX. All test
data and results were submitted separately to the State Bureau
of Air Quality Control by the Engineering Testing Laboratories,
Inc.
The stack tests performed on the concentrate dryer baghouse
and acid plant tail gas showed that particulate emissions
were well within the process weight table requirements. SO?
analyses were also made to complete sulfur balances. Enclosed
are schematic illustrations of process and test resulting mate-
rial balances for particulates and sulfur.
From the above results, it is shown that Inspiration's modified
smelter facility is well within the allowable particulate
emissions and has met the 90% sulfur removal requirement of
the Conditional Permit. Therefore, Inspiration Consolidated
Copper Company is requesting an Operating Permit.
If any additional information is required, please contact me.
Sincerely,
5^ <^/^^
2#
William E. Pattullo
Director of Environmental' Control
WEPrma
Enclosure
-------
Bureau of Air Pollution Control
Division ol Cnvironmcnl.il Hcslili Services
ARIZONA DEPAKTMCNT OF HEALTH SERVICES
1740 West Adams Street
Phoenix. Arizona 65007
. Phone. (602) 271-45-10
APPLICATION FOR OPERATING PERMIT
thg Jbavg or{inlullon .
Same
4. Equipment LocJlIon
*M -*«-•».. .
Qlnd,v,dual 0-ne,
.?• Camril Nitur* of BuilRiti .
Mining, Milling, Smelting and Refining Copper
I. E«ulpntnl Of icrlflllon >
Smelter and Appurtenances
u Govern, Agea. Hualiat 473-2411, Extension 201
-10-
-------
I-. Rotary Dryer Baghouse Emissions Tests
Feed to Electric
Furnace
Vented Gas
Frrrl — •
Natural Gas-*
Rotary
Dryer
Moist Flue Gas
Baghouse
1
Test
No.
1
2
Date
5/29/75
5/30/75
Feed Rate
To Dryer CT/Hr)
70
70
Emissions
Particulate (.?/Hr)
18
18
SO2 CPPM)
79.5
99.3
Note: Conversion of SO 2 PPM to #/Hr sulfur is 13*/Hr and 16#/Hr
respectively for Test *1 and #2.
-------
II. Acid Plant Tail Gas Emission Tests
Slag
Feed
Electric
Furnace
fonv. Slap
Mntte
I
Cold Dope
SO2 Gas
I
Hot
Cottrell
•Cold Dope
•Flux
—>Blister Copper
Acid
Product
Sludge Containing
251
-------
ACID PLANT TAIL CAS EMISSION TESTS (CONTINUED)
\) Material In
3} Sulfur Balance
In (Lbi/llr)
Out (Lbs/llr)
In (Lbi/Hr)
Out (Lbs/llr)
' TEST
KO.
11
(6-17-7S)
12
(6-17-75)
11
12
11
12
Note: A
FEED
T/HR
GO
70
80
70
40.320
35,280
auna reaa
i
SLAG
T/1IR
40*
40
1,760
1.760
nlng mlfu
COLD DOP1!
IN T/IIR
37. SO
37. SO
17. SO
37. SO
6.S47.S
6.S47.S
• al fugltl
COLD DOPE
OUT T/IIR.
37. SO
37. SO
«.J47.S
6.S47.S
• 109I«S
FLUX
T/IM
37. SO
37. SO
37. SO
37. SO
75
75
CONV. FLUE
DUST T/IIR
1.2S
1.2S
250
2SO
SLUDGE
(SOLIDS)
T/IIR
0.014
0.014
Trace
Tract
2 SI II2S04
T/IIR
0.699
0.699
114
114
ACID
921
T/IIR
SI
SO
34.147
30.041
EMISSIONS
•ARTICU-
LATES
'/lilt
10
11
-
m
SO,
pp
-------
a. Process treated - Refer to Fart B - PROCESS
b. Type of fuel consumed per unit - The acid plant
preheater consumes fuel during acid plant start-up,
shutdown and during low strength S02 situations.
Type of fuel - natural gas with alternate of #2 diesel.
c. Quantity of fuel consumed per unit - varies and is un-
predictable.
d. Method of determination of design parameters - will
discuss.
e. Engineering drawings or block flow diagrams - Refer to
Part B - PROCESS
f. Expected life of control system - Unknown if properly
maintained.
g. Plans to upgrade existing system - Unknown at present.
2. Electrostatic precipitators
a. Manufacturer, type, model number -
Research Cottrell
Electrostatic using Opzil type collecting plates
Model No. SI9ARC-20
b. Manufacturer's guarantee - outlet concentration of
0.02 grains per cubic foot (987. Recovery) .
c. Date of installation or last modification and a detailed
description of the nature and extent of the modification -
1973
d. Description of cleaning and maintenance practices, including
frequency and method - when necessary due to malfunction.
e. Design and actual values for the following variables:
DESIGN ACTUAL
(1) Current (amperes) 750 MA 750 MA
(2) Voltage 70,000 volts 40,000
(3) Rapping Freq.
(Times/Hr.) 30 Times/Hr. 24/Hr.
(4) No. of Banks 1 Unit Same
(5) No. of stages 3 sections ea.
have 29 ducts Same
(6) N/A
(7) N/A
(8) N/A
(9) Gas flow rate scfm 38,000 scfm 15-25,000
-15-
-------
DESIGN ACTUAL
(10) Operating Temp 750°F 460-750°F
(11) N/A
(12) N/A
(13) Pressure Drop (inches
of water) - 10"- +5" N.G. N/A
Electrostatic precipitators - Converters (3)
a. Manufacturer - Research Cottrell
Type - Electrostatic using Opzel type collecting plates
Model No. - (S19ARC-20)
b. Manufacturer's Guarantee - collection efficiency of 95%
when treating gas capacity of 34,000 scfm per precipitator
at a gas temperature of 750°F and at a negative pressure.
Outlet concentration of 0.02 grains per cu. ft.
c. Date of installation - 1973
d. Description of cleaning and maintenance practices -
As necessary.
e. Design and actual values for the following variables:
DESIGN ACTUAL
(1) Current Amperes 750 MA 750 MA
(2) Voltage 70,000 Volts 40,000
(3) Rapping Freq. 30 times/Hr 30
(4) No. of banks One unit each Same
(5) No. of stages Each unit has 4 Same
(6) N/A Sections of 21
ducts
(7) N/A
(8) N/A
(9) Gas flow rate 34,000 scfm 30.000
(10) Operating Temp. 750°F 600-758°F
(11) N/A
(12) N7A
(13) Pressure Drop 10"- +5 W.G. N/A
Fabric Filters
a. Manufacturer - Fuller Co.
Type - 8 Zone No. 156 Plenum Pulse Collector
Model No. - No. 156
b. Manufacturer's guarantee - Efficiency of 97%.
c. Date of installation - Mechanically accepted 12/73.
d. Description of cleaning and maintenances practices - As
Necessary
-16-
-------
e. Filter media - 14-16 oz. Nomex FF80
f. Filter Weave - Needled fabric supported
g. Bag replacement frequency - as required.
h. Forced or induced draft - Induced draft.
i. Design and actual values for the following variables:
DESIGN ACTUAL
(1) Bag area 13,000 11,700
(2) Bag spacing 6" 7"
(3) No. of bags 1248 1120
(4) Gas Flow Rate scfm 78,000 36,300
(5) Operating Temp 350°F 205°F
(6) N/A N/A N/A
(7) N/A N/A N/A
(8) Pressure Drop 3-7" 3-7"
4. Scrubbers
a. Manufacturer, type, model number -
Cyprus Steele
Type - Venturi .
Number - N/A
b. Manufacturer's guarantees - N/A
c. Date of installation of last modification and a detailed
description of the nature and extent of the modification -
1972-1973
d. Description of cleaning and maintenance practices, including
frequency and method - As required.
e. Scrubbing media - N/A
f. Design and actual values for the following variables:
DESIGN ACTUAL
(1) Scrubbing media flow
rate 4060 GPM N/A
(2) Pressure of scrubbing
media 79 psi 65 psi
(3) Gas Flow rate 96,000 scfm 105,000 scfm
(4) Operating temp. 575°F 550°F
(5) Inlet Part. Cone. N/A
(6) Outlet Part. Cone. N/A N/A
(7) Pressure drop 5" 2"
-17-
-------
5. Sulfuric Acid Planes
a. Manufacturer - Designed by Lurgi
b. Manufacturer's guarantee - maximum flow rate - 129,000 scfm
at 8.3% S02; 500 ppm S02 in tail stack; 100 mgr Mm3 acid
mist expressed as 803.
c. Date of installation or last modification and a detailed
description of the nature and extent of the modification -
1972-73.
d. Description of cleaning and maintenance practices, including
frequency and method - As required.
e. Frequency of catalyst screening - As required
f. Type of demister - Stainless steel with teflon fibers.
g. Design and actual values for the following variables:
DESIGN ACTUAL
(1) Production 1330 T/D 1000
(2) Conversion rate 99.5 99.6
(3) Acid Strength 93-98% 92-95%
(4) Number of catalyst beds 4 4
(5) Gas flow rate 129,000 105,000
(6) Operating Temperature 104°F 100-105°F
(7) Inlet S02 concentration 7% 6.5%
(8) Outlet S02 Concentration less than SOOppm 300 ppm
(9) Acid Mist 100 mgr Km3 29.4
(10) Blower pressure 8 psig 4 psig
6. Liquid S02 Plants - Not applicable
7. Detailed description of how the particulate and sulfur dioxide
emission control systems operate - Refer to Part B - PROCESS GENERAL
8. Description of instrumentation 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 - Will discuss
9. Description of typical types of control system malfunctions,
including frequency of occurrence and anticipated emission
results - Will Discuss
STACKS
1. Detailed description of stack configuration, including process
and/or control system units exhausted - Refer to Part B -
PROCESS GENERAL.
-18-
-------
2. Identification by stack of:
Acid PI.
Dryer ByPass Tail Gas
a. Height (Ft. above terrain) 143 200 200
b. Elevation of Discharge 3,690 3,759 3,759
Point (Ft. above sea level)
c. Inside Diameter 4'-8" 7'-5" 6'-3"
d. Exit Gas Temp (°F) 375° 550° 150°
e. Exit Gas Velocities (Ft/Sec) 76 40.5 57.0
-19-
-------
APPENDIX C
SIP REGULATION APPLICABLE
" TO INSPIRATION
-------
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:
S 52.126 Control strategy mid regula-
tions: 1'articululc matter.
• • • • •
(b) Replacement regulation for Regu-
lation 7-1-3 6 of the Arizona Rules and
Regulations for Air Pollution Control,
Rule 31 (£) o) Reaulation III of the Man-
copa County Air Pollution Control Rules
and Regulation?, and Rule 2i/?> 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 (§ 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 Emission Process Emission
Wright rato rule weight rato rale
(pounds (pounds (pound-. (pounds
per hour) per hour) per hour) per hour)
»-.
100
no
1.000
s.ooo . ....
10.000..
20,000
038
0 55
1..13
2 25
6 34
B 73
14.99
60.000
80.0110
1'JO.OiX)
ira.om
SOU 000
400.000
1.000.000
70 60
31 19
33 28
34 85
38 11
40 35
4C72
(i) Interpolation of the data in the ta-
ble for process weight rates up to GO.OOO
Ibs/hr shall be accomplished by use of
the equation:
£=3.59 P°.n PS 30 tons/h
and interpolation and extrapolation of
the -data for process weight rates in ex-
cess of 60,000 Ibs/hr shall be accom-
plished by use of the equation:
JS=17JIP«.«« P>30tons/!r
Where: E=Emlss!ons in pounds per hour
P=Process weight In tons per hour
(11) Process weight is the total wdcht
of all materials and solid fuels introduced
Into any specific process. Liquid and
gaseous fuels and combustion air will
not be considered as part of Uic pi OCCT..S
weight. For a cyclical or hatrh operation.
the process wcinht per hour will be de-
rived by dividing the total process weniht
by the pumbcr of hoins in one complete
operation from the bc-innm;-. r>f the
' given process to the completion theieot.
excluding any time durum which the
equipment is idle For a continuous op-
eration, the process \vcicht per houi will
be derived by dividing the piocc^s weiiint
for a given period of time by the num-
ber of hours in that period
(ill) 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 lb/ h.
(3) No owner or operator of a Poit-
land cement plant in the Phoenix-Tucson
Intrastate Region it 81 36 of this chap-
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 02 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 m 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 particulatc
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 ft1 (170 m1). cor-
rected to standard conditions on a dry
basis.
(ii) The volumetric flow rate of the
total effluent shall be determined by us-
ing method 2 and travel sing 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 bum 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.
FEDERAL REGISTER, VOL. 38. NO. 92—MONDAY, MAY 14. 1973
-------
APPENDIX D
CALCULATIONS OF GAS FLOW RATES
-------
FLOWRATE AT STANDARD CONDITIONS'
pivi Psvs Vs = Pi Ts
1 1 - s s • or s -~- x -A- x
T1 Ts rs
where: P. = given pressure = 14.7 psi therefore P.. = P
V. = given gas volume
T = given temperature in °R = 520 °R
P = pressure @ std condns (14.7 psi or 760 mm Hg)
Vs = gas volume @ std condns (in same units as
TS = temperature @ std condns (530 °R)
Electric Furnace
Vs = 15,000 (530) =15,288scfm
520
= 25,000 (530) . 2M81 scfm
520
Converters
= 20.000 (530)
520
= 23.000 (530)
520
* Reference 1 reports standard conditions as 760 mm Hg (14.7 psi) and
16 °C (60 °F). The calculations below are simple adjustments of
reported values.
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