ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
PHELPS DODGE
MORENC
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
EJBD DENVER. COLORADO
ARCHIVE J^ **b
R-
76-
009
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p.-
STATE IMPLEMENTATION PLAN
INSPECTION OF
PHELPS DODGE CORPORATION
MORENCI BRANCH SMELTER
MORENCI, ARIZONA
SEPTEMBER 1976
US EPA
-•.dquarters and Chemical Libraries
SPA West Bldg Room 3340
Mailcode 3404T
13Q1 Constitution Ave NW
Washington OC 20004
202-566-0556
Repository Material
'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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CONTENTS
INTRODUCTION 1
PROCESS DESCRIPTION 2
EMISSION SOURCES AND RELATED
CONTROL EQUIPMENT 7
EMISSIONS DATA 12
BIBLIOGRAPHY 14
TABLES
1 Smelter Process Equipment and
Operating Data 4
2 Smelter Air Pollution Control
Equipment and Operating Data 9
3 Particulate Matter Emissions
Test Results 13
FIGURES
1 Phelps Dodge, Morenci Process Flow
Diagram 3
2 Phelps Dodge, Morenci Plant Layout
Process Exhaust Flow and Air
Pollution Control Systems 8
APPENDICES
A NEIC Information Request Letter
to Phelps Dodge
B Phelps Dodge Response to NEIC
Information Request
C SIP Regulation Applicable to
Phelps Dodge
D Calculations of Gas Flow Rates,
Duct Diameters, and
Isokinetic Variations
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PHELPS DODGE
Morenci, Arizona
SUMMARY AND CONCLUSIONS
Phelps Dodge Corporation operates mines, concentrators, oxide ore
leach operations and a smelter in Morenci, Arizona. An inspection to
acquire data with which to evaluate the design and operation of exist-
ting particulate matter air pollution control equipment at the smelter
was conducted by EPA personnel on February 2, 1976. Substantial amounts
of process, control equipment, and stack sampling information were re-
quested of, and received from, Phelps Dodge.
The following conclusions are based on the inspection and a review
of the information obtained:
1. The Engineers Testing Laboratories (ETL), Phoenix, November
1975 source tests are not valid tests for the following reasons: (a)
at least 24 sampling points on two diameters at the reverberatory fur-
nace stack and at least 28 sampling points on two diameters at the
converter stack are required rather than the points actually sampled
and (b) isokinetic variations ranged from 71 to 81% for the reverbera-
tory furnace stack runs and 51 to 61% for the converter stack runs;
these variations are lower than the acceptable lower limit of 90%.
Without valid test results and calculated allowable emission rates, no
definitive conclusions can be made as to the status of compliance of
this source.
2. No definitive conclusions as to the adequacy of existing con-
trol systems can be made from the design and operating data supplied by
the Company.
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INSPECTION OF
PHELPS DODGE CORPORATION
MORENCI BRANCH
Morenci, Arizona
February 2, 1976
602/865-3772
INTRODUCTION
The Phelps Dodge Corporation, Morenci Branch, operates open pit
mines, concentrators, oxide ore leach operations, and a smelter at
Morenci, Arizona to produce anode copper. During 1975 average anode
copper production was 410 m. tons (452 tons)/day.
On December 17, 1975 the Manager of the Morenci Branch was re-
quested by letter to provide process and air pollution control infor-
mation on the Morenci operation and informed of a planned plant inspec-
tion [Appendix A]. On February 2, 1976 the following EPA personnel
conducted a plant inspection: Mr. Reid Iversen, OAQPS; Mr. Gary D.
Young, NEIC; and Mr. Jim V. Rouse, NEIC. The requested data were not
available at the time of the inspection but were subsequently furnished
by letters dated February 6 and 26 [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 process equipment, the particulate
matter emission sources, and the air pollution control equipment, focus-
ing primarily on the smelter, were examined.
Company personnel were cooperative throughout the inspection.
Those participating included: Mr. John E. O'Neill, Manager; Mr. John
Bolles, General Superintendent; Mr. Stewart W. Towle, Smelter Superin-
tendent; Mr. James E. Foard, Metallurgist, Phelps Dodge Western Cor-
porate Office, and Mr. Grant Howard.
-------
The applicable regulation contained in the Arizona State Implemen-
tation Plan (SIP) of interest for this inspection is the approved process
weight regulation Article 7-1-3.6 titled Process Industries [Appendix
C). This regulation provides an allowable emission rate for each process
unit based upon the production feed rate.
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.
Concentrates from the concentrators are delivered by conveyor belt
to the bedding plant. After a bed has been completed, it is analyzed
and the proper amounts of lime rock and siliceous flux are removed from
storage bins and distributed over the concentrate on the bed. Separate
charge compositions are maintained for the roaster charge and for the
direct smelting reverberatory furnaces.
Charge for the fluo-solids roaster is reclaimed from the 227 m. ton
(250 ton) capacity bins adjacent to the roaster. A feeder system trans-
fers the charge onto a series of belt conveyors and a bucket elevator
for elevation to the surge hoppers above the roaster feeder system The
blended materials are then fed to the fluo-solids roaster by a rotary
drum feeder. The roaster feed rate averages 48 m. tons (53 tons)/hr
when in operation with a daily throughput of about 1,000 m. tons (1 100
tons)/day.
Fluidizing air for the roaster is supplied by a blower to maintain the
blended feed (solids) in a fluidized state. Normal blower rate is
approximately 578 std m3/min (20,400 scfm). 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. The gases exiting the roaster
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CONCENTRATES
LIMEROCK
REVERTS
FLUOSOLIDS
ROASTER
CYCLONES (32)
SILICA
FLUX
AIR
O
I-
£
UJ
CD
>
£
IU
(0
REFORMED GAS
CONVERTERS
(9)
SLISTER
ANODE
FURNACES
(99.6%)
ANODES TO
REFINERY
CASTING WHEELS
(2)
Figure I.. Pfie/ps Dodge/ Morenci Process F/ow D/agram
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Table 1
SMELTER PROCESS EQUIPMENT AND OPERATING DATA
PHELPS DODGE CORPORATION
Morenci, Arizona
Parameter Roaster
No. of Units 1
Feed Constituents8 C
Feed Rate m tons/day
C 758
Size of Unit m
diameter 7
height 5
Operation (hrs/mo) 470
Gas Volume ,
Generated m /min
433-
694
Exit Gas Temperature °C
566-
621
tons/day
835
ft
22
17
scfmc
15,300-
24,500
°F
1050-
1150
Reverberatory
Furnaces
SC
m tons/day
SC 1 956
CS 1 073
Total 3029
m
(#l-4)width 7.8
length 31 .
(#5) width 11
length 35
m /min
5,660-
11,300
°C
316-
399
5
,CS
tons/day
2155
1182
3327
ft
25.5
2 102.5
36
115.3
680
scfm
200,000-
400,000
°F
600-
750
Converters
9
M.F
m tons/day tons/day
M 1167 1286
F 320 352
Total 1487 1638
m ft
diam. 4 13
length 30
4100b
m /min scfm
437Cd 154,500
°C °F
NRe
8 Concentrates (c)3 Solid Charge (SC-includes calcine3 concentratest precipitates*
reverts), Converter Slag (CS)3 Matte (MJ3 Flux (F).
b Estimate based on 6 converters in operation per shift.
C Standard conditions are 760 mm Hgf (29.92 in Hg or 14.7 psia) and 21°C (70°F).
d As measured at the stack sampling station.
e NR = not reported.
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pass through primary and secondary cyclones, an integral part of the
process, from which approximately 90% of the solids (calcine) are col-
lected. The material collected by the cyclones is conveyed and stored
in bins above the two calcine smelting furnaces.
The No. 3 and 4 reverberatory furnaces have been modified for cal-
cine smelting. The furnaces are fed from 91 m. ton (100 ton) calcine
bins at each side of the furnaces by a drag conveyor which discharges
into the furnace through a rotary vane feeder or a valved bypass chute
at the side near the top of the furnaces. The other three reverberatory
furnaces (No. 1, 2 and 5) are designed to handle unroasted concentrates
and precipitates (direct charge). These three furnaces are fed from
227- m. tons (250- tons) charge bins at each side of the furnaces by
hand-feeders into a drag conveyor which discharges into the furnace
through chutes at the side of the furnace near the top.
Reverberatory furnaces No. 1-4 are each 7.8 x 31.2 m (25.5 x 102.5
ft) in width and length respectively, while reverberatory furnace No. 5
is 11 x 35 m (36 x 115 ft). Furnaces Nos. 1, 2 and 4 have sprung arches,
sidewalls and endwalls constructed of silica brick. The bridge walls
and front walls are faced with chemically bonded magnesite brick with a
band of magnesite brick surrounding the furnace wall at the bath line.
The furnace uptakes are of suspended brick construction with high alu-
mina firebrick in the walls and magnesite brick in the arches. These
three furnace roofs are maintained by hot patching using silica slurry.
Furnace No. 3 is similarly constructed with the exception that the
furnace roof is a suspended arch. It is patched by a special chemically
bonded tile. Furnace No. 5, the newest of the furnaces, is a panelized
basic brick suspended roof furnace. This furnace has approximately
double the capacity of the older direct charge furnaces No. 1 and 2 at
1,225 m. tons (1,350 tons) solid charge per furnace day. The No. 5
furnace is maintained by replacing panels or using bonded tile.
-------
Slag is removed from the sides of furnaces No. 1-4 near the waste
heat boiler uptake end through one skim hole. Slag from the No. 5
furnace is removed from tap holes on both sides of the furnace. Slag is
skimmed into 6 m3 (225 ft3) steel pots and hauled to the dump by el-
ectric locomotives. Matte is tapped through tap holes on either side of
the reverberatory furnaces into matte launders. The launders discharge
into ladles in the converter aisle. However, matte from the No. 5
furnace discharges into ladles on motorized matte cars located in the
tunnel below the furnace and are then transferred into the converter
aisle.
Matte ladles are picked up by overhead cranes and charged to one of
the nine Fierce-Smith converters which are 4x9m(13x30ft)in
diameter and length, respectively. The converters are charged with five
ladles of matte amounting to about 64 m. tons (70 tons), and additional
matte is added after fluxing, blowing and skimming. During blowing, air
is introduced through tuyeres into the charge. Air volume during the
blow averages 694 std m /min (24,500 scfm) for each converter. Silica
flux is periodically added to bind the iron into a slag. The slag
produced is then returned to a reverberatory furnace by the overhead
crane. Additional matte is added to the converter to produce light
blister copper.
The blister copper is poured into ladles and carried by overhead
crane to one of the four anode furnaces. These furnaces are smaller
than the converters, measuring 4 m (13 ft) in diameter by 8 m (25 ft) in
length. Additional air is blown into the charge through tuyeres to
remove the sulfur. Slag is skimmed off and reformed natural gas is
introduced through the tuyeres for final copper reduction. The anode
grade molten copper is cast into approximately 320 kg (700 Ib) anodes on
either of two casting wheels. The anodes are cooled, inspected and
shipped by rail to the Phelps Dodge Refinery in El Paso, Texas.
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EMISSION SOURCES AND RELATED CONTROL EQUIPMENT
The primary participate matter sources at the Morenci smelter are
the fluo-solids roaster, reverberatory furnaces 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 emis-
sions from feeding concentrates, skimming converter slag, returning con-
verter slag, or tapping matte or slag at the furnaces are not treated
but are exhausted through the converter stack or directly to the atmos-
phere. Converter "smoke" not collected by the primary hood system is
exhausted untreated through the converter aisle roof vent. The anode
furnaces also emit some untreated particulate matter directly to the
atmosphere above the converter aisle; however, since the gas stream is
not collected, the concentrations are indeterminate.
Figure 2 is a diagram of the Morenci Smelter layout, the air pollu-
tion control system and the exhaust gas flow. Table 2 summarizes cer-
tain 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 gases which contain calcine pass to one of the four
calcine cyclone banks through refractory lined ducts. Diversion dampers
are used to cycle the gas stream to each calcine smelting furnace on a
four-hour cycle. Gases enter the primary cyclones at 454 to 510°C (850
to 950°F). Each furnace has sixteen cyclones arranged in banks of four
primary and four secondary cyclones to each side of the furnace.
Cyclone efficiency will be 92% removal of calcine at startup following
the annual shutdown for repair and will decrease to approximately 82%
immediately before shutdown.
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CATALYST CHAMBERS
HEAT EXCHANGERS
DRYING TOWERS
ABSORBING TOWERS
/T\
ESP
(6)
1
(5;
X
^REVERB
STACK
__ PROCESS PLOW
_ EXHAUST GASES
)
I
\
v>
r
/<<**^*""^
FLUOSOLIDS'
ROASTERX"^
V.
PRIMA
CYCLC
iT^
J o > **
\y^
RY ^-^
NES (32)
1
WASTE
BOILER
CO
UWAST
BOILE
1
^REVERBERATORY
\FURNACES (5)
\
\
"
j
CONVERTERS)
0) 1
i 1
HEATH]
Bt"g
HL-t
NVERTER STAC
E HEAT
RS (10)
DRYING
TOWER HEAT EXCHANGERS
\f V^\*" JCATALYST CHAMBER
x+v ( -^-v3 ''
*•"*{,.) X^XABSORBING TOWER
* PEABODY ^
SCRUBBER \
- j
EXHAUST
EXHAUST k
In' '
ANOHF /\uS*~**/\
^_ M 11 «-< U C / y- ~V \AMOO=S TO
(•*) \f^r y
U U CASTING WHEELS
C2)
1
HUMIDIFYING MiST ESP (B^
-^sQ.Q.^.^
- ^ -«~»- -x_x- ^ ' * |
i A« svOi _/^\ > — \_ i
i [? \J""XJ — \_/
ft-7~N COOLIN5
K^f '^\»— TOWERS
CO
Figure 2. PJiofps Oedga, Merenci Pfanf layout, Procosi Exhousl Flow, and Air Pof/ution Canfrol Sr«»«mi
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Table 2
SMELTER AIR POLLUTION CONTROL EQUIPMENT AND DESIGN DATA
PHELPS DODGE CORPORATION
Morencit Arizona
Control
Device
Cyclones
Scrubber
Acid Plant
ESP
ESP
ESP
ESP
Acid Plant
Manufacturer
NRb
Ducon
Parsons-
Jurden
Koppers
Research-
Cottrell
Buell
Research-
Cottrell
Chemical
Construct.
Date of
Installation/
Modification
2/65
1972
1968
10/64
3/71
NR
12/69
10/74
No. of Gas Flow Operating
Units Rate Temp. Pressure Drop
32
1
1
2
2
2
4
1
mV
677
1100-
1240
2830
7700
2520
4690-
17,500
2890-
7700
min scfma °C °F cm H20 ip
Roaster
NR 454- 850- NR
510 950
23,900 18 65 NR
38,700- 454- 850- NR
43,800 593 1100
Reverberatory Furnaces
100,000 316 600 2.5 1
272,000d 343 650 1.3 0.5
89,000d 316 600 1.3 0.5
Converters
165,600- 204- 400-
616,300 260 500 1.3 0.5
101,900- 438- 820-
271,800 593 1100 NR
Collection
Area Velocity
m2 ft2 m/sec ft/ sec
NAC NR
NA NR
NA NA
2890 31,100 0.7 2.40
9930 106,920 2.0 6.60
9190 98,940 1.0 3.28
20,500 220,320 0.6 2.10
NA NA
Retention
Time
sec
NR
NR
NA
8.52
8.14
8.22
12.8 *
NA
a Standard conditions are 760 mm Hg (29.92 in Hg or 14.7 psia) and 21°C (70°F)
b NR = Not reported
c NA = Not applicable
d Design values
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10
The off-gases pass directly from the cyclones to a Peabody gas
scrubber where entrained solids are removed. Following the Peabody
scrubber the gases are further cleaned in mist electrostatic precipi-
tators (ESP's) and dried in a drying tower. Between 1,110 to 1,240 std
o
m /min (38,700 to 42,800 scfm) then enters a conventional contact acid
plant in which the gas stream is dried, the S02 is converted to SO.,, and
the S0~ is absorbed in acid to form the final strength acid. Although
designed to produce 680 m. tons (750 tons)/day of 95% strength sulfuric
acid, 455 to 545 m. tons (500 to 600 tons)/day of 93.5% sulfuric acid
is actually produced. The roaster acid plant tail gas is ducted into a
flue and is discharged through the 184 m (603 ft) converter stack.
Reverberatory Furnace Control System
The principal reverberatory furnace exhaust gases pass through
pairs of waste heat boilers following each furnace. The gases from
reverberatory furnaces No. 1-4 enter four ESP's. Two of these ESP's
(Koppers) were designed to handle 2,830 std m3/min (100,000 scfm), while
the other two (Research Cottrell) were designed to handle 7,700 std
m /min (272,000 scfm) [Appendix D]. Each Koppers ESP consists of four
banks (parallel units) of three sections each (units in series) with a
total collection area of 2,890 m (31,100 ft2). Gas retention time is
estimated to be 8.5 seconds with an average gas velocity of 0.7 m (2.4
ft)/sec. The pressure drop across the Koppers units is 2.5 cm (1 in) of
water. Each Research Cottrell ESP also is arranged with four banks and
three sections. The collection area is 9,930 m2 (106,920 ft2) and the
gas retention time is just over 8 seconds with an average gas velocity
of 2.0 m (6.6 ft)/sec. The gases from reverberatory furnace No. 5 enter
a pair of Buell ESP's. These ESP's were designed to handle 2,520 std
m /min (89,000 scfm). Each ESP consists of three banks and three stages
with a total collection area of 9,190 m2 (98,940 ft2). Gas retention
time is 8.2 seconds with an average gas velocity of 1.0 m (3.3 ft)/sec.
The pressure drop across the Research Cottrell and the Buell units is
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11
less than 1.3 cm (0.5 in) of water. The exhaust from all six ESP's
flows through a common duct into the 184 m (603 ft) reverberatory fur-
nace 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
and copper sulfides. An average of 4,370 std m3/min (154,500 scfm) of
converter gas is produced when six converters are in operation. After
flowing through a radiation cooling system, infiltration air dilutes the
gas volume to between 4,690 and 17,500 std m3/min (165,600 and 616,300
scfm) depending upon the number of converters in operation. The exhaust
gas then enters one of four ESP's arranged in parallel. The ESP's are
designed to handle the maximum gas flow of 17,500 std m3/min (616,300
scfm) and are arranged in four banks with three sections. The collection
area is 20,500 m2 (220,320 ft2) and the gas retention time is about 13
seconds with an average gas velocity of 0.6 m (2.1 ft)/sec. The pres-
sure drop across the units is about 1.3 cm (0.5 in) of water.
Following the ESP's the gas stream flows through humidifying towers,
cooling towers, and mist ESP's to further cool and clean the gas stream.
The gas stream then enters the dual train, single absorption acid plant
where it is dried, the S02 is converted to S03, and the S03 is absorbed
in acid to form the final strength acid. Although designed to produce
2,270 m. tons (2,500 tons)/day of 93% strength sulfuric acid, approxi-
mately 455 to 1,360 m. tons (500 to 1,500 tons)/day of 94% sulfuric acid
is actually produced. The exit gas from the final absorption tower
passes through a two-stage demister before being exhausted from the 184
m (603 ft) converter stack.
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12
EMISSIONS DATA
Two separate source tests were conducted at the Morenci Smelter
during November 1975 by Engineers Testing Laboratories (ETL), Phoenix.
The first test was conducted at the reverberatory furnace stack sampling
station; the second was conducted at the converter stack sampling
station. The sampling locations are at approximately the 99 m (325 ft)
level of the 184 m (603 ft) stacks. The reverberatory furnace stack
sampling station is 5.8 stack diameters downstream from the top of the
flue entry, while the converter stack sampling station is 5.4 stack
diameters downstream from the top of the flue entry [Appendix D]. Based
on these distances, the required sampling points according to Method 1
would be 24 and 28, respectively,
The Method 5 impinger train was modified as follows: 80% isopropyl
alcohol was placed in the first two impingers, the third impinger was
left empty, 15% hydrogen peroxide was placed in the fourth and fifth
impingers, and silica gel was placed in the sixth and final impinger.
Moisture content was measured as impinger weight gain corrected for SO
and S03 in the gas stream. 2
Five test runs were performed on the reverberatory furnace stack
and three test runs on the converter stack. In each case only three
points on two perpendicular diameters were sampled. Process weights
were not determined for any of the test runs. There was no calculation
of isokinetic flow rates in the test report; however, using the given
data, the calculations can be constructed [Appendix D]. In each case the
isokinetic variation was outside the allowable range (90 to 110%). The
results of both tests are presented in Table 3.
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13
Table 3
PARTICULATE MATTER EMISSIONS TEST RESULTS
PHELPS DODGE CORPORATION
Morenci, Arizona
Test
Run
R-l
R-2
R-3
R-4
R-5
C-l
C-2
C-3
Date
(1975)
11-4
11-6
11-7
11-11
11-12
11-13
11-14
11-14
Stack
Temperature
op oc
361
472
475
437
457
209
206
221
183
244
246
225
225
98
97
105
Gas Moisture
Volume Content
acfm mVmin %
432,000
486, 000 '
498,000
528,000
586,000-
392,000
343,000
343,000
12,200
13,800
14,101
15,000
16,600
11,100
9,700
9,700
11.0
7.9
16.2
10.9
14.6
1.6
0.4
1.3
Actual
Emissions
Ib/hr kg/hr 1
675
485
695
880
1480
114
162
115
306
' 220
315
399
671
52
73
52
Allowable
Emissions
Ib/hr kg/hr
NR1"
NR
NR
NR
NR
NR
NR
NR
t NR = Not reported
'I
*
I "
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14
BIBLIOGRAPHY
1. Letter from John E. O'Neill, Manager, Morenci Branch, Phelps Dodge
Corporation to Thomas P. Gallagher, Director, EPA, NEIC, Denver,
Feb. 6, 1976.
2. The Morenci Smelter of Phelps Dodge Corporation at Morenci, Arizona.
L. L. McDaniel, 1949.
3. The Morenci Smelter - 1975. Stewart W. Towle, May 3, 1975.
4. Compilation and Analysis of Design and Operating Parameters of the
Phelps Dodge Corporation, Morenci Branch Smelter, Morenci, Arizona
for Emission Control Studies. Pacific Environmental Services, Inc ,
Santa Monica. Jan. 1976.
5. Letter from Peter F. Allard, Engineers Testing Laboratories, Inc.,
to Stewart Towle, Smelter Superintendent, Morenci. Preliminary
results of Smelter Compliance Tests. Nov. 21, 1975.
6. Letter from John E. O'Neill, Manger, Morenci Branch, Phelps Dodge
Corporation to Thomas P. Gallagher, Director, EPA, NEIC, Denver!
Feb. 26, 1976.
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APPENDICES
A NEIC Information Request
Letter to Phelps Dodge
B Phelps Dodge Response to
NEIC Information Request
C SIP Regulation Applicable to
Phelps Dodge
D Calculations of Gas Flow
Rates, Duct Diameters,
and Isokinetic Variations
-------
APPENDIX A
NEIC INFORMATION REQUEST LETTER
TO
PHELPS DODGE
-------
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL FIELD INVESTIGATIONS CENTER- DENVER
BUILDING 53. BOX 25227. DENVER FEDERAL CENTER
DENVER. COLORADO 80225
December 17, 1975
John E. O'Neill
Manager
Morenci Branch
Phelps-Dodge Corporation
Morenci, Arizona 85540
Dear Mr. O'Neill:
The Environmental Protection Agency has undertaken a program to
evaluate the performance characteristics of participate 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 - pressure (psi) and temperature (°F) -
used to calculate SCFM
-------
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
-------
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 participate 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
A. 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
i. 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:
i. 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 l^SO^)
iv. Number of catalyst beds
v. Gas flow rate (SCFM)
vi. Operating temperature (e'F)
vii. Inlet S02 concentration (ppm)
viii. Outlet S02 concentration (ppm)
ix. Acid mist (Ibs ^SO^/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
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 S02 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
PHELPS DODGE RESPONSE
TO
NEIC INFORMATION REQUEST
-------
Morenci Branch. Morenci. Arizona 85540
February 6, 1976
Mr. Thomas P. Gallagher, Director
Office of Enforcement
National Field Investigations Center - Denver
Environmental Protection Agency
Building 53, Box 25227, Denver Federal Center
Denver, Colorado 80225
Dear Mr. Gallagher:
Enclosed are three copies of a report, "Copper Smelter
Information, Morenci Branch, Phelps Dodge Corporation. This
report is in response to your letter dated December 17, 1975. It
responds directly to and is numbered in accord to the questionnaire
sent with that letter.
The field visit by Gary Young, Jim Rouse and Reid Ivorsen
was accomplished on schedule Monday, February 2, 1976. It was only
after that visit that we could complete our report, since some
questions were not understood here.
Yours very truly,
rohn E. O'Neill
'Manager
JEO:wb
Enclosures
-------
INDEX
COPPER SMELTER INFORMATION
MORENCI BRANCH, PHELPS DODGE CORPORATION
MORENCI, ARIZONA
-A. General
B. Process
1. General
2. Concentrators
3. Roasters
4. Reverberator/ Furnaces
5. Converters
6. Refining Furnaces
C. Emissions 19 _ 20
D. Control Systems 21
1. Detailed Description 21 - 27
2. Electrostatic Precipitators 27 - 29
3. Fabric Filters 29 - 33
4. Scrubbers 34 - 41
5. Sulfuric Acid Plants 42
E. Stacks 47
Appcndix
Item 1 - The Morenci Smelter, L. L. McDaniel
Item 2 - The Morenci Smelter, S. W. Towle
Item 3 - Fuel Specifications
Item 4 - Sulfur Emissions Calculations
Item 5 - Preliminary Results of Smelter Compliance
Tests
Item 6 - Morenci Branch Drawing D-940
Item 7 - Morenci Smeller, General Plant Area,
Drawing MS 61-1-01
Item 8 - Smeller Area, General Location of Dust
Control Equipment, Drawing 170-89
Item 9 - Smeller Converter Slack T( st Platform Floor
Plan, Drawing 170-120
Item 10- Smeller Reverb Stack Test Platform Floor
Plan. Drawing 170-137
-------
COPPER SMELTER INFORMATION
MORENCI BRANCH
PHELPS DODGE CORPORATION
MORENCI, ARIZONA
Prepared at the request of
Environmental Protection Agency
Office of Enforcement
National Field Investigations Center
Denver
February 6, 1976
GENERAL,
1. Morenci, Arizona 85540
2. Contact
Mr. J. E. O'Neill, Manager
Phelps Dodge Corporation
Morenci Branch
Morenci, Arizona 85540 Telephone: 602-865-3772
3. Attached Morenci Smelter Flow Sheet dated January 1, 1974.
PROCESS
1. GENERAL
a. Description
Presented in attached articles:
"The Morenci Smelter of Phelps Dodge Corporation at
Morenci, Arizona,11 L. L. McDaniel, Metals Transactions AIME,
January, 1949.
"The Morenci Smeller - 1975," Stewart W. Towlc, Un-
published presentation at Spring Meeting, Smelting Division, Arizona
Section, AIME, May 3, 1975.
-------
MORENO I SMELTER FLOW SHEET
JANUARY 1,1374
SILICA LIUEROCK Kf VERTS
I J. I
SMELTER CRUSHING
PLANT
ROTARY KfLff
LIMESTONE
STORAGE BINS
Of/CD CONCENTRATES
f% MOISTURE
FLUX
\BURNT LIME)
YTY
MILK
Of
LIME
PLANT
PYRITE t
UORfNCI 22-24% CU.
TTKOHf 10-22% CU.
TO
>CONCENTRATOR
MID TANKS
SPENT GAS
TO STACK
^RAIL fl TRUCK
LOADING !
TO \
CONCENTRATOR \
'ACID
PLANT
C
fCLOtlE
u Or
o of
r> ol
,
NO.3,4
^= •> K V£HSSK£JOf>Y n/m4C£S 25'C'x'lOZ'6" *-?-
^IREl-EffSffWTOfrY FU'iVJCE 2C'0"XH5'4%'£.
CONVERTER SLAG
\
TIT
9' CAST STEEL
UPTAKES
VESSELS
T
_ GAS
REFORMERS j
A
I
I Li
if. //I \ \\V//// j \\V\
1 ZZJ
COMVEYOR DELIVERY SYSTEM °~~° OUST
£ ^3
K
S&
WASTE HEAT BOH.I.
B AT S0.000 LBS
PER HR EA.
f AT7I,SOO LOS.
PER HR. EA.
=^&?> SLAG TO DU
ff5 STEAM
i
A 7O POWER PLANT
\ff>
DUST HANDLING SYSTEM ,
S _f
ffS
LOS
EA.
~LL
\ ^1
-» J
-
a
i
>TTffELL DUST
>LANT
J
SLAG
/^KS
ANODE CASTING WHEELS
\. /
NATURAL GAS
KAIL
AW
TRUCK U'
LOA01NC-
S.' O<
REiNrqncrn co\cf/crr STACKS
39 IHStOf OIA I'OTTOM
H'lNStHC. [>IA. TOP
AHOftFS TO i
-------
B. PROCESS (Cont'd.) -2-
b. Normal operation depends upon the level of production estab-
lished by the company for the Smeller. Normal full production
capacity operation consists of the operation of four of five installed
rcverberatory furnaces, a fluidizcd roaster-acid plant complex, all
of the nine installed converters that maintenance permits, two anode
casting plants and the required ancillary equipment to smelt up to
3,000 tons per operating day of concentrate, variable tonnages of
copper precipitates, plant reverts and the required fluxes.
c. Actual production rate for 1975 was 37,667 pounds per hour of
anode copper at 99.64% Cu. Blister copper is not a standard measure-
ment for this plant. Production rate is input grade dependent. Design
average production rate for normal operating conditions is calculated
at 47. 083 Ib. /hr. at 99. 6% Cu.
d. Fuel
Information relating to specifications of fuel used is
shown on an attachment marked Item 3, Appendix.
e. Ore Composition:
Morenci Mine
Ore Composition Typical Range
Total Copper 0.80% 0.50-1.50%
Oxide Copper 0.14% 0.12 - 0.25%
SiO2 66.3% 64.1-68.0%
A1203 15.7% 14.7 - 16.3%
Fe 4.1% 3.3 - 4.7%
S 2.70% 2.19 - 3.29%
MoS2 0.015% 0.013-0.019%
FeS2 4.7% 3.8- 5.9%
CaO 1.3% 0.8 - 1.8%
Metcalf Mine
Ore Composition Typical Range
Total Copper 0.81% 0.63-1.13%
Oxide Copper 0.17% 0.08 - 0.33%
Fe 4.2% 2.6- 6.2%
S 2.4% 1.2- 3.0%
MoS2 '0.014% 0.011-0.017%
FeS2 4.23% 2.10 - 5.23%
-------
- 3 -
B. PROCESS (Cont'd.)
f. Flux composition including a typical percentage and range of per-
centages for each chemical constituent.
Percentage SiO2 AJ203 Fe CaO
(1)
.
0
(2)
(3)
Pit Ore
Typical
Range
Barren
Typical
Range
67.
63.
9
1-69.5
14.
13.
Cu
8
9-16.3
= 0.8
4.
3.
1
0-6.2
1.
0.
0 2.3
5-1.6 1.5-3.9
Red Quartz
86.
83.
8
0-92.0
4.
1.
9
9-6.5
2.
2.
5
0-3.0
1.
0.
0
8-1.1
Limerock
Typical
Range
4.
3.
4
1-5.7
0.
0.
7
4-1.4
0.
0.
5
4-0.7
50.
48.
7
0-56.0
MgO =1.0
g. Standard conditions used to calculate SCFM
. Pressure = 14.73 psia
Temperature - 60F
2. CONCENTRATORS
MORENCI CONCENTRATOR
a. Design Process Feed Rate - 50,000 TPD, 2083 tons/hour
b. Actual Process Feed Rate - 60,000 TPD, 2500 tons/hour
Feed rate measurement is accomplished by weightomcters on
belt conveyors. Accuracy is _+ 1.5%.
c. Average Operating Hours per Month - 600
d. Process Instrumentation
Typical Range
Ball Mill Feed Rate, TPH 2500 2250-2700
Particle Size, % in 65 Mesh 18 15-21
Collector, Lbs./Ton ~" 0.05 0.03-0.07
Frothcr, Lbs./Ton 0.03 0.02-0.05
Precipitant, Lbs./Ton 1.5
Flotation pH 10.5 10.5-11.0
Leach Drum pH 2.0 1.5-2.5
-------
- 4 -
B. PROCESS (Cont'd.)
2. CONCENTRATORS (Cont'c*.)
MORENCI CONCENTRATOR (Cont'd.)
e. Samples of Process Material
Mill Feed - Hand cut at each ball mill
(4) Flotation Feed - Automatic - central
(4) Rougher Concentrate - Automatic - central
Rougher Tailing (Orig.) - Hand at each section
(Ext.) - Automatic - central
Final Tailing (Ext.) - Automatic - central
Scavenger Tailing - Automatic - central
Final Concentrate - Automatic - central
Hand - Filter Plant
f. Process Fluctuations
Feed Rale - 54,000 to 65,000 TPD. Due to ore hardness which
varies daily. Emission results probably vary slightly since all
equipment continues to operate.
g. Expected life of process equipment - Indefinite.
h. Plans to modify or expand process production rale - None.
METCALF CONCENTRATOR
a. Design Process Feed Rate - 30,000 TPD, 1,250 Tons/Hr.
b. Actual Process Feed Rate - 40,000 TPD, 1,667 Tons/Hr.
c. Average Operating Hours per Month - 600.
d. Process instrumentation consists of control loops to control feed
rate to crushers, ball mill feed rate, ball mill discharge density, flota-
tion feed slurry density, flotation feed particle size and pl-l, slurry level
in flotation machines and pump sumps, and density of tailings thickener
underflow.
Typical readings are:
Process Variable Typical Range
Ball Mill Feed Rate 120 90-140
Ball Mill Discharge Density 1.796 1.719-1.879
Flotation Feed Density 1.255 1.226-1.326
Flotation Feed % Plus 65 Mesh 17 12-20
Flotation Feed pH 11.5 10.5-12.0
Tailings Thickener Underflow
Density 1.372 1.316-1.395
-------
- 5 -
B. PROCESS (Cont'd.)
2. CONCENTRATORS (Cont'd.)
METCALF CONCENTRATOR (Cont'd.}
e. Samples of process material arc automatically collected at the
following points.
Sample Collector Location
Rougher Feed Auto. Central
Rougher Tailings Auto. Central
Rougher Concentrate Auto. Central
Scavenger Concentrate Auto. Central
Scavenger Tailings Auto. Central
Cleaner Concentrate Auto. Central
Final Concentrite Auto. Central
Final Tailing Auto. Remote
f. Process Fluctuations:
Feed Rate: 30,000-45,000 tons per day as a result in variations
in ore hardness. Emission results may reflect variations in flow
rate of material.
g. Expected life of process equipment is indefinite.
h. There are no plans to expand the process production rate.
-------
- 6 -
3. Roasters
a. 'Design process feed rate lOO.'iOO Ib/hr.
b. Actual process feed rate (ibs. conccntrate/hr.) includinc
method and estimated accuracy of measurement.
Actual feed rate = 75,000 - 108,ljOO Ib/hr.
Method of measuring: Belt weigh scales with an estimated
* 2.5J5 accuracy.
c. Desicn process gas valume (SCFM) 23,MO.
d. Actual process gas volume (SCFM)
15,000 - 2li,000 SCFM with nornal flow at 20,000. Flow is
measured with standard orifice and flow is continuously
• recorded in the roaster acid plant control room.
e. Actual process temperature HOOF.
f. Average operating hours per month. Excluding strikes and
the scheduled annual shutdown. Operation for an average 30.
day month was:
j.97'i l<70.9 hours/month
1975 1*68.6 hours/month
g. Process instrumentation used, including data for a typical
reading and range of readings.
(1) Air flow to roaster bod - typical = 20,000
range = 15,000 - 23,000 scfm
(2) Thermocouples which give temperature profile of
roaster bed, roaster freeboard and cyclones.
Poaster Bed - typical TR-1 1050-1350 °F
TR-2 1050-1150 °F
TR-3 1050-1150 °F
TR-81 1050-1150 °F
range = same as typical
roaster freeboard typical 1000-1050 °F
range - same as typical
cyclone typical TR-6, TR-7 600°-700°F
range = same as typical
(3) Draft iiir.truntcntn which give level of roaster
Jluidizcd bed and freeboard draft.
Bed level typical = 50" W.G.
range = liO"-65" W.G.
l-'rccbo.'ird typicul -• 20"
range = 15-25" W.G.
-------
- 7 -
h. Description of where mid how samples or process material c-tm
be collected.
(1) Feed
Feed is blended in a bedding r.ystem in 5,000 to 6,000
Ions beds by weip.ht. Component samples an; taken separ-
ately as belt crab camples. A rough sample of the
blended nix can be taken by belt sampling.
(2) Calcine
The system is closed to the reverberatory furnace feed
drag conveyors. Samples are taken once per shift from
these conveyors by dipping and placing in a closed metal
bucket.
(3) Acid plant surubbor sludge.
Sample 5s taken by dipping from the scrubber thickener
. underflow.
i. Description of typical types of process fluctuations and/or
malfunctions, including frequency of occurrence and anticipated
emission results.
Following isalist of process malfunctions uhich shut the roaster
dovn broken down ivito four major groups, (l) roaster feed system,
(2) gas cleaning system, (3) roaster acid plant, (')) reverberatory
furnace.
(l) Roaster System - includes bedding plant feed system, con-
centrate bin weighfcedcrs, four conveyor belts in roaster
area, one bucket elevator, one rotary feeder, surge hoppei
and 600 hp blower. Also included in this grouping are the
roaster cyclones and the roaster itself. The tota] roaster
feed system typically accounts for 'iO£ of the total downtime.
(2) Gas Cleaning System - includes mist prccipitators and Peabody
scrubber with all of its associated pumps, piping and heat
exchangers. The gas cleaning system typically accounts for
3J5 of the total downtime.
(3) Roaster Acid Plant - this system includes drying tower, ab-
sorbing tower, 3>000 hp blower, converter, acid circulation
system and acid cooling system. This system typically ac-
counts for 31? of the total downtime.
-------
- 8 -
Rcvcrbcrntory Furnaces - when reverberatory furnuce
operational upsets occur such that they can 't take
as much calcine as the roaster is producing the cal-
cine receiving bins fill and the roaster has to be
shut down. This occurrence typically accounts for
of the total downtime.
(5) Frequency of occurrence is nearly daily with one to
three occurrences normal. Operating time of the com-
plex averaged 17-81 hours per actual operating day
in 197't vith the system available to operate on 87. 0$
of scheduled operating days and 17-56 hours per actual
operatine day in 1975 with the system available to
operate on 87.8/J of scheduled operating dii/s. In
addition to actual shutdown, the operating level may
be reduced to 63 to 75? of normal frequently to sus-
tain partial operation during periods of reverberatory
furnace trouble or loss of one of the two mist prec_pi-
tators. The effect on emissions on total shutdown is
a net reduction of emissions of approximately 1.6 tons
per hour of sulfur due to production capacity loss.
J. Expected life of process equipment (years) not knoun. This
is dependent more upon the requirements of pollution legis-
lation than equipment as repair, component replacement or
rebuilding can be done to keep the equipment operating in-
definitely.
k. Plans to modify or expand process production rate.
Original and modified plant design failed to solve problems
in hot gas cleaning and in the acid plant acid circuits.
Plans arc to continue pursuing development of means foj- hot
gas cooling to permit use of a dry prccipitator ahead of the
scrubber and of acid circuit changes to attain greater re-
liability and original design capacity.
-------
- 9-
l|. Reverboratory Furnaces
a. fc b. Design Process Feed Rate Lb/IIr, Actual Rcvcrbcratory
Plant:
Solid Charge
Liquid Converter Slag
Operating Hours 1975
Design
2l<5,666
120,1)17
Maximum
29'i ,800
111 1», 500
Actual (1975)
170,228
97,600
0,220
Measurement of oolid material by belt scales in bedding plant
at accuracy of - 1.5%. Process rate by combination of bed
reclaiming footage removed, belt scale and visual estimation
of bin inventory once per 2b hours. Rate accuracy - 10% on
a daily basis. Smelter accounting period is the 2'i hours
from 7:30 a.m. to 7:30 a.m. Final figures arc obtained by
reconciliation with copper production, inventory balances
and receipts in the end of month accounting report.
Liquid converter slag by counting ladles charged to furnace @
13 tons per ladle: accuracy - 10%.
c. Design process gas volumes
These figures are rather indeterminate at this time due to a
lack of knowledge of original design limitations, the practice
of designing and providing excess capacity due to trial and
error nature of application to minerals and the numerous changes
made over the many years of plant operation. Original plant
stack capacity was 1,000,000 scfm for both the rcvcrbcratory
and converter plants. This stack no\> serves only the reverb-
eratory side. Process gas at the furnace off-take is establish-
ed by firing rate.
d. Actual process gas volumes
200,000 to 1(00,000 SCFM measured at the stack sampling station.
In-stack sampling.
-------
- 10 -
e. Actual process temperatures
Dependent upon material and location. Typical temperatures
arc:
Matte 1930-2050 F
Sing 2050-2360 F
Bath Surface 2350-2'i50 F
Uptake 2350-2li50 F
Arch 2350-2550 F
Gas process temperatures typically are:
Waste Heat Boiler- Exit 600-750 F
Reverberatory Stack Inlet fc50-600 F
Stack Sampling Station Ii50-560 F
f. Average number of hours of operation per month
Definition is needed of operating hours.
The reverberatory plant operates 2^ hours per day, 3^0 days
per year on average with a three week shutdotm in summer
for maintenance and partial operation immediately prior to
and subsequent to the shutdown for shutdown and startup
procedures and is reduced to approximately 50? for Labor
Day and two days at Christmas. Operating hours for pro-
duction record purposes is defined by a percentage of full
firing or a production norm. The imposition of SCS is re-
sulting in widely varying figures.
E. Process instrumentation used
(l) Furnace fuel flow recorders and indicators
0 to 180,000 CFH natural gas
0 to 2'i 0,000 CFH natural gas
0 to 30 GPM fuel oil
(2) Prcheater
a. Fuel flow recorder
0 to 'lO.OOO CFH natural c&s or equivalent fuel oil
l
b. Process air and fuel to prchcater
c. Furnace process air volume nnd temperature
0-35 MSCFM
600-7'iO F
-------
-11 -
d. Miscellaneous burner control gauges and fiiil-sufe
equipment.
(3) Draft recorders, controllers and indicators * 0.0]0
to -0.030 in. W.G.
(li) Orsat: typical analyses attached
(5) Oxygen analyzer - air to fuel ratio control
(6) Thermocouples and pyrometers
(7) Fuel and air line pressure gauges
(8) Flue pressure gauges
0 to 1.8 in. W.G.
h. Samples
(l) Concentrate, flux limcrock, fluxing silica and reverts:
Grab or belt sample in bedding plant by dipping from
moving stream on a belt or by halting and clearing a
length of belt.
(2) Liquid converter slag: By inserting a sample bar in the
slag stream vhile skimming a converter to catch a chill
sample.
(3) Calcine: Spoon sample by dipping into calcine vhile it
is being run at the feed system rotary feeder.
(1<) Matte: Dipping spoon samples in stream flowing from
matte tap hole where tapping.
(5) Reverb Slag: Dipping a chill bar in the slag stream
during skimming and plunging into a container of water
to granulate.
i. Process fluctuations
(l) Fluctuations - operational
a. Firing rate changes - daily
i. No SCS restriction - converter capacity is
limiting - adjust furnace output to converter
capacity or to operational requirements.
ii. SCS control reductions - weather and seasonal
dependent on average cr.timatcd to be 11.6#
reduction in normal rate.
ill. Boiler restriction of firing rate through
pluggagc of r.ns piiCBaj'.oB or boiler failure -
tvo to tlircp time:; per yoar. Frequent nearly
duily short term reductions for boiler luncinr,
crown.
-------
- 12 -
b. Firing rate or draft, control changes for normal main-
tenance requirements - daily.
C. Feed i-.ystcm failure: Nearly daily varying from furnace
to furnace on feed system components or on piohJcms in
the feed reclaiming or distribution cyst cm.-5.
d. Hot metal runaway or breakout. Several times per month.
e. Smelt5IIG rate adjustments - daily on one or another for
furnace conditions - to balance liquid inventory in fur-
nace to removal of cither matte or slag or to compensate
for fact smelting charges, a lack of feed or a lack of
fettling or feed protection of sidewalJs.
(2) Anticipated emission result is a firing rate proportional
reduction or increase between full and idle firing rates.
J. Expected life of process equipment.
Indefinite - dependent upon still to be developed economic alter-
nate or the course of air pollution regulation. Equipment may
be maintained indefinitely through repair replacement and per-
iodic overhaul.
k. Plans to modify or expand process production rate:
No major modification planned. Control and operating equip-
ment will be modified or replaced as regulations permit in
continuation of past slow developmental progress as modifi-
cations become available and arc economic.
5. Converters
a. Design process feed rate
Design is based upon feed rate only to the extent of deter-
mining the size and number of the batch processing converters
required. Ue have nine standard 13'x30' converters. Original
design data is not available. Hcccnt engineering design used
for each operating converter 28,976 Ib/hr matte, 7,6'iO Ib/lir
flux to produce 21,3b'i Ib/hr of slag at a 2,500 Tl'D concen-
trate rate. Secondaries were not calculated assuming a balance.
.1
•
b. Actual process feed rate
In 1975 un average of 5.96 converters wnn operated per shift
Vitli blowing 5I|.£I|I'' ol' scheduled operntinr. time, fie. v en con-
verter.-. IDC required to be in operation for tliu 2,'jOO Tl'l)
concentrate rate. Actunl proce:,:s rate:; arc quite vnrtable
being dependent upcm mutto /-.rude, converter condition, j'J ux
composition, operations scheduling of converters etc. Typical
figures per converter are 19,0(10 Jb/hr m.-itte, 5,2.''0 Ib/lir
flux to produce 15,702 Ib/hr slug on avcrngc. Metliod of
measurement i:; the monthly nccoiniti ng bnliincu of jiroce:,-.
vcjp.litr. with a luiHe count of m:iLte find sin/; balanced n/'.ninr.t
used for converter process material:;. Acc'uracy ia
-------
PATE / A3 0/76
No. 1
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-------
Page 12 (b)
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-------
Page 12 (c)
-------
- 13 -
estimated at - 10%. One further word of caution, these
figures arc averages for the months operating time for
nil converters. Actual per hour rates vary considerably
from the above due to the batch process used.
c. Design process gas volumes
203,000 scfm average
d. Actual process gas volumes
Actual process gas volume is variable dependent upon the
actual level of operation experienced and the feed input
to the smelter. A typica] figure is the average for
December, 1975, at 151,600 scfm for 2,370 TPD concentrate
input. This was estimated from the volume of blower air
recorded in the power house assuming 100* dilution. Actual
process gas volume wi]l vary from zero to acid pJant capa-
city of 252,100 scfm measured by the acid plant flow meters.
e. Actual process temperature
1900-2200 F
f. Average number of hours of operation per month.
The convertei plant operates continuously on a 2'i-hour basis
vith the exception of a three week annual shutdown. In
recession curtailed 1975 average converter hours of operation
per 30.'i day operating month was '{,101 hours. Normal maximum
expected is 5,836 hours per month.
g. Process instrumentation
(l) Blowing air recorder, integrator
0 to 30,000 scfm, 2>i,000 typical.
(2) Event recorder
Measuring time blov air is on which is taken as converter
blowing time.
(3) Padiation pyrometer
0-2200F
00 Flux timer
h. Samples
Muttc: Spoon sample at revcrbcratory furnace tap hole
-------
Page 14
•-,-. v -•;.... v - •.
• •>... \.. . \ ,-,...
-------
- 15 -
Flux: Individual components or mix by belt sampling in
bedding plant:
Converter Slag: Sample bar while skimming.
Reverts: Grab from aisle - no good way to obtain re-
presentative sample or from belt sample of
material recycled to bedding plant.
Blister Copper: Spoon sample while transferring.
i. Process fluctuations
(l) Simultaneous varied blowing of from one to eight con-
verters dependent upon batch status and servicing re-
quirements.
(2) Charging of varying quantities of matte or secondary
materials, blowing at different rates - all the standard
operating interruptions of normal converter operation
including skimming, combination of charges, transfers,
etc.
(3) Malfunctions
(a) Plugged tuyeres - nearly daily
(b) Lo3S of reaction - infrequent
(c) Foaming - infrequent
(d) Explosions - infrequent
(e) Mechanical or electrical breakdown of mechanical
components about 15-20£ of time.
(f) Problems with gas systems - less than IJf of time.
(g) Short of matte - periodic '(-5JJ of time.
(h) Short of manning of converters or cranes - 'i-5/5.
(i) Crane breakdowns or delays 5-0?.
(J) Scaling of mouth - each shift.
-------
- 16 -
('i)' Anticipated ciiiisr;'ion effect in to decrease gas pun bin;;
to the acid plant proportionally but to increase ncad
plant emission for tlic rate of p,us handled through
upset of conditions, losr, of acid plant efficiency,
if effect is major and is not gradual.
J. Expected life of process equipment.
Indefinite - equipment can be kept serviceable indefinitely
by regular maintenance and component replacement.
k. Plans to modify or expand process production rate.
None other than to obtain better equipment efficiency through
supervisory control of operations. Possible conversion to
all Caspe punchers to increase productivity of installed
units.
6. Refining Furnaces
a. Refining furnaces are standard sized equipment, two are
13'x25'L and two are 13'x30'L. Refining furnace operation
is a batch process. At a smelter concentrate feed rate of
2,500 tons per day, it is expected to produce 6jO tons per
day of anode copper.
b. Actual process feed rate (1975 average)
1|52 tons/day or 37,667 Ibs/hr blister copper
Anode shipments weighed on main R. R. scales and calculated
back to blister copper by assay.
c. Design process gas volumes
Off gas is not mindlcd, no design. Assuming it is equal
to input gas then:
1,200 scfln air
1,200-1,300 scfln reformed gas
d. Actual gas volumes
Mot measured - Assume same as above.
e. , Actual process temperature
2,100-2,300 °F
-------
- 17 -
f. Average number of liourr. of operation per month (December, 1975)
Blowing = 171.8 hours
KcducJnr, = 363.9 hours
I'our = 53 P.7 hour's.
Total JO'iU.'i hours
B. Process instrumentation
Blowing air and reducinc C«s fl°w recorder.
Stypical chart attached.
h. Samples
Blister Copper - spoon sample at converter stand.
Anode Copper - spoon sample at casting wheel pouring spoon.
i. Process fluctuations
Plugged tuyeres during blowing or reducing operations. Time
is lost in clearing tuyeres. 3-^/mo. frequency.
Pouring equipment breakdown. Holds up casting. Frequency
2-3/weck.
Mo emission changes as fuel usually is not reduced.
J. Expected life of process equipment (years).
Indefinite - normal maintenance and replacement wi31 keep
equipment operational.
k. Plans to modify or expand production rate - none.
-------
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-------
- 19 -
C. KHTSSTOHS
1. Li?;I of sourrps of p.irllc-iil.ilc nni.-.slon.'; in the pi.int. (Including
tur.ltivc omissions)
a. Five (5) Kcvo.rb Furnaces.
b. Charge Bins lo Furnaces.
c. Nine (9) Pcircc Smith Converters 'seven operating).
d. Four (4) Anode Furnaces.
e. Fluid lied Roaster (35% total plant feed).
£. Furnace Waste Heat Boilers and Uptake System (fugitive emissions).
2. Level of uncontrolled participate emissions by source (lb«;/hr. or t/yr.)
There is a total of seven (7) wet scrubbers associated with the
smelter and the smeller crushing plant. They are as follows:
(1) Smelter No. 22 Conveyor Belt. (Duron Si KG 96 U\.'-'i)
(2) Lime Hydrating Plant. (Ducon Size 60 UW/0
(3) Smelter Crushing Plant No. 1. (Ducon Size 114 Ul.Vi)
(4)' Smelter Crushing Plant No. 2. (Ducon Size 8/1 UA.'/O
(5) Smelter Limestone Storage Kxhnuct. (Ducon Size 53 Type L Multivjnc)
(6) Sample Tower Unit No. ]. (Ducon Size 96 Type UW-4)
(7) Smelter Fluiilizing Reactor. (Ducon Size 8^1 Type UW-4)
The only scrubber that has been recently tested for cmir.oions was (.be
scrubber associated vith the Swelter F]uidix.in& Rc.ictor. (Item Ho. 7 of the above.)
'/he emissions test on this scrubber showed that the uncontrolled cmj 'irJonn
to-be- app> o.Nimatcly 0.00555't Ib.o/hour. TliJs is far below the .illow.iblc of
13.0S9 lbt;/hour, based on a process weight of 5.655 Tons/hour for the
FluidJ zing Ke.ictor.
-------
- 20 -
3. Exir.tinn Bourcc test data employed for participator. l>y .".tack, process
unit, or control device,
a. Test Method.
EPA Modified Method Five (5) was used for both the reverb
and converter stacks. See enclosed report.
b-e. For data acquired, sec Engineers Testing Laboratories, Inc. Report,
which is enclosed with this report.
4. Particle size and chemical composition of uncontrolled paniculate
emissions, including method of determination:
No definitive test.
5. Love] of uncontrolled visible emissions by source (percent opacJiy)
and ncthod of determination:
No definitive test.
6. Extent of and reason for variance' of partJciilntc emission?- with:
Statement docs not apply.
-------
- 21 -
D.. -CONTROL SYS'IT.IIS
Tlir smelter particulntos from bcth the reverboratory and converter
Bides are routed through clcctroslatic prccipilators. There is a total of
ten (10) prccipitators, four (4) on the converter side and the remaining
'six (6) on the revcrberatory side of the smelter.
On the reverbcratory side the prccipitators are located after the
vaste heat boilers and before the reverb stack. Four (/i) of the six (6)
prccipilators, the Koppers and Research Cottrcll, take the flue gases from
four (/i) revcrberatory furnaces (furnaces one (1) through (4) ). The two (2)
Bucllprecipilators receive the flue g.isos from the new No. five (5)
revcrberaLory furnace.
The four (/t) Research CotLvcll prccipiLators on the converter side
of the smelter take the off gases immediately after the gas coolers. The
gases arc then routed to the new converter gas scrubbers and then to the new
acid plant. The tail gases from both the new and the old acid plants are
then routed to the converter stack.
-------
- 22 -
Present SmoHcr Control n.vr.tcm Mod if]cation Runs
With the new No. 5 rcvcrbcratory .furnace, the new No. 9 converter and
the new 2pOO VFD acid plant in their startup phases, there arc no immcdjalc
plans for additional modifications to plant or process.
2. Electrostatic Precipitation
a. Manufacturer, Type and Model Number.
Research Cottrell - Converter Electrostatic Prccipitrv'.or.
b. Manufacturer's Guarantees, if any.
Research Cottrell guarantees when the equipment is adjusted and operated
at the normal conditions of 300,000 to 1,000,000 actual cubic feet of gas per
minute at l400°to 500°F, with an inlet grain loading of 1.0 to 2.5 gr/ACF, that
95$ of the entering particulate matter shall be removed.
c. Date of InstallatJon, or Last Modification, and a Detailed Doncrip-
tion of the Nature and Extent, of Modification.
Date of Installation: December, 1969.
cL Description of Cleaning and Maintenance Practices^ Jjnclud iry; Frequency
i
and Method.
This electrostatic precipitator is checked each month for dust biuld-up.
Wie dust is loosened when necessary with air lances and removed with screw
conveyors.
Electrical maintenance is given us required.
A thorough inspection is made once each year and any extensive repairs
required arc made then. This occurs during the nximmcr shut-down.
• •
e. Dcnir.n and Actual Values for the PnJlowiiir. Variables:
(The values given below arc design values unless otherwise stated)
-------
- 23 -
Research Cottrcll
1 &.. jj. The four electrostatic prccipitators arc arranged in
parallel. The high voltage, uni-dircctional, power supply for
energising each pair of precipHaters consists of three, 70 KV peak
(l»5 K.V. Avg.), 1500 MA silicon rectifier-transformer sets.
One rectifier-transformer set energizes the inlet sections of
the two precipitators; one set energizes the two center sections,
and one set energizes the two outlet sections.
jlii. The collecting plates of each pair of precipilators are
cleaned of collecte-i material by means of 1»8 magnetic impulse grc /it;
impact (MIC.!) roppcrs. There are 2>i rappers for each precipitator,
or 8 rappers per section.
The main component of the rapper control circuit is a >iO point
distribution svJtch. This switch rotates at 1/2 RPM j.nd_therefore
cnerKJx.es each associated rapper once every two minutes, or 30.tames
per hotir.
iv & y. Bach section of each precdpitator (three sections per
precipitator) is equipped with 36 collecting plates. These plates
arc arranged in four banks.
yj. Particulatc Resistivity (ohm - centimeters): Unknown.
vn'i. Does not app3y.
viii. Does not apply.
ix. Gas F\OM JTatc: 300,000 to 1,000,000 ACFM.
x._ Operating Temperature: I|00°-500°F.
xi. Inlet rtii'ticulatc Concentration: 1.0 to 2.5 gr/ACK.
xjj^ OwtlcL ParticxO.atc Concentration: Not known.
xi1_l._ Pressure Drop: MaxJmiun pressure differential throvjgh
precipltntor to be 0.5" W.O. or .Icr.a.
-------
- 24 -
EIect.rosi.ttt Ic lVcc.lpli.ator for Smelter Rcvcrlicrntory Cas.
O. Manufact\ircr, Typc^ Itodel 1 lumber.
Research CottreLl, Inc., Tag Ko. 25Du'i002.
b. Manufacturer'.': Cuarantccsj if any.
Research Cotlrell, Inc. Guarantees, when equipment is adjusted and opera-
ted the normal conditions of 570,000 actual cubic feet of gas per minute at
600° F, with an inlet grain loading of 0.5 to 1.5 gr/ACF, that 95$ of the
entering particulate matter shall be removed as represented by Performance Curve
Wo. 1598, dated Hoy 23, 1969.
At conditions below normal, with inleL loadings below 1.0 gr/ACF, at the
the option of Research Cottrell, an outlet concentration of 0.025 gr/ACF at
600°F, shall constitute fulfillment of the guarantee.
c. Pate of _Install.".Lion or Last Modification and a Detailed Description
of the Nature and Extent of the Modification.
Date of Installation: Mr.rch,1971. In November of 1975, the static
support braces were replaced with anti-sway bars.
d« Description of Cleaning and Maintenance Practices, Including Frequency
and Method.
Eiis prccipitator is inspected once every two months for dust build-up.
B>e dust 3s removed by air-lancing and screw conveyors. Electrical repairs are
made as required.
IH November, 1975, oil baths were checked. Dielectric strength and color
are checked every tiro years.
e. Dcgjpn nnd Actual Values for the Following VarJabJcs;
(Design values arc GJVCIJ unless otherwise stated)
i fc 3*. Current (amperes) and voltage: Olio high voltage,unidirec-
tional, power supply for cncrcl/.Jnc the two prcclpitutora consiatn of
thvoo. 70 KV peak Ci'j K.V. Avr.) 3500 MA. .-.•ilJcon rectiricr-trnnnfonncr
-------
- 25 -
oet cncrcizcs the inlet sections of the two prccipitators; one set ener-
gises the two center sections, and1 one set oncrc^-os the outlet sections.
iii,iv,v. Hie collecting plates of tlic two precipj tutors are cleaned
of collcctinc materials by means of l|8 magnetic impulse gravity Impact
(HIM) rappers. There arc 2»i rappers for each precipitator, or 8 rappers
per section.
Each section (three (3) sections per precipitator) of cacli prccipi-
tator is equipped with 3'i collecting plates. These plates are arranged
in four banks of 8 or 9 plates each.
The main component of the rapper control circuit is a I|8 point distri-
butor switch. This switch rotates at 1/2 MM and therefore energises
each associated rapper once every two minutes, or thirty times per hour.
vi. Particulatc resistivity (ohm-centimeters): Nnt Known.
vii. Do not apply.
yiii.. Do not apply.
ix fe x. The inlet B^s volume desJ^n for 570,000 ACM1 max. The inlet
gas temperature is 650°F.
xi. Inlet parlicxaate conccntratjon: 'Hie inlet eas loadinc w
vary up to 1.5 Qr/ AFC approximately. Particle size maximvim, 65 mesh.
>:ii. Outlet particulatc concentration: Unlpjio\.m.
xiii. Pressure Drop: Maxjmum pressui-e differential through
precipitator to be 0.5" v.£j. or less.
Eloctror.iri.tic rrcclyubator for Hmcltcr Rcvcrbcratory G.is.
a. Mamifaclurer, iy.no, Mortnl Niunbpr.
Bucn Encinccrinc Division of EnviroLcch Corroration. Tag Ito. 60r«5'i01.
Electrostatic Prccipitator for the No. 5 Itovcrb.
b. HanMructurer's Ruarnntcc, if any:
Bucll Kn-jinecrJiv: guarantees, \/hcn equipnent in adjusted nnd operatod
-------
- Z6 -
at the normal conditions of 178,000 actual cubic feet of gas prr minute at 600 F,
With an inlet grain loading of 1.0 gr/ACF that 99% of the entering particular
matter shall be removed, as represented by Performance Curve No. 19085-02,
dated December 2, 1970.
At conditions below normal with inlet loadings below 1.0 gr/ACF, at the
option of Bucll Engineering, an outlet concentration of 0.010 gr/ACF at 600 F
shall constitute fulfillment of the guarantee. Bucll further guarantees that,
when the equipment is adjusted and operated at normal conditions of 178,000
actual cubic feet of gas per minute at 600 f with an inlet grain loading of
1.0 gr/ACF, that 98% of the entering particulate matter shall be removed when
the total gas stream is passed through one body.
c. Pate of Installation or Last Modification, and a Detailed Description
There is an anticipated modification to the Bucll prccipitator
in that a purge air system may be incorporated in order to increase the
efficiency by protecting the insulators from the accumulation of material.
d. Description of Cleaning and Maintenance Practices, including
Frequency and Method
This electrostatic prccipitator is checked every second month for
dust build-up. The dust is loosened by air-lancing and removed by screw conveyors.
Electrical maintenance is given as required.
A thorough inspection is made once each year and any extensive repairs
I
required arc made then. This occurs usually during the summer shutdown.
e. Dcsir.n -"ul Actual Values for the Following V.iriahlos:
j. ft ii. Current (amperes) and Voltage: Three individual
transformer rt'ctitiers.
Input Hating: 225 amperes @ MO volts single phase.
Output K.iting: l/iOO 1>.C. inillJnmprrcfl nnd /i5 KV DC.
-------
- 27 -
jjj. flapping Frequency: There are 36 collecting vibrators
• • •
and 10 emitting vibrators.
iv. Number of Banks: 3 banks per each cub-section.
V. Number of Staces: 3 stages per each sub-section.
vi._ rarticulnte Resistivity: OliM-CM 1.37 to 1.80 x 10
yii, viii. Does not apply.
3x. Inlet Gas Volume: 170,000 ACFM @ 600°F. Because of
the nature of the reverberatory operation, the inlet gas volume will
vary over a considerable range. The volume is the anticipated normal
maximum.
x± Operating Temperature: Inlet gas temperature may range
from 500°F to 700°F. (Normal temperature - 5't5°F)
xi. Inlet Particulale Concentration: Inlet grain loading
is approximately 1.0 grains per ACFii inaxoiaura.
xii. Outlet PaiLiculate Concentration: Set Item 2b.
Manufactui'er's guarantee, actual value is unknown.
xjjl. Pressure Drop - Maximum Resistance Through Prccipitator:
0.5" V/.G. @ conditions.
Electro.".tatic Pj-ecj.Tiit.itor.':.
a. MfinufacLurc-r, Typo, Model Number..
Koppcrs Company, Inc., Metal Products Division, furnished to rarsons-
Jurden Corporation. Electrostatic precipitaLor for revcrberatory fvu-nacc.
Tag Ito. 05-Ii708.
• ' This prccipitator is located after the waste heat boiler and before the
reverb stack. Its purpose in to clean from the flue (janes from four revcrbera-
tory furnaces, the duct containing varying amounts of copper, silver, gold, etc.
b. Hnnnfiicl.m'cr'r. Gua van tern, if nny:
Koppcrn guarantee."., with an Inlet gua volxime of 200,000 actiuil cubic
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- Z8 -
feet of gas per minute at 600°F, with an inUct grain 3 ogling of 0.5 gr/ACF,
that 95$ of the entering dust will be removed.
c. mto of TnstnJJation, or Last Modjr3c.itJon, and a Detailed ncscrin-
tion of the Nature and IX tent of the Modification.
Date of Installation: October, lyG'i.
The only modification was the replacement of collector plates.
d. Bescription of Cleaning and Maintenance Practices, Including Fre-
quency and Method.
This electrostatic precipitator is checked every second month for
dust build-up. The dust is loosened by air-lancing and removed by screw con-
veyors as required.
Electrical maintenance is given as required.
A thorough inspection is wade once each year and any extensive repairs
required are made then. This occurs usually during the summer shutlo-.-m.
e. Design and Actual Values for the Following Vavj.iblcs;
This installation (Koppcrs) consists of one (1) tiro-chamber, tvo-
field copper smelting precipitator energized by t\.x> (2) 750 millifunp double half
wave silicon type Askarcl filled power units.
1. i:i. Silicon Rectifier, 750 J'A, 'i5 KV-D.C. output, with 'lOO
volts, 60 cycle input (transformer/rectifier Ackurel cooled transformer,
1KX> V to 53.3 KV., 60 cycle, single phase.)
iii. Repeat cycle timer, 10 switch, A.T.C. (Typo 2300),
1/5 im-i and repeat cycle timer, ^ switch A.T.C. (Type 2300), 1/5 RIM.
I
•J.v. Number of Banks: Eacli sitlc of the precipjtator is
divided into three sections.
v^ Number of &tagc&: Each side is divided into three (3)
ccctjons or stages.
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- 29 -
yj. Farticulatc Resistivity (O)D-J-Ccntimctors): Hot known.
vii, viii. Docs not apply.
Ix. Gas Flow Rate: Under normal conditions of operation,
the Gas fl°w is approximately 200,000 ACFM.
*._ Operatins Tcmperatxrre (°F): Inlet temperature 600°F at
pressure of 1.0" W.C. below atmospheric pressure.
xi. Inlet participate concentration is approximately 1.1622
gr/ft^ vlien gas volume is at 100,000 CFM for Chamber B, and is approxi-
mately 0.61j68 gr/ft3 at 101,300 CFM for Chamber A.
xii. Outlet participate concentration (outlet residual) is
approximately O.OOol gr/ft3 vhcn gas volume is at 100,000 CFM for
Chamber B and is approximately 0.031Ji gr/ft3 "hen gas volume is at
301,300 CFM for Chamber A.
Items xi and xii above vere test results as of ApriJ 15> 19&5.
xiii. Pressure Drop: Maximum resistance through prccipitator,
0.5' w.g. @ conditions.
3. Fabric Filters (Bag Houses).
Hie following bag house is located in the Roaster Acid Plant of the
smelter. Not in use at this time.
a. Northern Blover Division - Buell Encinccrinc Company, Inc., ItoCtel
"itorblo" Automatic Air Shaker Dust Arrester. Model number 156-A, Series 39-
Tag No. 05-')7.
Collector for liandling dust laden air from a dry solids systems, handling
burnt line and raw concentrate:;.
b. Manufacturer' r. Hnivantcc;
Hot located.
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- 30 -
c. Dntc of Jjistallfit5on, or Last Modjf.1o.ition, and a Detailed Descrip-
tion of the Nature and Rrtprcb of the Mod if J cat ion:
Date of installation: March-AprxL, 19^5.
d. Description of Cleaning and Maintenance Practices;
No longer in use.
c. Filter Material:
Bag holder for 39 bags. Bags are 61 dia. x 8"-3" long. Cotton bags.
f. Filter Weave:
Not given.
B. ,Baft Replacement Frequency:
Not used.
h. Forced or Induced Draft;
Bio unit is induced draft.
i. Design and Actual Values for the Following Variables:
$._ Bag Area (ft2): 12 sq. ft/bag, '168 sq.ft/39 bags; 1,072 total
square feet.
ii. Bag Spacing: Not stated.
iij. Number of Bags: 156
jlv. Gas Flov Rate: 3^00 OFJ-i design flow rate.
v._ Operatinc Temperature: Approximately 100°F.
yl. liiLet RirtirulaLe Concentration: 10 to 15 crains/C.F.
yil. Eressure Drop (in. of water): Not known.
3. Fabric FJlbors (P.TX llouscr.) continued.
Mic following fabric fillers arc used for dust collection off t\ro 250 ton
concentrate charge hjns (l)usL Collector Unit No. 6'< D 2^101 ic over Bin No. 5A;
Unit Ito. 6'< D 25101 is over Bin No. 5B (ito. 5 Reverb)). Unit No. 6»l D 25102
nlco pulls cilicii dust from nilica bin.
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- 31 -
a. Manufacturer, Type, Model Number;
North Monccn Co. - Mttcro Pulsaire Model 6>iS-6-20 (r. Order No. 2025.
Acct. No. Qi D 25101).
b. Manufacturer's Guarantees, 5f any:
None located.
c. Dale of Installation, or Last l-todification, and a Detailed Descrip-
tion of the Nature and Extent of the Modjf Lc.ition:
Star I up date approximately August 18, 197'i.
No modifications.
d. Description of Clean Jng and Maintenance Practices, including Frequency
and Method:
Cleaning and maintenance performed as required.
e. Filter Material:
Each unit holds 6h Dacron bags, l)-l/2" dia. x B'-O" long.
f. Filter Weave:
Not
g. Bag ^cplaceinont Frequency:
As required.
)i. Forcc-d or Induced DrafL:
These units arc both induced draft.
1. DesJ/'.ii and Actual Values for the Pol3owjn,7, Variables:
i». Dag Area (ft2): 1*52 sq. ft. each.
ii. Da/j Spacing: Not Given.
13 i. Number of Bacc: 6'i per each unit.
JLV. Gas Flow Rate: ADT vol\unc 3,500 GCFM each unit.
v._ Opcratinc Temperature: 100°F cacli unit.
yi. Inlet rarUeulnte Concentration: 15 Gr/}*\3 or 'l50 Ibs/lir.
yjj. Outlet ParliciLlulc Concentration: Not stated.
viiJ. 1'rt'iisurc Drop On. of VMtcr): 6' ± WE-
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- 32 -
3. Fabric. FiJtorr. (B.iR House*; - ConlimicJ)
i The following Bag House is associated with Che Lime Kiln Exhaust System.
o. Manufacturer - Joy Baghousc.
bi Manufacturer*s Guarantee: Hot located.
c. Date of Installation, or Last Modification:
Date of Installation: March 21, 1962.
e
d. Description of Cleaning and Maintenance Practices:
Cleaning and maintenance performed as required.
e. Filter Material: Fiberglass Bags.
• f. Filter Weave: Unknown.
g. BnR Replacement Frequency: As required.
hi Forced or Induced Draft; This unit is forced draft.
i. PesiRn and Actual Values Cor the following VariaMcs:
j. l)_a_%_ Area: 14,870 square feet.
ii. Bar. Spacing: Not given.
iii. Number of Bags; 216.
iv. Gas Flow Raio: 28,000 CHI at 550 F Maximum temperature.
y^ OpcralinR Tomperniiire; Assumed operating LcmpcraLurc at 580° F.
vi. Tnlel Parricul.ilc Concentration: 3.5 crains/cu. f'_. dust load.
vii. Outlet Particulaic Concentration: Unknown.
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- 33 -
DUST CONTROL SYSTEH
tOCATION Lime Kiln Fx
1'AH & KOTOll CFECII'ICATT.OJIS ' Dflto luatallcd .tor. 21.
Jypo Tea __Jnff.llo. Si 7.0 fin I'.V ... _ FCQ R.P.M. • 1000 _
Rotation ^ff^JpjxJ.fcl.lMPt-.aA _ Rated Volurx- ^ Qjgg C. I\ H. @
Motor R.P.H. ^J^OO _ llotor Vrcats ^Tyiv 1 60 _ Voltacc ^.LliIL __ I'-P- >iO.
Motor Dhcavc ^jn^O _ PD. HhaCt Dia. 2.1/fl" _
V&n fihcavu L2- TD. Shaft Dla. 3. 3/36"
__
Faf Ps'N'^S & Collar
Fnu Boivicgfl S1V-303K SAOL _ Tyijc Drivco S.y __ RTJ^
a DATA
Typo Collected ^Joy^ Ra
Sprny D^ta Typo ^_^r_._J_ ____ t GFM r ______ _ (? _______ 1'SI.
Conctruciiou '_ __ ___ . ____ , ___ __
JUiQUISITIC'-x 1:3
Fan
Collector
).|KVG. Koo.
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- 34 -
1|. Scrubbers.
Smelter - Scrubber to the No. 22 Conveyor Exhaust.
a. Manufacturer, Type and Model I-?umbor:
Ducon Size 96 UWJt (collector) with Ducon fan.
b. Manufacturer's Guarantees, if any:
Bie guaranlecd efficiency is stated to be 99-5?o with particle size
of 2 microns.
c. Date of Installation, or Last Modification, and a Detailed Descrip-
tion of the Nature and Extent of the I'odifi cation:
Original dust collector installed August '), 1970. Replaced with
same type and specifications only in a stainless steel model. Date of replace-
ment was February 15, 1972.
d. Description of Cleaning and Maintenance Practices, including Frequency
and Method:
Hie unit is cleaned and/or repaired as required.
e. Scrubbing Media;
Water.
f. ncsJf.n and Actual Values for the Following Variables:
i ft ii. Scrubbing Media and Flow Hate (gals/min. ) and Treasure (P3l)
water: 51 GIM @ 21 PS I, 26 GFM @ 12 FST.
iii. ' Gafc Flow JUte: t?3,700 C.F.M.
iv. Operating Tempei-atiire: Approximately 65°F.
v-vlt.' Wot Kno\m.
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- 35 -
DUST COirrROI. SYSTEM
IX>C.YTIO;i Smelicr
M Convi-yor Exhaust.
FAN & 150TOK. SPJ'.CIFICATIOIIS
FAB Dueon
Dfltc Intt.-illcd R-Ji-70
Fnn R.LMJ, 008
Rotfttioa CTt
Rated Volucc
C.F.H. 6 ki2..T
MDCOJ: R.P.H. 1800
llocor FrcEC JiMjT ___ Volfcocc 2300 lip. 100
Motor Shocvo 9.75_
Pan Sheave 21.2
PD. Shaft »ia. _J_3../L
PD. Shrift Din.
Shror-Aljgn
Driven
COLLCCTIU DATA
Type CoilccLor ^
JJprny Data
Typ«>
GI',1
Pnn
Collector
DWG. lloo. , K-96363-1 -B
PSI,
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LOCATION
- 36-
DUST COHTKOI. SYSTBI
Ca]cincr
Date Installed 9/1/75
Fnn R.P.ll. 500
FAN & HOTOK SPECIFICATIONS
Type Tan Due0"
Rotation CCW Rated Volume 20,000 C.F.M.
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- 37 -
DUST CONTROL SYSIQ1
LOCATION r.mcltcr r.njnnVo 1V)\/c;r llr^jj^//!
FAH & KOTOa SPECXFICATI011S • >>nto
Dxicon Fan IU1.M1,
Fan Bcarinso Dodnc r.phcv_-Aljgn _ Typa Drivco
COTJLECiCIi DATA
Collector
Collector
\
DHG. Kos. K-60363-l
'^il3FC 55. 12
fiprcyfata
Construction
REQUISITION Kon.
Fa n
RoUtion counLcreJocfcHi.-.e Ratoc! Vole:ri _^,j?00_ ___ C.F.M. @ j5.-JJ_.Ta. C.P,
Motor R.P.H. 1000 Itotor Frcita _ JjOgT _ VolLrso ..g'lOO ---- »!?.
Itotor Sheave 10.9. O.n. _ ra. Shaft Din. _
Fan Sheave ^ £1.2.0. T), _ I'D. Slinft Diu. __
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- 38 -
DUST CONTROL SYSTEM
LOCATION Lime Hyilratinp. Plant
& KOTOR S?BCiriC.'.TZOKS
I
Typo Pnn | flucon
Pan R.l'.JJ.
Dftto Inntallcd March, 1973
TOjO
Rotation r_ counterclockwise _____ Rated Voluna ___JV500 _ C.F.H. @ _ Jj _ In. S0P.
Motor ReP.H. 172^ _ Motor Frnraa 32'«T _ Voltase __ !i!l2 __ ):i5" _ !iP __
Motor Sheavo 9-g^ P.P. PD. ShnCt Din. g-l/O" __
PD. Shaft »in.
Fan fllicavc
" O.D.
Fan BcfiirtuEO Dodge Sphcr-Al i,;n
COLLECTOR DATA
Typo Collector Ducon SJ?.c 60
Sprr,y DatA Tj-po JELJjSlM!^
Conotructica 10 Ra. Carbon_Ricel
HCITIOH Kao.
20
10
10
7
I'SI.
Pan 9671'H
Collcctcr
DVJG. Koa. K-YOl'i7-U
RE1JAWCS
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- 39 -
DUST COIHKOL SYCEM
LOCATiou _ iterilsJcJCniPbi rc.I3.?nfc— Vnii-J!! ---
F/iH & liOTOll SPECiriCATZOHS " Dote InBtrtllcd
i
Ffin _J>icon __ Pan 11. 1?. H. _ 6,12
Rotation ffl? __ Rated Vol.ur.-e Jj>|022 _ C.r.M. 0 JL^L1"' S°
Itotor R.P.H. .,1200 _ Motor I'caiaa JjIjuLT _ Voltncc .2300
Motor Shonvc __15^.^ __ H). Shaft Jiia. _ UJ/8L! __
Fnn dicave _ ^2^? __ TD. SlinCu Dia. ^
Fan Becrlcsa ^Dpdr.c^^har^Aljp.n Type drivcc
coLLi:crrorv DATA
Collacta*- TX'con _ Sijn nl|_uT.!j
"" "
_ _ ________ L __ . ___
TF j&'-c" 72 12
Sprr.y Datn Typo B='t£L_JCK50pTjji5, ___ CPM _J6_ _ 0 __ Jb ____ FSI.
Oonotrueticn 3/J6" C.irtc.n Stcol
^ -*» »V~4^^<
Tan
Collector
.'G, Koc. K-6P363-2-C
RI3LAJUCO Installrcl l-y Sic or us & P>
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- 40 -
LOCAVIOil J
PAN f« JJOTO.I SKscinavfions
I
3fypc 1'an _____
Kotnticn _Cg'
Hotor P..P.1I. ,10.00
Motor Chcavo __!0/j_
Fnn Slicave .m2>|._0
Pan ncaringo
COIiECTOS DATA
7^T>s Collcccc;
fiprr.y Dnta
DU3T C01.VROL CYSTEll
Infitnllcd
R.P.I i« _______ ?
TtaCcd Volur:.o JL^gOO ____ C.F.IU 0 h.._? _ In. S.P.
Itotor )'r£'.-,o JibjiT VoltcfiC __2300_
PD. ClioCt Die. 1.JJ/R
PD. Shaft Dia. 3_1!?/3 6
Tyre: Drives
UV.i
Bate TFhOrC
Construction 3/36' Carbon £j,qgj
Ton
iDil^JL
Collector
DUG. lloo. K-68
Installed by Sl.carncnodrcr!.
. //7
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- 41 -
DUST cowrnoL SYSTEM
LOCVnOH t,|>T.o1 j.p r ., jr.jmo^toiy; L.SJ
TAN 6 1JOTOS SPECIFICATIONS • Dnto InfltallGd .b.n.
Pn'n ff3H.oy.inJ- L.i_//h?3_uAjrjr.rJ'i Fnn U.P.1I. 930 ___
RotcLion Ctf JIiiMrnh __ Ratod Voluv.c 91 00 __ C.lMIo 0 _JL_Tji. S»5?.
Ho tor R.P.1I. t 1 flop _ Itotor Trarac _____ P_B6n __ Voltngc ^??0/I|)|P^ 11? . ?0 _
Motor Sheave . 10.6 PI). Sho.Cfc Dia. 1 '^/fl" __
Pan Sheave j ^PO.O __ PD. Shnf'u DJlo. 2 11/16" _
Pan Eccrinso JF.T(\ ? .U/J.6" J,SAQ __ Type Driven __ T/.-o CIO;?
COLLCCICS DATA
CollccCui- i^oi S11'-e3-T.l\-'J . _NO
Spr«y Data Typo _jj-_np,t.c '._Jf-1 G?JI ^,36 _ @
Oo not j: u c t ion
' JPnn
CoJloctor
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- 42 -
5«- Sulfuric AcJil Plunts
'I. Hoastcr Acid Plant
a. Manufacturer, type, model number
Manufactured by rarsons-Jurden Corporation, single absorption
contact process, special dcr.jf-n - no model number.
b. Manufacturers guarantee
There is no Guarantee as such in "the orif.inal design. Design
vas established on the basis of sulfur potcntiaJ of the roast-
ing of 1,300 tons per day of concentrate and known acJd re-
quirements. This was set at 87£ conversion of S02 to 503 of
a gas stream of 22,000 SCFM containing J5.70£ 809 by volume.
c. Date of installation cr last modification including detailed
description of tlie nature and extent of the modification.
Original date of installation vas in 196'i-1965 with startup
in February, 1965. Last major modification was in 1968 by
Leonard Construction Company. Overall objective was to in-
crease production from 600 tpd to 750 tjul by an increase in
conversion efficiency from &{% to 95/3 and increase in GCIS
Ihrouchput . 1'ijor clcr.ents of the r.odification included
installation of Jailer acid purips, a 3,000 hp blower to re-
place the 1,500 hp blower, larger c£s ducts, an intermediate
heat cxch.incer and a tlurd manr. in the catalyst converter.
Also to facilitate the extra ^as load an additional set of
roaster cyclones had been added over tlie l.'o. 3 revcrbcratory
furnace, a new vertical lefi combustion nar prcheatc-r had been
installed, a spray cliai.ibcr for coo] in;; t)jo liot roaster pases
had been installed, a hot du:.t prccipitator added and a
scrubber booster blower in i,hc line.
In 3972 the acid cooling and pump tank r.yotcras were replaced
with a duPont TanLcoil systcu.
197'« t)ie tail gas was vented to tlie converter stu- •
d. DescripLion of cleaning and naintcnancc practiccr-, including
frequency and method.
(l) Pcabody scrubber - trnyn cleaned every 2-3 month-, dcpcnd-
upon pressure drop. Trays urc rc-movcd and sand blunted.
i
(2) Mist procjpitiitors - ori-r.njnc. repairs arc made to ]c»d tubes
miiO:; iu-o cJcuni.-d witli built in :;pruy Jicad:; on u daily
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- 43 -
(3) HryJiiK tower mint, pud:; - pads arc denned in place
every 2-3 wcckfl by i.pr.-iying Jiglitly with a water hose.
(l|) Cua to r,ar. converter hont exchangers - duct work.
KetullJ/.ing of heat exchanger surfaces is done durinc
each summer shutdown.
(5) 3,000 lip blower - stripped down Tor impeller chance
nnd major overhaul at least once and sometimes two
limes per year.
(6) Absorbtion tower Brinks dcm^ster pads - pads are given
a licht water wash every 3-'i weeks.
(7) Dupont tank coil acid coolers - these require a high
degree of operational and maintenance attention to
maintain adequate flow for proper absorption towe,
acid cooling. Coils have to be pulled every 1-2
months for leak repairs. Flow lias to be reversed
veekly to maintain 0.125" ID tubes in a clean condition.
(8) Tank coil filters - 12 tank filters containing sand
which have to be emptied and reclas,sificd and rechanged
every three years.
(0) The roaster contains equipment which when dovn for normal
maintenance and cleanup causes the acid plant to go down.
These include repajrs to the concentrate bin pan feeders,
repairs to the four conveyors and one bucket elevator
vhich carry concentrate to the roaster feeder, repairs
to the rotary feeder, repairs to the 600 lip blower wliicli
produces the fluidizing air for the roaster and any leaks
vhich develop in the roaster cyclone.
e. Frequency of catalyst screening
Until this year the first mass required screening every 3-5
months, but now we are trying to get by with just raking
since last August (1975)• This, new approach scenic to be work-
ing in that we may be able to go until 1976 summer shutdown
vithout screening first ma^s catalyst. Our best prediction
now in screening of the fir.',t fwo catalyst masses at least
once per year nnd the third mass once every Ji-5 years.
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- 44 -
f. Typo of dcmistor
Brinks
E. DCS in" «md actual valves for Die following variables:
Den if." Actual
(1) Production (Tons acid/day) 750 500-600
(2) Conversion rate (percent) 95 93-5
(3) Acid strength (% Jl2SO)|) 93, 98, olciiin 93, 90, olcui
•('i) Iluinber of catalyst beds 3 3
(5) Gas flow rate (SCFM) 'i9,000 38 ,000-)i3 ,000
(6) Operating temperature
1st catalyst mass 850-1080 050-1300
2nd catalyst mass 830-080 850-980
3rd catalyst mass 830-8liO 790-805
Note: Tlie actual values arc only point values and
can fluctuate over a range depending upon
conditions (time from startup ct.c
(7) Inlet DOg concentration (ppm) 80,000 60,000-70,000
(8) Outlet SC>2 concentration (ppm) !j,510 '<,000-5,000
(9) Acid mist Dbs. l^SOI./T of acid H.A. 0.218-0.656
(10) Blower pressure 3-07 2-52-7-22
II. Converter Acid Plant
a. Manufacturer, type, model number.
Manufactured by Chcnica] Construction Corporation, single ub-
corption contact process, contracted design - no mode] number.
b. Manufacturers guarantees
The plant vao designed to meet certain specifications. If these
can be considered to be a "guarantee", tlie plant meets tlie
following operating characteristics:
(1) Total capacity of 2,500 TPD of sulfuric acid (lOOtf basis)
vhcn supplied witli adequate quantity of sine]tor gas con-
taining u minimum of ').'/» f>02-
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- 45 -
(2) Product acid to contain no more thun 60 ppm S02
at 310 V oiul JiO spig.
(3) £502 concentration in effluent to contain less thun
1,000 pnia U02 at 20 in. U. G. nbovo atmospheric
pressure.
c. Duto of installation or last modification.
Plant was installed in 3973-197'' and started up on October 6,
197'l- No major modifications over original design have been
made.
d. Description of cleaning and maintenance practices, including
frequency and method.
(l) Humidifying towers - inspected for nozzle and mortar
deterioration every 2-3 months. When lovers are opened
necessary repairs are made to nozzle piping and brick
mortar.
(2) Mist precipitators - support insulators are cleaned every
eight to ten weeks to prevent tracking of insulators-, and
eventual breakage. Precipitator internals are inspected
as often an possible for dirt buildup, broken wires etc.
(3) Drying towers - normal cleaning schedule was not been
established for mist pads, however both drying tower pads
have been washed with IlgO twice since startup.
CO Schack heat exchangers - normal schedule not established,
but once a year we may have to do some high pressure water
cleaning on the tube :?ide of these exchangers. Maintenance
repairs to these units is projected to be a continuous
activity because of recurring leaks in factory welds.
(5) Prchcatcr - the prcheatcr wi.1l be shut down at least once
per year for internal inspection and necessary repairs
to burners, refractory, insulation etc.
(6) Absorption towers - normal c3caning schedule not established,
1 but mist eliminators have (been washed two times since plant
startup.
(7) 3>500 hp blowers - once or twice per year each of the five
blower iiiipel3crs wil] be washed to maintain proper balance
and motors receive the required scheduled time service.
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- 46 -
(0) Instrumentation mid ruiloinril.ic control v/i]vc:. - cali-
bration of ill] i!i:.(.nr:M>tr. and rc-jiuj r of controJ vulvo::
on-coinc i» order to keep plant in i.ioct efficient mode
of operation.
(9) Tiii) gas duct - tlic return tuil r/i'> duct to tlio 600' r.t-irk.
vill be inspected yearly - ncccu'iury cleaning and repair:.
vill be done and inflection will be made for potential
corrosion problems.
e. Frequency of catalyst screening - has not been established,
but in predicted we can possibly G° 2-3 years before r.creen-
ing is required.
f. Type of demistcr
York-tiro stage dcmister (Type S)
g. Design and actual valves for the following variables.
Dosicn Actual
(1) Production (Tons
acid/day) • 2,500 500-1500
(2) Conversion rate (percent) 97-0 97-0
(3) Acid strength 93-0 9^.0
('0 Number of catalyst beds 3/train 3/train
(5) Gas flow rate (SCFM) 253,88»i 100,000-266,666
(6) Operating-temperature
1st Catalyst Mass (In-Out) C50-1080 F 020-JDOO F
2nd Catalyst Mass (In-Out) 830-880 F B30-870 F
3rd Catalyst Mass (Tn-Out 830-81*0 F 820-865 F
Hotc: The actual vn]\icr; arc on]y in:;tnnt.ancou:. values
and can fluctuate* uc inucli as i 30°F dcj>ending
upon conditions. ',
(7) Inlet S02 concentration (ppm) 50,000-60,000 10,000-80,000
(8) Outlet 502 concentration , '
(ppm) "1,800 3500-2100'
(9) Acid mint (ibs. 112r,0'i/T N.A. < = 0.6'i
of acid)
(10) lUovcr pn».-.nure (puic.) 5-37 3- 6-6.D'I
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- 47 -
E. Slacks
1, Detailed description of stuck configuration including process
and/or control system units exhausted.
Sec attached flow sheet.
Iteverbcratory stack exhausts gas from all fi\c rcvcrberatory
furnaces.
Converter stack exhausts roaster acid plant tail cas» converter
acid plant tail gas, No. 5 furnace ground smoke control £>in and
in an emcrcency when the converter neid plant is totally or
partially inoperalional excess copper converter can can be dir-
ected to this stack. It will also liandDo ventilation ['.as from
secondary hoods on the converters sometime in mid-year 1976.
2. Identification by stack of:
Reverb Converter
Stack Stuck
a. Heights (ft. above terrain) 600 600
b. Elevation of discharce points
(ft. above sea level) 'i,93fl 'a,930
c. Inside diameters (ft.) at top of
flue entry.
Elevation '1393-75 'i'i06.25
Diameter 37-625 38.15
d. Inside diameter (ft.) at test station.
Elevation 'i6l2 Ii6l2.75
Diameter 29.69 32.27
e. Inside diameter (ft.) at discharge.
25-02 2'i.23
f. ' Exit cas temperature (°P) velocities
Exit w* temperature and velocity is not measured. The only
available measurements are at the test stations. These Measure-
ments are: i
Tempertiture (°K) 560 320
clocity (ft/r.cc) 13-0 17-99
3. General drawings of the test platforms and sampling ports for
each of tlie two stacks are included in the appendix to this report
as items 8 and 9.
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'(Corporation Morenci Branch. Morenci. Arizona 85540 TV^t
February 26, 1976
Mr. Thomas P. Gallagher, Director
Office of Enforcement
National Field Investigations Center - Denver
Environmental Protection Agency
Building 53, Box 25227 Denver Federal Center
Denver, Colorado 80225
Dear Mr. Gallagher:
On February 24, Mr. Reid Ivorsen of your organization telephoned
with a request for additional information relating to our report, "Copper Smelter
Information, Morenci Branch, Phelps Dodge Corporation." The report had been
mailed to you with my letter of February 6, 1976.
The following summarizes the answers to Mr. Ivorsen's questions, and
will confirm the data given to him by telephone on February 26.
ADDITIONAL DATA ON ELECTROSTATIC PRECIPITA TORS
Collection Gas Residence
Area, sq. ft. Velocity, FPS Time, Sec.
Reverberatory Plant *
Buell Precipitators 98,940 3.28 8.22
Koppers Precipitators 31,100 2.40 8.52
Research Cottrell 106,920 6.60 8.14
Converter Plant **
Research Cottrell 220,320 2.10 12.8
* Velocity used in these calculations comes from a measured volume taken at
the Stack Sampling Station and prorated to the several precipitators. There-
fore velocity is under actual conditions and maximum flowrate.
** Velocity was calculated at maximum flowrate conditions using the capacity of
the Converter Acid Plant blowers at standard conditions as the basis. Volume
at Standard Conditions was calculated to actual Conditions per the following:
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- 2 -
Temperature Pressure
Standard 60°F 29.92 in. Hg.
Actual 500°F 25.5 in. Hg.
I trust the foregoing does completely and adequately answer Mr.
Ivor sen's questions.
Yours very truly,
Zffifu.
'John E. O'Neill
Manager
JEOrwb
cc: JEF
JFS
SWT
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APPENDIX C
SIP REGULATION APPLICABLE
TO
PHELPS DODGE
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ARIZONA STATE DEPARTMENT OF HEALTH
Amendments to Rules nncl nc{r,«lations for Air Pollution Control
ARTICLE 7
Effective Date: 5/30/72
^^-rt^mi ^??£UL any eise hour. The ncthoJ y?erl for cet.-r.Jinir.r; allowable rate., of
emission bascc? oa procffss w-ight toblss is as fo]lc'.;s: Interpolafion of che
cat«i in thfe pvcr.-jss uoi^Iit table for process vaig'.io ratcc. cu to 60,000 Ib.s/hr
shall be accorp] •!.»:•.«' by vsc of the equPLior F. = 4.30 F 0.6?, ST:d interpolaMon
and extteirjolatic-n c£ tht dafa for procos.s weighc r.itss in excess of 60,000
Ibs/iir shaJl be a.-ccr.p; is>.eri by use of tha equation F. - 55.0 P 0.11 _ 40, where
E = rate or £faissio:i in Ibs/hr and P = process we.ighr rate in tc-.s/hr. (Sec
following e.
-------
EXAMPLE A: Process weight =* 6 tons per hour
Equation - Z = 4.10 P°'67
Log E = Log 4.10 + (0.67) (Log 6)
Log E = 0.6123 + (0.67) (0.7782)
Log E = 0.6128 * 0.5214
Log E = 1.1342
E = Anti-log 1.1342
E = 13.6 pounds per hour
EXAMPLE B: Process weight = 60 tons per hour
Equation - E » 55.0 P0-11 - 40.0
Lo5 (E+40.0) = Log 55,0 + (0.11) (1.03 60)
LoS (E+40.0) = 1.7/.04 + (3.11) a.7722;
Log (E+40.0) = 1.7404 + 0.1956
Log (E+40.0) = 1.9360
(E-fAO.O) = Anti-log 1.9360
(E+40.0) =86.3
E • 26.3 - 40.0
E =46.3 pour.rs per houi
B. Stcclc emission t^sts to def.eraine the amoun* of p?rticulate matter emitted
shall be performed in accordance wich Reg. 7-1-3.3.C.
RF.C. 7-L-3.3 IKCluTiRATION
* * A * *
c£a» Itie £cr}'-ult °^ pEvcJcvlatc r.;.itfc<-T ec-Ltced shall b:- dcterc'inod by gcners 1 ly
rcto,:".i;ocl sianlrn-s or s--thf-J.i, of nzjsur^.int. Tl:e AS: 12 Test Cj.ie for "Dust
Sej-.VuHiiv; App.-octiis", PIC 21, the: AS'fJ Tost Cede for "Dc-ter' t"in» Dost Concenti-s-
tir:.«i In Cri Str".ic-.o", PTC 27, and rho l.-ttct issue of the Los An-cles County Source
TcFtLiij; H-'uval shall be used as geiicr-'-l guides, biit tl-csc r?> bs modified, adjusced,
or nldcd to by th« director to suit specific sr.ai;>l\ns cotnlitvons or needs based upon
good practice, ju'j£,r..?nt sntf eyp«ri.cncc.
-------
WHERE:
"Particulate matter" means any finely divided liquid cr solid material,
other than unconbined water, as measured by Method 5 described in 40 Code of the
Federal Regulations, Part 60, dated December 23, 1971 or by an approved equivalent
ASI1E testing procedure.
"Process" means one or nore operations, Including equipment and tech-
nology, used" in the production of goods or services or the control of by-products or
waste.
"Process waig^t" mesns the total weight of all materials introduced
into a source operation, including fuels, where these contribute to pollution gener-
ated by the process.
"Process weight rate1' means a rate established as follows:
/
a. For continuous or long-run, steady-state source operations, the
total process weight for the entire parlnd of cont/lnuous operation or for a typical
portion thereof, divided by the nuuber of hours of such period or portion thereof.
b. For cyclical or batch souvce. operations, thr. to';al process -.-/eight
for a period uhirh covers £ complete operation or an integral number of cycles,
divided by the hours ol actual proc^.^s operation durius such pe
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APPENDIX D
CALCULATONS OF GAS FLOW RATES,
DUCT DIAMETERS, AND ISOKINETIC VARIATIONS
-------
Flow Rate at Standard Conditions
Psvs
or
x T.
where:
given pressure
given gas volume
given temperature in °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
Vs avg = 20,000 (530)
520
24,000 (530)
520
15,000 (530)
520
V max
o
mm =
Converters
20,385 scfm
24,462 scfm
15,288 scfm
V indiv =
V total avg
Roaster Acid Plant
24.000 (530)
520
-- 151,600 (530)
520
24,462 scfm
= 154,515 scfm
Design: V?
*
Actual: V.
49.000 (530)
520
38,000 (530)
520
43,000 (530)
520
49,942 scfm
38,731 scfm
43,827 scfm
t In the cases where 520°P is used, the calculation is an
adjustment of reported standard conditions (60°F) to EPA
standard conditions (70°F).
-------
Roaster Scrubber
V = 23,700 (530) = 23,926 scfm
5 525
Reverberatory Furnace ESP'S
#1-4: Koppers: Vc = 200.000 (530) = 100,000 scfm
s 1060
Research-Cottrell: Vc = 570.000 (530) = 272,162 scfm
s 1110
#5: Buell: Vc = 178,000 (530) = 89,000 scfm
s 1060
Converter ESP's
V min = 300.000 (530) = 165,625 scfm
s 960
Vs min = 1.000,000 (530) = 616,279 scfm
Converter Acid Plant
s 860
Design: Vc = 253,884 (530) = 258,766 scfm
s 520
Actual: V, min = 100.000 (530) = 101,923 scfm
5 520
s 520
V,. max = 266.666 (530) = 271,794 scfm
Feed Rate (Roaster)
C = 108,400 Ib/hr 0 468.6 hrs/mo (30.4 day/mo)
Ton = 108.400 Ib v 468.6 hr 1 mo IT
day hr x mo x 30.4 day x 2000 Ib
= 835 T/day
Feed Rate (Reverberatory Furnaces)
SC = 178,228 Ib/hr (1975)
SC = 97.800 Ib/hr (1975) G> operating hrs
276,028
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Feed Rate (Reverberatory Furnaces)
SC = 178,228 Ib/hr (1975)
SC = 97,800 Ib/hr (1975) @
276,028
Ton _ 276 Q0g Ib
day ' hr
8220 hr
yr
8220 operating hrs
x ] yr x ] T
x 340 days x
2000 11
= 3337 T/day (2155 SC + 1182 CS)
Feed Rate (Converters)
M = 19,068 Ib/hr/converter
F = 5.220 Ib/hr/converter
24,288 Ib/hr/converter
Ton/day = 24.288 Ib x 4101 converter-hr x 1 mo x I T
converter-hr mo 30.4 day 2000 Ib
Duct Diameters (Reverberatory Furnace Stack)
Elevation test station: 4612.00
Elevation-top of flue: 4391 .75
220.25
Diameter-top of flue: 37.625
Dp = 220.25 = 5.8
K 37.625
Duct Diameters (Converter Stack)
Elevation test station: 4612.75
Elevation-top of flue: 4406.25
206.50
Diameter- top of flue: 38.15
Dr = 206.50 = 5.4-
c 38.15
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ISOKINETIC VARIATION
100%
Where 1 = percent of isokinetic sampling
Vms = meter volume corrected to stack conditions, CF
Vs = average stack gas velocity during test, ft/sec
2
A = nozzle area, ft
0 = total sampling time, sec
Area of a 1/2" nozzle =
01 = 240 min x
93
R-l R-2
Vms (ft3) 143.91 1
Vs(ft/sec) 10.4
An (ft2) .00136 .00136 .00136 .00136 .00136 .00136 .00136 .00136
0(sec) 14,400 10,800 10,800 10,800 10,800 7200 7200 7200
I (X) 70.7 79.0 79.9 75.9 80.6 61.3 50.8 53.8
•IP - * '
. 1 1:
60 sec
1 min
10,800 sec
7200 sec
! R-3
70 140.81
7 12.0
:i/2)2 in2 x
4
14,400 sec
R-4 R-5
141.54 167.01
12.7 14.1
1ft2
144 in2
C-l
52.22
8.7
C-2 C-3
37.82 40.04
7.6 7.6
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PAGE NOT
AVAILABLE
DIGITALLY
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