EPA-800/2-76-036g
February 1976
Environmental Protection Technology Series
DESIGN AND OPERATING PARAMETEI
FOR EMISSION CONTROL
Phelps Dodge, Morenci, Copper
Industrial Environmental
Office of Research and
U.S. Environmental
Research Triangle Park,
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate •further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
E PA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Approval
does not signify that the contents necessarily reflect the
views and policy of the Agency, nor does mention of trade
names or commercial products constitute endorsement or
recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-76-036g
February 1976
DESIGN AND OPERATING PARAMETERS
FOR EMISSION CONTROL STUDIES:
PHELPS DODGE, MORENCI, COPPER SMELTER
by
I. J. Weisenberg and J. C. Seme
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, California 90404
Contract No. 68-02-1405, Task 5
ROAP No. 21ADC-061
Program Element No. 1AB013
EPA Project Officer: R. D, Rovang
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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TABLE OF CONTENTS
Page
A. INTRODUCTION AID SUMMARY 1
B. PLANT LOCATION, ACCESS AND OVERALL GENERAL ARRANGEMENT 1
C. PROCESS DESCRIPTION ..... 5
D. EMITTING EQUIPMENT . 7
a. ROASTERS ........... 7
b. REVERBERATORY FURNACES . 7
c. CONVERTERS ............. 10
d. OTHER EMITTING EQUIPMENT 11
E. EXISTING CONTROL EQUIPMENT ......... 11
F. GAS SYSTEM DUCTWORK 13
G. SULFUR BALANCE AND GAS COMPOSITION AT SYSTEM EXIT . 13
H. GAS CHARACTERISTIC VARIATION 15
I. STACK DESCRIPTION 17
J. PRESENT TECHNIQUE FOR SOLID WASTE HANDLING .... 18
K. FOOTING AND STRUCTURAL REQUIREMENTS ...... 18
L. EXISTING AND POTENTIALLY AVAILABLE UTILITIES ... 18
M. POTENTIALLY NEW CONTROL EQUIPMENT INSTALLATION
PROBLEMS . 18
REFERENCES . 19
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LIST OF FIGURES
1. LAND CONTOUR MAP OF SMELTER AREA (USGS MAP) . . 2
2. OVERALL SMELTER GENERAL ARRANGEMENT ..... 4
3. PROCESS FLOWSHEET AND SULFUR BALANCE 6
4. MORENCI SMELTER TRANSVERSE SECTION
LOOKING SOUTH ....... 8
LIST OF TABLES
1. AVERAGE SULFUR BALANCE SUMMARY 14
2. GAS STREAM CHARACTERISTICS .......... 16
THE FIGURES II THIS DOCUMENT ARE NONKEPRQDUCIBLE
»
THEREFORE ARE EXCLUDED FROM THIS REPORT.
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A. INTRODUCTION AND SUMMARY
The purpose of this report is to present background design
data on the Phelps Dodge Corporation, Morenci Branch smelter at
Morenci, Arizona, in sufficient detail to allow air pollution con-
trol system engineering studies to be conducted. These studies
are primarily concerned with lean S0_ streams that are currently
not being captured.
Physical layout of the smelter and surrounding area along
with existing smelter and control equipment is presented. Duct-
work that would be considered for future system tie-in is defined.
Emissions from operating equipment, gas flow rates, temperatures,
sulfur balance and process flow sheet are included. Utilities,
stack dimensions, footing requirements, and solid waste handling
are defined. Available area for new control equipment, gas charac-
teristic variation and potential new control equipment Installa-
tion problems are discussed.
The greatest source of uncontrolled SCL emissions at this
smelter is the reverberatory furnaces.
There are presently 92,854 TPY of sulfur passing from the
reverberatory furnaces to the stack (Ref. 2). This is equivalent
to 836 TPD of acid. The major reduction in S02 emissions can be
obtained by controlling the reverberatory furnaces. With both
the roaster and the converters controlled by acid plants, the
total sulfur captured is 62% (maximum). The remaining sulfur
emissions are from the reverberatory furnaces.
B. PLANT LOCATION, ACC_ESS- AND OVERALL GENEBAL A5BANGEMENT
The Phelps Dodge Corporation Smelter is located adjacent to the
town of Morenci, Arizona, The plant vicinity taken from a USGS map,
with land contours is shown in Figure 1. Design altitude for the plant
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"PRODUC.BLE lift
H. 23 E. R.30E. 659«»m-E iN««(on-oct.Li>c.c«L sbnvev,
Dy*
Figure 1.
-------
is 4300 ft. with plant site coordinates of latitude 33 05* N and
longitude 109° 21' W.
Overall plant and smelter general arrangement are shown in
Figure 2. The primary particttlate emission sources are the crushing
and screening operations, the roaster, the reverberatory furnaces
and the converters. The primary sources of sulfur dioxide are the
roaster, the reverberatory furnaces, and the converters. The
smelter portion of the plant consists of initial ore handling and
nixing equipment, contained in the bedding plant. A single fluid
bed roaster produces calcines for two of the five reverberatory fur-
naces. The three remaining reverberatory furnaces are charged with
green feed. Typically four of five reverberatory furnaces are oper-
ating. The copper matte produced in the furnaces is processed in nine
Peirce Smith converters. Typically seven converters are operating at
one time. Blister copper produced in the converters is sent to four
anode furnaces and finally to two casting wheels where anodes are
cast for shipment. Also operated at Morenci is a lime kiln and lime
reactor, a precipitate kiln and concentrate dryers.
Pollution control equipment consists of wet scrubbers and bag-
houses for the concentrate dryers, precipitate kiln, lime kiln, and
lime reactor. Roaster gases are treated in cyclones where the cal-
cines are recovered, a wet scrubber, and finally a single contact
acid plant for SCL removal before being discharged to a 605 foot tall
stack. Gases from the reverberatory furnaces are passed through
electrostatic precipitators and then discharged from a second 605 foot
tall stack. Ho control of SCL from the reverberatory furnace gases
is currently being attempted at Morenci. The converter gases, after
cooling, are passed through an electrostatic precipitator, a humidi-
fying tower, cooling tower, packed tower, an additional precipitator,
a drying tower, and finally a new single contact acid plant with a
rated maximum capacity of 2500 tons per day.
Figure 2, which shows the overall plant site .and general arrange-
ment, indicates that space for new control equipment could be found
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FIGURE 2
GEHEBAL ARRANGEMENT DRAWING
(Located in envelope inside the back cover)
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at some distance from the immediate smelting operations. This
would require the added expense of long ductwork.
c- PROCESS DESCRIPTION
The smelter flow sheet diagram is shown in Figure 3. Feed for
the smelter consists of precipitates, concentrates, lime, and flue
dust. Two of the five reverberatory furnaces operate on calcined
charge produced in the concentrate roaster. The roaster, a fluid
bed design, is capable of handling about 35% of the total plant feed.
The remaining three reverberatory furnaces are fed green charge,
directly from the bedding plant. The furnaces use preheated air,
flux, and natural gas fuel to produce slag and matte. Slag is removed
to the dump.
The matte produced in the reverberatory furnaces is taken to the
nine Peirce Smith converters where normally seven operate at any one
time. The converters produce blister copper which is placed in one
of the four anode furnaces. A reducing gas is burned to further refine
the blister copper. Following the anode furnaces, two casting wheels
cast the copper product into anodes for shipment.
Gases from the roaster pass through cyclones, a wet scrubber,
an electrostatic precipitator, a 600 ton per day (rated) single contact
acid plant and then out a 605 foot stack. Gases from the reverberatory
furnaces pass through waste heat boilers, electrostatic precipitators
and out a second 605 foot tall stack,
Gases from the converters are cooled, pass through electrostatic
precipitators, gas cleaning equipment, and through a new 2500 tons per
day (rated) single contact acid plant. Tail gases are discharged to
a 605 foot stack.
Temperatures, volumetric flow rates, and S0« percentages are
indicated on the flow sheet.
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NOTE; Plant operates approximately 340 days per year,
Plant Water
f-—
Plant Water
**
Tent
Atmo
No
To
sphere
soz
'•
Bag
SOUSC
T 1*500 °F
j / Reverb fercace
j f I Off-Gas
\ "o"
^1472.000 "SCJM
H (after dilution)
54 TPD
/Slurry te \
[Tailings Bam
1 2 TPD
0.9 TPD-S
Stack
00°F t
1
Electrostatic
Preclpltatori
(96.431 Eft.)
!
Gas
<
, L
Pis
Stack
Figure 3.
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D. EMITTING EQUIPMENT
a. Roaster
A fluid bed roaster capable of handling 35% of the total plant
feed produces an average of 875 TPD of calcines, the charge for two
of the reverberatory furnaces. The roaster feed consists of very
fine, 6-10 mesh maximum size range, material from the bedding plant.
No recycle material is put through the roaster. Approximately 84%
of the total roaster charge is concentrate. The remainder consists
primarily of silica and lime. The roaster gases, approximately
V
24,000 SCFM at 1400°!, typically contain 11.3% SO,,.
b. Reverberatory Furnaces
There are four old and one new reverberatory furnaces operating
at the Morenci smelter. The four original furnaces, built in 1942
and 1943, are side charged furnaces 24 feet 6 inches wide by 102
feet 6 inches long (inside dimensions)(Ref. 1). The new reverberatory
furnace, Figure 4, is 36 feet wide by 115 feet 4-g inches long. The
four old reverberatories of sprung silica arch construction are each
fired with six 8 inch gas burners with a normal firing rate of 175,000
cubic feet of natural gas per hour. Fuel oil is a standby fuel, but
is very seldom used.
Provision is made for charging silica flux into the bath in case
the slag becomes too basic. There are four slag tap holes in each of
the four old furnaces, two on each side tapping into cast copper launders
which carry the matte into ladles in the converter aisle. Skimming of
slag is through one sidewall tap close to the end of the furnace.
The new No. 5 furnace has five matte tap holes and two slag tap
holes. Only four matte tap holes in the new furnace normally are used.
All of the matte tap holes for the No. 5 furnace are enclosed in a room.
The hole punching machine is also enclosed in this room which is then
vented to the collection system. This minimizes fugitive emissions
and appears to be a promising control approach.
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FIGURE 4
MORENCI SMELTER TRANSVERSE SECTION
LOOKING SOUTH
(Located in envelope inside back cover)
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Considerable heat leaves the furnace roofs. The heat loss
depends upon the insulation qualities of the refractory brick. No,
5 roof is limited to 15" thick tnagnesite brick because of structural
considerations,
The reverberatory furnaces are normally operated at negative
pressure of 0.5 to »01 inches w.c. (water column). Charging takes
place approximately every hour for a period of about two minutes and
tends to produce positive internal pressures resulting in an increase
of fugitive emissions. Fugitive emissions are currently being encoun-
tered from the furnace waste heat boilers and uptake system. Hot
patching of the furnace brickwork is done at Motenci. Silica rock
with over 90% SiO_ is sprayed by guns to maintain the furnace arches
and sidewalls. This technique has been developed at Morenci to the
point where indefinite life of the furnace brick structure is expected.
Of the five reverberatory furnaces, normally two receive calcine
feed from the roaster and the remaining three receive green charge.
One furnace may handle either green or calcine feed. Furnaces No. 1
and No. 2 use 175,000 SCFH of gas, furnaces No. 3 and No. 4 use 165,000
SCFH of gas.
Furnace No. 5 generates 240,000 SCFM of gas (Ref. 2). Of the
240,000 SCFM of No. 5 reverberatory furnace offgas, approximately
100,000 SCFM is dilution air that enters through openings in the fur-
nace walls and roof.
The S09 concentration of the No, 5 furnace offgas is approxi-
mately 1.2%, A higher percentage of dilution air enters the four
original reverberatory furnace offgas .streams and resulting in an
overall S07 concentration of 0.9 to 1.0% in the reverb offgas stream.
No more than four furnaces can be operated at one time because the
converter capacity is not sufficient to handle more,
The new No, 5 furnace cannot take calcines because it is fed by
a rubber belt. The new furnace burner capability is not sufficient
to operate a maximum furnace capacity. Preheated air must be used to
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make up the additional 15% heat generation capacity required to meet
the design. The older furnaces do not use preheated air. The new
furnace uses Hauck burners capable of burning any fuel from natural
gas to No. 6 fuel oil. The burners are all automatic and can be
adjusted to place the flame at optimum position in relation to the
charge. Automatic chute return of the slag is provided. This chute
enters the furnace during feeding and is withdrawn when not in use.
This minimizes fugitive emissions.
c. Converters
A. total of nine Peiree-Smith converters are installed and
operating. With this large number of converters the average number
of converters blowing is 3.37 when seven-units are active (Ref. 2).
This can provide a relatively even SO- stream quantity and concentra-
tion to the acid plant. An average of SO,, concentration of 6.5% is
attained.
Close fitting hoods are used for all the converters. Figure 4.
Hood pressure is maintained by a series of damper controls. Both a
plug damper to completely shutoff the converter hood when not blowing
and an opposed blade damper for volume and system balancing control
are employed in the exhaust system for each unit. Remote closed cir-
cuit television is used to survey the uncollected emissions from the
converter. Damper controlled reduction of hood pressure is used to
eliminate uncollected emissions. The converters are 13 feet in
diameter and 30 feet long with 52 tuyeres per converter. The con-
verters are lined with burned basic brick which is not insulated
from the shell. Magnetite lining of the converters has been done
successfully. Three 60 ton cranes with dc motors service the con-
verter aisle. With the matte grade averaging about 301 nearly all
reverts are resmelted in the converters. Blister copper produced
in the converter department is transferred by crane to the anode
furnaces for further refining and casting into anodes.
10
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d. Other Emitting Equipment
Four anode furnaces are operated at Morenel. Presently
reducing gas introduced through tuyeres is used. Originally green
oak logs- were used for copper reduction. Two casting wheels are used
to cast the molten copper into anodes for shipment. The anode fur-
nace dimensions are 13 feet by 25 feet.
Crushing and bedding equipment generate particulate matter.
The crushing plant is controlled with wet scrubbers. Lime kiln
emissions are controlled with a baghouse,
Ladles holding matte and slag produce fugitive emissions.
Leaks in ducts and at various pieces of equipment are the source of
S0? and particulate emissions.
E. EXISTING CONTROL EQUIPMENT
Roaster gases go through a series of cyclones for recovery of •
the calcines and then to a scrubber for dust removal before entering
the old 500 ton per day acid plant. After dilution an average of
42,000 SCFM of roaster gas with an S0~ concentration of about 6.5%
enters the single contact acid plant. This acid plant with a nominal
rating of 600 ton per day was built in 1965. The original design was
for a 750 ton per day capacity, but even after years of continual
modification and improvement, the average capacity is 560 tons per day
(Sef. 4). The acid plant produces 100% H SO^ with a tail gas S02
concentration of 0.2%, Approximately 150 tons per day of the acid
produced is used in the plant with the remainder being sold. Operating
time for this acid plant averages 21 hours per day. A 3000 Hp blower
moves the acid plant gas at a rate of 18,000 to 24,000 SCEM.
Eeverberatory furnace gases pass through waste heat boilers and
then an electrostatic precipitator. Approximately 97% dust collection
is accomplished neglecting sulfates (Ref. 3). At the precipitator inlet
the gas flow ranges from 282,000 to 580,000 SCFM at 700°F depending
on the number and combination of furnaces operating. Typically four
11
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of five furnaces operate at one time. Reverberatory furnace gases
after dust collection, and some dilution, are discharged from a 605
foot stack. A new precipitator was installed to control particulates
from the No. 5 reverberatory furnace.
Converter gases are treated in gas conditioning equipment and
then a new 2500 ton per day acid plant before being discharged to the
atmosphere. After gas cooling the converter gases are passed through
an electrostatic precipitator with a reported efficiency of 96.5%
neglecting sulfates (Kef. 3). Additional dust removal by scrubbers
occurs before entering the new acid plant. The acid plant, built
by Chemieo Corporation, is a single contact design. It was designed
so that it is possible to add a double contact circuit (Ref. 2). Cur-
rently about 1500 tons per day of 100% H^SO, is produced from the con-
verter offgas. This indicates that additional capacity is available,
or that the system is capable of handling wide fluctuations in input.
The new acid plant gas conditioning system consists of a humidi-
fying tower, cooling tower, packed tower, precipitator, and drying
tower followed by the remainder of the plant. Parallel gas systems
are used after the initial hot gas precipitator immediately downstream
from the smelter. Thus, the major portion of the acid plant is in two
trains allowing independent operation of each side.
A preheater can be used to operate one side of the system to
allow acid production even when gas stream concentration is as low as
2.5% SO , The plant is designed to make 93% acid using 6.5% SO .
£• <£*
Acid plant blowers deliver 89 ,000 ACFM at 110°F with a suction
pressure of 11.3 PS1A and a discharge pressure of 17.7 PSIA. Acid
plant tail gas is estimated to be 328,700 ACFM at 175°F.
Average yearly operating days for this smelter is 350.
Emissions from the lime kiln and lime reactor are controlled by
baghouse collectors. The particulate emissions from the concentrate
dryers and precipitate kiln are collected in wet scrubbers.
12
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F. GAS SYSTEM DUCTWORK.
Fluid bed roaster offgases pass through a series of cyclones
for calcine recovery and then pass through a scrubber for final dust
removal before entering a 500 ton per day acid plant. The acid plant
tail gas is discharged to the 605 foot converter stack,
Four older reverberatory furnaces, arranged in line along a
north-south line, are each equipped with a pair of waste heat boilers.
The reverberatory furnace gases then travel through a common flue to
two parallel electrostatic precipitators. The cleaned gases are
discharged to the 605 foot reverberatory furnace stack.
The new No. 5 reverberatory furnace, located south of the
Nos. 1-4 furnaces, is also equipped with a pair of waste heat boilers,
Figure 4. Following the boilers the gases are passed through two
parallel electrostatic precipitators. The gases travel by flue to the
605 foot stack where they join the offgases from the other four fur-
naces .
The nine converters, laid out along a north-south line, are
equipped with hoods which collect the offgases, Figure 4. The gases
pass through gas coolers and are combined in a header. Four parallel
electrostatic precipitators clean the converter gases prior to final
cleaning and conditioning in a scrubbing plant. The gases then are
ducted to a new acid plant. Acid plant tail gases are discharged to
the 605 foot converter stack,
G. SULFURBALANCE AMDGASCOMPOSITION ATSYSTEM EXIT
A typical sulfur balance for the Morenci smelter is shown in
Table 1. At a total sulfur input of 981.2 TPD, presently 668.4 TPB
of sulfur are captured (645.3 TPD captured in the acid plants and
23.1 TPD are discarded with the slag and solid wastes). This repre-
sents an overall capture efficiency of 68%. It is estimated that
13
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TABLE 1. PHELPS DODGE M01ENCI SMELTER
Average Sulfur Balance Summary*
Sulfur
Input
TPD-S
981.2
Roas
%so2
11.3
ter
TPD-S
175.1
Reve
%so2
0.9
rb
TPD-S
273.1
Conve
%so2
6.5
rter
TPD-S
492.9
Slag &
Solid Waste
TPD-S
23.1
Fugitive
Emissions
TPD-S
17.0
Present
Sulfur
Captured
TPD-S
668.4
Stack
Emissions
TPD-S
295.8
*Reference 2
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295.8 TPD of sulfur are emitted from the reverberatory furnaces which
are presently uncontrolled for SO. Fugitive emissions account for
approximately 17 TPD of sulfur.
An average of 42,000 SCFM of roaster gases after dilution to
6,5% SCL are treated in the old acid plant. The acid plant tail gas
at an SO concentration of approximately 0.3% is discharged from a
605 foot stack. The converter gases after cooling, dust removal
and treatment in the new acid plant are also vented to the same 605
foot stack as roaster gases. Converter gases average 117,200 SCFM
with an SO, concentration after treatment in the acid plant of 0.2%.
It is reported that at the 275 foot level in the stack, the gas
temperature is 360 F, and the particulate emission rate is 29.2
pounds per hour or 118.8 tons per year (Ref. 3). The stack gas volume
averages approximately 350,000 SCFM due to dilution and addition of
the vent system gases.
Reverberatory furnace gases are discharged after dust removal
from a separate 605 foot stack. After dilution a stack gas flow rate
of 472,000 SCFM is estimated. At the 275 foot level in the stack the
temperature is reported to be 530 F with a particulate emission rate
of 33.3 pounds per hour or 135.5 tons per year (Ref. 3). The S0_ con-
centration in the stack gas is estimated to be 0.9%.
Table 2 presents gas stream characteristics reported by the Phelps
Dodge Corporation (Ref. 5).
H. GASCHARACTERISTIC VARIATION
It can be expected that SO,, concentration .in the off gas from the
reverberatory furnaces will vary significantly" with time. This results
from the variation in time required for decomposition or reaction of
'the various sulfide ores charged to the furnace. This variation in
S0_ content has been known to vary as much as 10 to 1 within a given
charging time cycle. While no data are yet available from.this smelter
concerning this point, it should be considered for control system
design. The gas composition at the stack also depends on the number
and combination of furnaces operating. The reverberatory furnaces
charged with calcines from the roasters generate a lower S0« concen-
tration in the offgases.
15
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Table 2. SAS STREAM CHARACTERISTICS
OF
PHELPS DODGE CORPORATION
MORENCI COPPER SMELTER
SO, Source
Weak Strong
Reverb.
Roaster
Conv.
Flow Rate
Scfm @
70°F 14,7 Psi
285,000
20,000
78-234,000
Concentration
Percent
so2
1.5
15
4-6
so3
0.1
0.1
O.-l
°2
5
2
10-12
Particulate
Treatment
Precipit,
Cyclones
Scrubber
Precipit,
Scrubbers
Outlet
Loading
gr/ACF
0.2 gr
Nil
0.2 gr
Nil
Disposition of
Gas Stream
Plant
Type
Capac-
ity TPD
Emitted through stack
Temp. 450°F
Acid
*Acid
Dual
Train
Single
Absorp-
tion
Single
Absorp-
tion
750
2500
Product
Disposition
Used
X
X
Smal 1 qu
acid .is
ance is
neutral i
Sold
antity of
sold bal-
used or
zed
Plant
Age
1943
Remarks |
Physical size and
congestion in
plant would make
installation of
additional units
extremely difficult
*Control units be-
.ing installed at the
present time.
Note: The plant generates its own power from waste heat steam and direct fired boilers. Water supply is limited. Uniform Smelting charge
characteristics
Reference 5.
16
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SO concentration in the converter offgas will also vary
considerably for an entirely different reason. The operation of a con-
verter includes several, usually three, slag blows and one copper
blow. Between these blows the converter may be rolled out for slag
pouring or material charging. When the converter is not blowing the
hood above the converter is closed off by dampers so that the gases do
not pass through the collection system to the acid plant. The average
number of converters blowing is 3.37 when seven converters are active.
This provides a relatively even S0? stream quantity and concentration
to the acid plant. Usually a converter will be provided with 25,000
to 30,000 SCFM to the tuyeres. An additional 100% of dilution air is
generally estimated to be added to this gas flow resulting in a total
gas flow from each converter in the range of 50,000 to 60,000 SCFM.
When a converter is blowing there will usually be approximately 60,000
SCFM at an SCL content of 6.5%.
Because of the normal fluctuation in converter feed and opera-
tion, the SCL concentration can vary over a relatively wide range.
In addition, the gas volume flow from the converter line to the control
system acid plant can usually vary over a wide range from maximum to
zero. Operation of the control system must be conducted in a manner to
compensate for these fluctuations. Acid plant operation at this smelter
appears to be typical providing reasonably satisfactory control,
I. STACK DESCRIPTiny
Roaster/Converter/Acid Plant Stack (Ref. 3).
Height 605 feet
Diameter* 32.27 feet
Gas temperature* 360 P
Gas Velocity* 13.2 feet/sec,
Reverberatory Furnace Stack (Ref. 3)
Height 605 feet
Diameter* 29.69 feet
Gas temperature* 530 F
Gas Velocity* 19.2 feet/sec.
*At the sampling point 275 feet above the ground
17
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J. PRESENT TECHNIQUE FOR SOLID WASl_E__HANDLltTG
Slag from the reverberatory furnaces is disposed of in a slag
dump at an average rate of 1925 TPD. Reverberatory furnace and con-
verter flue dusts collected in the precipitators are conveyed to a pug
mill where they are processed to allow handling for feeding to the
reverberatory.furnace.
The liquid effluent from the acid plants are discharged to the
tailings pond.
K. FOOTING AND STRUCTURAL REQUIREMENTS
No local codes apply. The National Uniform Building Code is
used. Seismic zone 2, a wind load of 20 PSF, and a snow load of
15 PSF are used for design. Ambient temperature range is 107 F to
19°F.
L. EXISTING AND POTENTIALLY AVAILABLEUTILITIES
The power plant utilizes both waste heat and four boilers which
can burn either natural gas or dieael fuel. Natural gas is normally
used at a rate of ten million cubic feet per day. The diesel fuel,
actually a number 4 fuel oil, is used only when natural gas is not
available. Each of four boilers has a separate stack. The plant
includes six 12,500 kw units.
M- POTENTIALLYNEW CONTROL EQUIPMENTINSTALLATION PROBLEMS
There appears to be sufficient space adjacent to this smelter
for additional control equipment. Water supply may be a problem if
the control system requires a large quantity of makeup water.
18
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REFERENCES
1. Smelting Practices of Phelps Dodge in Arizona M.G. Fowler,
Phelps Dodge Corporation, Douglas Arizona
2. The Evaluation of the Controllability of SCL Emissions from
Copper Smelters in the State of Arizona, Weisenberg I.J, and
G.E. Umlauf, Pacific Environmental Services, June 1975
3. Air Pollutant Emissions Report (OMB form 158 R75) Environmental
Protection Agency, submitted by Phelps Dodge Corporation,
Morenci Branch, December 17, 1973
4. Information in support of petitition for conditional permit-
Morenci Smelter, Phelps Dodge Corporation, October 14, 1970,
5. Letter from John H, Davis, Jr., Chief Mechanical Engineer,
Western Engineering Department, Phelps Dodge Corporation,
February 12, 1975.
19
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TECHNICAL REPORT DATA
(Please /sad tiairucrions on the reverse before completing}
1. REPORT NO.
EPA-600/2-76-036g
2.
4, TITLE AND SUBTITLE
Design and Operating Parameters for Emission
Control Studies; Phelps Dodge, Morenci, Copper-
Smelter
7, AUTHOR(S)
I. J. Weisenberg and J. C. Serne
9. PERFORMING ORG \NIZAT1ON NAME AND ADDRESS
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, CA 90404
3. RECIPIENT'S ACCESS!ON>NO,
S, REPORT DATE
February 1976
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO,
10. PROGRAM ELEMENT NO.
1AB013; ROAP 21ADC-061
11. CONTRACT/GRANT NO.
68-02-1405, TaskS
12, SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13, TYPE OF REPORT AND PERIOD COVERED
Task Final; 4-10/75
14. SPONSORING AGENCY CODE
EPA-ORD
15, SUPPLEMENTARY NOTES
EPA Task Officer for this report is R.Rovang, 919/549-8411, Ext 2557.
16. ABSTRACT
The report gives background design data for a specific copper smelter.
The data is sufficiently detailed to allow air pollution control system engineering
studies to be conducted. These studies will be concerned primarily with lean S02
streams that currently are not being captured. Physical layout of the smelter and
the surrounding area is presented, along with existing control equipment. Ductwork
that would be considered for future system tie-in is defined. Emissions from
operating equipment, gas flow rates, temperatures, sulfur balance, and a process
flow sheet are included. Utilities, stack dimensions, footing requirements , and
solid waste handling are defined. Available area for new control equipment, gas
characteristic variation, and potential new control equipment installation
problems are discussed.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lOENTIFIERS/OPEN ENDED TERMS
c. cos AT I Field/Group
Air Pollution
Copper
Smelters
Design
Sulfur Dioxide
Utilities
Air Pollution Control
Stationary Sources
Emission Control
Operating Data
Solid Waste Handling
Wastes
13B
07B
11F
18. DISTRIBUTION STATEMENT
Unlimited
19, SECURITY CLASS (This Report)'
Unclassified
te S £ C U R i T Y CL ASS (This page)
-Unclassified
•if' -
|21. NO. OF PAGES
6PA Form 2220-1 (9-73)
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