OEPA 

United States Off1ce of A1r Quality EPA 450/3-83-018b 

Env1ronmental Protection Plannmg and Standards March 1984 

Agency Research Triangle Park NC 27711 

Revie\w of 

New !Source 

Perfo.-mance 

Stand,ards for 

Primat·y Copper 

Smeltt�rs 
ENVIRONMENTAL PROTECTION AGENCY 

REVIEW OF NEW SOURCE PERFORMANCE STANDARDS 

FOR 

PRIMARY COPPER SMELTERS 

Prepared by: 

Director, Emission Standards and Engineering Division 

U.S. Environmental Protection Agency 

Research Triangle Park, North Carolina 27711 

f ate) 

1. Existing standards of performance for primary copper smelters were 

promulgated in 1976. Section 111 of the Clean Air Act (42 USC 7411), 

as amended, directs that the Administrator periodically review promulgated standards. 

2. Copies of this document have been sent to the following Federal departments: Labor, Defense, Interior, Health and Human Services, Agriculture, 

Transportation, Commerce, and Energy; EPA Regional Administrators; and 

other interested parties. 

3. For additional information contact: 

Dr. James U. Crowder 

Industrial Studies Branch (MD-13) 

U.S. Environmental Protection Agency 

Research Triangle Park, NC 27711 

Telephone: (919) 541-5601 

4. Copies of this document may be obtained from: 

U.S. EPA Library (MD-35) 

Research Triangle Park, NC 27711 

National Technical Information Service 

5285 Port Royal Road 

Springfield, VA 22161 

iii 
1. 

2. 

3. 

TABLE OF CONTENTS 

S UMMARY .................. . . . . . .. . 

1 . 1 REGULATORY ALTERNATIVES ....... ... . . .. . 

1 . 1 . 1 Reverberatory Smelting Furnace Exempti on 

1 . 1 . 2 Contro l of Reverberatory Furnace Part i cul ate 

1 . 1. 3 

1 . 1.4 

1. 2 IMPACTS 

Matter Emi ssions 

E xpansi on ... .. 

Fugi t i ve Emi ssi ons 

INTRODUCTION . . . . . . . . . . 

2 . 1 BACKGROUND AND AUTHORITY FOR STANDARDS . 

2 . 2 SELECTION OF CATEGORIES OF STATIONARY SOURCES 

2 . 3 PROCEDURE FOR D EVE LOPMENT OF STANDARDS OF PERFORMANCE 

2.4 CONSIDERATION OF COSTS ... ... .. . 

2 . 5 CONSIDERATION OF ENVIRONMENTAL IMPACTS . 

2.6 IMPACT ON EXISTING SOURCES ........ . 

2 . 7 REVISION OF STANDARDS OF PERFORMANCE ... . 

THE PRIMARY C OPPER SME LTING INDUSTRY : PROC ESSES AND POL LUTANT 

EMISSIONS . . . . . . . . . . . . 

3 . 1 GENERAL ......... . 

3 . 2 PROCESS D ESCRIPTION ... . 

3 . 2 . 1 Roast i ng and D ryi ng 

3 . 2 . 2 Smelting ..... . 

3 . 2 . 3 Converti ng .... . 

3.2.4 Fire Ref i n i ng .. . 

3 . 2 .5 Cont i nuous Smelti ng Systems 

3.3 EMISSIONS FROM PRIMARY COPPER SME LTERS. 

3 . 3 . 1 General . . . . ...... . 

3 . 3 . 2 P rocess Emi ssions ...... . 

3 . 3 .3 Fugi tive Emi ssi ons . . .... . 

3 . 3.4 S ummary of Fugi tive Emi ssi ons Data . 

3 . 4 EXPANSION O PTIONS FOR EXISTING FACILITIES 

3 . 4 . 1 Mul t i hearth Roaste rs .. 

3 . 4.2 Fluid-Bed Roa sters . . .. 

3 . 4 . 3 Reverberatory Furnaces .. 

3. 4. 4 E l ectric Furnaces . . . . 

3.4 . 5 O utokump u Fl ash Furnaces. 

3 . 4 .6 Noranda Reactors .... . 

3. 4. 7 Converters . . . . . . . 

3 . 5 SUITABILITY OF ALT ERNATIVE TECHNOLOGIES FOR PROCESSING 

HIGH-IMPURITY FEEDS .... . ............ . 

v 

1- 1 

1- 1 

1- 1 

1- 2 

1- 2 

1-3 

1- 3 

2-1 

2-1 

2-5 

2- 7 

2-9 

2-10 

2-ll 

2- 12 

3-1 

3-1 

3-3 

3-4 

3-11 

3-28 

3- 37 

3-39 

3-44 

3-44 

3-44 

3-46 

3-57 

3- 62 

3-62 

3 -64 

3- 64 

3-79 

3-81 

3-81 

3-82 

3-83 
4. 

TAB LE OF C ONTENTS ( co n .) 

3. 5 . 1 Background. . . . . . ........... . 

3 . 5 . 2 Impurity Behavior D uring the Smel ting P rocess 

3 . 5 . 3 High-Impurity Feed P rocessing Experience with 

Outokumpu Flash Furnaces ... . . . .... . 

3 . 5.4 High-Impurity Feed P rocessing Experience with 

I nca Flash Furnaces ............ . 

3 . 5 . 5 High-Impurity Feed P rocessing Experience with 

the Mit s ubis hi P rocess ... ........ . 

3 . 5 . 6 High-Impurity Feed P rocessing Experience with 

Noranda Reactor s . 

3 . 5.7 Concl u sions .. . 

3 . 6 BASELINE EMI SSIONS ... . 

3. 6 . 1 Pro cess Source·s . 

3 . 6 . 2 Fugitive Sources ..... 

3 . 7 REFERENCES ...... . 

EMISSION CONTROL TECHN I QUES . 

4 . 1 GENERAL ...... . 

4 . 2 SU LFURI C AC ID P LANTS .. 

4 . 2 . 1 S ummary .... 

4 . 2 . 2 General Discu s sion. 

4.2. 3 Design and Operating Considerations 

4 . 2.4 Acid P l ant Performance Characteristics . 

4 . 3 SCRUBB I NG SYSTEMS ........ .. . 

4 . 3 . 1 Background ........... . 

4 . 3.2 Cal cium-Based S crubbing Systems . 

4 . 3 . 3 Ammonia-Based Scrubbing Sys tems . 

4 . 3.4 Magnesium-Based Scrubbing Systems 

4 . 3 . 5 Citrate Scrubbing Processes ... 

4.3.6 C oncl u s ions Regarding F l ue Gas Des u l furi zation 

Systems . . . . . . . . . . . . . . . . . . . 

4 . 4 I NCREAS I NG THE S02 STRENGTH OF REVERBERATORY FURNACE 

OFFGASES . . . . . . . . . . . . . . . . .. . 

4 . 4 . 1 E l imination of Converter S l ag Return. 

4 . 4 . 2 Minimizing I nfil tration . . .... . 

4. 4 . 3 Pre heating Combustion Air ..... . 

4.4. 4 Ope ration at Lower Air-to-Fuel Ratio . 

4. 4 . 5 Predrying Wet C harge ........ . 

4 . 4 . 6 Oxygen Enhanceme nt Techniques ... . 

4.4. 7 S ummary of Operating Modifications Useful for 

I ncreasing Offgas S02 Conce ntrations .. . 

4 . 5 GAS B LENDING. . . . . . . . . . . ... . 

4 . 5 . 1 Converter Schedul ing as a Means of Facil itating 

Gas B l ending ........ ......... . 

4 . 5 . 2 Wea k-Stream Blending as Appl ied to a New Sme l ter 

that Processes High-Impurity Ore Concentrates .. 

vi 

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3-85 

3- 10(1 

3 - 103 

3- 104 

3- 104 

3-107 

3- 111 

3- 111 

3 - 117 

3 - 118 

4- 1 

4-1 

4-3 

4- 3 

4- 6 

4-8 

4- 13 

4-20 

4-20 

4-22 

4-44 

4- 58 

4-68 

4-84 

4- 90 

4- 91 

4-92 

4-93 

4- 94 

4-95 

4- 95 

4- 117 

4- 120 

4-120 

4- 120 
TAB LE OF CONTENTS ( con. ) 

4 . 5.3 Partial Weak- Stream Blending as Appli ed to 

Exi s t i ng Sme l ters ... .... ..... . 

4 . 6 PARTICU LATE MATTER C ONTROL FOR REV ERBERATORY FURNACES 

4. 6.1 Important Factors Govern i ng the Spec i f i c at i on 

of a Part i cul ate Control Dev i ce for Reverberatory Fu rnace Offgases . . . 

4. 6. 2 Venturi Scrubbers . . . . . . . 

4 . 6 . 3 Fabric F i l ters ........ . 

4 . 6.4 E l ectrostati c Prec i pi tators .. 

4 . 6 . 5 Conclusi ons Regard i ng Particulate Removal F rom 

Reberberatory Furnace Offgases . . . . 

4 . 7 CONTROL OF FUGITIVE EMISSIONS FROM PRIMARY COPPER 

SME LTERS ......... . 

4 . 7 . 1 General ..... . 

4 . 7 . 2 Local Vent i l ati on . 

4.7 . 3 General Venti l ation 

4 . 7.4 Control of Fugi ti ve Emi ssions F rom Roasti ng 

Ope rat i ons . . . . . . . . . . . . . . . . . 

4. 7 . 5 Contro l of Fugi tive Emi ssions From Smelting 

F urnace Operati ons ............ . 

4 . 7.6 Capture of Fugi tive Emi ssi ons From Converter 

Operat i ons . . . . . . . . . . . . . . . . . 

4. 7. 7 S ummary of V i sible Emi ssi ons Data for 

F ugi tive Emi ssions Sources ........ . 

4 . 7.8 Removal of Parti cul ate Matter From Fugi t i ve 

Gases 

4.8 REFERENCES ... 

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4- 197 

5. MODIFICATIONS AND RECONSTRUCTION 5-1 

5 . 1 SUMMARY OF 40 CFR 60 PROVISIONS FOR MODIFICATION AND 

RECONSTRUCTION . . . . . . . . . . . . . . 5- 1 

5 . 1 . 1 Mod i f i cati on. . . . . . . . . . . 5- 1 

5 . 1.2 Reconstructi on. . . . . . . . . . 5-2 

5 . 2 APP LICABILITY TO PRIMARY COPPER SME LTERS . 5-3 

5. 2.1 General . . . 5-3 

5 . 2 . 2 Modi fi cat i ons . . . . . . . . . . 5-3 

5 . 3 REFERENCES. . . . . . . . . . . . . . . . 5-9 

6. MODEL P LANTS AND ALTERNATE CONTROL TECHNOLOGIES. 6-1 

6 . 1 INTRODUCTION . . . . . . . . . . . . . . . 6-1 

6 . 2 REVERBERATORY FURNACE EX EMPTION . . . . . 6-2 

6. 3 FUGITIVE EMISSION CONTROL . . . . . . . . 6-17 

6 . 4 EXPANSION OPTIONS AND A LTERNATIVE CONTROL TECHNOLOGIES . 6- 22 

6 . 5 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . 6-36 

v i i 
7. 

8. 

TAB LE OF CONTENTS ( con. ) 

ENVIRONMENTAL IMPACT . . . . . . . . . . . . . . . . 

7. 1 GENERAL . . . . . . . . . . . . . . . . . . . . 

7 . 1 . 1 New Greenfield High-Impurity Sme l ters--

Process Emissions ..... ... . . . 

7 . 1 . 2 New Greenfield High-Impurity Sme l ters--

Fugit ive Emissions ..... . . . . . 

7 . 2 AIR POL LUTION IMPACT .......... ... . 

7 . 2 . 1 S02 Contro ls for Reverberato ry Sme l t ing Furnaces. 

7 . 2 . 2 Fugitive Particul ate Emissio ns ... . 

7.2. 3 Expansion Sce narios .... . . .. . 

7 . 3 WATER POLLUTION IMPACT .... ....... . 

7 . 3 . 1 Gas C l eaning and Condit ioning Systems 

7 . 3 . 2 FGD Absorbent Purges. 

7.4 SOLID WASTE IMPACT ..... 

7.4. 1 Cal c ium B ased FGD's 

7 . 5 

7. 4. 2 Gas C l eaning Purges . . . . . . . . 

7 . 4 . 3 Particul ate Control on Reverberatory Sme l t ing 

E NERGY 

7 . 5.1 

7.5.2 

7 . 5.3 

Furnaces. . . . . . 

IMPACT . . . . . . . 

New Greenfield Sme l ters--Process Emissio ns. 

New Greenfield Sme l ters--Fugitive Emissions 

Expansion Scenarios 

COSTS. . . . . . . 

8. 1 INTRODUCTION .. 

8. 2 C ONTROL OF WEAK S02 STREAMS FROM NEW REVERBERATORY 

FURNACES .... 

8. 2. 1 Capita 1 Costs . . . . . . . 

8. 2 . 2 Annua l ized Costs ..... . 

8. 3 COSTS FOR FUGITIVE EMIS SION CONTROL 

8. 3 . 1 Capita l Costs ...... . 

8. 3 . 2 Annua l ized Costs ..... . 

8. 4 COST OF CONTROL LING PROCESS PARTICU LATE EMISSIONS 

FROM REVERB ERATORY FURNACES IF THE REVERBERATORY 

E XEMPTION IS RETAINED . . 

8. 4 . 1 Capital Costs .. 

8. 4 . 2 Annual ized Costs. 

8. 5 PROCESS COSTS ..... . 

8. 5. 1 Capita 1 Costs . . 

8. 5. 2 Annuali zed Costs. 

8. 6 EXPANSION SCENARIOS . . . 

8. 6 . 1 Inc remental Capita l and Annua l ized Process 

Costs for Expansion Scenarios . . . . . . 

8. 6 . 2 Incremental Capital and Annua l ized Costs 

for Contro 1 . . . . . . . . . . . . . . . 

8. 6 . 3 Summary of Expansion Scenario Incremental Costs 

viii 

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7-1 

7-1 

7-3 

7-3 

7-3 

7-7 

7-7 

7-9 

7-11 

7-11 

7-16 

7-17 

7-17 

7-18 

7-20 

7-20 

7-20 

7-20 

8-1 

8-1 

8-3 

8-5 

8-17 

8-29 

8-29 

8-33 

8-35 

8-35 

8-36 

8-38 

8-38 

8-38 

8-38 

8-40 

8-46 

8-50 
9. 

TAB LE OF CONTENTS ( co n . ) 

8. 7 COST- EFFECTIVENESS . 

8. 8 REFERENCES .... 

ECONOMIC IMPACT ..... 

9 . 1 I ND USTRY ECONOMIC PROF I LE 

9. 1 . 1 I ntroducti on ... 

9. 1 . 2 The Copper Sme l ters--Ownershi p, Locat i o n , 

Concentration ..... . 

9. 1 . 3 The Copper Refi ners .. . 

9. 1 . 4 Domesti c S uppl y .... . 

9. 1 . 5 Flow of Copper from Mi nes to U . S. Sme l ters . 

9. 1 . 6 Copper P roducti on Costs . 

9. 1 . 7 U . S. Copper Resources ..... . 

9. 1 . 8 Sme l ter Capac i ty G rowth .... . 

9 . 1 . 9 Trends in U. S. Product ivity .. . 

9. 1 . 10 U. S. Total Cons umption of Copper. 

9. 1 . 11 D emand by End Use ....... . 

9. 1 . 12 Copper Pri ces ......... . 

9. 1 . 13 Substi tutes . . . . . . . . . . . . . . 

9. 1 . 14 Wor l d Product i on and Consumption of Copper. 

9 . 2 ECONOMIC I MPACT ASSESSMENT ...... . 

9. 2 . 1 I ntroducti on ......... . 

9. 2 . 2 Methodol ogy of Impact Anal ysis. 

9. 2 . 3 Pri ce Elasti city of S uppl y ... 

9. 2 . 4 The Pri ce Elasti city of Demand. 

9 . 2 . 5 Anal ysis ....... . 

9. 2 . 6 Find i ngs .... ... . 

9.3 SOCIOECONOMIC IMPACT ASSESSMENT 

9. 3 . 1 Execut i ve Order 12291 . 

9. 3 . 2 Regu l atory F l exi b i l i ty. 

9. 4 REFERENCES ......... . 

Page 

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9-57 

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9- 79 

APPENDIX A EVOLUTION OF THE BACKGROUND I NFORMATI ON D OCUMENT A-1 

APPENDIX B I NDEX TO ENVIRONMENTAL IMPACT CONS I DERATI ONS . B- 1 

APPEN DIX C EMI SSION SOURCE TEST DATA . . . . . . . . . . . . C-1 

APP END IX D ( Not Used) 

APPENDIX E USE OF COAL IN THE OUTOKUMPU F LASH FURNACE AT THE 

TOYO SME LTER. . . . . . . . . . . . . . . . . . . E-1 

APPEND IX F COST ANALYS IS TO ESTIMATE THE I NCREMENTAL INCREASE IN 

CAP ITAL COST I NCURRED BY I NCREAS I NG SULFURIC AC ID P LANT 

GAS-TO-GAS HEAT EXCHANGE CAPAC I TY . . . . . . . . . . . F-1 

ix 
TAB LE OF CONTENTS ( con. ) 

APPENDIX G ANALYSIS OF CONTINUOUS S02 MONITOR DATA AND 

DETERMINATION OF AN U P PER LIMIT FOR THE INCREASE IN 

S02 EMISSI ONS DUE TO SU LFURI C ACID P LANT CATALYST 

D ETERI ORATI ON . . . . . . . . . . . . . . . . . . . G- 1 

APP ENDIX H SULFUR DIOXIDE EMISSION TEST RESU LTS FOR SINGLE-STAGE 

ABSORPTION SU LFURIC ACID P LANTS P ROCESSING METAL LURGICAL 

OFFGAS STREAMS FROM PRIMARY COPPER SME LTERS . . H-1 

APP END IX I ANALYSIS OF DUAL-ABSORPTION SU LFURIC AC ID P LANT 

CONTI NUOUS S02 MONI TORI NG DATA. . . . . . . . . I- 1 

APPENDIX J EXAMPLE CALCULATI ONS MODEL P LANT OPERATING PARAMETERS J- 1 

APPEND IX K MATHEMATI CAL MODEL FOR ESTIMATING POSTEX PANSION 

REVERB ERATORY GAS F LOW AND S02 CONCENTRATI ON FOR OXYGEN 

ENRICHMENT AND OXY- FUEL EXPANSION OPT I ONS . . . . K- 1 

APPENDIX L METHODOLOGY FOR ESTIMATING SOLID AND LIQUID WASTE 

D ISPOSAL REQU I REMENTS . . . . . . . . . L-1 

APPENDIX M D ETAILED C OSTS FOR GREENFIELD SME LTERS M- 1 

APPENDIX N FUG ITIVE EMISSION CONTROL COSTS . . . . N-1 

APPEND IX 0 D ETAILED C OSTS FOR EXPANSION SCENARIOS. 0-1 

APP ENDIX P METHODOLOGY UTI LIZED TO DETERMINE THE COSTS ASSOC I ATED 

WITH SU LFURI C AC ID P LANT PREHEATER OP ERATION. . . . . . P-1 

X 
Number 

3-1 

3-2 

3-3 

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3-7 

3-8 

3-9 

3-10 

3-11 

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3-15 

3-16 

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4- 5 

4-6 

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4-8 

4-9 

4-10 

4-11 

4-12 

4-13 

4-14 

FIGURES 

The convent i onal copper smelt i ng process. 

Types of roasters . . . . . . . 

Reverberatory smelti ng furnace . 

Electric sme lting fu rnace ... 

Inco f l ash smelti ng furnace .. 

Outo kumpu f l ash sme l t i ng furnace . 

Pe i rce-Smi th Conve rte r . . . 

Copper converter ope rat i on 

Hoboken conve rter . . . . . 

Noranda cont i nuous smelting 

Mitsub i sh i conti nuous smelti ng. 

Fugi tive emi ssi ons sources for pri mary copper sme l ters. 

Methods of oxygen addition. . . . . . ... 

Converter e l imi nat i on of arseni c as a funct i on of 

matte grade . . . . . . . . . . . . . . . . . . 

Converter e l imi nat i on of anti mony as a function of 

matte grade . . . . . . . . . . . . . ..... 

Converter e l imi nati on of bismuth as a functi on of 

matte grade . . . . . . . ... 

Contac t su l furic acid processe s 

Cal c i um- based sc rubb i ng processe s 

Effect of pH of cal cium su l f i te-bisu l fite so l ution on S02 

equ i l i br i um vapor pre ssure . . . . ..... 

Fl ow d i agram of the l i me/gypsum pl ant at the Onahama 

sme l ter ............... . 

Ammonia sc rubb i ng process wi th sul furic ac id 

ac i du l ati on ............. . 

Ammoni a sc rubb i ng process wi th ammon i um b i su l fi te 

ac i dulation. . . . ..... . 

Magne si um oxi de (MAGOX ) sc rubb i ng process 

Bureau of Mi nes c i trate sc rubb i ng process 

Fl akt-Bol i den c i trate sc rubb i ng p rocess 

Typi cal absorber con f i gurati on ..... . 

Methods of oxygen addi ti on ....... . 

Convent i onal copper reve rberato ry smelting furnace that 

has been conve rted to an oxygen sp r i nkl e smelt i ng 

furnace . . . . . . . . . . . . . . . . . . . . .... 

Oxy-fue l bu rner l ocat i ons in Reve rberato ry Furnace No. 3 

at the Cal etones sme l ter ......... . 

Pl an and e l evati on of Reverbe rato ry Furnace No . 3 .... 

xi 

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4-103 
Number 

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4-38 

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6-3 

6-4 

6- 5 

6-6 

6-7 

FIGURES ( con. ) 

Reverberatory furnace temperatures in the v i cinity of 

the furnace roofs wi th and wi thout oxygen- u ndershooti ng 

at I nco sme 1 ter . . . . . . . . . . . . . . . . . . . . 

Typi cal col l ecti on effici ency c urves for several types 

of part i cul ate removal dev i ces .... ... . . . . 

Venturi scrubber . . . ..... . . . ..... . . 

Typi cal rel ationship between fracti onal col l ection 

effi c i ency and pa rticl e si ze for venturi sc rubbers. 

Baghouse wi th mechan i cal shaki ng ... ... . . . . 

Baghouse wi th reve rse f l ow c 1 eani ng. . . . . . . . 

Baghouse wi th c l eani ng by jet pu l se . . ... . . 

E l ectrostatic prec i pi tator. . . . . . 

Il l u strat i on of nul l po i nt formati on. 

Spri ng-l oaded car top and venti l ation hood , 

ASARCO-Hayden . . . . . . . . . . . . 

Typi cal hoodi ng for a matte tappi ng port . 

Schematic of a typi cal fugi t i ve emi ssi ons control system 

for matte tappi ng ope rat i ons ....... . . . . 

Typi cal secti onal l au nder covers ..... . . . . 

Launder hoods uti l i zed at the Phel ps Dodge-Morenc i 

Sme l ter for the captu re of fugi t i ve emi ssi ons generated 

dur i ng matte tappi ng ope rat i ons . . . . ... . .. . 

Schemat ic of the matte tappi ng and l adle hoods at the 

ASARCO- Tacoma Sme l ter ..... . . . ...... . . 

Schemat ic of the sl ag ski mm i ng ( pl an view) fugi t i ve 

emi ssi ons contro l system at the ASARCO-Tacoma Smelter 

Contro l l ed a i rfl ow from a heated sou rce . . . . . . . 

Uncontro l l ed a i rfl ow from a heated sou rce . . ... . 

In l et- out l et openi ngs in converter bui l d i ng at ASARC OEl Paso . . . . . . . . . . . . . . . . . . . . . . . . 

A typical fixed secondary converter hood ...... . . 

Retractabl e- type secondary hood as empl oyed at ASARCOHayden. . . . . . . . . . . . . . . . . 

Entra i ned f l ow d i agram . . . . . . . . . 

Conve rter air curtai n/secondary hoodi ng system as empl oyed 

at the Onahama and Naosh i ma sme l ters ... . . . . 

Schematic diagram of the converter housi ng/a i r curta i n 

system at the Tamano sme l ter ... .... . . . . . 

Mode l pl ant for new 11greenfi e l d11 sme l ter processi ng 

high- i mpuri ty materi a l s . . ...... .... . 

Mode l smelter converter ope rat i ng schedu le .... . 

Mode l P l ant I fo r expansi on of exi sti ng sme l ters .. 

Mode l P l ant II for expansi on of exi sti ng sme l ters . 

Mode l P l ant III for expa nsi on of exi sti ng sme l ters. 

Mode l P l ant IV for expansi on of exi sti ng sme l ters 

Mode l P l an V for expansi on of exi st i ng sme l ters .. 

Yii 

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Number 

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9-8 

9-9 

F IGURES (con. ) 

Capi ta l cost of a DC/DA sul furi c ac id pl ant 

Capi ta l cost of an MgO FGD s ystem . . . 

Capi ta l cost of an ammoni a FGD s ys tem . 

Capi ta l cost of a l imes tone FGD s ys tem 

Capi tal cost of an SC/SA sul furi c ac id pl ant 

Pri nc i pal m i n i ng States and copper s melti ng and 

refi n i ng pl ants , 1978 ......... . 

U. S. s ources and uses of copper .... . 

Compari son of copper pri ce i ndex and m i ne and mi ll 

capi tal cost i ndex ........... . 

U. S. c opper smelter production ..... . 

Quarterly pri ce movements for copper wi rebars 

( 1973 to 1981 ) . . . . . . . . . . . . . . . . 

U. S. coppe r pr i ce . . ........... . 

Annua l recoverab le copper avai l able from dome stic deposits 

over a copper pri ce range of $1 . 10 to $1 . 30/kg .. 

Costs for smelti ng and ref i n i ng in Japan vs. costs at 

new smel ters in the Uni ted States . . . . . . . . . 

Costs for smelti ng and refi n i ng in Japan v s . costs 

at expandi ng smelters in the Un i ted States .... 

xi ii 

8- 6 

8- 9 

8- 12 

8- 14 

8-47 

9-3 

9-10 

9-19 

9-25 

9- 36 

9- 37 

9-41 

9-69 

9-70 
N umber 

1- 1 

1- 2 

1- 3 

3- 1 

3- 2 

3-3 

3-4 

3-5 

3-6 

3-7 

3-8 

3-9 

3- 10 

3- 11 

3-12 

3- 13 

3-14 

3- 15 

3- 16 

TAB LES 

Expansion Scenarios Se l ected for Economic Anal ysis. 

I mpacts of S02 Regu l atory A l ternatives of a Typical 

New G reenfie l d Sme l ter (Mul tihearth Roaster, 

Reverbe ratory Smelting Furnace , Converter) P rocessing 

H igh-Impurity Materia l s (Al l Impacts are Long Term 

Unl ess Otherwise Noted) . 

I mpacts of Particu l ate Matter Regu l atory A l ternatives of a Typical New Greenfie l d Sme l ter (Mul tihearth Roaster , Reverberatory Smelting Furnace , 

Converter) Processing H igh-Impurity Materia l s 

(Al l I mpacts are Long Term Unless Otherwise Noted ). 

Domest ic Primary Copper Sme l ters . . ..... . 

Major Copper-Bearing Minera l s . . . . ... . . 

Emissio ns Factors fo r Uncontro l l ed Major P rocess 

Sources 

Potential Sources of F ugit ive Emissions 

Summary of Fugitive S02 Emissions Factors for Primary 

Copper Sme l ting Operations. 

Summary of Fugit ive Particu l ate Emissions Factors for 

Primary Coppe r Sme l ting Operations. 

Maximum Acceptab le I mpurity Leve l s in Anode Coppe r , and 

Corresponding Leve l s in B l ister Copper P roduced at the 

ASARCO-Tacoma Smelter . 

Assays of Various H igh I mpurity Materia l s Processed at 

ASARCO-Tacoma . . 

D istribution of I mpu rity E l ements in Conventional 

Smelt ing When Processing H igh-Impurity Feeds. 

D istrib ution of I mpurity E l ements in the Noranda 

Process ( Matte P roduction Mode ) 

D istrib ution of Impurity E l ements in the Noranda 

Process (Bl ister Copper Product ion Mode ). . 

Impurity Assays of Feed Materia l s P rocessed in the 

Outo kumpu F l ash Furnace at the Ko saka Sme l ter ... 

Maximum Impurity Leve l s Recommended for the Outo kumpu 

F l a sh Furnace 

Range of Impurity Co nce ntrat ions Tested in the I nco 

Min ipl ant Fl ash Furnace 

Maximum Impurity Leve l s P rocessed in the Mit subishi 

Process 

Maximum Impurity Leve l s Recommended for the Noranda 

P rocess (Matte Product ion Mode ) . 

XV 

Page 

1-4 

1-5 

1- 6 

3-2 

3-2 

3-45 

3-47 

3-58 

3-59 

3-86 

3-87 

3-90 

3-95 

3-96 

3- 101 

3-102 

3- 105 

3- 106 

3- 108 
Number 

3-17 

3-18 

3-19 

4-1 

4- 2 

4-3 

4-4 

4- 5 

4-6 

4-7 

4-8 

4-9 

4-10 

4- ll 

4-12 

4-13 

4-14 

4- 15 

4- 16 

4- 17 

4- 18 

TAB LES (con . ) 

Summary of Experi ence Processi ng H i gh-Impur i ty Feeds 

in Al ternat i ve Smelti ng Techno l ogi es. 

Su l fur/Su l fur Dioxide Emi ssi on Limi tat i ons by State 

Part i cul ate Emi ssi on L i mitati ons by State . 

Est i mated Max i mum Impur i ty Limi ts fo r Metal l urgi cal 

Offgases Used to Manufacture Su l furi c Ac i d. 

Composi tion of Scal e F rom the Onahama Lime-Gypsum 

Process . 

Major Domestic Uti l i ty-Re l ated FGD Instal l at i ons That 

Use the Li mestone-Sc rubb i ng P rocess . 

Lime/Li mestone FGD Systems That Have Ac hi eved S02 

Removal Effi c i ences of 90 Percent or G reater on 

Offgases Generated by Coal -Fi red Steam Generators 

Summary of Emi ssi on Test Data for the Duval Sierrita 

Lime Scrubbi ng System, 1977- 1980 . . 

Perfo rmance Data on the Comi nco-Type Ammon i a-Based 

Sc rubb i ng Uni ts at Trai l, Bri tish Col umbia. 

F l ue Gas Desu l furi zat i on Processes Assessed for 

Appl i cat i on to Reverbe ratory Furnace Offgases 

Effi c i ency and Re l i abi l i ty Data for the FGD P rocesses 

Bei ng Consi dered in the NSPS Revisi on for Pri mary 

Copper Sme l ters 

General Spec i f i cati ons of the Type of Oxy- Fuel Burner 

Empl oyed at the Cal etones Sme l ter . 

General Spec i f i cat i ons of the Type of Oxy-Fuel Burner 

Empl oyed at the Onahama Sme l ter . 

Typi cal Reverberato ry Furnace Ope rat i ng Data Befo re 

and Afte r the Use of Oxy-Fuel Burners at the Onahama 

Sme l ter . 

Summary of Experi ence I nvolvi ng the U se 

of Oxygen in Reve rberatory Smelting Furnaces. 

Typi cal Fracti onal Col l ecti on Effi c i e ncies of 

Part i cul ate Contro l Equipment . 

Summary of Part i culate Test Data for the Spray 

C hambe r/Baghouse at the Anaconda Sme l ter. 

Summary of I n-Stac k/Out-o f- Stac k P art i cu l ate Matter 

Test Results at Reve rberatory Furnace ESP Out l ets 

Summary of Parti cul ate Test Data for the Spray 

C hambe r/Roaste r-Reverberatory ESP at the ASARCOEl Paso Sme l ter . 

Funct i on of A i r Curtai n and Secondary Hood System 

Duri ng Vari ous Modes of C onverter Ope ration at Tamano 

Sme l ter 

Summary of Desi gn Data fo r the ASARCO-Tacoma 

Converter Secondary Hoodi ng/A i r Curtai n System. 

xvi 

3- llO 

3- l13 

3- 115 

4-15 

4- 31 

4-33 

4-36 

4- 37 

4-56 

4-85 

4-86 

4- 104 

4- 106 

4- 107 

4- 118 

4- 125 

4- 137 

4- 142 

4- 144 

4- 179 

4-182 
Number 

4-19 

4- 20 

4- 21 

4-22 

4- 23 

4-24 

4-25 

4- 26 

6-1 

6-2 

6-3 

6-4 

6-5 

6-6 

6-7 

6-8 

6-9 

7-1 

TAB LES (con . ) 

Summary of Visi b le Emi ssi on Observation Data for 

Capture Systems on F ugi t i ve Emi ssi on Sources at 

ASARCO-Tacoma ................. . 

Visi b le Emi ssi on Observation Data for Reverberatory 

Furnace Matte Tapp i ng Ope rat i ons at the Phe l ps DodgeMorenci Sme l ter ............... . 

Vi sible Emi ssi on Data for Reverberatory Furnace 

Matte Tapp i ng Ope rat i ons at the Phel ps DodgeMorenci Sme l ter ............... . 

Visi b le Emi ssi on Observat i on Data for Reverberatory 

Furnace Sl ag Ski mmi ng Ope rat i ons at the Phe l ps DodgeMo renci Sme l ter . . . . . . . . . . . . . . . . . . 

Vi sible Emi ssi on Observati on Data for Converter 

Secondary Hood System D uring Matte Chargi ng at the 

Tamano Smelter. . . . . . . . . . . . . . 

Vi si b le Emi ssi on Observat i on Data for B l i ster 

D i scharge at the Tamano Sme l ter ..... 

Summary of Emi ssi o ns Test i ng Performed on the 

Converter Bui l di ng Evacuation Baghouse at ASARCOEl Paso . . . . . . . . . . . . . . . . . 

Summary of Emi ssi ons Test i ng Performed on the Cal cine 

D i sc harge Baghouse at Phe l ps Dodge- Dougl as ..... . 

Mode l Plant Charge Composi t i on and Su l fur E l i mi nat i on 

for Greenfi eld H i gh-Impuri ty Sme l ter ... ..... . 

Mode l P l ant--Greenfield H i gh-Impurity Sme l ter Representat i ve Converter Off gas Stream Profi 1 e . . . . 

Mode l Plant , New Greenfi eld H i gh- Impurity Sme l ter 

Contro l A l ternati ves ....... ..... .. . 

Parameters for Particul ate Contro l Al ternat i ves-­

Pri mary Offgases from D i rty Reverberato ry Furnaces. 

Summary of Fugi tive Part i cul ate Emi ssi ons Capture 

and Control Systems ....... ........ . 

Sme l ti ng Confi gurat i on/Expansi on Scenar i os .... . 

Mode l P l ant Co nfi gurat i ons and Ex i st i ng U . S. Sme l ters 

Model P l ant Expansi on Scenar i os: Exit Gases, 

Composi t i on, and Flow Rate ......... ... . 

Mode l P l ants for Expansi on Opt i o ns: Represe ntat i ve 

Feeds, Matte Grades, and Su l fur El imi nat i on Rates . 

Eval uated Co ntrol Opti ons for Control of Process S02 

Emi ssi ons at a Greenfi eld Copper Sme l ter (Mu l t i hearth 

Roaster-Reverbe ratory Sme l t i ng Furance-Converte r) 

Processi ng H i gh-Impuri ty Materi al s ......... . 

xv ii 

4-184 

4- 186 

4- 187 

4- 188 

4-191 

4-194 

4-195 

4- 196 

6-5 

6-10 

6-12 

6-18 

6-20 

6-24 

6-26 

6-33 

6-35 

7-2 
Number 

7- 2 

"7-3 

7-4 

7-5 

7- 6 

7-7 

7-8 

7-9 

7-10 

7-11 

7-12 

7-13 

7-14 

8-1 

8-2 

8- 3 

8-4 

8- 5 

TAB LES (co n . ) 

Eval uated A l ternat i ves for Control of Fugi tive Part i cul ate 

Emi ssions at a Greenfi e l d Copper Sme l ter P roces sing 

H i gh-Impuri ty Materi als (Mul t i hearth RoasterReverberatory Smelt i ng Furnace-Converter) ..... . 

Eval uated A l te rnatives for Contro l of Fugi tive 

Part i cul ate Emi ssions at a Greenfi eld Copper Sme l ter 

(F l ash Furnace-Converter) . . . . . . . . . . . . . 

A i r Pol l ut i on Emi ssion Impact of S02 Contro l A l ternat i ves for a New Green field Smelte r , Mul t i hearth 

Roas ter-Reve rberatory Furnace- Converter . . . . . . 

Ai r Pol l ution Fugi tive Parti cul ate Emi ssion Impact 

for Each Source and Control A l ternat i ves-- New 

G reenfi eld Sme l ters ......... , ..... . 

Air Po l l uti on F ugi t i ve P articul ate Emi ssion Impact for 

Expans i on at Exi sti ng Sme l ters .......... . 

Esti mated P roducti on Rate of So l i d and Liquid 

Effl uents Requiri ng D i sposal F rom Gas C l eaning and 

Condi t i oni ng Equ i pment , G reenfi e l d Sme l ters .... 

Esti mated Inc remental Inc rease in Effl uents 

Requiring D i sposal F rom Gas C l eaning and Condi t i oni ng 

Equi pment , Expansi on Opti ons . . . . . . . . . . . . . 

Esti mated Producti on Rate of So l id and Liqui d 

Effl uents Requ i ri ng D i sposal from FGD Sys tems 

Assoc i ated Wi th Greenfiel d Sme l ter Mode l s ....... . 

Esti mated Producti on Rate of Soli d and L i quid 

Effl uents Requ i r i ng Dispo sal from FGD Sys tems 

Associated Wi th Expans i on Opti ons ..... . 

Esti mate of Emi ssion Redu ction Due to Part i cul ate 

Control of Reverberato ry Smelting Furnace Pri mary 

Offgases--Hi gh-Impuri ty G reenfiel d Sme l ter ... 

Energy Impact--P rocess S02 Control A l ternati ves for 

New Greenfi eld Sme l te r, Mu l ti hearth RoasterReverberatory Fu rnace- Converter. . . . . . . . . . . 

Inc remental Energy Impact--Fugi t i ve Emi ssion Control 

A l ternat i ves for New Gree nfi e 1 d Smelters . . . . . 

Energy Impacts-- Expans i on Scenar i os for Exi s ting 

Pri mary Copper Sme l ters ... 

Control A l ternatives ..... 

Input Data to Cost Estimation, New H i gh-Impuri ty 

Sme l ter ............... . 

Labor and Uti l i ty Uni t Costs .... ..... . 

FGD Raw Material and Utili ty Usage Rate ... . 

Evaluated A l ternat i ves for Contro l of Fugi tive 

Particulate Emi ssions from a New Copper Sme l ter (Multi ­

hearth Roaste r, Reverbe ratory F urnace , Converter or 

Flash Furnace-Converter) P roce s sing Hi gh-Impurity 

Material s ... .............. ... . 

xvi i i 

7-4 

7-5 

7-6 

7-8 

7- 10 

7-12 

7-13 

7- 14 

7- 15 

7- 19 

7-21 

7-22 

7-23 

8-2 

8-4 

8-18 

8- 22 

8- 30 
Number 

8- 6 

8- 7 

8-8 

8-9 

8-10 

8- 11 

8- 12 

8- 13 

8- 14 

8- 15 

9-1 

9-2 

9-3 

9-4 

9-5 

9-6 

9-7 

9-8 

9- 9 

9-10 

9-11 

9-12 

9-13 

9- 14 

9-15 

9-16 

9-17 

9- 18 

9- 19 

9-20 

9-21 

·1 ,. ' 

TABLES ( con . ) 

Mode l P l ant Expansi on Scenari os . . . . ..... . 

Input Data to Cost Estimations , Expansi ons Opt i ons. 

Summary of Inc remental Costs Inc urred Due to Ac id 

P l ant P reheater Operati on . . . ... ... . 

Expansi on Costs ( Incl udes Cost of Control ling S02 

Emi ssi ons from New Roasters and Converters as Requi red 

by Exi st i ng NSPS) . . ......... ... .... . 

Cost- Effecti veness: Control of Reverberatory Furnace 

S02 Emi ssi ons in a New Copper Sme l ter ( Multi hearth 

Roasters, Reverberatory Furnace , Converter) P rocessi ng 

Hi gh- Impuri ty Materi al s . . ... . . .... . . 

Costs for Control of Fugi tive Part i cul ate Matter 

Emi ssi ons by Source , New Greenf i e l d Sme l ter .. 

Cost- Effecti veness of Expansi on Scenai ros .... 

Cost- E ffecti veness, Fugi tive Part i cul ate Matter Control , 

Expansi on Scenari os . . .... . . ... ..... . 

Inc reme ntal Cost Data , Least Cost Expansi on Scenar i os 

Inc remental Cost Data, Fugi ti ve Emi ssi on Control 

Least Cost Expansi on Scenari os . . . . . . . . 

Sme l ter Owne rsh ip, P roduct i on and Source Mate rial 

Arrangements ............ ... . 

U. S. Re f i ning Fac i l i ti es for Pri mary Copper 

Flow of Coppe r F rom M i nes to U . S . Sme l ters, 

M i ne Output . . . . . . . . . . . . . . . . 

Flow of Copper F rom M i nes to U . S . Sme l ters, 

Sme l ter Sources ..... ........ . 

Smelt i ng Cost Est i mates ......... . 

U . S. Copper Production by Mi ne ( 1977 ) , Cents per 

Ki l ogram and P roduction Capac i ty .. 

Copper Resources of U . S. Compan i es. 

Productiv i ty in the Copper Industry 

Output and P roducti v i ty Indi ces .. 

U . S. Copper Consumption .... . . 

U . S. Copper Demand by Market End Uses 

U . S. Shi pments of Copper- Base M i ll and Fou ndry 

Products--Gross We i ght .......... .. . 

U . S. Copper M i ne Capacity: Current and Potenti al 

Uni ted States and Wor l d Comparat i ve Trends in Refi ned 

Copper Consumpti on, 1963- 1979 . . ..... . 

Uni ted States and World Comparat i ve Trends in 

Copper P roduction: 1963-1979 . . . 

Price Elast i ci ty of Supp ly Est i mates ..... 

Price and Income E l asti cities of Demand Est i mates 

Cost Data for New High Impuri ty Greenfield Sme l ters 

Cost Data for New G reenfi eld Sme l ter P rocessing 

C l ean Concentrates Usi ng a Flash Furnace . 

Sme l ter Cost Data for Expansi on Scenari os 

Max i mum Percentage Pri ce Increase .... 

xi x 

Page 

8-39 

8-41 

8-51 

8-52 

8-53 

8- 54 

8-55 

8- 56 

8- 57 

8- 58 

9-5 

9-8 

9-12 

9-14 

9-20 

9-22 

9-23 

9-27 

9-28 

9-30 

9-32 

9-34 

9-42 

9-46 

9-47 

9-54 

9-56 

9-58 

9-59 

9-61 

9-72 
Number 

9-22 

9-23 

9- 24 

TABLES ( con.) 

Maxi mum Percent P rofit Reducti on .. . 

Summary of Sel ected C ases .... . . 

Number of Empl oyees at Compani es That 

Copper Sme l te rs .......... . 

XX 

Own Pri mary 

9-74 

9-75 

9-78 
APP ENDIX A 

EVOLUTION OF THE REVIEW DOCUMENT 
APPENDIX A 

EVOLUTION OF THE REVIEW DOCUMENT 

Th is study to rev i ew the exi sting standard of per fo rmance for 

pri mary copper sme l te rs began in 1980 , wi th Pac i fic Envi ronmental 

Se rv i ces, Inc . (PES) . In Septembe r 1980 , responsi bili ty for the 

project was assi gned to the Research Tri angl e Inst i tute ( RTI) . Major 

events si nce RTI was assi gned responsi bi l i ty are shown in Tab l e A-1. 

In i t i al RTI act i vities i nc l ude a rev i ew of the PES draft work 

pl an and the preparati on of the Phases II and III work pl an . D i scussi ons were he ld wi th PES and IE RL/C i nc i nnat i to i denti fy and expl i cate 

the i ssues and to gather i nformat i on documents for detai l ed study at 

RTI. In conjunct i on wi th EPA1s Emi ssi on Mon i tori ng Branc h, a source 

test pl an was prepared in June 1981. However , due to fundi ng probl ems , 

source test i ng did not start u nt i l November 1981 wi th compl eti on in 

January 1982 . Radian Corpo ration performed the tests wi th RTI personnel 

observi ng. 

Numerous pl ant visi ts were made duri ng 1981 for fam i l i ar i zation 

and data co l l ect i on purposes. Domestic sme l ters respo nded to 114 

l ette rs add i ng to the data base . 

F rom September 1980 to date, numerous tel epho ne and wri tten 

contacts were made wi th fore i gn and domest i c sme l te rs, equipment 

suppl i e rs, and domes t i c e l ectr i c uti l i ti es to obtai n i n formation on 

pri mary coppe r smel ter processes and emi s s i on control sys tems. 

The techni cal backgro und chapte rs des cr i bi ng the i ndustry, emi ssi on 

contro l techni ques, reconstruction and modif i cati on cons i derati ons, 

model pl ants, and regu l atory al ternat i ves were compl eted in March 

1982, and mai l ed to industry fo r rev i ew and comment. The pre l i mi nary 

A-3 
economic analysis was completed in September 1982 and the final economic 

analysis in October. 

Industry comments on the draft BID were analyzed and incorporated 

into a revised version that was sent to working groups October 1982. 

Revised Chapters 6-9 were distributed to litigants and intervenors for 

review and comment in November 1982. 

NAPCTAC review was accomplished in April 1983 and the notification 

package submitted for Steering Committee review and AA concurrence in 

September 1983 . 

A-4 
TAB LE A-1. MAJOR EVENTS AND ACCOMPLISHMENTS IN THE EVOLUT I ON 

OF THE BACKGROUND I NFORMATI ON DOC UMENT 

Month Event 

September 1980 

Octobe r 1980 

October 1980 

Octobe r 1980 

December 1980 

February 1981 

March 1981 

Apr i l 1981 

May 1981 

May 1981 

May 1981 

J une 1981 

July 1981 

September 1981 

Work begun by Pacific Envi ronmental Serv i ces ( P ES). 

PES Work Pl an submi tted to E PA. 

Work begun by the Research Tri angl e I nst i tute ( RTI). 

D raft wo rk pl an di scussed wi th I. J. We i senberg, 

fo rmerly project l eader for P ES e ffort. 

D raft Phases II and III Work Plan c ompl eted. 

D i sc ussi ons wi th I ERL/Cinc i nnati to i denti fy i ssues and 

to obtai n bac kground doc uments. 

Phases II and III Work Plan compl eted. 

Fami l i ari zation visi ts made to five U . S. sme l te rs-­

ASARCO/E l Paso, Phelps Dodge/Hidal go , Phelps 

Dodge/Mo renci, I nspi ration , and ASARCO/Hayden. 

Outo kumpu Oy contacted and i nformation obtai ned on the 

Outo kumpu f l ash smelti ng system. 

Visits made to !NCO Metals Company c orporate headquarters and the Copper C l i ff Sme l ter at Sudbury, Ontar i o, 

to assess capab i l i ti es of the !NCO flash furnace . 

Fam i l i ar i zation visit made to Kennecott/Garfi eld 

sme l te r. 

Secondary ai r c urtai n fo r ASARCO/Tacoma converter 

di scussed w i th ASARCO Engi neeri ng at Sal t Lake C i ty. 

D raft So urce Test Plan compl eted. 

Source Test Plan compl eted. 

P retest survey vi si ts made to P helps Dodge/H i dal go and 

Phelps Dodge/Mo re nci . 

Vi sible emi ssi on tests c onducted on converter secondary 

hoods at ASARCO/Tacoma. 

( conti nued) 

A-5 
Month 

November 1981 

D ecember 1981 

January 1982 

January 1982 

March 1982 

Apri l 1982 

September 1982 

October 1982 

October 1 982 

October 1982 

November 1982 

February 1983 

Apri l 1983 

September 1983 

October 1983 

TABLE A- 1 ( conti nued) 

Event 

Tests conducted at Phelps D odge/Hidal go and Phelps 

Dodge/Morenci . 

Tests conducted on el ectric sl ag cl eaning furnace 

scrubber and sl ag ski m at Phel ps Dodge/H i dal go. 

Addi tional tests conducted on el ectri c sl ag cl eaning 

furnace at Phel ps Dodge/H i dal ga. 

Prel i mi nary model pl ants defi ned. 

Techn i cal b ackground di stributed for external review. 

Tabul ar cost data devel oped. 

P rel i mi n ary economi c analyses completed. 

Cost study compl eted. 

Fi nal economi c analysis completed. 

Worki ng group package di stributed. 

Draft Chapters 6-9 di str i buted to l i ti gants and i nterv enors for review and comment. 

NAPCTAC package di stri buted 

Review document rev i ewed by NAPCTAC 

Steeri ng Commi ttee package di stributed 

Rev i ew document rev i ewed by NAPCTAC 

A- 6 
APPENDI X B 

I NDEX TO ENVIRO NMENTAL I MPACT CONSIDERATIONS 
AP PENDI X B 

I NDEX TO ENVIRONMENTAL IMPACT CONSIDERAT IONS 

Tabl e B-1 lists the l ocati ons in th is document of certain informati on pertaini ng to env i ronmenta l i mpact , as outl i ned in Agency Gu i delines (39 FR 37419, October 21, 1974). 

8-3 
TAB LE B-1 . LOCATIONS OF INFORMATION CONCERNING ENVIRONMENTAL 

IMPACT WITH IN THE REVI EW DOCUMENT 

Agency guide l ines for prepar ing 

regul atory action environmental 

impact s tatements ( 39 FR 37419 , 

October 21 , 1974) 

Bac kground and s ummary of emis s ion 

control al ternative 

Statutory bas is for review of the 

existing standard 

Re l ations hips to other regul atory 

agency actions 

I ndustry affected by the regul atory 

al ternative 

Spec ific p rocesses affected by the 

regul atory al ternative 

B- 4 

Location within the Review 

Document 

C hapter 6, Sections 6 . 2, 6 . 3, and 

6 . 4 

Chapte r 2, Section 2.1 

Chapters 3, 7, 9 

Chapter 3, Section 3 . 1, and 

Chapter 9, Section 9.1 

C hapter 3, Sections 3.2 and 3.6 
APPENDIX C 

EMISSION SOURCE TEST DATA 
APPEND IX C 

EMI SS I ON SOURCE TEST DATA 

C.1 SUMMARY OF TEST DATA 

EPA has u ndertaken several test p rograms in the past to assess 

the si gn i f i cance of and contro l tec hniques avai l able fo r both p rocess 

and fug i tive S02 and particulate matte r emi ss i o ns from primary coppe r 

sme l te rs. Port i ons of these data we re used in this study and are 

summari zed in Tables C-1 and C- 2. For deta i led discussions of these 

data , as we ll as di sc ussi ons of the sme l te rs i nvol ved in the prev i ous 

test i ng programs , o ne may refer to ei ther (1) the actual test reports 

from the U . S. Envi ronme ntal Protection Agency1s (EPA) Em i ssi on Measurement B ranch (EMB ) , as p resented in Tab l es C-1 and C- 2, or (2 ) prev i ously 

published EPA doc ume nts that have used the data-- e . g ., Arsen ic Emi ssi o ns 

from Pri mary Copper Sme l ters--Background I n fo rmat i o n for Proposed 

Standards , November 1980 . 

An addit i onal test program was undertaken as a part of the current 

study to characteri ze sme l ter o f fgas streams for wh i c h data were 

scarce or nonexi ste nt. Particul ate matter and S02 mass em i ssi on rates 

were determi ned for seve ral scenari os wi th c omb i ned EPA Re ference 

Methods 5 and 6. Visible emi ssions data we re also obtai ned for these 

sources wi th EPA Reference Method 9 and 22. 

Brief di scussio ns of eac h sme l ter and source tested duri ng this 

study a re p resented in Secti ons C.2 and C. 3, al ong wi th the test 

resu l ts. 

A great deal of visi ble em i ssi o ns data obta i ned dur i ng p rev i ous 

stud i es was used as referen ce mater ial fo r this study. The re fo re , for 

the reade r1s convenien ce , this data are presented in tabul ar form in 

Section C . 4. 

C- 3 
C.2 SUMMARY OF TESTING PERFORMED AT THE PHELPS DODGE-MORENCI SMELTER 

At the time of testing , the P helps Dodge-Morenci smelter had two 

reverberatory furnaces in operation , Nos . 3 a�d 5. Both furnaces were 

process ing a green charge . The furnaces are fired with fuel oil. 

Emis sions tests were conduc ted to characterize matte tapping and 

slag s kimming emis sions from the Nos. 5 and 3 furnaces, respectively. 

Visua l e mis sions data were also obtained to a s sess the effectiveness 

of the l ocal hooding used to capture these emis sions . The emis sions 

test data are summarized in Table C- 3, whil e the visua l emis sions data 

are s ummarized in Tabl es C-4 t hrough C-6. 

C . 3 SUMMARY OF TESTING PERFO RMED AT THE PHELPS DODGE-PLAYAS SMELTER 

Several sources were tested at the P helps Dodge- P l ayas s melter to 

characterize offgases associated with the ope ration of an Outokumpu 

fl ash s melter. Emis s ions tests were conducted to c haracterize offgases 

from f l ash furnace matte tapping and slag s kimming, as we ll as offgases 

from electric slag c l eaning furnace (ESGF) slag tapping. The primary 

offgas s tream from the ESCF was a l so tes ted before and after particul ate 

control by a wet venturi scrubber . These data are presented in Tables 

C-7 t hrough C- 9. Visual emis sions data were also obtained for the 

tapping and s kimming operations noted above . These data a re p resented 

in Table s C-10 and C-12 . 

C.4 SUMMARY OF VISIBLE EMISSIONS DATA OBTAINED PRIOR TO THE CURRENT 

REVISION 

Many emis sion? data obtained by EPA were used in the current 

study. The data used are s ummarized in Table C- 2 and detailed results 

are given in Tables C-13 through C-27. 

C-4 
n 

I 

(.]1 

TABLE C-1. SUMMARY OF EMISSION TEST RESULTS USED IN THE PRIMARY COPPER SMELfER NSPS REVIEW 

Plant 

Anaconda a 

Anaconda, Montana 

ASARCOa 

El Paso, Texas 

Phelps Dodgea 

Douglas, Arizona 

Phelps Oodgea 

Ajo, Arizona 

Phelps Dodqe 

f�orenc 1 , Arizona 

Phelps Dodge 

Playas, New Mexico 

Offg�s source 

Fluid-bed roaster 

electric smelting 

furnace converter 

Multihearth roasters 

and reverberatory 

furnace 

Reverberatory furnace 

matte tapping 

Converter building 

evacuation system 

Multihuarth roaster 

discharge 

Mult illearth roaster 

discharge 

Reverberatory furnace 

matte tapping 

Converter blow cycle 

Reverberatory furnace 

matte tapping 

Reverberatory furnace 

slag skinmling 

Flash furnace matte 

tappingc 

Flash furgace matte 

tapping 

Flash furnace matte 

tappinge 

Flash furnace slag 

skimming 

Electric slag clenninq 

furnace 

a

Test data obtained prior to this study. 

b

No control device used. 

Control 

equipment 

Spray chamber/ 

baghouse 

Spray chamber/ 

cold ESP 

Baghouse 

Baghouse 

b 

Baghouse 

b 

b 

b 

b 

b 

b 

b 

b 

Pa•·t icul ate 

scrubber 

c

At the flash furnace launder (without lancing emissions includE-d). 

Sampling 

location(s) 

Inlet and outlet 

Inlet and outlet 

Inlet 

Inlet and outlet 

Primary offgas 

flue 

Inlet and outlet 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Fugitive gas 

flue 

Inlet and outlet 

d

At the flash furnace doghouse enc 1 osure (without lancing emissions inc 1 uded). 

e

At the flash furnace doghouse enclosure (with lancing emissions included). 

Sample type 

Particulate matter 

Particulate matter 

Particulate matter 

so2 

Particulate matter 

502 

Particulate matter 

so2 

Particulate matter 

Particulate matter 

502 

Particulate matter 

5()2 

Particulate matter 

502 

Particulate matter 

so2 

Particulate matter 

so2 

Particulate matter 

so2 

Particulate matter 

502 

Particulate matter 

502 

Particulate matter 

so2 

Average 

particulate mass 

rate, kg/hr 

Inlet Outlet 

3,876 13.1 

1,129 37.2 

1.2 NA 

50.7 2.0 

1.0 NA 

285 1.2 

2.2 NA 

27.7 NA 

7.7 NA 

0.9 Nfl 

20.4 NA 

2.9 NA 

3.9 NA 

5.0 NA 

45.4 2.2 

Average 

S02 mass 

rate, kg/hr 

Inlet Outlet 

NA NA 

NA NA 

14.4 NA 

139 

2.4 NA 

NA NA 

115 NA 

1,192 NA 

136 NA 

7.7 NA 

143.8 NA 

13.2 NA 

10.9 NA 

59.0 NA 

81.6 44 9 

E�1B 

report no 

77-CUS-5 

78-CUS-7 

78-CUS-7 

78-CUS-7 

78-CU5-7 

78-CUS-8 

78-CU5-9 

78-CU5-9 

81-CU5-8 

81-CU5-8 

81-CUS-8 
TAB LE C- 2. SUMMARY OF VISI B LE EMI SSI ONS DATA USED IN THE 

PRIMARY COP PER SMELTER NSPS REVISION 

P l ant 

ASARCOa 

Tacoma , Washington 

Phel ps Dodge 

Morenci. Arizona 

Phel ps Dodge 

P l ayas, New Mexico 

a Tamano 

Japan 

Type of source 

Cal cine discharge 

Matte tap port and l aunder 

Matte discharge into l adle 

Sl ag skim port and l aunder 

Sl ag discharge into pots 

Converter sl ag return 

Matte tapping 

Sl ag skimming 

F l ash furnace matte tapping 

Sl ag skimming--el ectric sl ag 

cl eaning furnace ( ESCF) 

Matte tapping- - el ectric sl ag 

cl eaning furnace ( ESCF) 

Methodol ogy 

empl oyed 

EPA Method 22 

EPA Method 22 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

EPA Method 9 

EPA Method 22 

ESC F off- gas particul ate scrubber EPA Method 9 

Converter charging 

Converter copper b l owing 

Converter sl ag blowing 

Converter sl ag pouring 

EPA Method 9 

EPA Method 9 

EPA Method 9 

EPA Method 9 

a

These data obtained prior to this study. 

C-6 
TAB LE C-3. SUMMARY OF EMI S S ION RATES CALCULATED F ROM PARTICULATE 

AND SULFUR DIOXIDE TESTING AT THE PHELPS DODGE-MORENC I SMELTER 

Esti mated 

producti on Particul ate Sul fur dioxide 

Source/test Tons Taps l b/ha 1b/ton6 l b/ha l b/tonb 

Matte tappi ng 

(Reberb No. 5 ) 

EMB-004 MMT 185 8 19 0 . 1 290 1 . 6 

EMB- 006 MMT 250 10 18 0 . 072 290 1 . 2 

EMB- 008-MMT 275 11 15 0 . 054 310 1 . 1 

Average 17 0 . 076 300 1 . 3 

Slag s ki mmi ng 

(Reverb . No . 3) 

EMB- 003 MSS 80 2 2 . 0 0 . 025 15 0 . 19 

EMB-005 MSS 90 3 2 . 5 0 . 038 30 0. 33 

EMB-007 MSS 60 2 1 . 2 0 . 020 7 . 6 0 . 13 

Average 1 . 9 0 . 024 17 0. 21 

a

lb of pol l utant/h of samp l i ng. 

b

lb of pol l utant/ton of matte or slag produc ed duri ng samp l i ng. 

C-7 
TAB LE C-4. VISIBLE EMI SS ION OBSERVATION DATA FOR REVERBERATORY 

FURNACE MATTE TAPPING OPERATI ONS AA THE PHELPS DODGEMORENCI SMELTER 

Average opac i ty 

Durati on of obse rvati on for observat i on Range of 

peri od , mi n peri od , pe rcent i ndivi dual read i ngs 

8. 75 8 . 57 5 to 25 

8 . 50 2.06 0 to 25 

6 . 50 8 . 85 5 to 20 

8 . 50 8 . 09 5 to 30 

5. 00 7 . 25 5 to 10 

6 . 50 7 . 31 5 to 20 

9 . 00 11 . 39 5 to 20 

11. 00 15 . 68 5 to 30 

9 . 50 16 . 71 10 to 20 

4 . 00 10 . 00 5 to 10 

9 . 50 14 . 20 5 to 30 

6 . 50 18 . 46 10 to 30 

9.50 47 . 06 10 to 60 

8 . 00 17 . 34 10 to 40 

5 . 00 6 . 88 5 to 25 

7 . 75 18 . 23 10 to 30 

5 . 00 17 . 75 10 to 30 

7 . 50 14 . 50 5 to 35 

5 . 00 7 . 00 0 to 30 

9 . 25 24 . 86 10 to 70 

6 . 50 7 . 50 0 to 30 

3. 75 6 . 67 0 to 30 

a

Based on v i sual obs ervations made in accordance wi th E PA Method 9. 

C-8 
TAB LE C-5. VISIB LE EMISSION DATA FOR REVERBERATORY FURNACE MATTE 

TAP PING OPERATI ONS AT THE �HELPS DODGEMORENCI SMELTER 

Durati on of observati on Percent of ti me 

period , mi n em i s sions observed Li ght readi ng, 

6 . 0 100 350 

7. 0 100 175 

5 . 0 82 350 

5 . 0 100 88b 

a

Based on v i s ual observati ons made in acco rdance wi th EPA Method 22. 

b

Not a val id observation since the l i ght was l e ss than 100 l ux. 

C-9 

l ux 
TAB LE C-6 . VISIBLE EMI SSION OBSERVATI ON DATA FOR REVERBERATORY 

FURNACE SLAG SKIMMING OPERATIONS AT THE PHELPS DODGEMORENC I SME LTER 

Durat i on of observati on 

peri od , mi n 

30 . 00 

30 . 00 

33. 00 

6 . 25 

27.00 

30 . 00 

Durat i on of observati on 

peri od , mi n 

30 . 00 

Reference Method 9 resul ts 

Av erage opac i ty 

for observati on 

peri od , min 

0 . 00 

0 . 00 

2. 72 

11. 00 

0.00 

0 . 79 

Re fere nce Method 22 resul ts 

Percent of time 

emi ssions observed 

3 

a

No opac i ty read i ngs above 0.0 were observed. 

Range of 

i ndivi dua l readi ngs 

a 

a 

0 to 5 

5 to 30 

b 

5 to 10 

L i ght read i ng, l ux 

175 
TAB LE C-7. SUMMARY OF EMISSION TEST RESU LTS--MATTE TAPPING OF THE 

OUTOKUMPU FLASH FURNACE AT THE PHE LPS DODGE- P LAYAS SME LTER 

E stimated 

Eroduction Parti cul ate Sul fur d i oxide 

Source/test Tons Taps l b/ha l b/ton

b l b/ha l b/ton

b 

����� i���!�� ��u��:r

c 

EMB-009 HMT 200 9 51 0 . 25 320 1 . 6 

EMB-011 HMT 208 9 48 0 . 23 360 1.7 

EMB- 013 HMT 183 8 35 0.19 270 1 . 5 

Average 197 45 0 . 22 317 1 . 6 

Matte tapping at the 

f l ash furnace doghouse hoodi ng

c 

EMB-010 HDH 200 9 6.2 0 . 031 16 0 . 081 

EMB-012 HDH 208 9 9.9 0.048 37 0 . 18 

EMB-015 HDH 183 8 3 . 1 0 . 017 33 0 . 18 

Average 197 6 . 4 0.032 29 0 . 15 

Matte tappi ng at the 

flash f urnaced

doghouse hood i ng 

EMB-023 HDHL 144 7 8. 6 0. 060 24 0 . 16 

a

lb of pol l utant/h of samp l i ng. 

b lb of pol l utant/ton of matte tapped. 

c

Wi thout l anci ng. 

d

Wi th l anci ng. 

C- 11 
TAB LE C-8 . SUMMARY OF EMI SS IONS TESTS RESULTS- - SLAG SKIMM ING OF THE 

ELE CTRIC S LAG C LEAN I NG FURNACE AT THE PHE LPS DODGE- P LAYAS SMELTER 

Esti mated 

Qroducti on Part i cul ate Sul fur dioxi de 

Sou rce/test Tons Taps l b/ha l b/tonb l b/ha l b/tonb 

S l ag skimmi ng 

EMB- 054 HSS 142 3 11 0 . 075 120 0 . 86 

EMB-055 HSS 140 4 10 0 . 073 150 1 . 10 

EMB-056 HSS 180 6 12 0 . 069 120 0 . 68 

Average 154 11 0 . 072 130 0 . 88 

a

lb of pol l utant/h s amp l i ng. 

b

lb of pol l utant/ton of slag skimmed. 

C- 12 
TAB LE C- 9. SUMMARY OF EMI SSION TEST RESULTS- - E LECTRI C S LAG CLEANI NG 

FURNACE SCRUBBER AT THE PHELPS D ODGE- P LAYAS SME LTER 

Sul furic aci d Parti cul ate Sul fur d i oxi de 

Source/test l b/ ha 1 b/ha' 

l b/ha 

Inl et b EMB - 016 HS I 100 200 

EMB-020 HS I b 110 150 

EMB-022 HSI b 120 280 

EMB- 050 HS I 8c 0.06 100 170 

EMB- 052 HS I 8c 0 . 00 83 110 

Average 0 . 03 100 180 

Outlet b EMB- 017 HSO 1 . 3 160 

EMB-019 HSO b 0 . 98 63 

EMB-021 HSO b 1 . 4 17 

EMB- 051 HS08 0.10 19.0 70 

EMB- 053 HS08 0. 04 1 . 9 31 

Average 0 . 07 4 . 9 99 

a lb of pol l utant/h of s amp l i ng. 

b

Resul ts are to be cons i de red only approx i mate ly representati ve of the 

s crubber conditions due to abnormal operat i on of the ESCF dur i ng the 

s amp l i ng pe ri od. 

c

Oid not s ample for sul furic aci d m i st. 

C-13 
TAB LE C-10. SUMMARY OF VISIBLE EMI SSIONS DATA- - MATTE TAP PING OF THE 

OUTOKUMPU FLASH FURNACE AT THE PHE LPS DODGE- P LAYAS SMELTER 

Number of taps 

observeda,b 

3 

8 

1 

6 

1 

Number of taps 

obse rvedc 

1 

1 

1 

2 

Number of taps 

observedb,d 

1 

1 

1 

2 

Number of taps 

observedc 

1 

1 

1 

Average opac i ty , 

percent 

20 

20 

20 

40 

30 

Percent of time 

emi ssi ons observed 

100 

100 

100 

100 

Average opaci ty, 

percent 

30 

35 

45 

40 

Percent of time 

emi ssi ons observed 

100 

100 

100 

a

lanc i ng emi ssions not i nc l uded. 

Total observat i on 

time, m i n : sec 

32: 00 

55: 00 

21: 00 

30: 00 

4: 00 

Total observation 

time, mi n : sec 

9 : 36 

7 : 27 

11: 15 

12: 08 

Total observat i on 

time, m i n: sec 

13: 00 

10 : 00 

9 : 00 

23: 00 

Total observ at i on 

time , mi n : sec 

7:42 

10 : 20 

11: 05 

b

Based on v i s ual observat i ons made in accordance with E PA Method 9. 

c

Based on v i sual observati ons made in accordance with EPA Method 22. 

d

lanc i ng emi s sions i nc l uded. 

C- 14 
TAB LE C-11. SUMMARY OF VISI B LE EMI SSIONS DATA- -SLAG SKIMMING AND 

MATTE TAPPING OF THE E LECTRI C S LAG CLEANI NG FURNACE AT THE 

PHE LPS DODGE- P LAYAS SME LTER 

Operati on 

Slag ski mmi ng

a 

Matte tapp i ng

a 

Summary 

Method 9. Approxi mate ly 1 . 5 hours of opaci ty 

observati ons were made for two l aunders . The average 

opaci ty of fugi tive emi ssions escap i ng one l aunder 

was 40 percent , wh i le the average opaci ty of 

emi ssi ons from the other l aunder was l ess than 35 

percent. 

Method 22. Two slag skimming l aunders were obse rved 

for a total of 108 m i nutes . Emi ssi ons e scaped from 

one l aunder 99 percent of the time and from the 

other 81 percent of the time. 

Method 9. Based upon 24 m i nutes of observati on at 

a singl e l aunder , the fugi tive emi s s i ons e scaping 

capture had an average opaci ty of 45 percent. 

Method 22. One l aunder was observed for approx i ­

mate ly 11 m i nutes. Duri ng thi s peri od , fugi tive 

em i s sions were escap i ng 82 percent of the time. 

a

Lanci ng emi s sions i ncl uded . 

C- 15 
TAB LE C-12. SUMMARY OF VISIBLE EMISSIONS DATA- - ESCF 

OFFGAS PARTICULATE SCRUBBER 

The s crubber is not a fugitive source ; t herefore , no Method 22 

observ ations were performed. 

Method 9. Based on a total of approximate ly 8 . 5 hours of observ ations , 

the average s crubber opacity was l ess than 5 percent. 

C-16 
Run 

no . 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

TAB LE C-13 . VISIBLE EMI SSION OBSERVATI ON DATA FOR ROASTER CALC INE 

Date 

6/24 

6/24 

6/24 

6/25 

6/25 

6/25 

6/25 

6/25 

6/26 

6/26 

6/26 

6/26 

6/26 

D I SCHARGE I NTO LARRY CARS ( EPA METHOD 22) 

AT ASARCO- TACOMA 

Observer 1 

Durati on 

of % time 

operation, emi ssions 

mi n: sec observed 

1 : 20 0 

2:40 0 

1 : 20 0 

1 : 23 0 

1 : 58 0 

1 : 42 0 

1 : 12 0 

1 : 20 0 

2 : 50 0 

1:48 0 

2 : 30 0 

1 : 42 0 

3 : 04 0 

Observer 2 

Durati on 

of 

operation, 

mi n: sec 

1 : 15 

2:40 

1 : 20 

1 : 23 

1 : 52 

1 : 42 

1 : 13 

1 : 20 

2 : 49 

1 : 48 

% time 

emi ssions 

observed 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

Average 

C- 17 

Mean 

duration 

of 

ope rati on , 

mi n: sec 

1 : 18 

2 : 40 

1 : 20 

1 : 23 

1 : 55 

1 : 42 

1 : 13 

1 : 20 

2 : 50 

1 : 48 

2 : 30 

1:42 

3 : 04 

1 : 54 

Mean 

% time 

emi ssi ons 

observed 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 
TABLE C-14. VISI BLE EMI SSION OBSERVATION DATA FOR MATTE TAP PORT 

AND MATTE LAUNDER ( EPA METHOD 22) AT ASARCO-TACOMA 

Observer 1 

Durati on 

of % time 

Run operation , emi ssions 

no . 

a Date mi n: sec observed 

1 6/24 

2 6/24 

3 6/24 

4 6/24 

5

b 6/24 

6 6/25 

7 6/25 

8 6/25 

9 6/25 

10 6/25 

11 6/25 

12 6/25 

13 6/25 

14 6/25 

15 6/25 

16b 6/25 

17 6/25 

18 6/25 

6 : 24 

6 : 00 

4 : 51 

6 : 05 

2 : 58 

5 : 22 

5 : 36 

5 : 08 

6 : 02 

5 : 12 

4 : 50 

5 : 23 

5 : 17 

5 : 13 

5 : 58 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

Observer 2 

Durati on 

of % time 

operati on , emi ssions 

mi n : sec observed 

6 : 36 

6 : 00 

4 : 55 

6 : 10 

5 : 22 

5 : 36 

5 : 10 

5 : 33 

5 : 13 

6 : 37 

4 : 53 

5 : 22 

5 : 18 

Average 

1 

0 

3 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

Mean 

durati on 

of 

operati on , 

m i n: sec 

6 : 30 

6 : 00 

4 : 53 

6 : 08 

2 : 58 

5 : 22 

5 : 36 

5 : 09 

5 : 48 

5 : 13 

6 : 37 

4: 52 

5 : 23 

5 : 18 

5 : 13 

5 : 58 

5 : 26 

. Mean 

% time 

emi ssions 

observed 

0 . 5 

0 

1 . 5 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 . 13 

a

Method 22 data for corres pondi ng runs at the matte d i s charge i nto the l adle 

are presented in Table C - 15. 

b

Observati ons were made only at the matte d i scharge i nto l ad le; see Table C-15. 

C - 18 
TAB LE C-15 . VISIBLE EMI SSION OBSERVATI ON DATA FOR MATTE D I SCHARGE 

I NTO LADLE ( EPA METHOD 22) AT ASARCO-TACOMA 

Observer 1 Observer 2 

Durati on Durati on 

Mean 

duration 

of 

operati on , 

mi n: sec 

Mean 

of % time of % time 

Runa operation , emi ssions operation , emi s s i ons 

no . Date mi n : sec ob served mi n : sec observed 

1 6/24 

2 6/24 

3 6/24 

4 6/24 

5 6/24 

6

b 6/25 

7 6/25 

8 6/25 

9 6/25 

10 6/25 

11 6/25 

12 6/25 

13 6/25 

14 6/25 

15 6/25 

16 6/25 

17b 6/25 

18b 6/25 

6 : 30 

5 : 49 

4 : 53 

6 : 12 

5 : 09 

5 : 21 

5 : 02 

4 : 29 

5 : 12 

6 : 16 

4: 43 

5 : 13 

5 : 15 

5 : 41 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

5 : 40 

5 : 01 

6 : 10 

6 : 31 

5 : 02 

5 : 28 

5 : 03 

4: 32 

5 : 13 

4: 45 

5 : 15 

5 : 09 

5 : 50 

Average 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

6 : 30 

5 : 45 

4 : 57 

6 : 11 

6 : 31 

5 : 06 

5 : 25 

5 : 03 

4 : 31 

5 : 13 

6 : 16 

4: 44 

5 : 14 

5 : 12 

5:46 

5 : 30 

% time 

emi ssi ons 

observed 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

0 

a

Method 22 data for correspond i ng runs at the matte tap and l aunder are 

presented in Tab le C-14. 

b

Observat i ons were made only at the matte tape and l au nder; see Tab l e C-14. 

C- 19 
TAB LE C-16. VISI BLE EMISSION OBSERVATION DATA FOR S LAG TAPPING AT 

S LAG TAP PORT AND S LAG LAUNDER ( EPA METHOD 22) 

Run 

a no . Date 

1 6/24 

2 6/24 

3 6/24 

4

c 6/24 

5 6/25 

6

c 6/25 

7 6/26 

8 6/26 

9 6/26 

10 6/26 

lld 

AT ASARCO-TACOMA 

Observer 1 Observer 2 

Durati on Durati on 

of % time of % time 

operati on , emi ssi ons operati on , emi s sions 

mi n: s ec observed 

12 : 25

b 98b 

22 : 00 15 

14 : 07 35b 

14 : 10 13 

16 : 44 11 

17 : 26 2 

16 : 14 1 

13 : 45 0 . 3 

15: 45 0 

14 : 29 0 

m i n: sec obse rved 

12 : 26b 99b 

21: 36 0 

13 : 52

b 97

b 

Average 

Std. dev. 

Mean 

duration 

of 

operation , 

min: sec 

12 : 26 

21: 43 

14 : 07 

14: 10 

16 : 44 

1 7 : 26 

16 : 41 

13 : 45 

15: 45 

14: 29 

15: 40 

Mean 

% time 

emi ssi ons 

obse rved 

8 

13 

11 

2 

1 

0 

0 

0 

4 

11 

a

Method 22 data for corresponding runs at the slag skim discharge poi nt 

appear in Table C- 18. 

b

Observati ons were made at the enti re slag tap p rocess line i nc l ud i ng the 

slag tap port , slag l aunde r , and slag di s charge i nto l ad l e, and there fo re 

are not i nc l uded in computi ng the mean of obse rvati ons . 

c

Method 9 data for correspondi ng runs appear in Table C-17 . 

C-20 
TAB LE C-17 . VIS IBLE EMISSION OBSERVATION DATA FOR S LAG TAPPING 

AT SLAG TAP PORT AND S LAG LAUNDE§ ( EPA METHOD 9) 

AT ASARCO-TACOMA 

Duration Mean Mean 

of operation , opac i ty , opac i ty, 

Run no. Date min. % % 

1 6/25 14 . 75 1 . 3 10 

2 6/25 18 10 .3 30 

Average 16 . 38 6 

Maxi mum 30 

a

Emi ssion data were taken duri ng enti re slag tapp i ng operat i on. 

C- 21 
TAB LE C-18. VISIB LE EMI SS ION OBSERVATION DATA FOR S LAG TAPPING-­

S LAG D I SCHARGE I NTO POTS ( EPA METHOD 22) AT ASARCO-TACOMA 

Observer 1 

Durati on 

of % time 

Runa b operati on , emi ssi ons 

no . ' Date mi n : sec obse rved 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

6/24 12 : 46 

6/24 21: 09 

6/24 14: 06 

6/24 14 : 05 

6/25 16 : 34 

6/25 17 : 29 

6/26 15 : 54 

6/26 13 : 48 

6/26 15 : 48 

6/26 14 : 11 

6/26 14: 45 

97 

93 

97 

82 

91 

94 

90 

86 

77 

72 

82 

Observer 2 

Duration 

of % time 

operati o n , emi ssions 

mi n : sec observed 

12 : 26 

21: 43 

13: 52 

73 

99 

95 

Average 

Std . dev . 

Mean 

duration 

of 

operati o n , 

mi n: sec 

12 : 36 

21: 26 

13: 59 

14 : 05 

16 : 34 

17 : 29 

15 : 54 

13 : 48 

15 : 48 

14: 11 

14: 45 

15 : 31 

Mean 

% time 

emi ssions 

observed 

85 

96 

96 

82 

91 

94 

90 

86 

77 

72 

82 

86 

8 

a

V i sible emi ssion observati on data by EPA Method 9 for correspondi ng runs 

are p resented in Tab l e C-19 . 

b

V i sible emi ssion observati on data for correspond i ng runs for the slag tap 

port and l aunder are presented in Tab l e C-16 . 

C-22 
TAB LE C- 19. VISIBLE EMI SS ION OBSERVATION DATA FOR S LAG TAPPING 

AT S LAG D ISCHARGE I NTO POTS (�PA METHOD 9) 

AT ASARCO-TACOMA 

D uration Mean Mean 

Run no. b of operation , opac i ty , opacity, 

Date mi n % % 

1 6/24 c 

2 6/24 c 

3 6/24 c 

4 6/25 13. 75 22. 7 50 

5 6/25 16 . 75 11. 3 30 

6 6/25 11 . 75d 16 35 

7 6/26 15 14.8 40 

8 6/26 15 10. 3 20 

9 6/26 13 5 . 5 10 

10 6/26 15 3 . 7 10 

11 6/26 

Average 14 . 32 12 

Maxi mum 50 

a

Emi ssion data were taken duri ng enti re slag tapp i ng operation. 

b

Method 22 data for correspond i ng runs appear in Table C-18. 

c

No data were obta i ned by Method 9. 

d

Read i ng started afte r fi lling of fi rst slag pot. 

C-23 
TAB LE C-20. VISI B LE EMI SSION OBSERVAT ION DATA FOR CONVERTER S LAG RETURN TO 

REVERBERATORY F URNACE ( EPA METHOD 22) AT ASARCO-TACOMA 

Observer 1 Observer 2 Observer 3 Mean 

Durati on Durat i on Duration duration Mean 

of % time of % time of % time of % time 

Run operat i o n , emi ssi ons operat i o n , emi ssi ons operati o n , emi ssi ons operation , emi ssi ons 

a no. Date mi n: sec observed mi n: sec observed mi n: sec observed m i n: sec observed 

1 6/24 1: 04 100 1 : 05 89 0 : 58 100 1 : 04 96 

2 6/24 0:47 97 0 : 47 96 0 : 46 100 0:46 98 

3 6/24 0 : 54 100 0 : 53 100 0 : 55 100 0 : 53 100 

4 6/25 0 : 55 100 0 : 55 100 

n 5 6/25 1 : 03 100 1 : 03 100 I 

N 

-'=" 

6 6/25 0 : 52 100 0 : 52 100 

7 6/25b 

8 6/26 1 : 04 66 1 : 04 66 

9 6/26 1 : 00 85 1 : 00 85 

10 6/26 1 : 15 83 1 : 15 83 

11 6/26 0 : 55 82 0:41 93 0 : 48 88 

12 6/26 

Average 0 : 58 92 

Std . dev . 11 

a

V i sib l e emi ssion observati on data by E PA Method 9 for correspond i ng runs are p resented in Tab l e C- 21. 

b

No data obtai ned by Method 22. 
TAB LE C-21 . VISI BLE EMI SS ION OBSERVATION DATA FOR CONVERTER 

S LAG RETURN TO REVERBERATORY FURNACE ( EPA METHOD 9) 

AT ASARCO- TACOMA 

Observer 1 Observer 2 

Durati on D uration 

of Average Max i mum of Average Max i mum 

Run operat i on, opac i ty, opac i ty, operati on , opac i ty, opac i ty, 

no. Date mi n: sec % % mi n: sec % % 

1 6/24 a 

2 6/24 a 

3 6/24 a 

4 6/25 1. 00 17. 5 30 1. 00 16 25 

5 6/25 1. 25 20 40 

6 6/25 1. 00 23 35 

7 6/25 0 . 75 23 35 0. 75 23 30 

8 6/26 1. 25 5 10 

9 6/26 1 . 25 11 20 

10 6/26 1. 50 12 20 

11 6/26 1. 25 13 20 

12 6/26 0. 75 5 10 

Average opac i ty for a l l read i ngs-- 15% 

Max i mum opac i ty duri ng a l l readi ngs--40% 

a Data were not obtai ned by Method 9 on 6/24/80 . 

C-25 
('"

 

I 

N 

CJ') 

TAB LE C-22 . A SUMMARY OF METHOD 22 VISI B LE EMISS ION OBSERVATI ON RA6A FOR BLISTER D I SCHARGE 

F ROM CONVERTER AT THE TAMANO SME LTER IN JAPAN ' ,c 

Total time egua l to or greater than gi ven OEac i ty 

1st b l i s ter di scharge 2nd bl i s ter d i scharge 

Opacity, % of total % of total 

% m i n: sec time m i n: sec t i me 

5 8 : 00 53 11: 30 96 

10 5 : 00 33 8 : 45 73 

15 3 : 15 22 5 : 15 44 

20 1 : 30 10 3:15 27 

25 0 : 30 3 2 : 00 17 

30 0 : 15 2 0 : 45 6 

35 0 : 15 2 

a

Observation poi nt : converter secondary hood system. 

3rd b l i ster d i s charg� 

% of total 

mi n: sec ti me 

1 : 00 29 

0 : 30 14 

0 . 15 7 

Total b l i s ter charge 

% of total 

mi n: sec time 

20 : 30 67 

14: 15 47 

8 : 30 28 

4 : 45 16 

2 : 45 8 

1 : 00 3 

0 : 15 <1 

b

Data were based on a total of 30. 5-mi nute observat i ons for three s uccess i ve b l i ster d i scharges of the 

total four b l i ster di scharges duri ng one converter cycle. Duration of each of the three d i scha rges 

observed was 15 m i nutes , 12 mi nutes , and 3 . 5 m i nutes , respecti vely. 

c

Tab l e C- 23 s ummar i zes the observati on data i nto average opac i t i es for each set of 6-mi nute data . 

d

Total of the three i ndi v i dual b l i ster di scharges . 
Set 

1 

2 

3 

4 

5 

TABLE C-23 . SUMMARY OF AVE RAGE O PACI TY FOR 

BLISTER POURING AT THE TAMANO SME LTER 

IN JAPANa 

no . 

b Average opac i ty , c

% 

6 

8 

11 

10 

9 

a

Based on same observati on data used for Table C-22 . 

b

Observati on t i me for each set is 6 mi nutes. 

c

Average of a l l s ets is 9 percent . 

C-27 
("

 

I N 

co 

TABLE C-24 . 

1st matte discharge 

Opac i ty, % of tota l 

% mi n: sec time 

5 0:45 43 

10 

25 0:15 14 

SUMMARY OF METHOD 22 VIS IBLE EMI SSION DATA FOR INDIVIDUAL A�D TgTAL MATTE CHARGES 

TO A CONVERTER OBSERVED AT THE TAMANO SMELTER IN JAPANa , ,c, 

Total time egual to or greater than given opaci ty_ 

2nd matte discharge l!9 matte discharge 4th matte discharge Total matte charge 

% of tota l % of tota l % of total % of tota l 

min: sec time mi n: s ec time min: sec time min: sec time 

0 : 45 60 0:45 43 0 2 : 15 35 

0 : 15 20 0 : 15 14 0 : 30 8 

0 : 15 4 

a

Matte Charges 1, 2, and 3 were success i ve c harges; respective c hargi ng times for Matte Charges 1, 2, 3 and 4 were 1. 75 mi n . , 

1 . 25 min . , 1 . 75 mi n . , and 1 . 75 min. , respectively. 

b

Observation poi nt: converter secondary hood system. 

c

Data are based on a total of 6 . 5-mi nute observati ons for three s ucces sive matte charges at the beginning of one converter· 

cycle and an i ntermedi ate matte charging during the cycle. Average duration of each matte charge was 1 . 5 m i nutes . 

d

Tota l of the four i ndividual matte c harges ; average opac i ty for matte charging, based on total observation , is 3 . 0 percent . 
TABLE C-25. SUMMARY OF VISIBLE EMI SSION 

OBSERVATION DATA FOR COPPER BLQW AT THE 

TAMANO SMELTER IN JAPAN 

b Set no . Average opac i ty, % 

1 

2 

3 

4 

0 

0 

0 

0 

a

Observati on po i nt: conve rter secondary hood system. 

b

Each set is based on 6-mi nute observati on. 

C-29 
TAB LE C-26. SUMMARY OF VIS IBLE EMISSION 

OBSE RVAT ION DATA FOR S LAG B LOW AT THE 

TAMANO SME LTER IN JAPAN 

Set no. b Average opac i ty , % 

1 0 

2 0 

3 0 

4 0 

5 0 

a

Observati on poi nt : conve rter secondary hood system . 

b

Each set is made up of 6-mi nute observation ; f i rst two 

sets of data a re based on observati ons duri ng 1st slag 

blow and the rema i n i ng th ree sets of data are based on 

observati ons d uri ng 2nd slag bl ow of t he total three 

slag b l ows in a converte r cyc le at the Tamano sme l te r. 

C- 30 
TAB LE C- 27. SUMMARY OF VISI BLE EMI SSION 

OBSERVAT ION DATA FOR CONVERTER S LAG POURING 

AT THE TAMANO SMELTER IN JAPANa 

Set no .

b Ave rage opacity, % 

1 

2 

0 

0 

a

Observat i on po i nt: conve rte r secondary hood sys tem. 

b

Each of two consecutive sets of 6-mi nute obs ervat i ons 

are made duri ng one slag di s charge . 

C-31 
AP PENDI X D 

( NOT US ED) 
APPEND IX E 

USE OF COAL IN THE OUTOKUMPU F LASH FURNACE AT THE TOYO SMELTER 
APPENDIX E 

USE OF COAL IN THE OUTOKUMPU F LASH FURNACE AT THE TOYO SMELTER 

At the Toyo sme l ter in J apan �1 additi onal heat is s upp l i ed to t he 

fl ash furnace by preheated a i r� coal , and o i l. Thi s sme l ter is in the 

process of converti ng from o i l to coal because of the l ower pri ce of 

the l atter. The use of coal at the Toyo sme l ter began in Apri l 1981 

and has conti nued for over 9 month s. Initial ly, pul veri zed coal was 

substi tuted for hal f of the o i l requi rement of the furnace . The coal 

is fed to each of the concentrate b urners . The rate of coal additi on 

is contro l l ed carefu l ly in order to contro l the matte grade of the 

furnace--the coal be i ng combusted p referenti a l ly to the concentrate 

feed. Personnel at the Toyo s melter have reported that no p robl ems 

have been encountered re l ated to operat i on of the flash furnace , was te 

heat bo i l er, e l ectros tat ic p recipi tator, or ac id p l ant s i nce coal has 

been used . 1 Because of the s uccessful ope rati ons , the convers ion from 

o i l to coal has p roceeded at a greater rate than expected. 

REFERENCE 

1. Moriyama , K . , T. Terayama , T. Hayashi , and T. Kimura. The 

App l i cati on of Pul veri zed Coal to the Flash Furnace at Toyo 

Sme l ter. In: Copper Smelti ng- -An Update , George , D. B. and 

J. C. Taylor ( eds.). Wa rrenda l e, PA , The Meta l l u rg i cal Soci ety 

of AIME . 1981. p. 201- 212 . 

E-3 
APPEND IX F 

COST ANALYSIS TO ESTIMATE THE I NCREMENTAL I NC REASE IN 

CAP I TAL COST I NCURRED BY INCREAS I NG SULFURIC AC ID 

P LANT GAS- TO- GAS HEAT EXCHANGER CAPAC I TY 
Case I: 

APPENDIX F 

COST ANALYS IS TO ESTIMATE THE I NCREMENTAL INCREASE IN 

CAP I TAL COST I NCURRED BY INCREASI NG SULFURIC AC ID 

PLANT GAS-TO-GAS HEAT EXCHANGER CAPAC ITY 

I ncorporate addi ti onal heat exchanger capacity in the p l ant 

des i gn to l ower the autothermal ope rati ng requi rement for a 

doub l e contact/double absorpt i on (DC/DA ) p l ant from 4 . 0-

percent S02 to 3 . 5- percent S02 . 

Based on an overal l he�t transfer coeffi cient , U, of 4 . 0 Btu/hr • ft2 • 

Heat exchanger s urface area requi red wi th a 4 . 0- percent S02 gas 

stream enteri ng the ac id p l ant converter � 4 . 15 ft2

/scfm. 

Heat exchanger s urface area requi red wi th a 3 . 5- percent S02 gas 

stream enteri ng the ac id p l ant converte r � 5 . 70 ft2/scfm. 

Heat exchanger cost (mid- 1980 dol l ars) = $25 . 22/ft2. 

I ndex i ng to mi d- 1981 dol l ars ,

t we have 

H t h t � $25 . 22 717 . 9 - $27 77/ft2 ea exc anger cos = ft2 x � - . · 

Thu s , at 4-percent S02 , the total heat exchanger cost for a DC/DA 

pl ant is esti mated as : 

4 . 15 ft2 X $27 . 77 = 

$115 . 25 

scfm ft2 scfm 

Simi l arly, at 3 . 5- percent S02 , the total heat exc hanger cost can 

be esti mated to be $158 . 29 per scfm. 

*We i senberg , I. J . , and T. Archer. 11 Feasib ility of Pri mary Coppe r 

Sme l ter Weak S02 Stream Control Rel ative to Reverberatory Fu rnace 

NSPS Exempti on , 11 Dra ft Final Report , July 1978 . 

t

Marshal l and Swi ft Equi pment Cost I nd i ces , C hemi cal Engi neeri ng, 

February 8, 1982 . 

F- 3 
Thus , the i nc remental cost , �$ , is esti mated as : 

�$ = $158. 29 - $115.25 = $43 . 04 per s cfm . 

The total i nstal l ed capital cost for a DC/DA p l ant des i gned to 

operate a utotherma l ly at 4 . 0-percent 502 is presented in F i gure 8- 1. 

At 50 , 000 scfm , th is cost is esti mated to be $26 . 21 MM. The i nc rease 

in the i nsta l l ed cap i tal cost ( due to the i ncreased heat exchanger 

capac i ty) requi red to l ower the autothermal operati ng requi rement to 

3 . 5-percent 502 is est i mated as fo l l ows : 

$

!�f�4 x 50 , 000 scfm = $2 , 152 , 000 . 00 

Thus , the i nc rease in the i nstal l ed capital cost i nc urred as a 

result of l oweri ng the autotherma l operati ng requ i rement from 4 . 0- to 

3 . 5-percent 502 is ca l cu l ated as fo l l ows : 

$28,362 , 000 . 00 = (1 + f) X $26 , 210 , 000 . 00 , 

where f = the f racti onal i nc rease in the i nstal l ed capi tal cost. 

So lving for f yi elds 

f = 0 . 082 . 

Thus , as a resul t of l oweri ng the autothermal requ i rement from 

4. 0- to 3 . 5-percent 502 , the i nstal l ed capital cost of the p l ant 

i nc reases about 8. 2 percent at the 50 , 000 scfm l evel . 

Simi l arly , at the 200 , 000 scfm l evel , the i nstal l ed capital cost 

wou ld be expected to i nc rease about 12 .8 percent . Thus , over the 

50 , 000 to 200 , 000 scfm range , reduc i ng the autothermal operati ng 

requi rement for a DC/DA p l ant from 4 . 0- to 3 . 5-percent 502 would be 

expected to i nc rease the i nstal l ed capital cost by 8.2 to 12 .8 percent . 

Case II: I ncorporate additi onal heat exchanger capacity in the p l ant 

des i gn to l ower the autothermal operat i ng requi rement for an 

singl e contact/s i ngle absorption ( SC/SA) p l ant from 3.5-

percent 502 to 3 . 0-percent 502 . 

F -4 
Based on an overal l heat trans fer coefficient , U, of 4 . 0 Btu/hr 

· ft2 • 

°

F, 

Heat exchanger s urface area requi red wi th a 3 . 5-pe rcent S02 gas 

stream enteri ng the ac id p l ant converter � 1 . 80 ft2 /scfm. 

Heat exchanger s urface area requi red wi th a 3 . 0-percent S02 gas 

stream enteri ng the aci d p l ant converter � 2 . 45 ft2/scfm. 

Heat exchanger cost (mid- 1980 do l l ars ) = $25 . 22/ft2

. 

I ndexi ng up to mi d- 1981 do l l ars yi elds a heat exchanger cost of 

$27 . 77 per square foot. 

Thus , at 3 . 5-percent S02 , the tota l heat exc hange r cost for an 

SC/SA p l ant is esti mated as fo l l ows : 

1.8 ft2 

X $27 . 77 

= 

$50 . 00 

scfm ft2 scfm 

Simi l a rly, at 3 . 0-percent S02 , the total heat exchanger cost can be 

est i mated to be $68 . 00 per scfm. 

Th us , the i ncremental cos t , �$ . is esti mated as fo l l ows : 

�$ = $68. 00 - $50. 00 = $18 . 00 per scfm 

The total i nsta l l ed capital cost for an SC/SA p l ant desi gned to 

operate autothermal ly at 3 . 5- percent S02 is p resented in F i gure 8- 5. 

At 50 , 000 scfm , th is cost is esti mated to be $22 . 68 MM . The i nc rease 

in the i nstal l ed capital cost ( due to the i nc reased heat exchanger 

capac i ty) requi red to l owe r the autothermal operat i ng requi reme nt to 

3 . 0-percent so2 is esti mated as fol l ows : 

$ 18

·

00 x 50 , 000 scfm = $90 0 , 000 . scfm 

Th us , the i ncrease in the i n stal l ed cap i tal cost i nc u rred as a 

re sul t of l owe ri ng the autotherma l operat i ng requ i rement f rom 3 . 5- to 

3 . 0-percent so2 is ca l c u l ated as: 

$23 , 580 , 000 . 00 = (1 + f ) X $22 , 680,000 . 00 , 

whe re f = the fract i onal i ncrease in the i n sta l l ed capital cost. 

Sol v i ng for f y i elds 

F-5 
f = 0 . 0397 . 

Thus , as a res u lt of l oweri ng the autothermal requi rement from 

3 . 5- to 3 . 0-percent 502 , the i nsta l l ed capital cost of the p l ant 

i ncreases about 4 . 0 percent at the 50 , 000 scfm l evel . Simi l ar ly, at 

the 200 , 000 scfm l evel the i nstal l ed cap i tal cost wou ld be e xpected to 

i nc rease about 6.4 percent . Th i s, over the 50 , 000 to 200 , 000 scfm 

range , reduc i ng the autothe rma l operati ng requi rement for an SC/SA 

p l ant f rom 3 . 5- to 3 . 0-percent so2 wou l d be expected to i nc rease the 

i nstal l ed capital cost by 4 . 0 to 6.4 percent . 

F - 6 
APPEND IX G 

ANALYSIS OF CONT I NUOUS S02 MONITOR DATA AND DETERMI NAT ION OF AN UPPER 

LIMIT FOR THE I NCREASE IN S02 EMI SS IONS DUE TO SULFURIC AC ID P LANT 

CATALYST DETERIORATI ON 

P l ease note : To p rov i de the most comprehens i ve study possi b l e, th is 

appendi x is rep ri nted , with mi nor edi torial changes , from 

Vo l ume I, P roposal Standards , of Backgro und Information 

for New Source Performance Standards : Primary Coppjr, 

Lead , and Z 1 nc Smelters , p ub l i cat1 on number EPA 450 2-74-

002a . - --
AP P END IX G 

ANALYS IS OF CONT I NUOUS S02 MON I TOR DATA AND DETERMI NAT ION OF AN UPPER 

LIMIT FOR THE I NCREASE IN S02 EMISSIONS DUE TO SU LFURIC AC ID P LANT 

CATALYST DETERIORAT ION 

G . 1 EMI SS ION VAR IATION 

S02 emi ssi ons from the No . 7 sul furi c aci d plant , wh i ch is the 

newest of fi ve sing l e- stage abs orpti on p l ants operati ng on the offgases 

from the n i ne Kennecott coppe r converters at Garfi e l d, Utah , were 

analyzed . The em i s sions we re recorded by a Du Pont 460 conti nuous S02 

analyzer from September 15 , 1972 , to November 15 , 1972 . Thi s i nstrument 

is capab le of meas uri ng S02 conce ntrati ons wi thi n ±150 ppm (2 percent 

of ful l sca l e) and automati cal ly zeroes i tsel f every 8� mi nutes . The 

zero cal i brati on procedure requ i res 1� mi nutes ; thus the i nstrument is 

11on-line 11 85 percent of the time. 

A general rev i ew of the data generated revea l ed that several 

peri ods of data we re mi ssi ng due to prob l ems wi th the recorde r. Other 

segments contai ned l ong peri ods of p l ant s h utdowns fo r ma i ntenance or 

i nc l uded concentrati ons that we re obviously g reater than the upper 

l i mi t of the monitor. (A s horter absorpti on tube cou l d have been 

i nstal l ed to i nc rease the upper l i mi t of the monitor , if thi s s i tuation 

had been noti ced soone r . ) Consequent ly, on the bas is of data l egibi l i ty 

and cont i nu i ty , the peri ods of October 11- 27 , 1972 , and November 8- 15 , 

1972 , we re sel ected as rep resentati ve of the 2-month mon i to ri ng peri od . 

Peri ods of emi ssions duri ng wh i ch the average concentrat i o n 

appeared to be greater than 3,000 ppm or l ess than 1,000 ppm we re then 

noted . E i ghteen pe ri ods duri ng wh i c h emi s sions exceeded 3,000 ppm , 

i nc l udi ng two peri ods duri ng wh i c h emi ssio ns exceeded the reco rdi ng 

capac i ty of the Du Pont ana l yzer ( 7 , 500 ppm) , were i denti fied. Fourteen 

G- 3 
peri ods duri ng wh i ch emi ssi ons were l ess than 1,000 ppm were a l so 

i denti fied. Ac id p l ant operati ng l ogs and i n l et 502 vol ume and concentrati on conti nuous mo nitor data were anal yzed to ascerta i n if upsets , 

mal funct i ons , or startups and shutdowns occurred duri ng these peri ods . 

One major upset/mal function was d i scerned. It occurred duri ng 

one of the two peri ods dur i ng wh i ch the emi s s i ons exceeded the record i ng 

capac i ty of the analyzer. The upset/mal function resul ted from pro l onged 

l ow i n l et 502 concentrati ons , wh i ch caused a decrease in the normal 

temperature i nc rease across the f i rst catalyst bed . Consequently , 

th is peri od of exces sive emi s sions was del eted from the data . Six 

shutdowns and startups were noted. The six peri ods of l ow emi ssi ons 

fo l l owi ng these s h utdowns were del eted from the data because the ac id 

p l ant was not in operation. Two peri ods of high emi ssi ons were i denti ­

fi ed fo l l owi ng two of the six startups. These two peri ods of high 

emi s sions were al so del eted from the data. Due to the time constra i nts 

p l aced on the analys i s of these data , no i nvesti gati on of why four of 

these six startups had no associ ated peri ods of high emissions was 

conducted . A bri ef i nvesti gati on of the e i ght remai n i ng peri ods 

duri ng wh i ch emi s sions were l ess than 1,000 ppm , however , did reveal 

that these l ow emi s s i ons appeared to be the result of almost i deal 

operat i ng conditi ons wi thi n the ac id plant , wi th somewhat l ow i n l et 

gas vol umes and 502 concentrat i ons and a mi n i m um of f l uctuat i ons in 

e i ther of these vari abl es . 

Fol l owi ng th is review of ac id p l ant operati ng data , fi fteen 

peri ods duri ng wh i c h emi ssi ons were h i gher than 3 , 000 ppm remai ned . 

Thi s i nc l uded one of the two peri ods p reviously i denti fi ed as peri ods 

duri ng wh i ch emi s sions exceeded the capac i ty of the Du Pont analyzer. 

Thi s peri od was then del eted from the data for the fol l owi ng reasons . 

First , and most i mportant , because no knowl edge concern i ng numeri cal 

val ues of emissions was avai l abl e, thi s time peri od could not be 

mathemat i cal ly accounted for in the analysis. Second , because emi ssions we re apparently so great , thi s peri od of operation wou l d represent a violation of any reasonab l e standard deve l oped and thus wou l d 

add noth i ng to the anal ysis of " normal " operati ng emi ssi ons data to 

p rov i de a bas i s for s uch standards. 

G-4 
The l ong- term 502 emi ssions concentration average was then cal c ul ated for a l l the data generated duri ng the 11 normal operat i ng11 port i ons 

of the October 11- 27 and November 8-15 peri ods . F i fteen-m i nute i ns tantaneous 502 concentrati on val ues were used for thi s cal cul ati on , and 

the l ong- term emi ssion average was determi ned to be 1,700 ppm. It is 

sign i fi cant to note that thi s val ue is consi de rab ly l ess than the 

emi s sion concentrati on correspondi ng to Monsanto 's guaranteed conversion effi c i ency of 95 percent convers i on of 502 to 503 at 5 percent 

502 i n l et , i.e . , approxi mate ly 2 , 700 ppm . 

The 14 peri ods of high emi ssi ons that were not de l eted from the 

data were then exami ned by ave rag i ng these peri ods over var i ous time 

i nterva l s usi ng the 15-mi nute i nstantaneous 502 concentrati on val ues 

i denti fi ed duri ng the above ana l ysis. The time- ave raged concentrat i ons 

were then compared to vari ous out l et 502 concentrati on l eve l s to 

dete rmi ne the extent to wh i c h such averagi ng peri ods mas k vari ati ons 

in outl et concentrati on. The res ults are tabul ated in Tab l es G- 1 and 

G- 2. 

Seven of the fou rteen h i gh- emi ssion peri ods exceeded 2 , 700 ppm 

(equ i val ent to the manufacturer 's guarantee ) when ave raged for a 

6- hour duration. I nc reas i ng the averag i ng time to 7 hours decreased 

the number of peri ods exceedi ng 2,700 ppm to five. Further i nc reases 

in the averag i ng peri od resul ted in only mi nor decreases in the number 

of peri ods exceedi ng 2,700 ppm . I nc reas i ng the l evel of average 502 

emi ssion concentrat i on from 2,700 ppm to 3 , 000 ppm ( approxi mate ly 

10 percent) caused a significant reduction of the number of hi ghemi ssion peri ods that exceeded thi s l evel as compared wi th 2,700 ppm . 

For each ti me- averag i ng i nterva l , the number of peri ods for wh ich the 

averages exceed 3,000 ppm is about hal f the numbe r of peri ods correspondi ng to 2,700 ppm . I ncreas i ng the l evel of average 502 emi ssion 

concentrati on from 2 , 700 to 3,250 ppm ( approx i mately 20 percent) 

resul ted in only a s l i ght decrease in the number of peri ods exceedi ng 

th is leve l compared to the numbe r of peri ods exceedi ng 3,000 ppm . In 

genera l , therefore , i ncreas i ng e i ther the averagi ng time to peri ods 

greater than 6 hours , or i ncreas i ng the average 502 emi ssion concentraG-5 
TAB LE G- 1. SUMMARY OF PERIODS EXCEEDI NG THE REFERENCE LEVEL S02 

CONCENTRATION AS A FUNCTI ON OF AVE RAG I NG TIME 

Concentra- 4- h 6- h 7- h 8- h 12- h 

ti on ( ppm) average average average average average 

2,700 13 7 5 5 3 

3 , 000 8 4 3 3 1 

3 , 250 5 3 3 2 0 

TABLE G- 2. SUMMARY OF TOTAL TIME EXCEED I NG THE REF ERENCE LEVEL S02 

CONCENTRATION AS A FUNCTION OF AVERAG I NG TIME 

Concentra- 4- h 6- h 7- h 8- h 12- h 

ti on ( ppm) average average average average average 

2 , 700 112 (21) 76 ( 14) 62 (11) 62 ( 11) 42 (8) 

3,000 61 ( 11) 40 (7) 33 (6) 33 (6) 13 (2) 

3,250 40 (7) 30 (6) 30 (6) 22 (4) 0 (0) 

NOTE : Numbers in parentheses i nd i cate percentage of time for wh i ch 

the emi s sions wou ld exceed the reference concentrati on. The 

total 11norma l 11 operati ng ti me of 542 hours equa l s 100 percent . 

G-6 
ti on sel ected for compari son by more than 10 percent above the manufacturer 's guarantee , does not sign i fi cantly decrease the number of 

hi gh-emi ssion pe ri ods that exceed the l evel of S02 emi ssion concentrati on sel ected for compari son. 

Another approach is to exami ne the actua l time duri ng wh i c h S02 

emi ssi ons exceeded vari ous sel ected concentrati on l evel s, such as 

2,700 , 3 , 000 , and 3,250 ppm . These data are tabu l ated in Tab l e G- 2. 

An exami nati on of these data l eads to the same conc l usi ons p resented 

above . Thus , based on thi s analys is and not cons i deri ng catalyst 

deteriorati on , it appears that an averagi ng time of 6 hours is sui tab l e 

for dete rmi ning S02 emi ssion concentrat i ons and that emi s sions l eve ls 

estab l i s hed somewhat above commonly accepted vendor/contracto r guarantees by 10 to 20 percent could be v i ewed as acceptab le for purposes 

of a l l owi ng norma l , s ho rt- te rm fl uctuati ons . 

G . 2 CATALYST DETERIORAT ION 

Due to the l ack of substant i al numerical qual i fi cati on of the 

effect of catal yst deteri orat i o n on S02 emi s sions from sul furi c ac id 

pl ants , S02 emi ssion data gathered by simu l taneous U . S. Envi ronmental 

Protecti on Agency (EPA) source testi ng of the No. 6 and No . 7 p l ants 

at the Kennecott Garfi eld sme l ter duri ng the peri od of J une 13-16 , 

1972 , were analyzed . The No. 6 ( Parsons) p l ant began operati ng in 

February 1967 and was in the second month of i ts 12-month cata l yst 

c l ean i ng cycle duri ng the source test. The No. 7 ( Monsanto) p l ant 

began operat i on in S eptember 1970 and was in the twe l fth and l ast 

month of i ts cata lyst cleani ng cycle. The S02 emi s sion data are 

tabul ated in Table G-3. 

A stati stical analysis of these data l eads to the concl us i on that 

the 30- percent greater ave rage emi s s i ons of the No . 7 p l ant , compared 

to the average emi ssi ons of the No. 6 plant , are statistica l ly signifi cant at the 90-percent p robabi lity l eve l . It s houl d be noted , however , 

that th is di fference in em i s sio ns re f l ects not only cata l yst deteri orati on but other facto rs as we l l, s uch as a d i ffe re nce in emi ssi ons due 

to des i gn or construct i on variat i ons between Parsons 1967 ac id p l ant 

techno l ogy and Monsanto 1970 ac id p l ant technol ogy . On the other 

G-7 
Run 

2 

3 

4 

5 

6 

7 

8 

9 

10 

Average 

TAB LE G- 3. SUMMARY OF OUTLET S02 

CONCENTRAT IONS (ppm) 

No . 6 P l ant 

389 

753 

1,036 

1,745 

938 

1,608 

7 94 

1 , 1 28 

930 

1,036 

G-8 

No. 7 P l ant 

296 

855 

2,277 

1,207 

1,131 

2,553 

1 , 104 

1 , 355 

1 ,433 

1,357 
hand , it is p robab ly safe to assume that the major portion of th is 

d i fference in emi s s i ons is due to cata lyst deterioration. Thus , the 

res ults of th is ana lysis can be rev i ewed as i ndicat i ng f i rst , that 

cata lyst deteri o rati on does not have a s i gni fi cant effect on S02 

emi ssi ons and second , that wi th a 12-month catalyst c l ean i ng cyc l e, 

thi s di fference in emi ssi ons due to deteri oration appears to be of the 

order of magn i tude of 30 percent. 

G . 3 ADD IT IVE EFFECT OF EMI S S ION VAR IATIONS AND CATALYST DETERIORATION 

As di scussed above , not cons i deri ng catalyst deteri oration, 

sul furi c ac id p l ant performance standards based on 6-hour S02 emi ssion 

l eve ls 10 to 20 percent greater than commonly accepted vendor/contractor 

guarantees appear to be appropri ate to al l ow s hort- term fl uctuati o ns 

in S02 emi ssions . As al so di scus sed above , the i nc rease in S02 em i s ­

sions duri ng the 12-month catalyst cleani ng cycle can be esti mated to 

be 30 percent . Based on the conservat i ve assumpti on that cata lyst 

deteri oration is an i nc reas i ng exponential funct i on of time, almost 

a l l of the effect of catalyst deteriorat i on wi ll occur duri ng the 

second hal f of the cleaning cycle. Because the emi ssi on vari at i on 

data we re based on the fi fth month of the cata lyst c l eaning cycle, the 

data do not i nc l ude sign i ficant catalyst deteri oration and the i nc rease 

in S02 emi ssi ons due to catalyst deteri orati on s hould be added to the 

al l owance for new cata lyst em i s sion vari ati on. Thus , cons i deri ng 

s hort- term fl uctuat i ons of S02 emi s sions and usi ng conservat i ve as s umpt i ons regard i ng catalyst deteri orati on , new source pe rformance s tandards 

( NSPS ) can possibly be based upon 6- hour emi ssi on l eve ls estab l i s hed 

40 to 50 percent greater than commonly accepted vendor/contractor 

guarantees . 

G-9 
APPEND IX H 

SULFUR DIOXIDE EMISS ION TEST RESULTS FOR SING LE- STAGE 

ABSORPTION SULFURIC ACID P LANTS P ROCESS I NG 

METALLURGI CAL O FFGAS STREAMS F ROM 

PRIMARY COPPER SMELTERS 

P l ease note : To p rov i de the most comprehens i ve study poss i b le, th is 

append ix is repri nted , wi th mi nor ed i torial c hanges , from 

Vo l ume I, Proposal Standards , of Background I nformat i on 

fo r New Soruce Performance Standards : Pri mary Coppjr, 

Lead�nd Z 1 nc Sme l ters , p ub l 1 cat1 on number EPA 450 2- 74-

002a. - --
APPEND IX H 

SULFUR D IOX IDE EMISSION TEST RESULTS FOR SINGLE- STAGE 

ABSORPTION SULFUR IC AC ID P LANTS P ROCESS I NG 

METALLURGICAL O F FGAS STREAMS F ROM 

PRIMARY COPPER SMELTERS 

H . l BACKGROUND 

Before emi s sions te sti ng began in May 1972 , the U . S. Envi ronmental 

Protect i o n Agency ( EPA) s urveyed a l l sul fur d i ox i de ( S02 ) contro l 

systems at domestic primary copper smel ters to dete rmi ne wh ich were 

most e ffecti ve. Us i ng the survey re sul ts, EPA se l ected for em i s sion 

testi ng the fac i l i t i e s exhib i ti ng the most advanced system des i gn or 

h i ghest degree of 502 emi ssi on reduction. The fac i l i ti es sel ected 

cons i st of three sing l e- stage absorpt i on ac id p l ants that treat o ffgasses from two di fferent copper converti ng ope rati ons . A l l fac i liti es 

were tested fo r 502 emi s s i ons usi ng Reference Method 8 contai ned in 

Ti tle 40 of the Code of Federa l Regu l ati ons , Part 60 (40 CFR 60) , 

Append ix A, fi rst pub l i s hed in the Federal Regi ster on December 23 , 

1971. Later , after one had been i nstal l ed at a domestic copper smelter, 

a doub l e- absorpti on ac id p l ant was a l so te sted . The analys is of th is 

test is i nc l uded in Append ix I . 

Duri ng the i n i ti a l portion of the test i ng program , the best 

domes tic S02 contro l techno l o gy was consi de red to be sing l e- stage 

absorpt i on sul furi c aci d p l ants ( s ee Secti on 4 . 2). Thus , ac id p l ants 

handl i ng co nve rte r offgases had to be tested to determ i ne the effects 

on ac id plant pe rformance of h i gh ly va ri able inlet 502 concentrati ons 

and flow rates. 

A l l sing l e- stage abso rpt i on ac id p l ant tests were i n ital ly cond ucted us i ng Method 8 of 40 CFR 60. However, to ga in l ong-term 

operat i onal data , an 8-week conti nuous mon i tori ng test p rogram was 

H-3 
a l so conducted at one i nsta l l ation to monitor the frequently unsteady 

nature of converter offgas s treams . The converter operati on is a 

batch operati on and , dependi ng upon the number of converters in operati on and the i r schedu l i ng, wi ll p roduce S02 concentrat i ons and flow 

rates rangi ng from 0 percent to approxi mate ly 9 percent and f l ow rates 

rangi ng from 0 to the max i mum blowi ng capac i ty of the converters . 

P l ant operati ng l ogs , ac id p l ant i n l et vol umetri c flow rate 

charts , absorber and converter temperature charts , and i n l et concentration c harts were rev i ewed to determine the operati ng conditi on of ac id 

p l ants dur i ng the conti nuous mon i tori ng p rogram . Peri ods of startup 

and shutdown were e l imi nated from the data analysis, and the l ong-term 

S02 emi ssion concentrati on averages were determ i ned from the remai n i ng 

val id data po i nts . Fina l ly, vari ous ave ragi ng techn i ques were used to 

determine the most appropri ate averagi ng i nterval , thereby mas ki ng the 

effect of massi ve s hort-term f l uctuati ons . 

H . 2 SUMMARY OF TEST RESULTS 

H . 2 . 1 ASARCO- -Hayden , Ari zona 

The copper converter s i ng l e-absorpti on ac id p l ant at the ASARCO 

sme l ter in Hayden, Ari zona was tes ted duri ng the week of J une 19 , 

1972. The test consi s ted of e i ght separate runs us i ng Reference 

Method 8 of 40 CFR 60 . Two of the test runs were aborted because 

e i ther the test equ i pment or the ac id p l ant mal functi oned . Test 1 

consi sted of two samples , one for each orthogonal axi s, whose resul ts 

were comb i ned to determ i ne an overa l l emi s sions rate . In addi ti on to 

the manual tests , conti nuous S02 monitori ng was performed at the site 

for 2 days to p rov i de comparati ve data experi ence for future tests . 

No s tati sti cal analys i s of the cont i nuous mon i tori ng data was performed. 

The ASARCO sme l te r has fi ve copper converters , each requi ri ng 

approxi mate ly 8 hours to process a batc h of copper matte . The gas 

fl ow to the ac id p l ant from the converters is as h i gh as 2,830 Nm3/mi n 

( 100 , 000 scfm ) , depend i ng upon the number of co nverters in operati on. 

The gas s tream to the ac id p l ant has an S02 concentrat i o n of 4 to 

9 percent . 

H-4 
The converter emi s s i ons are contro l l ed by a 750-ton-per- day ( tpd) 

s i ngl e- absorption sul furi c ac id p l ant desi gned by C hemi ebau of West 

Germany and bui lt in 1972 by Rust Engi neeri ng , U.S. C hemi ebau 1s l i censee . 

Thi s ac id p l ant was des i gned to p rocess an i n l et gas f l ow up to 2 , 830 

Nm3/mi n ( 100 , 000 scfm) at an S02 concentrati on of 4 percent . The aci d 

p l ant has a four- stage capab i l i ty, but only three cata lyti c stages 

were active duri ng the test. 

Table H-1 s ummari zes the res u l ts of the Hayden emi ssion te sts . 

H . 2 . 2 KENNECOTT--Garf iel d, Utah 

The metal l urg i ca l , s i ng l e- stage absorpti on sul furi c ac id p l ants 

at the Kennecott sme l te r in Garfi e l d, Utah , were tested duri ng the 

week of J u ne 19 , 1972 . A tota l of 20 ac id mi st and S02 emi s sions tests 

were conducted on two of the five ac id p l ants . Spec i fi cal ly, P l ants 6 

and 7 we re tested usi ng Method 8 of 40 CFR 60 , wi th 10 tests performed 

on each. Tables H-2 and H- 3 summari ze the manual emi ssi ons test 

re sul ts from the Kennecott- Garfi e l d ac id p l ants . In addition, a 

conti nuous S02 monitor was used to record l ong- term emi ssi ons from 

pl ant 7. 

At the time of testi ng , 9 conve rte rs were in p l ace at the Garfi eld 

fac i lity. Al l offgas es from these converters we re ducted to six 

s i ngl e- stage absorpt i on sul furi c ac id p l ants . Converte r operations 

were schedul ed to ma i ntain a re l at i vely constant S02 concentrati on in 

the ac id p l ant feed s treams . Each ac id p l ant was des i gned to p rocess 

a gas stream wi th an 502 concentrat i on between 2 and 8 percent. The 

f l ow rate to each ac id p l ant vari ed from 850 to 1 , 980 Nm3/min ( 30 , 000 

to 70 , 000 scfm) , depend i ng upon the numbe r of converters in operation. 

Ac id p l ants 6 and 7 we re chosen for the tests because they we re 

then the newest i nsta l l ations at the fac i l i ty. P l ant 6, des i gned by 

Parsons Co. , began ope rati ons in February 1967 , was in the second 

month of i ts cata lyst clean i ng cyc le duri ng the test p rogram , and is 

capab le of proces sing up to 2,830 Nm3/m in (100 , 000 scfm) of gas at a 

concentrati on of 2 to 8 percent. P l ant 7, des i gned by Monsanto 

Env i ro-Chem and const ructed by Leonard Con struct i on Company , comme nced 

operati on in September 1970 , was des i gned to hand le the flow rate 

H -5 
TABLE H- 1. SUMMARY OF EMISS ION TEST DATA OBTAI NED ASARCO-HAYDEN , JUNE 1972a 

Run number 

1 2 3 4 5 Average 

Date June 20 June 20 June 21 June 21 June 22 

Test time (min) 145 144 144 145 144 144 

Stack effl uent 

Flow rate 

dscm/min 2 , 192 2,257 2,072 2,100 2,136 2,151 

(dscfm) ( 78 , 300) (80 , 600) ( 74,000) { 75,000) (76 , 300) (75, 770) 

Temperature , 

oc 47 37 43 34 40 40 

(OF) ( 116. 00) (99. 00) ( 110 . 00) (93. 00) ( 104 . 00) ( 104 . 00) 

Pres sure , 

mm Hg 699 708 708 694 694 701 

(in . Hg) (27. 5) ( 27 . 87) ( 27.87) (27. 33) (27. 33) (27. 58) 

::c 

I Cl Acid p 1-ant S02 

emi ssions 

ppm ( by vol ume) 2 , 238 3,994 3,313 2,593 3,086 3,117 

kg/dscm x 10 -3 29 .1 51. 9 43 .0 22 .9 40.1 3 7.4 

( l b/dscf x 10-5 ) ( 37 . 4) ( 66.8) ( 55.4) ( 29 . 5) (51. 6) ( 29 . 06) 

kg/h 3 , 850. 0 7,106.0 5,411. 5 2,920 .5 5,197 .0 4 ,896.6 

{lb/h) (1,750 . 0) (3,230) .0 (2,459. 7) (1,327 . 0) (2,36 2. 0) (2,225. 7) 

a

A s i ngl e- stage absorption of Chemi ebau des i gn was tested. The plant processed copper converter offgases. 
TABLE H�2. SUMMARY OF EMI SSION TEST DATA OBTAI NED AT THE NO. 6 ( PARSONS) � INGLE�STAGE 

ABSORPTION SULFURIC ACID PLANT AT KENNECOTT-GARF IELD , JUNE 1972 

Run number 

1 2 3 4 5 6 7 8 9 10 Average 

Date June 13 June 14 June 14 June 14 June 15 June 15 June 15 June 16 June 16 June 16 

Test time (mi n) 112 56 56 112 112 112 112 112 112 112 101 

Stack effl uent 

Flow rate 

dscm/min 1,744 1 ,494 1 , 661 1,606 1,975 1 , 914 1,891 1,894 1,972 1 ,850 1,800 

(dscfm) ( 62,800) (53 , 300) ( 59,800) ( 57,900) (71 , 100) (68 , 900) (68, 100 ) ( 68,200 ) ( 71,000) (66 , 600) ( 64,804) 

Temperature , 

oc 77 76 74 74 96 95 82 77 83 80 81 

(OF) ( 169.0) ( 167.0) ( 165 . 0) ( 164 . 0) ( 203.0) ( 196.0) ( 181. 0) ( 169 . 0) ( 182.0) ( 175. 0) ( 178 . 0 ) 

Pres sure, 

mm Hg 734 734 734 7 34 735 735 735 734 734 734 734 

(in. Hg) ( 28. 90) ( 28. 90) ( 28. 90) ( 28 . 90) ( 28. 92) ( 28 . 92) ( 28 . 92) ( 28. 90) (28. 90) (28 . 90) (28.9 1) 

I Concentrati on ( S02) 

'-J 

ppm (by vol ume) 126 388.5 752 1,036 1,744 938 1,608 7,940 1,128 .0 930.0 944.7 

-4 kg/dscm x 10 16 .3 50 .5 97. 1 134. 0 227. 0 122.0 209 . 0 103 . 0 146.9 930. 0 122.6 

(lb/dscf x 10�6

) ( 21) (65) ( 125) ( 173) (292) ( 157) ( 269) ( 133) ( 189) ( 155) ( 158) 

kg/h 174.0 457.4 986 . 7 1,322 .0 2,740 . 5 1,445 .0 2 ,417.8 1,156. 8 1,771. 0 1,361. 8 1,383. 3 

(lb/h) ( 79.1 ) (207.9) ( 448 . 5) ( 601.0) ( 1 , 245 . 7) (657 .0) (1,099.0) ( 544.0) ( 805 . 0) ( 619.0) ( 628 . 7) 

a

The ac id p l ant tested processed copper converter offgases . 
::c 

I 

C'J 

1 

Date June 13 

Test time (mi n) 111 

Stack effl uent 

Flow rate 

dscm/mi n 1,747 . 0 

( dscfm) ( 62,900) 

Temperature , 

oc 57 

( oF) ( 135. 0) 

Pressure , 

mm Hg 734 

(in. Hg) (28 . 91) 

Concentrati on ( S02) 

ppm ( by vol ume) 553 

-

4 kg/dscm x 10 71. 9 

( l b/dscf x 10-

6

) ( 92.5) 

kg/h 768. 0 

(lb/h) ( 349. 0) 

-

TABLE H- 3. SUMMARY OF EMI SSION TEST DATA OBTAINED AT THE NO . 7 (MONSANTO) SINGLE- STAGE 

ABSORPTION SULFURIC ACID P LANT AT KENNECOTT-GARF IELD, JUNE 1972a 

Run number 

2 3 4 5 6 7 8 9 

June 14 June 14 June 14 June 15 June 15 June 15 June 16 June 16 

56 56 112 112 112 112 112 112 

1,675. 0 1,500. 0 1,643 . 0 1,958 . 0 1,783 . 0 1,916. 0 1,875 . 0 1,930. 6 

( 60 , 300) ( 54,000) ( 59,150) ( 70,500) ( 64 , 200) ( 69,000) (67 , 500) (69, 500) 

51 59 56 60 56 64 56 56 

( 124 . 0) ( 138. 0) ( 134. 0) ( 139. 0) ( 133. 0) ( 146 . 0) ( 134. 0) ( 134 . 0) 

734 734 734 735 735 735 734 734 

(29 . 90) (28 . 90) (28. 90) (28. 92) (28. 92) (28. 92) (28. 90) (28. 90) 

296 855 2,277 1,207 1,131 2 , 553 1,104 1 , 355 

38.4 111. 1 296.0 160 . 0 146 . 9 331. 8 143 . 7 176.4 

(49.5 ) ( 143.0) ( 381.0) (202. 0) ( 189.0 ) (427.0) ( 185.0) ( 227.0) 

393 . 8 1,019 . 0 2,974. 8 1,879 . 8 1,601. 7 3 , 889. 0 1,648. 0 2,082. 5 

( 179. 0) ( 463.0) (1,352 . 0 ) (854.0) ( 728.0) (1,767 . 8) ( 749. 0) ( 946.6) 

a . 

The acid p l ant tested processed copper converter offgases. 

10 Average 

June 16 

112 100 . 7 

1,905. 6 1,793. 0 

(68 , 600) ( 64,560 ) 

56 

( 134 . 0) 

734 734 

( 28. 90) (28. 90) 

1,433 1,276 

186 . 5 166 . 0 

(240 . 0) (213.6) 

2,173 .0 1,842. 7 

( 987.8) ( 837.6) 
fl uctuati ons and S02 concentrati on associ ated wi th converter operat i ons , 

and is capab l e of handl i ng S02 concentrati ons rangi ng between 2 and 

8 percent. P l ant 7 was in the l ast month of i ts catalyst c l eaning 

cyc l e when the manual tests were performed . 

As noted earl i er, a cont i nuous mon i tori ng test p rogram was a l so 

conducted at the Kennecott-Garfi e l d fac i l i ty between September 15 , 

1972 , and November 15 , 1972 , on Ac id P l ant 7 to gather l ong- term 

emi ssi ons data . The data be i ng sought wou l d be used to determi ne an 

averagi ng time that wou l d effecti vely mas k fl uctuat i ons in ac id p l ant 

out l et concentrati ons and to eval uate the l ong- term performance capab i l ­

itie s of s i ngl e- absorpt i on ac id p l ants . These emi s sions data were 

reco rded by a Dupont 460 Conti nuous S02 Anal yzer. Because Section 4 . 2 

of thi s document di scus ses the resul ts of that test , t hey are not 

di sc ussed here . 

H - 9 
APPEND IX I 

ANALYS IS OF DUAL-ABSORPTION AC ID P LANT CONT I NUOUS S02 

MON ITOR I NG DATA 

P l ease note : To p rov i de the most compre he nsi ve st udy possi b l e, this 

append ix is repri nted , with minor ed i to r ial changes , from 

Vo l ume I, Proposa l Standards , of Background I n formation 

for New Soruce Performance Standards: Pri mary �, 

Lead�nd Z1nc Sme l ters , p ub l 1 cat1 on number EPA- 45U72- 74-

002a . - --
APPEND IX I 

ANALYS IS OF DUAL-ABSORPTION ACID P LANT CONTI NUOUS 502 

MON I TORING DATA 

I . l I NTRODUCTION 

The dua l - absorpti on sul furi c ac id p l ant at the ASARCO copper 

sme l ter at El Paso , Texas , was the fi rst system of i ts type to be used 

in the domesti c nonferrous smelt i ng i ndustry. The 502 emi ssi ons from 

thi s uni t were measured by the U . S. Evi ronmenta l P rotect i on Agency 

( EPA ) beg i nni ng May 17 , 1973 , and continuing through December 14 , 

1973 . 

The obj ecti ve of the test was to characteri ze the S02 emi ssions 

from a pri mary copper sme l te r usi ng a contro l sys tem of th is type. 

The data were ana l yzed to dete rmi ne the contro l sys tem effi c i ency and 

any conditi ons wh i ch would cause high emi ssions . F i na l ly, the emi s ­

s i ons data were used to exami ne rea l i stic and ach i evab le 502 emi ssion 

l i mi tati ons for nonferrous smelt i ng operat i ons wh i ch p roduce strong 

502 s treams . 

The ASARCO sme l ter at El Paso , Texas , is a custom copper sme l ter 

that p roduces 236 Mg/day ( 260 tons/day) of b l i ster coppe r. Approxi ­

mate ly 365 Mg/day (400 tons/day) 502 are a l so p roduced duri ng the 

smelti ng process . The sme l ter operates three converters , wi th two 

converters ope rat i ng at essenti al ly al l times whi le the thi rd converte r 

is in the pouri ng porti on of i ts smelting cycle. Th is type of converter 

schedu l i ng typical ly produces a re l ati vely steady stream contai ni ng 3 

to 7 pe rcent 502 . 

The converte r gases are contro l l ed by the dual-absorp ti on ac id 

p l ant that p roduces app rox i mate ly 450 Mg/day ( 500 tons/day) of sul furi c 

ac id. The ac id p l ant is desi gned to p rocess a gas stream wi th an 

1 -1 
average i n l et concentrati on of 4 percent , wi th an i n l et concentrat i on 

rangi ng between 2 percent to 10 pe rcent 502 , and an i n l et flow rate of 

up to 2 , 830 Nm3/min ( 100 , 000 cfm) . The system is equi pped wi th an 

automatic heater that permi ts efficient operati on of the ac id p l ant 

down to an i n l et 502 concentration of approx i mately 2 percent. The 

catal yst renewal cyc le of the ac id p l ant is des i gned to be approx i mately 

once every 2 years . 

The monitori ng i nstrumentati o n i nc l uded a Dupont 460 502 analyzer 

fo r mon i tori ng the outlet 502 concentrati o n ; a Bec kman i n l et 502 

concentrati on ana l yzer; and a West i nghou se E2B 4-channe l tape recorder, 

whi ch permi tted simu l taneous record i ng of time , i nl et 502 concentrati on , out l et 502 concentration , and inlet vo l umetr ic flow rate . The 

Bec kman i n l et 502 moni tor was an i ntegra l part of the A5ARCO 502 

control system that requi red modifi cati on to permi t record i ng of i ts 

output s i gnal by the E PA reco rders . 

The accuracy of the outl et 502 moni tori ng i nstrumentat i on was 

veri fied as outl i ned in the proposed EPA Method 12 of 40 CFR 60 . A 

total of nine manual Method 8 502 tests , de fi ned in 40 CFR 60 , were 

performed between July 9 and 12 , 1973 . Table I-1 s hows the resul ts 

of the manual 502 meas u rements as determi ned by Method 8 and the 

co rrespondi ng 502 readi ngs as determi ned by the Dupont 460 502 moni tori ng i nstrument . 

The enti re mon i tori ng program covered a peri od of 5 , 088 hours , or 

212 days . Duri ng thi s time span , the ac id plant was in operat i on for 

a tota l of 190 days , or 90 percent of the moni tori ng peri od. Duri ng 

the same time span , the monitori ng i nstrumentation was in operati on 

for 90 percent of the monitori ng peri od . I nc l udi ng peri ods when both 

ac id p l ant and monitori ng i nstrumentat i on were i noperati ve, data were 

col l ected duri ng 86 pe rcent of the duratio n of the mon i tori ng p rogram . 

The mon i tori ng i nstrumentation recorded one readi ng for each paramete� 

mon i tored every 3 mi nutes . At the end of each 15-mi nute i nterva l , an 

average of the p rev i ous five readi ngs was computed. The 15-minute 

ave rages were used as the base data poi nts for a l l subsequent computations and analyses . 

I -4 
TAB LE I-1. COMPARISON OF S02 MEASUREMENTS USING E PA METHOD 8 

AND THE DUPONT 460 S02 ANALYZER 

Test resul ts Ceem S02 ) 

Date and time started EPA Method 8 Dupont ana l yzer 

7/09/73 ( 1617) 12 .5 19. 9 

7/10/73 ( 1011) 122 . 0 121 . 2 

7/10/73 ( 1418) 21 .0 22. 1 

7/10/73 ( 1602) 117 . 5 116 . 3 

7/10/73 ( 1745 ) 53 . 0 48 . 5 

7/10/73 (0816 ) 19 . 5 22. 2 

7/10/73 ( 1000 ) 49 .5 51. 4 

7/10/73 ( 1627 ) 239 . 0 224 . 3 

7/10/73 ( 1805) 22 .5 23 . 1 

I -5 
I.2 VALI DATION OF DATA 

To ensure that the recorded data were representati ve of 11 normal 1 1 

operati ng condi ti ons , data val i dati on cri teri a were estab l i s hed. The 

ac id p l ant operati ons l og, the ac id p l ant engi neer 1s l og, the catal yst 

temperatu re charts , and the copper converter operati ng l ogs were 

revi ewed to determi ne the operati ng state of the converter operati ons 

and the ac id p l ant . Peri ods duri ng wh i ch the ac id p l ant was not 

operat i ng and peri ods of excess emi ssi ons duri ng startup were removed 

from the comp i l ed data . For purposes of ana lys is of the comp i l ed 

data , a l l other operati ng s i tuat i ons were co nsi dered norma l . 

Duri ng the the te st p rogram , the ac id p l ant experi enced a number 

of s hutdown and startup s i tuati ons . The peri ods of ac id p l ant downt i me 

l asted for as litt l e as 30 mi nutes to as l ong as 5 days . A general 

rev i ew of the data showed that the s horter durati ons of downti me 

produced shorter peri ods of h i gh emi ssi ons after startup than did the 

downti mes of l onger duration. Therefore , each peri od of downtime and 

startup was eval uated to deri ve a quant i tati ve re l ati onship between 

the duration of the downtime and the durati on of excess emi ssio ns 

after startup . 

In deve l op i ng an app rox i mate re l ati on ship between the duration of 

·abnorma l emi ssi ons and the duration of downtime, a fami ly of c urves 

was prepared to s how ave rage emi ssion vs. time afte r s tartup based on 

the data mon i tored. F i gure I-1 s hows the re l at i onship between the 

downti me durati on and the emi s sions rate i mmedi ate ly after startup . 

There were 25 startups dur i ng the monitori ng peri od. These we re 

categori zied i nto five groups depe nd i ng upon downti me duration. The 

curves represent the fo l l owi ng downt i me peri ods : 1 . 99 hours or l es s , 

2 to 5 . 99 hours , 6 to 9 . 99 hours , 10 to 13 . 99 hours , and g reater than 

or equa l to 14 hours . Each curve represents the fol l owing total 

number of downti mes : 7 downtimes of 1 . 99 hours or l e ss , 3 downtimes 

of from 2 to 5 . 99 hours durati on , 3 downtimes of from 6 to 9 . 99 hours 

duration , 4 downtimes of from 10 to 13 . 99 hours duration , and 7 downtimes of 14 hours or g reater duration. Normal operati on was cons i dered 

attai ned when the average emi ssi ons decreased to 500 ppm . 

I - 6 
-

E 

0. 

t"-

""" 

0 

� 

� ..... 

c: 

Q) 

I'.) 

c: 

0 

0 

N 

0 

(/) 

..... 

Q) 

-;:; 

:::l 

0 

1 ,700 r-

1 ,600 

1 ,400 

1 ,200 

1 ,COO 

800 

600 

400 

200 

0 

Shutdown greater than 14 hr 

10 to 1 3.99 hr 

2 to 5.99 hr 

<2 hr 

1 2 3 4 5 

Time After Startup (hr} 

Figure 1-1 . Average emissions after startu p versus time after startup. 

I-7 

6 
The analysis of the curves i nd i cates that downt i mes of up to 

1 . 99 hours di d not cause excess em i s sions. Downti mes of greater than 

14 . 99 hours , however, typ i cal ly re sul ted in excess emi ssi ons for up to 

approxi mately 5 hours after startup . Other s h utdown i nterval s resul ted 

in normal operati on after a peri od of time rangi ng between the two 

p rev i ous extremes . 

The exact durati on of excess em i s sions duri ng s tartup wi ll vary 

because the time requi red to atta i n normal operati on depends to a 

maj or degree upon the s kill of the ac id p l ant operator , h i s/her percepti on of t he system 1s i mbal ance and h i s/her response wi th co rrecti ve 

meas ures . Also , the time requi red to atta i n normal operati on is 

dependent upon the response time of the aci d p l ant process contro l 

sys tem to any correcti ve acti ons i n itiated by the operator. The 

curves of F i gure I-1 i nd i cate that there may be cons i derab l e e l apsed 

time afte r startup before the ac id p l ant rega i ns equ i l i bri um condi t i ons . 

Based on the curves , data val i dati on cri teri a were deve l oped for 

startup peri ods . Data poi nts duri ng the i nitial porti ons of an ac id 

p l ant startup were exc l uded from the analysis based on the fol l owing 

cri teri a, to the nearest hours : 

For s h utdowns of l ess than 2 hours , the fi rst val id datum 

po i nt occurs i mmedi ately after s tartup . 

For shutdowns of 2 to 5 . 99 hours , the fi rst val id datum 

po i nt occurs 3 hours after s tartup . 

For shutdowns of 6 to 9 . 99 hours , the fi rst val id datum 

po i nt occurs 4 hours after startup . 

For s hutdowns of 10 to 1 3 . 99 hours , the fi rst val id datum 

po i nt occurs 4 hours after startup . 

For s h utdowns of greater than 14 hours , the fi rst val id 

datum po i nt occ urs 5 hours after startup . 

I.3 D I SCUSSION OF THE DATA 

Wi th peri ods of ac id p l ant downti me and t he i n itia l portion of 

ac id p l ant startup e l i mi nated from the recorded data , the remai ning 

data consti tute emissi ons from normal smelting and ac id p l ant operat i ons . Th is i nc l udes peri ods of abnormally l ow i n l et concentration 

I -8 
when a l l converters were out of the hoods for s hort per i ods . These 

s i tuations are common occurrences in copper converter operati ons . 

As p rev i ously d i scussed , the inlet 502 concentration to the aci d 

p l ant was meas ured at 3-mi nute i n tervals. The readi ngs were then 

averaged every 15 mi nutes to dete rmi ne the 15-minute average base data 

po i nts . The i n l et gas s tream ave raged 3.80 percent 502 for the enti re 

test period, wi th a s tandard dev i at i on of 1.64 percent 502 . The 

hi ghest recorded 15-mi n ute average i nl et for the total mon i tori ng 

pe ri od was 9 . 19 percent 502 . 

An anal ys i s of the di stri bution of the 15-mi nute inlet 502 readi ngs 

i ndi cated that the ac id p l ant proces sed gases of greater than 3 . 5 percent for only approxi mate ly 55 percent of the time. F i gures I-2 and 

I-3 s how the concentrat i on d i stri bution and the c umu l ati ve frequency 

di stri buti on of the i n l et gas stream 502 concentrat i ons recorded 

during the monitori ng peri od. 

1 . 3 . 1 Cata lyst Deteriorat ion 

The effi c i ent operation of any ac id p l ant is governed to a major 

degree by the condition of the cata l yst that aids the convers i on 

react i on of 502 to 5 03. As the cata l yst is used , i ts condi tion can 

deteriorate and thus decrease the contro l effi c i ency of the sys tem . 

Th is natura l ly re su l ts in inc reased emissions from the ac id p l ant . To 

ascertai n any change in convers i on effici e ncy attributab le to cata lyst 

use , the change in effi ciency was determi ned for vari ous time i nterva l s 

over the tota l test peri od. The i mp l i ed ass umpt i on in thi s p rocedure 

was that any decrease in contro l effi c i ency wou l d be bas i cal ly due to 

the decreased react i vity of the cata lyst. 

The ac id p l ant convers i on effi c i ency was cal cul ated us i ng the 

fo l l owi ng de fi n i ti on: 

Effi ciency , E _

Mass S02 converted - Mass 502 avai l able 

Adopt i ng the i dea l gas l aw fo r 502 , the prev i ous defi nit i on can be 

rep resented by the equat i on: 

c

out 

E = ( l -C

in ) ( 1 + C

out + C

2

out + . . . + C

n

out ) 

I - 9 
-

� 

> 

(J 

c: 

QJ 

::I 

0' 

QJ "" 

u. 

c: 

0 

·;:; 

� 

::I 

a. ..

 0 

I 0. ..

 

0 

40 

50 r- 

30 

20 

10 

0 --

0 1 .0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 1 0.0 

S02 Concentration (%) 

Figure 1-2. Inlet S02 concentration frequency distribution. 
-<!) 

E 

i= 

-0 

� -

> 

u 

c: 

<!) 

:: 

0'" 

<!) ..

 

u. 

<!) 

> 

·;; 

� 

,_. ::

 

I E ..

 ::

 ..

 u 

110

1 00 

.-

 

80 

60 

40 

20 

I Mean Inlet Concentration, 

1

3.8% 80

2 

I 

I 

I 

I 

0

0 

�- 

1 2 3 4 5 6 

S02 Concentration (%) 

7 

Figure 1-3. I nlet 802 concentration cumulative frequency distri bution. 

8 9 10 
where 

c. = 502 concentrati on enteri ng the ac id p l ant 1n 

C t = 502 concentration l eav i ng the ac id p l ant . 

ou 

The ac id p l ant commenced ope rati on in December 1972 . Between 

May 1973 and December 1973 , the ac id p l ant was mon i tored wh i le operat i ng 

for approx i mately 171 days , or approxi mate ly 86 percent of the time. 

At the end of the monitori ng p rogram , the ac id p l ant has been in 

operat i on a tota l of 335 days . 

The norma l c l eani ng cyc l e for the ac id p l ant catalys t , based on 

the manufacturer 's design, is 2 years . Thus , the system was mon i tored 

duri ng the second quarte r of i ts norma l catalyst c l ean i ng cycle. Due 

to the fai l u re of parts of the gas p rec l eani ng system to operate 

properly, howeve r, the cata l yst deteri orati on rate was acce l erated , 

and the ac id p l ant catal yst was screened duri ng March 1974 . Based on 

thi s i n formation , the cata l yst renewa l cyc le therefore covered a 

peri od of 1 . 2 years , and the ac id p l ant was cons i dered to have been 

mon i tored duri ng the second and thi rd quarters of i ts catal yst c l eani ng 

cycle. 

One l east- squares regress i on analys is of the change in effi c i e ncy 

wi th usage covers the total test peri od from May 17 , 1973 , through 

December 14 , 1973 . Simi l arly, second and thi rd ana l yses of the change 

in effici ency wi th ti me were a l so made and i nc l uded the l ast 2 months 

and the l ast month of the mon i tori ng peri od , respect i vely. A rev i ew 

of the three res u l ts i ndi cates that the aci d plant ' s effi c i ency rema i ned 

es senti a l ly cons tant at an average of greater than 99. 70 percent 

duri ng the tota l test p rogram . The respecti ve c hanges in effi c i ency 

wi thi n the observed pe ri ods i ndi cated by the three ana l yses were 

-0. 20 x 10- 7, -5. 6 x 10-7

, and -8. 7 x 10-7 percent per day. The 

mi ni mum effi c i encies from these c hanges in effi c i ency were 99 . 750 

percent , 99. 643 percent and 99. 688 percent , respect i vely. Thus , 

ne i ther wi thi n a gi ven i nterval nor between one report i ng i nterval and 

other did the anal ysis s how s uffi c i ent c hanges in effici ency to i ndi cate 

a significant c hange in the cond i tion of the catalyst . 

I - 12 
I . 3 .2 E ffect of Inl et 502 Conce ntrat i on on Emi ssions 

The most i mportant aspect of the i n l et 502 concentrati on is i ts 

effect on ac id p l ant operati ng effi c i ency and the resulting outl et 502 

concentration. To ascerta i n the effects ot varyi ng inlet 502 concentrat i ons on the res ulting outl et 502 concentrati ons , a l l of the 

s i mul ta neous 15-mi nute inlet and outl et concentrat i o n data were used 

to deve l op a l east- s quares straight line. The resul ts of th is ana l ys is 

i ndi cated there is a d i rect linear re l ati onship between i n l et 502 

concentrat i on and the res ulti ng outl et 502 co ncentration. The corre l ation coef fici ent of the analys is was cal cul ated to be 0 . 413 and was 

determi ned to be significant enought to warrant a conc l us i on of 

l i neari ty. F i gure I - 4 shows the graph of the l east- squares line and 

i ts standard error. 

The i n l et 502 co ncentrati ons experi enced duri ng th is test were 

somewhat l ower than the concentrati ons of 5 to 6 percent ac h i evable 

from typ i cal copper conve rter operati ons . Wi th an average of 3.8 percent 502 and a s tandard deviati on of 1 . 64 pe rcent S02 , approx i mate ly 

68 percent of the readi ngs were between 2 . 2 and 5 . 4 percent 502 , 

i ndicat i ng that the i n l et concentrati ons a re b i ased l ow and thus 

res ult in l owe r out l et concentrat i ons . The fact that the ac id p l ant 

i n l e t concentration was typical ly l ow i nd i cates that the typical 

outlet concentrat i on was l ower than that expected from other simi l a r 

ac id p l ants operati ng at a h i gher ave rage i n l et concentrat i on. Th is 

facto r must be taken i nto account when determi ni ng emi ssi ons l i mits 

for other smelting operati ons , based on data from thi s te st. 

An i n l et concentration of 9 percent is approx i mate ly the maxi mum 

i n l et S02 concentrati on that can be proce s sed by most modern dua l - stage 

ac id p l ants . F i gure I-4 is significant , therefore , when p redi cti ng 

the expected em i ssi ons from a sme l ter generat i ng an i n l et gas stream 

wi thi n the obs erved range of th is te st (0. 02 to 9 . 16 percent 502 ). It 

shows that the average out l et co ncentrati on i ncreases app rox i mate ly 

50 ppm pe r 1 percent i ncrease in i n l et concentrati on above 3.8 percent. 

For i nstance , whe n the ave rage i n l et concentrat i on to the ac id p l ant 

was 9 percent 502 , the ave rage emi s s i on rate i ndi cated from the test 

I - 1� 
E 

c. 

-0. 

c: 

0 

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ro ..

 ..

 

c: 

Q) 

t) 

c: 

0 

u 

N 

0 

CJ) 

.. 

Q) 

-;: 

::J 

0 

350.0 r-

 

300.0 

250.0 

200.0 

1 50.0 

I 

I 

1 00.0 I 

50.0 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

Inlet S02 Concentration (%) 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

I 

Figure I 4. Outlet so2 concentration versus inlet S02 concentration. 

I-1 4 
was approx i mate ly three times the emi ssio n rate obtai ned at 3 . 8 pe rcent 

inlet S02 . Th is i nc rease is basica l ly due to i ncreased i n l et concentrati on at a constant convers i on effici ency . 

I . 4 RESULTS OF THE TEST P ROGRAM 

The res ults of the te st p rogram i ndi cated that duri ng norma l 

operati ons the ave rage emi ssion s , based on 15-mi nute readi ngs , ranged 

between 10 and 2 , 920 ppm. Approx i mate ly 90 percent of these val ues , 

however, were be l ow 2 50 ppm and we ll bel ow the typ i cal manufacturer' s 

guaranteed emi ssion rate of 500 ppm . 

There were , however, peri ods of re l ati vely high emi ssion s , even 

when ave raged over 6- hour peri ods , wh i c h could not be attri buted to 

ma l functi ons , startup s, or s hutdown s. It was thought that these 

peri ods m i ght be caused by re l ati vely high inlet concentrat i on s , 

re s u lting in a correspondi ng i nc rease in o utlet concentrat i ons . To 

exami ne thi s pos s ibi l i ty , 6- hour averages of 400 ppm or greate r we re 

l ocated in the data base , and the 24 IS-mi nute i n l et concentration 

read i ngs that made up the 6- hour ave rages we re reco rded. The concentrati on frequency di s tributi ons of the se i n l et readi ngs we re then 

compared wi th the i n l et concentration frequency d i str i bution for the 

enti re mo nitori ng peri od. In genera l , the i nd i vi dual di stri butions 

did not vary s i gn i f i c antly enough from the compos i te for the enti re 

mon i tori ng peri od to i ndi cate that the excurs i ons occurred duri ng 

peri ods of unusual ly high or du ri ng ab normal i n l et concentrati on 

condi ti ons . The cata l yst converter temperatures and i n l et gas f l ow 

rates were a l so revi ewed , but no abnorma l i t i es we re noted in these 

paramete rs . 

Because the peri ods of re l at i vely t1 i gh emi ssions we re not caused 

by abnormal i n l et gas condi ti ons or by abnormal operat i on of the ac id 

plant sys tem , the comp i l ed data we re ave raged over var i ous time i nterval s rangi ng from 1 to 10 hours to exami ne the effect of averagi ng 

time on damping of normal exc urs i ons. As a resul t, the effects of 

normal s hort- term excurs i ons were spread over succes sively l onger 

peri ods of time. Table I-2 shows a matri x, to the nearest 0 . 05 

I-15 
TABLE I -

2. THE EFFECT OF REF ERENCE CONCENTRATION LEVE L AND AVERAGING TIME ON THE PERCENTAGE OF EXCURSIONS 

Ave rag- Number Reference concentrati on l evel , [![!m i ng of Maxi mum concentime read i ngs 150 200 250 300 350 400 450 500 550 600 650 700 750 tration, ppm 

15 min 14 , 612 20. 00 15. 00 10. 00 7. 50 5.00 4 . 00 3.00 2 . 30 1. 60 1. 35 1 . 15 1. 05 1. 05 2,920 

.. 1 hr 3,628 20. 00 15. 00 10. 00 7 . 10 4 . 10 3 . 15 2.65 2 . 10 1. 75 1. 40 1. 00 0 . 90 0.80 1,982 I ..

 

0"\ 2 hr 3,702 20. 00 15. 00 10 . 00 5. 00 3 . 00 2 . 50 2.00 1. 75 1. 50 1. 25 1. 00 0 . 90 0 . 70 1,261 

3 hr 3,758 20. 00 15. 00 10. 00 5. 00 2.20 2 . 00 1. 60 1. 25 0.85 0.80 0 . 55 0.50 0 . 50 1,238 

4 hr 3,803 20. 00 8 . 15 6 . 10 3.00 2 . 20 1.40 1. 05 0.80 0 . 75 0 . 50 0.45 0.30 0.25 935 

5 hr 3 , 841 20. 00 10. 00 5. 00 2. 75 1. 75 1. 25 1. 00 0 . 75 0.55 0.40 0 . 30 0 . 25 0 . 15 935 

6 hr 3,876 20. 00 10. 00 5.00 2. 45 1. 75 1. 20 0 . 90 0 . 45 0 . 35 0 . 30 0.15 0 . 05 0.05 752 

7 hr 3 , 907 20. 00 10. 00 5. 00 2. 15 1. 40 1. 00 0. 55 0 . 30 0 . 20 0 . 10 0 . 05 0.00 0.00 662 

8 hr 3 , 935 15. 00 10. 00 5.00 2. 15 1. 40 0.80 0. 50 0.25 0 . 10 0 . 05 0.00 0.00 0.00 662 

10 hr 3,988 15. 00 10. 00 5. 00 2. 05 1. 20 0 . 55 0.25 0 . 10 0.05 0 . 00 0 . 00 0 . 00 0.00 576 
percent , of the perce ntages of the tota l read i ngs that exceeded g i ven 

concentrat i ons for vari ous averagi ng i nterva l s. 

It can be seen from Tab l e I-2 that , as the averagi ng time for a 

g i ven concentrati on l evel i nc reases, the percentage of excurs i ons 

above that concentrati on l evel tends to converge to zero . For examp l e, 

Table I-2 i nd i cates that from 20 to 15 percent of the recorded val ues 

exceeded 150 ppm , depend i ng on the averag i ng i nterva l s between 1 and 

10 hours . 

Simi l arly , in Tab le I-2 , an i ncrease in the concentrat i on l eve l 

for a g i ven ave rag i ng time wi ll a l so cause the matrix to conve rge 

rap i dly to a sma l l val ue . For examp l e, observing the 6- hour averag i ng 

i nterva l , there is a 20 percent excurs i on rate at the 150 ppm l evel . 

I nc reasi ng the concentration l evel to 300 ppm dec reases the exc urs i on 

rate to 2.45 percent ; i ncreas i ng the concentrati on l eve l to 750 ppm 

decreases the excurs i on rate to 0 . 05 percent . 

Based on the res ults of Tab l e I-2 , as e i ther the averag i ng time 

i nc reases , the concentrat i on l evel i nc reases , or both i ncrease , the 

pe rcentage of excurs i ons tends to converge toward a sma l l va l ue in the 

matri x. 

1.5 CONCLUS IONS 

As p reviously i nd i cated , the typ i cal manufacturer• s guarantee for 

a dua l -stage ac id p l ant is 500 ppm , based on a 5 to 6 percent ave rage 

i n l et 502 concentrat i on. The res ults of the test , howeve r, i nd i cated 

that the test was carri ed out at a 3 . 8 percent average inlet concentration, somewhat l owe r than the average i n l et concentrat i o n from typical 

copper convert i ng operations . The test res u l ts also i nd i cate that 

there is a d i rect l i near re l ationshi p between inlet gas- stream so2 

concentrati on and outl et gas-s tream S02 concentrat i on; the inlet 

concentration i nc reases in proport i o n to the o ut l et concentratio ns . 

Therefore , because the i n l et concentrat i on was somewhat l owe r than 

norma l , the resul t i ng out l et concentrati on was consi dered l ower than 

that from typical copper smelters . 

Because the manufacturer •s guarantee of 500 ppm is based on a 

5 to 6 percent inlet 502 concentrat i on i nto a typ i cal sme l ter conve rter 

I - 17 
ac id p l ant , the equ i va l ent 502 concentrati on for the A5ARCO ac id p l ant 

duri ng the test peri od was 400 ppm. Thi s is due to the typical ly 

l ower i n l et concentrations. 

As discus sed in Appendi x H, an appropri ate averagi ng time for 

mas ki ng outl et concentrati on fl uctuati ons from sing l e- stage absorpti on 

ac id p l ants was determ i ned to be 6 hours . The test of the A5ARCO 

p l ant i ndi cates that a 6-hour averag i ng time is a l so suffi c i ent to 

mas k fl uctuati ons from a dual - absorpti on aci d p l ant . The resul ts s how 

that an emi ssion rate of 400 ppm for a 6- hour averagi ng time wou l d 

resul t in 1 . 20 percent excurs i ons . 

Al though the res u l ts of thi s test p rogram i ndicate that a reasonab le emi ssi ons l i mi t equ i va l ent to the vendor •s guarantee (400 ppm) 

would resul t in only 1 . 20 percent viol ation rate , the effects of 

hi gher i n l et 502 concentrati ons at other smelti ng operati ons and ac id 

p l ant catalyst deteriorat i on must be taken i nto account. To account 

for s i tuati ons of i nc reased emi ssions due to h i gher i n l et concentrati ons 

of up to 9 percent , the resul ts of Tabl e I-3 requ i re prorating upward 

a max i mum of 200 ppm . 

The res u l ts of th is test were not conclusive as to the c haracteri s ti cs of i nc reased emi ssions due to catal yst deteri orati on because no 

deteri oration was observed duri ng thi s test. D i scu ssi ons wi th the 

des i gners of the A5ARCO ac id p l ant i ndicated that up to a 10- percent 

i ncrease in emi ssions was expected before renewa l of the cata lyst. 

Thi s factor , therefore , has to be taken i nto account when predi cti ng 

the expected emi ssions f rom a system of thi s type. Based on the 

prev i ous factors , the res u l ts of Table I-3 were p rorated upward to 

take hi gher i n l et concentrati ons and catalyst deteri orati on i nto 

account. 

Tab le I-3 s hows an ac id p l ant operat i ng at an i n l et of as high as 

9 percent and taki ng cata lyst deteri o rat i on i nto account. F rom 

Tabl e I-3 it can be seen that an ac id p l ant p rocess i ng the maxi mum 

expected i n l et concentrati o n cou l d be expected to mai nta i n an emi ssion 

rate of 650 ppm wi th only a 1 . 20 percent exc urs i on rate . 

1-18 
..

 

I 1-' 1.

 Percentage of 

averages exceedi ng outlet 502 

concentrati on 

150 200 250 

TABLE I-3. PRORATED EXCURSION PERCENTAGESa 

300 

Out l et SO:Lconcent�t i_()n , ppm 

350 400 450 500 

20. 00 10. 00 5 . 00 

550 

2.45 

a

Based upon a 6-hour averagi ng time and a total of 3,876 readings. 

600 650 700 

1. 75 1. 20 0.90 

750 

0.45 

Expected 

concentration , 

ppm 

977 
In general , however , a new source performance s tandard (NSPS) set 

at the 650-ppm l eve l and a 6- hour averag i ng time wou ld resul t in a 

p robabl e excurs i on rate of l ess than 1 . 20 percent. The general NSPS 

prov i sions ( 39 FR 9308) specify that each performance test for the 

purpose of comp l i ance s hal l cons i st of the ari thmetic mean of the 

res ults f rom three separate runs . To determine the number of times 

that the ASARCO ac id p l ant exceeded the 400-ppm l evel ( equ i valent to 

650 ppm in Tab l e I-2) , the recorded data from the test p rogram were 

rev i ewed. Each 6-hour average of 400 ppm or g reater was consi dered an 

excurs i on. Readi ngs for 24 hours both before and afte r the viol ation 

were revi ewed to determi ne whether the average of any two readi ngs 

together wi th the excurs i on wou ld exceed 400 ppm. The three 6- hour 

averagi ng peri ods were chosen so that none of the peri ods overl apped. 

The resul ts i ndi cate that , of 48 recorded read i ngs greater than 400 ppm 

duri ng the enti re mon i tori ng peri od , only 6 result in averages of 3 

runs greater than 400 ppm. F rom thi s eva l uation , the p robab le percentage of 6- hour averages in excess of 650 ppm , based on a 9 percent 502 

i n l et stream , would be approxi mately 0 . 15 percent. 

I - 20 
APPEND IX J 

EXAMPLE CALCULATI ONS 

MODEL PLANT OPERATI NG PARAMETERS 
APPEND IX J 

EXAMP LE CALCULATIONS 

MODEL P LANT OPERATI NG PARAMETERS 

Th is append ix contai ns examp l es of cal cul ati ons used in the 

devel opment of the Background I nformati on Document for the revi ew of 

the pri mary copper sme l ter NSPS . Cal cu l ati ons are for Contro l Al ternati ve I-G , new greenfi eld sme l te r process i ng high- i mpuri ty materi a ls 

( oxyfuel bu rners and 100 percent b l endi ng of the reverberatory furnace 

offgas stream) . Where procedures for the expans i o n scenarios di ffer , 

examp le cal cul at i ons are i nc l uded for sel ected expans i on scenarios. 

The fo l l owi ng i nput data obtai ned from C hapter 6 are reproduced 

for the reader 1s conven i ence . 

Feed: 

Mg/day 

Copper (%) 

Sul fur (%) 

I ron (%) 

Sul fur removal (%) 

Roaster 

Reverberatory fu rnace 

Converter 

Matte grade (%) 

I NPUT DATA 

New gree nfi eld 

sme l ter 

1,364 

22 .9 

27 .0 

19 .6 

19 .3 

28 .4 

52. 3 

40 .0 

Expan sion 

Scenari o 9 

2,045 

22 .4 

28 .4 

24 .8 

41 .2 

59. 8 

39 .0 

The ass umpt i ons us ed in these ca l c u l at i ons are those l i sted on 

pages 6- 6 and 6-9. Additi ona l assumpti ons are i nd i cated in the examp le 

ca l culat i ons . 

J-3 
J . 2 NEW G REENF IELD SME LTER PROCESS I NG H IGH- IMPURITY MATERIALS 

J . 2 .1 Materi al bal ance: 

Copper in feed: 

Matte fal l: 

I nert in matte : 

S as FeS : 

S in matte : 

S in feed: 

S removed in MHR and RV : 

S removed in MHR: 

S removed in RV : 

J.2 . 2 Mul ti hearth Roaster 

Vo 1 umetri c f1 ow: 

1 , 364 X 0 . 229 

3 12 . 4 + 0.40 

781 . 0 X 0 . 10 

32 312. 4 X 127 _ 1 

312 . 4 + 78. 7 

781 . 0 - 78 . 1 - 391 . 1 

32 311. 8 X 87 .8 

113 . 6 + 78. 7 

1 , 364 X 0 . 270 

368. 3 - 192 . 3 

0 . 193 176 · 0 X 0 . 193 + 0 . 284 

0 . 284 176 · 0 X 0 . 193 + 0 . 284 

= 

= 

= 

= 

= 

= 

= 

= 

= 

= 

= 

= 

71. 2 Mg S removed x 1 day x Mg· mol x 22 .4 x 103 Nm3 

day 1,440 mi n 32 Mg Mg · mol 

Fracti o n 02 : 

Theoreti cal ai r: 

D i l uti on air: 

x Nm3 offgas x 530 

0 . 045 Nm3 S02 492 

828 . 5 X 0 . 045 

0 . 21 

828 . 5 - 177 . 5 

651 . 0 X 0. 21 

828 . 5 

J -4 

= 

= 

= 

= 

312.4 Mg/day 

781 . 0 Mg/ day 

78. 1 Mg/day 

78 . 7 Mg/day 

391 . 1 Mg/day 

3 11 . 8 Mg/day 

1 13 . 6 Mg/day 

192 . 3 Mg/day 

368 . 3 Mg/day 

176 .0 Mg/day 

71. 2 Mg/day 

104 . 8 Mg/day 

828 . 5 Nm3/mi n 

[ at 70° F, 1 atm] 

828 . 5 

0 . 165 

177 . 5 Nm3/min 

651 . 0 Nm3/mi n 

0 . 165 
J . 2 . 3 Reverberatory Furnace 

Natural gas equ i valent regu i red: a,b 

(1,364 . 0 - 71. 2) Mg cal cine x 1 day x 1 . 1 tons 

day 1 , 440 mi n Mg 

x (0. 6 x 4 . 5 x 106 ) BTO x ft3 natural gas 

Ton feed 1,000 Btu 

(2. 832 x 10-2 m3 ) 530 X ft X 492 

Combustion products ( CH4 + 202 � C02 + 2Hz0 ): 

162 . 6 X �:�i 

502 formed: 

104 . 8 Mg S removed x 1 day x Mg · mol 

day 1,440 mi n 32 Mg 

x ( 22 . 4 x 103 Nm3 ) x 530 

Mg • mol 492 

N2 in ai r to form 502 : 

Air l eakage : 

02 requi rements : 

N2 at 65/35 H2/02 : 

54 9 X 0. 79 

. 0. 21 

162 . 6 + 54 . 9 

2 17.5 X �:�� 

81. 3 Nm3 /mi n 

[ 70° F, 1 atm] 

= 81. 3 

= 81. 3 Nm3 /mi n 

= 1 62 . 6 Nm3/mi n 

= 6 11 . 7 Nm3/mi n 

= 

= 

= 

= 

54 . 9 Nm3/m in 

[ 79° F, 1 atm] 

54 . 9 

206 . 5 Nm3/m in 

511. 3 Nm3/mi n 

217 . 5 Nm3 /m in 

403 .9 Nm3 /mi n 

a

Natural gas equ i valents are used in reverberato ry furnace ca l c u l ati ons 

for conven i ence. It is assumed that combu sti on products per Btu of 

i nput from natural gas are essenti a l ly the s ame as combust i on products 

per Btu of i nput from other fo ssi l fuels. 

b

The l i terature i ndi cates a 40-percent reducti on in heat requi rements 

when usi ng oxyfuel bu rners . 

J-5 
Ai r l ea kage : 403 . 9 + 0 . 79 

Mo i sture in a i r 

( 70° F 40% RH ): 

511 . 3 X 0 . 00757 

Theoreti cal RV offgas : 

Component Nm3/mi n 

C02 81 . 3 

H20 166 . 5 

Combusti on ( 162 . 6) 

In ai r (3. 9) 

N2 403 . 9 

so2 54. 9 

Dry 65/35 ai r to resul t in 

1 percent 02 at offta ke: 

0 . 35 vol ume a i r 

Vo l ume a i r + 706 . 6 

N2 in makeup a i r: 20 .8 X 0 . 65 

02 in makeup ai r: 20 .8 X 0 . 35 

H20 in makeup air: 20 .8 X 0 . 00757 

RV offgas at offtake : 

Dry bas is Wet bas is 

Component 

C02 

H20 

( combu stion) 

( l eakage ai r) 

(makeup ai r) 

N2 

( l eakage air) 

(ma keup air) 

so2 

02 

Tota l 

Nm3/mi n % 

81 .3 14. 5 

417.4 74. 4 

(403 . 9 ) 

( 13.5) 

54 .9 9.8 

7 . 3 1 . 3 

5 60 . 9 

Nm3/mi n % 

81. 3 11. 2 

166 . 7 22 .9 

( 162 . 6) 

(3. 9) 

(0.2) 

417.4 57 .4 

(403 . 9 ) 

( 13. 5) 

54 .9 7 . 5 

7 . 3 1 . 0 

727 . 6 

J -6 

= 511. 3 Nm3/mi n 

= 3 . 9 

= 3 . 9 Nm3/mi n 

= 706 . 6 Nm3/mi n 

20 .8 Nm3/mi n 

= 0 . 01 

= 13 .5 Nm3/mi n 

= 7 . 3 Nm3/mi n 

= 0 . 2 Nm3/mi n 
Lea kage through waste 

heat boi l e r and ESP : 

RV gas to ac id p l ant 

(dry basis): 

Compo nent 

C02 

N2 

( at offta ke ) 

( l ea kage ) 

02 

( at offta ke ) 

( l eakage ) 

S02 

J.2.4 Converters 

Nm3 /mi n 

81. 3 

992.2 

(417.4 ) 

( 574 . 8) 

160 . 1 

( 7 . 3 ) 

( 152 . 8) 

54 . 9 

1,288 . 5 

% 

6 . 3 

77. 0 

12 .4 

4 . 3 

= 727 . 6 Nm3/m in 

= 1,284 .4 Nm3 /mi n 

J . 2 . 4 .1 Genera l . The avai l ab i l i ty of a s trong S02 stream can 

signi fi cant ly enhance the attracti veness of wea k- s tream b l endi ng as a 

means by wh i c h to control weak S02 streams . Consequent ly, a co nverter 

sc hedu l i ng scheme that wi ll maximi ze the converter offgas S02 concentrati on over time is highly des i rable. 

A typ i cal converter cyc le can take between 11 and 12 hours per 

c harge . In converti ng a 40- percent matte , a slag b l ow wi ll l ast 

app rox i mate ly 6 hours , wh i le a copper blow l asts about 3 hours . Time 

taken up by c hargi ng, pouring, and skimmi ng wi ll general ly be about 

2 hours per cycle. F i gure J- 1 presents the converter schedu le used in 

th is study to determi ne the time profi le of the total conve rte r offgas 

f l ow fo r a 40- perc ent matte . Copper and slag b l owi ng fume s wi ll 

change when other matte grades consti tute the co nverter c harge . A 

three-converter operat i on perform i ng f i ve conve rter cyc l e s per 24- hour 

peri od was c hosen as representative of domesti c practice. An i nte rcyc le 

time of 3- 2/3 hours was determi ned to be typica l . Offgas profi le of 

the conve rter ai sle is determi ned in the fo l l owi ng paragraphs. 

FeS : 

J . 2 . 4 . 2 Slag Blow. [ FeS + 1 . 5 02 = FeO + 502 ] 

FeS/cyc le: 311 . 8 5 

J - 7 

= 311 . 8 Mg/day 

= 62 .4 Mg/cyc le 
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J - 8 
= 47 .6 Nm3/mi n 

[ 70° F, 1 atm] 

62 .4 Mg FeS x 1 cyc le x Mg ·mol x ( 22 . 4 x 103 Nm3 ) x 530 = 47 6 cyc le 360 mi n 87 .8 Mg FeS Mg · mol 462 · 

Theo ret i cal 02 : 

Offgas before d i l ution: 

Of fgas a fte r d i l ution: 

Fract i on 02 : 

47 .6 X 1 . 5 

71. 4 7 0. 75 

95 2 X 0

·

79 

. 0 . 21 

47 .6 + 95. 2 

2 X 429 . 5 

71 .4 + 358. 1 

47 .6 7 859 . 0 

95 . 2 - 71. 4 + 0 . 21 X 429 . 5 

859 . 0 

= 7 1 .4 Nm3/mi n 

= 9 5 .2 Nm3/mi n 

= 358. 1 Nm3/m in 

= 429 . 5 Nm3/m i n 

= 429 . 5 

= 859 . 0 Nm3/mi n 

= 0 . 0554 

= 0 . 133 

= 0 . 133 

J.2 . 4 .3 Coppe r Blow [ C u25 + 02 7 2 Cu + 502 ]. 

Cu 2S: 

· c u2S/cycle: 

Actual 02 : 

Actual N2 : 

Of fgas before di l ution: 

Offgas after d i l ution: 

Fraction 502 : 

F raction 02 : 

= 391. 1 Mg/day 

391 . 1 7 5 = 78 .2 Mg/cyc le 

78 . 2 X 22 .4 X 103 X 530 

180 X 159 . 1 X 492 

65. 9 7 0. 75 

87 9 X 0 . 79 

. 0. 21 

330 . 7 + 87. 9 

2 A 418 . 6 

:: 

= 

= 

= 

= 

= 

65. 9 Nm3/mi n 

65. 9 

87 .9 Nm3/mi n 

330. 7 Nm3 /m in 

418 . 6 Nm;1 /mi n 

83 7 . 2 Nm�1/m i n 

65. 9 7 837 . 2 = 0 . 0787 

= 0 . 131 

87 . 9 - 65. 9 + 0 . 21 X 418 . 6 = 0 . 131 837 . 2 

J - 9 
J.2 .4.4 Offgas P rofi le. Usi ng the converter ai sle s tation 

presented in F i gure 6 . 2 and the slag and copper b l ow f l ows determi ned 

above the fo l l owi ng converter ai sle offgas profi le can be devel oped. 

Converter a i sle s tatus 

Number of converters 

Slag Copper Off- Hr/ 

blow blow stac k day Nm3/mi n S02 (%) Oz (%) 

-2- 1 -0 4 . 0

a 2,555 .2 6 . 30 13 . 2 

2 0 1 5 . 2 1 , 718. 0 5 . 54 13 .3 

1 1 1 9 . 5 1,696 . 2 6 . 69 13 .2 

1 0 2 2 . 3 859 . 0 5 . 54 13 . 3 

0 1 2 1 . 7 837 . 2 7 . 57 13 . 1 

0 0 3 1 . 3 0 

Ave rage f l ow 1,611. 1 6 . 31 13 .2 

a

Examp le cal cul ation: 

Flow: 2 X 859 . 0 + 837 . 2 = 2,555. 2 Nm3/mi n 

Average fl ow: 

J.2.5 Ac id P l ant 

2 X 859 . 0 X 0 . 0554 + 837 . 2 X 0 . 0787 = 0 . 063 2,555. 2 

F l ows 

L hr pendi ng x Nm3/mi n 

24 

J . 2 . 5 . 1 Feed . B l ended MHR, RV , and CV streams are fed to the ac id 

p 1 ant . P rofi le of thi s b l ended stream is determi ned as s hown be l ow: 

Stream Hr/da:l Nm3/mi n S02 (%) Oz (%) 

Mu l ti hearth roaster 24 828 4. 50 16. 5 

Reverberatory furnace 24 1,284 4. 30 12 .4 

Converter ai sle 4 . 0 2,555 6 . 30 13 .2 

5 . 2 1 , 7 18 5 . 54 13 .3 

9 . 5 1,696 6 . 69 13 .2 

2 . 3 859 5 . 54 13 .3 

1 . 7 837 7 . 87 13. 1 

1 . 3 0 

To ac id p l ant 4. 0

a 4,667 5.43 13 .6 

5 . 2 3 , 830 4. 90 13 .7 

9.5 3 , 808 5.41 13 .7 

2.3 2,971 4 . 71 13 .8 

1 . 7 2,949 5 . 37 13 .8 

1 . 3 2,112 4. 36 14 . 0 

Average 3, 723 5 . 21 13 .7 

a

Examp le cal cul ati on ( see next page): 

J - 10 
Flow: 828 + 1 , 284 + 2,555 

Fract i on 502 : 

828 X 0 . 045 + 1 , 284 X 0 . 043 + 2,555 X 0 . 063 

4,667 

= 4,667 Nm3/mi n 

= 0 . 0543 

J.2. 5 . 2 Effl ue nt. Ac id p l ant effl uent is based on average 

f l ows , 98 . 3 percent convers i on effi ciency , and on the ass umpt ion that 

on ly 502 is removed from the dry gas in the ac id plant. T he fo l l owi ng 

mode l was deve l oped for th is purpose . 

V: 

5: 

0: 

502 conve rted : 

02 used : 

Effl uent : 

Vo l ume of dry gas to the 

ac id p l ant 

Fracti o n of 502 in d ry 

inlet gas 

F ractio n 02 in dry i n l et 

gas. 

0 . 983 V5 

0 . 983 vs 

2 

v - 0 . 983 vs -

0 . 983 vs 

2 

= v - 1. 4745 vs 

= 3 , 723 - 1 . 4745 X 3 , 273 X 0 . 0521 

= 3 , 437 Nm3/min 

F ract i on 502 : 0 . 00096 

( 1 - 0 . 983 ) (3,7 23) (0. 0521) 3 , 437 

J.2.6 Ai r Pol l ution I mpact 

J.2 . 6 . 1 Table 7 . 4- - so� Control Al ternative. 

Base l i ne 

Emi ssions/yr ( total ): 

J-11 

76 , 495 Mg/yr 
MHR: 

RV : 

CV : 

71 .2 Mg S removed x 350 days x 64 Mg 502 

day year 32 Mg S 

x 0 . 017 Mg emi tted 

Mg to acid p l ant 

104 . 8 X 350 X 64 

32 

192 . 3 X 350 X � X 0 . 017 

Contro l Al ternati ve I-G 

Emi ssi on/yr ( total ): 

MHR: 

CV : 

847 Mg/yr 

= 847 

= 73 , 360 Mg/yr 

= 2 , 288 

4 , 382 Mg/yr 

847 Mg/yr 

2)288 Mg/yr 

RV : 104 . 8 X 350 X � X 0 . 017 = 1,247 

Emi ssion reducti on: 76 , 495 - 4,382 = 72 , 113 

B l i ster copper/yr: 1,364 x 0 . 229 x 350 = 109 , 324 Mg/yr 

( 99% recovery , 99% p uri ty, 

350 days/yr) 

Reducti on per uni t of 

bl i ster: 72 , 113 X 1,000 7 109 , 324 = 659 

J.2 . 6 . 2 Tabl e 7-5--Fugi ti ve Parti cul ate Control . 

Basel i ne) MHR: 

109 , 324 Mg bl i ster x 5 . 2 Kg fugi tive x 1 Mg 

year Mg bl ister 1 ) 000 Kg 

Reducti on ) MHR: 

568 Mg uncontro l l ed x 0 . 90 Mg c aptured 

year Mg uncontrol l ed 

Contro l l ed) MHR: 

x 0 . 99 Mg col l ected 

Mg captured 

568 - 506 

J - 12 

568 Mg/yr 

= 568 

506 Mg/yr 

= 506 

= 62 Mg/yr 
Contro l %: 506 568 = 89 percent 

Reducti on: = 4. 6 kg/Mg b l i s ter 

506 Mg particu l ate x 1,000 Kg x year 

Year Mg 109 , 324 Mg blister 

J.2 . 6 . 3 Table 7-7-- Sol id and Liqu i d Effl uents from Gas Cleani ng 

and Condi ti oni ng. Use factors from Append ix L. 

Vo l ume to ac id p l ant: 3,725 Nm3/mi n 

or 3,725 X 273 35. 31 X 122 , 100 scfm 294 = 

122 , 100 X 2 . 8 X 10-5 = 3 . 4 Mg/yr 

Li qui d: 122 , 100 X 1 . 8 x 10-4 = 22 .0 Mg/yr 

J.2. 6.4 Table 7-9- -Sol id and Liquid Wastes from FGDs . Use 

facto rs f rom Append ix L. 

Vol ume to sc rubbe r 

(Table 6 - 3 ) : 

or 

3 , 315 X 273 35 . 31 X 294 

108 , 700 X 1. 7 X 0 . 034 

108 , 700 X 1 . 7 X 1 . 8 

= 3 , 315 Nm3/mi n 

at 12% S02 

= 108 , 700 scfm 

= 6,282 Mg/yr 

sol id was te 

::c 332 , 622 Mg/yr 

l i qui d waste 

J . 2. 6.2. 5 Table 7- 12- -e nergy i mpact. Ene rgy requi reme nts in 

Tab le 7-12 were est i mated u s i ng re l atio n s h i ps deve l oped for the cost 

ana l ys is ( Chapter 8) . 

J.3 EXPANSION SCENARIOS 

Wi th the except i o n of conve rter analysis and distribution of ac id 

p l ant fl ows to the exi sti ng single ac id p l ant and a new doub le ac id 

p l ant for scenari os requ iring a new ac id plan t , the procedures for 

determi ning expans i on s cenar io paramete rs are the s ame as those used 

fo r new greenfi eld smelters . Example s of eac h of these except i ons 

fo l l ow. 

J - 13 

( °C) 
J . 3 . 1 Co nverter Analys is 

Usi ng the same p rocedures used in Secti on J.2, the fol l owi ng converter 

profi le, before d i l ution , is determi ned for Base l i ne II. 

Converter ai sle status 

Converters on: 

S l ag b l ow COEEer blow Off s tac k Hr/da� 

2 1 0 4 . 0 

2 0 1 5 . 2 

1 1 1 9 . 5 

1 0 2 2 . 3 

0 1 2 1 . 7 

0 0 3 1 . 3 

Average 

D i l ution to attai n 

4 . 3 percent S02 : 4-:3 

12. 3 

Converter profi le after d i l ution: 

Converte r ai sle status 

Converters on: 

Sl ag Copper 

bl ow b l ow 

2 1 

2 0 

1 1 

1 0 

0 1 

0 0 

Average 

a

Examp le: 

Flow: 

Offs tac k 

0 

1 

1 

2 

2 

3 

J . 3 .2 Ac id P l ant F l ows 

Hr/ 

� Nm3/mi n 

4 . 0

a 4,435 

5 . 2 3,267 

9 . 5 2 , 793 

2 . 3 1,583 

1 . 7 1,168 

1 . 3 

2 , 838 

1,550 .8 X 2 . 860 

12 . 3 .;. 2 . 860 

Same procedure used in 

Section J . 2.4 

Flow so2 

( Nm3/m i n ) (%) 

1,550. 8 12 .3 

1,142 . 2 11. 1 

979 . 6 13 .0 

553 . 6 11. 1 

408 . 5 15. 8 

0 

992 . 3 12. 3 

= 2 . 860 

502 (%) 02 (%) 

4 . 30 15 .5 

3 . 88 15. 5 

4 . 55 15 .5 

3.88 15 .5 

5 . 52 15 .5 

4 . 3 15 .5 

= 4,435 Nm3/mi n 

= 4 . 3 percent 

The p rocedures descri bed here i n app ly to Expansi on Scenari os 11 

through 14 . The examp le covers Scenar io 11 . 

J - 14 
Us i ng the p rocedures descri bed in Secti on J . 2, the fo l l owi ng 

parameters are deve l oped : 

Flow so2 0 2 

( Nm3/mi n ) (%) (%) 

RV , to ac id p l ant 1,440 3 . 0 15 .6 

O l d CV 2, 770 4 . 3 15 .4 

New CV 970 6 . 2 13 .3 

In thi s scenari o, the f l ows from both the old and new converter 

are b l ended to smooth out vari ati ons encountered in i ndividual conve rter 

operations . The new double aci d p l ant is preferenti a l ly dri ven by sendi ng a constant vol ume of the comb i ned CV stream a l ong wi th the RV stream 

to be contro l l ed to the p l ant . The rema i nder of the c omb i ned CV stream is 

treated in the ex i sti ng sing l e ac id p l ant . 

Comb i ned CV stream : 

Old CV 

New CV 

Comb i ned 

Equ i val ent new CV flow: 

Doub le ac id p l ant i nput: 

cv 

RV 

Comb i ned 

Flow 

Nm3/m in 

2, 770 

970 

3,740 

so2 

(%) 

4 . 3 

6 . 2 

4 . 8 

2 , 770 X 4 . 3 + 970 X 6 . 2 

3,740 

970 X 6 . 2 

4 . 8 

Flow 

Nm3/m in 

1,253 

1,440 

2,693 

S02 

(%) 

4.8 

3 . 0 

3 . 8 

Sing l e ac id p l ant i nput: 3,740 - 1,253 

J-15 

0 2 

(%) 

15. 4 

13. 3 

14 . 9 

= 4 . 8 

= 1,253 Nm3/mi n 

02 

(%) 

14 .9 

15 .6 

15. 3 

= 2,487 Nm3/mi n 
APPENDIX K 

MATHEMATI CAL MODEL FOR ESTIMATI NG POSTEXPANSION REVERBERATORY GAS 

F LOW AND 502 CONC ENTRATION FOR OXYGEN ENR I CHMENT 

AND OXY- FUEL EXPANSION OPTIONS 
AP PEND IX K 

MATHEMATICAL MODEL FOR ESTIMAT I NG POST EXPANS I ON REVCRBERATORY GAS 

F LOW AND S02 CONCENTRATION FOR OXYGEN ENRI CHMENT 

AND OXY- FUEL EXPANSION OPTIONS 

As s umpti ons : 

1. Ten percent excess 02 . 

2. F i fty percent of base case off- gases is d i l ution ai r. Amount of 

di l uti on ai r does not vary wi th expansion. 

3. Fuel is equ i va l ent to CH4 for determ i n i ng vo l ume of combustion 

products . 

Notation: 

V = vol ume rate of off-gas 

S = vol ume fracti on of 502 

C = vo l ume of combustion products , exc l udi ng n i troge n , 

at theoreti cal 02 

0 = vol ume rate of exce ss 02 

N = vol ume rate of ni trogen 

P = vol ume fracti on of oxygen in combustion ai r 

E = Rati o of expans i on capac i ty to base case capac i ty 

H = ratio of expans i on fue l to base case fue l 

s ubscri pt b = base case 

s ubscript e = expansi o n 

Procedure : 

1. V

b = di l uti on a i r + S02 + C

b + O

b + N

b 

K- 3 
2. 

3. 

4 . 

v 

D i l ution ai r = _£ 2 

Three vol umes of combust i on products requ i re, at 10 percent excess 

02 , 2 . 2 vol umes of 02 and 2 . 2 x �i or 8. 3 vol umes of n i trogen. 

Th is represents 0 . 2 vol umes of excess 02 . 

6. Us i ng ratios of C

b , Ob

, Nb determ i ned in 4, the fo l l owi ng rel ati onshi ps wi th v

b + sb are determi ned : 

7. 

8. 

9. 

v

b ( l- 2S

b

) 0 . 2 o

b = 2 x 0 . 2 + 3 + 8 . 3 = o . oo87 v

b ( l- 2 Sb

) 

N -

v

b ( l-2Sb

) 

x 8 ·

3 = 0 . 3609 v

b ( l- 2S

b

) b - 2 II:5 

v

b V

e = --2 + 502 + C + 0 + N e e e 

C = HC e b 

= 0 . 1304 HVb ( l- 2Sb

) 

K- 4 

( from 6) 
10. 0 = H 0 e b 

= 0 . 0087 H V

b ( 1-2Sb

) ( from 6) 

11. From 5, 3 vol umes of combustion products requi re, at 10 percent 

( 1-P) excess 02 (0 .2 vol umes ) , 2 . 2 vol umes of oxygen and 2.2 --

p --

vol umes of n i trogen. 

Each vo l ume of combustion p roducts is there fore associ ated wi th 

(1-P) 2.2 � vo l umes of N2 . 

N2 = 0 . 1304 HVb ( 1-2Sb

) 2 . 2 ( 1;�

) ( from 9) 

= 0 . 0956 HVb ( 1-2Sb

) ( 1�P) 

12 . Combining 7, 8, 9, 10 , 11 

v

b V

e = � + EVb

S

b + 0 . 1304 H Vb ( 1- 2S

b

) + 0 . 0087 HVb ( 1-2Sb) 

13 . 

v = v e b 

= v b 

0 . 5 + ESb + H(1- 2S

b

) 0 . 1391 + 0 . 0956 ( 1�P) 

0 . 5 + ESb + H(1-2Sb) [o. 1391 + 0 . 0956 ( 1�P )] 

K- 5 
APPEND IX L 

METHODO LOGY FOR ESTIMATI NG SO LID AND LIQUID WASTE 

DISPOSAL REQUIREMENTS 
APP END IX L 

METHODOLOGY FOR ESTIMATING SOLID AND LIQUID WASTE 

D I SPOSAL REQU I REMENTS* 

L . l GAS C LEAN I NG AND COND ITIONING SYSTEMS 

Scrubb i ng water purged from gas cleani ng and cond i t i oni ng equi pment 

must be neutra l i zed s i nce th is eff l uent is in fact a weak sul fur i c 

ac id sol uti on. The effl uent is neutra l i zed via the fo l l ow i ng reaction: 

Thus , as i nd i cated , l i mestone ( CaC03) is used as the neutra l izing 

agent , p roducing cal cium sul fate ( CaS04 ), carbon d i ox i de gas , and 

water. Matthews et a l .1 report the fo l l owi ng l i mestone u sage rate s , 

based upon 0.03 percent S03 in the inlet gas stream: 

0.09 lb CaC03/106 scf ( regenerat i ve systems ) 

0 . 07 lb CaC03/106 scf ( nonregene rative sys tems ). 

Thus , by noti ng the s toich i ometry of the neutra lizat i o n reaction , an 

expressi on that re l ates the amount of cal cium sul fate p roduced and 

the vol ume of gas c l eaned can be devel oped as fol l ows : 

Let V = the i n l et gas stream vol umetri c f l ow rate in scfm ( 0° C) 

CaS04 product i on rate = V x 0 . 09 (or 0. 07) i�6

C

=��3 

x lb · mo l CaCO� x �l l b �m�ol C_aS0�4_�r�o�d�u�c�ed 

100 lb CaC03 lb mo l CaC03 o s umed 

x _1]£..lE_�.i�_S_Q.1 ;., §O

h

-�

r

ni n x 8, 400 h rs of operat i o n 

lb • mo l CaS04 yr 

*Becaus e sources from wh i c h data we re obta i ned us ed scfm at 0° C, 

the facto rs are cal cul ated on th is basis. Flows s hown in thi s BID 

mus t be converted to th is bas is be fore us i ng the facto rs. 

L -3 
Simi l ar 

x 1,000 g C aSO� � 

2 . 2 lb CaS04 x 10 g 

= 2.8 X 

2 . 2 X 

expres sions can be deri ved for 

in Mg per year 

10-

5 or v ( regenerat i ve) ' 

10-

5 v ( nonregenerative ) . 

the water producti on rate : 

Water p roducti on rate = 3 . 7 x 10-

6 V ( regenerative ) , or 

2 . 9 x 10-

6 V ( nonregenerat i ve). 

Once the CaS04 p roducti on rate is determi ned , s toich i ometry can be 

envoked o nce aga i n to determi ne the amount of ac id neutra l i zed: 

2 . 8 x 10-

5 v Mg CaS04 x � g · mo l H2S04 neutra l i zed 

yr Mg x 1 g • mo l CaS04 formed 

x 98 g H2 S04 x � x g • mole CaS04 in Mg per year g · mo l 10 g 136 g CaS04 ' 

= 2 . 0 x 10= 5 V ( regenerati ve ) , or 

1 . 6 x 10 5 V ( nonregenerati ve) . 

Then , once the amount of ac id neutra l i zed is determi ned , the total 

amount of l i qu id (cal c u l ated as water) requi ri ng d i sposal can be 

esti mated as fo l l ows : 

Not i ng that the purge is norma l ly about 10 percent H2S04 by we i ght , 

Total l i qu id effl uent rate - 2 0 x 10- 5 V x ( 1- 0 · 10) 

- . 0 . 10 

+ 3 . 7 x 10-

6 V = ( 18 x 10-

5 + 3.7 x 10-

6) V, in Mg per year 

-4 

= 1 . 8 x 10 V ( regenerat i ve ) , or 

1 . 5 x 10-4 V ( nonregenerat i ve) . 

L . 2 L IME/LIMESTONE SLURRY SCRUBBING PROCESS 

Matthews et al .1 report that s l udge cons i st i ng primar i ly of 

cal c i um sul fi te ( CaS03

) is produced at the rate of 6 to 7 l b s per lb 

L - 4 
of 502 absorbed . Thus , the rate of s l udge generati on can be esti mated 

as fo l l ows : 

S l udge generati on rate = V ( scfm) x C (% 502 ) x lb • mo l S02 

100 359 ft3 502 

64 lb 502 � 60 mi n 8 , 400 hr 6 lb s l udge x lb · mo l 502 x 100 x hr x 

yr x lb · 502 absorbed 

x 1•000 g x Mg in Mg per year , where n = the FGD S02 remova l 2 . 2 lb 106 g ' 'I 

effi c i ency ( 90 percent) . 

Condens i ng terms yi elds a s l udge gene rat i on rate (Mg/yr) of 2. 2 VC . 

Typica l ly, a mi xture of 15 we i ght percent s l udge 1 and 85 we i ght percent 

water is ponded ; therefore , the amount of l i quid that must be p umped 

to the pond can be esti mated as fol l ows : 

Liquid effl uent rate = 2 . 2 VC X ( 1-0. 15) 

0 . 15 

= 13 VC , in Mg/yr. 

L . 3 MAGOX SLURRY SCRUBBING PROCESS 

A s c rubber costs program deve l oped by PEDCo2 was used to esti mate 

the amo unt of absorbent purge taken from the MAGOX system . Thi s was 

done by assumi ng that the amount of sol id material purged ( assumed to 

be MgS03) is sto i chi ometri cal ly equ i val ent to the amount of MgO fed as 

makeup . The s ubrout i ne SMTMG l from the PEDCo p rogram cal cul ates the 

MgO makeup feed rate as fol l ows : 

a. 

b. 

c. 

d. 

502 feed rate ( l b/hr) = V ( s c fm) x C (% SOz ) x 60 x 64 

100 386 . 7 

so2 absorbed (lb/hr) = a. x S02 remova l effi c i ency 

100 

MgO actual ly cons umed (lb/hr) = b . x 0 . 625 

MgO requi red (lb/hr) = c . x 1 . 1 x 100 

502 removal effi c i ency 

e. Make up MgO (lb/hr) = d . x 0 . 0 5 

L-5 
As i nd i cated by expres sion 11 e11 above , the MgO makeup rate is expre s sed 

as 5 percent of the MgO actua l ly requi red. Assumi ng an S02 removal 

effi c i ency of 90 percent , Equati ons (a) through (e) can be condensed 

to yi eld the fo l l owi ng express i on: 

MgO makeup rate = 0 . 0034 VC , in lb MgO per hr. 

Convert i ng to Mg per year yiel ds a MgO makeup rate (Mg/yr) = 0 . 013 VC . 

As ment i oned previously, it has been ass umed that the amount of sol id 

material purged (assumed to be MgS03) is s toichi ometri cal ly equ i va l ent 

to the amo unt of MgO fed as makeup. The fo l l owi ng reaction was chosen 

to be representati ve of the stoich i ometry i nvol ved : 

As i nd i cated , the MgS03 is in the form of a hyd rated c rysta l . S i nce 

one mol of MgO is cons umed in the formati on of o ne mole of MgS03 • 

6H2 0 , an expres sion for the MgS03 · 6H20 purge rate can be deve l oped 

as fo l l ows : 

x lb · mo l MgO x 1 lb · mo l MgS03 

40 lb MgO lb · mo l MgO 

X 104 lb MgS03 X 1,000 g � lb · mol MgS03 2. 2 lb MgS03 

x 10 g 

x 8,400 hr 

= yr 

0 . 034 VC , in Mg per year. 

Next , assumi ng that the mi xture to be ponded is 2 we i ght percent 

sol i ds , 3 an express i on for the l i quid effl uent rate can be deve l oped 

as fol l ows : 

Li quid effl uent rate ( Mg/yr) = 0 . 034 VC x 1�0��2 

= 1 . 7 vc . 

L - 6 
L . 4 PARTICULATE MATTER CONTRO L ON REVERBERATORY SME LTI NG FURNACES 

To assess the i mpact of the evaporati ve coo l i ng procedu re on the 

gas stream vo l umetric f l ow rate , an energy bal ance is used to esti mate 

the amount of water that is evaporated in reduci ng the gas stream 

temperature from 400° C to 100° C. The energy bal ance has the fo l l owi ng 

form: 

- mG C

p llTG = m

w llHV , 

G w 

( L -1) 

where 

. 

m

G = the mo l ar f l ow rate of the gas s tream 

c

P = the specifi c heat capac i ty of the gas stream 

G 

= the tempe rature c hange assoc i ated wi th cool i ng the gas 

stream 

. 

m

w = the mo ls of water evaporated per unit time 

llHv = the l atent heat of vapori zati on of water at 100° C. 

w 

Si nce m

W is the quanti ty of i nterest , Eq . ( L-1) can be rearranged to 

yi eld: 

( L - 2 ) 

An average spec i f ic heat capac i ty for the reverberatory furnace o ffgas 

stream can be esti mated usi ng the fol l owi ng gas -stream compos ition: 

Component 

so2 

02 

N2 

H20 

C02 

Vo l % 

1.0 

11. 0 

The average heat capac i ty can then be cal cul ated as fol l ows : 

L- 7 
whe re 

y . = the gas stream vol ume fracti on of spec ies i 1 

c

P . 

= the speci fic heat capac i ty of spec i es i. 

1 

The fo l l owing pure component spec i f i c heat c apac i t i es are used: 

Com�onent S�ec i fi c heat ca�aci t� @ 

A l so , 

$02 39. 8 J/g . mol 

02 29 .4 J/g • mo l 

N2 29 .1 J/g · mo l 

H20 33 .6 J/g . mo l 

C02 37. 1 J/g 

c

P _ co. o12) ( 39 . 8) + co. o99 ) ( 29 . 4) 

G 

+ (0. 083) (29 . 1) + (0. 096) ( 33 . 6) 

· mo l 

+ (0. 044) ( 37 . 1) = 32 .4 Jig · mo l °K. 

�Hv = 40 .7 kJ/g · mo l @ 100° c 

w 

Now , mW can be estimated us i ng Equati on ( L-2) . 

L . 5 REFERENCES 

O

K 

O

K 

O

K 

O

K 

O

K 

25° c 

1. Matthews , J. C . , F. L. Bel l egi a, C. H. Good i ng, and G. E. Weant . 

502 Co ntrol Proces ses fo r Nonfe rro us Sme l ters . Researc h Tri ang l e 

I nsti t ute , Research Triang l e Park, N . C. Publ i cat i on No . EPA- 600/ 

2-76- 008. January 1976 . 

2. PEDCo Envi ronmenta l, I nc . , "Users Gu i de, Computeri zed Approach to 

Esti mati ng S02 Sc rubber Costs at Nonferrous Sme l ters , " E PA Contract 

No . 68-03- 2924 , Ap ri l 1982 . 

3. Anderson , K. P . , et a l ., " Defi nitive SO Contro l Process Eval uati ons : Li mestone , Lime , and Magens ia FGD P rocesses ," TVA ECDP B-7 , 

January 1980 . 

L-8 
APPENDIX M 

DETAI L ED COSTS FOR G REENF I E LD SMELTE RS 
C opper Smelter C osts 

Plant type : 

Exoansion Ootion : 

Control Option : 

Plant Scenario : 

MHR-RV-CV 

Not Applicable 

Ba.se Ca.se 

New 

Da.te : 0'?/1 4/82 

Time : 12:17 

Process costs indud � new hard w arE.> associatt:.>d with coppt-r p roduction. Fo r the oreen­

fielll sm�lter. the p rocess cost is the Baseline C ase Cost <Smelter p lus fugitive capture). 

For the expc10sion scenai"ios. pi"ocess costs indude any new roaster or convel" ter, 

Control costs indud� all equipm"'nt associ.:A.ted with emission reduction . Oxygen enrichmen t and m:

yfuel costs are considered as control msts alon2 �;-1ith acid plant and FGD costs 

fay the g reenfield smelter, Oxygen enrichment and oxyfuel costs are con sidered as expansion costs for existing p lants. 

CaP ital Cost 

Annua l i z ed Costs 

Raw Mater ials 

P r ocess water 

C oo l i n g water 

E l ectr icit":l 

SuPP • heat < N a t . qas ) 

B unker C Fue l Oil 

S o lid s disPosal 

Labor : D i r e ct OPe r a t i n g 

SuPe rvisio n 

Main t . : Labor & M at l . 

S •-• P e r v i s i on 

Over head 

T a xes . i ns •• a d Min . 

T o tal OPer at i ng Cost 

CaP ital Recov er":l Cost 

Annua l i zed Cost 

P r ocess 

1 6 2.o o o . o o o . 

688 . 62 5 . 

1 0 5.55 5 . 

0. 

3 49.86 0 . 

0 • 

9.5 3 8 . 8 3 0 . 

0. 

1 . 53 8 . 45 0 . 

307 . 6 9 0 . 

6.4 8 0.0 00. 

9 7 2 . 000 . 

4.6 4 0.0 7 0 . 

6.4 8 0 . 0 00. 

3 1 .11 0.1 00. 

2 6 . 3 6 5.5 00. 

57 . 4 7 5.6 00. 

Negative values indicate sa.vmgs over b a�e case costs. 

M-3 

Contr ol 

4 6 . 278.4 00. 

1 9 . 92 2 . 

1 34 . 899 . 

9 3 . 52 6 . 

6.4 7 1 , 85 0 . 

0 • 

0 • 

0 • 

309 . 8 1 2 . 

6 1 . 96 2 . 

1.85 1 . 1 4 0 . 

2 77.6 7 0 . 

1,25 0 . 2 9 0 . 

1 . 8 5 1 , 1 4 0 . 

1 2 . 322 . 200 . 

7 . 53 1 . 8 1 0 . 

1 9 . 8 5 4 . 000 . 
Plant type 

Expansion Option 

Control Option 

Pl�nt Scen�rio 

Cop per S me1ter Cost s 

KHR-RV-CV 

Not Applicable 

4 5" Blending + DC/DA CI-A> 

New 

Date : 02123/8 3 

Tille : 1 0 :18 

Process costs include new hardware a ssociated with copper production. For the g reenfield s•elter, the process cost is the B�seline Case Cost <Smelter plus fugitive capture>. 

For the expansion scenarios, process costs include any new ro�ster or converter. 

Control costs include all equipment associated with e11ission reduction. Oxygen enrichllent and oxyfuel costs a re considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Anr-.ua l i z ed Cost s 

Raw rn a t e �·ie:o.ls 

P �- ocess wa t e �­

Cc•o 11 ng wat e r' 

E 1 ect t· i cit y 

Supp. heat ( Na t . g as) 

B u n ker C Fue l O i l 

So l 1 ds dlS P O:•sa l 

L a bor : D1r ect O per a t i n g 

S '·'· pet'V 1 s i on 

!Yi.:u n t . : Lab·=· �- & Mat 1. 

Supe t'V 1 s 1 •:•n 

Ove�·head 

T a xes, i ns . , adm i n . 

Tot al O oerat 1 n g Cost 

C a pital Recovery Cost 

Annua 1 i zed C o:•st 

0. 

0. 

0. 

0. 

0. 

0. 

0. 

0. 

0. 

0. 

0. 

121. 

0. 

0. 

0. 

0. 

C on t �· o l 

61, 1 87 , 1 00. 

E: B, 660 . 

1 6 4, 99'3. 

1 34 , 550. 

9 , 310 , 590. 

E. , 700 . 

0. 

0. 

30'3 , 812 . 

bl, '362 . 

2, 44 71 4812•. 

367, 1 22. 

1' 533, 1 9 0. 

2 , 447, 480. 

1 6 , 872, 5.210. 

'3, 'JSfl , 1 '3 0. 

2£., 83121 , 700. 

Negative val ues indicate savings over base case costs. 

M-4 
Plant type : 

Exoans1on Option : 

Control Ootion : 

Plant Scenario : 

MHP.-RV-CV 

Not Applicable 

MgO FGD + DC/DA <I-B> 

New 

Date : 09/1 4./82. 

Time : 12:1 ::: 

Process costs indude new hard w an� associated with capp�r p roduction. Foy t he oreenfieltJ smelter. the process cost i5 the Baseline Case Cost <Smel ter plus fugitive capture). 

For the expansion scenarios. p rocess costs indude any new roaster" or converter. 

Control cas ts indude all equipm•mt assod�ted with emission reduction. Oxygen enrichmen t and oxyfuel costs are considered as control costs along with acid p lant and FGD costs 

for the g reen field smelte'f'. Oxygen enrichment and oxy Fuel casts are considered as exp an sion costs for existing p lants. 

CaP ital Cast 

• �nnua l :L :z: ed Costs 

Raw Mat(: "f' ials 

Process water 

Coo linq water 

El(:ctr ici·t ·� 

SuPP . heat < N at. gas ) 

Bunker C Fue l Oil 

S o l i d s d i sPosal 

L a bor : Dire ct OPer a t i ng 

S up e rvision 

Main t . : Labor & M a t l . 

SuP e rvis i o n 

Over head 

Taxes . i ns � t a dMin . 

Tota l 0 P erstinq Cost 

CaP i t al Reco ver � C ost 

Annua l 1 z ed Cost 

P r ocess 

0 • 

0 • 

0. 

0. 

0 • 

0. 

0. 

0. 

0 • 

0 • 

0 • 

0 • 

0 • 

0 • 

0. 

0. 

0 • 

Negative values indicate savings over base case costs, 

M- 5 

Cont1�o1 

7 3 . 9 9 6.9 00 • 

5 98.64 1 . 

2 2 0 . 9 3 8 . 

1 0 7.53 8 . 

7.2Z 1 t 5 �3 0. 

0 • 

3.73 3 . 57 0 . 

0 • 

5 57.66 2 . 

:1.11.53 2 . 

2.95 9 . 88 0 . 

443 . 98 2 . 

2 . 0 36 . 5 3 0 . 

2.95 9 ., 88 0 . 

2 0 . 95 1 . 7 0 0 . 

1 2 . 0 4 3 . 000 . 

3 2 . 99 'f . 700 . 
Plant type ! 

Exoans1on Option : 

Con trol Ootion : 

Plant Scenario : 

MHR-RV-CV 

Not Applicable 

NH3 FGD + DC/DA <I-C > 

New 

Date : 0'?/1 4/82 

Time : 12!18 

Process costs include n ew hard ware associated with capper p roducti on. For the oreenfield smE-lter. th� p rocess cost is the Baseline C ase Cast (Smelter plus fug itiv� capture), 

For the expansion scenarios. process costs include any new roaster or converter, 

Control costs include all equipmen t associated with emission reduction. Oxygen enrichment and o.x:vFuel costs are considered as control costs along with arid plant and FGD costs 

for the g ree-;,field smelteY. Oxygen enrichment and oxyfuel costs are- considered as exp an sion costs for existing plants. 

CaP i -t a l Cost 

Annual i z ed Costs 

Raw Mater ials 

P r ocess water 

Coo l i nq wateT' 

Electr icit'j 

S up p . heat < N a t . qas ) 

Bunker C Fuel Oil 

Sol ids disPo sal 

Labor : Direct OPerating 

S uP ervision 

M a i nt . : Labor & M a t l . 

SuP e r vision 

Overhead 

Taxes . i ns •• a d Min . 

T otal 0Peratin q Cost 

CaP i t al R �cover � Cost 

Annua l i zed Cost 

P r ocess 

0 + 

0. 

0. 

0 • 

0. 

0. 

0. 

0 • 

0. 

0 • 

0 • 

0. 

0. 

0 • 

----------

0 • 

0 • 

-

---------

0 • 

Negahve values indicate savings over base case costs. 

M-6 

Contr ol 

6 2 . 83 9.200 . 

4.66 4 . 44 0 . 

1 4 7.1 4 1 . 

54-l . 95 5 . 

8.79 9 . 4 4 0 . 

0. 

0 • 

0 • 

743 . 54 9 . 

1 48.7 1 0 . 

2.5 1 3 , 57 0 . 

377 . 0 3 5 . 

1 . 8 9 1 . 43 0 . 

2.5 13,57 0 . 

---------

2 2 . 34 3,8 00. 

1 0 . 22 7.1 0 0 . 

---------

3 2 . 570 . 9 0 0 . 
�melten-- C osts 

Plan t bpe : 

Expansion Option : 

Control Option : 

Plan t Scenano : 

MHR-RV-CV 

Not Applicable 

LL FGD 11- DC/DA (I-Dl 

New 

Date : 09/ 1 4/8:::: 

Time : 12:19 

Procesc; costs include new hardware <lssoda,ted with copp�r p roduction. For t he oreenfield smelter. the p rocess cost is t he Baseline Case Cost (Smelter plus fugitive capture). 

For the expansion scenarios. p rocess costs include any new roaster or converter. 

Control casts include all equipment assodilted with emission reduction. Oxyg en enrichmf'nt and oxyFuel costs are con sidan�d as control costs along with add plant and FGD costs 

f0r the g reen field smelte'l". 0 .· ·�Jen enrichment and oxy fuel costs are considered as exp an sion costs for existing p la.f} ts. 

CaP ital Cost 

Annu a l i z ed Costs 

Raw Mater ials 

P r ocess water 

C o o l 1nq water 

E l ectr i c i t ':i 

S uP p . heat ( N a t . gas ) 

Bunk er C Fuel O i l 

S o lid s d i s P osa l 

Labor : Direct O P e r ating 

Super vision 

M a i nt . : Labor & Matl . 

SuP e rvis ion 

Overhead 

Taxes . i ns . , a ciMin . 

Tota l O P erat i ng Cost 

CaP i t al Recov er� Cost 

Annu a l i :z: <�d Cost 

Pr ocess 

0 + 

0 • 

0 • 

0 + 

0 • 

0 + 

0 • 

0 • 

0 • 

0 • 

0 • 

0 • 

0 + 

0 • 

0 • 

0 + 

0 • 

Negative values mdicate savings over base case costs. 

M- 7 

Contre>l 

6 9 . 7 4 2 . 000 . 

1 . 2 4 3 . 260 . 

217 . 3 l 3 . 

9 3 . 52 6 . 

6.7 5 2.5 l 0 . 

0 • 

0 • 

820 . 82 1 . 

t"557 . 662 . 

111.53 2 . 

2.78 9 � <S80 + 

418 . 45 2 . 

1 . 9 3 8 . 66 0 . 

2.78 9 . <SB O . 

1 7 . 7 3 3.:LOO . 

1 1 . 35 0 .500 . 

2 9 . 0 8 �:3 � 600 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Seen a rio : 

MHR-RV-CV 

Not Applicable 

1 00•t. Blending + DC/DA <I-E) 

New 

Date : 02/02/83 

Time : 1 3:31 

Process costs indude new hardware associated with copper production. For the g reenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For t he expansion scenarios, process costs indude any new roaster or converter. 

Control costs in dude all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap i tal Cost 

Annualized Costs 

Raw Mater ials 

P r ocess water 

C oo l i ng water 

Electr i c i t� 

S up p . heat < Na t . gas ) 

Bunker C Fue l O i l 

Sol i ds disp osal 

Labor : Direct O p erating 

Sup ervision 

M a i nt . : Labor & M at l . 

Sup ervision 

Over head 

Taxes , i ns . , a dMin. 

Tota l O p e r ating Cost 

Cap ital Recover � Cost 

Annua l i zed Cost 

Proces s · 

0. 

0 • 

0 • 

0 • 

0. 

0. 

o. 

0 • 

0 • 

0. 

0. 

0. 

0. 

0 • 

0. 

o. 

---------- . . 

0. 

Negative values indicate savings over base case costs. 

M- 8 

Contr ol 

7 .1, 23 1 , 1 00. 

3 9 , 32 2 . 

2 26,38 1 . 

1 8.1, 6 05. 

11, 5 2 7 , 7 0 0 . 

7 2 , 6 0 0 . 

o. 

o. 

278 , 83 1 . 

5 5 , 76 6 . 

2,969 , 2.10. 

.lf.lf5 , 38 7 . 

1,87 .1, 6 10. 

2,969 , 2.10. 

2 0 , 6.13,7 00. 

1 2 , 0 8 1 , 1 00. 

3 2 , 72 .1, 8 0 0 . 
Plant type 

EXP'!lnsion Option : 

Control Option 

Plant Scenario : 

C o p per Smelter Cost s 

MHR-RV-CV 

Not Applicl!lble 

Oxygen enrichaent • OC/DA CI-F> 

N ew 

Date : 0 2/07/8 3 

Tiae : OQ:4Q 

Process costs include new hardware associa ted with copper production. For the g reenfield smelter, the process cost is the Baseline Case Cost CSaelter plus fugi tive capture>. 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment associated with emission reduction . Oxygen enrichment and oxyfuel costa are conaldered •a control costa along with acid plant end FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel coats are considered as expansion costs for existing plants. 

Cap ital C o:.st 

Any, ua 1 i z ed Costs 

Ra w m a ter·ials 

P t·ocess wat e t' 

Co o:• l i n g wat e r' 

E 1 ec t r· i city 

Supp. heCl.t < Na t . gas) 

Bun ker C Fue l O i l 

So l i ds d 1 s o osa l 

L a bor : D i rect O perat i n g 

5 U PSt'V iS l C•Y"I 

M a 1 y-, t . : La bot' & Mat 1 • 

Supet· v 1 s i o:•n 

Ovet'head 

Ta xes, 1 ns . , a d rni n. 

Tot al Operat i n g Cost 

C a pital Recovery Cost 

P r' O:•cess 

Ill . 

Ill . 

Ill . 

121. 

Ill . 

121. 

-1, 716, '3'30 . 

0. 

Ill . 

Ill . 

Ill . 

121. 

Ill . 

Ill . 

-1, 71£, , 990. 

0. 

-1, 716 , 930 . 

Co:•Yit t'O:• l 

IS 7, 215 , 300. 

1, 9 4 1, BtSIZI . 

1 93, 775. 

1 5 8, IZlltS . 

9 , 867 , 310 . 

5, 700. 

Ill . 

Il

. 

278, 8 3 1. 

s =:., 766 . 

2, E. e.a, 610 . 

403, 232 . 

1 , 713 , 250. 

2 , 688, 610 . 

1 9 , 995, 17100. 

1 0 , 939 , 300. 

30, 93'+, 300. 

Nega tive values indicate savings over base case c osts. 

M-9 
C op per Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

MHR-RV-CV 

Not Applicable 

Oxy-fuel burners + DC/DA <I-G> 

New 

Date : 1 0/15/82 

Time : 14:10 

Process costs indude new hardware associated with copper production. For the oreenfield smelter. the process cast is the Baseline Case Cost (Smelter plus fugitive capture). 

For the expansicn scenarios. process costs indude any new roaster or converter. 

Control costs indude all equipment assada.ted with emission reduction. Oxygen enrichment and oxyfuel costs are considered as conh'ol costs along with add plant and FGD costs 

for the greenfield smelter, Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

CaP ital Cast 

Annua lized Costs 

Raw Mater ials 

P r ocess water 

C oo l i nq water 

E l ectr i c i t-; 

SuPP • heat ( Na t . qas ) 

Bunker C Fuel Oil 

So l i ds disPosal 

Labor : Direct Oper ating 

SuP e rvis i on 

Maint . : Labor & M at l . 

S •.•P e r vision 

Overhead 

Taxes . i ns •• a dMin . 

T otal 0Per atinq Cost 

Cap ital Recover� Cost 

Annua l i z ed Cost 

P r ocess 

0 • 

0. 

0. 

0 • 

0. 

0. 

- 3 .815.53 0 . 

0 • 

0 • 

0. 

0 + 

0 • 

0 • 

0 • 

------- ---

- 3.815.53 0 . 

0. 

--- ------ -

- 3 .815,53 0 . 

Negative values indicate savings over base case costs. 

M- 10 

Contr ol 

5 5 . 2 1 6 . 6 00. 

3.63 0 . 0 2 0 . 

1 86 . 034 . 

1 28.97 8 . 

8 . 0 54.0 9 0 . 

0. 

0. 

() . 

2 78.83 1 . 

55. 766 . 

2.2 08.66 0 . 

331 . 29 9 . 

1 . 43 7 . 28 0 . 

2.2 08,66 0 . 

---------

18.5 1 9 . 6 0 0 . 

8.98 6 . 49 0 . 

-------- -

2 7 . 5 0 6.100. 
APPEND IX N 

FUG ITIVE EMI SS I ON CONT ROL COSTS 
Fug i tive C on trol C osts 

Annualized Costs \$ 1 000's. June 1 981) 

Plant Capture System Collectlon System Capt•Jre + Collect1on 

w!EE iLil

 � � w1EE � 

Greenfteld Plants 

r1HR-RV-CV 

MHR 39 JQ 23'1 Z3"1 273 273 

RV 103 1 0 3 533 533 636 636 

cv 1 , 713 2,2 37 "1 , 1 8 5 1 • 'I 0 1 5.8 98 3,638 

FF-CV 

FF 78 78 358 358 436 436 

C 'J 1 , 713 2 � 237 "', 1 85 1,'1 01 5,8 98 3 , 638 

Expanswn Ease Cases 

T 

. MHR-!'1V-CV 

MHR 39 39 234 23"1 273 273 

RV 1 0 3 1 0 3 533 533 o36 o36 

cv 1 . 713 2 , Z37 '1 , 1 85 1 , "101 5,8 98 3 . 638 

II RV-Cl 

RV 1 0 3 1 0 3 533 533 o36 636 

cv 1 , 7 13 2,.2 37 4 , 1 8 5 1 , '101 5,3 98 3,638 

I! I FBR-RV-C'l 

F E: R 0 0 0 0 0 0 

RV 103 1 Q 3 533 533 1

636 636 

cv 1, 713 2,2 37 '1 , 1 85 1 , '101 5.8 98 3,6 38 

IV EF-CV 

EF 103 103 'l91 '191 59'1 5 9 4 

cv 1,7 13 2 , 2 37 'I, 1 85 1,'l 01 5.898 3t6 38 

v FF-CV 

FF 78 78 358 358 '!36 436 

ESCF 66 66 491 '191 557 557 

cv 1 , 713 2,2 37 4 , 1 8 5 1, 'IG 1 5,0 98 3,638 

C:..cpans1on Opt10ns 

<l-1 3 

cv 0 7 '! 6 'l2 579 '!2 1 . 3 25 

18 

F E:R 0 0 0 0 0 0 

CV 0 746 "12 579 '12 : ; 3 :-:

5 

==============:: 

- All labor costs are ass1gned to the collect10n � ystem <bag house) 

- Electncal usage rate 1s calculated as 2.5 * 10 kwh/yr- 1 000 scfm 

N-3 
Fug itive C on trol C osts 

Cao1tal Costs ($ 1 000's, June 1 981) 

Pla.nt Flow Caoture System Collection S:;stem 

\ 1 OOO's SCFM> Hoods a'ld d uctlng A1r CurtaJn \Bag house) 

'N/ BE w lAG �!£3.£ WIAC � W I AG_ 

Greenf1eld Plants 

HHR-RV-CTJ 

MHR 20 20 116 116 0 57 1 571 

RV 65 65 298 298 0 1 . 539 1.539 

cv 750 zoo 5.300 1 , 7 23 6 . 170 1 2 . 2 13 4 • 1 3:3 

FF-CV 

.-� r r 45 45 Z24 224 0 1,1 30 1.1 30 

C 'J 7 5 0 zoo 5,300 1 , 7 Z3 6 . 1 7 0 1Z. Z13 4 , \33 

E:x:pans1on E ase C ases 

I MRR-RV-CV 

MHR 20 zo 11o 1 1 6 c 571 571 

RV 65 65 298 298 0 1 . 5 39 1 . 5 39 

cv 750 200 5.300 1,7 23 6' 170 1 '2 , 2 13 � . 133 

I! RV-CV 

F:v 65 65 298 298 0 1 . 5 39 1 . :i 39 

cv 750 zoo 5.300 l t 7 23 6 . 170 1 � t 2 13 'l . 1 33 

IE FBR-RV-CV 

F E: J;· 0 0 0 0 0 0 0 

F: V 65 65 298 298 0 1 , 5 39 1 , 5 39 

cv 750 zoo 5.3 00 1 . 723 6 . 170 1 2 , 2 13 4 , 133 

IV EF-CV 

!:F 65 6� 298 298 [J 1 , 5 39 1 , 5 39 

cv 750 zoo 5.3 00 1 . 7 23 6 . 170 12, 213 4 , 133 

v FF-CV 

FF 45 45 Z24 224 0 1. 13 0 1.1 30 

ESCF 65 65 239 239 0 1 , �39 1 . 539 

C 'J 750 200 5 . 300 1 , 7 23 o . 1 7 0 12.2 13 4 . 133 

E:cpa.ns1on Optlcns 

'1- 13 

cv 0 0/ 575 2. 0 5 7 0 1 , 6 "'17 

13 

F E:R 0 0 0 0 0 

C tJ 0 67 0 c-c- .J/ ..

 • : . 0 5 7 0 l . o 47 

============== 

1No fug1tlve controls are requ1red on a i1u:d b ed roaster. <S2e Sectlon 4 ,7,.1) 

� 

'l:t !S assumed that a new converter •,o�ould be adaed 1n an ex1st1ng bu1ld1ng, Smce the !:lulldmg evac.Jatlon cost 1s 

a funct1on :Jnly .:Jf bu1ld1ng sue, no new =ost w culd be 1ncurred for fug1t1ve control w1th Eu1ld1ng Evacuanon. 

3.Th1s 1s 1!3 of the ASARCO-Taccma au curtain des1gn flow rate. 

N-4 
AP PENDIX 0 

DETAILED COSTS FOR EXPANS I ON SCENARIOS 
r. opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

MHR-RV-CV 

Oxygen enrichment 

PB - SC/SA 

1 

Date : 02/04/83 

Time : 0 1 :06 

Process costs indude new hard ware associated with copper production. For the greenfield smelter, the process cost is the Baseline Case Cost CSmelter plus fugitive capture>. 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs include all equipment associated with emi�sion reduction . Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cos t 

Annua liz ed Costs 

F\ aw Mater ial!:> 

Pr o ces�, water 

Co oling water 

E l ectr icit':1 

S up p . heat ( Na t . gas ) 

Bunker C Fuel O i l 

S o l i d-:; disposal 

Labo r : D i r ect Oper ating 

S up ervisi on 

Maint . : Labor & M a t l . 

Super v i !:> i on 

Overhead 

Taxes , i ns . t a dMin. 

Tota l O p erating Cost 

Cap i t al Recover ';:1 Cost 

Annua lized Cost 

P r ocess 

510 , 0 00. 

2,63 5 , 4 :3 0 . 

o. 

0. 

9,53 4 . 

0 • 

341 ,201 . 

o. 

0. 

o. 

2 0 , 4 0 0 . 

3 , 0 6 0 . 

11,73 0 . 

2 0 , 4 00. 

---· - ------

3,0 4 1 , 75 0 . 

8 3 , 0 02. 

----- ----·-

3 t 1 �� 4 , 75 0 . 

Negative values indicate savings over base case costs. 

0- 3 

Contr ol 

10,9 0 7 , 60 0 . 

9,52 9 . 

17,32 2 . 

4 4 , 737 . 

1,64 1 , 5 10. 

6 0 , 0 0 0 . 

0 • 

0. 

0. 

o. 

4 36t3 0 3 . 

6 5 , 4 4 5 . 

250 t 8 74 . 

436 , 3 0 3 . 

---------

2,962 , 0 2 0 . 

1 , 7 7 5 ,210 . 

---------

4,73 7 , 230 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

MHR-RV-CV 

Oxygen enrichment 

LL - SC/SA 

2 

Date : 02/04/83 

Time : oo:o 1 

Process costs indude new hardware associated with copper production. For t he greenfield smelter, t he process cost is t he Baseline Case Cost <Smelter plus fugitive capture). 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs indude all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap i tal Cost 

Annua l i zed Costs 

Raw Mater ials 

P r ocess water 

C oo l i ng water 

E l ectr icit� 

Supp . heat ( Na t . gas ) 

Bunker C Fue l Oil 

Sol i ds disp osal 

Labor : Direct Oper ating 

Supervis i on 

M a i nt . : Labor & M at l . 

Sup ervisi on 

Over head 

Taxes , i ns . , a dMin . 

Total Oper ating Cost 

Cap ital Rec over � Cost 

Annua l i zed Cost 

P r ocess 

5 1 0,0 00. 

2,63 5 , 430 . 

0. 

o. 

9,53 4 . 

0 • 

3 4 1 , 2 0 1. 

0. 

0. 

0 • 

2 0 , 4 00. 

3 , 0 6 0 . 

1 1 , 73 0 . 

2 0 , 4 0 0 . 

8 3 , 0 02. 

Negative values indicate savings over base case costs. 

0-4 

Control 

15,55 9 , 600 . 

230 , 27 0 . 

2 4 , 5 0 4 . 

2 0 , 25 8 . 

1,0 4 1 , 0 0 0 . 

o. 

0 • 

151 , 6 0 9 . 

278 , 83 1 . 

55 , 76 6 . 

622 , 38 4 . 

9 3 , 35 8 . 

5 25 , 170 . 

622 , 38 4 . 

2,53 2 , 33 0 . 

6 , 1 97,86 0 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

MHR-RV-CV 

Oxygen enrichment 

MgO - SC/SA 

3 

Date : 02/04/83 

Time : 00:02 

Process costs include new hardware associated with copper production . For t he g reenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

Ann•_.al i z ed Costs 

Raw Mater ials 

Process water 

Co o l i ng water 

Elect r icit� 

S up p . heat < Na t . gas > 

Bunker C Fuel O i l 

Sol i ds disp osal 

Labor : Direct Op e r ating 

Super vision 

M a i nt . : Labor & M a t l . 

Sup ervis i on 

Over head 

Taxes , i ns . , a dMin. 

Tota l O p erating Cost 

Cap ital Recover� Cost 

Ann•-• a 1 i zed Cost 

P r ocess 

510 , 0 00. 

2,63 5 , .lf 3 0 . 

o. 

0 • 

9,53 .t. 

0 • 

3 .lf 1 , 2 0 1 . 

0. 

0 • 

o. 

z o , .to o . 

3,0 6 0 . 

11,73 0 . 

2 o , .too. 

------- ---

3 , 0.lf1 , 75 0 . 

83, 0 0 2. 

----- -----

3 , 12.lf , 75 0 . 

Negative values indicate savings over base case costs. 

0-5 

Contr ol 

17,58 9,6 0 0 . 

1 1 13 , 93 2 . 

23 , 37 1 . 

2 3 , 63 5 . 

1 , 0 56,68 0 . 

0 • 

7 25 , 197. 

0. 

278 , 83 1 . 

5 5 , 76 6 . 

7 0 3 , 58 3 . 

1 0 5,53 7 . 

57 1 , 85 8 . 

703 , 58 3 . 

--- ------

4,36 6 , 97 0 . 

2,862,7 00. 

---------

7,229 , 67 0 . 
Plant type 

Expansion Option 

Cont rol Option 

Plant Scenario : 

C c• p p (-:>- ..- S n1 e 1 t e -r-·· C c•st s 

MHR-RV-CV 

Oxygen enr ichment 

NH3 - SC/SA 

4 

Date : 02/08/8 3 

Time : 09:01 

Pr ocegs coets include new hardware a ssociated with copper production. For the greenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For the e x pansion scenarios, process costs include any new roa ster or converter. 

Cont rol coste include all equ ipment a ssoci a ted wi th emi ssion reduction. Oxygen enrichment and oxyfuel costs are considered as control costs a long with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel coats are conBidered as expansion costs for exist ing plants. 

"b v-J r.1 ,:,. t e .,, i. 2 l s 

J:' ! · �:· c t.�· :� s �#>J 3 t f'-:> r-. 

[ ,-, .:·, : J 1'1 t:; \•I i-< t E� ·,-. 

E l e c t ,- J c i t y 

S •J LJ :>, ·-: '? <.•.t ( :·1 ;:-. ;:. s :-· ") 

Lun'.( er' C F •-'1:21 •J 1l 

S ,_-, l i C. :_ C 1 "" :.• C• ::; i� } 

�- -� '�.:. � - � D L r' C:c: :� i :• >c:>) - ,_< '. l t • r: 

s l_l c: �· .- \1 i �=' i CIY· 

'

' ;:. 1 n t . : L :' �-i o r·· (,_ tv ,� t � . 

C'l C: f1l i Y': . 

Tot al O p erat i n g Cost 

Pl- C• r: E: ,., s 

5:;_1Z,, 1N �0. 

E:, £,35, Lf 2": �71. 

0. 

0. 

9, ��3 4. 

0. 

:;;) . 

IZ' . 

. ..:. :?t � '+ G •7 • 

:w 1 , -, 2 ,Lf • 

• :: ·ZI , '+ ::: •<·I • 

E�3, 17102 . 

':� 09, (711 il. 

_ l \ 4 1ZI ;=� . 

l 1 1Z' , ;=: 37. 

1' L> 28, 1 4 0. 

i? . 

IZ· . 

�=' · 

't t: l� .. 7 � J3 " 

r-l ;: 'l ·:�. !, 4 • 

c: -� t�· I L-t 7 '3 . 

:: :: l�·. " 't �� £ . 

::. -�. ::.:. •. 4 7'3. 

Neg a tive values indicate savings over base case costs. 

0-6 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxygen enrichment 

PB - SC/SA 

7 

Date : 02/04/83 

Time : 16:48 

Process costs indude new hardware assodated with copper production . For the greenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture>. 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs inc:lude all equipment associated with emission reduction . Oxygen enrichment and oxyfuel costs are considered as control costs along with add plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing p lants. 

Cap i t al Cost 

Annua l i zed Cost!:> 

Raw Mater ial!=> 

Process water 

C oo l i ng water 

Electr icit':1 

Sup p . heat < Na t . gas ) 

Bunker C Fue l Oil 

S o l i d s disp os a l 

Labor : Direct Oper ating 

S up ervision 

M a i nt . : Labor & M at l . 

S up ervis:i orr 

Over head 

Taxes , i ns . , adM i rr. 

Tota l O p erating Cost 

Cap ital Recove r 'j Cost 

A nnual i zed Cost. 

Process 

5 1 0,0 00. 

2,69 0 , 98 0 . 

0 • 

o. 

4 , 66 2 . 

0 • 

-158,76 0 . 

0. 

0 • 

0 • 

2 0 , 4 00. 

3,0 6 0 . 

11, 73 0 . 

20,4 0 0 . 

---- - - --- - -

2,59 2 , 4 7 0 . 

8 3 , 0 0 2 . 

- -· - - --- ---

2,67 5 , "1 7 0 . 

Negative values indicate savings over base case costs, 

0- 7 

Contr ol 

1 1 , 36 0 , 90 0 . 

1 0 , 6 0 8 . 

1 2 , 4 7 3 . 

4 9 , 8 0 2 . 

1 , 631 , 45 0 . 

14,:3 0 0. 

0 • 

0 • 

0. 

0 • 

454 , 4 3 6 . 

6 8 , 1 6 5 . 

261 , 3 0 1 . 

454 , 4 36 . 

- - -- - - ----

2,956 , 980 . 

1 1 84 B , 9 9 0 . 

------ ---

4,8 0 5 , 96 0 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxygen enrichment 

LL - SC/SA 

8 

Date : 02/04/83 

Time : 1 5:4b 

Process costs include new hardware associated with copper ;'roduction. For t he g reenfield smeltert t he process cos.� is t he Baseline Case Cost <Smelter plus fugitive capture>. 

For the expansion scenariost process costs include any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for t he greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

Ann•.1 a l i zed Costs 

F� aw Mater ials 

P r ocess water 

C oo l i ng water 

E l ectr icit'j 

Supp . heat < Na t . gas ) 

Bunker C Fue l Oil 

S o l i ds disp osal 

Labor : Direct O p erating 

Super vision 

Maint . : Labor & M a t l . 

Sup ervision 

Over head 

Taxes , i ns . , a dM i n. 

T otal O p er ating Cost 

Cap ital Recover'j Cost 

Annua l i zed Cost 

P r ocess 

5 1 0,0 00. 

2,69 0 , 98 0 . 

o. 

0. 

4,66 2 . 

0. 

-158,76 0 . 

0. 

0. 

0 • 

2 0 , 4 00. 

3 , 060 . 

11,73 0 . 

2 0 , 4 0 0 . 

------ -- - -

2,59 2 , 4 7 0 . 

8 3 , 0 02. 

- - ------ --

2,67 5 , 47 0 . 

Negative values indicate savings over base case costs. 

0-8 

Contr ol 

17,5 07,9 0 0 . 

-'t 1 4,89 6 . 

3 5 , 4 0 2 . 

2 5 , 32 3 . 

1 , 1 35,7 0 0 . 

0 • 

o. 

274 , 76 3 . 

2 78,83 1 . 

5 5 , 76 6 . 

7 0 0,3 17. 

1 0 5 , 0 4 7 . 

5 69,98 1 . 

7 0 0 , 3 1 7 . 

---- -- - - -

4,29 6 , 34 0 . 

2,849,4 1 0 . 

- -- ---- - -

7 , 1 45 , 7 6 0 . 
Copper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxygen enrichment 

MgO - SC/SA 

9 

Date : 02/04/83 

Time : 1 6:23 

Process costs indude new hardware associated with copper production. For t he g reenfield smelter, t he process cost is t he Baseline Case Cost <Smelter plus fugitive capture). 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs indude all equipment associated with emission reduction . Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

Annua l i zed Costs 

Raw Mater ials 

Pr ocess water 

C oo l i ng water 

E l ectr i c it� 

S up p . heat ( Na t . gas) 

Bunker C Fue l Oil 

S o l i d s disp os a l 

Labor : Dire ct Oper ating 

Supervision 

M a i nt . : Labor & M a t l . 

Sup ervis i on 

Overhead 

T a xes , i ns . , a dMin. 

Tota l O p e r a t i ng Cost 

Cap ital Recover � Cost 

Annual i zed Cost 

P r ocess 

510 , 0 00. 

2,69 0 , 98 0 . 

0 • 

0 • 

.t 662 . 

0 • 

-158,7 6 0 . 

0. 

o. 

0 • 

2 0 ,"100 . 

3,0 6 0 . 

11,7 3 0 . 

2 o , .q o o . 

2,59 2 , "1 7 0 . 

8 3 , 0 02. 

2,6 7 5 , "1 7 0 . 

Negative values indicate savings over base case costs. 

0-9 

Control 

2 0 , 2 0 "1 , 9 0 0 . 

207 , 96 3 . 

3 1 , 98 "1 . 

2 9 , 5"1 "1 . 

1 , 1 6"1 , 310 • 

0 • 

1 , :314 , 5 0 0 . 

0 • 

2 78,83 1 . 

5 5 , 7 66 . 

808 , 1 95. 

121 , 22 9 . 

6 32,011. 

808 , 1 95. 

5 , "1 52 , 52 0 . 

3,28 8 , 35 0 . 

8,7 "1 0 , 87 0 . 
Plant type 

Exp.gnsion Option 

Cont rol Opt ion 

Pl�nt Scen�rio : 

Copper Smelte r Co�t� 

RV-CV 

Oxygen enrichment 

NH3 - SC/SA 

1 0 

Date : 0 2 /08/8 3 

Time : 09:03 

Process costs incl ude new hardware a ssociated with copper production. For the greenfield smelter, the p r ocess cost is the Baseline Case Cost CSmelter plus fugitive capture). 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment a ssociated with emission reduction. Oxygen e nrich -

ment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expa nsion costs f or existing plants. 

C c? IJ �_t,�l Cost 

C c· o l i v, g �·L< te. ' 

E :. ect �' l r: J. ty 

S •.•. r::r p. f·: c <, t < �-�""'t . l>'-·- �;: .l 

B ·-� i"d-< t=· r' C F '-' e l \l 1 l 

S·:· 1 i d c:. d 1. ': ;1 •.:.•S <.i l 

l __ d, b C•t� : [' .& 'r"' f� �--. t CJ ::JE'r-.c\t .i i'"J r_l 

S u p c� .,. .. v J � � ··:a r1 

t( a 1 n t . : !.. <:1 tK.•�" .P,. i7. ,'1 t l. 

£. 1J ;:lf:'l"V i. <:=. i 0:0 �"1 

OvP.•'h ead 

1 c-=t X E? S , i n :.;, • ' M C fl1 j l'"J • 

C'•·r""C•C€:.· C.: S 

!:o -" IZ\ 1 �� I?!QI. 

2 ., G'30� S8tZ1. 

IZI . 

il. 

'+, 6SE�. 

IZI . 

-- �L '=:. 19 ' 7 G �71 .. 

0. 

'.'ZI . 

0. 

c' :Zl, �� v.: 0. 

2., tlu:':,0. 

11' 7 ::.IZi. 

.=:::, 4-:Zi i/) . 

;::, 5'32 , 47lZI. 

[ C•nt. t" O l 

1 5 , 57 6, IZ'iZ•IZI. 

1, t=- =�g� s .:: IZI . 

9, 7 17:.-'3. 

1 8.�. , 9 [•. E, . 

1, 0 '+.E:., 'f l;': l{l . 

0. 

iZI . 

0. 

·+E>'�, 7113. 

C);:· l •] L: �� • 

f�.j ': ��. ' (',/; 0. 

r:-1 �. ; 4· 5 !"".:. • 

6 7..7' 07":3. 

� -=· ::, 041Z• • 

L::� ':3 4 , 'J'J0. 

Negative values indicate savings over base case costs. 

0- 10 
C opper Smelter Costs 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxy-fuel burners 

PB - DC/DA 

11 

Date : 02/04/83 

Time : 1 5!47 

Process costs indude new hardware associated with copper production. For the g reenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture>. 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs indude all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with add plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing p lants. 

Cap ital Cost 

A nn'-'a l i zed Costs 

Raw Mater ials 

P r ocess water 

Coo l i ng water 

E l ectr icit� 

S'-'PP • heat < Na t . gas ) 

8'-'nker C Fue l O i l 

So l i ds disposal 

L abor : Direct Opera t i ng 

S upervision 

M a i nt . : Labor & Matl . 

Super vision 

Overhead 

T axes , i ns . , a dMin. 

Tota l Operating Cost 

Cap ital Recover � Cost 

Ann•.•al i z ed Cost 

Process 

3 2 , 8 00,.0 0 0 . 

7 , 031 , 76 0 . 

0 • 

o. 

11,. 63 � . 

0. 

-992,25 0 . 

o. 

92 , 9� � . 

18,58 9 . 

1,3 1 ��,0 00. 

1 96,8 00. 

8 1 0 , 1 66. 

1 , 3 12, 000 . 

- - --- ---- -

9 , 793 , 65 0 . 

5,338,2 0 0 . 

---- - -----

15, 131 , 8 00. 

Negative values indicate savings over base case costs. 

0- 11 

Cont r ol 

� 0 ,. 013,2 0 0 . 

16, 002 . 

9 2 , 1 2 6 . 

7 5 , 1 2 5 . 

�,69 1 , 1 9 0 . 

0. 

0. 

0. 

278 , 83 1 . 

5 5 , 76 6 . 

1 , 600 , 53 0 . 

2�0 , 0 79. 

1 , 0 87 , 600 . 

1,6 00,5 3 0 . 

- - -- - - - - -

9,73 7 , 78 0 . 

6,5 12, 150 . 

- --- - ----

1 6 , 2�9,9 00. 
Cop p er Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxy-fuel burners 

LL - DC/DA 

12 

Date : 02/04/83 

Time : 1 5:48 

Process costs include new hard ware associated with copper production. For t he greenfield smelter, t he process cost is the Baseline Case Cost (Smelter plus fugitive cap ture). 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment associated w ith emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

A rrnr.raliz ed Costs 

Raw Mater i a ls 

P r ocess water 

Coo l i ng water 

Electr icit� 

S up p . heat < Na t . gas ) 

Bunker C Fue l O i l 

Sol ids d i spo sal 

Labor : Direct Oper ating 

Sup ervision 

M a i nt . : Labor & M at l . 

S trper vis i orr 

Over head 

Taxes , i ns . , adM i rr. 

Total O p erating Cost 

Cap ital Recover � Cost 

Annua lized Cost 

Process 

3 2 ,800 , 0 00. 

7 , 0 3 1 , 76 0 . 

0 • 

o. 

11 ,63 4 . 

0. 

-992 , 25 0 . 

0. 

9 2 , 94 4 . 

18,58 9 . 

1 , 3 1 Z , OOO . 

1 96,8 00. 

8 1 0 , 1 66. 

1 , 3 1 Z , OOO . 

- - --- --- - -

9,7 93,65 0 . 

5,338,2 0 0 . 

- - - ---- - - -

15, 131 , 8 00. 

Negative values indicate savings over base case costs, 

Contr ol 

4 1 , 32 1 , 2 00. 

1 , 0 2 1 , 1 9 0 . 

110,739 . 

3 4 , 6 08. 

2,589,5 10. 

o. 

0 • 

680 , 23 8 . 

557 , 6 6 2 . 

11:L , 5 32 . 

1 , 65 2 , 85 0 . 

247 , 92 7 . 

1 , 28 4 , 98 0 . 

1 , 65 2 , f350 . 

________ . .... 

9,94 4,0 8 0 . 

6,725,0 2 0 . 

- - - - - - - - -

16,6 69,10 0 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Oxy-fuel burners 

MgO - DC/DA 

13 

Date : 02/04�83 

Time : 15:48 

Process costs include new hardware associated with copper production . For the greenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture), 

For the expansion scenarios, process costs include any new roaster or converter, 

Control costs include all equipment associated with emission reduction, Oxygen enrichment and oxyfuel costs are considered as control costs along with add plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

C ap i t al Cost 

A nn•.• a l i zed Costs 

Raw Mater ials 

P r ocess wat,er 

C oo l i ng water 

E l ectr icit � 

Supp . heat < N a t . gas ) 

Bunker C Fuel Oil 

So lids d i sposal 

L abor : Dire ct Operating 

Sup E�r vision 

M a i nt . : L a bor & Matl . 

S up ervision 

Over head 

Taxes , i ns . , a dMin . 

Total Oper ating Cost 

Cap ital Recover � Cost 

Annua l i zed Cost 

P r ocess 

3 2 , 8 00,0 00. 

7 , 031 , 76 0 . 

0. 

0. 

11,6 3 4 . 

o. 

-·992 , 25 0. 

0. 

9 2 , 94 4 . 

18,58 9 . 

1,3 1 2 , 0 00. 

1 96,8 0 0 . 

8 1 0 , 1 66. 

1 , �H z , o o o . 

9 , 793, 65 0 . 

5,3 38 , 2 00. 

15, 131 , 8 00. 

Negative values indicate savings over base case costs . 

0 - 13 

Control 

4 7 , 461 ,100. 

4 94 , 012. 

1 28,38 7 . 

4 7 , 2 7 0 . 

3 , 1 96,52 0 . 

o. 

3 , 1 85 , 120 . 

0 • 

557 , 66 2 . 

1 :l:L , 532 . 

1 , 8 9 8 , 4 4 0 . 

284 , 76 7 . 

1 , 42 6 , 2 0 0 . 

1 , 8 9 8 , 4 4 0 . 

1 �3,22 8,4 00. 
Plant type 

Expansion Option 

Control Opt ion 

Plant Scenario : 

Copp er Smelter Coat� 

RV-CV 

Oxy - fuel burners 

NH3 - DCIDA 

14 

Date : 0 2 /08/8 3 

Time : 09:04 

Process costs include new hardware a ssociated with copper production. For the g reenfield smelter, the process cost is the Baseline Case Cost (Smelter plus fugitive capture). 

For the expansion scenarios, process costs incl ude any new roaster or converter. 

Control costs include all equ ipment associ ated with e mission reduction. Oxygen enrichment and oxyfuel costs are considered as control coste along with acid plant and FGD costs 

for the g reenfield smelter. Oxygen enrichment and oxyfuel costs are consi d ered as expansi on costs for existing plants. 

Annu� l i z ed [o�t s 

Pa w ro c:ttt:?l� .t cJ l s 

c• .,. · ,:-, c >.:-? �= s 'rJ 24 t e t .. 

C:•:• •::-• 11 r" 1 ;:) W c.it t? t' 

Elt?Ct t· t cit y 

SuuD. ne3 t ( '-� ::-. t . �E, s ) 

Cun�er C �ue l 0 1 l 

So l i d :=. d j. �: =-••::-•:: <ctl 

L c-l b 0:0 t' : D i l · L:? C t [: i:J f? ,- 2 t 1 r • � 

S '-' p t? r- v i s l C• ·n 

[' 3. J. n t . : !. - ::. lJ =· t' e. i'o1 ,") 1; l • 

S l. c: E? t"' V J =: i C• t-1 

C• ·.f e r' h t?ad 

T a x e s , i n s • , ,:

, 0. rn 1 n • 

Tot al D o erat i n g Cost 

C � c1tal Rec c � ery Cost 

7, 0 3 1 , 7 E. 0 . 

0 . 

0. 

1 1 ' fJ 3 L.. 

ill, 

-·'J':?.�� , �7:50 . 

0. 

'J ;� � S t� t+. 

1 E) ., �; ���. ·J . 

1 � � 1 .-:· . IZI�'� li� . 

�. 'J �."t :.J8;z.l. 

13 ; 0 � ". t_:. r; . 

1 � :� 1 2 .. 0 .:"z' L 

Cor.t t· O:• 1 

.3 7, 415 � :Z: IZ1 1Z1 . 

3, 9GC":, 4 [\tZi , 

C9, ;;: ,:::8. 

/1 ,:: t?i , 0 3 � , 

4, 640, It J. IZI. 

0. 

IZI . 

0. 

7 !. :;;. 5 14 '3 . 

1 '+8, 710 . 

1 ., /J. ·:-q; '} c ('i 1.� • 

Negative values ind i c ate savings over base case costs. 

0-14 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

RV-CV 

Caldne charge 

DC/DA 

15 

Date : 02/02/83 

Time : 09:02 

Process costs include new hardware assodated with copper production. For the greenfield smelter, the process cost is the Baseline Case Cost (Smelter plus fugitive capture). 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with add p lant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing p lants. 

Cap i t al Cost 

Annual i zed Costs 

F� aw Mater ials 

P r ocess water 

Co o l i ng water 

E l ectr icit � 

S up p . heat < Na t . gas ) 

Bunker C Fuel O i l 

Sol i ds d i sposal 

Labo r : Direct Ope rating 

Super vis i <)n 

M a i n t . : L a bor & M a t l . 

Super'vis i on 

Over head 

Taxes , i ns . , adM i n . 

Tota l Oper a t i ng Cost 

Cap i t al Recover� Cost 

Annualized Cost 

P r ocess 

44, 000 , 0 00. 

4 67,85 0 . 

0 + 

0 • 

595 , 56 0 . 

0 • 

3,82 8,0 8 0 . 

0. 

46'ft 718 . 

9 2 , 9 4 4 . 

1,76 0 , 0 00. 

2 6 4 , 000 . 

1,29 0 , 83 0 . 

1,76 0,0 00. 

-------- -- -

10,52 4,000. 

7 , 161 , 0 00. 

- -·---- - - - -

17 t 68!':'i t 0 0 () • 

Negative values indicate savings aver base case costs. 

0 - 15 

Contr ol 

2 6 , 841 , 3 0 0 . 

10,42 8 . 

8 1 , 0 0 2 . 

4 8 , 95 8 . 

3,0 5 7 , 1 8 0 . 

0 • 

0. 

0. 

2 78,83 1 . 

55 , 7 66 . 

1 , 0 7 3,65 0 . 

161 , 048 . 

7 84,6 4 8 . 

1 , 0 7 3,6 5 0 . 

---------

6,625 , 1 6 0 . 

4,36 8 , 4 2 0 . 

---------

1 0 , 99 3 ,600 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

FBR-RV-CV 

Oxygen enrichment 

PB - SC/SA 

18 

Date : o 21 o 4/8 3 

Time : 1 5:49 

Process costs include new hardware assodated with copper production. For the g reenfield smelter, t he process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment assodated with emission reduction . Oxygen enrichment and oxyfuel costs are considered as control costs along with add plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

Annua l i zed Costs 

Raw Mater ials 

P r ocess water 

C oo l i ng water 

E l ectr i c i t� 

S up p . heat < Na t . gas ) 

Bunker C Fue l O i l 

S o l i ds disp osal 

Labor : Direct Op e r a t i ng 

S up ervision 

Maint . : Labor & M at l . 

S up er v ision 

Over head 

Taxes , i ns . , a dMin . 

Tota l Operating Cost 

Cap i ta l Recover � Cost 

Annr.ra 1 i :zed Cost 

P r ocess 

5 1 0 , 000 . 

z , ooo,o 8 o . 

0. 

0. 

8 9 , 0 4 0 . 

o. 

- 1 , 52 5 , 68 0 . 

0. 

0. 

o. 

2 0 , 4 0 0 . 

3 , 060 . 

1 1 , 73 0 . 

2 0 , 4 00. 

6 1 9,0 2 1 . 

702 , 0 24 . 

Negative values indicate savings over base case costs. 

0-16 

Cont rol 

2,93 8 , 39 0 . 

5,57 4 . 

3 1 , 37 6 . 

26 , 1 6 7 . 

1 , 0 49 , 770 . 

0 • 

0. 

0 + 

0 + 

o. 

117,53 6 . 

1 7 , 63 0 . 

6 7 , 58 3 . 

117,536 . 

1 , 43 3 , 1 7 0 . 

478 , 22 3 . 

1, 91:L , 39 0 • 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

FBR-RV-CV 

Oxygen enrichment 

LL - SC/SA 

19 

Date : 02/ 0 4 /8 3 

Time : 1 5:49 

Process costs include new hard ware associated with copper production. For t he greenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing p lants. 

Cap ital Cost 

Ann•.•al i z ed Costs 

Raw Mater ia 1 �:; 

P r ocess water 

C oo l i ng water 

E l ectr icit -::� 

Supp . heat < Na t . gas ) 

Bunker C Fue l O i l 

Sol i cts dis p os a l 

Labor : Direct Oper ating 

Super visiDn 

Ma i nt . : Labor & Matl . 

Sup ervision 

Overhead 

Taxe s , i ns . , a dMin. 

Tota l O p era ting Cost 

Cap i t al Recover -::� Cost 

Annua l i zed Cost 

P r ocess 

5 1 0,0 00. 

2 , ooo , o 9 o . 

o. 

o. 

8 9 , 0 '1 0 . 

0 • 

- 1 , 52 5 , 68 0 . 

o. 

0 • 

o. 

2 o ,.qoo. 

3,0 6 0 . 

11,73 0 . 

2 0 , '1 00. 

- ---------

619, 021 . 

8 3 , 0 02. 

----------

702 , 02'1 . 

Negative values indicate savings over base case costs. 

0 - 1 7 

Control 

5,7 0 0 , 67 0 . 

1 :38 t 555 . 

.lf 1 , .lf 9 5 . 

5,9 0 9 . 

.lf6:3 , 602 . 

0. 

o. 

92 , 1 2 1 . 

278 , 83 1 . 

5 5 , 766 . 

2 28 , 027 . 

3 .lf , 2 0 .lf . 

2 98,.lf 1.lf. 

2 28 , 0 27 . 

------- - -· 

1 , 8 6 .lf , 95 0 . 

927 , 78 3 . 

---------

2,7 92 , 73 0 . 
C opper- Smelter- C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

FBR-RV-CV 

Oxygen enrichment 

MgO - SC/SA 

20 

Date : 0210 4 /8 3 

Time : 1 5:50 

Process costs include. new hardware associated with copper production. For the greenfield smelter, the process cost is the Baseline C ase Cost <Smelter plus fugitive capture>. 

For the expansion scenarios, process costs indude any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid p lant and FGD costs 

for t he greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap i tal Cost 

Annua l i zed Costs 

Raw Mate r ials 

Process water 

Cool i ng water 

E l ectr icit'3 

S up p . heat C Na t . gas ) 

Bunker C Fue l O i l 

S o l i d s disp osal 

Labor : Direct Op e r ating 

Super vis i on 

M a i nt . : Labor & M at l . 

S upervi sion 

Over head 

T a xes , i ns . , a dMin . 

Total O p e r a t i ng Cost 

Cap i tal Recover'3 Cost 

Ann•-• al i z ed Cost, 

P r ocess 

510 , 0 0 0 . 

2 , ooo , o 8 o . 

0. 

o. 

8 9 , 0 .t0. 

o. 

- 1 , 52 5 , 68 0 . 

0. 

0. 

0. 

2 0 , lf O O . 

3 , 0 6 0 . 

11,73 0 . 

2 0 , lf O O . 

619 , 0 2 1 . 

8 3 , 0 02. 

702 , 02lf . 

Negative values indicate savings over b ase case costs. 

0-18 

Contr ol 

6,970,25 0 . 

7 2 , 1 lf5. 

lf 0 , 177 . 

6,75 3 . 

lf08 , 0 3 lf . 

0. 

lflf1 , 67 0 . 

o. 

278 , 83 1 . 

55 , 76 6 . 

2 78,8 10. 

lf 1 , 82 2 . 

3 27 , 61lf . 

2 78,8 10. 

2,23 0 , lf3 0 . 

3,36 4 , 81 0 . 
Pltint type 

E :..:p::in !11un Opt ion 

Control Option 

Pl·!!nt Scenario : 

Cop per Smelter Costs 

FBR- RV-CV 

O�ygen enr ichment 

NH3 - SC/SA 

21 

Date : 0 2 /08/8 3 

Time : 09:05 

P r ocess costs include new hardware associated with copper prod u c t ion. For the g reenfield srr• elter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture). 

For the expan sion scena r ios, process costs include any new r oaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrich -

ment a nd oxyfuel costs are con sidered as control costa along wi th acid pl a n t and FGD costs 

for the g r eenfi eld smelter. Ox ygen enr ichm ent end oxyfuel costs are consi dered as expansion costs for existing plants. 

Annu ali� �d Cost s 

RD. w rn E ... t. l � 1 - J

. c-, 1 s 

::-· r-· 1-:' c t:� : ; ·-;. �t-J <:'t t C? tC·�"-:-• 1 i ,

.

, �J �-J c.{ ·:� t:

t' 

F: J e c t t· l c l t y 

S ·_I Q:J .. he{.:-\ t ( '"J ::. t. r: c, :.� ) 

E� l q-l �' 12 ,... c: r: I I ·� l 0 ] l 

1 (_1 �.J C1I- ! :J J ! "' t_-;:; l�:' t (J :'· E)- .?1 1_: 2. Y"' �1 

� tJ D =.· 'r"' "./ 1 ::� i C1 ·n 

LJ v e r'head 

T a � e s ., i ·n s. , .:=t. d rn i. y-, . 

[ � Dlta l R e covery Cost 

,=_· , i?, IZ'· IZI , 08•?• . 

:;a . 

1{1 . 

e ·9 • 1Z1 L, .;�, • 

0. 

0. 

0. 

�"': . 

�:'J/i , L! 00 a: 

3� '.;:'I C.l?i , 

1 1 ., ; :�e:. 

( 01'1 -':-)'0 1 

2 , ,.:w. L ? f .. n 0. 

::,53, 1 50. 

=� .=.:' 7 LJ- 3. 

5 8,, E. :�2. 

5 7 �), 3 4 5. 

0. 

0. 

(71. 

/4 (, L1 , 7 ·, [;. 

·_ • f_ . • • �·s 7. 

l 7 'J .IJ 4 (� .. 

--�. L, 5 ' f: 5 . 

� · .:. , ::_ ,� 7 . 

N egative value s ind icate sav ings over base case costs. 

0 - 19 
C opper SmelteY C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

EF-CV 

Calcine charge 

DC/DA 

23 

Date : 02/02/83 

Time : 09:04 

Process costs include new hardware associated wjth copper production. For t he g reenfield smelter, t he process cost is t he Baseline Case Cost <Smelter plus fugitive capture>. 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment associated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with acid plant and FGD costs 

for the greenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

Annua lized Costs 

Raw Mater ials 

Pr ocess water 

Coo l i ng water 

E l ectr icit� 

S up p . heat < Na t . gas ) 

Bunker C Fue l O i l 

S o l i ds disp osal 

Labor : Direct Oper a ting 

Sup e rvis i on 

M a i nt . : L abor & M at l . 

Sup e rvision 

Overhead 

Taxes , i ns . , a dMin . 

Tota l Operating Cost 

Cap i t al Recover � Cost 

Annua liz ed Cost 

P r ocess 

.t6,6 0 o , o o o . 

.t\67 , 85 0 . 

0. 

0. 

5 83,8 00. 

0. 

3,666,0 9 0 . 

o. 

371 , 77 .t. 

7 .t, 35 5 . 

1 , 8 6 .t, o oo. 

2 79,6 00. 

1,29 .t, 86 0 . 

1 , 8 6 .t, o o o . 

----------

10, .t6 6 , 3 00. 

7,58.t, 1 5 0 . 

----------

18, 050 , 5 0 0 . 

Negative values indicate savings over base case costs, 

0-20 

Contr ol 

3 7 , 5 0 .t, 9 00 • 

1 .t, 56 .t • 

8 3 , 8.t5. 

6 8 , 37 2 . 

.t, 269 , 5 1 0 . 

o. 

0 + 

0 + 

2 78,83 1 . 

55 , 766 . 

1 , 500 , 1 9 0 . 

225 , 0 29 . 

1,0 2 9 , 9 1 0 . 

1 , 5 0 0 , 1 '1 0 . 

---------

9 , 0 26,22 0 . 

6 , 1 0 3,92 0 . 

---------

15, 1 3 0 , 100 . 
C opper Smelter C osts 

Plant type : 

Expansion Option : 

Control Option : 

Plant Scenario : 

FF-CV 

Oxygen enrichment 

DC/DA 

26 

Date : 02/04/83 

Time : 1 6t20 

Process costs include new hard ware assodated with copper production, For the greenfield smelter, the process cost is the Baseline Case Cost <Smelter plus fugitive capture), 

For the expansion scenarios, process costs include any new roaster or converter. 

Control costs include all equipment assodated with emission reduction. Oxygen enrichment and oxyfuel costs are considered as control costs along with add plant and FGD costs 

for the g reenfield smelter. Oxygen enrichment and oxyfuel costs are considered as expansion costs for existing plants. 

Cap ital Cost 

A nn•.•al i zed Costs 

Raw Mater ials 

Process water 

C oo l i ng water 

E l ectr i c it� 

S up p . heat < Na t . gas ) 

Bunker C Fuel Oil 

Sol i ds disposal 

Labo r : Direct Oper a t i ng 

S upervision 

M a i nt . : Labor & M at l . 

S up ervision 

Over head 

Taxes , i ns . , a dMin. 

T otal Oper ating Cost 

Cap ital Recover � Cost 

Ann1.• a 1 i zed Cost 

P r ocess 

5 1 0 , 000� 

1,4 5 7 , 230 . 

o. 

o. 

5,8 17. 

0. 

-158,76 0 . 

o. 

o. 

o. 

2 0 , 4 00. 

3 , 0 6 0 . 

1 1 , 73 0 . 

2 1 , 93 0 . 

1 , 361 ,400 . 

8 3 , 0 02. 

Negative values indicate savings over base case costs, 

0-21 

Contr ol 

5 , 0 88 , 63 0 . 

3,95 6 . 

3 0 , 72 5 . 

18,57 0 . 

1 , 1 59,62 0 . 

o. 

0. 

0. 

2 78,83 1 . 

5 5 , 76 6 . 

203 , 54 5 . 

3 0 , 53 2 . 

284 , 33 7 . 

218 , 8 1 1 . 

2,28 4 , 69 0 . 

8 28 , 1 75 . 

3,11 2,87 0 . 
APPEND IX P 

METHODOLOGY UTI LIZED TO DETERMINE THE COSTS ASSOCI ATED 

WITH SULFURIC AC ID P LANT PREH EATER OPERATI ON 
APP END IX P 

METHODO LOGY UT I L IZED TO DETERMINE THE COSTS ASSOC I ATED 

WITH SULFUR IC AC ID P LANT PREHEATER OPERATI ON 

P . 1 DETERMI NAT ION OF THE STANDARD HEAT OF REACTION 

where 

(@ 298 K) for the convers i on reaction. 

502 + 1/2 02 � so3 

�HR = the standard heat of reaction at 1 atmosphere and 298 K 

v. = the stoich i ometric coeffi c i e nt of spec i es 1 

H0 = the standard heat of formati on (1 atm , 2 98 K) of s pec i es i f . 

1 

P = reaction products 

R = reactants 

�H0 = - 296 . 06 kJ/g · mo l * f

so2 

�H0 = 0 . 0* fo2 

�H0 = - 395. 18 kJ/g · mo le. * f

$03 

Thus , �HR = - 395 . 18 - [-296 . 06] = -99. 12 kJ/g · mo l . 

*Barrow , G. M . , P hys i cal Chemi stry, 3rd Ed. New York. McGraw H i ll, 

1973 . 

P -3 
P . 2 DETERMINATI ON OF THE HEAT OF REACTI ON AT THE TEMPERATURE OF THE 

CATALYST B EDS 

where 

Optimum convers ion temperature �438° C = 711 K 

�H7 11 = heat of reacti on at 711 K 

_ o 7 11 K �H7 11 -

�HR + f298 K �Cp dT 

�c = l v. c - l v. c

p p 1 P P ; R 1 ; 

C = the specific heat capac i ty of species i 

P; 

\). 1 

= the stoichiometric coeffi c i e nt of species 

c Pso

3 

= 50 . 63 J /g . mo l O

K* 

c = 39 . 79 J /g · mo l O

K* 

Psoz 

c Paz 

= 29 . 36 J/g . mo l o

K . * 

i 

Thu s , �C

P = 50 . 63 - [ ( 0 . 5)( 29 . 36) + 39 . 79] = - 3 . 84 J/g · mo l °K 

711 K J

298 K �Cp

dT = -3.84 [711 - 298] = - 1 , 586 J/g • mo l 

Thus , 

kJ �H711 = -99. 12 g . mo l 

103 J X -- - kJ 

= - 100 , 706 J/g · mo l . 

J 1,586 

9 . mo l 

* Letter and attachments from Arzabe , H. A . , Monsanto Envi ro- Chem , 

to Wood , J. P . , Research Tri angle I nsti tute . August 3, 1982 . Response 

to request to rev i ew D raft Chapter 4 of BID and ac id p l ant p reheater 

operat i ng cost esti mati on p rocedure . 

P - 4 
P.3 CA LCULATION OF THE HEAT DE FICIENCY THAT RESULTS WHEN THE GAS 

STREAM 502 CONCENTRATION FALLS BELOW THE AUTOTHERMAL REQUIREMENT 

where , 

n 

J = 251 , 140 I T.V. (CA

- C.) 

i=1 1 1 1 

J = the heat defici ency duri ng a 24- hour cyc le ( kilojoul es ) 

n = the number of time peri ods duri ng a 24- hour cyc le duri ng 

wh i ch the gas stream S02 concentrat i on is be l ow that 

requi red for autothermal operation. 

T . = the durati on of time peri od i ( hours ) 1 

V . = the gas stream vo l umetri c f l ow rate in ev i dence duri ng 1 time pe ri od i ( Nm3/mi n) 

C = the gas stream S02 concentrati on requi red to s usta i n A autotherma l operat i on ( vo l ume po rtion) 

C . = the gas stream S02 concentrati on in ev i dence dur· ng time 1 peri od i (vol ume portion) 

P . 4 I L LUSTRATION OF THE COST ESTIMATION PROCEDURE 

Cons i der the fol l owi ng 24- hour gas stream profi le: 

No. of hours 

per day 

4 . 0 

5 . 2 

9 . 5 

2 . 3 

1 . 7 

1.3 

Gas stream 

vol umetri c fl ow rate 

( Nm3/min) 

6,690 

5 , 860 

5 , 830 

5,000 

4,980 

4 , 146 

. P-5 

3 . 8 

3 . 2 

3.6 

2 . 8 

3 . 2 

2 . 3 
A sing l e contact/s i ng l e absorption ac id p l ant is spec i f i ed. From the 

i nformati on presented above , it can be determi ned that n = 4. Thus , 

n 

1 . 2 � T.V. ( CA

-

C

i

) �H711 

i=l 1 1 

= 1 . 2 [ 5 . 2 hrs x 5 • 860 Nm3 x (0. 035 - 0 . 032) + 2 . 3 x 5 , 000 mi n 

X (0. 035 - 0 . 028) + 1 . 7 X 4,980 X (Q. Q35 - 0 . 032) + 1 . 3 X 4,140 

60 mi n 101 kJ g • mo l _ x (0. 035 - 0. 023] x hr x g • mo l x 0 . 02413 m

3 ( 21o C) -

78 . 9 

x 106 kJ per 24 hours 

As s umi ng that the heat i ng val ue of natural gas is 37 , 228 kJ/m3 , that 

the cost of natural gas is $97 . 82 per 103m3 , and that the fac i l i ty 

operates at 8,400 hr/yr , the annual cost attri butable to preheating 

requi rements can be estimated as fol l ow� : 

78 .9 x 106 kJ x m3 $97 . 82 8 ,400 hr 

= 24 hours 37 , 228 kJ x 103m

3 x yr $72 , 586 per year . 

P-6 
TECHNICAL R EPO RT DATA 

(Please rrod Imrmcrwns on rhe rnerse before completing) 

1. REPORT N O. ,2 3. RECIPIE NT"S ACCESS ION N O. . 

EPA-450/ 3-83-�0.u.l1�8b!L-_. __ --l.

 ___________ --t�-----------t 

4. TITLE AND SUBTITLE 5. R E PORT 0/\Tf: 1 

Review of New Source Perfo rmance Standards for 

Prima ry Copper Sme l ters 

, __ .r_1=arch 1 984 ___ _ 

6. PERFORMING ORGANIZATION CODE 

7. AUTHOA(S) 8. P::OAFORMING ORGANIZATION REPORT N O. 

9. PERFORMING ORGANIZATION NAME AND ADDR ESS 1 0. PROGRAM ELEMENT NO. 

O ffice of Ai r Qua l i ty P l anni ng and Standards 

U.S . Envi ronmenta l P rotecti.on Agency 

Research Tri a ngle Park , North Ca ro l i na 27711 

1 1 . CONTR ACT/G RANT NO. 

68-02- 3056 

12. SPONSORING AGENCY NAME AND ADD RESS 1 3. TYPE OF REPORT AND PE R IOD CO VERED 

Offi ce of A i r Qua l i ty P l anni ng and Standards 

Office of A i r, Noi se , and Radi a tion 

U.S. Envi ronmenta l P ro tection Agency 

Resea t'ch Tri a ngl e P a rk , North Ca ro 1 i na 27 711 

Dra ft 

1 4. SPONSORING AGENCY CODE 

EPA/200(04 

1 5 . SUPPLEMENTARY N OTES 

1 6. A B STR ACT 

1 7. 

Sta nda rds of performa nce for the control of emi ssions from prima ry copper smel ters 

we re p romu l ga ted 1n 1 976 . Devel opments s i nce p romu l gati on necess i tated that the 

fol l ow i ng be i nc l uded in the pe r i odi c rev i ew of the s tandards : ( 1 ) reexam i n a tion 

of the current ex�mpti on for reverberatory furnaces processi ng h i gh- i mpuri ty materi a l s, 

(2) asses sment of the fea s i bility of control ling pa rt i cul a te ma tter emi ssi ons from 

reverberatory furnaces p roces sing hig h - i mpuri ty materi als , (3) reeva l uation of the 

i mpact of the c urrent s ta ndard on the abi lity of e x i s t i ng smel ters to expa nd 

production , and (4) assessment of the techn ical and econom i c fea sibility of contro l ling 

fugit i ve emi ssi ons at prima ry c opper smel ters . The resul ts of the revi ew i nd i cated 

tha t no cha nges should be ma de to the ex isti ng s ta ndard . T h is document contains 

ba ckground i nfo rmati on and envi ronmental and econom i c asses sments consi d ered in 

a rri v i ng at th is conc l u sion. 

Th is report is publ i s hed in two vo l umes . Vol ume 1, EPA 450/3-83-0 18a , contains 

Chapters 1 through 9. Vol ume 2, EPA 450/ 3-83-018b , conta i n s the Appendi xes . 

KEY WO R DS AND DOCUM ENT ANA LYSIS 

�---------------------------------------------�------------.- 

J. DESCR I PTORS b. I D ENT IFIERS/OPEN ENDED T E R .'.� S c. COSATI f-ield/Group 

t-----�------

A i r pol l ut i on 

Pol l uti on control 

Standa rds of performa n ce 

Prima ry copper sme l ters 

Sul fur ox i des 

Pa rticulate ma tter 

A i r Pol l ution Control 1 38 

l'

I 

����-��----------------------- -------7��������������������---4 ;b. O·S r ii i ElUToON STATE.MENT 19 St.CUi�ITY C LASS (7itH !<t:porTJ 21.

1 50

. OF f'A GES 

Uncl ass i fi ed u n 1 i m i ted Sosf.: C-U--R-, · =-Y=----C-L =-s=-- s:.

(_T t:;_pa_ge �- --l22. pRIcE 

U n c l ass i fi ed 

!:Pl. F o•m 2270-1 (Rev. 1. -77) �-' J-4� VIOUS L DITI O t � I �, < • ''', ;lLL T L