Emission rates for CALPUFF modeling, AZ RH FIP Jan. 2014

Baseline Scenario

Emission Source Stack

(lb/day) (lb/hr) (g/s)

Primary Hood/Acid Plant Main stack - inner 14,294 596 75.0 1

Secondary Hood/Uncontrolled Main stack - annular 146,947 6,123 771.5

Fugitives Converter Bldg Fugitives 9,692 404 50.9

1 Respresents baseline period corresponding to standard catalyst usage

2 Per WRAP modeling, all particulate matter represented as PM2.5 in model runs

Acid Plant control scenario - Expanded use of cesium catalyst in acid plant

Emission Source Stack

(lb/day) (lb/hr) (g/s)

Primary Hood/Acid Plant Main stack - inner 4,860 202 25.5 1

Secondary Hood/Uncontrolled Main stack - annular 146,947 6,123 771.5 2

Fugitives Converter Bldg Fugitives 9,692 404 50.9 2

1 Based on full use of cesium catalyst, relative to standard catalyst usage

2 Maintain at baseline emission rate?

Secondary emissions control scenario - construction of new acid plant

Emission Source Stack

(lb/day) (lb/hr) (g/s)

Primary Hood/Acid Plant Main stack - inner 14,294 596 75.0 2

Secondary Hood/Acid Plant Main stack - annular 328 14 1.72 1

Fugitives Converter Bldg Fugitives 9,692 404 50.9 2

1 Assumes baseline secondary emissions are controlled to a level equivalent to existing acid plant

2 Maintain at baseline emission rate?

Secondary emissions control and expanded use of cesium catalyst in new and existing acid plants

Emission Source Stack

(lb/day) (lb/hr) (g/s)

Primary Hood/Acid Plant Main stack - inner 4,860 202 25.5 1

Secondary Hood/Acid Plant Main stack - annular 112 5 0.59 2

Fugitives Converter Bldg Fugitives 9,692 404 50.9 3

1 Based on full use of cesium catalyst, relative to standard catalyst usage

2 Assumes baseline secondary emissions are controlled to a level equivalent to a cesium promoted existing acid p

3 Maintain at baseline emission rate?

SO2

N

otes

SO2

N

otes N

otes

SO2

SO2

N

otes
(lb/hr) (g/s) (lb/hr) (g/s)

0.94 0.119 1.90 0.24

10.88 1.371 8.02 1.01

0.00 0 7.22 0.91

promoted existing acid plant

NOX

PM2
Question #6

Asarco SO2 BART-CALPUFF Modeling Inputs

Name UTM 12 NAD83 E (m) UTM 12 NAD83 N (m) Stack Height (m)

AZ10 ASARCO (Main Stack) 520923.24 3651928.46 304.8

AZ11 ASARCO (Annulus Stack) 520923.24 3651928.46 302.24

AZ13 ASARCO (Anode Furnaces) 520970.75 3651782.23 25.298

AZ14 ASARCO (Converters) 520972.21 3651686.6 24.872

Coordinate Parameters Cont.

Lambert Conformal 

Conic (LCC-X) km

Lambert Conformal 

Conic (LCC-Y) km

AZ10 ASARCO (Main Stack) -1279.485 -677.437

AZ11 ASARCO (Annulus Stack) -1279.485 -677.437

AZ13 ASARCO (Anode Furnaces) -1279.46 -677.589

AZ14 ASARCO (Converters) -1279.474 -677.684

Note: The LCC coordinates used in the updated CALPUFF modeling were derived from the above mentioned UTM 1

*Stack Diameter Cont. Diameter (m) Dimensions (m)

AZ13 ASARCO (Anode Furnaces) 14.644 3.453765 X 48.768 

AZ14 ASARCO (Converters) 24.144 4.2672 X 107.2896 

Note: The numbers for the anode furnaces and converters' stack diameter (in the first table) represent the area of 

The two numbers shown in 'Stack Diameter Cont.' section represent the diameters and dimensions of the anode fu

represented as a circle and as a rectangle. The circular diameter version for the anode furnaces and converters wa
Elevation (m) Stack Diameter (m) Exit Velocity (m/s) Exit Temperature (K)

651.662 5.182 83.989 416.483

651.662 7.288 38.425 321.844

646.481 *168.433 m20.61 310.928

646.481 *457.826 m21.536 310.928

 from the above mentioned UTM 12 NAD83 coordinates.

e first table) represent the area of the building (m2 ). 

ers and dimensions of the anode furnaces and converters' areas if they were

anode furnaces and converters was used in the updated CALPUFF modeling.
Original WRAP baseline emissions

name LCC X (km) LCC Y (km) Stack height(m) Elevation (m) Stack diameter(m) Exit velocity(m/s)

AZ10 Main Stack ASARCO - Hayden Smelter -1279.791 -677.829 304.800 633.984 5.182 5.791

AZ11 Annulus Stack ASARCO - Hayden Smelter -1279.791 -677.829 280.416 633.984 7.150 10.363

AZ13 Anode Furnaces ASARCO - Hayden Smelter -1279.791 -677.829 198.120 633.984 Fugitive Emission Fugitive Emission

AZ14 Converters ASARCO - Hayden Smelter -1279.791 -677.829 198.120 633.984 Fugitive Emission Fugitive Emission

ASARCO revised baseline emissions - based on ENVIRON modeling report provided from March 6, 2013 comment letter (See docket item H-09)

name LCC X (km) LCC Y (km) Stack height(m) Elevation (m) Stack diameter(m) Exit velocity(m/s)

AZ10 Main Stack ASARCO - Hayden Smelter -1279.791 -677.829 304.800 633.984 5.182 5.791

AZ11 Annulus Stack ASARCO - Hayden Smelter -1279.791 -677.829 280.416 633.984 7.150 10.363

AZ13 Anode Furnaces ASARCO - Hayden Smelter -1279.791 -677.829 198.120 633.984 Fugitive Emission Fugitive Emission

AZ14 Converters ASARCO - Hayden Smelter -1279.791 -677.829 198.120 633.984 Fugitive Emission Fugitive Emission
Exit temperature (K) SO2 Rate (g/s) NOX Rate (g/s) PM25 Rate (g/s)

423.706 67.800 0.119 14.595

330.372 914.400 1.371 14.595

Ambient 1.710 0.780 5.796

Ambient 66.840 0.000 29.030

cket item H-09)

Exit temperature (K) SO2 Rate (g/s) NOX Rate (g/s) PM25 Rate (g/s)

423.706 71.180 0.119 0.240

330.372 578.270 1.371 1.010

Ambient 2.150 0.780 2.310

Ambient 37.610 0.000 0.910
Printed 2/19/2014

ASARCO Hayden

Fugitive SO2 Control Scenario Summary

Scenario Primary 

Hood 

Capture

Acid Plant 

Exhaust1

Secondary 

Hood 

Capture

"Fugitive"/ 

Annular Stack

Tertiary Hood 

Capture

"Fugitive"/ 

Annular Stack

Fugitive/ 

Uncontrolled

% (tons/day) % (tons/day) % (tons/day) (tons/day)

Baseline (2011) 85% 0.91 85-95% 73 NA NA 5 2

Control Scenario 1 97% 0.72 90-97% 0 95% 0.00 0 3

1 This represents converter emissions from the acid plant, and does not include flash furnace emissions vented to the acid plant

2 Capture rates are back-calculated from 2011 EI calcs

3 Based on interpretation that NSPS Subpart P applies to all captured emissions, not just at the acid plant.

N

otes

Arizona Regional Haze FIP

ASARCO Hayden Smelter

Page 1 of 2

Summary - Fugitives

U.S. EPA Region 9

Air Division
Printed 2/19/2014

Total SO2 

Emissions

79

1

Arizona Regional Haze FIP

ASARCO Hayden Smelter

Page 2 of 2

Summary - Fugitives

U.S. EPA Region 9

Air Division
Smelter Sulfur Balance

Concentrate3

Sulfur Content

(tons/day) wt% (tons) lbmol lbmol (tons)

2,467 29% 715 44,714 44,714 1,431

1 Sulfur MW 32 lb/lbmol

2 SO2 MW 64 lb/lbmol

3 Maximum daily production observed over 2008-12 time period. ASARCO has asserted a CBI claim for the raw 

Converter Operations SO2

 Flowrate

(from 

converters)

Capture 

Efficiency

(tons/day) (%) (tons/day) Destination

Blowing Operations 569 85% 481 acid plant

Charging/Skimming Operations 4 0% 0 --

Converter Operations SO2

 Flowrate

(uncaptured 

by primary)

Capture 

Efficiency

(tons/day) (%) (tons/day) Destination

Blowing Operations 0 95% 83 annular stack

Charging/Skimming Operations 0 85% 3 annular stack

Exhaust Point

(tons/day) (lbs/day)

Main stack (primary hood/acid plant) 0.91 1,828

Annular stack (secondary hood) 73.47 146,947

Fugitive 4.85 9,692

Total 79.23

Acid plant removal efficiency 99.81% Provided by ASARCO in July 11 letter

Secondary baghouse ctrl eff 15%

Emission Rate

Captured

Sulfur SO2

Primary Hood

Secondary Hood

Captured
SO2

Process Area Fraction (lbs/day)

Flash Furnace 60% 859

Converters 40% 572

erted a CBI claim for the raw production data.

(tons/day) Destination

88 secondary hood

4 secondary hood

(tons/day) Destination

4 fugitive

1 fugitive

Uncaptured

rimary Hood

condary Hood

Uncaptured
Smelter Sulfur Balance

Concentrate1

Sulfur Content SO2

(tons/day) wt% (tons) lbmol lbmol (tons) Process Area Fraction (tons/day)

2,467 29% 715 44,714 44,714 1,431 Flash Furnace 60% 859

Converters 40% 572

1 Maximum daily production observed over 2008-12 time period. ASARCO has asserted a CBI claim for the raw production data.

32 lb/lbmol S

64 lb/lbmol SO2

Converter Operations SO2

 Flowrate

(from 

converters)

Capture 

Efficiency

(%) (tons/day) Destination (tons/day) Destination

Blowing Operations 569 97% 552 acid plant 17 secondary hood

Charging/Skimming Operations 4 0% 0 -- 4 secondary hood

SO2 Flowrate

(uncaptured by 

primary)

Capture 

Efficiency

(%) (tons/day) Destination (tons/day) Destination

Blowing Operations 17 97% 17 acid plant 0.51 tertiary hood

Charging/Skimming Operations 4 90% 3 acid plant 0.36 tertiary hood

SO2 Flowrate

(uncaptured by 

secondary)

Capture 

Efficiency

(%) (tons/day) Destination (tons/day) Destination

Blowing Operations 0.51 95% 0.49 acid plant 0.03 fugitive

Charging/Skimming Operations 0.36 95% 0.34 acid plant 0.02 fugitive

Captured Uncaptured

Tertiary Hood

Captured Uncaptured

Secondary Hood

Sulfur SO2

Primary Hood

Captured Uncaptured
Exhaust Point Emission Source Emission Rate Notes

(tons/day) (lbs/day)

Main stack primary hood/acid plant 0.717 1,434 1,3

Main stack secondary hood/acid plant 0.026 51 4

Main stack tertiary hood/acid plant 0.001 2 5

Fugitive 0.043 87

Total 1

1 Acid plant removal efficiency 99.87%

2 Secondary hood baghouse SO2 ctrl efficiency 15%

3 Converter emissions only; does not include emissions from flash furnace

4 Based on emissions from charging/skimming captured by secondary also being sent to acid plant

5 Based on emissions captured by tertiary being sent to acid plant
Printed 2/19/2014

ASARCO Hayden

Acid Plant SO2 Control Scenario Summary

Scenario

Emission 

Factor1

SO2 Emission 

Rate Removed Notes

(lb/hr) (lb/day) (lb/ton) (tpy)

NSPS Subpart P baseline 1,012 24,295 N/A 6 N/A N/A

Standard Catalyst (historical) 596 14,294 7.12 846 -- Includes time period from 1/2008 to 11/2010

Partial Cs Catalyst (historical) 359 8,626 4.08 4 625 -- Includes time period from 11/2010 to 3/2012

Full Cs Catalyst (from standard) 202 4,860 2.42 5 288 558 From standard catalyst use

Full Cs Catalyst (from partial Cs) 241 5,780 2.74 5 419 206 From partial Cs catalyst use

Notes:

1 lb/ton value does not represent the max observed 24-hr lb/ton value. It is calculated based on max 24-hr emission rate divided by max 24-hr production rate

4 reflects Cs catalyst use in first and fourth pass

5 Full use of Cs catalyst assumes the following control efficiencies:

66% control from standard catalyst use

33% incremental control from partial Cs catalyst use

6 Based on 650 ppm

SO2 Emission 

Rate

Highest 24-hr value Annual Emissions

N

otes

Arizona Regional Haze FIP

ASARCO Hayden Smelter

Page 1 of 1

Summary - Acid Plant

U.S. EPA Region 9

Air Division