**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 plant 3 Maintain at baseline emission rate? **SO2 N** **o t** **e s** 

**SO2 N** **o t** **e s** **N o** **t e** **s SO2** 

**SO2 N** **o t** **e s** **(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

Assumes baseline secondary emissions are controlled to a level equivalent to a cesium promoted existing acid plant **NO X**  **PM 2** **Question #6**

**Asarco SO 2** **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 12 NAD83 coordinates.

***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 building (m The two numbers shown in 'Stack Diameter Cont.' section represent the diameters and dimensions of the anode furnaces and converters' areas if they were represented as a circle and as a rectangle. The circular diameter version for the anode furnaces and converters was used in the updated CALPUFF modeling.**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 m 2 0.61 310.928 646.481 *457.826 m 2 1.536 310.928

: The LCC coordinates used in the updated CALPUFF modeling were derived from the above mentioned UTM 12 NAD83 coordinates.

: The numbers for the anode furnaces and converters' stack diameter (in the first table) represent the area of the building (m 2 ). The two numbers shown in 'Stack Diameter Cont.' section represent the diameters and dimensions of the anode furnaces and converters' areas if they were represented as a circle and as a rectangle. The circular diameter version for the anode furnaces and converters was used in the updated CALPUFF modeling.**Original WRA P baseline emissions**  nam e LCC X (km) LCC Y (km) Stack height(m) Elevation (m ) Stack diameter(m) Exit velocity(m/s)

AZ10 Main Stack ASARCO - Hayden Sm elter -1279.791 -677.829 304.800 633.984 5.182 5.791 AZ11 Annulus Stack ASARCO - Hayden Sm elter -1279.791 -677.829 280.416 633.984 7.150 10.363 AZ13 Anode Furnaces ASARCO - Hayden Sm elter -1279.791 -677.829 198.120 633.984 Fugitive Em ission Fugitive Em ission AZ14 Converters ASARCO - Hayden Sm elter -1279.791 -677.829 198.120 633.984 Fugitive Em ission Fugitive Em ission

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

nam e LCC X (km) LCC Y (km) Stack height(m) Elevation (m ) Stack diameter(m) Exit velocity(m/s) AZ10 Main Stack ASARCO - Hayden Sm elter -1279.791 -677.829 304.800 633.984 5.182 5.791 AZ11 Annulus Stack ASARCO - Hayden Sm elter -1279.791 -677.829 280.416 633.984 7.150 10.363 AZ13 Anode Furnaces ASARCO - Hayden Sm elter -1279.791 -677.829 198.120 633.984 Fugitive Em ission Fugitive Em ission AZ14 Converters ASARCO - Hayden Sm elter -1279.791 -677.829 198.120 633.984 Fugitive Em ission Fugitive Em issionExit 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 Am bient 1.710 0.780 5.796 Am bient 66.840 0.000 29.030

**AS AR** **CO revised baseline emissions - based on ENVIRON modeling report provided from March 6, 2013 comment letter (See docket 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 Am bient 2.150 0.780 2.310 Am bient 37.610 0.000 0.910Printed 2/19/2014

**ASARCO Hayden Fugitive SO**  **2 Control Scenario Summary** 

**Scenario Primary**  **Hood Capture**  **Acid Plant**

**Exhaust 1**  **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 o** **t e** **s**

Arizona Regional Haze FIP ASARCO Hayden Smelter Page 1 of 2 Summary - Fugitives U.S. EPA Region 9 Air DivisionPrinted 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**

**Concentrate 3**  **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 production data.

**Converter Operations SO**  **2 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 SO**  **2 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 SO** **2**

**Primary Hood**

**Secondary Hood Captured** **SO 2** 

**Process Area Fraction**  **(lbs/day)** Flash Furnace 60% 859 Converters 40% 572

Maximum daily production observed over 2008-12 time period. ASARCO has asserted 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 Primary Hood** 

**Secondary Hood Uncaptured** **Smelter Sulfur Balance**

**Concentrate 1**  **Sulfur Content SO** **2 (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 SO** **2 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 **SO 2** **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 **SO 2** **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**  **SO 2** 

**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 plantPrinted 2/19/2014

**ASARCO Hayden Acid Plant SO** **2 Control Scenario Summary** 

**Scenario Emission**  **Factor 1**  **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 o** **t e** **s**

Arizona Regional Haze FIP ASARCO Hayden Smelter Page 1 of 1 Summary - Acid Plant U.S. EPA Region 9 Air Division