Me m o r andu m t o F il e

Sub j e c t: M eet i ng s b et w e e n E P A a nd w i t h A sa r c o o n B A R T FI P

F r o m: C o l l ee n M cKa ugh a n

, A ss o ci a te D ir e c t o r, A ir D i v i si o n

, E P A R e g i o n 9

T o: F il e

D a t e: Jun e 1 6

, 2 0 1 4

P a r t i c i pan ts :

As a r c o: J ac k Garri t y

, T e c hn ical S e r v ic e s M a n a g e r

Kris hn a P ar a m e s w ara n

, D ir e c t o r, S t a te a n d F e d e ral R e gu la t o r y A ffai r s

Eric H is e r

, A t t o r n e y

S t e v e G a ss e r

, S m e l t e r M a n a g e r

M a t t R u s s e ll, C o n s u l t a nt

EP A: C o ll ee n M c K a ugh a n

, A ss o cia t e D ir e c t o r

, A ir D i v is i o n

E ug e n e C h e n

, E ng i n ee r, P e r m i t s Offi ce

G e o ffr e y Gla s s, P e r m i t s Off i c e

T h o m a s W e bb

, P la nn i ng Offic e

C h arl o tt e Wi t h ey

, A t t o r n e y

Su mm a ry: A s arc o d isc u ss e d i t s p r o p o s e d c o n v e r t e r r e t r o fi t p r o j e c t a nd t h e i m p l i ca t i o n s f o r t h e R e g i o n a l

H a z e B A R T F I P

. A sar c o al s o p r ov i d e d a dd i t i o n al i n f o r m a t i o n o n c o n t r o l o p t i o n s m e n t i o n e d i n i t s

c o m m e n t s o n t h e p r o p o s e d R e g i o n al H a z e FI P

.

Ma t e ri a ls : A g e nd a

P o w e r p o i n t P r e s e n t a t i o n

F o ll o w up E m a i ls w i t h In f o r m a t i o n t o G e o f fr ey Gl a ss o n 5 / 19 / 2 0 1 4

, 5 / 2 0 / 2 0 1 4 ( 2 ),

5 / 2 1 / 2 0 1 4

### M a y 15

, 201 4 A sa r c o / E P A B A R T F IP M ee t i ng

A G E N D A

1

. I n t r o d u c t i on s

2

. A s a r c o ’ s ob j e c t i v e s fo r m e e t i n g

3

. H a y den S m e l t e r ope r a t i on s a nd p l an s

a

. A s a r c o ’ s g oa l s

b

. T h e C on v e r t e r R e t r o f i t P r o j e c t

c

. F i tt i n g a ll t he r e g u l a t o r y and en g i n e e ri n g p i e c e s t o g e t he r

4

. Se c o n da r

y v en t il a t i on a c i d p l a n t f ea s i b ili t y

5

. Se c o n da r

y v en t il a t i on W e t sc r u bb i n g f ea s i b ili t y

6

. E x i s t i n g p ri m a r

y a c i d p l an t

a

. N eed fo r li m i t s

b

. M ea s u r e m e n t li m i t a t i o n s a n d im pa c t o n BA R T

c

. L i m i t fo r m / l e v e l

7

. Add i t i o na l q ue s t i o n s

8

. N e x t s t ep s

# R egional H a z e F IP D i sc u ss ion

Ma y 15

, 2014

# M ee ti ng A genda

• I n t r odu c t ion s

• As a rc o’ s obje c t i v e s fo r m ee t ing

• Ha y den Sm el t e r ope r a t ion s and plans

– As a rc o’ s goals

– T he Con v e r t e r Re t r o f i t Pr oje ct

– F i tt ing all t he r egula t o r y and enginee r ing pie c e s t oge t her

• S e c onda r y v en t ila t ion a c id plan t f ea s ibili ty

• S e c onda r y v en t ila t ion w e t scr ubbing f ea s ibili ty

• E x i s t ing p r i m a r y a c id plan t

– Need f

o r li m i ts

– M ea s u r e m en t li m i t a t ion s and i m pa c t on BA RT

– Li m i t f o rm / le v el

• A ddi t ional que s t ions

• Ne x t s t eps

# A sa r co ’ s O b

j ec ti ves f o r M ee ti ng

• E x plain Ha y den Sm el t e r ope r a t ion s and plan s t o p r o v ide EPA c on t e x t fo r

di sc u ss ion

• Di sc u ss w h y a pe r

fo rm an c e s t anda r d i s needed and no t a s pe c i f i c m e t hod

o f c on t r ol

• E x plain w h y s e c onda r y v en t ila t ion a c id plan t i s no t f ea s ible

• E x plain li m i t a t ion s on w e t scr ubbing

• Di sc u ss li m i t s fo r e x i s t ing p r i m a r y a c id plant

• A n s w e r an y que s t ion s EPA m a y ha v e abou t t he Ha y den Sm el t e r ope r a t ion s

and As a rc o’ s FI P c o mm en ts

# H a y den S m e lt e r O pe r a ti ons

• S m e l t e r i nc l udes an I NC O F l ash f u r nace

, P e i r ce S m i t h C onve r t e r s

, A node

r e f i n i ng f u r naces and anc ill a r y equ i p m ent

• A sa r co ope r a t es 5 P e i r ce

- S m i t h C onve r t e r s

, 4 BA R T

- e l i g i b le

– P r i m a r

y hoods e x haus t t o t he A c i d P l ant

– S econda r

y hoods e x haus t t o t he S econda r y H ood B aghouse

– F ug i t i ves e x haus t t o a t m osphe re

• A c i d P l an t con t r o l s t he f l ash f u r nace p r ocess gas i n add i t i on t o t he p r i m a r y gas

f r o m a ll f i ve conve r t e rs

• A sa r co ’ s goa l i s t o upg r ade t he conve r t i ng ope r a t i on t o m ee t a ll Cl ean A i r A c t

r equ i r e m en ts

– M an y r equ i r e m en t s ( R eg i ona l H aze

, SO

2 

# , P M

, P b N AA Q S

, N SPS

, N ES H AP

, S I P)

– E ng i nee r i ng m us t ba l ance a ll o f t hese r equ i r e m en ts

• G oa l : A n y li m i t s o r app r oaches deve l oped unde r an y one p r og r a m m us t no t

h i nde r ab ili t y t o ach i eve deve l op m en t o f i m p r oved s m e l t e r t ha t can m ee t a ll

app li cab l e r equ i r e m en ts

# H a y den S m e lt e r SO

2 

# E m i ss i ons

– C u rr en t ( P T E)

# P e i r ce

- S m it h vs

. H oboken C onve r t e rs

• ASA RCO 

# H a y den ope r a t e s P ei rc e

- S mi t h c on v e r t e r s w hi c h di ff e r f r om

t he H obo k en c on v e r t e r s u s ed a t FM I Miami



# H obo k en C on v e rt e r P e i r c e

- S m i t h C on v e rt er

# P e i r ce

- S m it h vs

. H oboken C onve r t e rs

Hobo k en O pe r a t ion

• Off

- ga s s y phoned t h r ough end w all t o c lo s e -c oupled s p r a y c ha m ber

• T y pi c all y no hood o v e r c ha r ge m ou th

• S o m e f ugi t i v e s c an e sc ape c ha r ge m ou t h i f no c o v er

• Di ff i c ul t t o c ap t u r e s e c onda r y e m i ss ion s lo c ally

• M ia m i c on v e r t e rs in s t alled a t angle t o ai s le

P ei rc e -Sm i t h O pe r a t ion

• Off

- ga s e x i t s c ha r ging m ou t h in c en t e r o f v e ss el

• T y pi c all y ha v e a t igh t p r i m a r y hood o v e r m ou t h and la r ge r s e c onda r y hood

o v e r t he p r i m a r y hood

• G a s e s e sc aping m ou t h c ap t u r ed b y p r i m a r y and s e c onda r y hoods

• E a s ie r t o c ap t u r e s e c onda r y e m i ss ion s lo c ally

– A llo w s f

o r lo w e r e x hau s t r a t e and highe r SO

2 

# s t r eng th

# C onve r t e r O ff G as D es i gn

– Bl o w i ngV e l oc it y ( FP M)

4,900

4,700

4,400

4,200

3,900

3,700

3,400

3,200

3,000

2,700

2,500

2,200

2,000

1,700

1,500

1,200

1,000

700

500

200

0 

# P r i m a r y H ood C F D M ode li ng

- R esu lts

# C onve r t e r S econda r y G as SO

2 

# T r ea t m ent

• C on v er

t er sec ond ar

y b a ghou se g as

– c u rre n t op era t ion

– 275

, 000 S C F M a t 100

- 200 °F

– 1

, 580 pp m v SO

2 

# a v e r age ( 0 t o 10

, 000 pp m v v a r iabili t y)

– 95

. 4% f r o m blo w i n g

, 4

. 6% f r o m s e c onda r y a c t i v i t ies

• EP A ’ s FI P p r opo se d a c on t r ol e ff i c i e n c y o f 99

. 8 % f o r t h e c on v er t er

sec ond ar

y g as s t ream

• D oubl e C on t ac t A c id P l a n t N o t F eas ibl e f o r t hi s g as s t ream:

– SO

2 

# c on c en t r a t ion w ell belo w 6% SO

2 

# ( 60

, 000 pp mv) t o ope r a t e au t ot he rm ally

– Unp r o v en in t hi s appli c a t ion

– no t a w a r e o f an y a c id plan t s t ha t:

• ope r a t e a t t hi s lo w o f inle t c on c en t r a t ion

, o r

• a c hie v e 5pp mv ou t le t c on c en t r a t ion

– T o m a k e a DCD A a c id plan t w o rk in t hi s appli c a t ion

, 100% e x t e r nal hea t ing

plu s r ehea t ing w ould be r equi r ed

– High m oi s t u r e c on t en t r ela t i v e t o SO

2 

# c on t en t w ould r equi r e ene r g y

in t en s i v e dehu m idi f i c a t ion fo r p r ope r a c id s t r eng t h and e ff e c t i v e c on v e rs ion

– High e x t e r nal hea t ing load w ould c on t r ibu t e e x c e ss i v e c olla t e r al e m i ss ions

# C onve r t e r S econda r y G as SO

2 

# T r ea t m ent

• W e t a l ka li scr ubbing i s t ec hni ca ll y f eas ibl e bu t ca nno t p r o v id e 99

. 8 %

rem o v a l e ff i c i e n cy

– B e s t c a s e e ff i c ien c ie s o f be t w een 85% and 95% po ss ible depending on

inle t c on c en t r a t ion and r eagen t u s ed

– B a s ed on e x i s t ing c on v e r t e r s e c onda r y ga s c ondi t ion s

, an e ff i c ien c y o f

a r ound 90% w ould be e x pe c t ed on a 30

- da y ba s is

– BA R T FI P s hould no t r equi r e a r e m o v al e ff i c ien c y s t anda r d be y ond

w ha t i s a c hie v able b y w e t al k ali scr ubbing

# S m e lt e r SO

2 

# E m i ss i ons

– P os t- R e t r o fit ( P T E)

# C onve r t e r S econda r y G as SO

2 

# T r ea t m ent

• Th e c on v er

t er re t r o f i t p r oj ec t w i ll ac hi e v e em i ss ion re du c t ion s t h a t

w i ll excee d t ho se t h a t w ou l d res ul t f r o m a ppli ca t ion o f B A R T t o t h e

p rese n t c on f igu ra t ion

– S e c onda r y hood e x hau s t du r ing blo w i n g w ill be s en t t o a c id plant

• Rep r e s en t s 95

. 4% o f c u rr en t s e c onda r y baghou s e SO

2 

# e m i ss ions

– Con v e r t e r s e c onda r y baghou s e SO

2 

# e m i ss ion s r edu c ed b y 95

. 8%

– T o t al r oo f line f ugi t i v e SO

2 

# e m i ss ion s r edu c ed b y 87

. 3%

– S igni f i c an t pa r t i c ula t e and m e t al s e m i ss ion s r edu c t ion al s o a c hie v ed

– 67 pp m v a v e r age SO

2 

# c on c en t r a t ion in s e c onda r y baghou s e ou t le t

po s t -r e t r o f it

# E m i ss i ons R educ ti on C o m pa r i son

A nnu a l C on v er

t er SO

2 

# E m i ss ion s E s t i ma t e

- T PY (P o t e n t i a l t o E m i t

– 8

, 760 h rs)

S ou r ce Cu rr e nt Con v e r ter

Sec ond a r

y

Sc r ubb e r

85 % Eff. Con v e r ter

Sec ond a r

y

Sc r ubb e r

95 % Eff. Con v e r ter

R et r o f i t

P r o j ect

T o t al SO

2 

## Genera t e d b y C on v er t er s 166

, 44 0 166

, 44 0 166

, 44 0 166

, 440

T o t al SO

2 

## f ro m C on v er t er s t o A P 143

, 89 5 143

, 89 5 143

, 89 5 165

, 251

- SO

2 

## C ap t ured b y Pri m ar y H ood t o A P 143

, 89 5 143

, 89 5 143

, 89 5 160

, 438

- SO

2 

## C ap t ured b y Se c ondar y H ood t o A P 0 0 0 4

, 814

SO

2 

## C ap t ured b y Se c ondar y H ood t o

Se c ondar y Baghou se 22

, 23 5 22

, 23 5 22

, 23 5 936

SO

2 

## C ap t ure d b y T

er t iar y H ood t o S t a c k 0 0 0 240

R oo f line SO

2 

## F ugi t i v e E m i ss ions 31 0 31 0 31 0 13

Se c ondar y Baghou s e SO

2 

## E m i ss ion s 22

, 23 5 3

, 33 5 1

, 1 1 2 796

A c id Plan t T

ail Ga s SO

2 

## E m i ss ions 18 6 18 6 18 6 202

T o t al C on v er t er SO

2 

## E m i ss ions 22

, 73 1 3

, 83 1 1

, 60 8 1

, 251

T o t al C on v er t er SO

2 

## R e m o v al E f f i c ien cy 86

. 3 % 97

. 7 % 99

. 0 % 99

. 2%

# C onve r t e r S econda r y G as SO

2 

# T r ea t m ent

• C on v er

t er Re t r o f i t p r oj ec t SO

2 

# rem o v a l p er f o rma n ce w i ll excee d

scr ubbing o f c u rre n t sec ond ar y g ases

– T o t al c on v e r t e r SO

2 

# r e m o v al w ill be 99

. 2% v e rs u s 97

. 7% t o 99

. 0% f r o m

scr ubbing c u rr en t c on v e r t e r s e c onda r y gas

– Con v e r t e r r oo f line f ugi t i v e SO

2 

# e m i ss ion s w ill be r edu c ed f r o m 300 t o 13

t p y

• F la s h f u r na c e r oo f line f ugi t i v e SO

2 

# e m i ss ion s w ill al s o be r edu c ed

f r o m 326 t o 68 t py

• No f ugi t i v e s r edu c t ion a c hie v ed b y scr ubbing c u rr en t c on v e r t e r

s e c onda r y gas

# E x i s ti ng A c i d P l an t I ssues

• E x i s t ing li m i t s on Ac id P lan t ha v e a c hie v ed s ub s t an t ial r edu c t ion s and

m ain t ained t he m o v e r long t e rm

– w h y a r e t he y no w inadequa t e i f goal i s t o

m ain t ain s t a t u s quo?

• S e tt ing ne w li m i t s i s di ff i c ul t: M u s t add r e ss s pi k e s and v a r iabili ty

• M ea s u r e m en t li m i t a t ion s c on s t r ain c hoi c es

– Acc u r a c y

/ p r e c i s ion o f p r o c e ss inpu t s and p r odu c ts

– Acc u r a c y

/ p r e c i s ion o f m ea s u r e m en t de v i c es

– Cu m ula t i v e e rr o r w he r e ± 1% m a y equal ± 1000 t on s o r m o r e o v e r y ear

– I ss ue s a r e c o m pounded a s app r oa c h “ uni t y”

• A n un w o rk ab l e li m i t bene f i t s no one

# E x i s ti ng A c i d P l ant

• Pr opo s ed c on t r ol e ff i c ien c y and lb /t on a c id p r odu c ed a r e no t f ea s ible

– 99

. 8 x li m i t w a s de r i v ed f r o m t a k ing e s t i m a t ed annual po s t

- CR P a c id

plan t e m i ss ion s and c o m pa r ing t he m t o e s t i m a t ed annual po s t

- CR P

s ul f u r inpu t s and adju s t ing c on t r ol e ff i c ien c y t o m a k e t he m m ee t,

c on s i s t en t w i t h enginee r ing judg m ent

– No c on s ide r a t ion gi v en t o le ss t han annual e m i ss ion s v a r iabili t y o r

i m pa c t o f s t a r t up / s hu t do w n c y c le

– M ea s u r e m en t li m i t a t ion s a r e a c on c e rn

• V a r iabili t y i s c on s ide r able : ( n = 10 y ea rs)

– Hou r l y pp m M ean : 128 w i t h ± 176 s t anda r d de v ia t ion (m a x

2000 +)

– 30

- da y pp m M ean : 128 w i t h ± 72 s t anda r d de v ia t ion (m a x 388)

– Hou r l y pp h M ean : 127 w i t h ± 166 s t anda r d de v ia t ion (m a x

2750 +)

– 30

- da y pp h M ean : 127 w i t h ± 76 s t anda r d de v ia t ion (m a x 384)

# S u mm a ry

• As a rc o i s c o mm i tt ed t o enginee r ing and in s t alling ne x t gene r a t ion c on t r ol s

on i t s ope r a t ion r e s ul t ing in de v elop m en t o f an i m p r o v ed sm el t e r t ha t m ee t s

all en v i r on m en t al r equi r e m en ts

• B a s ed on c u rr en t Ha y den Sm el t e r c on f igu r a t ion and ope r a t ing c ondi t ion s

, BA R T s hould be e s t abli s hed a s:

– Con v e r t e r s e c onda r y ga s e m i ss ion s li m i t s hould be a 30

- da y

pound / hou r o r r e m o v al e ff i c ien c y li m i t ba s ed on w ha t i s a c hie v able w i t h

w e t al k ali scr ubbing a t no m o r e t han 90% r e m o v al e ff i c ien cy

– Ac id plan t t ail ga s e m i ss ion s li m i t s hould no t be an una c hie v able s ho r t

t e rm c on t r ol e ff i c ien c y li m i t bu t r a t he r a t ail ga s pp m v c on c en t r a t ion li m i t

u s ing t he e x i s t ing N SPS li m i t o f 650 pp mv

, w i t h 1

. 5% e x c eedan c e pe r

qua r t e r

, o r an al t e r na t i v e annual o r 30

- da y pp m v li m i t

• BA R T li m i t s need t o be s e t s o t ha t t he y do no t inhibi t t he abili t y o f t he

sm el t e r t o m o v e t o i t s f inal i m p r o v ed c ondi t ion w he r e i t c an m ee t all

en v i r on m en t al r equi r e m en tsF r o m: G a rri t y

, Ja ck [ ma il t o : J G a rri t y @ a s a r c o

. c om ]

S e n t: Mo n d a y , M a y 1 9

, 20 14 4: 0 5 P M

T o: G L A S S

, G E O FF RE Y ; Pa r ame s wa r a n

, K ris hn a

C c: Wi t h e y

, C h a rlo tte ; M c K a u g h a n

, C oll ee n; C h e n

, E u g e n e ; E ri c H i s e r ; M att R u s s e ll ; Vee k

, Am y

S u b j e c t: RE : Q u e s t i o n s a b o u t c o n t rol op t i o n s at H a y d e n S me l te r

G eo f f r e y :

T h a n k y ou f o r y ou r e m a il

. A s a r co ap p r e c i a t e s y ou r t a k i n g t he ti m e t o m ee t wi t h u s l a s t T h u rs d a y and

s ub s e q ue n tl y p r o v i d i n g ad d i t i on a l opp o r t un i t y t o t r y t o c l a r i f y t he p o t e n t i a l o pe r a ti on o f v a r i ou s con t r o l

s y s t e m s a t i t s H a y den S m e l t e r

. We ha v e r e s pon d ed t o y ou r ob s e r v a t i o n s and que s ti o n s b e l o w wi t h t he

i n f o r m a ti on t h a t w e h a v e a v a il a b l e t oda y . We w i l l f o r w a r d y ou an y

add i t i on a l i n f

o r m a ti on t h a t w e c an

de v e l op a s qu i c k l y

a s po s s i b l e

.

We wi ll f i r s t r e s po n d t o yo u r

ob s e r v a t i on s f

r o m t he m ee t i n g . We h a v e s e t t h e s e o u t wi t h an y f u rt h e r

c l a r i fi c a t i on s t h a t w e w a

n t t o p r o v i de

.

1. B e c au s e o f t he l o w i n l e t c oncen t ra t i on, GC S b e li ev e s t h a t an a c i d p l an t co u l d on l y a ch i e ve

96 % SO 2 con t ro l on t h e s econdar y s t re a m

. GC S a l s o e s ti m a t e s t h a t o u r e s t im a t e o f ca p it a l

co s t s and e n ergy co s ts a re t oo l o w by appro x i m a t e l y a f a c t or o f t w o.

I t i s i m po rt a n t t o und e r s t a n d GC T ’ s and A s a r co ’ s po s i ti on on t he a c i d p l a

n t

. A n a c i d p l a n t on t he ex i s t i n g

con v e rt e r s econ d a r y

o f f g a s cou l d t he o r e ti c a l ly a c h i e v e a t m o s t 9 6 % SO 2 c o n t r o l

. H o w e v e r

, f

o r t h e

r ea s on s s e t f

o rt h i n A s a

r c o ’ s and G C T ’ s co mm en t s , an ac i d p l a n t o n t h e con v e r

t e r s econ d a r y i s no t a

prac t i ca b le o p t i on b e ca u s e o f t h e v a r i ab i l i t y i n t he i n l e t co n ce n tr a t i on s

, v o l u m e s

, and op e r a ti o na l

con s t r a i n t s on t he s y s t e m

. T h e r e f o r e, t r y i n g t o e s t a b l i s h an SO 2 co n tr o l p e r c en t a g e f o r t h i s o p t i on m a k e s

l i t t l e s en s e be c au s e i t i s no t p r a c t i ca l l y ac h i e v ab l e ( e. g

. , it w o n ’t w o r k a s a p r a c t i c a l m a tt e r) and h enc e

doe s n o t q u a l if

y a s BA R T unde r t he G u i d e l i ne s

.

T h e e s ti m a t ed co s t o f $160 m illi on f o r t he ba s e u n it co m e s fr o m M EC S, an a c i d p l a n t p r o v i d e r

, and i s

con t a i n e d i n t h e M EC S l e tt e r

.

2. GC S reco m m en d s a co n t r o l e ff i c i ency n o h i g h er t ha n 95 % f o r ca u s t i c s crub b i ng. GC S d i d

no t que s t i on ( b u t a l s o d i d no t co n f i r m ) our co s t e s t i m a t e s o f $28, 0 00,000 i n ca p it a l c o sts or

$9,000,00 0 i n o p er a ti ng c o sts ( pro v i ded b y A s ar c o i n an ea r l i er d a t a req u e s t) nor t he

e s t im a t e s f

o r s l udge ha u l i ng.

GC T ’ s be s t e s t i m a t e f

o r m ax i m u m SO 2 con tr o l e f

f i c i en c y f o r t h e A s a

r co con v e r t e r s eco n da r y s y s t e m i s

90 % f o r t he r e a s on s s t a t e d b y M a tt R u ss e ll a t t he T hu r s da y m ee ti n g

. A dd i t i on a l c o s t i n f o r m a ti on i s

p r o v i ded b e l o w

.

3. GC S st a t ed t h a t C an s o l v i nd i c a t ed t h ey co u l d a ch i e ve an “ a lm o st 99 pe r ce n t ” redu c ti on,

w i t h an i n s t a l l ed c o st o f $ 70,000,00 0

. C an s o l v w ou l d requ i re 30 t ph o f s t e a m w h i ch

pre s u m ab l y w ou l d c o m e f ro m a n e w bo i l e r.

GC T and C a n s o lv do n o t r eco m m end C an s o l v t e chn o l og y f o r t h i s ap p li c a t i on f

o r t he r e a s on s s t a t ed b y

M a t t R u s s e l l d u r i n g t he T h

u rs da y m ee ti n g

. T he c onc e n tr a t i on s a r e l o w e r an d m o r e e r

r a t i c t h a n de s i r ab l e ;

ex t e n s i v e s t ea m

hea t w ou l d

be r e qu i r ed and w o u l d r e q u ir e p r o v i s i on o f

a bo i l e r

, a

nd t he ad d i t i on a l c o s t o f

C an s o l v do e s no t w a r

r a n t t he v e r y s m a ll i m

p r o v e m en t t h a t w ou l d l i k e l y r e s u lt o v e r c a u s ti c

s c r ub b i n g

. GC T ha s e s t i m a t ed t h a t t h e t o t a l i n s t a l l ed c o s t f o r C a n s o l v w ou l d be $ 85 m illi o n on c e t h e

bo i l e r and c o o l i n g t o w e r s y s t e m a r e i n c l ude d w i t

h t h e $70 m ill i on C an s o l v bud g e t p r i c i n g

.I n r e s pon s e t o y ou r s p ec i f i c que s ti o n s

, A s a

r co can p r o v i de t he f

o l l o wi n g i n f

o r m a t i on a t t h i s t i m e :

1. D o you have m o r e r e fi n e d co st i n f o r m a t i on on con st ruc t i on and o p er a ti on o f a conve n ti o n a l

w e t s c rubber on t he s e c o n dary e m i ss i on s ?

We ha v e n o t de v e l o ped an y m o r e r e f i ned cap it a l c o s t e s ti m a t i n g on t h i s i t e m

. T h e e s t i m a t e s t o d a t e h a v e

been p r e li m i na r y

bud g e t a r y e s t i m a t e s f

o r co m pa ris o n p u r

po s e s o n l y . Fu r t

he r r e fi n i n g t he m t o a de f i n i t i v e

co s t e s ti m a t e w o u l d r eq u ir e a f e w m on t h s o f

en g i n ee ri n g

. GC T a l s o p r o v i d ed e s ti m a t e s o f a n nu a l

ope r a t i n g co s t s o f $14 m il li on f o r ca u s t i c s c r

u bb i n g a n d $9.3 m il l i on f

o r C a n s o l v

. T h e ca u s t i c s c r

u bb e r

expen s e w a s i n c r e a s ed fr o m $9 m illi on t o $ 13.9 m il li on a f t e r i n c l u d i n g expe n s e f

o r ad d i t i o n a l p o w e r

r eq u ir e m en t s f

o r t h e f an s

, p u m p s and o t h e r s y s t e m

anc i ll a r i e s

, m a k eup w a t e r , and m o r e accu r a t e s l ud g e

hand l i n g co s ti n g ( $6 0 / t on )

.

2. D o you have m o r e r e fi n e d i n f o r m a t i on on qua n t i ti es o f s l udge an d s l u d ge ha n d li ng co s ts ?

GC T d i d n o t p r e v i ou s l y

e v a l u a t e t he s l u d g e g ene r a t i o n r a t e o r s l ud g e han d li n g c o s t s p r o v i ded b y

E P A

. GC T h a s s i nce e v a l u a t ed t he s l ud g e g ene r a t i on r a t e a n d e s ti m a t e s a s l ud g e g ene r a ti o n r a t e

o f 3 t on s ca l c i u m s u l f

a t e s l ud g e pe r t on o f

SO 2 r e m oved. S l u d g e hand l i n g co s t s a r e v e r y s i t es pe c i f i c a nd i m pu r i t y

- s pec i fi c and h a v e no t b een e s t i m a t ed b y GC T

. GC T u s ed $ 60 / t on p r o v i ded

b y E P A i n t he o p e r a t i n g c o s t e s t i m a t e. I f t he s l ud g e i s ha z a r dou s

, w h i c h A s a r co b e l i e v e s m a y be

t he c a s e

, t h e co s t w o u l d be c l o s e r t o $2 0 0 / t on a nd ad d o v e r

$7 m ill i on t o t h e ann u a l o p e r a t i n g

co s t s

.

3. F r eepo r t ha s r a i s ed t he p o ss i b i l i t y o f u s i n g s pe n t s c rubber li qu o r t o co o l ga se s b e f o re

s end i ng t h e m t o t h e i r d u s t c o ll e c t i on s y s t e m / a c i d p l an t a t t he M i a m i S m e l t er

. Wou l d

s o m e t h i n g l i ke t h i s be f

e a s i b l e a t t he H ay d en S m e lt er? T h i s w ou l d redu c e t h e m a s s o f w a st e

and redu c e hand l i ng c o s ts

.

GC T and A s a r co do n o t s e e an y bene f it o f d o i n g t h i s a t A s a r c o

. GC T doe s no t s ee t h i s a s r ed u c i n g w a s t e.

A n y m a t e ri a l s p r a y ed i n t o t he g a s co o li n g un i t s w i l l e n d up i n du s t r e qu i ri n g d i s p o s a l o r i n t h e a c i d p l a n t

b l o w do w n s l ud g e. I t a l s o w i l l n o t s a v e w a t e r con s u m p t i on a s i t w ou l d r e s u l t i n e qu i v a l e n t m a k eup w a t e r

r eq u ir e m en t s t o t he s c r

ubb e r s y s t e m

. I t a l s o m a y p r e s e n t p r o ce s s r i s k s t o t h e p r o ce s s g a s han d li n g s y s t e m

i n t e r m s o f p l u gg ed s p r a y no zz l e s

, E SP and o t h e r

eq u i p m en t bu il d

up, e t c.

4. D o you have o p er a ti ng c o st i n f o r m a ti on f

or a C an s o l v a mi n e s c rubber ? T he GC S l e t t er o n l y

prov i d ed e x p li c i t i n f

o r m a ti on o n t he i n s t a l l ed co s t

.

GC T e s ti m a t e s an annu a l o pe r a ti n g c o s t o f $9. 3 m illi o n f

o r t h e cu r r e n t c o n v e rt e r s econd a

r y

g a s e s

. C an s o l v w ou l d a l s o r eq u ir e 30 t on / h ou r s t ea m s uppo r t , o r 58 M M B t u

/ ho u r

, w h i ch wil l a l s o l ead t o

t he f o l l o w i n g c o l l a t e r a l e m i ss i o n s b a s ed o n A P

- 42, C h ap t e r 1.4, T ab l e s 1

. 4

- 1 and 1.4

- 2 ( 7 / 98 ) f o r ex t e r n a l

co m bu s ti o n :

NO x : 12.5 t o n s / y e a r

CO : 20.9 t o n s / y e a r

SO 2 : 0.02 t o n s / y e a r

PM T ot al 1.9 t o n s / y e a r

V OC : 1.4 t o n s / y e a r

L e ad : 0.00012 t on s / y ea r

CO 2 : 29, 8 87 t o n s / y ea rT h e s e ca l cu l a t i on s do n o t a dd r e s s c o l l a t e r a l e m i s s i on s f o r e l e c t ri c de m and.

A ll c o s t s p r o v i d ed i n t h i s e m a il a r e b ud g e t a r y e s t i m a t e s ba s ed on k

no w l ed g e o f s i m il a r

p r o j e c t s . F i n a l l y

,

a s A s a r co m u s t up g r a d e t he con v e r t e rs t o m ee t t he 1

- hou r SO 2 NAAQ S, t he BA R T li m it s n eed t o b e s e t

s o t h a t t he y

do n o t i n h i b it t he s m e lt e r ’ s a b i l it y t o m o v e t o i t s fi n a l i m p r o v ed cond it i on w h e r e it can m ee t

a ll en v ir on m en t a l r eq u ir e m en t s

.

R e g a r d s

,

J ac k G a r r it y

F r o m: G L

A S S

, G E O FF RE Y

[ ma il t o : G L

A S S

. G E O F F RE Y @E PA

. G OV ]

S e n t: F rid a y , M a y 16

, 2 0 1 4 3: 4 8 P M

T o: G a rri t y

, Ja c k ; Pa r ame s wa r a n

, K ris hn a

C c: Wi t h e y

, C h a rlo tte ; M c K a u g h a n

, C oll ee n; C h e n

, E u g e n e

S u b j e c t: Q u e s t i o n s a bo u t c o n t rol op t io n s at H a y d e n S me l te r

J a c k and K r i s h n a :

T han k yo u f o r m ee t i ng w i t h u s i n S a n F r an c i s c o

. T h ere i s a l ot o f u se f u l i nf o r m a t i o n i n yo u r

c omm e n t s to t h e pr o p o se d B A R T F I P and i n t h e pr e se n t a t i o n yo u s h a re d w i t h u s

y es t e r da y

. H o w e v e r , w e n ee d s o m e ad d i t i o n a l i n f o r m a t i o n i n o r d er to m a k e d i r e c t

c om p a r i s o n s be t w e e n t h e t h ree c o n t r o l o p t i o n s o f an a c i d p l an t

, a n a m i n e ( C an s ol v )

s c r u b b e r

, and a c a u s t i c s c r u bb e r

.

B a s e d o n t h e l e tt e r f r o m G CS yo u pr o v i d e d a s an a tt a c h m e n t to yo u r c omm e n t s :

1. B e c a u se o f t h e l o w i n l e t c o n c e n t r a t i o n

, G CS b e l i e v es t ha t an a c i d p l an t c o u l d

o n l y a c h i e v e 96 % S O2 c o n t r o l o n t h e s e c o n d a r y s t r e a m

. G CS a l s o e s t i m a t es t ha t

o u r es t i m a t e o f c a p i t a l c o s t s and e n e r g y c o s t s a re too l o w b y a p pr o x i m a t e l y a

fa c t o r o f t w o

. 2. G CS r e c om m e n d s a c o n t r o l e f f i c i e n c y n o h i gh e r t han 95 % f o r c a u s t i c s c r u b b i ng

. G CS d i d n ot q u es t i o n ( b u t a l s o d i d n ot c o n f i r m ) o u r c o s t es t i m a t es o f $28

, 000

, 000

i n c ap i t a l c o s t s o r $9

, 000

, 000 i n o p e r a t i ng c o s t s ( pr o v i d e d b y A s a r c o i n an e a r l i er

da t a r e q u es t ) n o r t h e es t i m a t e s f o r s l ud g e hau l i ng

. 3. G CS s t a t e d t ha t Ca n s ol v i n d i c a t e d t h e y c o u l d a c h i e v e an “ a l m o s t 99 pe r c e n t ”

r e d u c t i o n , w i t h an i n s t a l l e d c o s t o f $70

, 000

, 0 00

. C an s o l v w o u l d r e q u i r e 30 t p h o f

s t e a m w h i c h p re s u m a b l y w o u l d c om e f r om a n e w b oi l e r

.

M y q u es t i o n s :

1. D o yo u h a v e mo re r e f i n e d c o s t i nf o r m a t i o n o n c o n s t r u c t i o n and o pe r a t i o n o f a

c o n v e n t i o n a l w e t s c r u bb e r o n t h e s e c o nd a r y e m i s s i o n s ?

2. D o yo u h a v e mo re r e f i n e d i n f o r m a t i o n o n q uan t i t i es o f s l ud g e a n d s l u d g e

hand l i ng c o s t s ?

3. F r e e p o r t h a s r a i s e d t h e p o s s i b i li ty o f u s i ng s pe n t s c r u b b er l i q u o r t o c oo l g a ses

be f o re se n d i n g t h e m to t h e i r d u s t c oll e c t i o n s y s t e m/ a ci d p l an t a t t h e M i a m iS m e l t er

. W o u l d s om e t h i ng l i k e t h i s b e f e a s i b l e a t t h e Ha y d e n S m e l t e r ? T h i s w o u l d

re d u c e t h e m a ss o f w a s t e and r e d u c e han d li ng c o s t s

. 4. D o yo u h a v e o p e r a t i ng c o s t i nf o r m a t i o n f o r a C an s o l v a m i n e s c r u bb e r ? T h e G CS

l e tt e r o n l y pr o v i d e d e x p l i c i t i n f o r m a t i o n o n t h e i n s t a l l e d c o s t

.

I n o r d er to m ee t o u r r e gu l a to r y d e a d l i n e , w e n ee d to h a v e a d e c i s io n f o r i n t e r n a l

r e v i e w b y t h e e nd o f n e x t w ee k

. I wil l n ee d t h i s i nf o r m a t i o n o n M o n d a y i n o r d e r to

i n c o rp o r a t e i t i n to a f i n a l d e c i s i o n

.

T han k yo u

________

_ _____ _ _____ __ ________

_ _____ _ _____ __ _ G eo ff r e y L

. G l a ss

E n v i r o n m e n ta l E n g i n e e r

Ai r P e rm i t s O ff i c e

, E P A R e g io n 9

4 1 5

. 9 7 2

. 34 98F r o m: G a rri t y

, Ja ck [ ma il t o : J G a rri t y @ a s a r c o

. c om ]

S e n t: T u e sd a y

, M a y 2 0

, 2 0 14 8: 4 3 A M

T o: G L A S S

, G E O FF RE Y

C c: Wi t h e y

, C h a rlo tte ; M c K a u g h a n

, C oll ee n; C h e n

, E u g e n e ; E ri c H i s e r ; Pa r ame s wa r a n

, K ris hn a

S u b j e c t: RE : Q u e s t i o n s a b o u t c o n t rol op t i o n s at H a y d e n S me l te r

G e o ffr e y

,

I f I r e f e r r ed t o a c o mm u n i q ué fr o m C anso l v as a l e tt er

, I m i ssp o k e

. W e h av e a l e tt e r fr o m

M ECS t ha t w as a t t ache d t o ou r co m m e n t s

. W h a t w e ha v e fr o m C anso l v i s an e m a il ( a tt ache d )

i n w h i ch a C anso l v en g i nee r ad d r esse s app li ca t i on o f t he i r t e chno l o g y

t o l o w concen tr a t i on SO 2

s tr e a m s

. T ha t spec i f i c d i scuss i on r e su l t ed fr o m i s sues r a i se d i n ou r F O V n e g o t i a t i ons an d

r e l a t es t o p o s t

-r e tr o f it e m i ss i ons con t r o l

. F u r t he r d i scuss i on w i t h ou r con s u l t an t s

, G C T

, i n f o rm e d A sa r co ’ s unde r s t and i ng t h a t C anso l v i s bes t su i t ed (m o s t cos t e f f ec t i v e ) f o r co n tr o l o f

SO 2 conce n tr a t i ons r a n g i ng fr o m abou t 1 % o r 10

, 000 pp m t o t h e l o w e r t h r esho l d o f w ha t can

p r ac t i ca ll y be t r ea t e d b y a con v en t i ona l ac i d p l an t ( abo u t 4 % )

. Lo w e r con c en tr a t i ons

, such a s

ou r p r e -r e t r o f it second a r

y g as t h a t a v e r a g es 15 8 0 pp m

, a r e m o r e p r a c t i c a l l y con tr o ll ed b y

caus t i c s c r ubb i n g

. T h e r e f o r e

, o u r c o m m en t s t o y ou r obs e r v a t i on #3 be l o w shou l d be

cons i de r ed a s an e x t r a p o l a t i on o f t h e a t t ached e m a il f r o m C anso l v as q u a li f i ed b y M a tt R usse ll

du r i ng l as t T hu r sda y ’ s m ee t i ng

. I apo l o g i z e f o r a n y con f u s i on

.

R e g a r d s

,

Ja c k

F r o m: G L

A S S

, G E O FF RE Y

[ ma il t o : G L

A S S

. G E O F F RE Y @E PA

. G OV ]

S e n t: Mo n d a y , M a y 1 9

, 20 14 4: 2 8 P M

T o: G a rri t y

, Ja c k ; Pa r ame s wa r a n

, K ris hn a

C c: Wi t h e y

, C h a rlo tte ; M c K a u g h a n

, C oll ee n; C h e n

, E u g e n e ; E ri c H i s e r ; M att R u s s e ll ; Vee k

, Am y

S u b j e c t: RE : Q u e s t i o n s a b o u t c o n t rol op t i o n s at H a y d e n S me l te r

T han k s , J a c k

.

A t t h e m ee t i ng l a s t w ee k yo u m e n t i o n e d a l e tt er f r om C a n s o l v

. I d o n ’t see i t i n t h e

a tt a c h m e n t s to yo u r

c omm e n t l e tt e r

. C o u l d yo u p l e a se pr o v i d e a c o p y ?

F r o m: Garri t y

, J ac k [ m ai l t o : J Garri ty @ asar c o

. c om ]

S en t: M o nd a y

, M a y 1 9

, 20 14 4 : 0 5 PM

T o: G L ASS

, G E O FF RE Y ; P ar a m e s w ara n

, Kris hn a

C c: Wi t h e y

, C h ar l o t t e; M cK a ugh a n

, C o ll ee n ; C h e n

, E ug e n e; Eric H is e r ; M a t t R u s s e l l ; V e e k, A m y

S ub j e c t: RE : Q u e s t i o n s a b o u t c o n t r o l o p t i o n s a t H a y d e n S m e l t e r

G eo f f r e y :

T h a n k y ou f o r y ou r e m a il

. A s a r co ap p r e c i a t e s y ou r t a k i n g t he ti m e t o m ee t wi t h u s l a s t T h u rs d a y and

s ub s e q ue n tl y p r o v i d i n g ad d i t i on a l opp o r t un i t y t o t r y t o c l a r i f y t he p o t e n t i a l o pe r a ti on o f v a r i ou s con t r o l

s y s t e m s a t i t s H a y den S m e l t e r

. We ha v e r e s pon d ed t o y ou r ob s e r v a t i o n s and que s ti o n s b e l o w wi t h t he

i n f o r m a ti on t h a t w e h a v e a v a il a b l e t oda y . We w i l l f o r w a r d y ou an y

add i t i on a l i n f

o r m a ti on t h a t w e c an

de v e l op a s qu i c k l y

a s po s s i b l e

.We wi ll f i r s t r e s po n d t o yo u r

ob s e r v a t i on s f

r o m t he m ee t i n g . We h a v e s e t t h e s e o u t wi t h an y f u rt h e r

c l a r i fi c a t i on s t h a t w e w a

n t t o p r o v i de

.

1. B eca u s e o f t h e l o w i n l e t co n cen t ra t i on, GC S b e l i ev e s t h a t an a c i d p l an t c o u l d on l y ac h i eve

96 % SO 2 con t ro l on t h e s econdar y s t re a m

. GC S a l s o e s ti m a t e s t h a t o u r e s t im a t e o f ca p it a l

co s t s and e n ergy co s ts a re t oo l o w by appro x i m a t e l y a f a c t or o f t w o.

I t i s i m po rt a n t t o und e r s t a n d GC T ’ s and A s a r co ’ s po s i ti on on t he a c i d p l a

n t

. A n a c i d p l a n t on t he ex i s t i n g

con v e rt e r s econ d a r y

o f f g a s cou l d t he o r e ti c a l ly a c h i e v e a t m o s t 9 6 % SO 2 c o n t r o l

. H o w e v e r

, f

o r t h e

r ea s on s s e t f

o rt h i n A s a

r c o ’ s and G C T ’ s co mm en t s , an ac i d p l a n t o n t h e con v e r

t e r s econ d a r y i s no t a

prac t i ca b le o p t i on b e ca u s e o f t h e v a r i ab i l i t y i n t he i n l e t co n ce n tr a t i on s

, v o l u m e s

, and op e r a ti o na l

con s t r a i n t s on t he s y s t e m

. T h e r e f o r e, t r y i n g t o e s t a b l i s h an SO 2 co n tr o l p e r c en t a g e f o r t h i s o p t i on m a k e s

l i t t l e s en s e be c au s e i t i s no t p r a c t i ca l l y ac h i e v ab l e ( e. g

. , it w o n ’t w o r k a s a p r a c t i c a l m a tt e r) and h enc e

doe s n o t q u a l if

y a s BA R T unde r t he G u i d e l i ne s

.

T h e e s ti m a t ed co s t o f $160 m illi on f o r t he ba s e u n it co m e s fr o m M EC S, an a c i d p l a n t p r o v i d e r

, and i s

con t a i n e d i n t h e M EC S l e tt e r

.

2. GC S rec o m m end s a c on t r o l e ff i c i ency n o h i g h e r t han 95 % f or ca u s t i c s c r ubb i ng. GC S d i d

no t que s t i on ( b u t a l s o d i d no t co n f i r m ) our co s t e s t i m a t e s o f $28, 0 00,000 i n ca p it a l c o sts or

$9,000,00 0 i n o p er a ti ng c o sts ( pro v i ded b y A s ar c o i n an ea r l i er d a t a req u e s t) nor t he

e s t im a t e s f

o r s l udge ha u l i ng.

GC T ’ s be s t e s t i m a t e f

o r m ax i m u m SO 2 con tr o l e f

f i c i en c y f o r t h e A s a

r co con v e r t e r s eco n da r y s y s t e m i s

90 % f o r t he r e a s on s s t a t e d b y M a tt R u ss e ll a t t he T hu r s da y m ee ti n g

. A dd i t i on a l c o s t i n f o r m a ti on i s

p r o v i ded b e l o w

.

3. GC S st a t ed t ha t C a n s o l v i n d i c a t ed t hey cou l d a ch i e v e an “ a l m o s t 99 p e r c en t ” r educ t i on,

w i t h an i n s t a l l ed c o st o f $ 70,000,00 0

. C an s o l v w ou l d requ i re 30 t ph o f s t e a m w h i ch

pre s u m ab l y w ou l d c o m e f ro m a n e w bo i l e r.

GC T and C a n s o lv do n o t r eco m m end C an s o l v t e chn o l og y f o r t h i s ap p li c a t i on f

o r t he r e a s on s s t a t ed b y

M a t t R u s s e l l d u r i n g t he T h

u rs da y m ee ti n g

. T he c onc e n tr a t i on s a r e l o w e r an d m o r e e r

r a t i c t h a n de s i r ab l e ;

ex t e n s i v e s t ea m

hea t w ou l d

be r e qu i r ed and w o u l d r e q u ir e p r o v i s i on o f

a bo i l e r

, a

nd t he ad d i t i on a l c o s t o f

C an s o l v do e s no t w a r

r a n t t he v e r y s m a ll i m

p r o v e m en t t h a t w ou l d l i k e l y r e s u lt o v e r c a u s ti c

s c r ub b i n g

. GC T ha s e s t i m a t ed t h a t t h e t o t a l i n s t a l l ed c o s t f o r C a n s o l v w ou l d be $ 85 m illi o n on c e t h e

bo i l e r and c o o l i n g t o w e r s y s t e m a r e i n c l ude d w i t

h t h e $70 m ill i on C an s o l v bud g e t p r i c i n g

.

I n r e s pon s e t o y ou r s p ec i f i c que s ti o n s

, A s a

r co can p r o v i de t he f

o l l o wi n g i n f

o r m a t i on a t t h i s t i m e :

1. D o you h a ve m ore r e f i ned c o st i n f

o r m a t i on on c on st r u c t i on and o p er a ti o n o f a c onven t i on a l

w e t s c rubber on t he s e c o n dary e m i ss i on s ?

We ha v e n o t de v e l o ped an y m o r e r e f i ned cap it a l c o s t e s ti m a t i n g on t h i s i t e m

. T h e e s t i m a t e s t o d a t e h a v e

been p r e li m i na r y

bud g e t a r y e s t i m a t e s f

o r co m pa ris o n p u r

po s e s o n l y . Fu r t

he r r e fi n i n g t he m t o a de f i n i t i v e

co s t e s ti m a t e w o u l d r eq u ir e a f e w m on t h s o f

en g i n ee ri n g

. GC T a l s o p r o v i d ed e s ti m a t e s o f a n nu a l

ope r a t i n g co s t s o f $14 m il li on f o r ca u s t i c s c r

u bb i n g a n d $9.3 m il l i on f

o r C a n s o l v

. T h e ca u s t i c s c r

u bb e r

expen s e w a s i n c r e a s ed fr o m $9 m illi on t o $ 13.9 m il li on a f t e r i n c l u d i n g expe n s e f

o r ad d i t i o n a l p o w e r

r eq u ir e m en t s f

o r t h e f an s

, p u m p s and o t h e r s y s t e m

anc i ll a r i e s

, m a k eup w a t e r , and m o r e accu r a t e s l ud g e

hand l i n g co s ti n g ( $6 0 / t on )

.2. D o you h a ve m ore r e f i ned i n f o r m a ti o n on qua n ti t i e s o f s l ud g e and s l ud ge hand li n g co s ts ?

GC T d i d n o t p r e v i ou s l y

e v a l u a t e t he s l u d g e g ene r a t i o n r a t e o r s l ud g e han d li n g c o s t s p r o v i ded b y

E P A

. GC T h a s s i nce e v a l u a t ed t he s l ud g e g ene r a t i on r a t e a n d e s ti m a t e s a s l ud g e g ene r a ti o n r a t e

o f 3 t on s ca l c i u m s u l f

a t e s l ud g e pe r t on o f

SO 2 r e m oved. S l u d g e hand l i n g co s t s a r e v e r y s i t es pe c i f i c a nd i m pu r i t y

- s pec i fi c and h a v e no t b een e s t i m a t ed b y GC T

. GC T u s ed $ 60 / t on p r o v i ded

b y E P A i n t he o p e r a t i n g c o s t e s t i m a t e. I f t he s l ud g e i s ha z a r dou s

, w h i c h A s a r co b e l i e v e s m a y be

t he c a s e

, t h e co s t w o u l d be c l o s e r t o $2 0 0 / t on a nd ad d o v e r

$7 m ill i on t o t h e ann u a l o p e r a t i n g

co s t s

.

3. F r e epo r t ha s ra i s ed t he po s s i b i l i t y o f u s i ng s p e n t s c rubber li q u or t o co o l ga s e s b e f o re

s end i ng t h e m t o t h e i r d u s t c o ll e c t i on s y s t e m / a c i d p l an t a t t he M i a m i S m e l t er

. Wou l d

s o m e t h i n g l i ke t h i s be f

e a s i b l e a t t he H ay d en S m e lt er? T h i s w ou l d redu c e t h e m a s s o f w a st e

and redu c e hand l i ng c o s ts

.

GC T and A s a r co do n o t s e e an y bene f it o f d o i n g t h i s a t A s a r c o

. GC T doe s no t s ee t h i s a s r ed u c i n g w a s t e.

A n y m a t e ri a l s p r a y ed i n t o t he g a s co o li n g un i t s w i l l e n d up i n du s t r e qu i ri n g d i s p o s a l o r i n t h e a c i d p l a n t

b l o w do w n s l ud g e. I t a l s o w i l l n o t s a v e w a t e r con s u m p t i on a s i t w ou l d r e s u l t i n e qu i v a l e n t m a k eup w a t e r

r eq u ir e m en t s t o t he s c r

ubb e r s y s t e m

. I t a l s o m a y p r e s e n t p r o ce s s r i s k s t o t h e p r o ce s s g a s han d li n g s y s t e m

i n t e r m s o f p l u gg ed s p r a y no zz l e s

, E SP and o t h e r

eq u i p m en t bu il d

up, e t c.

4. D o you h a ve op e ra t i n g co s t i n f o r m a t i on f

or a C an s o l v a m i ne s crubb e r? T he GC S l e t t er on l y

prov i d ed e x p li c i t i n f

o r m a ti on o n t he i n s t a l l ed co s t

.

GC T e s ti m a t e s an annu a l o pe r a ti n g c o s t o f $9. 3 m illi o n f

o r t h e cu r r e n t c o n v e rt e r s econd a

r y

g a s e s

. C an s o l v w ou l d a l s o r eq u ir e 30 t on / h ou r s t ea m s uppo r t , o r 58 M M B t u

/ ho u r

, w h i ch wil l a l s o l ead t o

t he f o l l o w i n g c o l l a t e r a l e m i ss i o n s b a s ed o n A P

- 42, C h ap t e r 1.4, T ab l e s 1

. 4

- 1 and 1.4

- 2 ( 7 / 98 ) f o r ex t e r n a l

co m bu s ti o n :

NO x : 12.5 t o n s / y e a r

CO : 20.9 t o n s / y e a r

SO 2 : 0.02 t o n s / y e a r

PM T ot al 1.9 t o n s / y e a r

V OC : 1.4 t o n s / y e a r

L e ad : 0.00012 t on s / y ea r

CO 2 : 29, 8 87 t o n s / y ea r

T h e s e ca l cu l a t i on s do n o t a dd r e s s c o l l a t e r a l e m i s s i on s f o r e l e c t ri c de m and.

A ll c o s t s p r o v i d ed i n t h i s e m a il a r e b ud g e t a r y e s t i m a t e s ba s ed on k

no w l ed g e o f s i m il a r

p r o j e c t s . F i n a l l y

,

a s A s a r co m u s t up g r a d e t he con v e r t e rs t o m ee t t he 1

- hou r SO 2 NAAQ S, t he BA R T li m it s n eed t o b e s e t

s o t h a t t he y

do n o t i n h i b it t he s m e lt e r ’ s a b i l it y t o m o v e t o i t s fi n a l i m p r o v ed cond it i on w h e r e it can m ee t

a ll en v ir on m en t a l r eq u ir e m en t s

.

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J a c k and K r i s h n a :

T han k yo u f o r m ee t i ng w i t h u s i n S a n F r an c i s c o

. T h ere i s a l ot o f u se f u l i nf o r m a t i o n i n yo u r

c omm e n t s to t h e pr o p o se d B A R T F I P and i n t h e pr e se n t a t i o n yo u s h a re d w i t h u s

y es t e r da y

. H o w e v e r , w e n ee d s o m e ad d i t i o n a l i n f o r m a t i o n i n o r d er to m a k e d i r e c t

c om p a r i s o n s be t w e e n t h e t h ree c o n t r o l o p t i o n s o f an a c i d p l an t

, a n a m i n e ( C an s ol v )

s c r u b b e r

, and a c a u s t i c s c r u bb e r

.

B a s e d o n t h e l e tt e r f r o m G CS yo u pr o v i d e d a s an a tt a c h m e n t to yo u r c omm e n t s :

1. B e c a u se o f t h e l o w i n l e t c o n c e n t r a t i o n

, G CS b e l i e v es t ha t an a c i d p l an t c o u l d

o n l y a c h i e v e 96 % S O2 c o n t r o l o n t h e s e c o n d a r y s t r e a m

. G CS a l s o e s t i m a t es t ha t

o u r es t i m a t e o f c a p i t a l c o s t s and e n e r g y c o s t s a re too l o w b y a p pr o x i m a t e l y a

fa c t o r o f t w o

. 2. G CS r e c om m e n d s a c o n t r o l e f f i c i e n c y n o h i gh e r t han 95 % f o r c a u s t i c s c r u b b i ng

. G CS d i d n ot q u es t i o n ( b u t a l s o d i d n ot c o n f i r m ) o u r c o s t es t i m a t es o f $28

, 000

, 000

i n c ap i t a l c o s t s o r $9

, 000

, 000 i n o p e r a t i ng c o s t s ( pr o v i d e d b y A s a r c o i n an e a r l i er

da t a r e q u es t ) n o r t h e es t i m a t e s f o r s l ud g e hau l i ng

. 3. G CS s t a t e d t ha t Ca n s ol v i n d i c a t e d t h e y c o u l d a c h i e v e an “ a l m o s t 99 pe r c e n t ”

r e d u c t i o n , w i t h an i n s t a l l e d c o s t o f $70

, 000

, 0 00

. C an s o l v w o u l d r e q u i r e 30 t p h o f

s t e a m w h i c h p re s u m a b l y w o u l d c om e f r om a n e w b oi l e r

.

M y q u es t i o n s :

1. D o yo u h a v e mo re r e f i n e d c o s t i nf o r m a t i o n o n c o n s t r u c t i o n and o pe r a t i o n o f a

c o n v e n t i o n a l w e t s c r u bb e r o n t h e s e c o nd a r y e m i s s i o n s ?

2. D o yo u h a v e mo re r e f i n e d i n f o r m a t i o n o n q uan t i t i es o f s l ud g e a n d s l u d g e

hand l i ng c o s t s ?

3. F r e e p o r t h a s r a i s e d t h e p o s s i b i li ty o f u s i ng s pe n t s c r u b b er l i q u o r t o c oo l g a ses

be f o re se n d i n g t h e m to t h e i r d u s t c oll e c t i o n s y s t e m/ a ci d p l an t a t t h e M i a m i

S m e l t er

. W o u l d s om e t h i ng l i k e t h i s b e f e a s i b l e a t t h e Ha y d e n S m e l t e r ? T h i s w o u l d

re d u c e t h e m a ss o f w a s t e and r e d u c e han d li ng c o s t s

. 4. D o yo u h a v e o p e r a t i ng c o s t i nf o r m a t i o n f o r a C an s o l v a m i n e s c r u bb e r ? T h e G CS

l e tt e r o n l y pr o v i d e d e x p l i c i t i n f o r m a t i o n o n t h e i n s t a l l e d c o s t

.

I n o r d er to m ee t o u r r e gu l a to r y d e a d l i n e , w e n ee d to h a v e a d e c i s io n f o r i n t e r n a l

r e v i e w b y t h e e nd o f n e x t w ee k

. I wil l n ee d t h i s i nf o r m a t i o n o n M o n d a y i n o r d e r to

i n c o rp o r a t e i t i n to a f i n a l d e c i s i o n

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T han k s , J a c k.

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C o ll een / G e o ff r e y

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, EPA s h ou l d p r o v i de t ha t an y e x ceedance t h a t A s a r c o ca n de m on s tr a t e i s due

t o t he f l a sh f u r nac e i s n o t a v i o l a t i on o f t h e BART li m i t. A s a p r a c t i ca l m a tt e r

, t h i s m i g h t t a ke t he

f o r m o f d e m on s tr a t i ng t h a t i f ce r t a i n f l as h f u r nac e

- on l y hou r s o f op e r a t i on a r e e x c l uded fr o m t h e

co m p li ance de m ons t r a t i o n and t he BA R T li m it i s m e t

, t hen n o v i o l a t i on o f BAR T ha s

occu rr e d

. A sa r co doe s n o t a n t i c i pa t e an y suc h e x ceedances

, bu t be li e v es t he p r i nc i p l e i s

i m po rt a n t.

Si m il a r l y

, f o r t he p r opos e d w e t sc r ubb i n g o n t he c on v e rt e r s e conda r y g as e s

, shou l d EPA dec i de

t ha t i t i s w a rr an t e d as B A R T

, A sa r co be li e v es t ha t a li m it based o n 9 0 % c o n tr o l e ff i c i enc y i s

p r ac t i cab l e

. B ase d on t h e 20

, 34 1 t on s / y ea r base l i ne w i t h f i v e con v e rt e r s

, t h i s w ou l d be 4

, 068

t ons / con v e r

t e r

, w i t h f o u r con v e rt e r s con t r o ll ed t o 407 t on s eac h and 1 co nv e rt e r a t 4

, 068 t on s

f o r a t o t a l o f 5

, 69 6 t on s / y ea r

. A ss u m i n g 33 0 ope r a t i ng da y s i n a t y p i ca l y e a r ( an op e r a t i n g da y

be i n g an y da y

t h a t b l a s t a i r i s i n t r oduced i n t o a B AR T

- e li g i b l e con v e r t e r )

, a 30

- da y

r o lli ng

a v e r a g e o f 1

, 438 po u nd s / hou r and a r o lli ng 12

- m o n t h s u m o f 5

, 69 6 t on s / y ea r w ou l d be

app r op r i a t e

.

F i na l l y

, i n li g h t o f t h e i m p end i n g con v e r t e r r e tr o f i t p r o

j e c t

, A sa r co r e q ues t s t ha t EPA c l a r i f y i n t he

p r ea m b l e t o t h e f i na l r u l e t h a t t he BA R T li m it s ap p l y on l y t o t h e BART

- e li g i b l e un i t s an d do n o t

app l y i f t hose un i t s a r e r e m o v ed

.

R e g a r d s

,

Ja c k

F r o m: G a rri t y

, Ja ck

S e n t: T u e sd a y

, M a y 2 0

, 2 0 14 11 : 4 8 A M

T o: M c K a u g h a n , Coll ee n ( M c K a u g h a n .Coll ee n @ e p a

. g ov ) ; GL A SS

, G E O F F RE Y

( GL A S S

. G E O FF RE Y @ E PA

. G OV )

S u b j e c t: A s a r c o 5 / 15 / 14 P r e s e n tat io n

C o ll een / G e o ff r e y

,

H e r e a r e t h e s li des o f o u r p r esen t a t i on l as t T hu r s da y

. Y ou ’ll r eca ll t ha t w e a l so sha r e d add i t i ona l

t ho u g h t s o f poss i b l e a l t e r na t i v es t o t he e ff i c i enc y li m i t f o r ou r e x i s t i ng ac i d p l an t. W e w ill sendou r r eco m m end a t i on o f t he m o s t ap p r op r i a t e f o r m o f li m it a s soon a s w e ha v e f i n i shed r e v i s i n g

da t a t o EPA’ s p r e f e rr e d “ ope r a t i n g ho u r s on l y ” f o r m a t.

R e g a r d s

,

Ja c k