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Technical Review and Evaluation AIR QUALITY PERMIT NO. 66039 FREEPORT MCMORAN MIAMI, INC. - SMELTER I. INTRODUCTION This Class I renewal permit is being issued to Freeport McMoRan Miami Inc., the Permittee, for the continued operation of a copper smelter in Miami in Gila county, Arizona. This permit renews and supersedes Operating Permit No. 53592. A. Company Information Facility Name: Freeport McMoRan Miami Inc. (FMMI) Mailing Address: P.O. Box 4444 Claypool, Arizona 85532 Facility Address: Hwy 60, North of Miami Miami, Gila County, Arizona 85532 B. Attainment Classification Miami area is currently designated as a non-attainment area for Particulate Matter less than 10 microns (PM10) and SO2 (1-hour, 75 ppb standard). II. FACILITY DESCRIPTION A. Material Handling and Bedding Plant Copper concentrate is delivered to the bedding plant by truck and rail car. In the bedding plant, stockpiles of smelter feed are built up and prepared for feed to the IsaSmelt® (Isa) furnace. The metallurgical characteristics of each pile are determined, and the flux requirements are calculated. The concentrate is conveyed to bins, then to the blending belt where fluxes, reverts, and coal (optional) are blended with concentrates of copper and other metals, routed to a paddle mixer, and then to the Isa furnace. The option to direct the feed to through a pelletizer also exists. Flux and reverts are transported by dump trucks that dump onto receiving stockpiles. Flux and reverts from the stockpiles are then routed through crushing and screening circuits, one for reverts and another for flux, to reduce the size of the material down to specification levels and then stored in individual storage bins. From the storage bins, these materials are then metered onto the blending belt that carries concentrate to the paddle mixer. B. Smelter The IsaSmelt® furnace is the primary smelting furnace. New metal bearing material (NMBM), fluxes, lime, reverts, and coal (optional) are fed, along with oxygen enriched air and fuel to the Isa furnace. In the IsaSmelt® process, heat is utilized from the partial TSD for Permit No. 66039 Page 1 of 14 August 22, 2017 Freeport McMoRan Miami Smelter oxidation of sulfide charge, thus saving energy costs. The electric furnace receives the matte/slag mixture from Isa vessel and converter slag by ladle. Once the copper matte settles to the bottom of the electric furnace, the slag on the top of the bath is removed and hauled to slag storage area. Matte is tapped from the electric furnace into ladles and transported by cranes to four Hoboken converters. Blister copper from converters is transferred by ladles to either of the two anode furnaces for further oxidation of residual sulfides and refining to meet residual dissolved oxygen specifications for the off-site refinery. Anode copper is then cast into molds to make anodes for further refining. The process off-gas from the Isa is routed through a waste heat boiler (WHB) where a portion of entrained dust settles out. The collected dust is returned to the bedding plant or reverts bin. The gases from the WHB are routed to an electrostatic precipitator (ESP). Dust from the ESP is collected and sent to electric furnace or reverts bin. The gases are routed to a double contact acid plant. Process off-gas from electric furnace are cooled in an off-take duct with water sprays and then routed to the acid plant. Process off-gas from converters is cooled by water sprays and combined with gases from the Isa vessel and electric furnace, and routed to the acid plant. These gases are converted in the acid plant to make sulfuric acid. The unconverted SO2 is exhausted through the acid plant tail gas stack. Emissions from the electric furnace matte tapping launders, furnace converter slag return launders, furnace slag tapping launders, and the Isa vessel matte tapping launders are collected by the vent fume system. These gases pass through a chemical scrubber and wet electrostatic precipitators (WESPs) and then exhaust through the vent fume stack. Electrolytic Refinery The cast anodes are transported to the electrolytic refinery at El Paso, TX or Miami (when operating). In the refinery, copper is separated from impurities by electrolysis. Metallic impurities settle at the bottom sludge of refinery tanks as a sludge. The sludge is removed and sold to recover precious metals. Rod Plant At the Rod Plant cathodes from various sources are melted in a gas-fired shaft furnace, and molded into copper rods using a continuous caster and rolling mill. The rod is brightened by cleaning with isopropyl alcohol, wax, coated onto the rod to prevent oxidation and coiled in preparation for shipment. Scrap copper is returned to the smelter. III. COMPLIANCE HISTORY There have been a total of 248 air quality inspections (247 file reviews and 7 facility on-site inspections) associated with this facility since 2012. Four air quality violations were identified for this facility as the result of these inspections. All these have been closed. TSD for Permit No. 66039 Page 2 of 14 August 22, 2017 Freeport McMoRan Miami Smelter IV. FACILITY-WIDE EMISSIONS The following tables provide summary of the facility-wide potential-to-emit (PTE). TABLE 1: FACILITY-WIDE PTE Upon Project Start Pollutant Current up Tons per year PM 598 506 PM10 363 310 PM2.5 282 196 SO2 2537 644* NOX 316 265 CO 133.2 133.5 VOC 200.6 198 H2SO4 104 127 Pb 5.01 4.03 *The SO2 PTE Facility Wide limit changes to 624 tons per year upon A.A.C R18-2-C1302 effective date V. APPLICABLE REGULATIONS VERIFICATION The Permittee has identified the applicable regulations that apply to each unit in the permit application. The following table summarizes the findings of the Department with respect to applicability or non-applicability of applicable regulations that apply to each unit. TABLE 2: APPLICABLE REGULATIONS VERIFICATION Unit ID Control Applicable Verification Equipment Regulations Material Handling Baghouses for A.A.C. R18-2- Standards of Performance for Existing and Bedding Plant individual 702.B.3 Primary Copper Smelters A.A.C. R18- storage bins, 2-715 are applicable to any Copper water sprays A.A.C. R18-2-715 Smelter process including the following “affected facilities”: material handling and bedding plant. Until project start up, the particulate matter emission limits from Installation permit #1232 are retained in the Title V permit. Process Gases from Acid Plant, 40 CFR 60 Subpart P The IsaSmelt® furnace is an “affected the IsaSmelt and Chemical facility” subject to NSPS Subpart P Furnace and Scrubber for because constructed commenced after Converters (Acid control of SO2 October 16, 1974. Plant Tail Gas emissions Stack) The National Emission Standard for 40 CFR 63 Subpart Hazardous Air Pollutants (NESHAP) QQQ Subpart QQQ is applicable to any TSD for Permit No. 66039 Page 3 of 14 August 22, 2017 Freeport McMoRan Miami Smelter Unit ID Control Applicable Verification Equipment Regulations existing or new copper smelter that is a major source of HAP emissions. A.A.C. R18-2-715 Particulate limits and Standards of A.A.C. R18-2-715.01 Performance for Existing Primary Copper Smelters A.A.C. R18-2-715 and 715.01 are applicable to the smelter facility. Once A.A.C. R-18-2-C1302 becomes applicable, standards from A.A.C. R- A.A.C. R18-2-C1302 18-2-715 and-715.01 shall cease to apply. Additionally, the particulate matter, lead, and SO2 emissions are subject to the emission standards from the installation permit #1232 - until project startup. Also, NOX emission limitation from the PSD permit revision #1000266 is retained. Regional Haze, 40 Requirements from Regional Haze, 40 CFR 52.145 (m) CFR 52.145 (m) are applicable to the Electric Furnace and the batch Copper Converters. Vent Fume Stack Wet scrubber, 40 CFR 63 Subpart “Affected sources” under Subpart Wet QQQ QQQ include tapping operations are Electrostatic A.A.C. R18-2-715 subject to NESHAP 40 CFR 63 Precipitators A.A.C. R18-2-715.01 Subpart QQQ. (ESPs) Standards of Performance for Existing Primary Copper Smelters A.A.C. R18- 2-715 and 715.01 are applicable to the smelter facility. Additionally, the particulate matter, lead and SO2 emissions are subject to the emission standards for the vent fume stack from installation permit A.A.C. R18-2-C1302 #1232- until project startup. Once A.A.C. R-18-2-C1302 becomes applicable, standards from A.A.C. R- 18-2-715 and-715.01 shall cease to apply. Smelter Fugitives A.A.C. R18-2- Opacity standard from A.A.C R18-2- 702.B.3 and E 702.B and E are applicable to A.A.C. R18-2-715 emissions from the smelter building. A.A.C. R18-2-715.01 Fugitive emissions from primary copper smelting operations are also 40 CFR 63 Subpart subject to NESHAP 40 CFR 63 QQQ Subpart QQQ. TSD for Permit No. 66039 Page 4 of 14 August 22, 2017 Freeport McMoRan Miami Smelter Unit ID Control Applicable Verification Equipment Regulations Once A.A.C. R-18-2-C1302 becomes applicable, standards from A.A.C. R- 18-2-715 and-715.01 shall cease to A.A.C. R18-2-C1302 apply. Converters (not N/A 40 CFR 61 Subpart O The copper converters are subject to otherwise covered this standard for arsenic emissions above) under 40 CFR 61 Subpart O Anode Furnaces Steam A.A.C. R18-2- Opacity standard from A.A.C R18-2- and Utility Vessels Injection 702.B.3 and E 702.B and E are applicable to System emissions from the anode furnaces and utility vessels.
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