AP-42 Section Number: 12.9 Reference Number: 4 Title: Emission Factors and Emission Source Information for Primary and Secondary Copper Smelters US EPA US EPA December 1977 I ~ -1 EPA-450/3-77-05 1 EMISSION FACTORS 0 AND EMISSION SOURCE INFORMATION . FOR PRIMARY AND SECONDARY .' COPPER SMELTERS I 0 by G.E. Umlauf and L.G. Wayne Pacific Environmental Services. Inc. 0 1930 14th Street Santa Monica, California 90404 Contract No. 68-02-1890 0 Task Order No. 3 EPA Project Officer: Arch McQueen 0 Prepared for ENVIRONMENTAL PROTECTION AGENCY Office of Air and Waste Management 0 Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 December 1977 I O! This report is issued by the Environmental Protection Agency to report technical data of interest to a limited number of readers. Copies are available free of charge to Federal employees, current contractors and grantees, and nonprofit organizations - in limited quantities - from the Library Services Office (MD-35), Research Triangle Park, North Carolina 0 27711; or, for a fee, from the National Technical Information Service, 5285 Port Royal Road, Springfield, Virginia 22161. 0 This report was furnished to the Environmental Protection Agency by Pacific Environmental Serbices , Inc . , 1930 14th Street, Santa Monica, California 90404, in fulfillment of Contract No. 68-02-1890, Task Order 0 No. 3. The contents of this report are reproduced herein as received from Pacific Environmental Services, Inc. The opinions, findings, and conclusions expressed are those of the author and not necessarily those of the Environmental Protection Agency. Mention of company or product names is not to be considered as an endorsement by the Environmental Protection Agency. 0 0 Publication No, EPA-450/3-77-051 0 0 ACKNOWLEDGEMENT Successful completion of this project depended upon the cooperation of many individuals including, especially, personnel of EPA Regional Offices and of the air pollution control agencies of many states and of several cities and counties. We wish to express our appreciation to all who participated, even though we forbear to list their names because of the excessive length of the roll. iii ABSTRACT This document constitutes the final report of a project, carried out under U.S. EPA Contract No. 68-02-1890 (Task Order No. 3), to upgrade emission factors and engineering management information for primary and secondary copper smelters. The main body of the report describes procedures and methodology used in obtaining relevant information regarding these indus- tries and the operational characteristics of process equipment used therein. Related information regarding alloying and cast- ing has been included in the description secondary copper smelter processes, and information about emissions from similar furnaces used in nonferrous foundry operations was also collected. New information on source tests was coded for entry into the AEROS SOTDAT files; newly identified sources were coded for entry in- to NEDS, and information as to the precision of emission factors was furnished for use in the SIEFA data base. New source clas- sification codes (SCC's) were proposed for a number of processes. Appendixes to this document are the following project de- liverables: Appendixes A and B for inclusion in AP-42, "Compilation e of Air Pollutant Emission Factors." namely Section 7.3, Primary Copper Smelting and Section 7.9, Secondary Copper Smelting and Alloying; Appendix C, Primary Copper Smelting Process Compendium; and Appendix D, Secondary Copper Smelting Process Compendium. e fV e TABLE OF CONTENTS Section 1.0 INTRODUCTION ..................... 1-1 1.1 Scope of Work .................. 1-1 1.2 Task Description ................ 1-1 1.3 Organization of Final Report .......... 1-2 2.0 RESULTS AND CONCLUSIONS ............... 2-1 0 2.1 Project Deliverables .............. 2-1 2.2 Development of Emission Factors ......... 2-1 3.0 DATA GATHERING .................... 3-1 9 4.0 DATA ANALYSIS .................... 4-1 4.1 Data Analysis Procedures ............ 4-1 4.2 Emission Factors for Primary Smelter Processes . 4-6 4.3 Emission Factors for Particulates From -Furnaces Used in Secondary Copper Smelting Processes ... 4-15 8: 5.0 FUGITIVE EMISSIONS .................. 5-1 5.1 Introduction .................. 5-1 5.2 Primary Copper Smelters ............. 5-1 e. 5.2.1 Pollutants ................ 5-1 5.2.2 Sources ................. 5-3 5.3 Secondary Copper Smelters ............ 5-6 5.4 Fugitive Emission Control ............ 5-7 6.0 RECOMMENDATIONS FOR FURTHER SOURCE TESTING ...... 6-1 6.1 Precision of Emission Factors .......... 6-2 6.2 Recomnendations for Additional Testing ..... 6-6 7.0 REFERENCES ...................... 7-1 0 e V Section APPENDIX A. SECTION 7.3, PRIMARY COPPER SMELTING APPENDIX B. SECTIXI 7.9, SECONDARY COPPER SMELTING AND ALLOYING APPENDIX C. PRIMARY COPPER SMELTING PROCESS COMPENDIUM * APPENDIX D. SECONDARY COPPER SMELTING PROCESS COMPENDIUM vi e i., i., LIST OF ILLUSTRATIONS Figure & 4-1 Check List for Emission Source Information ...... 4-3 4-2 Typical Example of Formatted Test Results ...... 4-5 LIST OF TABLES Table 2-1 Emission Factors for Particulates From Secondary Copper Smelting and Alloying Processes Without Controls ....................... 2-2 2-2 Emission Factors for Sulfur Dioxide for Primary Copper Smelting Processes Without Controls ...... 2-5 2-3 Emission Factors for Particulates From Primary Copper Smelting Processes Without Emission Controls . 2-7 4-1 Emissions From Converters in Primary Copper Smelters . 4-7 4-2 Emissions From Reverberatory Furnaces in Primary Copper Smelters ................... 4-10 4-3 Combined Emissions From Multiple-Hearth Roasters and Reverberatory Furnaces in Primary Copper Smelters . 4-12 4-4 Emission Factors for Smelter Processes Derived From Published Literature ................. 4-1 6 4-5 Emission Factors for Particulate Matter From Furnaces Used in Secondary Copper Smelting and Alloying Processes ...................... 4-1 7 5-1 Possible Fugitive Emissions From Primary Copper . Smelters ....................... 5-2 5-2 Fugitive Emission Source, Quantity and Control .... 5-9 6-1 SIEFA Standard Deviations and Precision Factors for Primary Capper Smelting Processes (Particulate Emissions) ...................... 6-3 8!! 6-2 SIEFA Standard Deviations and Precision Factors for Primary Copper Smelting Processes (Sulfur Dioxide Emissions) ...................... 6-4 6-3 Primary Copper Smelting Processes for Which Emission Factors Should be Developed ............. 6-7 .' vi i ! I lo 1.0 INTRODUCTION This report describes the methodology followed and the results achieved by Pacific Environmental Services, Inc. (PES) pursuant to EPA Contract No. 68-02-1890, Task Order No. 3, initiated in October 1976. 1.1 SCOPE OF WORK The scope of work for this project called for an intensive engineering evaluation of air pollutant emission sources at primary and secondary copper smelters in the United States. It required collection of reference data for primary smelters and for the secondary smelting and alloying industry, as well as the develop- ment of emission factors for major types of air-pollution emitting operations and equipment. Y 1.2 TASK DESCRIPTION Deliverables contemplated by the contract included a series of documents dealing with process descriptions and emission factors for primary and secondary copper smelter emission sources. These docu- ments were to be prepared in formats consistent with those of the following publications: 1. AP-42, "Compilation of Air Pollutant Emission Factors"* 2. "Engineering Support Manual for NEDS Users"(Ref. 2) 3. AP-42, Appendix C, Source Classification Codes In addition, machine-readable data inputs were required for updating AEROS component data systems: SOTDAT, NEDS, and SIEFA. c Subtasks designed for the implementation of the work were as fol 1ows : * Reference 1, hereafter referred to as "AP-42," 1-1 .' I 1. Preparation of a list of information sources, including I.. I.. governmental agencies, research organizations, consultants, and nonferrous smelter industry experts, and preparation of a bibliography. 2. Contacting the information sources to obtain information on process descriptions for both primary and secondary smelters and documented point source emissions data both for criteria pollutants and for certain other non-criteria pollutants, including arsenic, cadmium, lead, beryllium, boron, and antimony. The best available information on fugitive emissions was also to be obtained. 3. Analysis of the data to determine emission factors and the AEROS systems input elements. 1.3 ORGANIZATION OF FINAL REPORT The remainder of this report consists of five sections (Sec- 0 tions 2.0 to 6.0). In Section 2.0, results and conclusions emerging from the study are briefly summarized. In Section 3.0, experience gained in carrying out the data-gathering task is recounted and discussed. In Section 4.0, the methodol.ogy of data analysis is reviewed and the results summarized and discussed, in terms of emission factors developed for both primary and secondary smelters. Section 5.0 reviews findings related to the nature and sources of fugitive emissions in smelter operations and discusses suggested means of control or abate- ment of these emissions. Finally, recommendations regarding further source testing to improve knowledge of smelter emissions, emission factors, and the conditions affecting them are presented and dis- cussed in Section 6.0. 1-2 I 0 2.0 RESULTS AND CONCLUSIONS This section summarizes the