Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 58
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146 In efforts to reduce worker exposures to lead, some new installations
of secondary smelting may utilize completely enclosed, remote controlled
operations.
In these cases, debugging the new technology of remote control
material hJ3.ndling may require several months •
. Startup Operations
'~e
lead blast furnace (cupola) has a startup procedure similar to the
b1.ast furnace used
i~
the iron and steel industry.
The startup procedure first
requires the hand stacking of wood in the furnace.
The time required for this
operation will depend on the size of the furnace, however, it should not take
more than a few hours.
The next procedure which' takes 2-3 hr to accomplish,
is the charging of the furnace with oil-soaked coke and upon completion the
furnace is ready for ignition.
Combustion air is introduced at the bottom of
the furnace through tuyeres at a gauge pressure of 3.45 to 5.17 kPa (8-12 oz/
in 2 ,)
About 6-8 hr are allowed for the blast furnace to achieve operating
temperature.
Hard lead is charged into the cupola at less than full capacity'
to provide molten metal to fill the crucible.
Normal charges of slag, coke,
iron and limestone are added to the furnace.
As the level of molten metal
rises, the slag is tapped off at intervals while the molten lead flows from
the furnace at a more or less continuous rate.
If the first few preliminary
pours are successful, larger quantities of scrap lead will be charged until
maximum capacity is achieved.
Assuming no problems occur during initial
startup operations, a facility can usually achieve its maximum prOduction rate
in 4 to 7 days.
The official startup date should begin when oil-soaked coke
is ignited.
After pre-startup and heatup operations of a reverberatory "furnace, the
material is slowly fed into the furnace to prevent thermal shock and to main-
tain a stable temperature while keeping a small mound of unmelted material on
top of the bath.
As the mound becomes molten, ore material is charged.
The
time required to reach maximum production is 3 to 5 days after material is
first introduced into the furnace.
The total time required from a cold start
to maximum production will range from
4-6
days.
The 180-day performance test
period should begin when material is charged into the furnace.
"
FollOWing pre-startup and heatup procedures, the charge is then slowly
Introduced into the furnace developing a molten pool of lead.
Since this is
a batch operation, . the charging continues until the vessel is filled to rated
capacity.
TIle time required to achieve maximum production depends on the
size of the furnace.
Normally, maximum production can be reached in a few
days.
The official startup date should begin when the furnace is first charged
t<llth lead.
46
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