Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 75
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146 Introduction
PRIMARY COPPER SMELTERS - SUBPART P
§60.l60 - 60.168
The standards of performance for primary copper smelting affect the dry-
ing, roasting, smelting and copper converting facilities.
Gases which contain
particulate matter in excess of 50 mg/dscm (0.022 gr/dscf) from any dryer and
sulfur dioxide in excess of 0.065 percent by volume from any roasters, smelt-
ing furnaces or copper converters cannot be discharged into the atmosphere.
The standard for visible emissions limits opacity to 20 percent for dryers and
facilities using
8
sulfuric acid plant to comply with the standards.
Addition-
ally, sources shall install and operate a continuous monitoring system for
opacity and sulfur dioxide.
Sources constructed, reconstructed or modified
after October 16, 1974, are subject to these requirements.
Process Description
The copper bea·ring ores are either smelted as they corne from the mine or
are subject to a preparatory process of grinding and floatation to transform
low-percentage ores into high-percentage ores.
Ore corning directly from the
mine normally passes through a dryer to remove the moisture while grinding-
flotation processed ore is subsequently smelted down either directly or after
partial roasting.
Roasting removes part of the sulfur from the ore.
There
are two main types of roasters used in the industry:
multiple hearth and
fluidized bed.
In the smelting furnace, iron oxide combines with siliceous
flux to form a slag and leaving a material known as matte composed of copper,
iron and sulfur.
Two commonly used smelting furnaces are reverberatory and
electric smelting.
nle matte in the smelting furnace is reduced to copper in
two stages of blowing with air in a unit called a converter.
The first stage
eliminates sulfur and forms an iron oxide slag by adding a siliceous flux.
The slag is· then removed from the melt.
In the second stage, the copper sul-
fide is reduced to metal; sulfur is eliminated as S02 leaving a material known
as blister copper.
The blister copper may be further refined to remove sulfur
and oxygen,to be cast into anod-es for electrolytic refining.
Figure 14 illus-
trates a combined flow sheet of a variety of choices in current and developing
technology offered to smelter designers.
The unit/processes chosen for startup
evalatuion appear
t~
be typical for the copper smelting industry in the United
States.
63
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