Asarco - Hayden Smelter

Acid Plant Database May 27, 2009

Owner	American Smelting and Refining Company - ASARCO
Background	1994 - Acquisition by Southern Peru Copper Corporation 1999 - Grupo Mexico purchases shares of Asarco for $2.2 billion (including debt); retains Asarco as wholly-owned U.S. operating subsidiary. 2005 - ASARCO files for Chapter 11 Bankruptcy
Location	Ray Complex Hayden Smelter P.O. Box 8 640 Asarco Avenue Hayden AZ USA 85235
Website	www.asarco.com
Plant	Hayden Smelter
Coordinates	33º 0' 8" N, 110º 46' 22" W
Type of Plant	Metallurgical
Gas Source	Copper Inco Flash Furnace (installed 1983) Converter (installed 1969)
Plant Capacity	2820 MTPD
SA/DA	DA
Emissions	SO₂: < 650 ppm, < 9,521 lb/h (annual average) Opacity: < 20%
Status	Operating
Year Built	1984
Technology	MECS
Contractor	MECS
Remarks	Acid Plant Stack: Diameter: 17 ft, Height: 1000 ft, Exit Gas Velocity: 19 ft/s, Temperature: 303^oF
Permits	Arizona Department of Environmental Quality www.azdeq.gov/environ/air/permits Air Quality Class I Permit
	Permit No.	Issue Date	Expiry Date	Details
	1166	September 13, 1982	-	Installation Permit
	0308-85	April 9, 1984	-	Operating Permit
	1215	April 4, 1989	-	Installation Permit
	1240	August 7, 1992	-	Installation Permit
	1000276	February 13, 1996	-	Minor Permit Revision
	1000462	November 11, 1998		Minor Permit Revision
	1000042	October 9, 2001	October 9, 2006	-
	-	-	-	-
Pictures
General	Hayden, Arizona, is located approximately 90 miles southeast of Phoenix on State Highway 177, along the Gila River, below the confluence of the Gila and San Pedro Rivers. The town was founded in 1912 to provide housing for the workers at the Ray open pit mine complex and the copper smelter complex, originally built by the Kennecott Copper Company. The town has a current population of approximately 900, and shares many services, including the local school district, with the town of Winkelman, population 600, located one mile to the south. The towns also share a common history regarding the emissions from the smelter operations. There have been several smelters on the site of the current Asarco smelter, with emissions being discharged into the air in Hayden and Winkelman since operations began in 1909. Historic emissions contained large quantities of lead, arsenic, sulfur dioxide (SO₂), particulate matter, and other materials. These contaminants drifted over the entire region in the air and many of the materials contained in these emissions fell out of the atmosphere and settled on the ground. The first emission controls placed upon the smelters were installed in 1920. These electrostatic precipitators were designed to remove particulate matter from the stack emissions. The smelters within the complex operated with these minimal emission controls prior to 1969, when requirements under the forthcoming Clean Air Act amendments of 1970 required that controls be installed to limit SO₂ emissions. Acid plants were added in 1969 and 1971 to reduce SO₂ and particulate emissions. Additional controls were added to the current smelter in 1984, further reducing the SO₂ emissions. The current smelter stack height was designed to elevate the emissions above the valley air shed and better facilitate dispersion. The residential areas of Hayden are located on two ridges that run parallel to each other, in an east/west direction, east of Highway 177. Houses line the main street on the north ridge. Houses on the south ridge are scattered among several streets intersecting Velasco Avenue. The main street in Hayden is Hayden Avenue, which runs east-west from the smelter property line on the eastern edge of town, to Fourth Street, a distance of approximately 3/8 mile. It is along this street that the primary business district is located. The ASARCO smelter is a large complex of approximately 200 acres at the eastern end of the town. Two large emission stacks dominate the horizon. One is about 1,000 feet tall and the other is 250 feet tall. There are also several smaller stacks visible at buildings throughout the complex. A large slag pile, a solid glass-like waste material, is on the eastern end of the facility, adjacent to the town.
References	-
News	-

MTPD - Metric Tonne per Day STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

* Coordinates can be used to locate plant on Google Earth


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