Instructions

 The EPA secondary aluminum production test program requires emissions and other test data for several pollutants. EPA understands that you own one or 

more secondary aluminum production facilities. 

 For at least one thermal chip dryer and at least one scrap dryer/delacquering kiln/decoating kiln that you own, you must perform a stack test for volatile and 

semi-volatile organic HAPs as specified in the letter and instructions accompanying this file. You should collect emissions samples for the identified pollutants 

downstream of the last relevant emissions control device (i.e., stack or other point representing the composition of the flue gases at the exit to the 

atmosphere), unless otherwise indicated. (Contact the EPA project lead for situations with multiple stacks or other complex emissions points for the unit.)

Sample and analyze the particulate matter collected in the hopper from at least one bag house used to control particulate matter from each type of affected 

source subject to 40 CFR 63, subpart RRR at your secondary aluminum production facilities. Choose bag houses that are used to control particulate matter 

from each of the six different types of affected sources (i.e.group 1 furnaces, scrap shredders, chip dryers, scrap dryers/delacquering kilns/decoating kilns, 

dross only furnaces, and rotary dross coolers) if you have these controlled affected sources at your facilities. Where more than one bag house discharges 

solids to a common hopper, a single sample will be adequate. In cases where solids from different compartments of a single bag house are collected in 

multiple hoppers or multiple collection sacks, a single composite sample will be adequate. If you have a total of three or fewer bag houses at all of your 

facilities, sample and analyze particulate matter from all of them, even if they are controlling the same type of affected source. It is not necessary to conduct 

a stack test for multi-metals analysis. 

Sample and analyze the lime used for injection to any of the lime-injected bag houses from which particulate matter samples were collected. If lime of the 

same type, obtained from the same supplier, is used for more than one lime injected bag house, a single sample will be adequate to represent the lime used 

in these bag houses.

You must report the results of these tests and chemical analyses in this Microsoft® Excel Emission Test Template. The Excel templates are specific to each 

type of pollutant. You must report the results of each test on the appropriately labeled worksheet corresponding to the specific tests and analyses conducted 

at your facilities. If more than one source was tested, you must make a copy of the worksheet and update the source ID in order to distinguish between each 

separate test of a chip dryer or scrap dryer/ delacquering kiln/decoating kiln at each facility and each different source of particulate matter. After completing 

the worksheet, you must also submit an electronic copy of the emission test report and the chemical analyses. (PDF format preferred).

Please refer to the cover letter of this packet (CAA section 114 letter) for additional testing information. Please note that you do not have to submit a test 

plan to EPA for approval prior to testing; however, we recommend that you prepare a test plan for your own use to assist in the planning and to verify that 

you address all of the testing and reporting requirements. You must follow all of the procedures as specified in the test methods, including the quality 

assurance and quality control measures, and document the results in any test report provided to EPA. 
Facility Name and Address Unit Description Process Unit ID Control Device ID

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/23/2010 8/24/2010 8/24/2010

Feed/Charge Rate 5.8931016 5.918814815 4.65577 Mg/hr

Afterburner Operating Temperature 1410 1450 1450 degree F

Type of Charge:_______________________________________________________________________ Aluminum Chips

Compound

Volatile Organic HAP 

Emission Rate Sample 1 

(kg/hr) 

Volatile Organic HAP 

Emission Rate Sample 1 

(kg/Mg of feed/charge) 

Volatile Organic HAP 

Emission Rate Sample 

2 (kg/hr) 

Volatile Organic HAP 

Emission Rate 

Sample 2 (kg/Mg of 

feed/charge) 

Volatile Organic HAP 

Emission Rate Sample 3 

(kg/hr) 

Volatile Organic HAP 

Emission Rate 

Sample 3 (kg/Mg of 

feed/charge) 

Test Method 

Used

Detection Limit 

Information 

(BDL,DLL,ADL)

Other Supporting 

Information

Acrylonitrile 107-13-1 (<.00000065054) (<0.000000110362) (<0.0000001628) (<0.000000027514) (<.0000001673) (<0.000000035938) M0031 BDL

Benzene 71-43-2 0.0000006160 0.000000104534 0.0000004267 0.000000072096 0.0000001823 0.000000039155 M0031 ADL

Bromodichloromethane 75-27-4 0.0000000498 0.000000008459 0.0000000278 0.000000004704 0.0000000250 0.000000005369 M0031 ADL

Carbon disulfide 75-15-0 0.0000000715 0.000000012125 0.0000000641 0.000000010836 0.0000000852 0.000000018302 M0031 ADL

Carbon tetrachloride 56-23-5 0.0000001428 0.000000024232 0.0000000901 0.000000015217 0.0000000616 0.000000013222 M0031 ADL

Chloroprene 126-99-8 (<.0000000535) (<0.000000009076) (<0.0000000603) (<0.000000010190) (<0.000000062) (<0.000000013311) M0031 BDL

Chlorodibromomethane 124-48-1 0.0000000215 0.000000003648 0.0000000249 0.000000004212 0.0000000189 0.000000004060 M0031 ADL

Chloroform 67-66-3 0.0000006121 0.000000103862 0.0000002144 0.000000036226 0.0000001821 0.000000039110 M0031 ADL

Dibromomethane 74-95-3 (<0.0000000112) (<0.000000001906) (<0.0000000127) (<0.000000002140) (<0.000000013) (<0.000000002795) M0031 BDL

1,1-Dichloroethane 75-34-3 0.0000000213 0.000000003612 0.0000000126 0.000000002123 0.0000000067 0.000000001442 M0031 ADL

1,2-Dichloroethane 107-06-2 0.0000000524 0.000000008894 0.0000000146 0.000000002463 0.0000000123 0.000000002640 M0031 ADL

trans-1,2-Dichloroethene 156-60-5 (<0.0000000107) (<0.000000001815) (<0.0000000121) (<0.000000002038) (<0.0000000124) (<0.000000002662) M0031 BDL

1,1-Dichloroethene 75-35-4 0.0000000310 0.000000005264 0.0000000203 0.000000003431 0.0000000121 0.000000002596 M0031 ADL

1,2-Dichloropropane 78-87-5 0.0000000181 0.000000003068 0.0000000111 0.000000001868 0.0000000105 0.000000002263 M0031 ADL

cis1,3-Dichloropropene 542-75-6 (<0.0000000091) (<0.000000001543) (<0.0000000103) (<0.000000001732) (<0.0000000105) (<0.000000002263) M0031 BDL

trans1,3-Dichloropropene 542-75-6 (<0.0000000064) (<0.000000001089) (<0.0000000072) (<0.000000001223) (<0.0000000074) (<0.000000001597) M0031 BDL

Methylene chloride 75-09-2 0.0000008579 0.000000145574 0.0000001950 0.000000032948 0.0000005701 0.000000122455 M0031 ADL

Tetrachloroethene 127-18-4 0.0000000494 0.000000008386 0.0000000470 0.000000007948 0.0000000180 0.000000003860 M0031 ADL

Toluene 108-88-3 0.0000023687 0.000000401944 0.0000002761 0.000000046654 0.0000002341 0.000000050291 M0031 ADL

1,1,1-Trichloroethane 71-55-6 0.0000000072 0.000000001216 0.0000000060 0.000000001019 0.0000000067 0.000000001442 M0031 ADL

1,1,2-Trichloroethane 79-00-5 0.0000000535 0.000000009076 0.0000000603 0.000000010190 0.0000000620 0.000000013310 M0031 ADL

Trichloroethene 79-01-6 0.0000000423 0.000000007170 0.0000000224 0.000000003787 0.0000000339 0.000000007276 M0031 ADL

Trichlorofluoromethane 75-69-4 0.0000000995 0.000000016881 0.0000000979 0.000000016542 0.0000000968 0.000000020786 M0031 ADL

Speciated Volatile Organic HAP Emission Data
Facility Name and Address Unit Description Process Unit ID Control Device ID

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/23/2010 8/24/2010 8/24/2010

Feed/Charge Rate 5.8931016 5.918814815 4.65577 Mg/hr

Afterburner Operating Temperature 1410 1450 1450 degree F

Type of Charge:_______________________________________________________________________ Aluminum Chips

Compound

Semi-volatile Organic HAP 

Emission Rate Sample 1 

(kg/hr) 

Semi-volatile Organic HAP 

Emission Rate Sample 1 

(kg/Mg of feed/charge) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 2 (kg/hr) 

Semi-volatile Organic HAP 

Emission Rate Sample 2 

(kg/Mg of feed/charge) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 3 (kg/hr) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 3 (kg/Mg of 

feed/charge) Test Method Used

Detection Limit 

Information 

(BDL,DLL,ADL)

Other Supporting 

Information

Acenaphthene 83-32-9 7.22841E-06 1.22659E-06 3.60102E-06 6.08403E-07 1.80892E-07 3.88532E-08 M0010 ADL

Acenaphthylene 208-96-8 3.44046E-06 5.83811E-07 7.94943E-07 1.34308E-07 1.18872E-07 2.55321E-08 M0010 ADL

Anthracene 120-12-7 2.35127E-05 3.98986E-06 4.94291E-06 8.35119E-07 4.22425E-06 9.07316E-07 M0010 ADL

Benz[a]anthracene 56-55-3 1.67701E-07 2.84571E-08 5.77522E-08 9.7574E-09 3.87625E-08 8.32569E-09 M0010 ADL

Benzo[a]pyrene 50-32-8 1.33123E-07 2.25897E-08 6.62452E-08 1.11923E-08 4.73764E-08 1.01758E-08 M0010 ADL

Benzo[b]fluoranthene 205-99-2 3.30215E-06 5.60341E-07 1.78353E-06 3.01331E-07 5.0822E-07 1.09159E-07 M0010 ADL

Benzo[g,h,i]perylene 191-24-2 1.79803E-07 3.05107E-08 7.81354E-08 0.338235294 8.26934E-08 1.77615E-08 M0010 DLL

Benzo[k]fluoranthene 207-08-9 (<7.2336E-07) (<1.22749E-07) (<7.10692E-07) (<1.20074E-07) (<7.20811E-07) (<1.54E-07) M0010 BDL

Chrysene 218-01-9 6.39683E-07 1.08548E-07 2.31009E-07 3.90296E-08 1.39545E-07 2.99725E-08 M0010 ADL

Dibenz[a,h]anthracene 53-70-3 0.0000004 6.10214E-08 0.0000002 3.38639E-08 0.0000001 1.1471E-08 M0010 ADL

Fluoranthene 206-44-0 2.28211E-06 3.87251E-07 1.05313E-06 1.77929E-07 5.53012E-07 1.1878E-07 M0010 ADL

Fluorene 86-73-7 3.32116E-05 5.63568E-06 1.04124E-05 1.7592E-06 5.16834E-07 1.11009E-07 M0010 ADL

Indeno(1,2,3-cd)pyrene 193-39-5 1.48683E-07 2.523E-08 4.75607E-08 8.03551E-09 4.18635E-08 8.99175E-09 M0010 ADL

Naphthalene 91-20-3 0.000152141 2.58168E-05 4.92593E-05 8.32249E-06 2.88393E-05 6.19432E-06 M0010 ADL

Phenanthrene 85-01-8 4.46049E-05 7.569E-06 1.29093E-05 2.18107E-06 2.46357E-06 5.29144E-07 M0010 ADL

Pyrene 129-00-0 1.84989E-06 3.13908E-07 9.00256E-07 1.52101E-07 8.09706E-07 1.73914E-07 M0010 DLL

Speciated Volatile Organic HAP Emission Data
Facility Name and Address Unit ID 

Unit Type (Chip dryer or 

scrap dryer /delacq 

/decoating kiln)

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/23/2010 8/24/2010 8/24/2010

Feed/Charge Rate 5.8931016 5.918814815 4.65577 Mg/hr

Afterburner residence time 1.1 1.1 1.1 sec

Afterburner Operating Temperature 1410 1450 1450 degree F

1 8/23/2010 13:49 8/23/2010 15:49

2 8/24/2010 8:22 8/24/2010 10:22

3 8/24/2010 12:15 8/24/2010 14:15

Run Number THC Emission Rate (kg/hr) 

THC Emission Rate (kg/Mg 

of feed/charge) Data Flag (ADL, BDL, DDL)*** Detection Limit 

(ng/dscm)

1 0.00E+00 0.00E+00 ADL 4.25E+04

2 0 0 BDL 4.25E+04

3 0 0 BDL 4.25E+04

*** See Appendix A to Enclosure 1

Run Number Test Start Date Test Start Time Test End Date Test End Time
Facility Name and Address Unit Description Process Unit ID Control Device ID

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/23/2010 8/24/2010 8/24/2010

Feed/Charge Rate 5.8931016 5.918814815 4.65577 Mg/hr

Afterburner Operating Temperature 1410 1450 1450 degree F

Flow Rate 38,646.69 37,322.02 37,765.38 actual M3

/min

Flow Rate 28,555.65 27,618.91 27,745.35 dry sM3

/min

Emission Test Results Constituent

Composition 

Sample 1

 (%)

Composition 

Sample 2

 (%)

Composition 

Sample 3

 (%)

Test Method Used

(ex. U.S. EPA Method 3B) Other Supporting Information

O2 21 21 21 US EPA Method 3A

CO2 0 0 0 US EPA Method 3A

H2O 5.36 6.06 5.61 US EPA Method 3A
Facility Name and Address Unit Description Process Unit ID Control Device ID*

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Sample ID No._H0I090000-062___________________

Type of Sample (Lime or Particulate):_____________________________ Particulate Baghouse Dust

Date Sampled Date(s) Analyzed

8/23-24/10 14-Sep

HAP Metal mg/kg

Antimony 191.0

Beryllium 3.2

Chromium 1300.0

Hexavalent chromium 0.0156

Lead 2080.0

Mercury 0.58

Selenium 1.5

Arsenic 17.9

Cadmium 10.9

Cobalt 45.2

Manganese 1230.0

Nickel 6670.0

* Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.
Facility Name and Address Unit Description Process Unit ID Control Device ID*

Superior Aluminum Chip Dryer Dryer #1 Baghouse

14214 Edgerton Road, New Haven IN 46774

Sample ID No._____________________

Type of Sample (Lime or Particulate):_____________________________ No lime injection

Date Sampled Date(s) Analyzed

na na

HAP Metal mg/kg

Antimony

Beryllium

Chromium

Hexavalent chromium

Lead

Mercury

Selenium

Arsenic

Cadmium

Cobalt

Manganese

Nickel

* Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.