# 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 4.65577Mg/hr Afterburner Operating Temperature 1410 1450 1450degree 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 0.000000039155M0031 

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

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

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

### 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 0.000000004060M0031 

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

### 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 0.000000001442M0031 

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

### 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 0.000000002596M0031 

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

### 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 0.000000122455M0031 

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

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

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

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

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

### 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 4.65577Mg/hr Afterburner Operating Temperature 1410 1450 1450degree 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 4.65577Mg/hr Afterburner residence time 1.1 1.1 1.1sec Afterburner Operating Temperature 1410 1450 1450degree 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 **Test End Time**

**Run Number Test Start Date**  **Test Start Time Test End Date** 

### Facility Name and A**ddress 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 4.65577Mg/hr Afterburner Operating Temperature 1410 1450 1450degree 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 0US EPA Method 3A H2

### O 5.36 6.06 5.61 US EPA Method 3A

## Facility Name and A **ddress 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___________________ **Ty pe of Sample (Lime or Particulate):_____________________________**  Particulate Baghouse Dust


## Date Sampled **Date(s) Analyzed** 8/23-24/10 14-Sep



## HA**P 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 A ddress**  **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._____________________ **Ty pe 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.**