# TRC Results you can rely on



# .. 

# Anode Bake Furnace POM Test Program Report Certification ALCOA Warrick- MACT 195691 Page 2 of 188



## I certify

## thatto the best ofmyknowledge: o Testing data and all corresponding mformation have been checked for accuracy and completeness. o 

## Sampling and analysis have been conducted in 

## accordance \Vitb the approvedprotocol and applicable reference methods (as applicable). o 

## All deviations, method modifications, or sampling and analytical anomalies are sum:...'llarized 

## in the appropriate report narrative(s). 

## f{.--

# :Ja ·- 

# I?...- Date 

## TRC. 

## w_as operating in confonnanoe with

## the. requirements ofASTM. D7036-04 during this testprogram. · 

# ~!W~:l Jeffrey . Butdette 

## TRC Ali

## Measurements Technical Director

### ALCOA WARRICK OPERATIONS , SUMMARY OF A-446 REACTOR TEST RUN TIMES 

### ,, ' ·'''

**~--·** ... **-··-·······-----'---~~-~~-·**·--·-----···-·· ····-·-······-···- .....- ---- -. ... ... 

### -- .. . **;··----~-** . 

# . A-446 REACTOR# .1 and A-446 REACTOR# 2 - POM 

### -------· ····----- . :+. ··. 

### .. .

### .

**~** . 

# 'I "' ' Sample 

### Train 'Re#ctor# 1 Rsa::tor# 2 RUN# ·'sTART DATE: TIME: TIM:2: Duration lsoklnetlc 

### lsokineiic·.·· {minutes) Rate Rate Run# 1 Tuesday, October 23,:2012 8:46AM 11:54 AM 144 96.2. 

### 101.3 Run#2 Tuesday, Ociober 23, 2012 12:20 PM 3:06PM 144 103.6 

### 102.1'. Run# 3 Tuesday, October 23, 2012 3:36PM 6;17 PM 

# I 144 103.7 . 101

**~5** ·.

### Alcon.- Warrick Operations NewburcrM 

### LlV ALCOA Warrick - MACT 195691 Page 8 of 188

__

### ,



# __________;_ 

# ____ _ ) 

### SlJMMi(RY OF 

## TEST RESULTS Table 

## 1.. S1:lDlmarizes the PM and P01V! results for the A-446 react_ors, The 

## mass emissiornate· 

## ofPMand POM·from each reactor 

## and the combined 

### massemissionrate"from 

## b'ofu 

# re~ctors 

# ai6> sho·wn as lblbr 

## values as well as on the basis oflbs/ton ofgreen anode 

## ·throughput.-· The average· . ' . . . . . 

## PM emission

**r~te** 

## from the 

## A-446 Reactor 

## # 1 was 

## 0.0387 lbs of PM per 

## ton ·af. 

## green anod·e throughput. The average POM emission 

## rate from the A-446 Reactor# l_yvas 0.0275 lbs of POMper 

## ton of green ano.de_ 

## The average PM emission 

## rate from 

## the A-446 Reactor 

## # 2 

## was 0.0138 lbs 

## ofPM per 

## ton of 

### green anode 

## throughput. The. 

### average POM 

### emission rate fr6ni the_ . ' - ' ' f 

### A-446 Reactor# 2 was 0.0233 lbs **ofPOM.per.~on** 

### of green anode. The combined.PM 

## eriJ.ission. rate for the A-446 Reactors was 

## 0.0525 lb/ton 

## ofgreen anode.. The combined POM emission

## rate· 

## for the A-446 Reactors was 0.0508 lb/ton ofgreen anode. The stack test data and test results for each test method and each test run conductedare provided in more detailed tables presented 

## in 

## Section 7

## .0. '· 

### ..

**~·**

...· ..

### · Alcoa- Warrick Operations :Newburoh IN

..

**:_:~** __.:.:;_._..
**~-.-·** 

### METHOD 315 PM & 

### PPM TEST RESULTS A-446 REACTORS

**ALCOA~** 

### WARlliCK OPERATIONS 

### NEWBURGH, lN .A-446 REACTOR# 1

. . 

### tons/hr Green. 

### Anode Throughput · lblhr . Reactor PM Emission Rate · lbs/ton ofGreen Anode· Emission Rate ofPM Run#l .17.30 0.657 0.0380 Run#2 

### 17.30 

### 0.711
. 0,0411 ALCOA Warrick- MACT 195691 Page II of 188



### Run#3 

# i ! 

# I 

# .' 

# .... Average 17.30 

## ·!.:. 17.30 M42 

### .11 

### 0.670 0.0371 I 

### 0.0387 I 

## l lb/hr . Reactor 

### POM

**~niission** 

### Rate 0.628 0.214 0.585 

## ! 0.476 lbs/ton ofGreen Anode Emission 

### Rate (,fpQM 

### 0.0363 0,0124 0.0338· 

## I 0.0275 . . . I 

# __________________________:_________________·--------------------,------f----.::.____
. A-446 REACTOR# 

### .2 

# I 

# I tonslhr lblhr 

### lbs/ton ofGreen Ancide Green Anode Throughput . Reactor PM Emission Rate . Emission Rate ofPM 17.30 0.171 0.0099 17.30 0.320 0.0185 17.30 

## ! 17.30 

# I 0.226 

## j· 0.239 -0.0131 ;0.0138 1blhr · · Reactor POM Emissi·on 

### Rate 0.465 0.464 0.279 · 0.403 

### lbs/tOJi. ofGmm Anode Emission Rate ofPOM · 0.0269 0.0268 0.0161 0.0233 

# . _____..:___.:_____________________________________________________.:__..:_·_____j__**~--~..:...;;.**

# _____ tonslhr lblhr 

### lbs/ton of Green Anode 

### lblhr lbs/torr ofGreen. Anode COMBIJ\'ED A-446 REACTORS# 1 & 

### # 2 

### Green Anol;le Throughput Reactor PM Emission Rate Emi-ssion Rate ofPM Reactor POM Emission

**~te** 

### Emission 

### Rate 17.30 0.828 0.0479

1.093 0.0632

J:\190000-2099!19_Job#l)95691- Wmiclt-Primll!)' 2012\Ropons\Tcst Rcpost-PotJin.., &.&l:c Furnace l\pi·20l2:doc 

### 17.30 1.031 0.0596

. 0.678 0.0392 

# I 

# I 17.30 

# I . 1730 0.868 

# l. .0.909 l 0.0502 . 

### l; .. 0.0525· I I 

## i. 0.864 

### 1: .· 0.878 

## o.0499 1 

## o.osos I 

## .....•'

•' 

### Alcoa - Warrick Operations 

### Newburgh, IN

.. 

### ---------------·- 

# . . DESCRIPTION OF SOURCES AND S.Al\fi>LING 

## LOCATIONS 

## 3.1 DESCRIPTION OF PROCESS ALCOA Warrick - MACT 195691 Page 12 of 188


## The anode baking furnace is comprised of one green anode ring baking furnace controlled by 

## a common Alcoa designed A-446 

## emission control device. The baking furnace structure" is· 

## a series of

**int~connected** 

## refractory flues connected to side main exhaust

**manifolds~** 

## .Products of combustion and other emissions created 

## in the bakingfurnace are drawn into the refractory flues and exhausted to the common _control equipment through a 

## series ofducts. The furnace is fueled : 

## \'\lith natural gas. In 

## the baking

**furnace~** 

## green anodes are stacked·' into

**sub~surface** 

## pits formed by the interconnecting flue structures. After being placed in 

## the pits, the green. anode material is surrounded and covered with 

## petroleum coke referred to as "packing material".. The baking process is operated to allow recently filled pits to be preheated for a period oftime. before being · actively fired. Likewise, after

**firing~** 

## baked anodes are allowed to cool 

## in the pits before they are . removed and used in the smelting process. Natural gas burners supply heat to the furnace and promote the



## combustio~ of organic constituents drawn into the flues during the.baking..process... The preheatiiJ.g, heating, and cooling processes are sequenced around the furnace in either a clockwise.or counter clockwise direction. Emissions from the anode bake furnace are collected and treated by an integrated system of ducting and a pollution control system. The control system employed at the Warrick Operation. anode .baking fumace is a multi-unit, fluid-bed reactor type system with 

## fabric filtration downstream ofthe reactor beds. Smelting grade alumina is :introduced into olie end oftheAlcoa. designed A-446 reactors. The alumina is fluidized by an auxiliary fluidizing fan blowing ambient air through a series of perforated plates in the bottom of the reactor chamber. Anode baking furnace emissions are introduced into the fluidized bed through exhaust gas manifolds · along each side ofthe reactor. The fluid bed provides a site for fluoride to react with 

## the alumina and for the gas 

## stream io be cooled.. The fabric filtration devices are positioned atop ofthe fluid beds to collect entrained alumina particles and other particulate matter present in the gas stream. • I •'**~--------** -------------- **--····-·--·-·----·-------~---·--·------~~--**

**~~** 

### Alcoa- Warrick Operations 

## Newburgh, IN ALCOA Warrick- MACT 19569 I Page I3 of 188 

## The anoqe bake 

## furnace primary system consists ofa single 

## dry alumina scrubber 

## control device 

## with

**tbr~** 

## (3) 

## reactor sections or compartments. Two compartments (Reactor No. 1 and 

## Reactor No.2)

**9n,ei;~ ~ode**  

## furnace control device have three stacks and one compartment (R.eactofNo.' ..,.. . . **·~P~** 

### ,._, . .. 

## 3) has only one stack.

---

**~** --- **--~--------------~----~--~-**

## ..

**~'** ',1. 

### Alcoa- Wqrrick Operations Newbur!!h, 17'{ · 

## 3 "1



# . .., I

**~** ' ' . ·'
. _·, 

### . .;; ;. 

# .' ALCOA Warrick- MACT · · 195691 

### Page 14 ofl88

. c.·' ... ._ .. _,,..._.· .-

**~** .. :._ '. ·.



# 1Yfeth~.4; 1 datasheets.



# ~d **fraveJ;:~~ p.~il;lt**  locations 

## ·are proyided in 

# _AppendixA·for-.~ach- of 

# the ;, '• ·. '. 

## samplll:\g

**l,ocat~ori~**

## . . i ·. :.: •. . · . .·. ·. •·. ..• .... :' ·:.· .. . ··--:-· ··."," ., 

## The Green 

## Anode Baking Ring



## F:Jim~ce exhaust; tbiougb 

## seven (7) 

## separate stacks. 

## .Thiiee stacks· -. · .. •for



## R~actorNo. 1BlJ.d three stacks fofReactorNo. +and



## ·o:ti~ stackfor



## React~rNo. 3. · The stacks

for Reactor No. 

## 1 and Reactor No. 

## 2 

# are identicaL These vertical stacks have 

# an 'internal diameter 

## of26:25-inches. The .location of

## the t\vo test ports (90° apart) 

# aie 60-:inches (2.3 duct . .diameters). downstream from the nearest disturbance, and 232-inches (8.8 duct 'diameters) · 

## :upstr~am 

## from the



## elili~11s~~, **Fo~** Reactor

# Nq. 3, 

## the inside diameter ofthe 

## stack is



## 46~inches, and· · · it has two test ports (90° apart). The ports are
**92.5~incbes** 

## (2 ductdiameters)do"Wnstream 

## from
. . 

# ·the. nearest .disturb.ance, and 192-inches 

## (4.2 duct .diaril;eters) upstream from the

**e~haust** 

## .For:·



## particulate 

## ln.easurements.corifo~g 

# to 1\1efuod

# t (as 

## :referenced in 

## Method 13A. and 

## Method . . . . . ·. . . -· . 

## 315) 

## .a total 

## of 24 traverse points were used



## ~t each stack 

# for the velocity and TF and POM ·

## measm~ents, 12 traverse points per port. 

## Figu;e, 3-2 jllustrates 

## the A-446



## Rea~tor 'S'tacks at .Reactor No.1 and ReactorNo. 2 .

.

**~.- -~**  ;, .. . . .

**~** ,' . . .·_;.. .

'.

**-.:~.** ,: I

, __ :-j

! 

### Alcoa- Warrick Operations 

### Newbur-h, IN



# .. ·FWW •' ALCOA Warrick - MACT 195691 Page,16 ofl88



## Figure 3-2. A-446 Reactol' No.1 and Reactor No.Z Stack Sampling Locations ·. _;

### Alcoa- WarrickOperations 

### Newbur<J"h, IN 

### SECTION 4.0 SAMPLING AND ANALYTICAL PROCEDURES ALCOA Warrick- MACT 195691 Page 17 of 188 

### The sampling and analytical procedures that were used 

## in this test program are described below.: .. · The referenced EPA sampling and analytical procedures are available from the EPA TTN EMTIC electronic bulletin board. 

## 4.1 SAMPLING TRAVERSE POINTS The number and location of the sampling traverse points were determined ·according to the · procedures outlined in EPA Method 1. Prim· to conducting the emission tests,

## TRC measured the ·· stack dimensions and distances to gas flow disturbances. The actual number and .location ofthe traverse points were determined using EPA Method 1. 

## 4.2 VOLUMETRIC FLOW 4.2.1 Flue Gas Velocity The yelocity was determined according to the.procedure.s outlined 

## in EPA Method 2. Velocity head (delta P) measurements were made using Type S Pitot tubes conforming to the geometric. specifications outlined in EPA Method 2 and having a coefficient of 0.84. 

## The differential · pressures were measured using a fluid manometer. The exhaust gas temperatures were measured · using chromel-alumel thermocouples and associated digital readouts. 

## 4.2.2 Exhaust Gas Composition The potline flue gas contains ambient air that is drawn from hoods above the pots inside. of the . smelting building. The oxygen content was close to 20.9% and the carbon dioxide was close to 0%. The anode furnace A-446 reactor flue gas composition was measured by collecting integrated Tedlar bag samples during each test run. These bag samples were analyzed onsite with a calibrated analyzers in TRC's Trailer.

# l

; ·' 

# I· Alcoa- Warrick Operations 

## Newburgh, IN 4.4 

### POLYCYCLIC ORGANIC MATTER
. 

# . . 

# .. ALCOA Warrick - MACT 195691 Page 19 of 188

. 

# . .. Method 315 "Detennination ofParticulate and Methylene Chloride Extractable Matter (MCEM) from Selected Sources at Primary Aluminum Production Facilities" was used to measure;the polycyclic organic matter (POM) emissions. This method·uses 

## aMethod 5 style sampling train. 4.4.1 

### Sample Collection 

### Samples were collected isokinetically (90% to 110%) from the stack using 

# an EPA Method 5 style sampling train. 

### The sampling train consisted of a glass nozzle, connected to a glass-lined probe with . a Type S. Pitot·. tube attached. The

# ~iimpl~ .was passed through a heated filter. Ill.aintained at 248 

## op (within 25 °F) provided by Alcoa. After passing 

## thrdugh the filter, the sample stream was connected to the Method·5 style

## b~ck- halfwhich consisted offour :impingets. The first two impingers each contained 100-ml of deionized distilled (DI) water, the third impinger was empty and the fourth impinger contained silica gel. Each impinger was weighed prior to sample train assembly. The sample train was connected to a standard Method 5 metering console. 

## 4.4.2 Sample Recovery and Analysis After the completion ofthe test run and following the post-test leak check, the filter was¥emoved from·the filter holder and placed in a glass sainplejar or petri dish. Following·fue:test

# Bin, each of the impingers was.weighed 

## to determine the post-test weight. The weight of**wat~** 

### vapor · condensed in the impingers and the weight ofwatei vapor c61lected in the silica gel 

## wa:s summed

and subsequently entered mto moisture content calculations. The nozzle, probe, and front-half of · the filter holder were rinsed with acetone into a glass samplejar. Following the acetone rinses the front half ofthe sample train was rinsed with methylene chloride which was collected in. a separate glass jar. The impinger catch was poured into a glass sample jar and then the sample train back-half glassware was rinsed 

## first with water, 'acetone and then with methylene chloride. The water rinse was added to the impinger catch sample jar. The two back-half solvent rinses were placed in a separate glass sample jar. The filter, impinger_ catch and DI and solvent rinses were analyzed 

## by Alcoa laboratory personnel per Method 315 procedures to detennine the polycyclic organic matter (POM) content,ALCOA Warrick- MACT 195691 Page 20 of 188 

### Alcoa - Warrick Operations 

## .file'wburgh, IN 

## SECTION 5.0 QA/QC PROCEDURES AND RESULTS 

## As 

# a guide, TRC

**us~s** 

## the 

## EPA. document Quality Assurance 'Handbook

## .for;Air . Pollution Measurement System,·Voltime 

## III.· TRC's QA/QC plan



## h~··incorporated certain·.considerations·to 

## the production ofquality data in 

## all ofits sampling work regardless ofthe 

## scope and purpose ofthe testing. These considerations include: • Planning the testing

**progr~;** 

## • Use ofreliable and·we11-rriamtained 

## equipment; • Use ofappropriate forms forrecording sampling data; 

## • Establishing a sample 

## coding system to ensure proper chain of 

## custody (i.e., 

## sample identification, laboratorytracing and storage, analysis and reporting); • Use of calibration and audit gases traceable to the National Institute of Standards and Technology (NIST); • Coritrol errors 

## by checking data inputs and perfonning redundant calculations; • .Adherence to



# establish~cl**proto~l.** . . 5.1 BARO:METER 

## Barometric pressure values for the 

## testing period 

## were recorded from a calibrated digital barometer on-site and verified by 

## side by 

## side comparison to a mercurial barometer located in the TR:C Field Office in Raleigh, NC. 

## 5.2 PITOT TUBES Each 

## Pitot tube used in this sampling program met the

**de~ign** 

## specifications for Type S Pitot;wfues 

## in EPA Method 

## 2. Therefore 

## in accordance with Method 2 procedures, a baseline



# coefficien~~~j)) :-"



### . : i •,

### Alcoa- Warrick Operatimts 

### Newburf!h, IN , · 

## ,... ALCOA Warrick • MACT 195691 Page21 ofl88 

### of 0.84 was assigned to each Pitot tube. Calibration at the manufacturer for Pitot face-opening

**~** 

## . 

# . alignment included measuring the external tubing diameter (dimension.Dt), the base-to-opening risalignment angles, with all terms as described in Figures 2-2 and 2-3 ofEPAMethod 2: Pi tot tubes were visually inspected priorto and at the completion ofthetest to insure structuraHntegrity.· 5.3 . CALIDRATION METER AND METERING SYSTEM The calibration procedure desCription for the dry gas metering system using critical orifices 

## in lieu of the wet test meter is given 

## in Section.16.2 of EPA Method 5. A leak check of the metering system before calibratio:IJ. was performed as shovm 

## inFigure 5.2 ofEP A Method 5. The ·

**met~ng** 

### system1

### s pump is operated for 5 minqtes

**usin~** 

### the smallest orifice to

**h~a,t** 

### up the pump-. and system to stabilize the meter inlet and outlet teniperatures. Values for the orifice meter · ... { 

### setting (delta B),. corresponding 

### dry test meter volume 

## C\'d), dry test meter inlet·andoutlet. gas temperatUres 

## (tm and tdn), and time were recorded for the initial calibration. The ratio of the critical orifice volume to the- 

### dry test meter. volume 

## (y or gamma) and the orifice pressure differential that equates to 0.75. 

## pftn at standard conditions (delta 

## H@) were then calculated. A · copy ofthe metering system calibration is included

### in Appendix C ofthe Test Report. 5.4 POST-TEST :METER CALIBRATION 

## As au alternative to perfonning post-test meter calibration checks, TRC follows EPA

**Alt~ative-** 

### . . 

### 009. This procedure is performed on-site using the data collected for each ofthe test

**ru~s.** 

## It is preferred by EPA because 

## it eliminates the questions about possible meter damage dtuing'1fansport . 

## after the emission test and, because the calibration data is available in the field imn£ediately ' . .

**~** . 

### following the test, it eliminates the costly travel, remobilization, and scheduling 

## .Of a

**r~test** 

### should the meter fail the post-test calibration. These calibration checks are 

### included with the field · · datasheets in Appendix A ofthis Test Report. 

## ' 5.5 THERMOCOUPLES 

## AND DIGITAL INDICATORS

Thennocouples were calibrated by comparing them against an ASTM-3F

**mercu.ry-in.~glass** 

### thermometer at approximately 32°F (ice water), ambient temperature and approximately 212op (boiling water). Each thermocouple was calibrated againsttemperature ranges to which it was to ·be typically exposed during test conditions, and they must agree within 1.5 percent

**(expressediin-'~** 

### of the reference thennometer throughout the entire calipration range. A post calibration 

## :;was performed in accordance with EPA AL T-011 using a single point calibration against an



# AS~M

### Alcoa- Warrick Operations Newburgh, 

## IN ALCOA Warrick - MACT 195691 Page 22 of 188 

## mercury-in-glass thenn,pmeter 

## iri addition to a continuity check . of the therm6couple_ .The continuity check invofves · verifying that the thermocouple read-out trends :ih 

## fue · appropriate· direction when exposed'to a temperature change. Digital indicators were checked byintroducing a series ofmillivolt signal strengths.to the inputand. · ·comparing the :indicator reading with the actual signal strength. Acceptable calibration 

# error does not exceed 0.5 percent when temperatures are expressed in °R. 

## 5.6 ANALYTICAL BALANCE The analytical balance was calibrated by comparing readings :fi:om its own internal· qalibration weight against a 100 gram NIST (formerly NBS) Class-Sl standard weight: Linearity of the' balance was demonstrated by further comparison ofits readings against other selected (0.5g, lg, 10g, 50g) NIST Class S-1 weights. The NIST class S-1 weights were calibrated by the NC Department ofAgricultural Standaids Laboratory :in Raleigh, NC. 5.7 REAGENT BLANKS ANI) FIELD BLANKS TRC collected reagent blank samples for Methods 13A and 315. These reagent blanks were analyzed along with the field samples. 

# s;s CHAIN OF CUSTODY A list or log of all samples was prepared and used to maintain the· chain of custody of the samples. Copies ofeach "sample log" or chain ofcustody form are included with the laboratory report. The field teain leader prepared the sample log onsite_ during or at·'the conClusion of sample recovery activities. Samples were carefully packed for transport to· the analytical laboratory. The samples were transported to the laboratory byTRC. -,I

---- -- **~---- ----~--**  -- -- - ------ -- ------·-- -··------- ·-·----·-· ------------ **-··-----~---·-· -~----**  **------~** ---·-------------------------------- -----------ALCOA Warrick- MACT 19569 I Page 23 of 188 

## Alcoa- Warrick Operations Newburgh,..IN 

# ·" SECTION6.0 CALCULATION OF RESULTS " Emission rates in 

## terms ofpounds per hour (lbs!hr) were calculated using the pollutant·ern.ission concentration expressed in terms of

# grams per. dry 

## standard cubic feet and milligrams 

## per cubic
. meter 'times the volumetric gaS



# fl~w·**iat~ ~xpressed**  in



# t~s ofdry



# stand~d cubic feetperrcinute,

. . . 

### . . 

## Emission rates in 

## terms of pounds per hour (lbs/br) were calculated using the pollutant emission· · rate 

## in terms of micrograms per dry standard cubic foot (ug/dscf), flowrate - dscfin (Qs), 60 minutes/hour, divided by453,600,000 ug/lb. lbs!hr 

# = (ugldsd} X 

## Qs ·X 

## 60 . "453.6 Xl'06 

## Emissionrrates in 

## terms ofpounds per hour (lbs!hrY were ccilculated using the pollutant.emission rate in tenns of parts per million (ppm/dry), flowrate - dsc:fm (Qs), molecular weight of the pollutant 

## (MW), 60 minutes/hour, divided by

## 385.3 X 106 

## dscf/lb-mole@ 

## 6S!>p (20°C). Ibslbr 

# =pnm X Os X MW X 60 385.3 

## X 106

··-------·------------ .. :' ' 

## " ME'.i"H.OD 315 

### POM TEST RESULTS " ALCOA-WARRICK OPERATIONS A-446 REACTOR# 1 (Three Stacks)
.

**~** NEWBURGH, IN 

### RUN NUMBER M315-BH#l-1 M315-BH#l-2 

### RUN DATE 10/23/2012 . 10/23/2012 RUNTIME .. 

### 0846-1154 1220-1506 MEASURED DATA (Y) Meter BoxY .. 

### 0.9949 0.9949 Avg Delta H, inches 

## Hi> (DeltaB) 2.34 2.64

(Pbar) Barometric Pressure, inches 

### Hg 29.63 

### 29.63 (Vm) Meter Volume, ft3 

### 121.772 130.082 (Tm) Avg Meter Temp, deg F 82. 89 

### (Pg) .Static Pressure, inches H 2

### 0·.. · -0.26 ..(),28 

### (Ts) Avg StackTemp, deg F 171 

## .. 173 (Vlc) Water Collected, rilL 

### 252.3 274.3 (%C02) Carbon Dioxide, % '· 

### 3.0 3.0 (%02) Oxygen,% 17.0 17.0 (%N2) ·Nitrogen, % 80.0 80.0 (Cp) Pitot Tube Coefficient 0.84 0.84 (DeltaP) 

### Avg Sqrt DeltaP, (inches H20)Y,_ 0.816 0.803 (Theta) Sample Time, 

### min 144 144 (Dn) NozzleDiameter, inches 0.260 0.260 CALCULATED DATA (An) 

### Nozzle 

### Area, square feet 0.000368701 0.000368701 (Vmstd) Standard Meter Volume, 

### ffl 117.448 124.099

(Ps) Stack Pressure, inches Hg 29.61 29.61 (%H20) Moisture,% 9.2 9.4 (Vwstd) 

### Standard Water Vapor Volume, fP 

### 11.896 12.933 (Mfd) Dry 

### Mole Fraction 0.908 0.906 (Md) Molecular Weight-dry, lb/lb-rnole 29.16 29.16 (Ms) MolecularWeight-wet, lb/lb-mole 28.13 28.1 I (Vs) Velocity, ftls 

### 51.0 50.3 (A) Stack Area ofThree Stacks, ft2 

### 11.27 11.27 (Qa) Volumetric flow, acfm 34,507 34,031 (Qs) Volumetric flow, dscfin 25,927 25,442 (I) Isokinetic Rate, % 96.2 103.6 EMISSIONS DATA PARTlCVLATE MATTER (PM) (grams) Total PM Catch, g 0.0225 0.0262 (rng/dscrn) Concen., mg/dscm 6.8 7.5 (mg/acm) Concen., mg/actual 

### m 3 5.1 

### 5.6 (gr/dscf) Concen., gr/dscf 0.00296 0.00326 (gr/acf) Concen., gr/actual cf 0.00222 0.00244 (lb/hr) Emission Rate, ]b/hr 0.657 0.711 POLYCYCLIC ORGANIC MATTER (POM) (milligrams) Total POM Catch, mg 21.5 7.9 (mg/dscm) Concen., mg/dscrn · 6.464 2.248 (mg/acm) Concen., rng/actual m 3 

### 4.859 

### 1.681 (gr/dscf) Concen., gr/dscf 0.002825 0.000982 (gr/acf) Concen., gr/actual cf 0.002123 0.000735 (lb!hr) Emission Rate, 1blhr 0.628 0.214 M315-BH#l-3


### . 10/23/2012

1536-1817 0.9949

2.47 

## · ...

**:~** 

### 29.63 126;309 ' 

### 87 -{t25"

173
.287.6 

### 3.1 17.0 79.9 0.84 0.787



### 144 0.260 

### 0.000368701 120.884

29.61

10.1 13.560 0.899 29.18 28.05 49.3 11.27 33,377 24,768

103.7 0.0237



### ; 6.9 5.1 

### 0.00303 0.00225

0.642 21.6 6.309 4.684 0.002757 0.002047 {).585 ALCOA Warrick - MACT 195691 Page 31 of 188



# .. i AVERAGE 

## l I ··, ·' 

### . .. 

# I 

# l I . • .. 

# I I I. 

## I 

# I 3.0 ,. 

### . 17.0 . . 80.0 . 

### I 

# I I 

# l 

# I ! .. 

# I 9.6 

# I i : 

## ! I . I 50.2 . 

# i l. 

### 33,972 

### i. ; 

### I 25,379 

# I : 

## I 

# I I 0.0141 

# I 7.0 ,. 

### 5.3 0.00308 I. 

### O.<ip230 

## I 

## ! 0;()70 : 

# I 5.007 3.741 . O.OQ2l 88 0.001635

0.476 L

# I

I 

## I I· ;

I I I 

### I. MEtHOD 315 POM TEST

**RESULT~'** ... ALCOA- WARRICK OPERATIONS A-446 REACTOR# 2 (3 Stacks) NEWBURGH, IN (Y) 

### (DeltaH)

(Pbar) (Vm) (Tm) (Pg) {Ts) 

### (VIc) (%C02) 

# c%ov (%N2) (Cp) (Del

### taP) (Theta)

(Dn) RUN NUMBER· RUN DATE RUNTIME MEASURED DATA Meter 

### BoxY Avg Delta H, inches H 2

### 0 Barometric

**Pres~··re,** inches Hg Meier Volume, 

### fr 

### AvgMeterTemp, degF Static Pressure, inches H 2

### 0 Avg Stack Temp, deg F Water Collected, 

### mL Carbon Dioxide, 

### % Oxygen,% Nitrogen,% Pitot Thbe Coefficient. Avg Sqrt 

### Delta P, 

### (inches H20)Y, Sample Time, 

### min Nozzle Diameter, inches CALCULATED DATA 

### (An) Nozzle .Area, square feet (Vmstd). . Standard Meter 

### Volume,

**ft~**

(Ps) Stack Pressure, inches Hg (%H20) Moisture, % (Vwstd) 

### Standard Water Vapor Volume, ft3

(Mfd) PryMole Fraction (Md) Molecular Weight-dry, lb/lb-mole (Ms) Molecular Weight-wet, 

### lb/lb-mole (Vs) Velocity, ft/s 

### (A) Stack Area 

### ofThree Stacks, 

### :ft2 (Qa) Volumetric flow, 

### acfm (Qs) Volumetric flow, dscfrn (I) Isokinetic 

### Rate, % (grams) (mgldscm) 

### (mg/acrn) (gr/dscf) (gr/acf) (lblhr) 

### EMISSIONS DATA PAR'I;ICULATE MATTER (PM). Total 

### PM Catch, g Concen., mg/dscm Concen., mg/actual m 3 Concen., gr/dscf 

### Concen., gr/actual cf Emission Rate, lb/hr M315-BH#2-l · 10/23/2012 

### 0846-1154 0.9747

2.84 29.63 137.289 80 -0.50



### 175 263.8



### 2.5 ,
**17~5** 

### 80.0 0.84


### . 0.900 144 0.254 0.00035188 130.492

29.59

8.7 12.438 0.913 29.10 . 28.13



### 56.5 11.27 38,198 28,667

101.3 0.0059 

### 1.6 1.2 0.00070 0.00052

0.171 (milligrams) (mg/dscm) POLYCYCLIC ORGANIC MATTER (POM) Total POM Catch, mg 

### 16.00 4.330 (mg/acm) (gr/dsc£) (gr/ac£) (lblhr) 

### Concen., mgldscm Concen., mglactual m 3 Concen., gr/dscf Concen., gr/actual cf Emission Rate, lblhr 3.251 0.001892 0.001420 0.465 **M315"BH#2~2** 10/23/201.2 1220-1506. 0.9747

2:85 29.63 138.164 83 

### -0.50

176 274.8



### 2.6 17.3 80.1 0.84 0.898

144 0.254 0.00035188 130.659

29.59

9.0 

### 12.957 0.910 

### 29.11 28.11

56.3 11.27 38,119 28,485

102.1 0.0111 3.0 

### 2.2 0.00131 0.00098



### 0.320 16.10 4.351. 3.253 0.001901 0.001421 

### 0.464 ALCOA Warrick - MACT 195691 Page 32 of 188

**M315-BH#2~3**

10/23/2012 . 1536-1817 i AVERAGE· 

# .!·· .

i 

# I . 0.9747
. 2.86 '29.63 137.402 

### . 78 

## :..o.so .1

175 

# II 286.9 

# ..

**1~:!**

**~~~** .80.0 .0.84 0.908 

# I

144 

# •.,.. I 0.00035188 I 131.025 ..

# l

29.59 

## i

9.4 

# l 13.527 I o.9o6 

# I 2;6 17.4 .80.0 ..
9.0



# ;~:~~ **.,:~**



# ~~~~ ,::



# ;!~,:~ **~:** 56.6 38,303 28,631 0.0078 2.1 1.6 0.00092 0.00068

0.226 9.60 2.587 

### 1.928 0.001131 0.000842 0.279 

### I I 

# I i 

# I 0.0083 

### 2.2 1.7 0.00098
. 0.69073 Oi239 3.756 

## 2&J.O O.qQ}641 0.001228



## o~@31

. I



# i i I I I 

# .I



# I

..I '·.: .. ·'•'

..

:_. 

# '!'. ' '.·· ·, 

### .. , 

# J I .J



### . I



### I J 

# .I 

# J 

# J l J 

# I _j .J 

### METHOD 

## 1WORKSHEET Summary of Location Setup



### . GOMPANYNAME: .· ·.· ·.•· · .·FACILITY 

## LOC!\TIOr\J (City, State) ' •. . ..


### . · · · ·sAMPLING LOCATiON:·. .Circumference 

# · ·. Far Wall to Outside ofPort

inside Wall to Outside of Port


### .DIAMETER OF STACK DIAMETER OF STACK**~ Near~st**  

### Upstream**Disturban~-** 

### · _Nearest Dowstreain -Disturbance Nearest Upstream Disturbance Nearest Dowstream Disturbance ' .
. 

## "' Enter.lnform?tion ·Below: · f '

### '~ALCOA-~WARRICK 

### OPERATIONS . . : ..... ' 

### Newburgh, IN · · ·.···, 

### ;A:-446 REACTPR 

### # 1 or# 

### 2 (Each 

## ot3. Stacks) 

## 30
. 3.75 26.25 2.19

. -60 :. 

### :. '2.3.2' 

### -2.3 8.8 · Inches Inches Inches · Inches Feet**ln~hes** 

### . Inches Diameters Diameters USE 12 TRAVERSE POINTS PER PORT TOTAL TRAVERSE POINTS
. EXPECTED RUN DURATION TIME PERTRAVERSE POINT READINGS EVERY EXPECTED READINGS 24 

### 144



### 6 -6 24 24 

### pt 

## X 3 Stacks minutes minutes 

### minutes ALCOA Warrick- MACT 195691 Page 80 of 188

·-----. . ................. --- -··---- --------·---------------------·-**·-----~----------------··--------·-··--------~---·-~·--~---------~--------·--------··--·--·---·----··' ~**  ·•.·. ':.• 

### · METHOD 1 · ·· ··TRAVERSE POINTS



### .ALCOA· **WAR~ICK** OPERATIONS



### · · ·. **Newbur~h,** 

### !N

.. A-446 REACTOR·# 1·,or# 2 

# (Each

**~f3** Stacks)·.

'

**~** ' ' • , • , I ' • . . . . . . 

### Far Wall·toO[Jtslde 6fPort . Inside 

## Wall to Outside of Port DIAMETER 

## OF STACK Nearest Upstream Disturb!'lnce Nearest Dowstream Disturbance ·. · NUMBER of.Traverse Points per Port " 

### 30 

### Inches 3.75 

### Inches 26.25 

### Inches 60. 

### Inches .232- 

### Inches

12 POINT' %of Depth D.iameter ·Distance ·Distance····.·. 1 

### 2 3 

### 4 5 6 7 

### 8 9 10 11 

### 12 ·. from Inside w/ 

### Nipple 

## a·.oz1 2.6.25. 

### '0..551 4.301 

### 0.067 

### 2C3:25 '1.759 5.509 0.118 . 26..25 .. ' 3'.098 6.848
. 0.177 26.25 4.646 

### 8.39£? 0.25 26.25 6.563. 10.313 0.356. 26.25 . 9.345 13.095 0.644 26.25 16.905 20.655

0.75 26.25 19.688 23.438 0.823 

### 26.25. 21.604 25.354 0.882 26.25 23.153 26.903 0.933 26.25. 24.491 28.241 ... 0.979 26.25 25.699 29.449 

## Ali measurements 

# were verified in the field. ,· ·Two Available Pcirts with 12 

### Traverse Points per Port Expecting 

### 3 to 

### 4 hour runs SAMPLE EACH POINTFOR READINGS EVERY

. ,. .·...


### M1-REACTOR#1 

### or #2 

### 6 

### 6 

### Diameters

. 2.3



## 8.8 42/8 '54/8 

### 6 7/S 8 3/8 10' 3/8 

### 131/8 

## 2o 5/8 

### .23 418 

### 25 3/8 26 7/6 28 2/8 

### 294/B 

### Minutes Minutes ALCOA Warrick - MACT 195691 Page 81 of 188

..' 

### .. . . ' :. '• '· 

# I ! 

# ·. ·I T 

## .. ·I .



# I

. I

1.·



### .. IL ___

---- L _____ _ L __ _ L----- FACJLITI{ NAME **!ALCOA~**

WARRICK OPERATIONS I SAMPLING LOCATION IA-44a

REACTOR 1-1 flke Sll.cksl [

. CITY ANT> STATE·

I

NEWBURGH. IN. I STACK Dl!lfENSJ:ONS **~c~~!:.~:l s~:.251** 

t..rsrth J w-dth J

I NOZZLE lNStDIJ: DlAMnr:R
er

.. 1 I R.Jml [ Rtm.l J RleaJ I IN022!..E

DIAMETER I ··=·r=:=::A= I 0.225 I JRW -101221i2 DRY GAS METER DATA _, • I """

....... 1.7H ·VOLlJME 1\fK'Ili:'RED **c~t~;;;** 1 lcs\::Checlc;26n!

' Vobnf:.M::Ivuxi' o.ooo· .M'!!!! , ...... Ruo3 M-11 t".OO.CO , ..... 0.000 0.000 "''"" !lao M-11 0:0049 1.71>8 - 3.912 95..1!5 IJ.OOV 0.001 O.!ltlO MOO 91.904 OK **0~~ J.'RE§IJRED~**  Rca2 I Rtn Gnun31mb Cdlecftd MOJSTURJtDATA **~-----** liii **~CalchW4!Jiiit.=-:T** 2.12.lltt FILTERADL'El"ARTICU. ....----- Gr11m.'!: Colecled I U.DDIIO lUTAL FLUORIDES LAB DATA - lDl.l 2n2$8 •= 0.11000 **lMJEgt~S** Co!Jatted I

lb::ll O.l51 Rml ll.ll'il

Rnn 0.101

j K- FGCXlr r **R~n**

I { !'..unl ( R\Q:===t
K-F• ! I l..__._ , __ _ llabl:&ofry Nl1MBEROF.TRAVXRSZ.'POINTS!:2 (

., I 12i n I DELTAr ---- R1INIIl RIJNII1 RCNm

I 0.60 U.SJZ I .... 0,«10 I . ... 0.104

2 .... 0.800 2 """

**~** 2 .... 0.825 1 1

3 ..... o.m 3 .... 0.700 l t.73 O.I!S4

4 0:11· O'.B83 4 .... 0.115 4 .uo 0.1\9<

s o.to ..... ' 0.61 0.711 s U6 0.917 3 • 5

6

.. , **0~89** 6 OM 0.917 • . ... ....,

. 1

.... 0.752 ' l1liS 0.912 7 us 0.806

·g . .., 0.728 • 0.71 0.177 I .... 0.762

9 0.0 0.700 ' D.64 0.80D • **·~1** 0.71-4 7 8 9

10· : O.Al ..... " .... 0.1U 10 .... · O.Ul

·n .11.33 **o~·** II .... 0.(.6] II OJII 0.616

ll t.U ·= 12 ll31 0.601 " "-" 0$2

U· .... o.m ·" ..... 0.671 IJ 0.<4 **.~** ..

I< .... O.lt:!! 14 .... o.&ss I' .... **0~00**

... 1.72 ...... 15 .... . 0.707 IJ 0.£1 O.AIS'I

16 '·" ..... ,. IJ9J 0.7151' ,. 0.1.1 **0~<9**

17 1.11 '·"" 17 o.n ...... " n.11 Ulll

18

... , p.91l 18 O.RJ 0911 18 **·~· 0~22** 

19 **~· ~7fi8**  19 D.B7. o.m " **·~·** 0922 10 II 12 13 14 15 16 17 lB 19

"' •.sl_ lJ.714· 20 ..... 0.872 20 **0~7** o.m

.2i lAS M71 .21 .... 6.66< , **·~1** t'-121

22

..... 0.<1!2 22 09 0.73.S :n 9-:tl O.tm

23 f35 O.S\72 n .... **0.~.** n **·~·** o.m

l4

<31 O.ss7 14 0.33 D.S7-4 24 031 • O.:S6G

2S

.... 0.742 2.5 ·11..17 0.6%· 25 .... 0.775

""

.... 0.742 16 t59 0.7153 26 ..... OjQ 10 21 ,. lJ ,.. lS I 26

21 U1 0.781 27 . l.ll 0.79-4 :r. .... o.ns

21 1.71 .... , "' r.n 0.1143 "' n.?.c .. 27 l8

"' o:n o.m 29 .... .. ... 2'1 Ml 0.900 l9

30

..... 0.917 lO •. 17 0.9]3 "" .... 0.93R: ,.

ll 0.'13 o.m 31 Ul 0.954 ll .... 0.927

32 0.71 OJI.C9 32 0,"!7 O.Rn 3! 1.75 o.u.:

J) .., 0.787 33 038 0.762 "' ... o.nl

34

O.SI 0.114 34 O.C6 0.678 34 II.A1 0.636

)5

.... 0.632 Js 03' 0.&4 3S t.3S 0.616

36 ll.l5 0.!592 " o.zt . .,. 3G ll.l5 0.391

37

.... 0.173 J7 0.53 0.718 :r. .... 0.701:1

38

... , 0.781 3H .... 0.77S 31\ U! 0.1106

39 D.!l 0.162 39 0,71 OJU9 39 .... 0.806

.f<1

.... 01112 40 .... Ol01 «< o.n 0.114'1 !I )2 33 ,, 3s ,. 31 Jl 39 ...

.. 0.71 0.8!3 41 031 09,. 41 .., O.B11 "

., .... 0.921 ., 1.0$ ,.., "" uo 0.938 <2

" **·~** 0.933 43 .... 0.904 4J .... 0.917 "

.. . .... 0.87.2 .. .... ..... .... .... o.ru

"

.... 0.812 .., o.sT 0.7ll 4! tAil" 0.781 44 ..

..

.... ..., 46 **0~1** 0.714 ... .... 0.673 ..

47 .... ... ., <fl t!Al 0.6«1 47 .... 0.616

•• 0.31 O.filfJ ... ...,, **·~·** ... 0.3$ 0.592 ., ...

..

O.» 0.6>< ,, MT O.Jl9 •s .... O.GS <9

"' ... , 0.643 "' 0.71 OJU! "' M4 ..... !Ill

" ... , 0.700 " ...,, 0.872 5I OA 0.693

Sl Ul o.m s2 D.S2 0.906 Sl .... 0.7GR

51

.... CU131 53 ""' 0!113 51 .... OJill 51 S2 "

"' •• 0.917 "' 9.91 0954 "' OJU 0.917 ..

'' us 0.911 ss 0.,,

O.l!ll "' .... **0~27** ss

S6 0.77 om ,. .... 0.711 "' 0.72 0.149 ...

57 U4 '·""' S1 11.511 o.m7 Sl 11M 0.111 S1

.. ... , **~721** 50 ..., 0.700 ... 0.51 D.714 ..

.. . ... ..... "' ..... (),632 " ..,. 0.616

" t.» **·~·** " .3.

0.614 60 031 o.ssr

Gl eAl 0.6CO n .... O.Ul 01 O.A! 0.700

112

.... 0.678 " t.7J 0.14] ., .... O.lal

., '"' 0.656 <ll 8.74 ..... " .... 0.6111 • ,. 60 61 "' IS)

.... I.A1 **0.~6** 64 .... 0.917 ... .... 0.762

65

.... ':_DJ!Ofj' :65 .... 0.'>43 <3 a.:n. ...

.. 1.14 rum .. .... 0.959 .. U4 0.917

n U4 D.9I7 ., .... 0.804 61 ll7 11.933

.. un ...,. li8 . . .... 0.762 .. a.n 0.901l .. ., .. ., Ql

61 u• 01112. 1/} .... 0,748: 61 Ul O.lt\1

70

.... o.m ,. .... M78 711 9.54 0.7.15

11

.... O.!;fll 71 ..,. o.sno 71 t.37 O.lm

72

.... ""' . 1.1 Q.31 **~;1.¥** __ n__ e.lf

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1J. 9.000 7.1 ... 1J **~.000** "'

TD 71 12 73

,. 0.000 74 0.000 74 0.000

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.76 O.oo6 76 **D.~** "' 0.000

77 o.OOo 77 0.000 77 o.cmo

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80 Moo "' 0.000 80o.ooo74 15 76 11 78 79 80 5S.ln 56.095 SS.19-1 Avp:_&;:l **~** L..!!:m.!.... **~** .... .,:.,:.,.,...At'Til ... -1 DKLTAH RUNill

RUNU:. JlUNIG RUNII1
1.35

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### NEWBUR,GH, IN , A-446 REACTOR 

## # 1 (Three 

### Stacks)

.

# . <· ALCOA Warrick- MACT 195691 Page 83 of 188

: 

## ....

. .
**-~.** . ,.. . . ·.•. \:·.::· .· . **~\··.:.** .. 

# .· '

**c~u~m:ted** by: '' 

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### Mills . .. ..: **D~lta·I-I**

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### ... . .:, 

### · 

## ....

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### .



### Calculi~

# Yqafor eacli

**te-s~**

# I1Jri usmgthe-folloWing
**eq~tion:** ' ' 

# =!._. 0.0319 Tm· 29 ( 

# 'i:Ji) Yqa H "'/LJ.l1 avg 

## Vm\/ 

## 11H (P 

# +11

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## M d ··

**-~here:** 

# · " ··.:,, · .,. 

# . , Jqa:. Vm T_m 

### :Pb ' 0.0319 DHavg DH@ 

# Md . 29 13.6. 

# J· @ b 

## '13.6 ' . ·.dry
**gas.m~ter** 

### calibration check value, **~nsio_riless**

### . 

## ·total runtime, min. ·-. . · . 

## :·.:i . ·total satlJ,ple volume r:ileasu_.red by 

### qrygas mete,i:,4cf. 

### 'absolute average dry 

### gaS 

### meter temp,, 0

### R. . , , , . 

### · barometric pressure, in. 

### Hg. · · = 

### (29.92/528)(0.75)2 (in. 

### HgJO/R) 

### cfmZ.
.average 

### orifice 

### meter differential, 

### in. H20. 

### orifice meter calibration coefficient, in. 

### H20. dry 

### molecular weight 

### ofstack 

### gas, lb/lb-mole. dry molecular weight 

### ofair, lbllb-mole. specific gravity 

### ofmercury.

**~** 

# After each 

### testrun 

## serie8, do the 

### following: · 

### ·Average the three 

### ormore Yqa's 

### obtained 

### from the test 

### run series and · compare 

### this average 

## with the dry 

### gas meter calibration factor,:Y. ·



### The ·average 

### Yqa mustbe within 

### 5 percent ofY. .· . 

### Ifthe averageYqa 

### does not meet the +5 percent 

### criterion, recalibrate·tbe meter QVer 

### the:full range oforifice settings, as 

### detailed in 

### Section 5.3, 1of
_Method 5. then 

### follow the procedure in

### Section 

### 5.3 .3 

### of

### Method 

### 5, :



## I Test 1 Test2 · 

### time 

### 144 144 .. 

### Vm- total 90.86.4 " 

### 97.790 Tmavg ·. · 78.5 . ' 

### 88.5 Tm-R ..... 

### 538 ' .549 Bainmetric 

### 29:6 .29.6 -· 

### DHave. 1.272 

### 1.467 DH@ 1.7960· 1.7960 · Md stack 

### gas 29.16 29.16

MdAir 

### 29.00 29.00

**Met~r** 

### Box Gamma 0.9949 0.9949 QAGanuna 1.0003 1.0062 Difference: 0.5% 1.1% 

### within 5%? PASS PASS AVERAGE DIFFERENCE 0.7% ·.·

### .. ·
,·_.

... 

### - Test3

.. 144 

### 91.904

90.6 551 

### ,29,6 1.273 1.7960 '. 29.16

29.00 0.9949 0.9997
. o.s%· 

### PASS 

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### Check ALCOA- WARRICK()PERATIONS 

### NEWBUJ{GH, IN .A-446 REAC'f:OR#. l(Three·Stacks) ·:·.. ·.··· ·':·.·

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### .:····· ALCOA Warrick- MACT I95691 Page 96 of 188
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### . .

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### .**Cal~ate** 

### Yqa for 

### each test runusing 

### the following equation:
. . .· .. , 

### . . .. :



### · ,where:· 

### Yqa q'. 

## Vm Tm Pb. 

### 0.0319 DHavg DH@ Md 29 . 13.6 = 

# _!!_' 0.0319 Tm 29 

## {JMi) Yqa H avg 

## · Vm1l L\ rr 

## (P**+A~)Md** 

## . ·. V II@ b 

### }3.6.

. 

## . . 

### . 

### dry 

### gas meter calibration check value, dimensionless. · _total run 

### time, min. · 

### . total sample volume measured bydry

### gas meter, dcf.

absolute average dry 

### gas meter temp., 0

### R. 

### barometric pressure, in. Hg. · · · = 

### (29.92/528)(0.75)2 (in. 

### Hg/0

### /R) 

### cfm2.

average orifice meter differential, 

### in. H20. ·orifice meter calibration coefficient, in. H20. dry 

### molecular weight ofstack gas, lbllb-mole. dry 

### molecular weight ofair, 

### lb/lb-mole. · · specific gravity ofmercury. After each test 

### run series, do 

### the following: · A

vef.tge the

### thr~**o~** more Y qa's obtained from the test run series and compare 

### this average with the dry gas 

### meter calibration faCtor, Y. · 

### The**~.tveiage** 

### Yqa:must be within 5 

### percent 

### ofY. . If

### the average 

### Yqa does not meet the 

### +5 percent criterion, recalibrate the meter over the 

### full 

### range oforifice settings, as detailed in Section 5.3 .1 

### of . ·Method 

### 5. Then 

### follow ihe procedure 

### in Section 

### 5.3.3 ofMethod 5. · 

### Test 1 Test2 

# time .. 

### 144 144 Vm-total 121.772 130,082 ·Tmavg 82.3 88.7**Tm~R** . • .. 

### 542 

### 549 Barometric .•. 

### 29.6 29.6 DHava . 2.336 2.644 DH@ 1.7960 1.7960 Md stack gas 

### 29.16 29.16 MdAir 29.00 29.00 MeterBox Gamma 0.9949 '0.9949 QA GamJ:Ila 1.0115 1.0161 Difference: 1.7% 2.1% within5%? PASS PASS AVERAGE DIFFERENCE 1.8% Test3
.. 

### 144 •126.309 86.7 547· 29.6 2.474 1.7960 29.18 29.00 0.9949 1.0098

1.5% PASS

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## .METHOD 3 • ORSATANALYSIS 

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### Distillate Ort 1.260-1.413 Anthraclte/Ugnite Coal 1.015 -1.130 

### Residual Oil 1.210 ·1.370 

### Natural Gas 1.600

**~** 1.836 Wood/Bark 1.000

**~** 1.130 

### Date: 

### fa . Z"i· Z. t2 

### I Z.. Bituminous 

### Coal 1.083 - 1.230 Municipal Solid Waste 1.043- 1.177 i" -.. .. ·. 

### I 

# IL. L---- L __ _ L___ L___; **~ ~**  **~** '.'· FACIT.ll.YN/t.ME I.N..COI\.- WMRICit OPERATIONS I SM!rLING LOCATION .

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## l.i%. . 

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## METHOD 3 .. ORSAT ANALYSIS FIELD DATA ·client 

## Name Plant Name · City 

## I State 

## · ·Test Locatlbn Run

Run No. Run 

## "S(nLn.: r:Jz; / 

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### .'----L____'L..,.----,L..__;·L--,ExampleEquattonsVOLUMEOFDRYGASSAMPLEDATSTANDARDCONDITIONSVmstd=r17.64•Pbar+(De/tailI13.6)(460+Tm)Vmstd=0.9949*17.64*121.772*29.63+(2.336111I13.6)(460+82.2778)VOLUMEOFWATERVAPORATSTANDARDCONDITIONSVwstd=O.M7I5"VicVwstd=0.04715..252.311.896SCFPERCENTMOISTURE,BYVOLUME.ASMEASUREDINFLUEGAS'{,H20=Vwstd(Vwstcl+Vmstd)%H20=11.896(IJ.896+ll7.448)ABSOLUTEFLUEGASPRESSUREPs=PbarPs=29.63+..J:z.13.6+-0.2613.6DRYMOLEFRACfiONOFFLUEGAS.Mfd=M[d=%H209.2100DRYMOLECULARWEIGHTOFFLUEGASMd=rr.co,Md-(3..44)100..#100X100X10029.61+(r.o;.,.(.179.2%h!c:hesHg··umtie"____E_.)+(100·•32)----;-or;-(+TOO100M315-REACTORIII-cor=texmnple.117.44/fd!ICf...r.cozr.o,317-.--.-----________jI.""Page1of3"•·..28).jij(J7..28)29.16IJJ.Ilh-mok.__-·-·--·"'I:"'""o;;?::E!3.0';;;;J>ooo..,Example EquatioiiB

WET MOLECULAR:WEIGHT OF FLUE GAS llfs= ( Md .. Mfd ) + **jiVtH~O** .. 'YoH10 100
Ms- ( 29.16 a 0.908029 ) + 18 . * 9.2 28.13 ----:Joij AVERAGE FLUE GAS VELOCITY Vs= 85.49 .. Cp . Def.taP'

**·~** f ·rs -J- 460 Pi

... Ms

Vs= 85.49 .. 0.84 • 0.816013 .. l 171.25 + 4'60 29.6

• 28.13
WET VOLUMETRIC FLUE GAS FLOW RATE AT ACTUAL

**CONDID!~** Qa= 60 lis * A Qa= 60 .. 51.0 11.27 **34,5~7** tJcjin
DRY VOLUMETRIC FLUE GAS FLOW RATE AT STANDA@ CONDil1JONS
Qs= 60 .. Mfd .. Vs . .A 528 *

460 + Ts

Qs= 60 .. 0.908029

.. 51.0 . Il.27 528 .. 460

+ 171 PERCENT ISOKINETIC OF

**~AMPLING_RATE** [= Pstd • 100 * Ts + 460
460

+ i:rtd 60 Ps Vs *

l= 29.92 .. l!l!l. . 171 ·> 460
460

+ 68 60 29.61 •51.0098 * POLLUTANT CONCENTRAITON AND EMISSION RATE CALCULATIONS:

PM CONCENTRATION. GRAlNS PER DSCF grldsc;f= gr/dsif= 7,000 * groms 453.59 . Vmstd 'M2L_. 0.0225

. 453.59

117.448 O.IHJ296 grflf:rcf ·

PM CONCENIRATIQN, MILLIGRAMS PER DRY STANDARD CUBIC METER mg/<lscm = grams ,. 1.000 •. 35.314 **M315-fl.J0.~Ml-rot=t ext~niple**  Ps Pstd 29.61 29.92 . ·, lMb-mQle 51.0.. ftl& Vmstd Mjii.
. ll7.418 0.908. 25,!127 ofrr;fM . Theta 1# Page2of3 ..... ... An 96.:Z **~** 0.()0(}369 ... " ... **~** .. ...:> "'r

'-"n **~0** -> **~~** C§ C> -::!. We> "'"" 0 • ""< ;;;;

;;;:

oon -l\..._____.___L__L___L_______,-.:L__L--Vmstdmgldscm=0.02251,000•353UJI7.448PMEMISSIONRATE,POUNDSPERHOURlblhr=lblhr=60•453.592gramsVmstd,.Qs60*0.0225"'25.927453.59Il7.448POMCONCENJRAT!ONGRAINSPERDSCFgrldsif=grldscf=7,000..45359()gramsVmstd7.000..21.5453590117.4486.8·mg/d:m..0.657lblhr(J.f/0283gr/AscfPOMCONCENTRATION,MILLIGRAMSPERDRYSTANDARDCUBICMETERmg/dscm,=mg/dscm=milligrams•35.314VmsJd21.5•35.3U117.448POMEMISSIONRATE.POUNDSPERHOURlblhr=60*millig!_ams*453592Ymstd60..21.5,.453.590117.4486..16.mi:ftl."'!tfJQs,25,9270.628lblhrExampleEquationsM315-REACTOR#l-cOJreCteJtaJnplcL_.:_....!'...r .,....---.JPage3o£3.....·•...,,"'1\l"'3.0'"":S:;;;;)>ooo"-l.. .J. 

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# ALCOA.WARRICK LABORATORY REPORT

Method 315 PM 

# & POM

------ 

### -------------- --- .. -·--· ------- ALCOA Warrick- MACT 195691 Page 150 of188 1_

: i


### i. II. - **~"-----·** ----·-------- **----~** 

# NOV/02/2012/FR! 12:36 

# PM **Af.CJJ~Svarrick** • iviACT .195691 Page 153 of IBB· 

# {2-1- 2-

.. ·Method 315 **Partibulg:~te** 

# and MCEM Analysis

. . 

# . ., **~--~~------~--~----~--------------------------~~** 

## .P.etrtlouJateAnalysis 

## 'RunNo.

. Filter **No~** 

# . ., '. • **·~.** ·; '!> • • • • •' 

## ... I \':'• '·: . 

# . . .



### ... I M , ..

• ... 1 

### .. **·~ ~**  ···.
. 

# .... . . 

### Final 

### Weight. (g)· 

### Tare WeJght (g) 

## WeightGa!n 

## (mg) ' .: ,.
.. ·'· .....
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## No. 1 Contairu!lrNo. 2 ,• . 

## Total 

## ~it.

# 2.. ..

0 •' • 

## Less Acetone blank 

# Weight of

# Partloulate 

# matter

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## MoistureAnalysis. · .



## ..

# Fin~d Volume 

## (mg) .Jnitial 

## Volume (mg) 

# ·~uid Collected
**Impinge~** 

## Note 1 **Not~** 

## 1

. Sllioa Gel



## Total Note 1: Convert 

## volume of

# waterto weight 

## by multiplying

# :byihe density 0f

## water (1 

## g!ml). · Revision 

## Pate; 2010/03/31I

__ 

## I J 

# NOV/0212012/FRI 12:36 PM **A}?.,C~B-fM'arrick-** MACT 195691 Page 154 of 188 

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### of '· 

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## ·· Cqntainei ·. Final.· AcetoneWash 

### ·No.. **Humi~ty·** Welght'(g} 

## Aluminum . · :Gail'l 

### 'Volume (mL) 

## . _C_hJorldeWash

**bi.~h** 

### (g)· 

## ·.·' (1ll_g)' (%RH) . .. 

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## Wst3h aJank (mg) 

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### : 

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o **-~\·**

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### (mg) (notto· 

# . **·~.** 

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## ... 

## . . ' 

# . .. ' 

### exceed 1.5 

### mg!L of

### me1hylene chloride used) 

# ... **D-.0~~~~** Wt c 

### r;p,Evtw 

# ·..;: Less Ftiter Blank (mg) 

### (notto.exceed 1 mgffllter) '



# ~0 .

# +-JAil.'

. !=b 

## ... " " 

# I

MCEM Weight (mg) fflloiCEOM :::: **I.m~o~e,-** Wa- W1,.. Fb 

# 7;1

**~"A-~** 

### Notes•. 

### -- 

# - q 

### Blank analysis must he completed 

### before sample analysis Is started. 

### • ·Filter **~reparation** 

### Blank must 

## not exQeed: 1'mg/fHter. · .,. Aoetone Wash Reagent Blank 

### must ncrl exceed 1

## mgiL. .

**~** 

### Methylene Chlorltle R_eagent Blank: must not e?'oeed 1.5 mgfl...

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### Jmping&rWater Reagent-Blank must not exceed 

# 1.5. mg/L. . • 

# ) 

# ·"""

**·~** 

### Room Relative Humidity must

# be below

### 50% when samples are baing weighEtd. 

# .

Revision Date: 2010/03131 ,.

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## . 

# .. ·.,; 

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### . 

# .. '' '•



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., :


# . : ··,

., 

# .

# NOV/0212012/FRl 12:36 PM **A~9(H,~Varrick-** MACT 195691 Page 155 of188 

# .. Method 315 Partl.culate-and MCEM Analysis

. 

# .

.PartlouJata Anafys!S ·

**~**



## . :.FilterNo. .. . . 

# {{?,4 **~Am--o-un~tl~lq~uld~J-o~~-~Af~~·~·-~--~--------------------.-.~~~** 

## .. **~.~** 

## ... ·· dutin£Jtransport · LV()1!-S!.r;.. · · • :. ' **·.~:·** 

### · Acetone .Blank · •' 

# ... ·, 

### .. 

## Volume (ml) . ·· 

# Z.o DwU.., . . . .. . . . **~-~~~"--+--~-:......;:.:::;;._-.,--------...:._--l.....~~_;,.,o,-J** 

### ... 

### Acetone blank ooncentratlon 

### (Eq. 

# 0 O /

31&4)

# cmwmJ:J)· • **~ ~q**  

## Acetorie'wasn

**~** 

## : ·:I 

## blank (Eq. 31.5-5) 

# t?.' **{)~** 

## l--..;_.,l,_f:.:.:Jrmi1:u.-)··-· _.+--::-----r_;.;..,.........:..;--=_-_ 

## ~,.___..___J""""'__ 

## ~-.-------~-l 

# .. Room 

### Humidity 

## (%RH) · '" .. 

### Finer Weight 

### (g) Tare Wei,ght (g) 

### Weight Gain (mg) ' ·· Container 

### No. 1 .Container No.2 

# - Total Less Aoetone 

## blank Weight 

## 0f Particulate matter 

# Bz. 

# J4'! 1



# (~. 

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.··

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## MoisturtJ 

## Analysis 

# q.o

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## FJna1 

## Volume (mg) ·· 

# ln~lal Volume (mg) 

# t~~~d Collected ·· lmpfngers 

## Note 1 

## Note1 

## Silica. Gel Total Note 

## 1 : Cotwert volume of water to weight by 

## multiplying bythe density 

## Gfwater . 

## (1 g/ml). · Revision Pate: 2010/03/31 

# ..

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# NOV/02/2012/FRI 12:36 PM

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# . . 

## . ,· 

## .. ·_,;...

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# of Weight··. 

### · i-lumldtty Flnal Alurnlnlirn · :: Gain 

### Acetone 

## Wash No. .... 

### Weight (g} '·· 

### Vohune(mL) 

### (%RH) 

## .D(sn (g) . (mg).

..

# 1%. : 

### 1 

# ~-~&~?'r 

# fi~~· . 

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# ~ .. 

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# . 

# .·. **'JZ~.o** 

# ,,··\~~· .. Total .. 

# . Z. o181 **Iv~;.,** 

## . Less Aoeteme Wash 

## Blank (mg) . 

# . ... -" 

### (not to exr:sed 1mg/L. 

## cfacetone usecl) 

# - 

# .

-o.·o· **~** We • 

### c8P.ZY.w 

# . .. ·.· .. 

# . . Less Methylene Chloride Wash 

### Blank (mg) (notto 

# .. • .-:_::::7. 

## ..· . .,. ' 

### exoeed 1.5

## mg/L

## ofmefhyff:me chloride usE!d) ·· . . · '• .. 

# - 0. **DI!Vl~·** 

# ..

**~v,** 

# ::: c,I=>tZv;w Less Filter Blank (mg) 

# .. (not to 

### exceed 1.mgffiJtsr) .. . :. "'•· 

# .... o.JrW\t.. · Fb

MCEM Weight (mS) .. 

## .. l I .....,. mMOEOM ==.!miDI$/-

# w."':"w(- Fb. 

# ~~; 

# liiMlt..

. 

### ·.. ·--· ' 

# ... **·~'** 

# ). **~c:19Jf\1Warrick-** MACT 195691 Page 156 ofl88



## . . 

## Methylene
.. Chloride .Wash .· 

### Voll.lm~'(mL) . ' 

### .~4) 

# . 7fl'.-J../IN
. ..



## ~ 

# t-ro 'f'Jtl' ' 

# 8 Ev...,

# 1 /)

., 

## . .•



### .. ' •' 

# . 

# .. ' 

## . . 

# .
,, .. I ' 

# ..

,,


### Revision Date: 2010/0:3/31

# NOV/0212012/FRI !2:37PMMethod. 315 Particulate and MCEM 

# Anslysls ·.. · Plant: . Filter No. Particulate Analysis . 

# ~~~iU!VlW,.;baw:' /10. 

# ~**'!1·1~** { Run 

## No.. 

# . 5ff ' Amount liquid lost durin[transport '
. . Acetone Blank · 

### ··•· **Volum~** (ml)



### Aoeione blank concentration (Eq,

315-4)Jmg[mg) 

## Ar::etone wash ·blank 

# req. 316-5) . D 

## D . rrv. ,_ .



## · Jma} ·· · c · • · **~** 

### Room •' 

# '.. . ' •' ', ,.



# . .. 

### AE~0h,2.varrick. MACT 195691 Page 157 of 188



### .HumldftY Final Weight (g)

(%Rr6 ·- 

### Tare Well:lhf (g) 

### Weight **G~dn** 

### (rns) .. ·· ·. 

# 0.. I

. Container No. 

### 2 

# $'":

# 8 . Total .. 

## Less Acetone blank · .· Weight **ofParti~ul~ematter** 

# ' .Y:'J .·

**~** >,'•



## , . Moisture Analysis 

# ··· ..

# ·_·-~.--.

**Fin~!** Volumt! (mg) 'lnltlal 

## Volume (mg) 

# ~~~d **C~llect~d** .



## . Jmplngers Note 1 Note 1 Silica Gel ·· · 

## Total Note 1; 

## Convert 

## volume of 

## water

# to weight 

## by mult!plyin·g 

## by the density 

## Ci'f 

## water (1 g/ml). · Revision Data.: 2010/03/31
--------------- **··-------~-~-----·** 

## ... . '



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# NOV/0212012/FRI 12:37 

# PM **A'£~8l\3Narrick-** MACT 195691 Page 158 of 188

**~** ' ·i



# . . 

# .

-

• "-I 

# ~2.-l

.. • 

## MCEM Ana!Y,sis 

# . " 

## Date; . 

# I~\~

# -.j[·

**I~**

# li1". Time: ;:

**~** 

## .. 

# ... 

# - •'e• 

# . .

# .

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## Container; Rpom- Final 

### .Tare of **W~lght** 

### :AoetoneWash --- 

### M9ib~iene' 

### · .. Humidfty 

## ·.Aluminum Gain 

### Chloride:Wash· 

## -.

**Ne>~** 

### .Weight 

### (Q). " •'· 

### Volume (mL) .

**(~.RH)** 

### DJah (g) 

## (mg) **Vof~ml'!·** (mL) ;,·. 

# ·1);1'/ : -· 

### rz,_o#O 

# . J. 

# ~~~'11 **fl.1rB~ b-~··**  .... 

## ~7/ ' 

### ·- ·-· . 

# , ··,., 

# % . ,•. 

# (,o

**or~-** 

# (¢; 

# +)"'" -. 2+2M


# ~-~~*- 

# v ,$9/fB **q.~** '
. . ' ..

# % ,. . ···' -. 

# &-~?' **~-f> ~btl'**  ,. 

## 3W .-.



# ~- 

# ;8i1 

# . . : .. ·,• **···~** .. "



# -~ .. ' ,. 

### 3S· •.



# ~- **~~**

# sq· [t..**f.l~~·** 

# ~/t_ ft>. ., 

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# ..

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### .. 

# fL{O

**~mta1s1** 

# zv.w **Ivw,~** 

### Less Aoot!;ll'le Wash Blank (mg) -- ; 

### '. 

# .. ·' 

### (not

## to exoeed 1mg!L of **a~ne** 

### used) 

# -·o :0 . . .. ' 

# w., &::: CeP 

## ,Ev.w 

# . **'~··.** l..ess Methylene Ohl.or!de Wash Blank (mg) (not to
**~** 

# .. 

# . ,. 

# ..... ' 

# -· •.

_ **e){oae~** 

### 1.5 mg!L of 

## me!hyleme chloride used) 

## -·o.a.~_:. . '•. 

### W, 

# = c

1 

### P,!vNt . . ' ._ 

### Less Filter Blank (mg) .J_ 

### (not

## _to exceed 1 **mglf~ter)** 

### . - 

# ... 0 

# ·+IM-4. ' .. , . 

## · Fb ..
. - 

### MCEM Wei_ght·(mg) . 

# \~.0 ···' mMCHOM 

### =

### Zm.tr/l.i-

## w,-

# w,- F=b 

# """~ . .- '- ,. 

### ,. 

# ., .

**Notes~** '(I 

### ,Blank 

## analysis must 

### be 

## completed before 

## sa.rnple analysis 

### Is started. ·- ' .a- 

### Filter ?,reparation **Blan~** 

### muS'f not ex(feed: 1

### 'mglfJlter. i'· ,. .c . **Acetcin~Wash** 

### Reagent Blank **mu~t** 

### not exceed 1mg!L "'·· Methylene **Chlori~eReagent** 

### Blank must not !3J(Ceed 

### 1.5 rng/L. ·· • jmplnger Water

### -Reagent-Blank must 

### nOt exceed 1.5 

### mg/L · . •.



### . • Room **Rslativ~** 

### Humldlty 

### must be 

### below 50% when **sampl~** 

### 'are being weighed. •. 

# . , 

### 02-FORM-07 4 

### RevJslon Pate: 2010/03/31 .

### ·.·-· .

· .... ·- i

# II

# NOV/02/2012/FRI 12:37 PM **~ct)>f-.4Wnrrick-** MACT 195691 Pnge 159 of' 188 

# Method 315 Particulate and 

# MCEM Analysis Particulate 

### Analysis Filter No; 

## Amount liquid

## lost · . · r · durlno frarniport . . N 

# 0Y\ 

# e.. ' " 

## Aoetone Blank · 

# ...... .. 

## ' '\ 

# . .., 

# ..

• 1 t 0 0 I, 

# .. Volume 

# <mO · ZH-..,_;l.. · · . **~~~~~~-=~~----------------~~~~--~~~** olo 

### Acetone blank . · · , ·· • ''• I a .t 

### ooncentraflol'l 

### (Eq, ·

315--4)Jmg/m.a} Acetone wash 

### blank 

### (Sq. 315·5) 

# . (rna> **~ ~**  ,. 

# .. ·r;:.C>. **-~** , '• I 

## ·Room Humidity ·· Final Weight (g) Tare Weight 

### (g) 

## J%RH)' . Wel,ght Gain· (mg) •· 

## ContainerNo. 

# 1 

# ./ ll .oontainer **No~** 

## 2 

## Total 

# f/.1_~
.. 

## Less Acetone blank Weightof Particulate metter. . 

## .... 

# .., 1. 

# r: ......... .· Moisture 

## Anslysis ..I .···



## . . Final 

# Yolume (mg) ._lnftia! 

# Volume (mg) 

# _t~~}d Collected 

# !mpingers · Note 1 Note1 

## Silica Gel 

# Total Note 1: Convert 

## volume of water

## to weight by 

## multiplying by 

## the density Gf

## water. (1 

## gJrnr). 02-FDRM..{l7 4 Revision Date: 2010/03/31 **---------------~---------~- ~**  '. ·.' . : :

**·--~--·-~-~------~--------** . ! . .

I



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### ·.1 . 

# :I .

I 

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## ! . 

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# .. 

# .! r I ; 

# . '1-.
..1 

# J J 

# J j .. 

# J j NOV/02/2012/FRI !2:37PM **AR~f\5warrick-** MACT 195691 Page 160 of 188 

# ...

' 

# . - .... I •

....·. 

# . ... Time: NCEM Anely,sls 

# . ....

. **~** 

### R _T ·• . • 00111 

## Container **Huml~y** 

### , Final 

## No. (%RH) · 

## \'Yelght (g) 

## Tare of 

### Aluminum

Dish (g) 

## Weight Gain 

### (mg) Aceft:m.eWash


### .Volume (mL). 

## MetbyJen~ Chloride .Wash 

# ·Volume· (mL) · -



# ..

**~**

# . Less Aoetr:me Wash 

### Blank (mg)
.(not to 

### exceed 1 

### rng/L 

### of acetone used) We =csPe!Vaw 

### Less Methylene Chloride Wash Blank {mg) (not to exceed 1.5 mg/L of 

### tnelhylene chloride used) · · · 

## Wt

# = o,PJ:vrw · · - Less Filter Blank (m!;!) (not to exceed 1 mgffltter) 

### Fb . MCEM Weight (mg)

**mM~= rm,~-**  Wa-

# w,- Fb 

### Notes: 

## •· 

## . ' 

## .. 

## .
**-~0.** 

### 0. **·~·-** 

### ·. ·.· :.· 

### :~· -1.. ·•.. 

# ;;..-p. o, **~** 

# .. ' ::,·.

**-,~** 

# '• ..._, ' 

# -o·.+~·

.,.. Blank analysis 

### must be completed 

### before sample analysis ls ¢arted.

. o 

### Filter

### ~reparation Blank must not 

### exqeed: 1

### 'mgffilter. ·• • Acetone Wash 

### Reagent Blank must not exceed 1'mg/L. • **~hylane** 

### Chloride 

### Reasent Blank must r.Jot 

### exceed 1.5 mg/L • · lmpingar Water 

## Reageni.Biank must not exceed 1.5 

## mgiL , "' ·Room Relative Humidity 

### must be belOw 50% 

## when samples are being weighed. ' ' 

# . ·' 

### Revision Date: 2010/03/31

**--~----- -~--·--·--~---**  ' , •' . ·, 

# . 

# ••

. ·-:

# NOV/0212012/FRI 12:37 PM f.RQJ)r&,Varrick- MACT 19569! Page 16! of 188 

# Method 315 Particulate and MCEM Analysis ' 

# .. ,p •" 

### Partlr:ulate 

## Analysis Plant: 

## 'NftO-P..\G.\t.-

# IO'lta: 

# I It>•

# ~'!?· I '1..

# J .Run 

## No. 

# .lA4~k 

# fts-Ac:rDR.r..;,. R..,J#1:3 Filter 

### No. 

# .3A. 

# . .. 

## . •,• ; 

### Amount 

### liquid lost· 

# .. rJ **0~6"** .. 

### .. 

# . . .... ' 

### durlno transport '.. .. 

# ..

, 

## •·.·· Acetone **Sl~nk.** 

### ·.. 

# ····-~-~ ,. I '•• 

# ..

Volume (ml}_ 

# ..

# · .. 

# .. Acatone blank 

# . .. 

### concentration (Eq. 

# o,o **~I** W\o __ 

# ~ 

# ... &154) lmalma) **Aoeton~** 

### waah ' 

### .. 

### blank (Eq. a15-5) ... 

### o.o·~· **~. -~**  .. **~I** ... 

# .. . . (miJJ ' ' 

### . 

## ·f:Wom .. 

### Humidity Final Weight {g) 

### Tare Welghf(g) ' · Weight Gain 

# (mg) : 

# ..

.. 

### (%RH 1 

# ~~ 

# .84-.. /[{'/13 **e.~** 

# &EJ2;_ 

# .

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# .l4 v 

# 1(84;.' "!?/3)_ **lrMlt~li1** 

# 4-:-, J!f.?i (1E_I 

# 888~ 

# lltt**-~70** 

# 3 -1 .ContainerNo.2. 

# ?1'7!ct. 

# 8CZW

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# ~f.o/1'1; 

# f3~98

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# · .. 

# -~·8

# .. Less

# Acetone blank - (),0' 'M"-· 

## Weight'of Partir:ulate matter **~.** 

# i ... **B~·**
.. -· **~---~--** 

# ·**~-~- ~--------Moisture.Amib~~?-~·**  -·. **~** ... -.----------


### .. .. 

## Liquid Collected ·- 

## Final 

# Volume (mg) . 

# Initial VdiUfi!e (mg) . jmg) .• 

# . .. 

## lmpingers ._ Note 1 Note 1· .. .. 

## Sllica Gei ., .. 

# Total .. .

### .. 

## Note 1: Convert 

## volume of waterto weight by 

## multiplying by

## the density 

## ofwater. 

## (1 g/ml). · 0.2·FORM--07 

### 4 Rev)slon 

## Date: 201 D/03/31 .· .·i' ; : 

### . "

**~** ' .. , " . ·'

'·

**~**



### ....· 

# I



# ~-I ; ( 

## ' 

# i ..

### l 

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# J - •' 

# J 

# J

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# J J 

# J J J ..

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# NOV/02/2012/FRI 12:37 

# PM **AJ?,,C{j~'J#arrick-** MACT 195691 Page 162 of188



# . '•



# ...

:

### ..·



# .. 

# . 0



# .

. ,M.CEM Analr.sJs



# ..... 

# . . ..

# , .. 

## Room· 

## container 

## No. Humidity·. 

## (%RH) 

## ·· .Tare· of .· Wei9ht Flnal · ··Aluminum. · · Gain


## V\f~lght(g) . 

## pish (S) ·· · ·

## (mg) AoetoneWash 

### Volume (mL) 

### 1 

### 3W t · . 0. ' 

# . ,. 

# ·.· Total 

# lfo '-

**Ev~w.** 

### Less AcetoPle 

### Wash Biank (mg) 0

**~** 

### (notto exce&d 1 

### mg/l.:afeoetons used) . 

# --0. 0. **u.~··r:** Wa 

# = **Crl'~r~~** 

### ·· · · ·· ,......., 

### ·.· ·Metbylene · Ch!Qrlde 

### Wash



## Volu.r.ne· (mL) .. "J..-o" p. 

## OJ,PU o, 

## ;oo 

## +3a

.. Less Methylene Chloride Wash 

### Blank (mg) {not to 

# ::0 .{' exceed 1.fi rrig!L 

### of 

### ma!hyfene 

## c=hloride used) · · . . . -.. ,. {) • . 

# 0

**••** : :: 

# .. : 

# .···. Wr

# = **CtPit~~t.r_** 

### - 0 • __')_ •• 

### ~~~~~~~----------------~----------~~~----------~~ '



### Less 

## FUter Blank (mg) ,



# ~otto exoead 1mg./filter}. _ ·· . . - 

# 0 . **~ ~**  

# ... Notes: 

## .. J . II 

### Blank ilnalysis 

# int.it

# be completed before 

### sample analysis Is 

## started. • Filter 

## !:reparation .Blank must not exr;eed. fnigffllter. o 

## Acetone 

# Wash Reagent Blank 

## must not.exceed 1mgfL. 

### • MEith:Yfene Chloride Reagent 

### .Blank must not exceed 1.5 

### mg/L 

### • lmpinger

## ·wa~r Reagent.Blaf'!k must 

### not 

## a'xceed 1.5 

## mg/1...

.. Room Rel:ative 

## H~midlt.Y rriust be. 

### below 50% when samples 

### are being weighed.

. 

### '

**02-FORM~D74** 

### Revision Date: 2010/03/31 

# ... :, ·.·. ·' 

# . I I I

'I 

### I

. 

### :

# NOV/02/2012/FRI l2:36 PM **A~~(J@5J,Inrrick-** MACT 195691 Page 163 ofiSB 

# Method 315 Blank Analysis·

.Blank Analysis - Particulate Date;.· 

### / TJme: 

## ·I : •, ,.

.. · . ' . '



### Fll~r 

### N:o. I 

### ' 

# .. /t •
**~.** ' 

## .. ·.


### .. ' 

### ·Room 

## Pinal 

# Weignt (g) 

### WetghtGaln (g) . ' 

### Humidity Tare Weight (g) . •, .. 

## l%RH) I ..

. 

# - ""' ., . ' 

### Container 

### No. 1 . 

### . ·' 

# ... . ' 

### ...... " 

# - ... 

### . .

..

. ' **Blani~~Analysl!l ~**  

### MC5M 

## Date! 

# /te~h/t?-, **to/f~ ~**  Time: 

# I21CJo .' 

# ...

# . .Room ' ' . 

### Final · 

# ... Humidity. ·Tar-e 

## of Wel¢\t 

### Galn Wash 

### Container Welght 

### (g) 

## i:llank , 

## . £%RH}. Aluminum- .. **Velum~:** 

### Passlf~~- 

## No. Dish {g) 

### (L) 

## (mwl) · (g) 

### {mg) 

# :i/ ..·· 

# !VIr+ 

# f,~ili.P **Fll~ralk** 

# f7i5 _&.;B11- &:''!,8/3 ,.;.:-; 

## {)I 

# 4-

.. 

## Acetone Slk _

# 0 4. **3~4o** 

# &.3(t4-o ..:- 

# o.o **.~~n /~:.>**  1 J:,...VV 

### Methylene 

# 1% &.- **7:;7!~** 

# &·.'5118. 

# - Chloride Blk 

# o.o· ;·2.0J· .

WaterBJk 

# I% 1+0 **~.;o~q ·{~:~(R{Q**  

# - {).3 

# ·. 3o_o Notes: .. 

### • Blank 

### analysis must be completed before 

### sample analysis is started. o 

### i;=ilter 

### Preparation Shank must not exceed 1 mglfllter. " Acetone Wash Reagent Blank must not exceed 1mg!L. .e 

### Methylene Chloride Reagent Blank must not **excee~d** 

### 1.5-mg/l... 11 

### tmpinger 

### Water Reagent Blank must not exceed 1.5 mg/L . 

## ()n ·1.1 

# e.o 

# f. D

**~** 

### Room Relative Humldcty must be below 50% when samples al"e being weighed. 0.2-FORM..07:4 R.evision Date: 2010/03/31 

# ',p· 

# ..

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. I

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# I '• 

# }

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# J 

# ] I. j 

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# J j 

# J j j 

# NOV/02/2012/FRI 12:36 PM **A~~~~4Varrick-** MACT 195691 Page 164 of188 

# Method 3'15 Blank Analysis 

# ·"'· .
**~** 

### · Blank Analysis • Partlei.Jlate Date: 

# :·I Time: -/ · .,. 

# . ; . 

### ·Filter No. · ''• : ... 

# · Room· .. Humidity ·· Final Weight 

### (f!) 

## Tare Walght 

### (g) · Wsif1ht Gain (g) .. · • 

## (%RHl ..· Container

# No: 1 :-\ ,...... :. 

### BlankAnalysis - MCEM 

### Time: --- Room 

### H mldlty Final . Tare of .• C

### ontainer · . u Weight ( )



## ~( **.:.::Yo.c..:RH!...:.tif-+__...-- -l.**  · 

### ·Aluminum 

## No. Oish (g) 

### Weight 

### Gain. (g) (mg) ·wash



## Volum~ 

## · fllank : 

# PasslFall· (L) . . (mg/L) .



## Notes: ·' e. 

### Blank analysis

**mus~** 

### be completed before sample analysis 

### Is started. c 

### FnterPreparatlon 

### Blankmust nof exceed 1 mglfllter.

**~** 

### Acetone Wash Reagent Blank must no.t exoead 1 mg/L. • Methylene Chloride Reagent Blank must 

## not **excee~d** 

### 1.6 mg}L ·:. lmpingerWater Reagent Blank must not exceed 1.5 mg/L. , 

## • Room Relative Humidity must be below 50% when sampies 

## are being weighed. 02·FORM-074 Revision Date: 2010/03/::11 . .... . 

# ..SUMMARY OF EQUIPMENT

-- -·-- ... -· -·-·- .. - ...

I A-446 Reactor 2 M13A l'vH5 0.9747 1.828 9/6/2012 RPT-79/ R,P-3L

A-446 Reactor 2 M315 M-15 0.9747 1.828 9/6/2012 RPT-79·/ RP-3L

..
. ... ·. **··;~-·** ... **~._,l_y -·:·'~-**  .r·

-- **~.;~·**

.. -' ._.,.· .... ---- ....... Glass . ss 8.8 Glass

Glass G-5,73 '

. 0242 0.254 ' . "'

" ' . I -;t> ""r **~(')** 'DQ **~)>** ci',;:: I)Q - **~ ~-**  o-n a- "" 0 • "";;::

;;;>

oon '-1 \Do **~;t> ci'~**  **!~** 0'\ n· a-

"' 0 • :::;;:: oo;t> oon '-11\l!eterBo:X:IDGasMetet-Nu'mberCalibratedByOrificelDOrificeCoefficientK'AmbientTemperatureVacuum(2:14.1"Hg)DeltaHInitialVolumeFt3FinalVolumeFeTotalt=_5Ft1InitialDGMTemperature°FFinalDGMTemperature°FAverageTemperature"FTimeMinutesTimeSecondsDeltaH@Gamma(Y)Average(Y)DeltaH@tolerancec'. ..·.\.. .pryGasl\:Ieter5-PointFullTesti29S987_..·--.-.PassPasaCaljlmitionDate·'BarometricOrificeSetDatePMs(Y)Delt!iH@..........,..o91Gnotz·-·29A2-I0.9747IL828·..·.·.QAIQCChe9k:SignandDate.rl''/;'"'\.""').../}..'.)._&'---1.09.,.09-12.,.'··.:·..·,..:···:->"'0-p."",-'"':j§0'-,s:.;;;)>""n--!i. __ L ___ _ [__ __ _ L___. L___. .. **·:·~** L___. .·· .L___. **L~.~** L___j ------! ".:.. **·~·** ._. **-~; ~** 

**~** --- _:______) .r.:

· Dry Gas Meter Temperature Display Cali.bration MeterBoxiD Date Calibrated By Input Temperature :Mls 9/6/2012 T. Mills

1

- Channel temperatures must agree With+/- 5 <>p or 3 °C

2

- Acceptable teinperature difference is less **th~ 1~5%**  **lC~T;RC** I Reference Calibrator Serial NumberReference Calibration .:Qate Temperature Reading from Individual Thermocouple lnput 1 Dry Gas Meter Thermocouple Calibration 3 **rKo::a<:>JcH~.:~::** Thermometer 70 74

· .. " 0 **Orilega~CL23A**

T-235647

.. 8/23/2012 " 0 Pass -'·-:.:.·Dry gas meter thermicouple is compared to an ASTM type mercury in glass reference_ thermometer

qA I QC Check: Sign and Date {;4e) .. . H ·- ·og-69-12 · :_ _ _) **~> ~h** 

**~~**

;;?::e

(JQ Ill :::t a... o·

00 )'<"

0 ' :::s::

oo> ooo -l· ... ,. ·'\. ... - ])ry Gas Meter 5-Point Full Test J\lleter Box ID Gas Meter- Number Calibrated By M13 ·==:J 1-l --t7-4-s6-t-Vc=J. **~· G~.;.J!rrd**  ] Ca'libration Date Barometric Pressure. . 9/19/2012 29.45.

Orifice ID Orifice Coefficient K' Ambient Temperature Vacuum (2:14.1" Hg) Delta

H · Initial Volume Ft 3 Final Volume Fe Total (2:5

**Ft~** Initial

DGM Temperature °F Final DGM Temperature "F Average Temperature "F

. Time

Minutes TimeSewnds DeltaH@ Gamma(Y) Average Gamma (Y) Delta H@ tolerance .,iT .. ·RC····._·.··. ;Y>.". • Pass Pass Orifice Set

**Cali~i-ation** Date Gamma(¥) DeltaH@ Pass . l/3li2012 E . . 0 i:;;;--j
QA/ QC Check: Sign and Date. **--L2e~H** 10-.04-12.

··.,·,. • 0. -'\,.

**·-~** -> g:h ""0

-> **~~ ~~**  Q'\ n· """" 0 ' **~~** oo> ""n -Jl ____

_ [ ___ _ L__ L____ L____ L_______ L_______ **--~'** L___j ---

___ i .....
Dry Gas Meter Temperature Display Calibration·

·' .. · Meter Box ID

. ·- M18 ··Reference Calibrator.

- Omega-CL23A

Date

·· 9/19/2_012 ' · Serial Nu:inbet

· T-235647 Calibrated

By

· **j.}~** Byrd J . Reference .Calibratimi Date

. ·. 8/23/2012

' Input-Temperature··

1 - Channel temperatures must agree with+/- 5 °F or 3 °C

2 - Acceptable temperature difference is less than 1.5 % **~ ~·**  -C . . . - Temperature **Re~ding** from Individuai Thermocouple Input 1 Dry Gas Meter Thermocouple Calibration 3 Reference Thermometer
73 74 Pass . .

3 -- Dry !1f!S. meter thermicouple is compared to an ASTM typfl mercury in glass

**referen~ th~ometer**  **.ae~u-_**

.· .... · . . .. ·.10-04:..12.

QA I qc Check: Sign and Date -, ..... ·---' **~>** "'t- **~8 ~>**  **;;?~** ":3. -Jo 0;>.-" 0 ' ...,3:: ;;;;> ""o

>-j. Meter Box ID Gas Meter Number Calibrated By Orifice ID Orifice Coefficient K' Ambient Temperature Vacuum (:::14.1" Hg) Delta H Initial Volume Ft 3 Final Volume Ft 3 Total (2:5 Fe) Initial DGM Temperature °F Final DGM Temperature oy Average Temperature °F Time Minutes Time Seconds DeltaH@ Gamma (Y) Average Gamma (Y) Delta H@ tolerance nry Gas lVleter 5-Point Full Test **--6-Rr:-;9 2~-=~..**  . . .. L..----· -"._T_. **~** Calibration Date

..

Barometric Pressure Orifice Set Calibration Date GammaOO ileltaH@. 7{20!2012 29A7 ·· l/3lf20U ' . I 0.9949 I 1.796 ... **~**

QA /QC Check: Sign and Date C2e)-.U. 07-31-12 -> "'l- "'n **~0**

**~>** "' :€ **~ ~**  -::!. -:!() -,.-

0 • **~;s:** oo;>

oon

-l;__

-- -··- L-----·- L__ __ '---------- ''---.-----' L.__:

__ L--__J ._. __ , **~** : '

. ··: Dry Gas .Meter Te.ll,lperatur1e Display Calibration Meter Box.ID Date Calibrated By Input Temperature

· M11 7/20/2012 **T~** Mills

1 '- qtannel temperatures must agree with +/- 5 °F or 3 °C

2 - Acceptable temperature difference is less than 1.5 % T'RC,··· **R~ference Caiibtat~~**  .•· Serial

Nuniber Reference Calibration Date. **Te~perature** Reading

**fr~m** In.fividual

**Th,ennoc~upie** Iuput 1 Dr!r Gas Meter Thermocouple Calibration 3 !Reference Thermometer
71 73 . Omega-'CL23A T-235647 9/1/2011 Pass ....

3 '-"Dry gas meter therinicouple is compared to. an ASTM type mercury in glass reference thermometer

. - .

'•.' <).A I QC

**Chec~:** Sign and Date **W1~.~···** 07-31-12

'·' ·,;

. 1. **~;> ~?=;**  **~0 ~>-**  **;;?~** """' **~** 3. _,(')

N ,_.. 0 ' ....,:;;:: ;x;>- 00() '-lTHERMOCOUPLE CALIBRATION DATA. FORM THERMOCOUPLE ID: · **----~-------~~** RT-3L PITOT or PROBE 10: ·. RP-3L **--~-------------** 3-POINT CALIBRATION Reference · Reference Calibrated Source **Referenc~** Th_ennocouple Percent (specify)

' Error (i;.

Date Tf1ermometer lD

. CafibDate By;. Temp, °F T_emp, °F ·. Ambient

74 ... 74 :o.o

: 08/05/09 3P0095 01/13/09 ·J. Lowe Ice Bath 34 -- 34 0.0 l-icit Bath

. 205.

.. 205 o.o

\ EPA.APPROVED AL TER.NATIVE METHOD. (Aif- 011) SINGLE POINT CALIBRATION Reference ··Reference **~ibl"atecJ** Reference Date Thennometer ID

. Calib Date By Temp, "F (2J 07/30/10

3P0095 01/0B/10 ffi!iJW 73 01/05!11 3P0095 01/08/10 G. Connelly 73 09/29!11 6505 01/1 0{11 M. Brooks 74 01/09/12 3P0095 01/10/11 ·J. Evans .74 03/19/12 3P0095 01/10/11 D. Brewster 74 . ,

. . . .

. . . . .

1) %,error = {Thermocouple Temperature+ 460)

**~(Reference** TernpeJ?ture + 460) x 10.9 Reference

Teniperoture + 460 Thermocouple · Dif'ference C 3 J Conunuiiy Temp, "F · (within ± 2

o FJ check

**f~J** 72 .. -1 Good

.. 72 . -1 ·Good 73 -1 Good 74 0 ·Good 74 0 Good
··.·

.. **~** . .. .. should be < 1.5'*'' **---~-------_.·T·RC···.**

**~** .. . ' .

.

. . . **~-'.·** ·, r .... f.fanf!e,.,.

**~** Reviewed ·.Heat'-250F By

. N!A· C. Fink

.. .. Pass/ Reviewed Fail By Pass• · C.Rnk Pass. C.Rnk

· Pass• C. Fink

. 'Pass .. C.Rrik

. Pass C. Fink

' ,r •.

.. . • r . .. . .

.. . '

2) Reference Thermometer is mercury-in-glass and ASnA. certified, unless otherwise

**noted~** . . . .

3) After each test run series,

**ell~:** !he

**accu~cy ~f**  each thennocpuple

**~yatem** at ambient temperature. The tempemh.Jres of the ifterrriocoi.Jple arid

**~Ference'·toormometers** shall

**~gree ~ithin.:!:**  2°F

4)

The continuity check involves subjecting the tip ·of the thermocouple to a change. In temperature to check for ciirrips, lf?OSE! eonnectlor'IS, or reve..red connections. Thermocoui:J!e5 With crimps

and loose connections will not immediate!¥ respond to tempeiaWre changes, ari1:1 those Wtlh reversed conn?ctlons WID show a temper:ature change In tha qpposite t:firectlon.

RAL- TC CAL.XLS \. I I -;.... **~~ ~0**  -> **~:>=** ""

- ::. **~t** -..lo w ,;- 0

' ...,s: c;;

)'> =o -l. 

# }

. 

# J J

I 

# I

: I ALCOA Warrick- MACT 195691 Page 174 ofl88 :'1. . 'j .• - ·.-· •• , 

# TEMPERATURE'CAUBRATlON DATA FORM 

# 'TRC 

# C . - - ' 

### THERMOCOUPLE ID:· RT-2D

**~ --------~----**  

### PITOT 

### or PROBE ID: • 

### RP-2D **-.-+-----~-**

.. .. 

### 3--POINT CALIBRATION Calibrated 

### ·Source .Reference· Probe· Percent . Mantle Reviewed, 

### Dste• 

### By **.(~_pffy)** 

### Temp, °F 

### Tem_p, °F · 

### E"or (1 ) . Heat-250 F 

## By: Ambient Air 66.0 

## s6.o 0.00 04to1Ja3· 

### .. J. Lowe. Ice Bath 32.5 

### 34.9 0.49 

### NA :.··.· ' 

### C. Fink··
.. 

### Boiling Water 212.0 212:0. 0.00



### . Ambient Air 68.0 

### 69.0. 0.19 ' 

### 01i03/05 

### ·· J. Lowe Ice Bath 33.0. 32.0 -0.20 

### NA C. Fink Belling Water 212.0 210.0 

### -0.30 Ambient Air 78.0 76.8 -0.22 11/17/08 

### G. Gilbert 

### Ice Bath .32.0' 

### 34.3 0.47 

### NA C. Fink


### ... Balling Water . 212.0. .. 214.0,. 0.30
. ' 

### .... . 

### .



### EPAAPPROVED ALTERNATIVE METHOD (Ait • 011) SINGLE POINT CALIBRATION

Calibrated Reference 

### Thermocouple Difference <JJ Contlnulty 

### Pass! Reviewed Date 

### By Temp, 

### oF 121 · 

### Temp, 

### °F (within 

### ± 2

## °F) Check (4J 

### Fall· · 

### By 12/04/03 

### J. Lowe 70 71 

### 1 Good Pass C. Fink 01/09/06 

### J. Lowe 72 73 

### 1 Good Pass C. Fink 01/22/08 

### J. Lowe 76 77 1 

### Good Pass C. Fink 04/11/08 

### .D. Brewster 72 73 1 

### Good Pass C. Fink 01/05/09 

### J. Lowe. 76 75 -1 

### Good Pass C. Firik. 04/19/10 

### J;Evans 75 74 -1 

### Good Pass C. Fink 01/04/11 G. Connelly 73 73 0 

### Good Pass C. Fink 01/09/12 

### S.. Kennedy 74 72 -2 

### Good Pass 

# c. Fink·

### '
1) %error= (Thermocouple Temperature+ 460) ·(Reference Temperature+ 460) x 100, · should be< 1.5% Reference Temperature+ 460 2) Reference Thermometer is mercury-In-glass and ASTM certified, unless otherwise noted. 3) After each test run series, check the accuracy (and, hence, the **calibra~on)** of each thermocouple system at ambient temperature.

The temperatures of the thermocouple and reference thermometers shall agree within± 2°F 4) The continuity check Involves subjecting the tip of the thermocouple to a change In temperature to check for crimps, loose

connections, or reversed connections. Thermocouples with crimps and loose connections will not immediately respond to temperature changes, and ihose with reversed connections will show atemperature change In the opposite direction. RAL-TC CAL.XLS : -!

# TEMPERATURE CALIBRATION DATA 

# FORM ALCOA Warrick - MACT 195691 Puge 175 ofl88 

# CTRC THERMOCOU.PLE ID: RT-3G • _____ ...,:of;___ 

### PITOT or 

### PROBE 10:

**.~P-3G** _..__;::...,__ 

# ____
.... 

## 3-POr.NT CALIBRATION c;;allbrated Source Reference 

## ·Probe Percent 

### Mantle .Reviewed ··: Date 

## By (specify) 

### Temp, 

### °F Temp, °F 

### Error (tJ 

### Heat-250 F By .. 

### ·. Ambient Air 

### 71.0 

### 71.6 0.11 -··. 

### 04/01/03 

### . J,. Lowe : fee Bath 

### 35.0. 

## .· 35.0 0.00 NA 

## C. Fink Bolling Water ., 

### 212.0 211.0 -0.15

.

**··~**

- ... 

## EPA:APPROVE.D ALTERNATIVE METHOD (Ait· 011) SINGLE POINT CALIBRATiON · . ..



### .·Calibrated Reference Thermocouple 

### Difference (3J 

### Continuity Pass! Date By 

### Temp, 

### °F ( 2

### J· 

### ]emp, 

### °F (within 

### :!: 2°

# F) · Check < 4

### 1 · " r 

### Fail · 

### 12/04/03 J. Lowe 

### 71 72 1 Good 

### · ·Pass 

### 01/13/05 J. Lowe 

### 72 72 0 

### Good Pass. 

### 01/09/06 J. Lowe 73 

### 73 

### 0 Good Pass 

### 06/07/06 MP Riley 71 

### 71 

### 0 Good Pass 

### 12/13/06 

### J. Kunstling 70 71 

### 1 Good Pass 

### 01/23/08 J.Lowe 79 

### 79 .0 .. 

### Good Pass 

### 01/23/08 

### J. Lowe 

### 76 75 -1 

### Good ·Pass 

### 01/05/11 G. Connelly 73 

## 72 

# I -1 Good Pass 01/09/12 

### J. Evans 

### 74 75 1 Good 

### ··:Pass ... . .

,.



### . 

### . . ...

.. 

## .. .. 

### . .. .. ... 1.) %error= (Thermocouple Temperature+ 460)- (Reference Temperature+ 460) x 100, should be< 1.5% Reference Temperature+ 460 2)' Re.ference Thermometer Is mercury-In-glass and ASTM certified, unless otherwise noted. 3) After each test run series, check the accuracy (and, hence, the calibration) of each thermocouple system at ambient temperature.

The temperatures of the thermocouple and reference thermometers shall agree within +2"F 4) The continuity check Involves subjecting the tip of the thermocouple to a change in temperature to check for crimps, loose

connections, or reversed connections. Thermocouples with crimps end loose connections 

### wHI not immediately respond to temperature changes, and those with reversed connections will show a temperature change in the opposite direction. RAL-TC CAL.XLS 

### Reviewed.
. By 

### C. Fink C. Fink C. Fink
. C. Fink·

C. Fink C. Fink C. Fink C. Fink 

# c. Fink· '

I . I ' I 

### 1':

# l

-I1 

# J 

# ]

1 _J 

# j 

# j
I

J 

### I

**~** 

# Pitot TubeInspection Sheet Pitot Number: Alcoa- APT-4A


## .In.spection Date: 01/03/2012 ALCOA Warrick- MACT 195691 Page 176 of188 

## Calibrated

## By: _______ **J~**



### .

## .=.Lo.;;.w;.;..;e:....:.,;,;..____ ,.
.Reviewed 

## By: **-------=-J...;:S;.:e~m:..:.e;;;;.·_.;.**

## ____" Pitot 

### Type: Detachable Tip 1· 

### X · I 

### Fixed L..-1 _ ___,j 

### PMlO 

# ._I·_ ___.l Wind Tunnel 

### Calibration? 

### Diagram 1.



# oft~



# ~ **/~** Degree irnlloatlng level posltlon for determining n 1·and "'2. 

### Diagram 

## 2 Degree Indicating level position for determining 

### P 1 and P2· Degree indicaiing level position ior determining 

### r then calculate ;z.



# ~~ **~---** 

## -~~--<2 

# . t/ · Degree lndicirtlng level position for

determining 

### ethen calculate w. 

# NoW YesCJ·===--- 

### Coefficient: A sidec=l Bsidec=l Level? ·YES· 

### Obstructions? 

## NO Damaged? 

## NO DiagramJ -10° < a.1

# < +io6·,; 

### 0 

### -10° < a.2 

### <+10° = 0

.. 

### Diagram2 -So<Pt <+5o=. 0 

### -sa < P2 < +5o"'" 0 

### Diagram3 r= 0 8= 

### 0 

## A= 0.550 P

8 

### =Pli=A/2= 0.275 

## OJ 88"::: D 1 ::: 

### 0.375'' = 

### 0.255 1.05 0 1 

### < A/2 < l.5 

### D1

# = YES 

## z=A tan 'Y 

### < 

### 0.125" = 

### 0;0000 

## w=A tan

# e < 

### o.03125"''"" 0.0000 

## w and z

### meet 

### specs? YES 

### Comments: Installed onAlcoa Probe - 4A Stainless 4 ft Effective Probe for 

### In-Stack Filter 

### The pitot tube/probe meets or exceeds all specifications criteria and/or applicable design features and is hereby assignee apitot tube coefficient factor of0. 84, unless a specific wind tunnel calibration coefficientbas been determined. 40 CFR 60, Appendix A, Method 2. Verify the minimum 3/4 inch 

### separation between the pitot tube and the nozzle and minimum 2 inch 

### setback ofthe thennocouple (or 3/4" separation) 

### in the assembled probe.**~-** -----**-~- ~--** **~---~ ---~--------~-~-~-~---~--** **-----~--- -~----** **---·------·----·-~------** 

# ·Pitot Tube Inspection_ Sheet Probe Configuration ALCOA Warrick - MACT · 195691 Page 177 of 188 

### Pitot Number:. __ : .:...:Al=..:c:..=o=-{:.-=A"-=P:....;T:...-4..:.:·

### A~.______ 

## ··calibrated 

## By:**---~J.~Lo____;w_e_~--** 

## 01/03/2012 Reviewed 

## By: ...;._.__**J_S_e_m_e:.___~** 

## .**Insp~tion** 

## Date: A. 

## B. 

# c. D.

.

## Specific~tlons (EPA Method 2) 

### Dt = 

### 3/16" to 3/8" Dn=.l/2"· Pa=Pb..

## - 

## .·Dt=i 0.255 

# 'Dn=l 0.500 

# a=l 0.875



### .. Pa 

# =I 0.275



# -- Pb=i 0.275 

# b=l 1.375 

# c=l 4.000 

# d=l 5.250 

# e=l 2.125 

## OR 

# c=l NA

a ?; 

### 3/4" c 

# ;:::3" d 

## 2: 3 11 

### e

## 2: 3/4" f 

## 2: 2" 

### 1.05 Dt.::S P.::; 1.50 Dt b 

## 2: 0 jDOES PITOT CONFIGURATION lV.LEET SPECIFICATIONS? YES .

# .

# "j



# ] 

# J ·.1 

### J 

# J j 

# J j J

I I -' 

# Pitot Tube Inspection Sheet ALCOA Warrick- MACT 195691 Page 178 of188



### .1~



# '"~ . . . 

### - 

## PitotNumber: 

## ...,...,..__ **~RP::....:.:..T-4~R**

## ___.·.Calibrated 

## By: ___,..___ **....;S;;;.;.·~K==e~nn::.:e4:.::;:· :~...Y·** 



## ___ _ Bl/03/2012 Reviewed 

## By: ___,.-.-.----.,...-c.;.. . 

## ....;Fi~n.;..;.k·_;_·------- 

## Inspection Date: PitotType: Detachable Tip 

# I · X- 

# Fixed_~-'·-----~' ·Wind Tunnel Calibration? 

## Diagram 1



# -~"'a.1' I I ...

**~**

**~** 

## /

. Degree 

### lridlca1lng't~wil-'posltion · 

### · · ·tor de!ilrmlnlng "1 and !X.2. 

## Diagram 2 Degree Indicating level pOsition - for determining jl 1 and

**p~.** 

# NoQJ

. ·Diagram 3



# -~a-*~:

# _____# z 

# ~r,__..<: 1' . 

# fiA==.

**~** Degree indicating ievel position for determining r then calculate z.

·. Degrae Indicating level posftlon for -' determining 9 then calculate w. 

### Comments: . _Installed on Probe RP-2D (2253) . Yes ._l __ -1 

## ===*"- Level? Obstructions? Damaged? 

### Diagram 1 -10° < UJ 

### < +10°= -10°< 

## a2 

### <+10°= 

### Diagram 2 -S 0 

### <P1 <+5"= -so< 

# P2 <+so,.. 

### Diagram3 ·• 

### y= 

## ®= A= 

### Pa = 

### Pb = **AJ2~** 

### 0.188" 

### :SD1

### :S 0.375" 

## = 1.05 Dt< Al2 

## < 1.5 

### Dt = 

### z =A tan y< 0.125" =· 

### w 

### =A tan 

# e <0.03125""" w 

### and z meet specs? -YES-· NO. NO

·- 

### ·' ' - ..

### 0 

### 0 -2 '

**~2**
; 

### 0 0 '0.838 .. 

## ... 0.419 0.375 YES 0.0000 0.0000



## YES The pitot tube/probe meets or exceeds all specifications criteria and/or applicable design features and is hereby assigned apitot tube coefficient factor of0.84, unless a specific wind tunnel calibration coefficient has been detennined. 40 CFR 60, Appendix 

### A, Method 2. VerifY the minilnum 3/4 inch separation between the pitot tube 

### and the nozzle and minimum 2 inch setback ofthe thennocouple (or 3/4" separation) 

### in the assembled probe.

**·~~--~-- .~~---~-··----------------·---~----** 

## • 

# Pitot Tube Inspection Sheet Probe Configuration ALCOA Warrick· MACT 195691 Pugc 179 ofl88 

# .0TRq**~** 

## Pitot Number: ·**RPT~4R .Calibrate~**  

## By: S. 

## Kennedy Inspection

## bat~: A. 8.' 

# c. D.**--~----~----~~ -----~----~-----**  

## . 01/03/2012 ReviewedBy: ___,.__ 

## ._C_._F_in_k_.__ __

OR Speclflcations (EPA Method 2) 

### Dt = 

### 3/16" to.3/8" 

### Dn=l/2" 

## Pa=Pb 

## Dt""l 0.375 

## Dn 

## -=1 0.500



## a=l 1.125 Pa

# =t 0.419-. 

# Pb=l 0.419

b

# =I 0.500 c

# =I 4.375 

# d

# =I 1o.ooo e 

# =l 1.250 OR 

## c=l f=l


## a 2: 3/4" ..c 

### .2:3" 

### .d 

## 2: 3" e.2: 3/4n f 

## 2: 2" 1.05 Dt 

## :S P

### :S 1.50 Dt b .2: 0 jDOES PITOT CONFIGURATION MEET SPECIFICATIONS? YES ··.. 

### ·. ·-

# l I



## ~1

I 

# ·J

I .J 

## I 

# J 

# I l 

# .I I J I i 

## J 

# J !· ! 

# Pitot Tube Inspection 

# Sheet Pitot Number: 

## RPT-79 

# . Inspection Date: 01/03/2012 ALCOA Warrick- MACT 195691 Page 180 of 188 

# c Calibrated 

## By: .l:..'____ 

### ..;;;:s.:....;.-K=.::::enn:::::-::-e:::dy!.-~-"'---'-- 

### Reviewed 

## By: " ______ C;;;...';...F...:i.:..:n.:..:k_·----'-'- 

### l?itot Type: Detachable Tip 

# I X 

### Fixed ._I ----J 

### PMl0



# ~--~_ ___. Wind Tunnel Calibration? Diagram 1 ·


# .


# ~- "a;

.

. <I:! 

## / Degree inaic:atlng level position foraetermlnlng a,·and·az. ·• •· 

## Diagram2 Degree Indicating level poslllon for determining J3 1 and 

### Jl:!. 

# No[D

Diagram3 

# --o-



# \t~i_

# ____**~-** z



# ~r+-,t---.< 1'



# ~rA·~ Degree Indicating level posiUon for determining r then c:elculate z. Degree Jndlc:etlng level pcsmon for determining· 9 then calculate w. 

### Comments: Installed on MS probe RP-3L 

## TC: RT-3L Yes L-1 _....J 

# =='==,... Coefficient: 

### A sidec=J. ·
. Bsidec=J Level? YES· 

### Obstructions? 

# NO Damaged? NO ·.' 

### Diagram 1 .. ''. .·' 

### . ·' 

### -10° < 0.1 

### < +10° = 0
. -10° 

# <a.z < +10° = 0 Diagram2 

## -50 < 

## f3t < +50 = 

### 0 -50 <

## f32 <+50·= 0 Diagram3 

## y= 0 E)=: 

### 0 A=. 

### 0.927 P

8 

### =P0

### =A/2= 

# .. 0.464 0.188"

**~D**



### 1 **~** 

## 0.375 11 = 

### 0.375 1.05 Dt

### < A/2 < 1.5 D 1

### = 

### YES z =A 

### tan 'Y 

### < 0.125" 

# = 0.0000 

### w =A 

### tan 

# e < 0.03125" .:=. 

### ,· 0.0000 

### w and z meet specs? YES The pitot tube/probe meets or exceeds all specifications criteria and/or applicable design features 

### and is hereby assigned apitot tube coefficient factor of0.84, unless a specific Wind tunnel calibration coefficient has 

### been determined.. 40 CFR 60, Appendix A, Method 2. Verify the minimum 3/4 inch separation between the pitot tube and the nozzle 

### and minimum 2 inch setback ofthe thennocouple (or 3/4" separation) in the assembled probe.: ·, 

# Pitot Tube Inspection Sheet Probe Configuration· PitotNumber: . RPT-79 Inspection Date: 01/03/2012 A. 

## B. 

# c. OR 

## D. ALCOA Warrick - MACT 195691 Pnge 181 of188 

# C"fRC Calibrated By: 

## ·---s~·...;;:K=enn::=.::ed~y:....____:_ Reviewed By: . ____ C_._F_r:..:...;·n:..:...;k....._ __



### . 

# Dt=l 0.375

- 

# Dn=l 0.500 

# a=r 1.250

. . .

**~·**



### p~_=r 

### 0.464
, .. 

# Pb=l 0.464 

# b=l 0.375 

# c=l 4.625 

# d=l 5.000 

# e=l 1.625 

## OR 

# c=l f=l Specifreations (EPA Method 2) Dt = 

### 3/16" to 

### 3/8" Dn= 

## 112" 

## a ;::3/4" b 

## 2: 0 c 

### 2: 3" 

## d 2: 

## 3" e 

## 2: 3/4" f 

## 2: 2" Pa=Pb 

### 1.05

**Dt~** 

### P

**~** 

### 1.50 Dt jDOES PITOT CONFIGURATION MEET SPECIFICATIONS? 

### YES I 

### . I---1 I 

## ! 

# l I I 

# J

**~--·** 

# 1· 

# -J 

# j" 

# l _j

' ....J 

# J 

# J _j 

# J J

.J ALCOA Warrick- MACT 195691 Page 182 of188 

# STAINLESS STEEL NOZZLE CALffiRATION 

# . Date: 6n4/2012 

## Calibrated_By _ 

## S. Kennedy Nozzle BoxJD B Nozzle Type: Stainless; Nozzle Identification 

## Dl, inches D2, inches D3, :inches D, 

## inches __ Average Nuni.ber- ·. · 3B · .0.096 0.096 0.097 0.001 0.096 .. 4B 0.117 0.116 0.118· 0.002 0.117 

## SB 0.155 0.155 ... . 0.156 0.001 ·o.1ss 6B 0.176 . 0.177 0.176 0.001 0.176 . 7B .. 

## 0.225 0.226 0.225. _0.001 0.225 -· 8B 0.243 0.241 0.243 0.002 .0.242. 9B-1 0.273 0.272 .. 

## 0.274 0.002 0.273 lOB 0.316 0.315 0.316 0.001 0.316 llB-1 0.328 0.327 0.329 0.002 0.328

1.2.B 

## 0,368 0.367 0.369 0.002 n

**~t;lfi!** v...rvu 

## 13B-1 0.402 0.403 0.402 0.001 0.402

14B 0.439 0.440 0.439 0.001 0.439 15B-1 0.462 0.461 0.462 0.001 0.462

16B 0.496 0.497 0.498 0.002 0.497 24B ____________ _0.756 .. 0.758 0.757 0.002 0.757.

-- 

# Dl, D2, D3 =Nozzle diameter measured different diameter. Tolerance= 0.001 in: D =Maximum difference in 

## any two measurements. Tolerence 

# =0.004 in. 

## Average =Average

# ofD 1, D2, and D3.



# ~TRC

**~** --_ALCOA Warrick - MACT 195691 Page 183 of 188 

# STAINLESS STEEL NOZZLE CALIBRATION Date: 8/13/2012 Calibrated By 

## Richey Lowe · Nozzle Box ID · F · Nozzle Type: Stainless · ' . ,. 

## Nozzle ,, 

## Identification D1, inches D2, inches D3, inches D, inches Average Number ' . 

### . ' 

## 3F 0.129 0.127 0.128 0.002 0:.128 

## 4F 0.186 0.184 0.186 0.002 0.185 

# SF 0.212 0.210 0.209 0.003 0.210 

## 6F"l 0.239 0.236 0.237 0.003

**0.~37** .. 

## 7F"l 0.247 0.247 . 0.2.45 ·o.oo2

**0~~46**



## 8F 0.293 . 0.294 0.297 0.004

**0~295.** 

# 9F 0.298 0.298 0.300 0.002 0.299 

## lOF 0.360 0.362 0.363 0.003 0.362 

## llF 0.373 0.376 0.375 0.003

**0.37~** 

## 12F 0.402 0.400 0.403 0.003 0.402 

## 13F 0.435 0.434 0.435 0.001 0.435 

## 14F 0.431 0.434 0.432 0.003 0.432 

## 15F 0.488 0.488 0.489 0.001 0.488

**l~F** 

## 0.512 0.510 0.510 0.002 0.511·:' 

## 17F 0.625 0.622 0.625 0.003 0.624 Dl, D2, D3 =Nozzle diameter measured different
**cliameter~** 

## Tolerance= 

## 0.001 'in.

. . . 

## D =Maximum difference in 

## any two measurements. Tolerence= 0.004 in. Average= Average ofDl, D2, and D3. 

# TRC TRC Environmental Corporation .:·.iL

\.____ L____ L____ L.:_____

**~** :L____: TRC Raleigh, NC Glass

Nozzle Master List 11/2/2012 JRL Size Nominal Nominal Nozzle Designation

Diameter Diameter Iqentification · Date (Decimal

In.) {Fraction Jn.) Number Calibrated

5

0.250 1/4 G'-5-55 7/30/2007

5

0.250 1/4 G-5-73 6/1612008

5

0.250 1/4

.. G-5-76x 3/3/2011
.. **~.-::** (09-05-12) Glass Master for printing ! : c__· L______; Calibrated By JRL
. CWA CA L____ Dl,inches 0.261 0.254 0.260 . ·, **~** L..______j

**~** D2,inches D3,inches ,i•

•.. 0.259 0.260 .0.254 0.254 0.260 :0.260

\ ,I **~**

**-~~ -~--------**  ·----· **----~-~- -~---·---------------~** 

--------··- ____ ,. _ __ ; **~·--'** _,_j

.. " Nozzle I ·n,inches

Diameter (average) 0.002 0.260 0.000 0.254 0.000 0.260 .. " 11/2/2012 ___ I -> g:h **~~ ;;,o~**  (lO "' :::< oo

o· ... "'" 0

' **~3:::** OO;l> coo '-l