TRC 

Results you can rely on 

.. 

Anode Bake Furnace POM Test Program 

Report Certification 

ALCOA Warrick- MACT 

195691 Page 2 of 188 

I certify that to 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 approved protocol 

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{.--:J a ·- I ?...-

Date 

TRC. w_as operating in confonnanoe with the. requirements of ASTM. D7036-04 during 

this test program. · 

Jeffrey ~!W~:l . 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 of lbs/ton of green 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 of PM 

. ' 

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 of green anode .. The combined POM emission rate· 

for the A-446 Reactors was 0.0508 lb/ton of green 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 of Green Anode· Emission Rate of PM 

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 .1

1 

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 of Green 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 of Green Ancide 

Green Anode Throughput . 

Reactor PM Emission Rate . 

Emission Rate of PM 

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. of Gmm Anode Emission Rate ofPOM · 0.0269 0.0268 0.0161 0.0233 

. _____ ..:___.:__ ___________________________________________________ .:__..:_· _____ j __ ~--~..:...;;. ____ _ 

tonslhr 

lblhr 

lbs/ton of Green Anode 

lblhr 

lbs/torr of Green. 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 baking furnace are drawn into the refractory flues 

and exhausted to the common _control equipment through a series of ducts. 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 of time. 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 of the 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 of the 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 of the 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 I 3 of 1 88 

The anoqe bake furnace primary system consists of a single dry alumina scrubber control device 

with tbr~ (3) reactor sections or compartments. Two compartments (Reactor No. 1 and Reactor 

No.2) ..,.. 

9n,ei;~ . . ·~P~ ,._, 

~ode furnace control device have three stacks and one compartment (R.eactofNo.' . .. 

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. 1 BlJ.d three stacks fofReactorNo. +and ·o:ti~ stack for React~rNo. 3. · The stacks 

for Reactor No. 1 and Reactor No. 2 are identicaL These vertical stacks have an 'internal 

diameter of 26:25-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 of the 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- Warrick Operations 

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 of the 

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 of Particulate 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 a Method 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-half which consisted of four :impingets. 

The first two impingers each contained 1 00-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 of the test run and following the post-test leak check, the filter was ¥emoved 

from·the filter holder and placed in a glass sainple jar 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 of watei 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 sample jar. Following the acetone rinses 

the front half of the 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 of quality data in all of its sampling work regardless of the scope and purpose of the 

testing. These considerations include: 

• Planning the testing progr~; 

• Use of reliable and·we11-rriamtained equipment; 

• Use of appropriate forms for recording sampling data; 

• Establishing a sample coding system to ensure proper chain of custody (i.e., sample 

identification, laboratory tracing 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 of EPA Method 2: Pi tot 

tubes were visually inspected prior to and at the completion ofthe test 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 in Figure 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 of the metering system calibration is included in Appendix C of the 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 of this 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 against temperature 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 by introducing a series of millivolt signal strengths.to the input and. · 

·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 of its 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 of Agricultural 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 of each "sample log" or chain of custody 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 by TRC. 

-, 

I 

---- -- ~---- ----~-- ---- - ------ -- ------·-- -··------- ·-·----·-· ------------ -··-----~---·-· -~

---·---------------------------------
ALCOA Warrick- MACT 

19569 I Page 23 of 188 

Alcoa- Warrick Operations 

Newburgh,.. IN 

·" 

SECTION6.0 

CALCULATION OF RESULTS " 

Emission rates in terms of pounds 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 of dry stand~d cubic feet per rcinute, . . . . . 

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 of pounds 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 

(Del taB) Avg Delta H, inches Hi> 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 H20· .. · -0.26 ..(),28 

(Ts) Avg Stack Temp, 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 

(Del taP) Avg Sqrt DeltaP, (inches H20)Y,_ 0.816 0.803 

(Theta) Sample Time, min 144 144 

(Dn) Nozzle Diameter, 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) Molecular Weight-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 

P ARTlCVLATE 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 m3 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 m3 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 H20 

Barometric Pres~··re, inches Hg 

Meier Volume, fr 

AvgMeterTemp, degF 

Static Pressure, inches H20 

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) Pry Mole 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 m3 

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 m3 

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~@3 
1 . I 

i 

i 

I 

I 

I 

.I 

I .. I 

'·.: .. ·'•' 

.. :_. 

'.·· '!'. ·, ' .. , 

J 

I 

.J 

. I 

I 

J 

.I 

J 

J 

l 

J 

I 

_j 

.J 

METHOD 1 WORKSHEET 

Summary of Location Setup 

. GOMPANYNAME: .· ·.· ·.•· 

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

. · · · ·sAMPLING LOCATiON:·. 

.Circumference 

· ·. Far Wall to Outside of Port 

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.· 

.. I 
L 

___ 

---- 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 .g~ 1J. 9.000 7.1 ... 1J ~.000 TD "' 71 12 73 

,. 0.000 74 0.000 74 0.000 

7S 0.000 " 0.000 " 0.000 .76 O.oo6 76 D.~ "' 0.000 77 o.OOo 77 0.000 77 o.cmo 

70 0.000 "' .. 0.000 70 0.000 79 MOO 79 0.000 79 ·o.ooo 

80 Moo "' 0.000 80 o.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 I .IJIS I L5ll I 171 

1.>11 l ·L .. 1 .... 

.... ,·. :LJ! 3 LT.5 

uo • 1Al ., .,. 

' 171 3 177 

• 177 , ... s L6 5 us 

, ... • .: .. • 1.11) ' 1-.; 6 ,.,. 130 1 l.tfl ' I.SS 7 175 uo '· .... . •· tAt • "' ~,Ill_ ·'· t.SO . 9."/. 130 ·~· ID . LJo 10 .: :. I.J» U9 11 LOS tt . .... 9 10 "' ,;. 11 ,., 

u• 12 em u IW 12 ... 

130 'I) Lll " , ... 1l 17< ,..., 14 .... . .. L!ll .. 177 

.... lS 13 IS • 1.35 lS 177 

us 16 !AI ItS · • Lot! 16 170 '·"' 17 L7t 17; ,..,. 17 m 1.10 10 1.95 lR L71 It ,.,. 

1.20 19 2,11! 19 Ul 19 17! 

'"" 20 1.11 10 1.1! 20 115 09! 21 I.SS 21- .... 21 "' IW 22 ·.US .22 .... ., 172 0.7! 21 .., 2l .. ,. 21 In 

0.<4 " .. ,. " .... 2< 1.10 2S ...• 2S '" ·~ 2S Ill 1.21 ,. .... 20 us ! "' Ill L3l 27 .... 17 1.20 21 111 

L!! " us '21 1.511 2! "' L<S 79 IJO 29 .... ,. ,,, . ... 70 11!1 "' ,,,. JO ,., '·" 31 2.15 ll 1.TD 1.$5 11 .. uo 32 MD ll IIIJ li m 

L!! J) 13S J) un 33 : 1!1 

I. II " 1.10 "' ' IJ4 o.sc '; 35 U2 33 136 34 t?t . 3S ·m 0.73 36 U4 36 1.7h 36 I'M 

Uf 37 1.25 37 ].]5 " liL 1.311 "' , ... "' 1.:10 38 m 1.15 39 1.70 39· uo 

1.41 40 uo ... U5 

39 181 

40 1112 

'·" .. us •• ]~ &I 1112 1-" 42 uo ., 1.75 42 '"' ,.., ., U! 43 1:10 43 lJ3 

us ... ........ .... .. ,., 

Ul .. 1.35' -45 L>t .. lJ3 

U! "' 1.20 •• .... .. 171 IJ! 41 0.9'1 -47 ..... ., ... Ul ... 0,.,_ 4R ..,. .. ,. 

U< .. , .... .. . ..... "' ... !Ill .... so .... "' ... us 51 ,. ,, .... Sl 1<7 1.1! S2 135 .11 L2t S1 "' , ... 51 2Jl! , lA 51 16< 1.!5 54 l.IS .54 1.71 54 106 

.... 5S us 5S 1.71 ss 1<4 

us S6 lA! 56 1 ... S6 , .. 

,.., , l.lt , LlS ., , .. '·" ,. '"' " , ... ,. . ... "' " .... J9 .. .,. 59 '" 1.71 .. .... .. . ... "" 1!7 .... ., , ... 61 .... 61 '" .... G2 1.<!1 62 uo 112 '" 1.1:1 OJ 1.73 OJ Ul 6:1 ... 

uo ... 2.15 .. us "' m .... 65 ·~· ., lJJ ., "'' '"" .. 2.15 .. 1.71 .. 167 , ... ., us ., 1.7! ., lOS (,71 68 '135 ... . ... 

.... ··ll!l i .. n .. :., .... 

1.1! ,. l.H lO I.io 

.. 

.. ·'" , .. 

,. 1<4 

t.fJS. n. '-" 71 o.;.e 11 0.73 72 Ul n ... 12 "' "" 1J 1J 73 74 74 74 

15 1S 1! 

76 76 76 

" n· 77 78· 11!. 7! 

79 79 79 

so so ' .. .. 

i__lli. L....ML ~ L!m. 

. ,-. 

ll[.ur; GAS TEMP 

RI!Nn Rt!Nil 

I '" .I 2 m .. '"

177 

J >B 3 176 

4 "' • ·_t7

s U!l s .,.,

6 "' 6 •17

7 "' 7 _.l'tS • '" • ,.1"7

9 ., .. .. ,,

.10 JfG'. : 10 "

'li , .. 11 

. "" " "' ; ·-ll ·~ " ,,.. ;u I::C

14 'th ... ,,

IS .,., " ,,

16 m 10 L-.T 

IT "' 17 177

It 1)0 18 ,,

19 "" 19 lO . 170. 20 '"

,.,

21 "" 21 17

22 161 22 173 

2) !63 13 1;'1 

:M ... ,. 167 

2S ·~ ,. ·2S 1 .

In ·16 ... 

., 111 n ,., 

21 .llill llJ 181 

, ... 29 J~! :io 117 "' 1.':

" II! " Il

32 :1U 

3J 181 " ll "

I !<

.J.C Jill ·H- "

,. 171 ,. "

J6 li.S' JL'i lit 

31 !Bl J1 179 

38 11!3 Jl .l'i7 

39 111 39 .,ro 

.. lit .. 110 

" Ill " n6 ., IIi . -42 110 

.(! 179 43 Il

.... 178 ... 110 

... 177 4S ItO 

.. 176 .. 111 

.,. '" "' . 175 ... "" "' m ... ,,. <9 '" "' 17! "' tf1 Sl 17! 51 

Sl "

175 S2 J<t

53 ,,. 

54 174 .. " "' .., 

ss "' ss 166 56 174 56 115

51 174 51 '" ,. m ,. ..

59 , .. S9 161 

"' 11511 "' m 61 "" 61 m "' "' ., ..., .. '" ., ..., ... m .. ..., 

., 17< ., 1£7 

·67 "' '" " "" .... ., 10 

.. 174 .. 106 

.. 1.,. <JY . '116

,. !TJ 7(1 1<4 

71 IJ!l ·.7i "' " "" 72 ,., D 73 

,. ,. 

1! 75 

,. 76 

11 7! 

1ll 71 

.79 :19 

.. 110 

·.L.l&. ~ 
< - .. , . .--:_, ~ . ' . 

... 

· .... "' ,· .'·:·-·, 

'·. . . · ... · .. •··, 

Meter Box Post Test Calibration Check 

ALCOA- WARRICK OPERATIONS 

NEWBUR,GH, IN , 

A-446 REACTOR # 1 (Three Stacks) 

. . 

<· 

ALCOA Warrick- MACT 

195691 Page 83 of 188 

: .... 

. . -~. . ,.. . . 

·.•. \:·.::· .· . ~\··.:. .. .· ' c~u~m:ted by: '' 

j.::Pt,Cal" Date: . , Tyler Mills . .. . .: D~lta·I-I ... @ >..· 1 .. .7.9.6 .. · ... . . :, 

· .... 

,. ~:. ··::-· 

.... ~ . . 

: . . . . . 

, ·.I·· 

' 7/~0/2012 Ga:nuna~ initial . 0.9949 

:·' . ., ~ . 

Calculi~ Yqa for eacli te-s~ I1Jri usmg the-folloWing eq~tion: 

' ' =!._. 0.0319 Tm· 29 ( 'i:Ji) 

Yqa H "'/LJ.l1 avg 

V m\/ 11 H (P + 11 ~) 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,, 0R. . , , , . 

· 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 of stack gas, lb/lb-mole. 

dry molecular weight of air, lbllb-mole. 

specific gravity of mercury. 

~ After each test run serie8, do the following: · 

·Average the three or more Yqa's obtained from the test run series and 

· compare this average with the dry gas meter calibration factor,:Y. · 

The ·average Yqa must be within 5 percent ofY. .· . 

If the averageYqa does not meet the +5 percent criterion, recalibrate·tbe 

meter QVer the:full range of orifice settings, as detailed in Section 5.3, 1 of 

_ 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 

l 

,.. 

' --

' : .~· :: 
I 

j . 

I 

I 

) 

l· 

·I 

I 

I 

I 

.. J 

I 

J 

J 

J 

j 

J 

.... ·.· 

. :· .•. 

·, .. 

. , .. ·· 

.: .. 

"· . ' .· .. . .. · :-, ,._·' 

·.·.:- .. 

. .. ·· .. . . : .. ~: . · ... 

... ···'-t· 

Meter Box Post Test Calibration Check 

ALCOA- W ARRICK()PERATIONS 

NEWBUJ{GH, IN 

.A-446 REAC'f:OR#. l(Three·Stacks) 

·:· .. ·.··· ·':·.· 

. ; : '· . ' .. -~.: ... : .:····· 

ALCOA Warrick- MACT 

I 95691 Page 96 of 188 

' . . ~ . 

.. •· .. 

. :·· . 

. . Calib~t~ib~:· 

5~PtCal pate: 

.·. · TylerMili~. 

7/20/2012 ·. 

DeltaH@ L796 

----=__,;.,..;.,-,... Gatrima, initial 0.9949 --.::..:.;:c::.-:-=-=--

. Cal~ate Y qa for each test run using 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 by dry gas meter, dcf. 

absolute average dry gas meter temp., 0R. 

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 of stack gas, lbllb-mole. 

dry molecular weight of air, lb/lb-mole. · 

· specific gravity of mercury . 

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 of orifice settings, as detailed in Section 5.3 .1 of . 

·Method 5. Then follow ihe procedure in Section 5.3.3 of Method 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 

Meter Box 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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ISOKINETIC FIELD DATA SHEET 

METHOD METHOD 315. POM 

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METHOD 4 .. MOISTURE ANAL YS!S DATA SHEET 

. ,\,· 

Run Number . . . ONE TWO·· .. -. THREE 

Test Date .. " M· Z. 1· t{)l t . in · t ~ · t.tJ ti ·. J~ ·U~ z!J It- - ... ... 

Recovery Date JIJ•"" 'I.·Z.IJI'L JIJ· t ~ ·Uit. JIJ • Z.'l' • %-II ItRecovered By AAi~ . f..!~ :A.tui .. lmpinger 1 Dl Water " 

Final Weight, g V1.7·-f· . ct5~.t.,· . i:i60 ,7 

Initial Weight, g · lt9;/, . '5- -- . •- "'1 -~-ca .. '\ > ·7.S.'i. 5 .. 

· Net weight, g l"f I ;1,. ' l"lt.J.'J . ·z.~z. z.. 

lmpinger 2 DI.Water . . .. .. 

Final Weight; g .. ~(Jf.J --~ 9:tJq.( 7r"ll. 1 .. 

Initial Weight, g , ... u_ ... ~ "'1 . ic./Sf 7 7uf t 

Net weight, g 1~·.1_,1 - l..il.~ ~7 .( 

lmpinger 3 ~ . ' 

Final Weight, g /.~/) ·"L i. 5/ .. .f~ ~'Sl."7 

Initial Weight, g l..lL1 .H... -~'ltL 1. L. 4t.. 'l 

Net weight, g II .i,· . . -. '1 ~"'1 ..· . / . . ii 

lmpinger 4 Silica Gel 

Final Weight, g qv1·.9. .qs-s.u· ttt'l.s 

Initial Weight, g .. .. ..; /', 

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Net weight, g 21'.-z.- . i_q; l '2~ -~ 

lmpinger 5 

Final Weight, g .. "-

-• 

Initial Weight, g · .. --- --

Net weight, g ·· - ·.· --

lmpiriger 6 ' ',r. 

-· Final Weight, g 

Initial Weight, g · A ., 'B.: _(_ .. .. , . 

Net weight, g 

Filter ID # 

Final Weight, g · 

Initial Weight, g 

Net weight, g 

ITotal Catch, g Z.ft.. g z.1;. s 

CheckedBy: A.L~~~ ... Date: /l·t't.·tDIZ. 

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.METHOD 3 • ORSATANALYSIS FIELD DATA 

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·Avg 

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L~ MAn:.mer 

~ nr OA Manaoer \ 

QC Validation 

Fe= (20.9 ~ %02) I %C02 

. Expected Fa Ranges 

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" 

-.. .. ·. 

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SM!rLING LOCATION . 

IA-418 REACTOR I' :o! (38tJ!cb1 I 

CITY AND STATE 

INrnBtJRGH. IN I 

VOLUMEMF.IT.RED 

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RUN~ RUNI2 RUHI!'3 RUNrtl R~ ll'ONIU · llmlft . RUNA- am

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6 :ue JJt.t!1 6 Ll't. ~-~ 6 .u• t.ll.ll) t! 3,77 ' . c.w s :J."fl e 111 e 17!1 .r;· 

!: ~ .. ~:: ! ~= ~::~ : ~:: :::: ! . ~~ ::· -~~--! -~ ;--~-{:.:;: ; .:~; ~ 

' . t:' ::~ . ~:~ . .: i:f . -·::: ~~-- ::: ::~ ... ·1:... ~-= ·.~.: .. ~:~:: ~~.J! .. : ~ i:·.;·:':· /:~:- : .1: ':. ::~~~- ----~: .. : 

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13 IUJ 0.721 13 ~ 0.11i& l::t t,E;f 0.749 .13- JJtt 13 %.0d U 2.nt 13- · :J,.. . J3. .J7J. . 13 

14 0:64 0.800 - 14 . ._.., • ~.82'1 14. t.611 li.JII::Z 14 ~ 14 l!AJ 14 ::z.:!l(J 14 J~ J4 ... ·JM, 14 .>

" 0.11 O.Stl U . MJ. 0.906: IS 0.14 ti.JMI U 1.U H. -~ 1.5 ~ JS tr- JS J74 ·, ts . 

~~ ·.:;; ~; :~ ·t: ~= -:~ :: :;:;.. ~~ ::: :~·- -~---!~-~ ·-~-~ !~- .: --~~ !~ -~;·.·_-. 

:' !:: . -7, t: :: •. ~:-- ~= :: -~::: ~:: ~: ~: ·!_;· ~;: .. :: --~~ ~:- -!: ~~ !~ :-:: 

:m flH ~ Jo o.PIIl 'o.9!10 "2tl IUI8 IIS'!'O 20 3.%J io ; '-33 _?JJ _;,_,. 20 n- 20 ~T~ ZJ 

-21 .. Q.Il. ), 0!111 l1 OJri ,().933 lJ.. • .OJlS .• 11.9ll 21 2JtS 2l·-·. 3.14 lf. 2J!2 %l ~ ·ln .21 -.· 11'.f: 21 :..

~ ~::; -~~~ ~~ ::: . ~:: ;; ::- ::~: -~ .i: :·\ ~ --2~ ;;· '·.~'! ~ !: . ii --~~ ·: 

24 tl9 0.714 14 D.5f - 0.748 lrl-: 057 0.7.55 ~ L7S l4 l.t:5 ·24 ·'-1.M M ,·]6J •. 2-4 ·'173 24 

I ·~ ~= . ·~::. ~ :::: · ~:: ~ :~ ::~ . 2 ~ • ~ -~ i!i ~ :_;:: 2 :: · :: ~ :: ~ • 

~-· ~:: ~= ~: ::;: ~;~ ~ :::: :_:; .;:· ;~ ~ . -~~ -.~ ' !!! ~. ::: ~ ::: ;; 

: !!: !:: : ~: ~= : ::: ~: : ~ :. -~ = ~~: :. :: ;: ~= .-: .

31 U!- 1.072 31 't_e 1.025 :II J.l!J L07l Jl 3.H Jl 3M -~1 3.N '-1- "Q:l Jl 113· 31 

~ :: :~ ;; ~;:· :::: ;; :::: ~: ;; ~ : ~;! :; ~ ~ :: . : -_:: ~~. 

~ :~ ~~;: !; :: ::~~ ~ =~~ ~= ~' i: -~ . ~~ -~; .~ ~:: : . :: ;: _.l· ~:;: ;~ 

~ 1.5!1 0.742 3(1; 0.5P 0.1117 31! •..st o.m ~ 'J.IJ -~. 1.7S Jfi "U9 JG. ·.111 :!-« ·. 'ltll. 3cs. 

~ ::: ::;;; ~ ::: :~:! . : :.: :::~ ~! -~-= ·: '~~ ~;- ·=~ ~! !:! : ~~ -~~:: ._:;!~·· 

.39 e.M 0.'1127 39 •• N ~J127 39 'IJIG O.m JP 1.J5 39 3.(!11 JP !M 3'11' 111 39 -:liZ 'JII• 

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.Q· us 1.012 42 1.15 1.012 ~ 1.15 a.m 4l ,.,. 41· .c-JJ1 42 ,_,., -cz ·ts: 42 'tu ·.,z 

.of.l us t.OT.Z "' 1.e uizs o4J 1.10 1.o49 -e3 2.M -o :iM -o 3.17 -o 111 "' .tn 4l 

44 OJii6' 0.9BD <44 l.fi 0.9RO 44 l.tl 0.954 -C-4 J.:B A.C- .l.l$ 44 .S.lf .f-'1 . llf .(.t ~' « 

45 tUIS 11.9ll 43 IJO 0.911 43 1-N 0.921 .U Ul ·.u l.$10 45 :US . 45 · 1.11 45 . IIi . C5 

4f 0.'11 IU-49 46 1.44 O.!O.D 46 L1c5 O.tn -45 J.41 -'14 J.lJ 46· J:-51 <f5 11& -46 ·• 'Ill +S ~ 

47 o.tiO 0.715· 41 "J.ft. 0;;75 4T ,.· I.&J 0.19-1- 47 J-06 -47 2.t9 -47 %.115 -47 JM 47 •. -•. IN 41 

:: ~ ::~: : .:: ::~: ::. :: ::~;; : -~: ~= :- ~= : ·-~: : -.!:: 

,., Ost 0.%1!1' 'o •m o.7r. 'o ._73 o.u.& .!I~J J:..J.C .:111 :z.1o so ."C'O :so ti:J ·zo no so 

Sl 0.77 0.8"n" H •• '75 O.UIS 51 t.l!8 0.1122. 51 ·%.59 51 :Z~ 51 1112: Sl '113 51 171 ·51: 

51 ~ 0.9-t!:l 5% ••· 0.927 'l A.9lt 0.990 ~2 .J.U s:z .J.oo :52 ~ . n J7-4 s::z ··_nt n 

,;s lUI 0."0 'J . '-94 0.970 ~3 LOS 1.02:5 .!13 1AI .!13 33 '3 . 16(1 !3 174 !I:J '. Ill -.!3 

54 J.l5 t.cn:z .54 Ul UHP 5.f US 1.07) S<l 4.M $4 3.1454 .i.P-C 54 114 54 17154 

" uo 1.095 '' Lts 1.012 ,_, t.2fl 1.99!5 ss oUJ s:J ,._..., t.1:i "' J74 s,_ ·n1 ·.55 

;~ :: ~~~ ~~ :: ~!!~ ;~ ::: ::~ -~ ;: . ~:-- ~ -~ -i: ~ !;:- ~ -~;t ~ 

,_ 11.74 0-360 -51 0.7S ·· O.N5 !I e:n 0.154 58 :Z." :51 2..42 $8 2.J8 SJ '173 3! 111' .51" 

:so f\.15:1 o."" .so u.a o.N-4 5o w.at o.7Jn 3 ,.;J im su ::un so %.09 . 3 50 11'J 5P no. so 

1!0 0.9 11,7fJl 1'111 lt.!la 0.742 GO l.5f 0.7.1! 60 2.01 tiO 111 ISO t.Y.I cMJ 17l tiO l7U 60 

CU ._A D.71S 1SI n.SII ·• 0.762 41 •M 0.800 61 :.~ «'1 2.0 . 51 l.ll 151 173 ~~ 170 . 61 

41 .•.a 0.!~ ~2 P_67 • n.JH9 152 1.11 0.112 152 UT G1 . 134 62. "1..11 61 . -.174 61 170 . 52 

Ill '·"' o.tJ:' 10 0.11' 0,189 OJ .._. ... 0,.!)17 CO l3:J .(13 ·z.n CO UJ G3 -·l14 .:ro; .170 51. 

M 1.3f 0~ tS-4 G.lf 0.927 64 • ~ O.f49 ~ 3.11 04 3.0. cK 3.H 6-1 '174 64 110 6f 

45 ._,. 0.51110 '" o.MI .0.'1190 &S o.JII 0;..995 ~ -M:Z IS 1.-U S5 :tAO 65 115 65 .,. 6$ 

tlc:t 1.15 1.072 6o:S I.JS 1.012 -66 U5 l.OlS 66 ·UI: 16 4.01.615 3-'0 lk' r75 1!16 n. 6fi 

61 LIS. 1.071 1!7 1.15 l.On n ue l.HP 57 . .Ul fi7 .(.01 67 "3.T1 67 IT! lS1 J?lt ; 61 

fi~ •sc 0.970 .tit ... (1.990 R ._,6" G.HO U .US A J.G .!I ;.lP 61 17J 651 111. 6t 

69a.at o.9iJ ··m·-•.ac. MtT 69 8.17 0..9lJ ~ l.HfO- ,_,;,j!!J ue 150 n•·r.o tnl!io 

-:o o.n ·o.w 10- •.19: o.xa' 10 a.10 o.~7 10 l-'1 ,., , 1" 7D ; zAo To · 17-4 10 · 111 ·,o 

71 O.d3 0.'19-4 71 f.$ o.L't 71 fi.Q Q.7J7 11 l.11f 7J ~-1ft 71 · z.u 7J 114 ·· TJ 111 71 

12 ~ 0.7-U n · t.m o.ns 72 n.55· tt.7"2 12 ··u5 71.- ····'io; '72 t.ISI 12 ·--·173 n .· 1'71 7Z 

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7-'1 !U'>M . 7-'1- o,ooo 74 o:ooa 74 -74· 7-'1 7-4 .: ·.• 74 u 

7.5 o.ooo ' 1S a.oco 15 n.()Qo " -n 1$ 7.5 , ,-, ·. lS~ 

7d o.co:J '7!i a.ooo 715 11.000 '" -?IS 1a ~ 1cs ··r., 

11 .G.()OO 77 0.000 17 0.000 77 -r1 ~ 77 77 !"7 

71 0.000 18 0.000 11 0.000 7S 11 '71 71 ' 71 "?'" 

151 0.000 151 0.000 19 0.000 79 79' ; 79 19 1~ 19 

.. ,.: ·. ~- ,. .. ~ " ~ so~-"'.~;:'~ so~ :19~ ~l__
·" :, .: 

. ' . ' . ;. :·~ 

Meter Box Post Test C1ilibration Check 

... _..: ' ~-·. 

,· 

·ALCOA- WARRICK OPERATIONS 

· NEWBURG'[(, lN 

. A-446 REACTOR# 2 (3 Stacks) 

' . 

~ 

M:~terBnx#i M•15 '•:. ·''" 

.... ;_ 

_.• . . .. 

ALCOA Warrick- iviACT 

195691 Pngc 123 of 188 

.. · .. , .. 

·· ·· · ·.: ·~ ·· ·· · · C.!ili.bmtMby: · · .. , ;. · 5~~tp!ifDate: ~· .· 

. . . 

.. ·· Tyler M;uis ·.;~. . . . . ·.9/6/2012 

. :-· . . · DeltiH @ . . 1.82.8 

·i ·. 'Gamnin, initial . . 0.9747 . ., ... 

' .. ·.:. ; 

·:.·· ... 

:Calculate tq~ ·fcir each te~t~using tli6 folloWing e~ation: · ' . ~ : ' . . . .. . ·.'· ~ ... 

·: ~ . ;._ 

where:·. ,·· 

- ;·Yqa. ·. 

q 

· ·dey .gas meter calil;>rclion clieck·~aiue, dimensionless. 

total run tinie, min:.. · · · .· ·· . ·. 

. Vm 

Tm .. 

Ph 

.. ' total sampl~ voliime fueasured by dry, gas ¢eter, dcf. . 

abs.olute average dry ga.S meter temp., 0

R. 

: 0.0319. 

·nHayg 

DH@ 

Md 

29 

l3.6 

barometric preSSUre, in. Hg. 

= (29.92/528}(0.75)2 (in. HgfO/R) cfi.n2~ 

avemge orifice meter differential, in. H20. 

orifice meter calibration coefficient, in. H20. 

dry molecular weight of stack gas, lb/ib-mole. 

dry molecular weight of air, lbllb-mole. 

specific gravity of mercury. 

After' each· test fun series, do. the foll~wing: ···.· 

. Average the fllree o.r.more 'l{qa's ob~ed from the test run series and 

compare this average with the dry gas meter calibration .factor, y' · Xhe averageYqa m~st pe withk 5perc.eiltofY.·· · ' 

If 1he avemge Yqa does not meet the +s ~erce~t criterion, recalibrate the 

meter over the full range of orifice sef,tings, as detailed in Section 5.3 .1 of 

Method. 5. 'i'hen: foll~w the procedure ·ui:' Seciioi 5 .3:3 of Method 5. . . .. . ' . : .. . . . . ·.·" ·. ·. '. ... ; 

Test 1 Test2 

. time .-144 144 

Vm- total. .. 137.289 . 1'38.164 

Tmavg . .. .... 79.8 . 82.5 

Tm-R .. ·540 ... 543 .. .. 

Barometric 29.6 .. 29.6 

DII,v~ 2.839 2.853 

DH@ 1.8280 1.8280 

Md stack gas 29.1.0 -~ .. 29.11 

MdAir 29.00 29.00 

Meter Box Gamma 0.9747 0.9747 

QAGamma 0.9850 0.9838 

Difference: 1.1% 0.9% 

within 5%? PASS PASS 

AVERAGE DIFFERENCE l.i%. 

. .. 

... .... 

Test3 

144 

137.402 

:78.0 ' 

538 . 

29.6 

2.864 

1.8280 

29.11 

29.00 

0.9747 

0.9881 

1.4% 

PASS 

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1956?1 Page 124 of 188 

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195691 Page 132 of 188 

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METHOD 4 • MOISTURE ANALYSIS DATA SHEET 

Run Numbet·-· ONE TWO· . . :-.·· ,. 

Test Date.. · ·11.1'-t~ ·f.() It-. ltJ·t5-ut1.- . .. 

Recovery Date lln-"t'.!.•·'Z.IJit. 10·-i-i ·'LIJI"'l.. · 

Recovered By l-ilA. AAidl : • .. .. .. 

. lr:tlpinger 1 Dl Water .. 

Final Wfi)ight, g tfiJ "';. :; '1'l'il u .... .. 

Initial Weight; g . "1S'l .6 1-)-'l ,r..{: . ' . .. 

'· 

Net welgiJt, g · '"~- ~ 1'94. :z.. . -,. 

lmpinger 2DI Water •,, . . · ...• 

Final Weight, g ~,,_.-5 ,, ~.!d. 

Initial Weight, g "1'-l~ f· 1tll 1 

Net weight, g ':?1.. A c.ic.t.( 

lmpinger 3·~ 

Final Weight, g ! .. "1 'S' • I ttt.Q 

Initial Weight,_g . {_,f.J(J.{ ~54. t.l 

Net weight, g J4J, ~-< :- lrnpinger 4 Silica Gel · 

Final Weight, g ~7q.~ 41-i .t~ 

. · Initial Weight, 9 , __ '-/1 1.- q~.At, .·1... .. 

Netweight; g . -~2. ~ . 32.4 

-·. lmpinger 5 ··-

Final Weight, .g 

Initial Weight, g .. .. 

Net weight, g · -· 

Imp Inger 6 

Final Weight, g ... 

Initial Weight, g )( ).L - .. .-

. Net weight, g 

Filter ID # 

Final Weight, g 

Initial Weight, g 

Net weight, g 

lrotal Catch, g 

THREE 

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ALCOA Warrick- MACT 

195691 Page 133 of 188 

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ALCOA Warrick - MACT 

195691 Page 134 of 188 

METHOD 3 .. ORSAT ANALYSIS FIELD DATA 

·client Name 

Plant Name 

· City I State 

· · Test Locatlbn 

Run 

Run No. 

Run 

"S(nLn.: r:Jz; / C.t)z :Z/. '-/I )ct · Is' 

c'=> r: c. c. -sl.f~t:. 70 . 

f/1/;t: 0:./C.CJ-z. 'i.~·1'i/8 ."'l'i { 

~r: sG-~ tlf o JJ./s 

Z.G<"t>: Alz. 

. · Bag ID~ Operator 

Avg -~------~~~~~~ 

QC Validation 

F0 = (20.9 • %02) I %C02 

Distillate Oil 1 .260 - 1.413 

Residual Oil 1.21 0 - 1.370 

Natural Gas 1.600- 1.836 

Wood/Bark 1.000- :!.130 

Expected F o Ranoes 

Anlhracite!Ugnlte Coal 1.015 ·,1.130 

Bituminous Coal 1. 083 .:.j;23D 

.-;.·· 

Municipal Solid Waste 1.043->'.1:177 ;·:.· 

-',,· 

··: · ... 

i 

·' 
' .,. ·~ . ~· ' 

. ,'• '.: . ... : 

-:EXA·MPLE CALCULATIONS 

· A:..446 Reactor No. 1. M315 .Run 1 

ALCOA Wnrrick · MACT 

195691 Page 135 or 188 

,'·: 

"~'" ··~·· ;, . 
'---- L____ 'L..,.---- , L.. __; ·L--, 

Example Equattons 

VOLUME OF DRY GAS SAMPLED AT STANDARD CONDITIONS 

Vmstd= r 17.64 • Pbar + ( De/tail I 13.6 ) 

( 460 + Tm ) 

Vmstd= 0.9949 * 17.64 * 121.772 * 29.63 + ( 2.336111 I 13.6 ) 

( 460 + 82.2778 ) 

VOLUME OF WATER VAPOR AT STANDARD CONDITIONS 

Vwstd= O.M7I5 " Vic 

Vwstd= 0.04715 .. 252.3 11.896 SCF 

PERCENT MOISTURE, BY VOLUME. AS MEASURED IN FLUE GAS 

'{,H2 0= Vwstd 

( Vwstcl + Vmstd ) 

%H20= 11.896 

( IJ.896 + ll7.448 ) 

ABSOLUTE FLUE GAS PRESSURE 

Ps= Pbar Ps= 29.63 

+ ..J:z. 

13.6 

+ -0.26 

13.6 

DRY MOLE FRACfiON OF FLUE GAS. 

Mfd= 

M[d= 

%H2 0 

9.2 

100 

DRY MOLECULAR WEIGHT OF FLUE GAS 

Md= r r.co, 

Md- ( 3 

.. 44 ) 

100 

.. # 

100 

X 100 

X 100 

29.61 

+ ( r.o; 

.,. ( . 17 

9.2 % 

h!c:hes Hg · 

·umtie" 

____E_.) + ( 

100 

·• 32 ) 

----;-or;-

+ ( 

TOO 

100 

M315-REACTORIII-cor=texmnple 

. 117.44/f d!ICf . .. 

r.coz r.o, 

3 17 

-.--. -- 

I. 

.. 28 

jij(J7 

.. 28 
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# 

An 

0.()0(}369 
\...__ ___ . __ _ L __ L___ L_______,-. : L__ L--

Vmstd 

mgldscm= 0.0225 1,000 • 353U 

JI7.448 

PM EMISSION RATE, POUNDS PER HOUR 

lblhr= 

lblhr= 

60 • 

453.592 

grams 

Vmstd 

,. Qs 

60 * 0.0225 "' 25.927 

453.59 Il7.448 

POM CONCENJRAT!ON GRAINS PER DSCF 

grldsif= 

grldscf= 

7,000 .. 

45359() 

grams 

Vmstd 

7.000 .. 21.5 

453590 117.448 

6.8 ·mg/d:m.. 

0.657 lblhr 

(J.f/0283 gr/Ascf 

POM CONCENTRATION, MILLIGRAMS PER DRY STANDARD CUBIC METER 

mg/dscm,= 

mg/dscm= 

milligrams • 35.314 

VmsJd 

21.5 • 35.3U 

117.448 

POM EMISSION RATE. POUNDS PER HOUR 

lblhr= 60 * millig!_ams * 

453592 Ymstd 

60 .. 21.5 ,. 

453.590 117.448 

6..16 . mi:ftl."'!tfJ 

Qs, 

25,927 0.628 lblhr 

Example Equations 

M315-REACTOR#l-cOJreCt eJtaJnplc 

L_.:_....!'. 

.. 

r . 

·• .. 
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·"' 

ALCOA.WARRICK 

LABORATORY REPORT 

Method 315 PM & POM 

--------------------

--- .. -·--· -------

ALCOA Warrick- MACT 

195691 Page 150 of188 

1_ 

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- ~"-----· ----·--------

----~ 

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.etrtlouJate Analysis 

'Run No . 

. Filter No~ . ., 

'. • ·~. ·; '!> • • • • 

•' ... I \':'• 

'·: . 

. . . 

... I M , .. 

• ... 1 

. . ·~ ~ ··· . 

. .... . . 

Final Weight. (g)· Tare WeJght (g) WeightGa!n (mg) ' .: ,. 

.. ·'· ..... 

Con~lnar No. 1 

Contairu!lrNo. 2 ,• . 

Total ~it. 2.. .. 0 •' • 

Less Acetone blank 

Weight of Partloulate matter . ·.- . . : . .· 

Moisture Analysis. · . 

. . Fin~d Volume (mg) .Jnitial Volume (mg) ·~uid Collected 

Impinge~ Note 1 Not~ 1 

. Sllioa Gel 

Total 

Note 1: Convert volume of water to weight by multiplying :by ihe density 0f water 

(1 g!ml). · 

Revision Pate; 2010/03/31 
I __ 

I 

J 

NOV/0212012/FRI 12:36 PM A}?.,C~B-fM'arrick- MACT 

195691 Page 154 of 188 

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Date: ~ltJM~ith,. '. 

Time:. 

' .. ' :. '. . ' ,. . ., •' .. 

· Roam'· Tare of '· Walght ., 

.Methyh~ne · · Cqntainei ·. Final.· AcetoneWash 

·No .. Humi~ty· Welght'(g} Aluminum . · :Gail'l 'Volume (mL) . _C_hJorldeWash bi.~h (g)· ·.·' (1ll_g)' (%RH) . .. Volu.r.nf:!" (mL) · · .... 

'lj/% ~ 

~.Jsq";Pj '. : ~- 1 '' 

&.-3150· 2-·'". ... 

. 2+2M &fk ~.g~'o. &-3~¥ . ~ -~ .. ~- '("" ri1 r{) 

'). ~ " 

~-v/ .,. . ·' .. 

3W 

~~ Ht.;s~ I a;· .. 3so1Jl. ;~ .. 1-1 •· :JA~. 

.. '' 

~-v •' •. '. .. s s· ~ .;r;~o t.~ .. i9'·' z .. o ~ '· {fill/1 V"~f .. _, 

1A)' . Total . B·?· l~' ' - . .. !:mtoal . .rv..., . .rv,... 

Less :Ac~tol'le Wst3h aJank (mg) . . : .. (not to e~eed 1 mgf1. of acstone used) - o .. o -~\· .. W1 : C,,P~VIIw 

Less Methylem!'l ChJprlde Wash Blank (mg) (not to· . ·~. 

,-;..,. ... . . ' . .. ' 

exceed 1.5 mg!L of me1hylene chloride used) ... D-.0~~~~ Wt c r;p,Evtw ·..;: 

Less Ftiter Blank (mg) 

(not to. 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. .. 

~ 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 

,. 

~ ' . .. ·.,; :; ' 

' . 

.. 

'' 

'• 

. . ·• 

., 

: 

. : ··, 

., 

. 
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 · ~ 

. :.Filter No. .. . . {{?,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 

(~. t4:JQ) 

.·· ~ ' -·. ' 

MoisturtJ Analysis 

q.o 

.. ..J: 

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 by the density Gf water . 

(1 g/ml). · 

Revision Pate: 2010/03/31 

.. 

. i 
NOV/02/2012/FRI 12:36 PM 

i 

'i 

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.. /

.· .... 

I 

-1 

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.. MCEM AnaiY..sls .. : . : . 

Date: h.cJ.iJr. :.:1i/i ~ Ti~e: . .. .. . . . ,· .. ·_,;... .. - . . 

•, ( 

. · .· C::ont.alner' Roorn ia.re of Weight··. 

· i-lumldtty Flnal Alurnlnlirn · :: Gain Acetone Wash 

No. .... 

Weight (g} 

'·· Vohune(mL) 

(%RH) . D(sn (g) . (mg). .. 

1%. : 

1 

~-~&~?'r fi~~· . \~~-- .. 

~ .. 

.2+2M ~* r&.!rtt-~ b.1v·fu.J \u·Dr .. 

% \-q .. .. 3W 

~.~3 98 u, ;~&~' 

~· v,s· ... 

3S· &~31~ .~ .. ?1~3' !""' .. g1t-

. .·. 'JZ~.o ,,··\~~· .. Total .. 

. Z. o181 Iv~;., . 

Less Aoeteme Wash Blank (mg) . . ... -" 

(not to exr:sed 1 mg/L. cf acetone usecl) - . -o.·o· ~ We • c8P.ZY.w . .. ·.· .. . . 

Less Methylene Chloride Wash Blank (mg) (not to .. • .-:_::::7. ..· . .,. ' 

exoeed 1.5 mg/L of mefhyff:me chloride usE!d) ·· . . · '• .. 

- 0. DI!Vl~· .. ~v, ::: c,I=>tZv;w 

Less Filter Blank (mg) .. (not to exceed 1. mgffiJtsr) .. . :. "'•· 

.... o.Jr W\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 !2:37PM 

Method. 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• . . . ~ . . ' 

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>. ., {j<J<ti~ .. .. .. , ' .. \~ .1( Totar · 1 ~ CJ .. fL{O ~mta1s1 zv.w Ivw,~ 

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

(not to exoeed 1 mg!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, = c1

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 1 mg!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 0 Y\ 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) •· 

Container No. 1 

./ ll 

.oontainer No~ 2 

Total f/.1_~ .. 

Less Acetone blank 

Weight of 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 

---------------~---------~-

~ '. ·.' . : : 

-·-~-~------~--------

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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 

--~-----

-~--·--·--~---

' , •' 

. ·, . 

•• 

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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.-I O'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) : .. .. (%RH1 

~~ . 84-.. /[{'/13 e.~ &EJ2;_ . 

. container No. 1 .l4 v 1(84;.' "!?/3)_ lrMlt~li1 4-:-, 

J!f.?i (1E_I 888~ lltt -~70 3 -1 

.Container No.2. ?1 '7!ct. 8CZW .. ~ f.o/1'1; f3~98 

Tof~:l! · .. -~·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 water to weight by multiplying by the density of water. 

(1 g/ml). · 

0.2·FORM--07 4 

Rev)slon Date: 201 D/03/31 

.· .·i' 

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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 1 mg./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 1 mgfL. 

• 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 

. .. 

:, ·.·. 

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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/ .. ·· 

Fll~ralk f7i5 _&.;B11- &:''!,8/3 ,.;.:-; {)I 4- !VIr+ f,~ili.P .. 

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 1 mg!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 

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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 :-\ , ...... 

:. 

Blank Analysis - MCEM 

Time: ---

Room 

H mldlty Final . Tare of .• 

Container · . 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 Blank must 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 

·:. lmpinger Water Reagent Blank must not exceed 1.5 mg/L. , 

• Room Relative Humidity must be below 50% when sam pies are being weighed. 

02·FORM-07 4 Revision Date: 2010/03/::11 

. .... . .. 
SUMMARY OF EQUIPMENT 

I 

-- -·--

... -· -·-·- .. - ... 

A-446 

A-446 Reactor 2 M13A l'vH5 0.9747 1.828 9/6/2012 RPT-79/ R,P-3L Reactor 2 M315 M-15 0.9747 1.828 9/6/2012 RPT-79·/ RP-3L 

.. 

. ... 

·. 

··;~-· 

... ~._,l_y 

-·:·'~- .r· 

-- ~.;~· .. -' 

._.,.· 

.... 

----

....... 

Glass . ss 

Glass Glass G
1\l!eter Bo:X:ID 

Gas Metet- Nu'mber 

Calibrated By 

Orifice lD 

Orifice Coefficient K' 

Ambient Temperature 

Vacuum (2:14.1" Hg) 

Delta H 

Initial Volume Ft3 

Final Volume Fe 

Total t=_5 Ft1 

Initial DGM Temperature °F 

Final DGM Temperature °F 

Average Temperature "F 

Time Minutes 

Time Seconds 

DeltaH@ 

Gamma(Y) 

Average (Y) 

Delta H@ tolerance 

c ' 

. . . 

·.\ 

. . . 

pry Gas l\:Ieter 5-Point Full Test 

i29S987 _ .. ·--. -. 

Pass Pas a 

Caljlmition Date·' 

Barometric 

Orifice Set Date 

PMs 

(Y) 

Delt!i H@ 

91

·-·2

I 0

L

. QA I QC Che9k: Sign and Date 

.rl' '/; '"'\ . ""') ... /} 

.'.)._ &'---1 . 

., 

·, .. : 

···: 
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 lnput1 

Dry Gas Meter Thermocouple Calibration3 

rKo::a<:>JcH~.:~:: Thermometer 

70 74 

· .. 

-'·-:.:.·Dry gas meter thermicouple is compared to an ASTM type mercury in glass refere

qA I QC Check: Sign and Date {;4e) .. . H ·- 
])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. 

. 9/1

2

Orifice ID 

Orifice Coefficient K' 

Ambient Temperature 

Vacuum (2:14.1" Hg) 

Delta H · 

Initial Volume Ft3 

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/3l

E .. 0i

QA/ QC Check: Sign and Date. --L2e~H 

··.,·,. 
l 

____ _ [ ___ _ L __ L____ L____ L_______ L_______ 

--~' 

L___j 

--

Dry Gas Meter Temperature Display Calibration· 

·' .. · 

Meter Box ID . ·- M18 ··Reference Calibrator. 

Date ·· 9/19/2_012 ' · Serial Nu:inbet 

Calibrated By · j.}~ Byrd J . Reference .Calibratimi Date . 

' 

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 Input1 

Dry Gas Meter Thermocouple Calibration3 

Reference Thermometer 

73 74 

. 

3

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

.· 

.ae~u-_ 

.... · . . .. 

·

QA I qc Check: Sign and Date 
. Meter Box ID 

Gas Meter Number 

Calibrated By 

Orifice ID 

Orifice Coefficient K' 

Ambient Temperature 

Vacuum (:::14.1" Hg) 

Delta H 

Initial Volume Ft3 

Final Volume Ft3 

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

29

·· l/3lf

I 0.

1

QA /QC Check: Sign and Date C2e)-.U. 
;__ -- -··- 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 Iuput1 

Dr!r Gas Meter Thermocouple Calibration3 

!Reference Thermometer 

71 73 

3'-"Dry gas meter therinicouple 

. 

is compared to. an ASTM type mercury in glass referenc

-

'•.' 

<).A I QC Chec~: Sign and Date W1~.~··· 0

'·' ·,; 

. 1. 
THERMOCOUPLE 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 C3J 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'*'' 

..

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'·toormom

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. Th

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:

RAL-TC CAL.XLS 

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ALCOA Warrick- MACT 

195691 Page 174 ofl88 

:'1. . 'j .• - ·.-· •• , 

TEMPERATURE'CAUBRATlON DATA FORM C'TRC 

. 

- - ' 

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 . ' .... . . 

EPA APPROVED 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 a temperature 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 

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l 

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1 

_J 

j 

j 

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Pitot Tube Inspection 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 n1 ·and "'2. 

Diagram 2 

Degree Indicating level position 

for determining P1 and P2· 

Degree indicaiing level position ior 

determining r then calculate ;z. 

~~ ~---

-~~--<2 . t / · Degree lndicirtlng level position for 

determining e then 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 

P8 =Pli=A/2= 0.275 

OJ 88"::: D1 ::: 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 on Alcoa 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 

a pitot tube coefficient factor of 0. 84, unless a specific wind tunnel calibration coefficient bas 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 

of the 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_~--

. Insp~tion Date: 01/03/2012 Reviewed By: ...;._. __ J_S_e_m_e:.___~ 

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: 311 

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~ 

. . 

'"~ . -

Pitot Number: ...,...,.. __ ~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 jl1 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 

-S0 <P1 <+5"= 

-so< P2 <+so,.. 

Diagram3 

·• y= 

®= 

A= 

Pa = Pb = AJ2~ 

0.188" :S D1 :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 

a pitot 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 

of the 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 

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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 PMl 0 ~--~ _ ___. 

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 

P8 =P0=A/2= .. 0.464 

0.188" ~D1 ~ 0.37511 = 0.375 

1.05 Dt < A/2 < 1.5 D1 = 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 

a pitot tube coefficient factor of 0.84, 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 

of the 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 

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1· 

-J 

j" 

l 

_j 

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J 

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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 of D 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 ~ -~~ 

-~-------- ·----· 

----~-~-

-~---·---------------~ --------··-

____