Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 1 of 100 Facility Questionnaire for Primary Aluminum Reductio n Plants 1

, 2

Please provide the information requested in the following forms. Use additional copies of the survey forms for additional facilities, as needed, for your response.

This request for information is divided into four parts to be completed by each facility:

Part A General Facility Information

Part B Process and Emissions Control Devices

Part C Start

- ups and Shutdowns

Part D Previously Performed Testing and Test Report Data

Note, as stated in the cover letter from EPA, the survey response(s) ( Enclosure 1 ) and the new test results ( Enclosure 2 ) are due by May 31 , 2011

.

Please separate confidential business information (CBI) from non

- CBI for submittal to EPA. Please see the instructions in the cover letter for submitting CBI.

1 See Appendix A for an explanation of acronyms used in this document and Appendix B for a list of Hazardous Air

Pollutants (HAP).

2 Please make copies and complete these forms for each facility in your company subject to this request for

information, as described in the cover letter from EPA. If possible we would prefer receiving the completed forms

as electronic files in Microsoft® Word format . Please add additional rows to the tables as needed to contain your responses. Blank electronic forms are included on the disc provided with this package.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 2 of 100 PART A : GENERAL FACILITY INFORMA TION (Please fill out a separate form for each of your facilities )

1. Name and address of the PARENT COMPANY that owns the facility:

Alcoa, INC

________________________________________________________________ 201 Isabella Street

__________________________________________________________ Pittsburgh PA 15212

- 5858

____________________________________________________

2. Name and address of legal OPERATOR of the facility, if different than the legal OWNER :

_________________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

3. Complete street address of facility (physical location):

a. Address: State Ro ad 66 and 61

____________________________________________ b. City: Newburgh

_______________________________________________________

c. State: Indiana

_________________________________________________________ d. Zip: 47629

____________________________________________________________

e. County: Warrick

_______________________________________________________

4. Provide mailing address of the facility if di fferent than physical location:

a. Address: PO Box 10

____________________________________________________ b. City: Newburgh

________________________________________________________

c. State: IN

_____________________________________________________________ d. Zip: 47629

____________________________________________________________

5. Facility contact able to answer technical questions about the completed survey :

a. Name (First Name, Last Name): Chris Allen

_________________________________ b. Title: Sr. Environmental Eng

_____________________________________________

c. Telephone number: 812

- 853

- 4639

___________________________ ext.

_________ d. Fax number: 812

- 853

- 4851

_______________________________________________

e. E

- mail: chris.allen@alcoa.com

____________________________________________

6

. Please provide an electronic copy of your current Title V operating permit and any pending

Title V operating permit modification applications (pdf file s are preferred)

.

7

. Please provide a copy of the facility schematic showing all of the p rimary a luminum operations that are subject to 40 CFR Part 63, Subpart LL . Please i nclud e the control

device ID numbers in the facility schematic.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 3 of 100 PART B: PROCESS ES AND EMISSIONS CONTROL DEVICES

8

. P itch storage tanks :

2

_______________ Total number of pitch storage tanks at facility

no

______________ Is at least one of the pitch storage tanks empty at all times ?

27452

___________ Total amount of pitch used ( tons per year) assuming facility operation at maximum capacity

8a. Please provide the c apacity (tons) of each pitch storage tank at facility (use the same pitch storage tank ID numbers as were assigned in the schematic provided in response to question 7 and add columns if necessary):

ID No.: 251A 251B

____________ ____________ Capacity: 1000 1000

____________ ____________ 8b. Please provide a rationale, if applicable, for why application of an emission standard

to the p itch storage tank(s) is not practica b l e economically or technologically

Not practicable economically Not practicable economically: __Setting a Nati onally

applicable emission standard for pitch storage tanks that have no add

- on controls is

not technically or economically feasible because factors affecting emissions vary

widely over time and from site to site. Tank emissions result from either filling the

tank or diurnal temperature changes. On a short

- term basis (hourly or daily), tank

filling emissions will depend on the size of the tank and how much material is added

during filling. Both tank size and delivery volume (or frequency) will vary from one

smelter to the next, so establishing a short

- term emission limit applicable to all tanks

is not feasible. Emissions caused by diurnal temperature variations will vary

depending on climate.

Not practicable technologically:

__________________________________________________________

9

. A node bake furnaces:

1

_______________ Total n umber of anode bake furnaces at facility

187303

__________ Facility

- wide green a node production capacity (tons per year)

126657

__________ Total a mount of coke used for anode production ( tons per year) assuming facility operation at maximum capacity

1 0

. A luminum production , by potline (s) (use the same potline ID numbers as were assigned in the schematic provided in response to question 7) :

Total potlines (number) and combined aluminum capacity (tons per year):

Total potlines ( 5 ) Aluminum capacity ( 340,600 )Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 4 of 100 Individual potlines (add rows as necessary) and aluminum capacity (tons per year) :

Potline # 2 Aluminum capacity ( 68120 )

Potline # 3 Aluminum capacity ( 68120 )

Potline # 4 Aluminum capacity ( 68120 )

Potline # 5 Aluminum capacity ( 68120 )

Potline # 6 Aluminum capacity ( 68120 )

1 1

. Please describe your facility potline types (add rows as necessary and use the same ID numbers as were assigned in the schematic provided in response to question 7) :

1 1 a. Potline ID No. Potline Type * Total No. of Pots

Potline # 2 CWPB1 1 50

Potline # 3 CWPB1 1 50

Potline # 4 CWPB1 1 50

Potline # 5 CWPB1 1 50

Potline # 6 CWPB1 150

* Center

- work ed pre

- bake 1 (CWPB1); Horizontal stud Soderberg 1 (HSS1)

Center

- worked pre

- bake 2 ( CWPB2 ) ; Horizontal stud Soderberg 2 (HSS2)

Center

- worked pre

- bake 3 ( CWPB3 ) ; Vertical stud Soderberg (VSS)

Side

- worked pre

- bake (SWPB)

1 1 b. What is the average frequency, average number, and average duration of cell openings (side shield and/or door removals) for each potline?

Potline

ID Cell opening (side shield and/or door removals)

Average Frequency a Average Number b Average Duration c (minutes)

Side shield Door Side shield Door Side shield Door

2 10 6 20 12 30 20

3 10 6 20 12 30 20

4 10 6 20 12 30 20

5 10 6 20 12 30 20

6 10 6 20 12 30 20

a The average number of times that at least one side shield or door of a given cell of

the cited potline is open ed during a 24 consecutive hour period.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 5 of 100 b The average number of cell openings (i.e. side shields and/or doors removed from

all the cells in the cited potline) at any given time

.

c The average length of time, in minutes, t hat a given side shield or door of a cell of

the cited potline is removed

.

1 1 c

. Describe the exhaust capture/hooding system for each potline including the capture efficiency (if known) , evacuation rate, and damper system.

Potline ID Capture efficiency (%) Evacuation

rate (scfm) Damper system? (i.e. to allow high
and low flow evacuatio n rates)

Yes No

2 98.45% 369,081 Yes

3 98.45% 393,969* Yes

4 98.45% 393,969* Yes

5 98.45% 382,306 Yes

6 98.45% 390,810 yes

* The potlines exhaust to a common control device. The scfm provided is assumed to be 50% of the air pollution control device flow.

1 1 d. Please provide a copy of the method(s) used (e.g. inspection checklist or log) to ensure that the capture efficiencies cited in the table above are achieved. Daily walk through t o ensure no smoking pots, bent covers, covers are alien. We also test once a year to generate the capture efficiency %.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 6 of 100 1 2

. Is total fluoride emitted from the roof vents measured with a sampling manifold or a cassette system? ( CHECK one) ___________ Man ifold or _________ x

_____ Cassette

1 2 a

. What is the total typical exhaust rate from the roof vents of each pot room ( scfm )?

Potline ID Roof Vent

ID Roof Vent

Exhaust rate (scfm)

2 103M.1 505,354

2 104M.1 443,941

3 105M.1 588,043

3 106M.1 496,919

4 107M.1 537,735

4 108M.1 549,037

5 109M.1 680,215

5 110M.1 510,785

6 111M.1 668,318

6 112M.1 633,650

1 3

. Please describe your facility paste plant and emissions controls below :

0.598%

__________ Typical sulfur content of pitch

0.7%

____________ Maximum sulfur content of pitch cited in specifi cations provided to pitch suppliers , if applicable

1.937%

__________ Typical sulfur content of coke

2.0%

____________ Maximum sulfur content of coke cited in specifications provided to coke suppliers , if applicable

1 3 a. What is the availa bility and cost of coke and pitch with lower sulfur content s for your facility? What is the lowest sulfur content coke and pitch available?

Alcoa discussed at length the availability and cost of lower sulfur coke during a meeting with EPA on May 23, 2011. Please refer to the presentation provided by Alcoa for that meeting.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 7 of 100 1 3 b. What company (provide name and contact information) supplies your facility with the raw materials used in paste production? Please submit a copy of the current MSDS

for these mat erials.

Koppers INC

436 Seventh Ave

Pittsburgh, PA 15219

- 1800

naorgmqqds@koppers.com

Great Lakes Carbon LLC

4 Greenspoint Plaza, Suite 2200

16945 Northchase Drive

Houston, TX 77060

281

- 775

- 4741

Oxbow Group

1601 Forum Place Suite 1400

West Palm Beach, FL 33401

561

- 697

- 4300

info@oxbow.comEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 8 of 100 1 3 c. Is any coal tar pitch (as opposed to petroleum pitch) used in your facility?

Yes

13d. Please provide information on the methodology used [e.g. assumptions made, mass balance calculations, assumed variations associated with potline type (e.g. Soderberg

versus pre

- bake), etc.] to estimate COS emissions from the facility.

Carbonyl Sulfide ( COS) is manufactured as a byproduct of the primary aluminum production process.

The primary mechanism of COS formation is thermal desulfurization occurring when CO and CO2 migrate into the pores in the anode and react

with bound sulfur.

Since the primary controlling factor of the CO2/CO ratio is thought to be current efficiency, the resulting COS and SO2 formation equilibria may be closely tied to this process parameter.

Warrick Operations monitors COS generation (by continually calculating emissions) to ensure that information reported under CERCLA continuous release reporting requirements remains accurate. These calculations are

maintained in a CERCLA continuous release reporting spreadsheet. The calculation is completed as follows:

Potroom reactor stack

emissions: (0.136 * 0.9846 * lb C/lb Al * Aluminum Production, lbs * % S in baked anodes * 1.875 lbs COS/lb s)

where: 0.136 represents stack test information that 13.6% of sulfur was emitted from reactor stacks as COS, and 0.9846 represents the capture efficiency for the

reactors

Potroom roof emissions: (0.082 * (1

- 0.9846) * lb C/lb Al * Aluminum Production, lbs * % S in baked anodes * 1.875 lbs COS/lb s)

where: 0.082 represents stack test information that 8.2% of sulfur was emitted from roof monitors as COS, and 0.9846 represents the capture efficiency for the reactors, so that (1

- 0.9846) represents roof emissionsEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 9 of 100 1 4

. a. Please provide information on any air pollution control device(s) controlling emissions from the pitch storage tanks, the paste plant, the anode bake furnaces, and/or the potlines at this facility using Tables 1

, 2

, 3

, 4 , and/or 5 , as appropriate. Please use the

same ID numbers as were assigned in the schematic provided in response to question 7.

b. Does your operating permit include limits for emissions of particulate matter from the potlines and/ or limits o n the sulfur content of the pitch and/or coke used to produce anodes? If so, what are those limits? 0.8% sulfur in pitch

c

. Do you have any plans to install any new higher efficiency rated control devices

, or have any pending applications to add on any new controls on sources that are part of the primary aluminum reduction facility ?

( CHECK one) ___________ Yes

______ X

______ No

If “Yes,” please specify and include any copies of pending permit applications as requested in item 6 in Part A

.

d

. Please indicate below all emission controls that were installed or upgraded AFTER October 7, 1997 in order to meet the MACT standard s for primary aluminum reduction plants ( add rows as necessary and use the same ID numbers as were assigned in the

schematic provided in response to question 7

Description of new or upgrade d control Emission point Emission limit Date the control or upgrade became operational

GTC replaced old B3 (that formerly controlled

emissions from Potline 3 ) and old B4 (that formerly controlled emissions from Potline 4 ) GTC 1.9 lbs. TF per

ton A l tapped 2000Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 10 of 100 1 5

. Pollution prevention: Describe any procedures

, work practice standards

, or materials used at your facility to prevent or reduce emissions of HAP from pitch storage tanks, the paste plant, the anode bake furnaces , and/or the potlines at this facility ( as opposed to controlling pollution after it is formed )

.
NoneEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 11 of 100 Table 2 Combination Dry Alumina Scrubber /Bag House Description

1

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : (1) one fluidized bed scrubber and baghouse system consisting of (12) twelve fluidized bed scrubbers and baghouses identified as Potline No. 2 A398 pollution control system (C1) with a total gas flow of 480,000 acfm at 200°F, and exhausting at stacks 160C1 .1

- 1601.36. Secondary emissions are uncontrolled from the potline 2 and are exhausted at the roof
monitors 103M.1 and 104M.1

1

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary): See past sub mission

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

2

. Design collection efficiency and outlet concentration (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known)

PM unk Percent 0.055 mg /dscf 1

PM10 unk Percent 0.030 mg /dscf 2

PM2.5 unk Percent 0.054 mg /dscf 2

Total Fluorides 99.94 Percent 0.0069 mg /dscf 1

Hydrogen Fluorides 99.96 Percent 0.0030 mg /dscf 2

POM unk Percent unk mg /dscf

_________ COS 0 Percent 0.466 mg /dscf 1

Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

3

. Scrubber device type :

__ x

___ Fluidized bed

_____ Injection

_____ Other (specify or describe):

_________________________________________

4

. Bag cleaning method :

__ x

___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 12 of 100 5

. P ressure mode of operation: x p ositive pressure n egative pressure

6

. Typical gas temperature: inlet to scrubber 200 ° F outlet from bag house

° F

7

. Gas flow rate: 4 63

, 108 acfm (at bag house outlet) 3 68

, 306 dscfm

8

. Pressure drop: Across scrubber: 6

- 8” inches water column (in. H 2 O)
Across bag house: 4

- 10” inches water column (in. H 2 O)

9

. Solid to gas ratio: 0. 7 lb / 1,000 acf

10

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina 80 Tons/day

Recycled alumina 250 Tons/day

Other alumina (specify ring furnace ) 2 Tons/day

11

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

Potline #2 150 pots listed as potline #2

12

. Indicate what operational parameters of the control device are monitored to ensure that the

control device is operating properly :

_______ V olumetric flow rate X F an amperage

P ressure drop X Visible emissions opacity

O ther (specify): alumina feeder RPM

.
13

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 2465 F an amperage (amps)

P ressure drop (in. H 2 O) any visible emission Visible e missions opacity (%)

O ther (specify): 2.67 rpm alumina feed rate

.

14

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 13 of 100 T able 2 Combination Dry Alumina Scrubber/Bag House Description

2

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : One (1) alumina injection and fabric filtration system, identified as the GTC system, with a total gas flow rate of 1,000,000
acfm at 170 °F , and exhausting at the GTC stack. Secondary emissions are uncontrolled at potline #3 and 4 and are exhausted at th e roof
monitors 105M.1 and 106M.1 for line 3 and 10 7 M.1 and 10 8 M.1 for line 4

15

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary): See previous submittal

ID No.: _________ Latitude:

_______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

16

. Design collection efficiency and outlet concentration (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known)

PM unk Percent 0.221 mg /dscf

_____ 1

____ PM10 unk Percent 0.065 mg /dscf

____ 1

_____ PM2.5 unk Percent 0.217 mg /dscf

____ 1

_____ Total Fluorides 99.84 Percent 0.023 mg /dscf

_____ 1

____ Hydrogen Fluorides 99.86 Percent 0.011 mg /dscf

____ 2

_____ POM unk Percent unk mg /dscf

_________ COS 0 Percent 0.449 mg /dscf

____ 1

_____ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

17

. Scrubber device type:

__ ___ Fluidized bed

__ X

___ Injection

_____ Other (specify or describe):

_________________________________________

18

. Bag cleaning method :

__x___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 14 of 100 19

. P ressure mode of operation: p ositive pressure x n egative pressure

20

. Typical gas temperature: inlet to scrubber 170 ° F outlet from bag house

° F

21

. Gas flow rate: 986,195 acfm (at bag house outlet) 806,686 dscfm

22

. Pressure drop: Across scrubber: .75

- 1 inches water column (in. H 2 O)
Across bag house: 8

- 14” inches water column (in. H 2 O)

23

. Solid to gas ratio: .8 0 lb / 1,000 acf

24

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina 10 Tons/ Day

Recycled alumina 2 80 Tons/ Day

Other alumina (specify ring furnace ) 3 0 Tons/Day

25

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

Potline#3 150 pots know n as potline 3

Potline #4 150 pots know n as potline 4

26

. Indicate what operational parameters of the control device are monitored to ensure that the

control device is operating properly :

_______V olumetric flow rate X F an amperage

P ressure drop X Visible emissions opacity

O ther (specify): alumina feeder RPM

.
27

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 502 F an amperage (amps)

P ressure drop (in. H 2 O) any visible emission Visible e missions opacity (%)

O ther (specify): 4.37 rpm alumina feed rate for feeder #3

.
4.37 rpm alumina feed rate for feeder #4 .

28

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 15 of 100 Table 2 Combination Dry Alumina Scrubber/Bag House Description

3

. Control d evice description and ID number ( or numbers, if several identical control devices

are used to control a given emission source ) : (1) one fluidized bed scrubber and baghouse system consisting of (12) twelve fluidized bed scrubbers and baghouses identified as
Potline No. 5 A398 pollution control system ( B5 ) with a total gas flow of 480,000 acfm at 200°F, and exhausting at stacks 161B5

. 1

- 161B5.36 Secondary emissions are uncontrolled from the potlines and are exhausted at the roof
monitors 10 9 M.1 and 1 10 M.1

29

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary): See previous submittal

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitud e: ________________

30

. Design collection efficiency and outlet concentration (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known)

PM unk Percent 0.156 mg /dscf

____ 1

_____ PM10 unk Percent 0.046 mg /dscf

____ 2

_____ PM2.5 unk Percent 0.153 mg /dscf

____ 2

_____ Total Fluorides 99.85 Percent 0.009 mg /dscf

____ 1

_____ Hydrogen Fluorides 99.87 Percent 0.004 mg /dscf

____ 2

_____ POM unk Percent unk mg /dscf

_________ COS 0 Percent 0.490 mg /dscf

____ 1

_____ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

31

. Scrubber device type:

__x___ Fluidized bed

_____ Injection

_____ Other (specify or describe): _________________________________________

32

. Bag cleaning method :

__x___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 16 of 100 33

. P ressure mode of operation: X p ositive pressure n egative pressure

34

. Typical gas temperature: inlet to scrubber 200 ° F outlet from bag house

° F

35

. Gas flow rate: 4 55

, 004 acfm (at bag house outlet) 3 68

, 33 2 dscfm

36

. Pressure drop: Across scrubber: 6

- 8 inches water column (in. H 2 O)
Across bag house: 4

- 10 inches water column (in. H 2 O)

37

. Solid to gas ratio: .8 0 lb / 1,000 acf

38

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina 10 Tons/day

Recycled alumina 280 Tons/day

Other alumina (specify ring furnace ) 3 0 Tons/day

39

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

Potline#5 150 pot known as potline 5

40

. Indicate what operational parameters of the control device are monitored to ensure that the

control device is operating properly :

_______V olumetric flow rate X F an amperage

P ressure drop X Visible emissions opacity

O ther (specify): alumina feeder RPM

.

41

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 2549 F an amperage (amps)

P ressure drop (in. H 2 O) any visible emission Visible e missions opacity (%)

O ther (specify): 1.98 rpm alumina feed rate.

42

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 17 of 100 Table 2 Combination Dry Alumina Scrubber/Bag House Description

4

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : (1) one fluidized bed scrubber and baghouse system consisting of (12) twelve fluidized bed scrubbers and baghouses identified as
Potline No. 6 A398 pollution control system ( B6 ) with a total gas flow of 480,000 acfm at 200°F, and exhausting at stacks 161B6 1.1

- 161B6.36 Secondary emissions are uncontrolled from the potlines and are exhausted at the roof
monitors 1 11 M.1 and 1 12 M.1

43

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary): See previous submiital

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

44

. Design collection efficiency and outlet concentration (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known )

PM unk Percent 0.032 mg /dscf

____ 1

_____ PM10 unk Percent 0.010 mg /dscf

____ 2

_____ PM2.5 unk Percent 0.031 mg /dscf

____ 2

_____ Total Fluorides 99.94 Percent 0.009 mg /dscf

____ 1

_____ Hydrogen Fluorides 99.95 Percent 0.004 mg /dscf

____ 2

_____ POM unk Percent unk mg /dscf

_________ COS 0 Percent 0.455 mg /dscf

____ 1

_____ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

45

. Scrubber device type:

__x___ Fluidized bed

_____ Injection

_____ Other (specify or describe): _________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 18 of 100 46

. Bag cleaning method :

__x___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________

47

. P ressure mode of operation: x p ositive pressure n egative pressure

48

. Typical gas temperature: inlet to scrubber 200 ° F outlet from bag house

° F

49

. Gas flow rate: 49 8, 5 8 6 acfm (at bag house outlet) 3 87

, 8 0 1 dscfm

50

. Pressure drop: Across scrubber: 6

- 8 inches water column (in. H 2 O)
Across bag house: 4

- 10 inches water column (in. H 2 O)

51

. Solid to gas ratio: .82 lb / 1,000 acf

52

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina 10 Tons/day

Recycled alumina 280 Tons/day

Other alumina (specify ring furnace) 3 0 Tons/day

53

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

Potline#6 150 pot known as potline 6

54

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 2732 F an amperage (amps)

P ressure drop (in. H 2 O) any visible emission Visible e missions opacity (%)

O ther (specify): 2.49 rpm alumina feed rate.

55

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 19 of 100 Table 2 Combination Dry Alumina Scrubber/Bag House Description

5

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : Ring Furnace A

- 446

56

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary):

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

57

. Design collection efficiency and outlet concentra tion (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known)

PM 88.93 Percent 0.111 mg /dscf

_____ 1

____ PM10 51.76 Percent 0.287 mg /dscf

_____ 1

____ PM2.5 unk Percent unk mg /dscf

_________ Total Fluorides 99.99 Percent 0.00012 mg /dscf

_____ 1

____ Hydrogen Fluorides 99.99 Percent 1.13E

- 05 mg /dscf

_____ 1

____ POM 74.92 Percent 0.092 mg /dscf

_____ 1

____ COS unk Percent unk mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

58

. Scrubber device type:

__x___ Fluidized bed

_____ Injection

_____ Other (specify or describe):

_________________________________________

59

. Bag cleaning method :

__x___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________

60

. P ressure mode of operation: X p ositive pressure n egative pressure

61

. Typical gas temperature: inlet to scrubber 45 0 ° F outlet from bag house

° FEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 20 of 100 62

. Gas flow rate: 125,642 acfm (at bag house outlet) 97,184 dscfm

63

. Pressure drop : Across scrubber: 4

- 7” inches water column (in. H 2 O)
Across bag house: inches water column (in. H 2 O)

64

. Solid to gas ratio: 0.91 lb / 1,000 acf

65

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina 4840 lbs./hr.

Recycled alumina

Other alumina (specify ________________)

66

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

67

. Indicate what operational parameters of the control device are monitored to ensure that the

control device is operating properly :

V olumetric flow rate X F an amperage

P ressure drop X Broken bag detectors primary, Visible emissions opacity ,se condary

O ther (specify): dense phase units 24

- hour cumulative dumps for alumina flow

.
68

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 675, minimum F an amperage (amps) (24

- hour average basis)

P ressure drop (in. H 2 O) Broken bag detector alarm, Visible

emissions if broken bag detector is down

O ther (specify): 119 Dense phase unit dumps in 24

- hours.

69

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 21 of 100 Table 2 Combination Dry Alumina Scrubber/Bag House Description

6

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : Pitch Fume Treatment Center consisting of two dry coke scrubbers and two baghouses constructed in 1999 with a treatment capacity of 52.5 tons of green anode per hour, with an airflow rate of 70,000 acfm at 100 F exhausting at stack 254.13. The pitch fume treatment system has a minim um feed rate, as specified in the approved parametric monitoring plan of 3.6 tons per hour of calcined petroleum coke

70

. Stack or vent location of each control device ( use NAD83 and include six decimal places and add rows as necessary): See previous submitt al

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

71

. Design collection efficiency and outlet concentration (add rows as necessary) :

Pollutant Collection Outlet Source of efficiency * concentration * Estimation * (if known) (if known)

PM 99.34 Percent 0.093 mg /dscf

_________ PM10 95.85 Percent 0.102 mg /dscf

_________ PM2.5 unk Percent unk mg /dscf

_________ Total Fluorides 0 Percent 0 mg /dscf

_________ Hydrogen Fluorides 0 Percent 0 mg /dscf

_________ POM 19.88 Percent 0.082 mg /dscf

_________ COS 0 Percent 0 mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percent mg /dscf

_________ Other (specify) Percen t mg /dscf

_________

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 4 = Title V permit application 5 = Other (specify) _______________________

72

. Scrubber device type:

__ ___ Fluidized bed

___ X

__ Injection

_____ Other (specify or describe): _________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 22 of 100 73

. Bag cleaning method :

__x___ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________

74

. P ressure mode of operation: p ositive pressure X n egative pressure

75

. Typical gas temperature: inlet to scrubber 100 ° F outlet from bag house

° F

76

. Gas flow rate: 65,991 acfm (at bag house outlet) 64,234 dscfm

77

. Pressure drop: Across scrubber: 4

- 7 inches water column (in. H 2 O)
Across bag house: inches water column (in. H 2 O)

78

. Solid to gas ratio: 102.86 lb coke / 1,000 acf

79

. Alumina usage rate (differentiate between virgin and recycled alumina from potlines)

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina

Recycled alumina

Other alumina (specify ________________)

80

. Identify each emission source served by this control device (add rows as necessary).

Source ID No(s). Description(s)

10 coke and pitch mixers

2 anode block presses

Anode block feed conveyor

3 pressed anode block cooling belts

81

. Indicate what operational parameters of the control device are monitored to ensure that the

control device is operating properly :

V olumetric flow rate X F an amperage

P ressure drop X Broken bag detector primary, Visible emissions opacity secondary

O ther (specify): Coke feeder rpm’s.

82

. What level of a monitored operati onal parameter triggers corrective action ?

V olumetric flow rate (acfm) 100 per baghouse, minimum F an amperageEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 23 of 100 (amps , hourly average basis )

P ressure drop (in. H 2 O) Broken bag detector alarm Visible

emissions as back

- up if the broken bag detector is down opacity (%)

O ther (specify): each coke feeder, 4 rpm’s minimum.

83

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 24 of 100 PART C: START

- UPS AND SHUTDOWNS

Please provide the information in Table 6 and questions below for each Subpart LL p otline during start

- up (the commencement of operation for any purpose) and shutdown (the cessation of operation for any purpose) operatio ns. For the purposes of Part C of Enclosure 1 start

- up and shutdown refers to the commencement and cessation of operations of a potline, not of an individual pot (e.g. after anode changes).

1 6

. Please provide a rationale, if applicable, for why application of the Subpart LL standards to

a potline during start

- up or shutdown is not practica b l e economically or technologically

Not practicable economically: Not practicable economically: EPA Reference Methods 14

and 14A are designed to measure TF roof emissions o ver only a subset of the smelting pots

operating in a pot room (roughly 10 or 12 pots out of 130 or 150), with the assumption that

the pots being sampled represent the entire potline during steady

- state operation . During

potline startup, pots located unde r a Method 14 or 14A sampling system do not represent

the entire potline because pots throughout the room are in various stages of startup or non

steady

- state operation. So, it is not technically practicable to either establish a standard for

startup or s how compliance with a startup standard using the available EPA Reference

Method. Establishing a standard for startups is further complicated by the fact that startups

are rare and the conditions of a startup (and associated emissions) will vary depending on

whether a potline was shut down by an emergency power loss (e.g., an ice storm) or

whether the potline was intentionally shut down in a controlled manner. Work practice

standards are the only practicable means of regulating emissions during an aluminum

potline startup.

Collecting Method 14 or 14A samples representative of an the entire potline is not

economically practicable because this would require the installation and operation of 12 or

13 separate Reference Method sampling systems in each potroom to collect representative

compliance samples. These sampling systems typically cost more than $250,000 each to

install and this level of expenditure is not practicable for the rare occasion of startup at an

individual potline.

1 7

. Do you have te st data that show any potline hazardous air pollutant (HAP)

emissions during a start

- up or shutdown? (Check one) X  Y  N

If yes: Data is available. However, during the start

- up events that lasted around 1 month in duration, it is possible that some of the cassettes had no operating pots beneath them duringEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 25 of 100 portions of the sampling period. Such data would not be representative of no rmal operations.

a

. Provide a copy of the test data.

b

. Describe the operating conditions (e.g. tons of aluminum produced per day) at the time

of the testing.

________________ See attached spreadsheets of roof tests. Primary control device tests

were not performe d during this time

period.

________________________________________________________________

______________________________________________________________________

____________________________________________________________

1 8

. Do you have an operating plan t o minimize emissions during start

- up and/or shutdown (e.g. a SS Plan) ? ( CHECK one)

_____ X

______ Yes

____________ No

If “Yes,” please provide a copy of the operating plan

.

19

. Please indicate below how often you perform the following activities during start

- up of your potlines by adding the following codes: A, S, N for A lways, S ometimes, or N ever.

a a. Develop a potroom/potline start

- up schedule before start

- up

a b

. Perform daily assessment of start

- up pro gress and any schedule changes

a c

. Keep records of number of pots started per day

a d

. Bring potroom/potline scrubbers and exhaust fans on line prior to energi zing

first cell to be restarted

s e

. Supply alumina at a higher rate t han during normal pot operation

If so, how much higher? Varies (per cent)

a f

. Keep pots covered during start

- up

a g

. Limit removal of covers or panels to pots being worked on

a h

. Keep primary capture/control system operating at all times during the start

- up

a i. Monitor pot lines frequently during start

- up to identify sick or unstable pots

If so, do you u se the following methods to manage a “sick” or unstable pot

a Adjust exhaust flow from pots

a Adjust cell voltage and feeding levels

a Monitor and adjust anode current and liquid level

_____ Other corrective procedures. Please describe the corrective procedures applie d (use additional pages if needed):

Perform the necessary corrective actions to return the unstable pot to

being a s t able pot. Pot voltage, liquid levels, feed levels, and anodeEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 26 of 100 current balance are all me asured and corrected as quickly as

possible.

_______________________________________________________

_______________________________________________________

_______________________________________________________

_______________________________________________________

_____

2 0

. Please list any additional start

- up activities in the space below.

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 27 of 100 Table 6 D escription of most recent potline start

- up and shutdown of each potline (Make additional copies this table as needed)

Potline ID

(as assigned in

the schematic of question 7) Date(s), duration, and d escription (e.g. planned shutdown for ..., or emergency shutdown due to ...) of

start

- up or shutdown Was the start

- up or shutdown covered by a

contingency plan for controlling emissions? (Y/N) What actions were taken to minimize emissions?

1 12/4/01

– Emergency shutdown, due to power plant failure. Line

never re

- started, and has since
been removed. N

– Control device lost power when power plant failed None available

2 12/4/01

– Emergency shutdown, due to power plant failure. N

– Control device lost power when power plant failed None available

2 1/4/02

– 2/5/02 re

- start per the
SSM Y Activation of dry scrubber sections as pots came back on

- line

3 12/4/01

– Emergency shutdown, due to power plant failure. N

– Control device lost power when power plant failed None available

3 2/1/02

– 3/5/02 re

- start per the
SSM Y Activation of dry scrubber sections as pots came back on

- lineEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 28 of 100 Potline ID

(as assigned in

the
schematic of question 7) Date(s), duration, and

d escription (e.g. planned shutdown for ..., or emergency shutdown due to ...) of start

- up or shutdown Was the start

up or shutdown

covered by a contingency

plan for controlling
emissions? (Y/N) What actions were taken to minimize emissions?

4 12/4/01

– Emergency shutdown, due to power plant failure. N

– Control
device lost power when power plant
failed None available

4 12/15/01

– 1/29/02 re

start per the SSM Y Activation of dry scrubber sections as pots
came back on

- line

PART D : PREVIOUSLY PERFORMED TESTING AND TEST REPORT DATA

2 1

. Submit emission test report result s for calendar year 2010 for polycyclic organic matter (POM ) and total fluorides (TF) for any sources that have POM and/or TF emissions standards under Subpart LL. If available, s ubmit emission test report result s for any testing conducted from January 1, 2006 to the present for metal HAP (i.e. antimony, arsenic, beryllium, cadmium, chromium, hexavalent chromium, cobalt, lead, manganese, nickel, and selenium), TF

, hydrogen fluoride (HF), particulate matter (PM), POM, speciated organic HAP data, and/or carbonyl sulfide (COS) for primary aluminum sources that currently do not have emission standards for those pollutants under Subpart LL

.

W e would prefer electronic copies of these reports, if available . If electronic copies of the test reports are not available, hard copies may be provide d or test result summaries may be provided. The following details (at a minimum) must be included , if available :

(a) P ollutants and emission rates measured (e.g., lb/hr, gr/dscf, lb/ton),

(b) T he names of the test methods or procedures used,

( c ) I nformati on on actual production or pr ocessing rates during the test,

( d ) For COS emission tests, the sulfur content of the coke and pitch used in the anodes at the time the testing was conducted

, and

(e) A statement that the process and any control devices were operating normally during the test, or if not, identify any abnormal or unrepresentative conditions.

2 2

. If emission controls were installed or upgraded for primary aluminum sources after October 7, 1997 to control emissions of POM from prebake potlines, emissions of POMEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 29 of 100 from existing pitch storage tanks, and/or emissions of COS , please also include test reports

, if available, including the information specified in 2 1 (a) through ( e ), for the most recent emission testing that was performed before these controls were installed or upgraded and identify th em as “pre

- MACT test reports.”

2 3

. Has any air monitoring , such as Fourier Transform Infrared (FTIR) s pectroscopy

, been performed at your facility to measure COS concentration and/or emission s of sulfur

oxides ? If so, please provide the most recent data for a normal operating time period

. Please include a description of the locations of sampling (reference the schemat ic submitted in response to question 7) , sampling technique, duration of sampling, production rate during sampling, and potroom operations performed during the sampling.

2 4

. Has any air monitoring , such as FTIR s pectroscopy, been performed at your facilit y to

measure emission s of HF at the same time that TF samples were collected from the roof

monitor ? If so, please provide the most recent data for a normal operating time period. Please include a description of the locations of sampling (reference the schematic submitted in response to question 7), sampling technique, duration of sampling, production rate during sampling, and potroom operations perform ed during the sampling.Enclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

- April 22 , 2011 Page 1 of 3 Test Procedures, Methods, and Reporting Requirements for the Information Collection Request for the Primary Aluminum Reduction Source Category

This document provides an overview of approved methods, targ et pollutant s and units of measure, and reporting requirements for the primary aluminum reduction source category. See
Enclosure 3 for details about EPA’s authority under the Clean Air Act (CAA) section 114 (42

U.S.C. 741 4 ) to request source emission test data. All recipients must complete and submit test

results by May 31 , 2011

. This document will be referred to as the ‘primary aluminum reduction test program.’ The do cument is organized as follows:

1

. 0 Sampling and Chemical An alysis Procedures and Methods for M etallic HAP (including speciated hexavalent chromium)

2.0 How to Report Data

3.0 How to Submit Data

4.0 Co ntact Information for Questions on Test Plan and Reporting

1.0 Sampling and Chemical Analysis Procedures and Methods for Metallic HAP (including speciated hexavalent chromium)

1 .1 Sampling

- Bag House and Electrostatic Precipitator (ESP) Particulate Matter

Sample and analyze representative particulate matter (e.g. in the hoppers) collected by each of the bag houses or ESP used to control particulate matter emissions from primary aluminum potlines

. In cases where solids from different compartments of a single bag

house or ESP are collected in multiple hoppers o r multiple collection sacks, a single composite sample will be adequate. Also, if multiple potlines of the same type (e.g. HSS, SWPB, CWPB1, etc.) are supplied with alumina from the same alumina storage vessel, sampling of representative particulate matte r from the bag house or ESP associated with one of those potlines will be adequate

. Sampling should be conducted once per day for five consecutive operating days with a clean uncontaminated scoop or similar apparatus

. A ll samples collected should be the ap proximately the same weight and stored in a clean

air

- tight container.

Guidance on sample collection can be found in of Chapter 4 of the document Superfund Program Representative Sampling Guidance, Volume 1: Soil (EPA 540/R

- 95/141), which

is available thro ugh the following link:

http://www.epa.gov/tio/download/char/sf_rep_samp_guid_soil.pdf

1

. 2 Sampling

– Wet Scrubber Sludge , Injected Slurry (if applicable), and Discharge Water

Sample and analyze a representative grab sample of the scrubber sludge , injected slurry (if applicable)

, and any aqueous blowdown stream discharged from the wet scrubber. If a separate stream of scrubber blowdown is discharged from the scrubber, collect a representative grab sample of this stream. Also, if multiple potlines of the sam e type (e.g. HSS, SWPB, CWPB1, etc.) are supplied with alumina from the same alumina storage vessel, sampling of representative scrubber sludge, injected slurry (if applicable), and any aqueous blowdown stream from the wet scrubber associated with one of t hose potlines will be adequate

. Sampling should be conducted once per day for five consecutiveEnclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

- April 22 , 2011 Page 2 of 3 operating days. All samples collected should be the approximately the same weight or

volume and stored in a clean container.

1.3 Chemical Analysis

Analyze each sample of bag house or electrostatic precipitator particulate matter

, scrubber sludge , injected slurry (if any), and scrubber blowdown (if any) for individual

HAP metals as listed in Table 1 .1. Also analyze each sample for hexavalent chromium

. Methods for chemical analysis are given in Table 1 .2.

Table 1.1 HAP Metals

Antimony Arsenic Beryllium

Cadmium Chromium Hexavalent Chromium

Cobalt Lead Manganese

Nickel Selenium

Table 1 .2 Methods for Analysis of Samples

Analyte Procedure

HAP metals listed

in Table 1 .1 EPA Method 3051A digestion followed by ICP

- MS
as detailed in EPA Method 6020

Hexavalent

chromium EPA Method 3060A and EPA Method 218.6:

Extraction and Cr +6 Ion Chromatography

2.0 How to Report Data

2

. 1 Reporting Bag House or Electrostatic Precipitator Particulate Matter

, Wet Scrubber Sludge, Injected Slurry, and Discharge Water Chemical Analyses

You must report the results of the chemical analyses of your bag house or electrostatic precipitator particulate matter and wet scrubber sludge, injected slurry, and discharge

water in a Microsoft ® Excel Template which is provided

. If more than one sample is analyzed, y ou must make a copy of the worksheet and update the source ID in order to distinguish between each analysi s of particulate matter collected from each selected bag house. After completing the worksheet, you must also submit an electronic copy of the chemical analysis report (PDF format preferred).

2.2 Calculating and Reporting Values Measured Below Method Detection Levels

See Appendix C

– Guidance for calculating and reporting measurements less than detection levels for emissions data collection (ICR) programs

.Enclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

- April 22 , 2011 Page 3 of 3 3.0 How to Submit Data

Use one of three transmittal methods listed below. In order to avoid duplicate data and keep all data for a particular facility together, we request that you submit all of the data requested from your company in the same way. To submit your data:

• E

- mail an electronic copy of all requested files to primaryicr@epa.gov

.

• If the files are too large for your e

- mail system, you may upload the electronic files to a FTP site; if you would like to use this option, send an email to bahner@rti.org for

instructions on how to access the site.

• Mail a CD or DVD containing an electronic copy of all requested files to the EPA address shown in your Section 114 letter.

If you are submitting CBI, you must mail a separate CD or DVD containing only the CBI portion of your data to the EPA address shown in you r Section 114 letter.

4 .0 Contact Information for Questions on Test Plan and Reporting

For questions on the primary aluminum source category , contact:

David Putney (U.S. EPA) (919) 541

- 2016 putney.david@epa.gov

OR

Rochelle Boyd (U.S. EPA) (919) 541

- 1390 boyd.rochelle@epa.gov

For questions on the test methods contact:

Gerri Garwood (U.S. EPA) (919) 541

- 2406 garwood.gerri@epa.gov

OR

Raymond Merrill (U.S. EPA) (919) 541

- 5225 merrill.raymond@epa.gov

For questions on uploading files to the FTP site, contact:

Mark Bahner (RTI, International) (919) 541

- 6016

ba hner@rti.orgAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

- April 2 2 , 2011 Page 1 of 3 Abbreviations
, Acronyms , and Unit Conversions

acf actual cubic feet

acfm actual cubic feet per minute

acm actual cubic meters

acmm actual cubic meters per minute

ADL above detection level

APC air pollution control

ASTM American Society for Testing and Materials

atm atmospheres (unit of pressure)

BDL below detection level

Btu/hr British thermal units per hour

Btu/scf Briti sh thermal units per standard cubic foot

CAA Clean Air Act

CARB California Air Resources Board

CBI confidential business information

CEMS continuous emission monitoring system

CFR Code of Federal Regulations

CO carbon monoxide

COS carbonyl sulfide

Cr chromium

CS 2 carbon disulfide

CTM Conditional Test Method day/yr days per year

°C degrees Celsius

° F degrees Fahrenheit

D/F dioxins and furans

DLL detection level limited

dscf dry standard cubic feet

dscfm dry standard cubic feet per minute

dscm dry standard cubic meters

dscmm dry standard cubic meters per minute

EPA U.S. Environmental Protection Agency

ERT Electronic Reporting Tool

E SP electrostatic precipitator

ft foot or feet

ft 2 square feet

ft 3 cubic feet fpm feet per minute (acfm divided by ft 2 o f filter area) fps feet per second gal gallon

gpm U.S. gallons per minute gr/dscf grains per dry standard cubic foot

g gram HAP hazardous air pollutants

HCl hydrogen chloride

HCN hydrogen cyanide

HF hydrogen fluorideAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

- April 2 2 , 2011 Page 2 of 3 Hg mercury hr hour or hours hr/day hour s per day

ICR information collection request

in inch or inches

in

. H 2 O inches of water (pressure drop) kg kilogram

kPa kilopascals

kv kilovolt

kw

- hr kilowatt hour

lb pound lb/day pounds per day lb/gal pounds per U.S. gallon

lb/hr pounds per hour

lb/ton pounds per ton

m meter

m 3 cubic meters

MACT maximum achievable control technology

min minute or minutes Mg megagram

mg milligram mg/kg milligram per kilogram mg/l milligrams per liter

MM btu/hr millions of British thermal units per hour

MM scf millions of standard cubic feet

MM lb/yr million pounds per year μg/m 3 microgram per cubic meter

μm micrometer

NAICS North American Industry Classification System

NaOH sodium hydroxide

NESHAP National Emission Standards for Hazardous Air Pollutants

NO

x nitrogen oxides OAQPS Office of Air Quality Planning and Standards

OTM Other Test Method

PAH polynuclear aromatic hydrocarbon

PAL primary aluminum reduction facility pdf Image file format produced with Adobe© or similar software

PM particulate matter

PM 10 particulate matter that is 10 micrometers or less in diameter

PM 2.5 particulate matter that is 2.5 micrometers or less in diameter

POM polycyclic organic matter

ppmv parts per million by volume

ppmw parts per million by weight

RATA Relative Accuracy Test A udit

% percent

s second or seconds

scf standard cubic feet

scf/hr standard cubic feet per hourAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

- April 2 2 , 2011 Page 3 of 3 scfm standard cubic feet per minute

scm standard cubic meters

SO 2 sulfur dioxide

SPPD Sector Policies and Programs Division

SS start

- up or shutdown

TCLP toxicity characteristic leaching procedure

TF total fluorides

THC total hydrocarbons tpd tons (short) per day tph tons (short) per hour
tpy tons (short) per year TSP total suspended particulate
vol% volume percent, or percent by volume

wt% weight percent, or percent by weight

yr year

To convert from To Multiply by

°C °F m ultiply by 1.8 , then add 32

°F °C subtract 32, then multiply by 0.556

ft m 0. 3 048

ft/min m/min 0. 3 048

ft 2 m 2 0.0929

ft 3 m 3 0.028

g lb 0.0022 g/m 3 lb/ft 3 0.0000624

gr lb 0.000143 gr/ dscf mg/dscm 2,290

in

. H 2 O mm H 2 O 25.4

k g/hr lb/hr 2.205

lb g 454

lb gr 7000

lb/ft 3 g /m 3 16,000

lb/hr k g/hr 0.454

m ft 3.28

m/min ft/min 3.28

mm H 2 O in H 2 O 0.0394

m 2 ft 2 10.76 mg/dscm gr/dscf 0.00044

m 3 ft 3 35.31 Mg ton 1.1

ton (short) M g 0.907APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 1 of 5 

### List of Hazardous Air Pollutants (HAP )

CAS

Number Chemical Name

Antimony Compounds Arsenic Compoun ds (inorganic including arsine) Beryllium Compounds Cadmium Compounds Chromium Compounds Cobalt Compounds

Coke Oven Emissions Cyanide Compounds 1
Glycol ethers 2
Lead Compounds Manganese Compounds Mercury Compounds

Fine mineral fibers 3

Nickel Compounds Polycylic Organic Matter 4 ( Report individual polycyclic aromatic hydrocarbons by CAS number). Radionuclides (including radon) 5
Selenium Compounds

75

- 07

- 0 Acetaldehyde

60

- 35

- 5 Acetamide

75

- 05

- 8 Acetonitrile

98

- 86

- 2 Acetophenone

53

- 96

- 3 2

- Acetylaminofluorene

107

- 02

- 8 Acrolein

79

- 06

- 1 Acrylamide

79

- 10

- 7 Acrylic acid

107

- 13

- 1 Acrylonitrile

107

- 05

- 1 Allyl chloride

92

- 67

- 1 4

- Aminobiphenyl

62

- 53

- 3 Aniline

90

- 04

- 0 o

- Anisidine

1332

- 21

- 4 Asbestos

71

- 43

- 2 Benzene (including benzene from gasoline)

92

- 87

- 5 Benzidine

98

- 07

- 7 Benzotrichloride

100

- 44

- 7 Benzyl chloride

92

- 52

- 4 Biphenyl

117

- 81

- 7 Bis(2

- ethylhexyl)phthalate (DEHP)

542

- 88

- 1 Bis(chloromethyl)ether

75

- 25

- 2 Bromoform

106

- 99

- 0 1,3

- Butadiene

156

- 62

- 7 Calcium cyanamideAPPENDIX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 2 of 5 CAS

Number Chemical Name

133

- 06

- 2 Captan

63

- 25

- 2 Carbaryl

75

- 15

- 0 Carbon disulfide

56

- 23

- 5 Carbon tetrachloride

463

- 58

- 1 Carbonyl sulfide

120

- 80

- 9 Catechol

133

- 90

- 4 Chloramben

57

- 74

- 9 Chlordane

7782

- 50

- 5 Chlorine

79

- 11

- 8 Chloroacetic acid

532

- 27

- 4 2

- Chloroacetophenone

108

- 90

- 7 Chlorobenzene

510

- 15

- 6 Chlorobenzilate

67

- 66

- 3 Chloroform

107

- 30

- 2 Chloromethyl methyl ether

126

- 99

- 8 Chloroprene

1319

- 77

- 3 Cresols/Cresylic acid (isomers and mixture)

95

- 48

- 7 o

- Cresol

108

- 39

- 4 m

- Cresol

106

- 44

- 5 p

- Cresol

98

- 82

- 8 Cumene

94

- 75

- 7 2,4

- D, salts and esters

3547

- 04

- 4 DDE

334

- 88

- 3 Diazomethane

132

- 64

- 9 Dibenzofurans

96

- 12

- 8 1,2

- Dibromo

- 3

- chloropropane

84

- 74

- 2 Dibutylphthalate

106

- 46

- 7 1,4

- Dichlorobenzene(p)

91

- 94

- 1 3,3

- Dichlorobenzidene

111

- 44

- 4 Dichloroethyl ether (Bis (2

- chloroethyl)ether)

542

- 75

- 6 1,3

- Dichloropropene

62

- 73

- 7 Dichlorvos

111

- 42

- 2 Diethanolamine

121

- 69

- 7 N,N

- Diethyl aniline (N,N

- Dimethylaniline)

64

- 67

- 5 Diethyl sulfate

119

- 90

- 4 3,3

- Dimethoxybenzidine

60

- 11

- 7 Dimethyl aminoazobenzene

119

- 93

- 7 3,3'

- Dimethyl benzidine

79

- 44

- 7 Dimethyl carbamoyl chloride

68

- 12

- 2 Dimethyl formamide

57

- 14

- 7 1,1

- Dimethyl hydrazine

131

- 11

- 3 Dimethyl phthalate

77

- 78

- 1 Dimethyl sulfate

534

- 52

- 1 4,6

- Dinitro

- o

- cresol, and saltsAPPENDIX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 3 of 5 CAS

Number Chemical Name

51

- 28

- 5 2,4

- Dinitrophenol

121

- 14

- 2 2,4

- Dinitrotoluene

123

- 91

- 1 1,4

- Dioxane (1,4

- Diethyleneoxide)

122

- 66

- 7 1,2

- Diphenylhydrazine

106

- 89

- 8 Epichlorohydrin (l

- Chloro

- 2,3

- epoxypropane)

106

- 88

- 7 1,2

- Epoxybutane

140

- 88

- 5 Ethyl acrylate

100

- 41

- 4 Ethyl benzene

51

- 79

- 6 Ethyl carbamate (Urethane)

75

- 00

- 3 Ethyl chloride (Chloroethane)

106

- 93

- 4 Ethylene dibromide (Dibromoethane)

107

- 06

- 2 Ethylene dichloride (1,2

- Dichloroethane)

107

- 21

- 1 Ethylene glycol

151

- 56

- 4 Ethylene imine (Aziridine)

75

- 21

- 8 Ethylene oxide

96

- 45

- 7 Ethylene thiourea

75

- 34

- 3 Ethylidene dichloride (1,1

- Dichloroethane)

50

- 00

- 0 Formaldehyde

76

- 44

- 8 Heptachlor

118

- 74

- 1 Hexachlorobenzene

87

- 68

- 3 Hexachlorobutadiene

77

- 47

- 4 Hexachlorocyclopentadiene

67

- 72

- 1 Hexachloroethane

822

- 06

- 0 Hexamethylene

- 1,6

- diisocyanate

680

- 31

- 9 Hexamethylphosphoramide

110

- 54

- 3 Hexane

18540

- 29

- 9 Hexavalent chromium

302

- 01

- 2 Hydrazine

7647

- 01

- 0 Hydrochloric acid

7664

- 39

- 3 Hydrogen fluoride (Hydrofluoric acid)

123

- 31

- 9 Hydroquinone

78

- 59

- 1 Isophorone

58

- 89

- 9 Lindane (all isomers)

108

- 31

- 6 Maleic anhydride

67

- 56

- 1 Methanol

72

- 43

- 5 Methoxychlor

74

- 83

- 9 Methyl bromide (Bromomethane)

74

- 87

- 3 Methyl chloride (Chloromethane)

71

- 55

- 6 Methyl chloroform (1,1,1

- Trichloroethane)

60

- 34

- 4 Methyl hydrazine

74

- 88

- 4 Methyl iodide (Iodomethane)

108

- 10

- 1 Methyl isobutyl ketone (Hexone)

624

- 83

- 9 Methyl isocyanate

80

- 62

- 6 Methyl methacrylateAPPENDIX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 4 of 5 CAS

Number Chemical Name

1634

- 04

- 4 Methyl tert butyl ether

101

- 14

- 4 4,4

- Methylene bis(2

- chloroaniline)

75

- 09

- 2 Methylene chloride (Dichloromethane)

101

- 68

- 8 Methylene diphenyl diisocyanate (MDI)

101

- 77

- 9 4,4'¬

- Methylenedianiline

91

- 20

- 3 Naphthalene

98

- 95

- 3 Nitrobenzene

92

- 93

- 3 4

- Nitrobiphenyl

100

- 02

- 7 4

- Nitrophenol

79

- 46

- 9 2

- Nitropropane

684

- 93

- 5 N

- Nitroso

- N

- methylurea

62

- 75

- 9 N

- Nitrosodimethylamine

59

- 89

- 2 N

- Nitrosomorpholine

56

- 38

- 2 Parathion

82

- 68

- 8 Pentachloronitrobenzene (Quintobenzene)

87

- 86

- 5 Pentachlorophenol

108

- 95

- 2 Phenol

106

- 50

- 3 p

- Phenylenediamine

75

- 44

- 5 Phosgene

7803

- 51

- 2 Phosphine

7723

- 14

- 0 Phosphorus

85

- 44

- 9 Phthalic anhydride

1336

- 36

- 3 Polychlorinated biphenyls (Aroclors)

1 120

- 71

- 4 1,3

- Propane sultone

57

- 57

- 8 beta

- Propiolactone

123

- 38

- 6 Propionaldehyde

114

- 26

- 1 Propoxur (Baygon)

78

- 87

- 5 Propylene dichloride (1,2

- Dichloropropane)

75

- 56

- 9 Propylene oxide

75

- 55

- 8 1,2

- Propylenimine (2

- Methyl aziridine)

91

- 22

- 5 Quinoline

106

- 51

- 4 Quinone

100

- 42

- 5 Styrene

96

- 09

- 3 Styrene oxide

1746

- 01

- 6 2,3,7,8

- Tetrachlorodibenzo

- p

- dioxin

79

- 34

- 5 1,1,2,2

- Tetrachloroethane

127

- 18

- 4 Tetrachloroethylene (Perchloroethylene)

7550

- 45

- 0 Titanium tetrachloride

108

- 88

- 3 Toluene

95

- 80

- 7 2,4

- Toluene diamine

584

- 84

- 9 2,4

- Toluene diisocyanate

95

- 53

- 4 o

- Toluidine

8001

- 35

- 2 Toxaphene (chlorinated camphene)

120

- 82

- 1 1,2,4

- TrichlorobenzeneAPPENDIX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 5 of 5 CAS

Number Chemical Name

79

- 00

- 5 1,1,2

- Trichloroethane

79

- 01

- 6 Trichloroethylene

95

- 95

- 4 2,4,5

- Trichlorophenol

88

- 06

- 2 2,4,6

- Trichlorophenol

121

- 44

- 8 Triethylamine

1582

- 09

- 8 Trifluralin

540

- 84

- 1 2,2,4

- Trimethylpentane

108

- 05

- 4 Vinyl acetate

593

- 60

- 2 Vinyl bromide

75

- 01

- 4 Vinyl chloride

75

- 35

- 4 Vinylidene chloride (1,1

- Dichloroethylene)

1330

- 20

- 7 Xylenes (isomers and mixture)

95

- 47

- 6 o

- Xylenes

108

- 38

- 3 m

- Xylenes

106

- 42

- 3 p

- Xylenes

NOTE: For all listings above which contain the word "compounds" and for glycol ethers, the following applies: Unless otherwise specified, these listings are defined as including any unique chemical substance that contains the named chemical (i.e., antimony, arsenic, etc.) as part of that chemical's infrastructure.

1 : X'CN where X = H' or any other group where a formal dissociation may occur. For example KCN or Ca(CN)2

2 : Includes mono

- and di

- ethers of ethylene glycol, diethylene glycol, and triethylene glycol R

- (OCH2CH2)n

- OR' where :

n = 1, 2, or 3

R = alkyl or aryl groups

R' = R, H, or groups which, when removed, yield glycol ethers with the structure:

R

- (OCH2CH)n

- OH. Polymers are excluded from the glycol category. Also

excludes ethylene glycol monobutyl ether (EGBE) (2

- Butoxyethanol)
(Chemical Abstract Service (CAS ) No. 111

- 76

- 2) and surfactant alcohol ethoxylates and their derivatives (SAED)

.

3 : Includes mineral fiber emissions from facilities manufacturing or processing glass, rock, or slag fibers (or other mineral derived fibers) of average diameter 1

micrometer or less.

4 : Includes organic compounds with more than one benzene ring, and which have a boiling point greater than or equal to 100o C. Report individual polycyclic aromatic hydrocarbons by CAS number.

5 : A type of atom which spontaneously undergoes radioa ctive decay.APPENDIX C

Primary Aluminum Reduction Section 114 Appendix C

- April 2 2 , 2011 Page 1 of 1 Guidance For Calculating And Reporting Measurements Less Than
Method Detection Levels For Test Data Submitted in Response to Information Collection Request (ICR) Programs

Identify the status of measured values relative to detection levels on the spreadsheet using the following descriptions:

• BDL (below detection level)

– all analytical values used to calculate and report a fabric filter particulate matter

, electrostatic precipitator particulate matter

, sludge, or scrubber

blowdown metal analysis are less than the laboratory ’s reported detection level(s);

• DLL (detection level li mited)

– at least one

, but not all

, values used to calculate and
report a fabric filter particulate matter

, electrostatic precipitator particulate matter

, sludge,

or scrubber blowdown metal analysis are less than the laboratory’s reported detection level(s); or

• ADL (above detection level)

– all analytic al values used to calculate and report a fabric filter particulate matter

, electrostatic precipitator particulate matter

, sludge, or scrubber

blowdown metal analysis are greater than the laboratory’s reported detection level(s).

For each reported emission s value, insert the appropriate flag (i.e. BDL, DLL , or ADL) in

the Note line of the Microsoft® Excel emission t est spreadsheet template.

When reporting and calculating individual test run data:

• For analytical data reported from the lab as “nondetect” or “below detection level;”

− Include a brief description of the procedures used to determine the analytical
detection levels in the Note line of the Microsoft® Excel emission t est spreadsheet template.

− Describe these procedures completely in a separate attachm ent including the measurements made, the standards used, and the statistical procedures applied.

− Report the calculated emissions concentration or rate result as a bracketed “less than” detection level value (e.g., [<0.0105]) in the Microsoft® Excel emissio n t est spreadsheet template

− Report as numerical values (i.e., no brackets or < symbol) any analytical data measured above the detection level including any data between the analytical detection level and a laboratory

- specific reporting or quantification le vel (i.e., flag as ADL).