Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 1 of 100

Facility Questionnaire for Primary Aluminum Reduction 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 INFORMATION

(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 Road 66 and 61 ____________________________________________

b. City: Newburgh _______________________________________________________

c. State: Indiana _________________________________________________________

d. Zip: 47629____________________________________________________________

e. County: Warrick _______________________________________________________

4. Provide mailing address of the facility if different 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 files are preferred).

7. Please provide a copy of the facility schematic showing all of the primary aluminum 

operations that are subject to 40 CFR Part 63, Subpart LL. Please include 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: PROCESSES AND EMISSIONS CONTROL DEVICES

8. Pitch 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 capacity (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 pitch storage tank(s) is not practicable economically or technologically

Not practicable economically Not practicable economically: __Setting a Nationally 

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. Anode bake furnaces:

1 _______________ Total number of anode bake furnaces at facility

187303 __________ Facility-wide green anode production capacity (tons per year)

126657 __________ Total amount of coke used for anode production (tons per year) 

assuming facility operation at maximum capacity

10. Aluminum 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 )

11. 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):

11a. Potline ID No. Potline Type * Total No. of Pots

Potline # 2 CWPB1 150

Potline # 3 CWPB1 150

Potline # 4 CWPB1 150

Potline # 5 CWPB1 150

Potline # 6 CWPB1 150

* Center-worked 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)

11b. 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 opened 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, that a given side shield or door of a cell of 

the cited potline is removed.

11c. 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 evacuation 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.

11d. 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 to 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

12. Is total fluoride emitted from the roof vents measured with a sampling manifold or a 

cassette system? (CHECK one) ___________ Manifold or _________x_____ Cassette

12a. What is the total typical exhaust rate from the roof vents of each potroom (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

13. 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 specifications 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

13a. What is the availability and cost of coke and pitch with lower sulfur contents 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

13b. 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 materials.

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.com
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 8 of 100

13c. 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 emissions
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 9 of 100

14. 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 on 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 standards 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 

upgraded 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 Al tapped

2000
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 10 of 100

15. 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).

None
Enclosure 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 device 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 submission

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) _________________________________________________
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Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 12 of 100

5. Pressure mode of operation: x positive pressure negative pressure

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

°F

7. Gas flow rate: 463,108 acfm (at bag house outlet) 368,306 dscfm

8. Pressure drop: Across scrubber: 6-8” inches water column (in. H2O)

Across bag house: 4-10” inches water column (in. H2O)

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:

_______Volumetric flow rate X Fan amperage

 Pressure drop X Visible emissions opacity

Other (specify): alumina feeder RPM 

.

13. What level of a monitored operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 2465 Fan amperage (amps)

 Pressure drop (in. H2O) any visible emission Visible emissions opacity (%)

Other (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

Table 2 Combination Dry Alumina Scrubber/Bag House Description

2. Control device 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 the roof 

monitors 105M.1 and 106M.1 for line 3 and 107M.1 and 108M.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. Pressure mode of operation: positive pressure x negative 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. H2O)

Across bag house: 8-14” inches water column (in. H2O)

23. Solid to gas ratio: .80 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 280 Tons/ Day

Other alumina (specify ring furnace) 30 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 known as potline 3

Potline #4 150 pots known as potline 4

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

control device is operating properly:

_______Volumetric flow rate X Fan amperage

 Pressure drop X Visible emissions opacity

Other (specify): alumina feeder RPM 

.

27. What level of a monitored operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 502 Fan amperage (amps)

 Pressure drop (in. H2O) any visible emission Visible emissions opacity (%)

Other (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 device 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 109M.1 and 110M.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: _______________ Longitude: ________________

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) _________________________________________________
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Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 16 of 100

33. Pressure mode of operation: X positive pressure negative pressure

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

°F

35. Gas flow rate: 455,004 acfm (at bag house outlet) 368,332 dscfm

36. Pressure drop: Across scrubber: 6-8 inches water column (in. H2O)

Across bag house: 4-10 inches water column (in. H2O)

37. Solid to gas ratio: .80 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) 30 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:

_______Volumetric flow rate X Fan amperage

 Pressure drop X Visible emissions opacity

Other (specify): alumina feeder RPM 

.

41. What level of a monitored operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 2549 Fan amperage (amps)

 Pressure drop (in. H2O) any visible emission Visible emissions opacity (%)

Other (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 device 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 161B61.1-161B6.36

Secondary emissions are uncontrolled from the potlines and are exhausted at the roof 

monitors 111M.1 and 112M.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): _________________________________________
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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. Pressure mode of operation: x positive pressure negative pressure

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

°F

49. Gas flow rate: 498,586 acfm (at bag house outlet) 387,801 dscfm

50. Pressure drop: Across scrubber: 6-8 inches water column (in. H2O)

Across bag house: 4-10inches water column (in. H2O)

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) 30 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 operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 2732 Fan amperage (amps)

 Pressure drop (in. H2O) any visible emission Visible emissions opacity (%)

Other (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 device 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 concentration (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-05mg/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. Pressure mode of operation: X positive pressure negative pressure

61. Typical gas temperature: inlet to scrubber 450 °F outlet from bag house 

°F
Enclosure 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. H2O)

Across bag house: inches water column (in. H2O)

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:

 Volumetric flow rate X Fan amperage

 Pressure drop X Broken bag detectors primary, 

 Visible emissions opacity,secondary

Other (specify): dense phase units 24-hour cumulative dumps for alumina flow 

.

68. What level of a monitored operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 675, minimum Fan amperage (amps)

 (24-hour average basis)

 Pressure drop (in. H2O) Broken bag detector alarm, Visible 

emissions if broken bag detector is down

Other (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 device 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 minimum 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 submittal

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) Percent 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. Pressure mode of operation: positive pressure X negative 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. H2O)

Across bag house: inches water column (in. H2O)

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:

 Volumetric flow rate X Fan amperage

 

 Pressure drop X Broken bag detector primary, Visible 

 emissions opacity secondary

Other (specify): Coke feeder rpm’s. 

82. What level of a monitored operational parameter triggers corrective action?

 Volumetric flow rate (acfm) 100 per baghouse, minimum Fan amperage
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 23 of 100

 (amps, hourly average basis)

 Pressure drop (in. H2O) Broken bag detector alarm Visible 

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

Other (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 potline 

during start-up (the commencement of operation for any purpose) and shutdown (the cessation of 

operation for any purpose) operations. 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).

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

a potline during start-up or shutdown is not practicable economically or technologically

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

and 14A are designed to measure TF roof emissions over 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 under 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 nonsteady-state operation. So, it is not technically practicable to either establish a standard for 

startup or show 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. 

17. Do you have test 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 during 
Enclosure 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 normal 

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 performed during this time 

period.________________________________________________________________

______________________________________________________________________

____________________________________________________________

18. Do you have an operating plan to 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 Always, Sometimes, or Never.

a a. Develop a potroom/potline start-up schedule before start-up

a b. Perform daily assessment of start-up progress 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 energizing 

first cell to be restarted

s e. Supply alumina at a higher rate than during normal pot operation

If so, how much higher? Varies (percent)

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 use 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 applied (use additional pages if needed):

Perform the necessary corrective actions to return the unstable pot to 

being a stable pot. Pot voltage, liquid levels, feed levels, and anode 
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 26 of 100

current balance are all measured and corrected as quickly as 

possible.

_______________________________________________________

_______________________________________________________

_______________________________________________________

_______________________________________________________

_____

20. 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 Description 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 description 

(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-line
Enclosure 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 

description (e.g. planned 

shutdown for ..., or 

emergency shutdown due 

to ...) of start-up or 

shutdown

Was the startup 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 restart per the SSMY Activation of dry scrubber sections as pots 

came back on-line

PART D: PREVIOUSLY PERFORMED TESTING AND TEST REPORT DATA

21. Submit emission test report results 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, submit emission test report results 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.

We would prefer electronic copies of these reports, if available. If electronic copies of the 

test reports are not available, hard copies may be provided or test result summaries may be 

provided. The following details (at a minimum) must be included, if available:

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

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

(c) Information on actual production or processing 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.

22. 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 POM 
Enclosure 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 21(a) through (e), for the most recent 

emission testing that was performed before these controls were installed or upgraded and 

identify them as “pre-MACT test reports.”

23. Has any air monitoring, such as Fourier Transform Infrared (FTIR) spectroscopy, been 

performed at your facility to measure COS concentration and/or emissions 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 schematic 

submitted in response to question 7), sampling technique, duration of sampling, production 

rate during sampling, and potroom operations performed during the sampling.

24. Has any air monitoring, such as FTIR spectroscopy, been performed at your facility to 

measure emissions 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 performed 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, target pollutants 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. 7414) 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 document is organized as follows:

1.0 Sampling and Chemical Analysis Procedures and Methods for Metallic HAP 

(including speciated hexavalent chromium)

2.0 How to Report Data

3.0 How to Submit Data

4.0 Contact 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 or 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 matter 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. 

All samples collected should be the approximately 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 through 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 same 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 those potlines 

will be adequate. Sampling should be conducted once per day for five consecutive 
Enclosure 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, you must make a copy of the worksheet and update the source ID in order to 

distinguish between each analysis 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 your 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

bahner@rti.org
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 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 British 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

CS2 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

ESP electrostatic precipitator

ft foot or feet

ft2 square feet

ft3 cubic feet

fpm feet per minute (acfm divided by ft2of 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 fluoride
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 2011

Page 2 of 3

Hg mercury

hr hour or hours

hr/day hours per day

ICR information collection request

in inch or inches

in. H2O 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

m3 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/m3 microgram per cubic meter

μm micrometer

NAICS North American Industry Classification System

NaOH sodium hydroxide

NESHAP National Emission Standards for Hazardous Air Pollutants

NOx 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

PM10 particulate matter that is 10 micrometers or less in diameter

PM2.5 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 Audit

% percent

s second or seconds

scf standard cubic feet

scf/hr standard cubic feet per hour
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 2011

Page 3 of 3

scfm standard cubic feet per minute

scm standard cubic meters

SO2 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 multiply by 1.8, then add 32

°F °C subtract 32, then multiply by 0.556

ft m 0.3048

ft/min m/min 0.3048

ft2m

2 0.0929

ft3 m3 0.028

g lb 0.0022

g/m3 lb/ft3 0.0000624

gr lb 0.000143

gr/dscf mg/dscm 2,290

in. H2O mm H2O 25.4

kg/hr lb/hr 2.205

lb g 454

lb gr 7000

lb/ft3 g/m3 16,000

lb/hr kg/hr 0.454

m ft 3.28

m/min ft/min 3.28

mm H2O in H2O 0.0394

m

2 ft2 10.76

mg/dscm gr/dscf 0.00044

m3 ft3 35.31

Mg ton 1.1

ton (short) Mg 0.907
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 2011

Page 1 of 5

List of Hazardous Air Pollutants (HAP)

CAS 

Number Chemical Name

Antimony Compounds

Arsenic Compounds (inorganic including arsine)

Beryllium Compounds

Cadmium Compounds

Chromium Compounds

Cobalt Compounds

Coke Oven Emissions

Cyanide Compounds1

Glycol ethers2

Lead Compounds

Manganese Compounds

Mercury Compounds

Fine mineral fibers3

Nickel Compounds

Polycylic Organic Matter4 (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 cyanamide
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 salts
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 methacrylate
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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)

1120-71-4 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-Trichlorobenzene
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 radioactive decay.
APPENDIX C

Primary Aluminum Reduction Section 114 Appendix C - April 22, 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 limited) – 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 analytical 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 emissions value, insert the appropriate flag (i.e. BDL, DLL, or ADL) in 

the Note line of the Microsoft® Excel emission test 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 test

spreadsheet template.

− Describe these procedures completely in a separate attachment 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 emission test

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 level (i.e., flag 

as ADL).