## Hydro Aluminum North America Monett, Missouri East Remelt Furnace (EU 0010) Holding Furnace (EU 0030)
Permit Number OP2008-027 October 23 – 25, 2012



# Prepared By:

106 Ambient Airway  Starke, FL 32091  (904) 964-8440  Fax (904) 964-6675 

# LELAP A CCREDITED 

# L ABORATORY 

# C ERTIFICATION 

# N UMBER 

# 04064 LELAP A GENCY 

# I NTEREST 

# N UMBER 

# 100329

## Hydro Aluminum North America Monett, Missouri East Remelt Furnace (EU 0010)

Holding Furnace (EU 0030)
Permit Number OP2008-027 October 23 – 25, 2012

Prepared by: AMBIENT AIR SERVICES, INC. 106 AMBIENT AIRWAY STARKE, FLORIDA 32091 (904) 964-8440 LELAP Accredited Laboratory Certification Number: 04064 LELAP Agency Interest Number: 100329

## CERTIFICATION
Ambient Air Services, Inc. (AASI) of Starke, Florida has completed the testing as described in
this report for Hydro Aluminum North America (Hydro) located in Monett, Missouri. To the
best of our knowledge and abilities, all information, facts, and test data are true and correct.
Information supplied to AASI for use in this report from Hydro is perceived to be accurate and is
used as such where necessary.

This report contains pages 1 through 428.

This report was reviewed by:

David C. Sholtes, Quality Assurance Manager Date ·



# /<.Jo 

# '?Ir 2- 

## Dater 

# I

Questions and or comments regarding this report or process conditions should be directed to:
Mr. Steve Reid Hydro Aluminum North America 808 County Road Monett, MO 65708 Phone: 417-354-8225 Email:steve.reid@hydro.com

Hydr o Aluminum , M o n e tt 

## Mr. Joseph L. 

## Cooksey Ambient Air Services, Inc. 106 Ambient Airway Starke, FL 32091 Phone:904-964-8440 Email:joecooksey@ambientairservices.com

P a g e 2 o f 4 28 R ev i s i o n 0 : 1 2 0 5 1 2

## EXECUTIVE SUMMARY

On October 23-25, 2012 Ambient Air Services, Inc. (AASI) performed testing to measure Dioxin/Furan (D/F), hydrogen chlo ride (HCl), and particulate ma tter (PM) emissions from the East Remelt Furnace and hydrogen chloride (HCl) a nd particulate matter (PM) from the Holding Furnace at Hydro Aluminum North America (Hydro) located in Monett Missouri. A summary of the results is presented in the table below.

Executive Summary Hydro Aluminum North America Monett, Missouri October 23-25, 2012

Sources Parameters Permit Limits Test Results

Hydrogen Chloride (HCl) 0.40 lb/ton of aluminum charged 0.16 lb/ton of aluminum charged

Dioxin/Furan (D/F) 15ug of D/F TEQ / MG of aluminum charged 2 ug of D/F TEQ / MG of aluminum charged Aluminum Melting Furnace (EU 0010) East Furnace Particulate Matter (PM) 0.40 lb/ton of aluminum charged 0.22 lb/ton of aluminum charged
Hydrogen Chloride (HCl) 0.40 lb/ton of aluminum charged 0.005 lb/ton of aluminum charged Holding Furnace (EU 0030) Particulate Matter (PM) 0.80 lb/ton of aluminum charged 0.01 lb/ton of aluminum charged

## TABLE OF CONTENTS

PAGE CERTIFICATION 2
EXECUTIVE SUMMARY 3
TABLE OF CONTENTS 4 1.0 INTRODUCTION 6
1.1 General 6 1.2 Project Participants 8 2.0 PROCESS DESCRIPTION 9
3.0 SUMMARY OF TEST RESULTS 10 Table 3.1 Summary of Test Results 11 Table 3.2 Remelt Furnace (EU 0010) Summary of Dioxin/Furan (D/F) 12 Table 3.3 Remelt Furnace (EU 0010) Summary of Hydrogen Chloride (HC1) 13 Table 3.4 Remelt Furnace (EU 0010) Summary of Particulate Matter (PM) 14 Table 3.5 Holding Furnace (EU 0030) Summary of Hydrogen Chloride (HC1) 15 Table 3.6 Holding Furnace (EU 0030) Summa ry of Particulate Matter (PM) 16 4.0 TESTING METHODOLOGY AND PROCEDURES 17 4.1 Sampling Locations 17 4.2 Sampling Points 17 4.3 Velocity and Volumetric Flow Rate 17 4.4 Oxygen (O 2 

## ) and Carbon Dioxide (CO 2 

## ) 17 4.5 Moisture Content 18 4.6 Particulate Matter (PM) and H ydrogen Chloride (HC1) Testing 18 4.7 Dioxin/Furan (D/F) 22 5.0 PROTOCOL DEVIATIONS AND TEST COMMENTS 24 6.0 SAMPLE POINT LOCATIONS 25

## TABLE OF CONTENTS (Continued)

PAGE
APPENDICES 27

APPENDIX A ALUMINUM MELTING FURNACE (EU 0010) 28
APPENDIX A.1 PARTICULATE MATTER (PM) 29 AND HYDROGEN CHLORIDE (HC1) DATA APPENDIX A.2 DIOXIN/FURAN (D/F) DATA 72

APPENDIX B ALUMINUM HOLDING FURNACE (EU 0030) 131
APPENDIX B.1 PARTICULATE MATTER (PM) 132 AND HYDROGEN CHLORIDE (HC1) DATA

APPENDIX C TEST PROTOCOL 164
APPENDIX D LABORATORY ACCREDITATION 230
APPENDIX E PRODUCTION DATA 235
APPENDIX F HCl LABORATORY REPORT 270

Revision History

Revision Comments Issue Date
0 Original issued to Ryan Nall December 5, 2012

## 1.0 INTRODUCTION
1.1 General Hydro is subject to specific emission standard s in accordance with existing air quality permits issued by the Missouri Department of Natura l Resources (MDNR). In addition certain operations at the facility are subject to th e National Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Processing Facilities, promulgated at 40 CFR Part 63, Subpart RRR (“Subpart RRR”). The facility is a major source of hazardous ai r pollutants. The existing remelt furnaces and the holding furnace at the facility are “Group 1” uncontrolled furnaces under the provisions of Subpart RRR. Th ey are therefore pursuan t to applicable air quality limitations for dioxin/furan (D/F), hydrogen chloride (HC1), and particulate matter (PM) (Group 1 non-clean charge limitations). The holdi ng furnace is subject to the hydrogen chloride (HC1) and particulate matter (PM) limitations becau se it is a Group 1 – Clean Charge furnace. Hydro uses a reactive flux in the holder for qua lity control purposes. All other materials charged to the holder are considered clean charge.

Operating Permit OP2008-27 includes provisions regarding performance testing of the remelt furnaces and holding furnace for purposes of de monstrating compliance with applicable dioxin/furan (D/F), hydrogen chloride (HC1), and particulate matter (PM) emission limitations. The testing conducted meets the requirements for pe rformance testing in accordance with source testing provisions included within Subpart RRR. A summary of the testing conducted on October 23-25, 2012 is shown in Table 1.1.1.

## Table 1.1.1

Summary of Testing Hydro Aluminum North America Monett, Missouri October 23-25, 2012

Source Description Parameter EPA Reference Methods Duration of Tests (1)



## Hydrogen Chloride

(HCl)

Particulate Matter (PM) Aluminum Melting Furnace (EU 0010) East Furnace Dioxin/Furan (D/F) 40 CFR Part 60 Appendix A, Methods 1, 2, 3, 4, 5, 23, and 26A 3 test runs, each run for one furnace “batch”

Particulate Matter (PM) Aluminum Holding Furnace (EU 0030) Hydrogen Chloride

(HCl) 40 CFR Part 60 Appendix A, Methods 1, 2, 3, 4, 5, and 26A 3 test runs, each run for one furnace “batch”

(1) 

## Three runs, 1 operating cycle each, were conducte d on the east furnace stack. The testing was conducted sequentially beginning with the melter a nd ending with the ho lder for each operating cycle tested.

## 1.2 Project Participants

The personnel indicated in Table 1.2. 1 participated in this project.

Table 1.2.1

Project Participants Hydro Aluminum North America Monett, Missouri October 23-25, 2012

Name Affiliation Responsibility
David Pate Ambient Air Services, Inc. Project Manager, Field Testing Abram Lafferty Ambient Air Services, Inc. Field Testing Jack Jory Ambient Air Services, Inc. Field Testing

Andrea Yerina Ambient Air Serv ices, Inc. Report Preparation Joseph Cooksey Ambient Air Servi ces, Inc. Technical Director

David Sholtes Ambient Air Services, Inc. Quality Assurance Manager

Ryan Nall Hydro Aluminum North America Environmental Engineer Timothy Keesling Hydro Aluminum North America Corporate Environmental Director Eric Ewing CleanAir Engineering HCl Analysis Amber Kornegay SGS Analytical Perspectives Dioxin/Furan Analysis

Richard Swartz Missouri Department of Natural Resources Observation

## 2.0 PROCESS DESCRIPTION

The Remelt facility or cast house contains tw o natural gas fired melting furnaces and a holding furnace, an in-line argon fluxer/degasser, casting pit and homogenizing ovens. Clean and painted scrap aluminum mixed with prim e (ingot, sows) is loaded into the melting furnace in predetermined ratios.

Hot dross is skimmed from the molten aluminum and pressed and cooled prior to stockpiling in the dross area pending transport to an off-site f acility for metal recovery. Molten aluminum is fed from the melting furnaces to the holding furnace . Alloying and fluxing materials may be added during this transfer and while the metals are bei ng stirred in the holder. The metal is transferred from the holding furnace to the casting table for ve rtical, direct-chill casting into logs. During the transfer from the holder to the casting, the in-l ine fluxer or degassing un it injects argon gas into
the molten metal. Degassing removes hydrogen, oxides, and other im purities that can lead to formation of porosity/inclusions in the solidified metal. The cast aluminum logs are placed in a homogenizer
for heat treatment to achieve unif orm grain size in the metal prior to saw cut for shipment to an extrusion plant.

## 3.0 SUMMARY OF TEST RESULTS

Table 3.1 presents a summary of test results. Remelt Furnace (EU 0010) Table 3.2 presents a summar y of Dioxin/Furan (D/F) Table 3.3 presents a summary of Hydrogen Chloride (HC1) Table 3.4 presents a summary of Particulate Matter (PM) Holding furnace (EU 0030) Table 3.5 presents a summary of Hydrogen Chloride (HC1) Table 3.6 presents a summary of Particulate Matter (PM)

## Table 3.1

Summary of Testing Hydro Aluminum North America Monett, Missouri October 23-25, 2012

Sources Parameters Permit Limits Test Results

Hydrogen Chloride (HCl) 0.40 lb/ton of aluminum charged 0.16 lb/ton of aluminum charged

Dioxin/Furan (D/F) 15ug of D/F TEQ / MG of aluminum charged 2 ug of D/F TEQ / MG of aluminum charged Aluminum Melting Furnace (EU 0010) East Furnace
Particulate Matter (PM) 0.40 lb/ton of aluminum charged 0.22 lb/ton of aluminum charged

Hydrogen Chloride (HCl) 0.40 lb/ton of aluminum charged 0.005 lb/ton of aluminum charged Holding Furnace (EU 0030) Particulate Matter (PM) 0.80 lb/ton of aluminum charged 0.01 lb/ton of aluminum chargedTABLE 3.2ProductionContaminatedScrap Isokinetics11:2515:578:2512:548:0512:16R-1 R-2 R-31420 6230 9381.26E-101.84E-10 1.25E-05GR/SCFDDioxin Emissionsug/Mg0.94.245.43Percent44.9645.6845.66Percent1Aluminum Melting Furnace No. 1 (East)SCFD517945Moisture %Sample VolumeOctober 23-25, 2012StackRun10/23/2012Date Number GR/TONAASIVolumetric Flow RatesDioxin Emissions SummaryMonett, MissouriHydro Aluminum North AmericaAASI USEPA Method 5/23 60 Point Template - Rev 2/12-15-20054.36E-10 2.64E-05239.98E-10Average10/24/201210/25/20125.88E-057.89E-0617727812571698113780216379188590.61.95Time (CDT)109.951999110197119.08596.348114.420ACFM SCFMDTempoF646599627TPHTotal TEQ (picograms)7.27.37.87.462455Table 3.3ProductionContaminatedScrapIsokinetics11:2515:558:2512:548:0512:16Run 1 Run 2 Run 340660 251000 12350045.43Percent44.9645.6845.66Laboratory Results (g)0.150.16TPH7.27.37.87.4SCFMDTempoFHydrogen Chloride EmissionsLBS/TON0.050.28604AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-20051Aluminum Melting Furnace No. 1 (East)SCFD5PercentMoisture %ACFM0.01710.0045 0.33GR/SCFD LBS/HRRun10/23/2012Date Number Time (CDT)AASIVolumetric Flow RatesHydrogen Chloride Emissions SummaryMonett, MissouriHydro Aluminum North AmericaSample VolumeOctober 23-25, 2012Stack0.0182 1.17230.0330Average10/24/201210/25/20122.051.13176718574723176917832162321760619175554621633122.125109110104107137.891117.297111.186619Table 3.4ProductionContaminatedScrapIsokinetics11:2515:558:2512:548:0512:1645.43Percent44.9645.6845.667.4TPH7.27.37.80.130.360.160.22Moisture %Sample VolumeOctober 23-25, 2012StackACFM SCFMDTempoFTime (CDT)Particulate EmissionsLBS/TON122.125109110104107137.891117.297111.186619 55462163317671857472317691783216232176060.0246 1.60230.0424Average10/24/201210/25/20122.631.23AASIVolumetric Flow RatesParticulate Emissions SummaryMonett, MissouriHydro Aluminum North America0.01860.0129 0.95Run10/23/2012Date NumberGR/SCFD LBS/HR604AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-20051Aluminum Melting Furnace No. 1 (East)SCFD519175PercentTable 3.5ProductionIsokinetics15:3517:1512:3014:0011:5714:03Run 1 Run 2 Run 318220 430 2040257AASI USEPA Method 5 60 Point Template with HCl - Rev 0/12-15-20051Holding FurnaceSCFD3PercentMoisture %ACFM0.0120.00060.0068 0.240.020.00010/23/2012Date Number Time (CDT)StackSCFMDTempoFRun Hydrogen Chloride EmissionsLBS/TONGR/SCFD LBS/HRAASIVolumetric Flow RatesHydrogen Chloride Emissions SummaryMonett, MissouriHydro Aluminum North AmericaSample VolumeOctober 23-25, 201260480.0025 0.09230.0002Average10/24/201210/25/20120.014123375447824220322520959405271650294939541.21333.23556.87697Laboratory Results (g)0.0010.00543.775218.92303TPH19.521.715.5Table 3.6ProductionIsokinetics15:3517:1512:3014:0011:5714:03ACFM SCFMDTempoFTime (CDT) LBS/TON TPH43.7759794939541.21333.23556.876230 32322520959404123375447824220527165020.0046 0.17230.0030Average10/24/201210/25/20120.100.16AASIVolumetric Flow RatesParticulate Emissions SummaryMonett, MissouriHydro Aluminum North AmericaSample VolumeOctober 23-25, 2012Stack0.00380.0070 0.25Run10/23/2012Date Number GR/SCFD LBS/HRParticulate Emissions257AASI USEPA Method 5 60 Point Template with HCl - Rev 0/12-15-20051Holding FurnaceSCFD36048PercentMoisture %0.010.000.010.0119.521.715.518.9

## 4.0 TESTING METHODOLOGY AND PROCEDURES

4.1 Sampling Locations Samples were collected from the sampling ports in both the East Remelt Furnace stack and the Holding Furnace stack. The exhaust stacks and sa mple port locations are designed to meet minimum EPA Reference Method 1 requirements. The measured stack diam eters or depths and widths, upstream and downstream disturbance dist ances, and nipple lengths were verified onsite.

4.2 Sampling Points USEPA Method 1, as published in 40 CFR, Part 60, Appendix A, was used as the reference
method to determine the location of the traverse points for velocity, particulate matter (PM), hydrogen chloride (HCl), and di oxin/furan (D/F) measurements.

4.3 Velocity and Volumetric Flow Rate USEPA Method 2, as published in 40 CFR, Part 60, Appendix A, was used as the reference method to determine average gas velocity. Type “S” pitot tubes and oil manometers were used for velocity determination. Gas temperature was measured with a type K thermocouple. Calibration checks were performed on each pitot t ube to verify the face opening alignments, external tubing diameter, and ba se-to-opening plane distances. A base-line coefficient of 0.84 was assigned to each pitot tube.

4.4 Oxygen (O 2 

## ) and Carbon Dioxide (CO 2 

## ) USEPA Method 3, as published in 40 CFR. Part 60, Appendix A was used as the reference method to determine oxygen (O 2 

## ) and carbon dioxide (CO 2 

## ) concentrations of each stack. A tedlar type bag was filled from the meter box e xhaust of the particulate matter (PM) / hydrogen

## chloride (HCl) sampling system. A Fyrite sampler was used to determine both O 2 

## and CO 2 

## concentrations. O 2 

## and CO 2 

## concentrations were used in the calculation of molecular weight of the stack gas.

4.5 Moisture Content USEPA Method 4, as published in 40 CFR, Part 60, Appendix A was used as the reference method to determine moisture content. The samp le was collected at a known and regulated rate through a glass condenser system. The condenser consisted of the imp inger portion of the particulate matter (PM) / hydrogen chloride (HCl) or the dioxin/fu ran (D/F) sampling trains. The gas sample was extracted through the impingers (maintained at below 68 ° F in an ice bath) with a vacuum pump. The amount of gas sampled was m easured with a calibrated dry gas meter. The
amount of moisture collected du ring the test and the amount of gas drawn, corrected to dry standard conditions, was determined.

4.6 Particulate Matter (PM) and Hy drogen Chloride (HCl) Testing USEPA Methods 5 and 26A, as published in 40 CFR, Part 60, Appendix A, were used to determine the particulate matter (PM) and hydroge n chloride HCl emissions from each source referencing EPA Methods 1-4 for tr averse point selection, determ ination of stack gas molecular weight, stack gas moisture, and volumetric flow ra te. A schematic of the system is presented in Figure 4.6.1. The following is a synopsis of the method, a list of equipment and specifications, and a diagram illustrating the equipment used.

## Particulate emissions were withdrawn isokinetically from the source and collected on a filter and in a prefilter wash. The collected sa mples were dried and then weighed.

Gaseous and particulate hydrogen chloride emissi ons were withdrawn is okinetically from the source and collected on a filter and in absorbing so lutions. The filter collected particulate matter (PM) including halide salts. An acidic ab sorbing solution collected the gaseous hydrogen chloride (HCl). The impinger catch and rinses we re then sent to a NELAC accredited lab for HCl analysis by ion chromatography (IC). The particul ate matter (PM) recovered from the filter and the probe were analyzed following the procedures in Method 5.

Sampling Apparatus 1) Probe Nozzle Glass with sharp tapered leading edge. 2) Probe Stainless steel shea th with a 5/8” OD glass insert. 3) Pitot Tube Standard “type S”, attached to the probe. 4) Filter Holder The filter holder wa s constructed of glass. The gasket was made of Teflon. The filter holder is designed to provide a positive seal against leakage from the outside or around the filter. 5) Impingers Four (4) glass impinge rs connected in series with glass ball joint fittings. The third and fourth were of the Greenburg-Smith design modified by replacing the tip with a 1.3 cm (1/2 inch) Id glass tube extending to about 1⁄2 inch from the bottom of the flask. The first and second were of the Greenburg- Smith design with a standard tip. All were submerged in an i ce bath during the sample runs. The first two impingers contained 100 ml of 0.1N sulfuric acid. The third was empty and the fourth contained 350-450 grams of silica gel. 6) Meter Box Module containing a vacuum gauge, leak free pump, dry gas meter with a minimum of one percen t accuracy, valves, and related equipment to maintain isokinetic sampling rate and to determine sample volume.

## 7) Barometer Measured atmospheric pressure on-site to  0.05 inches of mercury. 8) Thermocouples Type K thermocoupl es were utilized to monitor temperatures for stack gas, last impinger, and dry gas meter. 9) Filters Teflon filter.

## Figure 4.6.1 Particulate Matter (PM) and Hydrogen Chloride (HCl) Sampling System

Impinger 1- 100 ml 0.1N H 2 

## SO 4 

## , standard tip Impinger 2- 100 ml 0.1N H 2 

## SO 4 

## , standard tip Impinger 3-Dry Impinger 4- 300-400g silica gel The optional cyclone and first knockout impinger were not used Note: The sodium hydroxide impingers referenced in Method 26A were not used. Chlorine (Cl 2 

## ) emissions did not need to be determined.

## 4.7 Dioxin/Furan (D/F) USEPA Method 23, as published in 40 CFR, Part 60, Appendix A, was used to measure dioxin and furan (D/F) concentrations in the remelt furn ace stack. The following is a description of the sampling apparatus. The sampling system (see Figure 4.7.1) used was identical to the Method 5/26A sampling system with the follow ing additions and/or modifications: Sampling Apparatus: Condenser A glass coil-type condenser wa s placed between th e filter and the dioxin trap. Ice water was the coo ling fluid used in the condenser. Absorbent Module A preloaded container with the proper fi ttings to connect to the condenser. The trap was filled with XAD-2 that had been cleaned according to methods specified in Section 3.1.2.1 of Method 23. The traps had already been spiked with 100 μ l of surrogate standard solution as specified in Section 4.1.1.2 Impingers 5 impingers connected by leak -free ground glass fittings. The first impinger was a knockout impinger with no stem. The second, fourth, and fifth impingers were of the Greenburg-Smith design modified by replacing the tip with a 1.3 cm (1/2 inch) ID glass tube extending to about 1⁄2 inch from th e bottom of the flask. The third impinger was of the Greenburg-Smtih design with a standard tip. The first impinger was empty. The second and third impingers each contained 100 ml of water. The fourth impinger was empty. The fifth impinger contained ~350-450g of silica gel. Thermocouples In addition to those list ed in Section 4.6, a thermocouple was used to monitor the temperature at the outlet of the condenser.
Filters Pre-cleaned Glass Fiber Filters Notes: Treatment of non-detects (ND): Results are calculated using the detection limit for ND compounds.

### Figure 4.7.1 Method 23 Sampling System

Type S Pitot Tube

Manometer

Orifice Temperature Sensors

Bypass Valve Main Valve Vacuum Gauge

Dry Gas Meter Air-Tight Pump Gooseneck Nozzle Heat-Traced Glass Lined Probe Temperature Sensor

Heated Area Particulate Filter Holder Temperature Sensor

Condenser Dioxin Trap

Knockout Impinger Empty 100 ml DI Water Empty Silica Gel Type S Pitot Tube Temperature Sensor

Gooseneck Nozzle

Vacuum Line

## 5.0 PROTOCOL DEVIATIONS AND TEST COMMENTS

1) The post-test leak check for Run 2 of th e dioxin test on the me lter exceeded the maximum allowable rate as specified in Method 5. The total sample volume was corrected using procedures discussed in Met hod 5. The isokinetics for the run were still
with the 90-110% allowable variance after the correction was applied.

2) Subpart RRR requires sampling for a complete batch. Sampling points were determined by estimating a run time. Once all of the samp ling points had been tested, the probe was
traversed in reverse order unt il the conclusion of the run. Ve locity and volumetric flow rate was calculated for each run using the av erage of the required traverse points and the average of all sampled points. In each case , the difference between the velocity and
volumetric flow rates from the two met hods was less than 2%. All mass emission
calculations utilized the av erage of all sampled points.

3) The full HCl lab report is included as an Appendix to this report.

## 6.0 SAMPLING POINT LOCATION Figure 6.1 Hydro Aluminum North America Monett, Missouri Aluminum Melting Furnace Number 1 (East) (EU 0010)

Diameters Upstream: 1.3 Sampling Points (inches)

Diameters Downstream 3.6 1 1.0”

Stack diameter 45.5” 2 3.0”
Drawing Date 09/26/2008 3 5.4”

4 8.1”

5 11.4”

6 16.2”

7 29.3”

8 34.1”

9 37.4”

10 40.1”

11 42.4”

12 44.5” 

## Drawing Not to Scale

24 Points 45.5 Inch Dia.



### Note: Two equal distances, ninety-degree ports. Two por ts with 12 points per port, 24 total points. All distances are approximate.

## Figure 6.2
Hydro Aluminum North America Monett, Missouri Holding Furnace (EU 0030)
Diameters Upstream: 1.9 Sampling Points (inches)

Diameters Downstream 7.5 1 1.5”

Stack diameter 33.5 2 4.9”
Drawing Date 09/26/2008 3 9.9”

4 23.6”

5 28.6”

6 32.0” 

## Drawing Not to Scale

Direction of Flow



### Note: Two equal distances, ninety-degree ports. Two ports with 6 points per port, 12 total points. All distances are approximate. .

## APPENDIX A ALUMINUM MELTING FURNACE (EU 0010) A.1 Hydrogen Chloride (HCl) a nd Particulate Matter (PM) Data A.2 Dioxin/Furan (D/F) Data APPENDIX B ALUMINUM HOLDING FURNACE (EU 0030) B.1 Hydrogen Chloride (HCl) a nd Particulate Matter (PM) Data

APPENDIX C TEST PROTOCOL
APPENDIX D LABORATORY ACCREDITATION
APPENDIX E PROCESS DATA
APPENIDIX F HCl LABORATORY REPORT APPENDICES

## •Example Calculations
•Emission Run summaries
•Field Data Sheets •Particulate Matter Laboratory Report •Hydrogen Chloride Laboratory Report (Summary Pages Only)
•Meter Box Pre-Test Calibration
•Meter Box Post-Test Calibration
•Pitot Tube Calibrations •Thermocouple Calibrations APPENDIX A.1 Aluminum Melting Furnace (EU 0010) Hydrogen Chloride (HCl) and Particulate Matter ( PM ) Data

### 1.

Example. P bar 

### = 28.51 P s 

### = 28.52 in. Hg.

P g 

### = 0.10 2.

Example. V lc 

### = 170.4 V w(std) 

### = 8.021 SCF 3.

Example. V m 

### = 147.127 V m(std) 

### = 137.891 SCF

P bar 

### = 28.51 T m 

### = 540.5 Y = 1.005 K 1 

### = 17.64 

### ∆ H avg 

### = 0.856 4.

Example. V m(std) 

### = 137.891 V t 

### = 145.912 SCF



### V w(std) 

### = 8.021 5.

Example. V m(std) 

### = 137.891 B ws 

### = 0.055



### V w(std) 

### = 8.021

Volume Water Vapor, (V w(std) 

### ). Monett, Missouri 

## Example Calculations, PM/HCl Test Run 1 Aluminum Melting Furnace No. 1 (East) October 23, 2012 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440



### Stack Pressure (P s 

### )

=

V m 

### x Y x 17.64 (P bar 

### + ( ∆ H/13.6))/T m



### = =

Total Volume Of Sample, (V t 

### ).

V w(std) 

### + V m(std)



### V w(std) 

### / (V w(std) 

### + V m(std) 

### ) AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



## Facility Hydro Aluminum North America 

## Location Source
Date

P s 

### = P bar 

### + (P g 

### / 13.6)

Moisture in stack gas, volume fraction (B ws 

### )

=

= V lc 

### x 0.04706

Meter Volume, corrected to Standard

Conditions, (V m(std) 

### )

### Monett, Missouri 

## Example Calculations, PM/HCl Test Run 1 Aluminum Melting Furnace No. 1 (East) October 23, 2012 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 

### AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



## Facility Hydro Aluminum North America 

## Location Source
Date 6.

Example. B ws 

### = 0.055 B wd 

### = 0.945 7.

Example. CO2 = 2.5 M d 

### = 29.10

O2 = 17.5 N2 = 80.0 CO = 0.0 8.

Example. M d 

### = 29.10 M s 

### = 28.49

B wd 

### = 0.945 B ws 

### = 0.055 9.

Example. M s 

### = 28.49 G s 

### = 0.983 10.

Example. C p 

### = 0.84 v s 

### = 1698.2 FPM

∆ p avg 

### = 0.3445 T s(abs) 

### = 1063.6 P s 

### = 28.52 M s 

### = 28.49 K p 

### = 85.49 = (K p 

### x C p 

### x ( ∆ p avg 

### )^0.5 x (T s(abs) 

### / P s 

### x M s 

### )^0.5) x 60 Velocity of Stack Gas, as feet per minute,

(v s 

### ). (0.44 x %CO2) + (0.32 x %O2) + (0.28 x %N2) + (0.28 x %CO)

Molecular Weight of Stack Gas, Dry, (M d 

### ).

=

(M d 

### x B wd 

### ) + (18.0 x B ws 

### ) Molecular Weight of Stack Gas, Stack

Conditions, (M s 

### ).

=

M S 

### / 28.99 = Specific Gravity of Gas, Relative to Air, (G s 

### ) Dry Stack Gas, volume fraction (B wd 

### )

1 - B ws 

### =

### Monett, Missouri 

## Example Calculations, PM/HCl Test Run 1 Aluminum Melting Furnace No. 1 (East) October 23, 2012 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 

### AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



## Facility Hydro Aluminum North America 

## Location Source
Date 11.

Example. v s 

### = 1698.2 Q s 

### = 19175 ACFM

A = 11.291 12.

Example. Q s 

### = 19175 Q d 

### = 18121 ACFMD

B wd 

### = 0.945 13.

Example Q d 

### = 18121 Q d(std) 

### = 8574 SCFMD

P s 

### = 28.52 T s(abs) 

### = 1063.6 P std 

### = 29.92 T std 

### = 528 14.

Q d(std) 

### = 8574 Q s(std) 

### = 9073 SCFMW

B wd 

### = 0.945 15.

Example. A n 

### = 0.0006417 I = 109 %

Ө = 260 P std 

### = 29.92 V m(std) 

### = 137.891 T std 

### = 528 T s(abs) 

### = 1063.6 P s 

### = 28.52 v s 

### = 1698.2 B wd 

### = 0.945 (100 x V m(std) 

### x 29.92 x T s(abs) 

### ) / (528 x v s 

### x Ө x A n 

### x P s 

### x B wd 

### ) =

=

= 

### Stack Gas Flow Rate, Standard Temperature

and Pressure, Dry, (Q d(std) 

### ) Actual Stack Gas Flow Rate (Q s 

### ).

Actual Stack Gas Flow Rate, Dry (Q d 

### )

A x v s



### Percent Isokinetic Sampled, (I)

Q s 

### x B wd



### Stack Gas Flow Rate, Standard Temperature

and Pressure (Q s(std) 

### ) Q d(std) 

### / B wd 

### Q d 

### x ((T std 

### x P s 

### ) / (P std 

### x T s(abs) 

### ))

### Monett, Missouri 

## Example Calculations, PM/HCl Test Run 1 Aluminum Melting Furnace No. 1 (East) October 23, 2012 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 

### AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



## Facility Hydro Aluminum North America 

## Location Source
Date 16.

Example. Mg = 115.2 C s 

### = 0.0129 Grs/ SCF.

V m(std) 

### = 137.891 17.

Example. C s 

### = 0.0129 Em = 0.95 Lbs/ Hr

Q d(std) 

### = 8574 18.

Example. Em = 0.95 Em/T = 0.13 Lbs/Ton

T = 7.2 19.

Example. g = 40660 C HCl 

### = 0.0045 Grs/SCF.

V m(std) 

### = 137.891 20.

Example. C m 

### = 0.0045 E HCl 

### = 0.33 Lbs/ Hr

Q d(std) 

### = 8574 21.

Example. E HCl 

### = 0.33 E HCl 

### /T = 0.05 Lbs/Ton

T = 7.2

(0.00001543 x g) / V m(std)



### Hydrogen Chloride Mass Emission Rate, Lbs

/ Hr, (E HCl 

### ). C m 

### x Q d(std) 

### x 60 / 7000 C s 

### x Q d(std) 

### x 60 / 7000 Particulate Mass Emission Rate, Lbs / Hr,

(Em).

Hydrogen Chloride Concentration, grains per Standard Cubic Foot, (C HCl 

### ). (0.01543 x Mg.) / V m(std) 

### Particulate Concentration, grains per Standard Cubic Foot, (C s 

### ).

Particulate Mass Emission Rate, Lbs / Ton,

(Em/T).

Em / T



### Hydrogen Chloride Mass Emission Rate, Lbs

/ Ton, (E HCl 

### /T). Em / T

### Monett, Missouri 

## Example Calculations, PM/HCl Test Run 1 Aluminum Melting Furnace No. 1 (East) October 23, 2012 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 

### AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



## Facility Hydro Aluminum North America 

## Location Source
Date

K = 0.005 English 

### K p 

### = 85.49 Velocity equation constant 

### K 1 

### = 17.64 °R/in. Hg 

### T std 

### = 528 °R 

### K 2 

### = 0.04706 ft 3 /ml 

### P std 

### = 29.92 inches Hg 

### K 3 

### = 0.0154 gr/mg 

### p W 

### = 0.9982 g/ml



### A = P s 

### = A n 

### = Q s 

### = B ws 

### = Q d 

### = B wd 

### = Q s(std) 

### = C p 

### = Q d(std) 

### = C HCl 

### = T s(abs) 

### = C s 

### T m 

### = D e 

### = v s 

### = Em = V lc 

### = E HCl 

### = V m 

### = I = V m(std) 

### =
m s 

### = V w(std) 

### =
m n 

### = V t 

### = M d 

### = Y = M s 

### = ∆ H avg 

### =
n = ∆ p avg 

### = P bar 

### = Ө = P g 

### = T = Em / T = E HCl 

### =μμ g = E HCl 

### = Stack Gas Flow Rate, SCFMD

Meter Temp (degrees R)

Volume Metered (ft 3 ) Gas Volume Sampled, STPD Volume Water Vapor, SCF Stack Temp (degrees R)

Average Stack Velocity,

FPM Condensate Volume (ml)

Meter Correction Total Volume Collected,

SCF

Number of Points

Static Pressure Barometric Pressure (inches Hg) Total Time (minutes) Molecular Weight of Stack Gas (Dry Basis) Molecular Weight of Stack Gas (Stack conditions) Delta H (inches H 2 O) Avg of SQRT of V.H. Actual Stack Gas Flow Rate, ACFM Nozzle Area (ft 2 ) Moisture in stack gas, volume fraction Dry Stack Gas, volume fraction Actual Stack Gas Flow Rate, ACFMD Stack Gas Flow Rate Wet,

SCFMW

Mass Emission Rate, Particulate, Lb/hr Equivilent Diameter (inches) Grains per DSCF / HCl Pitot Correction Factor

Grains per DSCF / Particulate Stack Pressure (inches Hg)

Mass Emission Rate, HCl,

Lb/hr Percent Isokinetic Prefilter Weight (grams) Total Particulate (grams) Stack Area (ft 2 ) 

### Constants

Variables

Mass Emission Rate, Particulate, Lb/Ton Production (Tons per Hour) Mass Emission Rate, HCl,

Lb/Ton Total HCl Weight Collected, micrograms Mass Emission Rate, HCl, Lb/Ton

### Data Request Entry Area PM/HCl Run 1 Volumetric Flow Calculations Worksheet

Hydro Aluminum North America 

### Facility
Monett, Missouri Aluminum M elting Furnace No. 1 (East)

10/23/12
1 11:25 15:55 Clear 260.0
24 28.51 0.10 45.50 0.343 1.005 0.84 471.339 324.212 128
42.4

0.0823 2.5 17.5 0.0 80.0

0.0329

Variable 

### Location Source Date Ru n Number Start Time Finish Time Weather Total Time (minutes) ( Ө ) Number of Points (n) Barometric Pressure (inches Hg) (P bar 

### ) Static Pressure (inches H 2 

### O) (P g 

### ) Stack Diameter (inches) (D) Nozzle Diameter (inches) (D n 

### ) Meter Y Factor (Y) Pitot Factor (C p 

### )

Nitrogen (%) Final Meter Reading (ft 3 

### ) Initial Meter Reading (ft 3 

### ) Condensate (grams or ml) Silica Gel Weight (grams) AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



### Filter Weight (grams) Prefilter Weight (grams)

Isokinetic Rate Factor Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440



### Total HCl Weight Collected (micrograms) 40660AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440

Traverse Point Velocity

Head (inches H 2 O) Meter

Orifi ce (inches H 2 O) Stack

Tempe rature ( o F) Meter Inle t

Temperature ( o F) Meter Outl et

Temperature ( o F) Square

Root of Velocity Head 

### 1 0.13 1.1 502 75 79 0.36 

### 1 0.1 3 1.1 664 79 78 0.36 

### 2 0.1 4 1.2 675 81 78 0.37 

### 2 0.1 5 1.3 707 83 78 0.39 

### 3 0. 1 5 1.3 680 84 78 0.39 

### 3 0.1 4 1.2 554 85 78 0.37 

### 4 0.1 1 0.95 410 85 78 0.33 

### 4 0.1 2 1.0 409 85 78 0.35 

### 5 0.1 3 1.1 533 85 78 0.36 

### 5 0.1 6 1.4 645 86 79 0.40 

### 6 0.1 6 1.4 565 87 79 0.40 

### 6 0. 1 5 1.3 670 86 79 0.39 

### 7 0.1 5 1.3 694 87 79 0.39 

### 7 0.1 3 1.1 639 86 79 0.36 

### 8 0.1 3 1.1 643 84 78 0.36 

### 8 0.1 5 1.3 716 85 78 0.39 

### 9 0.1 5 1.3 605 85 78 0.39 

### 9 0.1 2 1.0 652 85 78 0.35 

### 10 0

. 13 1.1 663 85 78 0.36 

### 10 0. 13 1.1 643 85 78 0.36 

### 11 0. 13 1.1 672 86 78 0.36 

### 11 0. 12 1.0 676 85 78 0.35 

### 12 0. 12 1.0 674 85 78 0.35 

### 12 0. 12 1.0 695 84 78 0.35 

### 1 0.1 9 1.6 597 77 76 0.44 

### 1 0. 1 9 1.6 628 78 77 0.44 

### 2 0.1 7 1.5 649 79 77 0.41 

### 2 0.1 7 1.3 635 79 76 0.41 

### 3 0.1 6 1.3 657 80 77 0.40 

### 3 0.1 5 0.84 640 80 77 0.39 

### Hydro Aluminum North America Aluminum Melting

Furnace No. 1 (East)

Port



### 1 Field Data Points - PM/HCl Run 1

2AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440

Traverse Point Velocity

Head (inches H 2 O) Meter

Orifi ce (inches H 2 O) Stack

Tempe rature ( o F) Meter Inle t

Temperature ( o F) Meter Outl et

Temperature ( o F) Square

Root of Velocity Head 

### 4 0.15 0.84 666 82 77 0.39 

### 4 0.1 3 0.73 664 83 77 0.36 

### 5 0.1 3 0.73 677 83 77 0.36 

### 5 0.1 2 0.67 675 83 77 0.35 

### 6 0. 1 1 0.62 703 83 76 0.33 

### 6 0.1 1 0.62 699 82 77 0.33 

### 7 0.0 9 0.5 711 82 77 0.30 

### 7 0.1 0 0.56 713 82 77 0.32 

### 8 0.1 0 0.56 701 82 77 0.32 

### 8 0.0 8 0.45 712 83 78 0.28 

### 9 0.1 0 0.56 714 82 78 0.32 

### 9 0. 1 0 0.56 707 82 78 0.32 

### 10 0. 10 0.56 719 82 78 0.32 

### 10 0. 10 0.56 724 82 78 0.32 

### 11 0. 10 0.56 425 82 78 0.32 

### 11 0. 10 0.56 400 82 78 0.32 

### 12 0. 10 0.56 385 82 78 0.32 

### 12 0. 10 0.56 356 83 78 0.32 

### 12 0

. 10 0.56 366 83 79 0.32 

### 12 0. 07 0.39 595 82 78 0.26 

### 11 0. 10 0.56 662 82 79 0.32 

### 11 0. 08 0.45 648 82 79 0.28 

### 10 0. 09 0.5 665 82 79 0.30 

### 10 0. 10 0.56 684 82 79 0.32 

### 9 0.1 0 0.56 404 83 79 0.32 

### 9 0. 1 0 0.56 498 83 79 0.32 

### 8 0.1 0 0.56 637 83 79 0.32 

### 8 0.1 0 0.56 680 84 80 0.32 

### 7 0.0 8 0.45 673 84 80 0.28 

### 7 0.1 0 0.56 436 83 80 0.32 

### 6 0.1 0 0.56 377 83 80 0.32 

### 6 0.1 1 0.62 392 82 79 0.33 

### Hydro Aluminum North America Aluminum Melting

Furnace No. 1 (East) Field Data Points - PM/HCl Run 1

Port



### 2AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440

Traverse Point Velocity

Head (inches H 2 O) Meter

Orifi ce (inches H 2 O) Stack

Tempe rature ( o F) Meter Inle t

Temperature ( o F) Meter Outl et

Temperature ( o F) Square

Root of Velocity Head 

### 5 0.10 0.56 506 83 79 0.32 

### 5 0.1 0 0.56 363 83 79 0.32 

### 4 0.0 8 0.45 502 82 79 0.28 

### Hydro Aluminum North America Aluminum Melting

Furnace No. 1 (East)

Port



### 2 Field Data Points - PM/HCl Run 1AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005 

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440

260.0 128.0 28.51 42.4 45.50 170.4 11.291 2.5 0.0006417 17.5 24 0.0 0.3445 80.0 1.005 147.127 0.343 0.8565 0.84 0.10 0.0823 28.52 0.0329 1063.6 0.1152 540.5 8.021 137.891 145.912 0.055 0.945 29.10 28.49 0.983 463.0 1698.2 1783.3 19175 18121 8574 8802 9073 109 0.0129 0.95 0.13 0.0045 0.33 0.05 

## PM/HCl Summary Run 1

(B ws 

### ) Moisture in stack gas, volume fraction

(I) Percent Isokinetic (C s 

### ) Particulate Grains per DSCF Excess Air (%) (v s 

### ) Average Stack Velocity, FPM (Based on all points) (Q s 

### ) Actual Stack Gas Flow Rate, ACFM (Q d 

### ) Actual Stack Gas Flow Rate, ACFMD

Stack Emissions: (E HCl 

### ) HCl Pounds per Hour (E HCl 

### / T) HCl Pounds per Ton (v s 

### ) Average Stack Velocity, FPM (Based on first 24 points only) Clear



### (Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Q s(std) 

### ) Stack Gas Flow Rate Wet, SCFMW (B wd 

### ) Dry Stack Gas, volume fraction (M d 

### ) Molecular Weight of Stack Gas (Dry Basis) (M s 

### ) Molecular Weight of Stack Gas (Stack conditions) (G s 

### ) Specific gravity of Stack Gas Relative to Air (V w(std) 

### ) Volume Water Vapor, SCF (V m(std) 

### ) Gas Volume Sampled, STPD Total Volume, STP

(Em) Particulate Pounds per Hour Hydro Aluminum North America
Mon e tt, Missouri Aluminum Melting Furnace No. 1 (East) 10/23/2012 1
11:25
15:55



### Nozzle Diameter (inches) (Cp) Pito t Correction Factor Filter Weight (grams) (m s 

### ) Prefilter Weight (grams) (A n 

### ) Nozzle Area (ft 2 

### ) (n) Number of Points ( ∆ p avg 

### ) Avg of SQRT of V.H. (Y) Meter Correction ( Ө ) Total Time (minutes) (P bar ) Barometric Pressure (inches Hg) 

### (D) Stack Diameter (inches) 

### (A) Stack Area (ft 2 

### )

(m n 

### ) Total Particulate (grams) Impinger Condensate (g or ml) Silica Gel Condensate (g) (V lc 

### ) Condensate Volume (ml) Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) Nitrogen (%) (V m 

### ) Volume Metered (ft 3 

### ) ( ∆ H avg 

### ) Delta H (inches H 2 

### O) (P g 

### ) Static Pressure (inches H 2 

### O) (P s 

### )Stack Pressure (inches Hg) (T s(abs) 

### ) Stack Temp (°R) (T m 

### ) Meter Temp (°R) Run Number Start Time Finish Time Weather

(Em / T) Particulate Pounds per Ton (C HCl 

### ) HCl Grains per DSCF (Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Based on first 24 points only) Facility Location Stack Run Date

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



### Filter Weight (grams) Prefilter Weight (grams)

Isokinetic Rate Factor Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) Nitrogen (%) Final Meter Reading (ft 3 

### ) Initial Meter Reading (ft 3 

### ) Condensate (grams or ml) Silica Gel Weight (grams) Stack Diameter (inches) (D) Nozzle Diameter (inches) (D n 

### ) Meter Y Factor (Y) Pitot Factor (C p 

### ) Total Time (minutes) ( Ө ) Number of Points (n) Barometric Pressure (inches Hg) (P bar 

### ) Static Pressure (inches H 2 

### O) (P g 

### ) Facility Location Source Date Run Number Start Time Finish Time Weather

0.0628

Variable 85
2 8 .4

0.2593 2.0 18.0 0.0 80.0 1.005 0.84 605.738 480.111 28.51 0.12 45.50 0.343 12:54 Scattered 260.0
24 

### Data Request Entry Area PM/HCl Ru n 2

Volumetric Flow Calculations Worksheet

Hydro Aluminum North America Monett, Mi ssouri Aluminum Melting Furnace No. 1 (East)

10/24/12
2 8:25



### Total HCl Weight Collected (micrograms) 251000

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

Traverse Point Velocity

Head (inches H 2 O) Meter

Orifi ce (inches H 2 O) Stack

Tempe rature ( o F) Meter Inle t

Temperature ( o F) Meter Outl et

Temperature ( o F) Square

Root of Velocity Head 

### 1 0.12 0.85 627 69 69 0.35 

### 1 0.1 4 0.99 604 72 69 0.37 

### 2 0.1 5 1.1 620 75 70 0.39 

### 2 0.1 4 0.99 609 77 71 0.37 

### 3 0. 1 3 0.92 607 79 72 0.36 

### 3 0.1 5 1.1 706 79 72 0.39 

### 4 0.1 5 1.1 723 80 73 0.39 

### 4 0.1 5 1.1 741 80 73 0.39 

### 5 0.1 4 0.99 710 79 74 0.37 

### 5 0.1 0 0.71 470 79 74 0.32 

### 6 0.0 9 0.64 447 80 75 0.30 

### 6 0. 0 9 0.64 500 82 76 0.30 

### 7 0.1 0 0.71 601 84 77 0.32 

### 7 0.0 7 0.50 638 84 77 0.26 

### 8 0.0 6 0.43 675 83 78 0.24 

### 8 0.0 6 0.43 670 83 78 0.24 

### 9 0.0 6 0.43 694 83 78 0.24 

### 9 0.0 7 0.45 701 83 79 0.26 

### 10 0

. 07 0.45 712 83 79 0.26 

### 10 0. 07 0.45 715 83 79 0.26 

### 11 0. 06 0.38 725 85 80 0.24 

### 11 0. 06 0.38 710 84 80 0.24 

### 12 0. 05 0.32 721 83 80 0.22 

### 12 0. 07 0.45 704 83 80 0.26 

### 1 0.1 2 0.70 676 79 79 0.35 

### 1 0. 1 3 0.75 700 83 80 0.36 

### 2 0.1 2 0.70 707 84 80 0.35 

### 2 0.1 2 0.70 687 85 81 0.35 

### 3 0.1 3 0.75 667 85 81 0.36 

### 3 0.1 1 0.64 699 86 81 0.33 Por t



### 1 Field Dat a Points - PM/HCl Run 2 

### Hydro Aluminum North America Aluminum Melting

Furnace No. 1 (East)

2

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

Traverse Point Velocity

Head (inches H 2 O) Meter

Orifi ce (inches H 2 O) Stack

Tempe rature ( o F) Meter Inle t

Temperature ( o F) Meter Outl et

Temperature ( o F) Square

Root of Velocity Head 

### 4 0.10 0.58 724 85 81 0.32 

### 4 0.1 0 0.58 713 85 82 0.32 

### 5 0.0 8 0.46 731 86 82 0.28 

### 5 0.0 8 0.46 723 87 83 0.28 

### 6 0. 0 7 0.41 479 88 84 0.26 

### 6 0.0 5 0.29 453 88 84 0.22 

### 7 0.0 5 0.29 476 87 85 0.22 

### 7 0.0 5 0.26 460 86 85 0.22 

### 8 0.0 4 0.21 339 86 85 0.20 

### 8 0.0 4 0.21 360 87 86 0.20 

### 9 0.0 2 0.10 323 87 86 0.14 

### 9 0. 0 5 0.26 517 86 86 0.22 

### 10 0. 07 0.36 639 86 86 0.26 

### 10 0. 09 0.47 655 89 87 0.30 

### 11 0. 08 0.42 677 90 87 0.28 

### 11 0. 07 0.36 675 89 87 0.26 

### 12 0. 09 0.47 500 90 87 0.30 

### 12 0. 07 0.36 672 89 87 0.26 

### 12 0

. 08 0.42 674 91 88 0.28 

### 12 0. 08 0.42 718 87 86 0.28 

### 11 0. 05 0.26 514 89 87 0.22 

### 11 0. 05 0.26 485 92 88 0.22 

### 2 Por t 

### Field Data Points - PM/HCl Run 2 

### Hydro Aluminum North America Aluminum Melting

Furnace No. 1 (East)

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

260.0 85.0 28.51 28.4 45.50 113.4 11.291 2.0 0.0006417 18.0 24 0.0 0.2897 80.0 1.005 125.627 0.343 0.5512 0.84 0.12 0.2593 28.52 0.0628 1080.6 0.3221 542.1 5.338 117.297 122.634 0.044 0.956 29.04 28.56 0.985 548.8 1437.6 1453.9 16232 15526 7231 7300 7560 110 0.0424 2.63 0.36 0.0330 2.05 0.28 

### Facility Location Sta ck Run Date Run Number Start Time
Finish Time Weather

(P g 

### ) Static Pressure (inches H 2 

### O) (P s 

### )Stack Pressure (inches Hg) (T s(abs) 

### ) Stack Temp (°R) (T m 

### ) Meter Temp (°R) (m n 

### ) Total Particulate (grams) Impinger Condensate (g or ml) Silica Gel Condensate (g) (V lc 

### ) Condensate Volume (ml) Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) Nitrogen (%) (V m 

### ) Volume Metered (ft 3 

### ) ( ∆ H avg 

### ) Delta H (inches H 2 

### O) ( Ө ) Total Time (minutes) (P bar ) Barometric Pressure (inches Hg) 

### (D) Stack Diameter (inches) 

### (A) Stack Area (ft 2 

### )

(Cp) Pitot Correction Factor Filter Weight (grams) (m s 

### ) Prefilter Weight (grams) (A n 

### ) Nozzle Area (ft 2 

### ) (n) Number of Points ( ∆ p avg 

### ) Avg of SQRT of V.H. (Y) Meter Correction

(Em) Particulate Pounds per Hour Hydro Aluminum North America

Mon e tt, Missouri Aluminum Melting Furnace No. 1 (East) 10/24/2012 2

8:25



### Nozzle Diameter (inches) 12:54 Scattered



### (Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Q s(std) 

### ) Stack Gas Flow Rate Wet, SCFMW (B wd 

### ) Dry Stack Gas, volume fraction (M d 

### ) Molecular Weight of Stack Gas (Dry Basis) (M s 

### ) Molecular Weight of Stack Gas (Stack conditions) (G s 

### ) Specific gravity of Stack Gas Relative to Air (V w(std) 

### ) Volume Water Vapor, SCF (V m(std) 

### ) Gas Volume Sampled, STPD

(I) Percent Isokinetic (C s 

### ) Particulate Grains per DSCF Excess Air (%) (v s 

### ) Average Stack Velocity, FPM (Q s 

### ) Actual Stack Gas Flow Rate, ACFM (Q d 

### ) Actual Stack Gas Flow Rate, ACFMD

Stack Emissions: (Em / T) Particulate Pounds per Ton (C HCl 

### ) HCl Grains per DSCF (E HCl 

### ) HCl Pounds per Hour Total Volume, STP (B ws 

### ) Moisture in stack gas, volume fraction 

## PM/HCl Summary Run 2

(v s 

### ) Average Stack Velocity, FPM (Based on first 24 points only)

(Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Based on first 24 points only)

(E HCl 

### / T) HCl Pounds per Ton

### Total HCl Weight Collected (micrograms) 123500 

## Ambient Air Services, Inc.

Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005



### Filter Weight (grams) Prefilter Weight (grams)

Isokinetic Rate Factor Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) Nitrogen (%) Final Meter Reading (ft 3 

### ) Initial Meter Reading (ft 3 

### ) Condensate (grams or ml) Silica Gel Weight (grams) Stack Diameter (inches) (D) Nozzle Diameter (inches) (D n 

### ) Meter Y Factor (Y) Pitot Factor (C p 

### ) Total Time (minutes) ( Ө ) Number of Points (n) Barometric Pressure (inches Hg) (P bar 

### ) Static Pressure (inches H 2 

### O) (P g 

### ) Facility Location Source Date Run Number Start Time Finish Time Weather

0.0311

Variable

88
27.2

0.1029

2.5 17.0 0.0 80.5 1.005 0.84 725.486 607.117 28.37 0.08 45.50 0.343 12:16 Cloudy 245.0

24 

### Data Request Entry Area PM/HCl Run 3 Volumetric Flow Calculations Worksheet

Hydro Aluminum North America Monett, Missouri Aluminum Melting Furnace No. 1 (East) 10/25/12 3 8:05

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

Traverse

Point Velocity Head (inches

H 2 O) Meter Orifice (inches

H 2 O) Stack Temperature ( o F) Meter Inlet Temperature ( o F) Meter Outlet Temperature ( o F) Square Root of Velocity

Head 

### 1 0.09 0.54 577 70 70 0.30 

### 1 0.06 0.36 656 71 70 0.24 

### 2 0.07 0.42 540 72 70 0.26 

### 2 0.05 0.30 562 73 70 0.22 

### 3 0.07 0.42 570 74 71 0.26 

### 3 0.08 0.48 559 75 71 0.28 

### 4 0.10 0.60 575 76 72 0.32 

### 4 0.09 0.54 631 78 73 0.30 

### 5 0.09 0.54 584 78 73 0.30 

### 5 0.09 0.54 560 78 73 0.30 

### 6 0.10 0.60 595 78 74 0.32 

### 6 0.13 0.78 742 79 74 0.36 

### 7 0.11 0.66 711 79 74 0.33 

### 7 0.14 0.84 799 79 74 0.37 

### 8 0.10 0.60 718 79 74 0.32 

### 8 0.10 0.60 652 80 76 0.32 

### 9 0.11 0.66 674 80 76 0.33 

### 9 0.12 0.72 767 80 76 0.35 

### 10 0.12 0.72 723 80 75 0.35 

### 10 0.12 0.72 726 79 75 0.35 

### 11 0.13 0.78 691 80 75 0.36 

### 11 0.13 0.78 685 80 75 0.36 

### 12 0.13 0.78 672 80 75 0.36 

### 12 0.12 0.72 661 80 75 0.35 

### 1 0.07 0.42 758 76 75 0.26 

### 1 0.08 0.46 741 77 75 0.28 

### 2 0.07 0.38 751 79 76 0.26 

### 2 0.08 0.43 710 78 76 0.28 

### 3 0.07 0.38 747 79 76 0.26 

### 3 0.08 0.43 743 78 76 0.28 

### 2 Port



### 1 Field Data Points - PM/HCl Run 3 Hydro Aluminum North A merica Aluminum Melting Furnace No. 1 ( East )

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

Traverse

Point Velocity Head (inches

H 2 O) Meter Orifice (inches

H 2 O) Stack Temperature ( o F) Meter Inlet Temperature ( o F) Meter Outlet Temperature ( o F) Square Root of Velocity

Head 

### 4 0.09 0.49 740 78 75 0.30 

### 4 0.07 0.38 743 79 75 0.26 

### 5 0.09 0.49 737 79 75 0.30 

### 5 0.08 0.43 756 79 75 0.28 

### 6 0.08 0.43 746 79 75 0.28 

### 6 0.08 0.43 756 79 75 0.28 

### 7 0.09 0.49 755 80 76 0.30 

### 7 0.09 0.49 451 79 75 0.30 

### 8 0.10 0.54 397 79 75 0.32 

### 8 0.10 0.54 361 79 75 0.32 

### 9 0.10 0.54 360 80 75 0.32 

### 9 0.09 0.49 318 80 75 0.30 

### 10 0.08 0.43 505 80 75 0.28 

### 10 0.10 0.54 612 78 75 0.32 

### 11 0.10 0.54 405 79 75 0.32 

### 11 0.10 0.54 468 79 75 0.32 

### 12 0.15 0.81 597 79 75 0.39 

### 12 0.17 0.92 607 80 74 0.41 

### 12 0.18 0.97 621 81 74 0.42 

### Hydro Aluminum North A merica Aluminum Melting Furnace No. 1 ( East )

Port



### 2 Field Data Points - PM/HCl Run 3

## Ambient Air Services, Inc. Environmental Consultants 106 Ambient Airway Starke, Florida 32091 (904) 964-8440 AASI USEPA Method 5/26A 60 Point Template - Rev 0/12-15-2005

245.0 88.0 28.37 27.2 45.50 115.2 11.291 2.5 0.0006417 17.0 24 0.0 0.3116 80.5 1.005 118.369 0.343 0.5651 0.84 0.08 0.1029 28.38 0.0311 1093.0 0.1340 536.2 5.422 111.186 116.609 0.047 0.953 29.08 28.56 0.985 385.2 1559.2 1547.7 17606 16787 7691 7632 8066 104 0.0186

1.23 0.16 0.0171

1.13 0.15 

### Stack Emissions: (Em / T) Particulate Pounds per Ton (C HCl 

### ) HCl Grains per DSCF (E HCl 

### ) HCl Pounds per Hour (E HCl 

### / T) HCl Pounds per Ton Facility Location Stack Run Date Run Number Start Time
Finish Time Weather

(P g 

### ) Static Pressure (inches H 2 

### O) (P s 

### )Stack Pressure (inches Hg) (T s(abs) 

### ) Stack Temp (°R) (T m 

### ) Meter Temp (°R) (m n 

### ) Total Particulate (grams) Impinger Condensate (g or ml) Silica Gel Condensate (g) (V lc 

### ) Condensate Volume (ml) Carbon Dioxide (%) Oxygen (%) Carbon Monoxide (%) Nitrogen (%) (V m 

### ) Volume Metered (ft 3 

### ) ( ∆ H avg 

### ) Delta H (inches H 2 

### O) ( Ө ) Total Time (minutes) (P bar ) Barometric Pressure (inches Hg) 

### (D) Stack Diameter (inches) 

### (A) Stack Area (ft 2 

### ) (A n 

### ) Nozzle Area (ft 2 

### ) (n) Number of Points ( ∆ p avg 

### ) Avg of SQRT of V.H. (Y) Meter Correction Nozzle Diameter (inches) (Cp) Pitot Correction Factor Filter Weight (grams) (m s 

### ) Prefilter Weight (grams)

(Em) Particulate Pounds per Hour Hydro Aluminum North America
Monett, Missouri Aluminum Melting Furnace No. 1 (East) 10/25/2012 3

8:05

12:16 Cloudy



### (Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Q s(std) 

### ) Stack Gas Flow Rate Wet, SCFMW (B wd 

### ) Dry Stack Gas, volume fraction (M d 

### ) Molecular Weight of Stack Gas (Dry Basis) (M s 

### ) Molecular Weight of Stack Gas (Stack conditions) (G s 

### ) Specific gravity of Stack Gas Relative to Air (V w(std) 

### ) Volume Water Vapor, SCF (V m(std) 

### ) Gas Volume Sampled, STPD Total Volume, STP

(I) Percent Isokinetic (C s 

### ) Particulate Grains per DSCF Excess Air (%) (v s 

### ) Average Stack Velocity, FPM (Q s 

### ) Actual Stack Gas Flow Rate, ACFM (Q d 

### ) Actual Stack Gas Flow Rate, ACFMD (Q d(std) 

### ) Stack Gas Flow Rate, SCFMD (Based on first 24 points only) (v s 

### ) Average Stack Velocity, FPM (Based on first 24 points only) (B ws 

### ) Moisture in stack gas, volume fraction 

## PM/HCl Summary Run 3

### CLIENT

SOURCE DATE COLLECTED DATE PROCESSED 10/29/2012 

### DATE Weighed 10/30/2012 

### Filter Media: Teflon 

### PM Filter R-1 R-2 R-3 R-4 Filter No. 2771 2752 2764 Final wt.(grams) 0.4022 0.5919 0.4258 Tare Wt.(grams) 0.3199 0.3326 0.3229 

### Net Wt. (grams) 0.0823 0.2593 0.1029 PM Wash Weight R-1 R-2 R-3 R-4 Sample No. G288 G289 G290 Sample Volume(ml) 70 100 75 Final wt.(grams) 110.9771 99.6939 103.2728 Tare Wt.(grams) 110.9441 99.6311 103.2417 Blank Correction 0.0001 0.0001 0.0001 

### Net gain (grams) 0.0329 0.0627 0.0310

Reagent Blank Reagent Acetone Sample No. G291 Sample Volume(ml) 100 Final wt.(grams) 106.8814 Tare Wt.(grams) 106.8813 

### Net gain (grams) 0.0001
Silica R-1 R-2 R-3 R-4 Sample No. 1 2 3 Final wt.(grams) 448.5 419.6 410.4 Tare Wt.(grams) 406.1 391.2 383.2 

### Net gain (grams) 42.4 28.4 27.2

Technician Raw Data Entry

Hydro Aluminum North America Aluminum Remelt Furnace (East)

David J Pate - 111412 10/23 - 10/25USING CALIBRATED CRITICAL ORIFICES3-POINT ENGLISH UNITSCalibration ConditionsConsole Number1DateTime11/1/20120830Std Temp528oRPre-test "Y' value1.005Barometric Pressure29.88in HgStd Press29.92inHgDGM ModelNumber275Theoretical Critical Vacuum114.1in HgK117.647oR/in HgDGM SerialNumber6842125CalibrationTechnicianJoryProjectHydro MO MF HCL1For valid test results, the Actual Vacuum should be 1 to 2 in. Hg greater than the Theoretical Critical Vacuum shown above.2The Critical Orifice Coefficient, K', must be entered in English units, (ft3*oR1/2)/(in.Hg*min).Calibration DataRun TimeMetering ConsoleCritical OrificeDGM Orifice VolumeVolume Outlet Temp Outlet TempSerialCoefficient Amb Temp Amb TempActualElapsed∆HInitialFinalInitialFinalNumberInitialFinalVacuum(Θ)(Pm)(Vmi)(Vmf)(tmi)(tmf)K'(tamb)(tamb)minin H2Ocubic feetcubic feetoFoFsee above2oFoFin Hg101.0773.700779.9715959550.4793585816101.0779.971786.2665959550.4793585816101.0786.266792.5475960550.4793585916Calibration FactorFlowrateValueVariation Std & Corr 0.75 SCFM Variation(Vm(std))(Qm(std))(Vcr(std))(Qcr(std))(Y)(∆Y)(Qm(std)(corr))(∆H@)(∆∆H@)cubic feetcfmcubic feetcfmNote 1cfmin H2O6.3870.6396.2920.6290.9850.0020.6291.4520.0006.4110.6416.2920.6290.981-0.0020.6291.4520.0006.3910.6396.2890.6290.9840.0010.6291.4520.0000.984Y Average(Note 2)1.452∆H@ AverageElasped Time(> 10 min)10 DGM Beginning 793.2DGM End 800.804Outlet Meter TempBeginning60Outlet Meter TempEnd61Yc0.980Note 1: For Calibration Factor Y, the ratio of the reading of the calibration meter to the dry gas meter, acceptable tolerance of individual values from the average is +-0.02.Note 2: For Calibration Factor Y, the resulting average difference shall not more than + or - 5% of the Pre-test Y value.I certify that the above Dry Gas Meter was calibrated in accordance with USEPA Methods, CFR 40 Part 60, using the Precision Wet Test Meter # 11AE6,which in turn was calibrated using the American Bell Prover # 3785, certificate # F107, which is traceable to the National Bureau of Standards (N.I.S.T.) and in accordance with AASI Shop SOP 3.3.B.Technician Sign:Date:Q A Signature:Date:ResultsAMBIENT AIR SERVICES METHOD 5 POST-TEST CONSOLE CALIBRATIONFactors/ConversionsDry Gas MeterCritical OrificeStandardized DataDry Gas Meter∆H @Meter Console InformationYc CalibrationJ. Jory11/1/201211/2/2012Rev 1, 070808

### Yes No Yes No

D t 

### a1 a2 b1 b2 Pa Pb P Max Min Angle Y 2 Degrees sin 0.035 Angle O 0 Degrees sin 0.000 0.030 Inches 0.000 Inches

I certify that the measurements contained within this form was conducted correctly and within the guidelines of EPA Method 2. 

### Technician Signature: Date: Quality Assurance Signature: Date: 

## Ambient Air Services, Inc. 106 Ambient Airway Starke, F l orida 32091 PITOT TUBE POST TEST CALIBRATION FORM

0 0.425 0.425

z = P sin Y w = P sin O 1.125 0.7875 

## Pitot ID Technician P r oject

x Pitot Assembly Lev el 6-1 Jory Hydro MO melting furnace HCL 

## Date: 11/1/2012

Pitot tube openin g damaged or out-of-round x

11/1/2012
11/2/2012 If damage is noted, comment below 

## Pitot Measurements Pitot tube outside diameter 0.375 1 0 0

z = < 1/8 Inch w = < 1/32 inch 0.85

J. Jory B 1 = < 5  B 2 = < 5  A1 = < 10  A2 = < 10 

W = < 1 / 3 2 "

A B

Z = < 1/8" Face Opening Planes Transverse Tube Axis
A B P a P b

P a = P b D t = T u b i n g O D P 1

. 0 5 D t < P < 1

. 5 0 D t

Angle O A n g l e Y



### Pitot Calibration Template Rev 3, 020112Type:ThermocoupleIDLocation6-1 Stack57 581PassHB 3 Filter57 581PassTC K Impinger60 582PassRS1-1 Meter In58 580PassRS1-2-1 Meter Out58 580PassTechnician Signature:Date:Quality Assurance signature:QA date:Comments:Indicated Temperature Reference Temperature Difference ( must be ± 2° ) Continuity ( Pass / Fail )J. Jory11/1/201211/2/2012TechnicianProject99700583Hydro MO MF HCLJoryModel Serial numberAmbient Air Services, Inc.106 Ambient AirwayStarke, Florida 32091Alternative (EMC ALT-011) Method 2 Thermocouple CalibrationTimeDate11/1/20120845208252BCRReferenceThermometerPyrometerSerial numberms in glassOmegaDP460Manufacturer:ManufacturerThermocouple (EMC ALT-011) CalibrationTemplate060112