Part 70 Air Quality Permit

Alcoa Mt. Holly (operating as Alumax of South Carolina) 

Highway 52 North 

Goose Creek, South Carolina 29445 

(permit revised 1/30/03, see page 2 for details)

In accordance with the provisions of the Pollution Control Act, Sections 48-1-50(5) and 48-1-110(a), 

and the 1976 Code of Laws of South Carolina, as amended, Regulation 61-62, the above named 

permittee is hereby granted permission to discharge air contaminants into the ambient air. The 

Bureau of Air Quality authorizes the operation of this facility and its applicable equipment specified 

herein in accordance with the plans, specifications and other information submitted in the Title V 

permit application dated January 15, 1996 and subsequent submittals. 

This permit is subject to and conditioned upon the terms, limitations, standards, and schedules 

contained in or specified on the 45 pages, with the accompanying attachments, of this permit. 

Permit Number: TV-0420-0015 Effective Date: October 1, 2001 

Issue Date: August 20, 2001 Expiration Date: September 30, 2004

Director, Engineering Services Division 

Bureau of Air Quality
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 2 OF 45

(permit revised 1/30/03, see page 2 for details) 

RECORD OF REVISIONS

Revision 

Number 

Final 

Revision 

Date 

Type of Revision 

(AA, 502(b)(10), MM, 

SM) 

Description of Change (Specific Parts, 

Sections, and Tables Revised or Added) 

1 1/30/03 AA 

Re-issue of permit to incorporate Construction 

Permit 0420-0015-CR and other administrative 

changes in Parts 5.0, 6.0, 7.0, and Attachment A 

AA = Administrative Amendment 

502(b)(10) = Operational Flexibility 

MM = Minor Modification 

SM = Significant Modification

Send copies of all revisions to Permit File, Main File, District EQC Office, US EPA, and Facility 

Contact. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 3 OF 45

(permit revised 1/30/03, see page 2 for details) 

TABLE OF CONTENTS

Part 1.0 GENERAL INFORMATION

A. Applicable Permit Dates 

B. Facility Information 

C. Facility Address 

D. Facility Billing Address 

Part 2.0 APPLICABILITY

Part 3.0 GENERAL CONDITIONS

A. Permit Issuance 

B. Permit Expiration and Renewal 

C. Severability 

D. Fee Assessment and Payment 

E. Submittal of Information 

F. Public Participation 

G. Permit Reopening 

H. Temporary Sources 

I. Emergency Provisions 

J. Property Rights 

K. Economic Incentives, Marketable Permits, Emission Trading 

L. Title IV Sources 

M. Administrative Permit Amendments 

N. Minor Permit Modifications 

O. Significant Modification Procedures 

P. Duty to Comply 

Q. Inspection and Entry 

R. Compliance Requirements 

S. Schedule of Compliance 

T. Need to Halt or Reduce Activity Not a Defense 

U. Operational Flexibility 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 4 OF 45

(permit revised 1/30/03, see page 2 for details) 

Part 4.0 FACILITY WIDE REQUIREMENTS

A. Emissions Limits and Standards 

B. Facility Wide Conditions 

Part 5.0 EMISSION UNIT REQUIREMENTS

A. Emission Unit Description 

B. Control Devices Description 

C. Equipment Description 

D. Emissions Limits and Standards 

E. Emission Unit Conditions 

Part 6.0 MONITORING AND REPORTING REQUIREMENTS

A. Monitoring and Reporting 

B. Monitoring and Reporting Conditions 

Part 7.0 ADDITIONAL CONDITIONS

A. Specific Conditions 

B. Operational Flexibility 

C. Compliance Schedule 

D. Permit Shield 

ATTACHMENT A - Modeled Emission Rates 

ATTACHMENT B - Insignificant Activities 

ATTACHMENT C - Applicable and Non-applicable Federal and State Regulations
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 5 OF 45

(permit revised 1/30/03, see page 2 for details) 

PART 1.0 GENERAL INFORMATION

A. APPLICABLE PERMIT DATES

ISSUE DATE: August 20, 2001 

EFFECTIVE DATE: October 1, 2001 

EXPIRATION DATE: September 30, 2004 

RENEWAL APPLICATION DUE: March 31, 2004 

B. FACILITY INFORMATION

ENVIRONMENTAL CONTACT: Randy Pulley 

CONTACT TELEPHONE NUMBER: 843-572-5294 

INTERNET E-MAIL ADDRESS: randy.pulley@alcoa.com 

FACILITY LOCATION: Highway 52 North - Goose Creek 

COUNTY: Berkeley 

SIC CODE: 3334 

AFS CODE: 4501500015 

C. FACILITY ADDRESS

FACILITY NAME: Alcoa Mt. Holly (operating as Alumax of South Carolina)

ADDRESS: PO Box 1000 

CITY, STATE, ZIP: Goose Creek, SC 29445 

D. FACILITY BILLING ADDRESS

FACILITY BILLING NAME: Alcoa Mt. Holly 

ADDRESS: PO Box 1000 

CITY, STATE, ZIP: Goose Creek, SC 29445 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 6 OF 45

(permit revised 1/30/03, see page 2 for details) 

PART 2.0 APPLICABILITY [SC Regulation 61-62.70.3(a)] 

The following sources are subject to permitting requirements of Part 70: 

1. Any major source; 

2. Any source, including an area source, subject to a standard, limitation, or other 

requirement under Section 111 of the Clean Air Act (Act); 

3. Any source, including an area source, subject to a standard or other requirement 

under Section 112 of the Act, except that a source is not required to obtain a permit 

solely because it is subject to regulations or requirements under Section 112(r) of the 

Act; 

4. Any affected source under the Title IV Acid Rain Program; 

5. Any source in a source category designated by the Administrator of the US 

Environmental Protection Agency (US EPA)(Administrator) pursuant to this Section; 

and 

6. Any source listed in SC Regulation 61-62.70.3(a) that is exempt from the 

requirement to obtain a permit under SC Regulation 61-62.70.3(b) may opt to apply 

for a permit under this Part 70 program. 

The following source categories are exempted from the obligation to obtain a Part 70 permit, but are 

not exempted from other SC Department of Health and Environmental Control (Department) and US 

EPA requirements [SC Regulation 61-62.70.3(b)(4)]: 

1. All sources and source categories that would be required to obtain a permit solely 

because they are subject to 40 CFR 60, Subpart AAA - Standards of Performance for 

New Residential Wood Heaters; and 

2. All sources and source categories that would be required to obtain a permit solely 

because they are subject to 40 CFR 61, Subpart M - National Emission Standard for 

Hazardous Air Pollutants for Asbestos, Section 61.145, Standard for Demolition and 

Renovation. 

Any person that operates or proposes to operate a particular source or installation may submit a 

request in writing that the Department make a determination as to whether a particular source or 

installation is subject to the permit requirements of this regulation. The request must contain such 

information as is believed sufficient for the Department to make the requested determination. [SC 

Regulation 61-62.70.3(e)] 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 7 OF 45

(permit revised 1/30/03, see page 2 for details) 

PART 3.0 GENERAL CONDITIONS

This section describes conditions and provisions applicable to all Part 70 sources. Specific source 

category conditions and requirements are contained in Part 5.0 of this permit. (Revised 05/21/99)

A. PERMIT ISSUANCE [SC Regulation 61-62.70.7(a)(1)] 

A permit, permit modification, or renewal may be issued only if the following conditions have been 

met: 

1. The Department has received a complete application for a permit, permit 

modification, or permit renewal; 

2. Except for modifications qualifying for minor permit modification procedures under 

SC Regulation 61-62.70.7(e)(2) and (3), the Department has complied with the 

requirements for public participation under SC Regulation 61-62.70.7(h); 

3. The Department has complied with the requirements for notifying and responding to 

affected States under SC Regulation 61-62.70.8(b); 

4. The conditions of the permit provide for compliance with all applicable requirements 

and the requirements of Part 70; and 

5. The Administrator has received a copy of the proposed permit and any notices 

required under SC Regulation 61-62.70.8(a) and (b), and has not objected to issuance 

of the permit under SC Regulation 61-62.70.8(c) within the required time frame. 

A Title V operating permit does not excuse any facility from the preconstruction permitting 

requirements under SC Regulation 61-62.1. 

B. PERMIT EXPIRATION AND RENEWAL [SC Regulation 61-62.70.7(c)] (Revised 11/13/98)

Permit expiration terminates the source’s right to operate unless a timely and complete renewal 

application has been submitted consistent with SC Regulation 61-62.70.5(a)(1)(iii), 61-

62.70.5(a)(2)(iv), and 61-62.70.7(b). In this case, the permit shall not expire until the renewal 

permit has been issued or denied. All terms and conditions of the permit including any permit shield 

that may be granted pursuant to SC Regulation 61-62.70.6(f) shall remain in effect until the renewal 

permit has been issued or denied. 

Permits being renewed are subject to the same procedural requirements, including those for public 

participation, affected State and US EPA review, that apply to initial permit issuance. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 8 OF 45

(permit revised 1/30/03, see page 2 for details) 

C. SEVERABILITY [SC Regulation 61-62.70.6(a)(5)] 

The provisions of this permit are severable, and if any provision of this permit, or application of any 

provision of this permit to any circumstance is held invalid, the application of such provision to 

other circumstances, and the remainder of this permit shall not be affected thereby. 

D. FEE ASSESSMENT AND PAYMENT [SC Regulation 61-62.70.6(a)(7)] 

The owners or operators of Part 70 sources shall pay fees to the Department consistent with the fee 

schedule approved pursuant to South Carolina Regulation 61-62.70.9. 

E. SUBMITTAL OF INFORMATION [SC Regulation 61-62.70.6(a)(6)(v)] 

The permittee shall furnish to the Department, within a reasonable time, any information that the 

Department may request, in writing, to determine whether cause exists for modifying, revoking, 

reissuing, or terminating the permit or to determine compliance with the permit. Upon request, the 

permittee shall also furnish to the Department copies of records required to be kept by the permit or, 

for information claimed to be confidential, the permittee may furnish such records directly to the 

Administrator along with a claim of confidentiality. The Department may also request that the 

permittee furnish such records directly to the Administrator along with a claim of confidentiality. 

F. PUBLIC PARTICIPATION [SC Regulation 61-62.70.7(h)] 

Except for modifications qualifying for minor permit modification procedures, all permit 

proceedings, including initial permit issuance, significant modifications, and renewals, shall provide 

adequate procedures for public notice including offering an opportunity for public comment and 

hearing on the draft permit. These procedures shall meet all requirements of SC Regulation 61-

62.70.7(h). 

G. PERMIT REOPENING [SC Regulation 61-62.70.7(f)] (Revised 05/21/99)

This permit shall be reopened and revised under any of the following circumstances: 

1. Additional applicable requirements under the Act become applicable to a major Part 

70 source for which three or more years remain on the original term of the permit. 

Such revisions shall be made not later than eighteen (18) months following 

promulgation of relevant standards or regulations unless the regulation specifically 

provides for a longer compliance period. No such reopening is required if the 

effective date of the requirement is later than the date on which the permit is due to 

expire, unless the original permit or any of its terms and conditions has been 

extended pursuant to SC Regulation 61-62.70.7(c)(1)(ii). 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 9 OF 45

(permit revised 1/30/03, see page 2 for details) 

2. Additional requirements, including excess emission requirements, become applicable 

to an affected source under the acid rain program. Excess emissions offset plans 

shall be deemed to be incorporated into this permit upon approval by the 

Administrator. 

3. The Department or EPA determines that the permit contains a material mistake or 

that inaccurate statements were made in establishing the emissions standards or other 

terms or conditions of the permit. 

4. The Administrator or the Department determines that the permit must be revised or 

revoked to assure compliance with the applicable requirements. 

In addition, the permit may be modified, revoked, reopened, and reissued, or terminated for cause by 

the Department. The filing of a request by the permittee for a permit modification, revocation and 

reissuance, or termination, or of a notification of planned changes or anticipated noncompliance does 

not stay any permit condition. [SC Regulation 61-62.70.6(a)(6)(iii)] 

Proceedings to reopen and issue a permit shall follow the same procedures as apply to initial permit 

issuance and shall affect only those parts of the permit for which cause to reopen exists. Such 

reopenings shall be as expeditious as practicable. Reopenings shall not be initiated before a notice 

of such intent is provided to the Part 70 source by the Department at least thirty (30) days in advance 

of the date that the permit is to be reopened, except that the Department may provide a shorter time 

period in the case of an emergency. 

H. TEMPORARY SOURCES [SC Regulation 61-62.70.6(e)] 

In accordance with SC Regulation 61-62.70.6(e), the Department may issue a single permit 

authorizing emissions from similar operations by the same source owner or operator at multiple 

temporary locations. The operation must be temporary and involve at least one change in location 

during the term of the permit. No sources subject to Title IV of the Act shall be permitted as a 

temporary source. 

I. EMERGENCY PROVISIONS [SC Regulation 61-62.70.6(g)(3)] (Revised 05/21/99)

In the case of an emergency, as defined in SC Regulation 61-62.70.6(g), the permittee shall verify an 

affirmative defense of emergency through properly signed, contemporaneous operating logs, or other 

relevant evidence that: 

1. An emergency occurred and that the permittee can identify the cause(s) of the 

emergency; 

2. The permitted facility was at the time being properly operated; and 

3. During the period of the emergency the permittee took all reasonable steps to 

minimize levels of emissions that exceeded the emission standards, or other 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 10 OF 45

(permit revised 1/30/03, see page 2 for details) 

requirements in the permit. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 11 OF 45

(permit revised 1/30/03, see page 2 for details) 

Additionally, the permittee shall submit verbal notification of the emergency to the Department 

within twenty-four (24) hours of the time when emission limitations were exceeded, followed by 

written notifications within thirty (30) days. This notice fulfills the requirement of SC Regulation 

61-62.70.6(a)(3)(iii)(B). This notice must contain a description of the emergency, any steps taken to 

mitigate emissions, and corrective actions taken. 

This provision is in addition to any emergency or upset provision contained in any applicable 

requirement. In any enforcement proceeding, the permittee seeking to establish the occurrence of an 

emergency has the burden of proof. 

J. PROPERTY RIGHTS [SC Regulation 61-62.70.6(a)(6)(iv)] 

This permit does not convey any property rights of any sort, or any exclusive privilege. 

K. ECONOMIC INCENTIVES, MARKETABLE PERMITS, EMISSION TRADING [SC 

Regulation 61-62.70.6(a)(8)] 

No permit revision shall be required, under any approved economic incentives, marketable permits, 

emissions trading and other similar programs or processes for changes that are provided for in this 

permit. 

L. TITLE IV SOURCES [SC Regulation 61-62.70.6(a)(4)] 

The permittee is prohibited from emissions exceeding any allowances that the source lawfully holds 

under Title IV of the Act or the regulations promulgated thereunder. No permit revision shall be 

required for increases in emissions that are authorized by allowances acquired pursuant to the acid 

rain program, provided that such increases do not require a permit revision under any other 

applicable requirement. No limit shall be placed on the number of allowances held by a source. The 

source may not, however, use allowances as a defense for noncompliance with any other applicable 

requirement. Any such allowances shall be accounted for according to the procedures established in 

regulations promulgated under Title IV of the Act. 

Where an applicable requirement of the Act is more stringent than an applicable requirement of 

regulations promulgated under Title IV of the Act, both provisions shall be incorporated into the 

permit and shall be enforceable by the Administrator. [SC Regulation 61-62.70.6(a)(1)(ii)] 

M. ADMINISTRATIVE PERMIT AMENDMENTS [SC Regulation 61-62.70.7(d)(3)] 

An administrative permit amendment as defined in SC Regulation 61-62.70.7(d) can be made by the 

Department consistent with the following: 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 12 OF 45

(permit revised 1/30/03, see page 2 for details) 

1. The Department shall take no more than sixty (60) days from receipt of a request for 

an administrative permit amendment to take final action on such request, and may 

incorporate such changes without providing notice to the public or affected States 

provided that it designates any such permit revisions as having been made pursuant 

to this paragraph. 

2. The Department shall submit a copy of the revised permit to the Administrator. 

3. The source may implement the changes addressed in the request for an 

administrative amendment immediately upon submittal of the request, except 

transfer/ownership which must comply with SC Regulation 61-62.1, Section II(E). 

N. MINOR PERMIT MODIFICATIONS [SC Regulation 61-62.70.7(e)(2)] 

Minor permit modifications can be made by the Department in accordance with SC Regulation 61-

62.70.7(e)(2)(i). An application requesting the use of minor permit modification procedures shall 

meet the requirements of SC Regulation 61-62.70.5(c) and shall include items as specified in SC 

Regulation 61-62.70.7(e)(2)(ii). 

The Department may modify the procedure outlined in SC Regulation 61-62.70.7(e)(2) to process 

groups of a source’s applications for certain modifications eligible for minor permit modification 

processing. Group processing of minor permit applications will proceed as outlined in SC 

Regulation 61-62.70.7(e)(3). 

O. SIGNIFICANT MODIFICATION PROCEDURES [SC Regulation 61-62.70.7(e)(4)] 

Significant permit modification procedures shall be used for applications requesting permit 

modifications listed in SC Regulation 61-62.70.7(e)(4)(i). Significant permit modifications shall 

meet all requirements of this Part 70, including those for applications, public participation, review 

by affected States, and review by EPA, as they apply to permit issuance and permit renewal. 

P. DUTY TO COMPLY [SC Regulation 61-62.70.6(a)(6)(i)] 

The permittee must comply with all of the conditions of this permit. Any permit noncompliance 

constitutes a violation of the SC Pollution Control Act and/or the Federal Clean Air Act and is 

grounds for enforcement action; for permit termination, revocation and reissuance, or modification; 

or for denial of permit renewal application. 

Q. INSPECTION AND ENTRY [SC Regulation 61-62.70.6(c)(2)] 

Upon presentation of credentials and other documents as may be required by law, the permittee shall 

allow the Department or an authorized representative to perform the following: 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 13 OF 45

(permit revised 1/30/03, see page 2 for details) 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 14 OF 45

(permit revised 1/30/03, see page 2 for details) 

1. Enter upon the permittee’s premises where a Part 70 source is located or emissionsrelated activity is conducted, or where records must be kept under the conditions of 

the permit. 

2. Have access to and copy, at reasonable times, any records that must be kept under the 

conditions of the permit. 

3. Inspect any facilities, equipment (including monitoring and air pollution control 

equipment), practices, or operations regulated or required under this permit. 

4. As authorized by the Act and/or the SC Pollution Control Act, sample or monitor at 

reasonable times substances or parameters for the purpose of assuring compliance 

with the permit or applicable requirements. 

R. COMPLIANCE REQUIREMENTS [SC Regulation 61-62.70.6(c)(5)] (Revised 05/21/99)

Consistent with SC Regulation 61-62.70.6(a)(3), this permit contains compliance certification, 

testing, monitoring, reporting, and record keeping requirements sufficient to assure compliance with 

the terms and conditions of this permit. Any document (including reports) shall contain a 

certification by a responsible official or designee that meets the requirements of SC Regulation 61-

62.70.5(d). 

The responsible official or designee shall certify, annually, compliance with the conditions of this 

permit. The compliance certification shall include the following: 

1. The identification of each term or condition of the permit that is the basis of the 

certification. 

2. The identification of the methods or means used for determining the compliance 

status with each term and condition during the certification period, and whether such 

methods or means provide continuous or intermittent data. 

3. The status of compliance with the terms and conditions of the permit for the period 

covered by the certification. 

4. Such other facts as the Department may require to determine the compliance status of 

the source. 

5. All compliance certifications shall be submitted to the Administrator as well as to the 

Department. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 15 OF 45

(permit revised 1/30/03, see page 2 for details) 

The annual compliance certification shall be sent to the Environmental Protection Agency (EPA) 

and the South Carolina Department of Health and Environmental Control - Bureau of Air Quality 

(SC DHEC - BAQ) at the following addresses: 

US EPA, Region 4 SC DHEC - BAQ 

Air Enforcement Branch Technical Management Section 

61 Forsyth Street 2600 Bull Street 

Atlanta, GA 30303 Columbia, SC 29201

S. SCHEDULE OF COMPLIANCE [SC Regulation 61-62.70.5(c)(8)] (Revised 5/21/99)

The permittee shall submit a compliance schedule that contains the following for all Part 70 sources 

that are not in compliance with all applicable rules: 

1. A description of the source’s compliance status and where appropriate a compliance 

schedule with respect to all applicable requirements as follows: 

(a) For applicable requirements with which the source is in compliance, a 

statement that during the permit term the source will continue to comply with 

such requirements. 

(b) For applicable requirements that will become effective during the permit 

term, a statement that the source will meet such requirements on a timely 

basis, unless a more detailed schedule is expressly required by the applicable 

requirement. 

(c) A schedule of compliance for sources that are not in compliance with all 

applicable requirements at the time of permit issuance. This schedule shall 

include a narrative description of how the source will achieve compliance, a 

schedule of remedial measures, including an enforceable sequence of actions 

with milestones, leading to compliance with all applicable requirements. 

This compliance schedule shall be at least as stringent as that contained in 

any judicial consent decree or administrative order to which the source is 

subject. Any such schedule of compliance shall be supplemental to, and shall 

not sanction noncompliance with, the applicable requirements on which it is 

based. 

2. A schedule for submission of certified progress reports no less frequently than every 

six (6) months for sources required to have a schedule of compliance to remedy a 

violation. Progress reports shall meet the requirements of SC Regulation 61-

62.70.6(c)(4)(i) and (ii). 

3. The compliance plan content requirements specified in this paragraph shall apply and 

be included in the acid rain portion of a compliance plan for an affected source, 

except as specifically superseded by regulations promulgated under Title IV of the 

act with regard to the schedule and method(s) the source will use to achieve 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 16 OF 45

(permit revised 1/30/03, see page 2 for details) 

compliance with acid rain emissions limitations. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 17 OF 45

(permit revised 1/30/03, see page 2 for details) 

T. NEED TO HALT OR REDUCE ACTIVITY NOT A DEFENSE [SC Regulation 61-

62.70.6(a)(6)(ii)] 

It shall not be a defense for a permittee in an enforcement action that it would have been necessary 

to halt or reduce the permitted activity in order to maintain compliance with the conditions of this 

permit. 

U. OPERATIONAL FLEXIBILITY [SC Regulation 61-62.70.7(e)(5)] 

In accordance with SC Regulation 61-62.70.7(e)(5), a permitted facility is authorized to make 

changes within their facility without requiring a permit revision, if the changes are not modifications 

under Title I of the Act and the changes do not exceed the emissions allowable under this permit. 

The permitted facility shall provide the Administrator and the Department written notification as 

required by SC Regulation 61-62.70.7(e)(5) at least seven (7) days prior to such changes. 

PART 4.0 FACILITY WIDE REQUIREMENTS

A. EMISSIONS LIMITS AND STANDARDS

Table 4.1 contains summaries of facility wide emission limits and standards. 

TABLE 4.1 EMISSION LIMITS AND STANDARDS

Pollutant Limit/Standard Regulation State Only 

Requirement 

Condition 

Number 

State New Source 

Review 

As Specified in 

Attachment A 

SC Regulation 61-

62.1, Section II (A) Yes 4.B.3 

Toxic Air 

Pollutants 

As Specified in 

Attachment A 

SC Regulation 61-

62.5, Std No. 8 Yes 4.B.3 

Hazardous Air 

Pollution 

Comply with 

Regulation SC Regulation 61-62.4 No N/A 

Open Burning Comply With 

Regulation SC Regulation 61-62.2 No N/A 

Fugitive 

Emissions 

Comply With 

Regulation 

SC Regulation 61-

62.6, Sec III No N/A 

Ozone Depleting 

Substances * 40 CFR Part 82, 

Subpart F No 4.B.7 

Asbestos * 40 CFR Part 61.145 No 4.B.8 

N/A = Not Applicable 

* Specific To Subpart

The maximum allowable emission limits above are derived from the various Federal and State 

regulations that govern the operation of this type of facility. All applicable facility wide emission 

limits and corresponding regulations are listed above. Additional operating requirements which may 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 18 OF 45

(permit revised 1/30/03, see page 2 for details) 

be more stringent than those above are contained in Part 5.0, Part 6.0, and Part 7.0 of this permit. 

B. FACILITY WIDE CONDITIONS (Revised 11/13/98) 

Condition 

Number Condition 

1. 

In accordance with SC Regulation 61-62.1, Section II, the permittee must comply with all applicable 

statutes and regulations of the United States and the State of South Carolina. This permit does not 

relieve the permittee from compliance with applicable local laws, ordinances, and regulations. 

2. 

Air dispersion modeling (or other method) has demonstrated that this facility’s operation will not 

interfere with the attainment and maintenance of any state or federal standard. Any changes in the 

parameters used in the air dispersion modeling may require a review by the facility to determine 

continuing compliance with these standards. These potential changes include any decrease in stack 

height, decrease in stack velocity, increase in stack diameter, decrease in stack exit temperature, 

increase in building height or building additions, increase in emission rates, decrease in distance 

between stack and property line, changes in vertical stack orientation, and installation of a rain cap 

that impedes vertical flow. Parameters that are not required in the determination will not invalidate 

the demonstration if they are modified. The emission rates used in the determination are listed in 

Attachment A of this permit. Higher emission rates may be administratively incorporated into 

Attachment A of this permit provided a demonstration using these higher emission rates shows the 

attainment and maintenance of any state or federal standard or with any other applicable requirement. 

 Variations from the input parameters in the demonstration shall not constitute a violation unless the 

maximum allowable ambient concentrations identified in the standard are exceeded. 

3. 

The owner/operator shall maintain this facility in compliance with the pollutant limitations in Part 4, 

Part 5, Part 6, Part 7, and/or the emission rates as listed in Attachment A of this Part 70 operating 

permit, whichever is more restrictive. This is a State Only enforceable requirement. Should the 

facility wish to increase the emission rates listed in Attachment A, it may do so by the administrative 

process specified in condition 4.B.2 

4. 

A list of equipment which are considered insignificant pursuant to SC Regulation 61-62.70.5(c) has 

been submitted with your Title V application and reviewed by our staff. The list, including source 

descriptions and citation for exemption, is summarized in Attachment B of the permit. Attachment B 

excludes those activities identified in Part A of the insignificant activities list. Written notification to 

the Bureau of Air Quality is required for the addition of any new equipment which may meet the 

definition of insignificant or exempt as described above, excluding those sources listed in Part A of 

the insignificant activities list. 

(Revised 11/13/98) 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 19 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Condition 

5.

In accordance with SC Regulation 61-62.1 Section II, (C)(3), for all sources not required to have 

continuous emissions monitors, in the event of any malfunction of air pollution control equipment or 

system, process upset or other equipment failure which results in discharges of air contaminants 

lasting for one hour or more and which are greater than those discharges described for normal 

operation in the permit application shall be reported to the local Environmental Quality Control 

(EQC) District office within twenty-four (24) hours after the beginning of the occurrence. The 

permittee shall also submit a written report within thirty (30) days of the occurrence. This report shall 

be submitted to the Manager of the Technical Management Section, Bureau of Air Quality (BAQ). 

The report shall contain as a minimum, the following: the identity of the emission unit and associated 

equipment where excess emissions occurred, the magnitude of excess emissions, the time and 

duration of excess emissions, the steps taken to remedy the malfunction and to prevent a recurrence, 

documentation that control equipment and processes were at all times maintained and operated, to the 

maximum extent practicable, in a manner that was consistent with good practice for minimizing 

emissions. Such a report shall in no way serve to excuse, otherwise justify, or in any manner affect 

any potential liability or enforcement action resulting from the occurrence. This defines the 

Department’s definition of prompt in its relation to the degree of reporting as specified by SC 

Regulation 61-62.70.6(a)(3)(iii)(b). 

6. 

In accordance with SC Regulation 61-62.1, Section III an emissions inventory will be completed for 

the previous calendar year and submitted by March 31 of every even calendar year to the Department. 

 The above requirement notwithstanding, an emissions inventory may be required at any time in order 

to determine the compliance status of any facility. 

7. 

The permittee shall comply with the standards for recycling and emissions reduction pursuant to 40 

CFR Part 82, Subpart F, Protection of Stratospheric Ozone, Recycling and Emissions Reduction, 

except as provided for motor vehicle air conditioners (MVACs) in Subpart B. If the permittee 

performs a service on motor (fleet) vehicles that involves ozone-depleting substance refrigerant in 

MVACs, the permittee is subject to all applicable requirements of 40 CFR Part 82, Subpart B, 

Servicing of MVACs. 

8. 

The permittee shall comply with the standards of performance for asbestos abatement operations 

pursuant to 40 CFR Part 61.145 and SC Regulation 61-86.1, including, but not limited to, 

requirements governing training, licensing, notification, work practice, cleanup, and disposal. 

PART 5.0 EMISSION UNIT REQUIREMENTS

A. EMISSION UNIT DESCRIPTION

Table 5.1 is a description of emission units located at this facility. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 20 OF 45

(permit revised 1/30/03, see page 2 for details) 

TABLE 5.1 EMISSION UNITS

Unit 

ID Unit Description Control Device Description 

01 Green Carbon Plant (12) Baghouses, (1) Scrubber 

02 Baked Carbon Plant (4) Baghouses, (1) Scrubber/Baghouse 

System 

03 Anode Rodding (8) Baghouses 

04 Potlines (19) Baghouses, (4) Scrubber/Baghouse 

Systems 

05 Pot Repair Baghouse System 

06 Cast House (4) Baghouses 

N/A = Not Applicable

B. CONTROL DEVICE DESCRIPTION

Table 5.2 is a description of control devices located at this facility. 

TABLE 5.2 CONTROL DEVICES

Control 

Device ID 

Stack 

ID Control Device Description Installation Date 

Pollutant(s) 

Controlled 

Efficiency 

Capture 

(Removal) 

ID 01 - GREEN CARBON PLANT

50058 12 2,200 cfm Dust Collector for Coke 

Unloading Station (252 DC-2) 1979 PM 0.005 

grains/cf 

50020 11 

3,600 cfm Dust Collector for Coke Storage 

Tanks #1, #2, and Fluid Coke Storage Tank 

(252A DC-1) 

1979/1994 PM 0.005 

grains/cf 

50012 19 11,735 cfm Dust collector for Coke 

Crushing System (254 DC-1) 1979 PM 0.005 

grains/cf 

50013 15 2,020 cfm Dust Collector for Butts 

Classifier System (254 DC-2) 1979 PM 0.005 grains/cf 

50014 13 4,065 cfm Dust Collector for Classifier 

Material Handling System (254 DC-3) 1979 PM 0.005 

grains/cf 

50015 16 5,805 cfm Dust Collector for Storage 

Reclaim System (254 DC-4) 1979 PM 0.005 

grains/cf 

50016 18 4,055 cfm Dust Collector for Aggregate 

Blending System (254 DC-5) 1979 PM 0.005 

grains/cf 

50005 14 3,200 cfm Dust Collector for Ball Mill 

Classifying System (254 DC-6) 1979/1993 PM 0.005 

grains/cf 

50006 17 1,000 cfm Dust Collector for Intermediate 

Classifying System (254 DC-7) 1979 PM 0.005 

grains/cf 

50057 10 10,700 cfm Dust Collector for Secondary 

Butt Crushing System (254 DC-8) 1979 PM 0.005 

grains/cf 

50056 09 10,000 cfm Dust Collector for Butts Storage 

Tank #1 and #2 (254Y DC-9) 1979/1996 PM 0.005 

grains/cf 

50051 20 600 cfm Dust Collector for Fines Recovery 

System (254 DC-10) 1982 PM 0.005 

grains/cf 

50054 85 Scrubber for Anode Forming Process 1992 POM N/A 

ID 02 - BAKED CARBON PLANT
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 21 OF 45

(permit revised 1/30/03, see page 2 for details) 

Control 

Device ID 

Stack 

ID Control Device Description Installation Date 

Pollutant(s) 

Controlled 

Efficiency 

Capture 

(Removal) 

53001 01 

Dry Scrubber System/Baghouse for North 

and South Bake Ovens (alumina used as 

scrubbing media) 

1979 Fluorides 

PM N/A 

50023 08 

5,200 cfm Dust Collector for Anode Block 

Cleaning and Material Transfer Operations 

261 DC-1 

1979/1995 PM 0.005 

grains/cf 

50024 06 4,100 cfm Dust Collector for Fresh Alumina 

Storage and Transfer 261G DC-1 1979/1993 PM 0.005 

grains/cf 

50025 07 

800 cfm Dust Collector for Fluoride 

Enriched Alumina Storage and Transfer 

261G DC-2 

1979 PM 0.005 

grains/cf 

89054 100 1,080 cfm Housekeeping Dust Collector 261 

DC-2 1986 PM 0.005 

grains/cf 

ID 03 - ANODE RODDING

50007 24 10,000 cfm Dust Collector for the Butt 

Blasting System 232 DC-3 1979 PM 0.005 grains/cf 

50008 22 21,970 cfm Dust Collector for the Butt 

Crushing Operations 232H DC-1 1979 PM 0.005 

grains/cf 

50059 23 8,350 cfm Dust Collector for the Rod and 

Stub Blasting System 232 DC-2 1979 PM 0.005 

grains/cf 

50064 26 

600 cfm Dust Collector for the Butt Blast 

Discharge and Truck Loading Station 232 

DC-5 

1979 PM 0.005 

grains/cf 

50050 27 7,000 cfm Dust Collector for the Anode Eye 

Cleaner System 232 DC-6 1979 PM 0.005 grains/cf 

50010 25 4,200 cfm Dust Collector for the 3 Induction 

Furnaces 232 DC-4 1979 PM 0.005 

grains/cf 

50055 101 700 cfm Dust Collector for the Cathode 

Collector Bar Cleaner 232 DC-7 1984/1996 PM 0.005 grains/cf 

89055 125 Anode Hole Cleaner Vacuum Exhaust 232 

DC-8 1992 PM 0.005 

grains/cf 

ID 04 - POTLINES

50053 29 15,600 cfm Dust Collector for Track Hopper 

140 DC-1 1980/1985 PM 0.005 

grains/cf 

50026 28 6,300 cfm Dust Collector for Screening 

Tower 140 DC-2 1980 PM 0.005 

grains/cf 

50029 32 6,250 cfm Dust Collector for “Lift Tower” - 

First of Three 140A DC-5 1980 PM 0.005 

grains/cf 

50027 33 4,100 cfm Dust Collector for “Separator 

Vent” - Second of Three 140Y DC-3 1980 PM 0.005 

grains/cf 

50028 34 4,100 cfm Dust Collector for “Separator 

Vent” - Third of Three 140Y DC-4 1980 PM 0.005 

grains/cf 

50031 39 

6,200 cfm Dust Collector for Fresh Alumina 

& Fluoride Storage Tanks (potline #2) 

142M DC-7 

1980 PM 0.005 

grains/cf 

50030 40 

1,600 cfm Dust Collector for Fresh Alumina 

& Fluoride Storage Tanks (potline #1) 

141M DC-6 

1980 PM 0.005 

grains/cf 

53002 02 

Scrubber and Dust Collector for Alumina 

Reduction Pots on Potline #1 (161E) - fresh 

alumina used as scrubbing media 

1980 Fluorides 

PM N/A 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 22 OF 45

(permit revised 1/30/03, see page 2 for details) 

Control 

Device ID 

Stack 

ID Control Device Description Installation Date 

Pollutant(s) 

Controlled 

Efficiency 

Capture 

(Removal) 

53003 03 

Scrubber and Dust Collector for Alumina 

Reduction Pots on Potline #1 (161W) - fresh 

alumina used as scrubbing media 

1980 Fluorides 

PM N/A 

50041 41 

2,400 cfm Dust Collector for Potline #1 

Enriched Alumina Conveying System 

“Pneumatic Conveyors” 141R DC-10 

1980/1996 PM 0.005 

grains/cf 

50039 42 

8,200 cfm Dust Collector for Potline #1 

Enriched Alumina Conveying System “Air 

Slides and Tanks” 141R DC-8 

1980 PM 0.005 

grains/cf 

50040 43 

2,400 cfm Dust Collector for Potline #1 

Enriched Alumina Conveying System 

“Pneumatic Conveyors” 141R DC-9 

1980/1996 PM 0.005 

grains/cf 

53004 04 

Scrubber and Dust Collector for Alumina 

Reduction Pots on Potline #2 (162E) - fresh 

alumina used as scrubbing media 

1980 Fluorides 

PM N/A 

53005 05 

Scrubber and Dust Collector for Alumina 

Reduction Pots on Potline #2 (162W) - fresh 

alumina used as scrubbing media 

1980 Fluorides 

PM N/A 

50044 44 

2,400 cfm Dust Collector for Potline #2 

Enriched Alumina Conveying System 

“Pneumatic Conveyors” 142R DC-13 

1980/1996 PM 0.005 

grains/cf 

50042 45 

8,200 cfm Dust Collector for Potline #2 

Enriched Alumina Conveying System “Air 

Slides and Tanks” 142R DC-11 

1980 PM 0.005 

grains/cf 

50043 46 

2,400 cfm Dust Collector for Potline #2 

Enriched Alumina Conveying System 

“Pneumatic Conveyors” 142R DC-12 

1980/1996 PM 0.005 

grains/cf 

50032 30 135,400 cfm Dust Collector for Bath 

Crusher and Storage 136 DC-1 1980/1983 PM 0.0035 grains/cf 

50052 31 3,031 cfm Dust Collector for Screens and 

Bath Storage Tanks 136 DC-2 1980 PM 0.005 grains/cf 

50033 35 1,600 cfm Dust Collector for Bath Feed 

Station at Potroom #101 DC-101K 1980/1982 PM 0.005 grains/cf 

50034 36 1,600 cfm Dust Collector for Bath Feed 

Station at Potroom #102 DC-102K 1980/1982 PM 0.005 grains/cf 

50035 37 1,600 cfm Dust Collector for Bath Feed 

Station at Potroom #103 DC-103K 1980/1982 PM 0.005 grains/cf 

50036 38 1,600 cfm Dust Collector for Bath Feed 

Station at Potroom #104 DC-104K 1980/1982 PM 0.005 

grains/cf 

ID 05 - POT REPAIR

50061-50063 21A 75,000 cfm Pot Repair dust collection 

system 138 DC-2 1997 PM 0.0035 

grains/cf 

ID 06 - CAST HOUSE

50045 47 18,722 cfm Dust Collector for Dross 

Cooling Operations 302 DC-3 1980 PM 0.005 

grains/cf 

50046 48 6,000 cfm Cyclone/Dust Collection System 

for Ball Mill #1 302 DC-1 1980 PM 0.005 

grains/cf 

50047 49 6,000 cfm Cyclone/Dust Collection System 

for Ball Mill #2 302 DC-2 1980 PM 0.005 

grains/cf 

50038 50 30,360 cfm Dust Collector Dross Pad 302 

DC-4 1980 PM 0.005 

grains/cf 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 23 OF 45

(permit revised 1/30/03, see page 2 for details) 

C. EQUIPMENT DESCRIPTION

A description of the equipment located at this facility is provided in the following tables: 

TABLE 5.3 UNIT ID 01 - Green Carbon Plant

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

71077 23 tons/hr Pitch Unloading Station 

(from rail cars) 1979/1995 N/A N/A 

83016 490 ton Pitch Storage Tank #1 1979 N/A 80 

83017 490 ton Pitch Storage Tank #2 1979 N/A 81 

83018 490 ton Pitch Storage Tank #3 1979 N/A 82 

73501 

1.6 x 106

 BTU/hr Hot Oil Heater for 

Pitch Unloading Station and Storage 

Tanks (burns natural gas and 

propane) 

1979 N/A 84 

80201 100 tons/hr Coke Unloading Station 

(from rail cars) 1979 50058 12 

83022 4500 ton Coke Storage Tank #1 1979 50020 11 

83022 4500 ton Coke Storage Tank #2 1979 50020 11 

83003 250 ton Fluid Coke Storage Tank 1979 50020 11 

81401 

16 tons/hr Coke Crushing Equipment 

(various conveyors, mills, feed tanks, 

are used) 

1979 50012 19 

81403 

10 tons/hr Butt Classifying 

Equipment (classify spent anode 

butts by size - various conveyors, 

mills, feed tanks are used) 

1979 50013 15 

81402 

12 tons/hr Classifier Material 

Handling Equipment (convey and 

store materials classified by size - 

various conveyors, mills, feed tanks, 

are used) 

1979 50014 13 

80503 

15 tons/hr Storage Reclaim 

Equipment (convey and store 

materials classified by size - various 

conveyors, mills, feed tanks, are 

used) 

1979 50015 16 

80222 

30 tons/hr Aggregate Blending 

Equipment (mix and blend sized 

material - various conveyors, mills, 

feed tanks, are used) 

1979 50016 18 

89004 13 tons/hr Ball Mill Classifying 

Equipment 1979 50005 14 

89005 12 tons/hr Intermediate Classifying 

Equipment 1979 50006 17 

81403 10 tons/hr Secondary Butt Crushing 

Equipment 1979 50057 10 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 24 OF 45

(permit revised 1/30/03, see page 2 for details) 

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

83019 200 ton Butts Storage Tank #1 (spent 

anode butt storage) 1979 50056 09 

83055 200 ton Butts Storage Tank #2/ 

conveyor (spent anode butt storage) 1996 50056 09 

89056 3 tons/hr Fines Recovery Equipment 1982 50051 20 

73502 

5.0 x 106

 BTU/hr Hot Oil Heater for 

Anode Forming Process (burns 

natural gas and propane) 

1979 N/A 83 

81605 

150,000 tons/yr Anode Forming 

Equipment (combine pitch, coke, and 

spent anode butts to produce green 

anodes) 

1979/1996 50054 85 

TABLE 5.4 UNIT ID 02 - Baked Carbon Plant

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

53001 North and South Bake Ovens (burn 

natural gas and propane) - NSPS 1979 53001 01 

73050-N 

& 73051-

S 

North and South Bake Ovens (Ridge 

Vents: Emissions to Ambient Plant 

Air) 

1979 N/A 01A 

80912 & 

80913 

130,000 tons/yr Anode Block 

Cleaning and Material Transfer 

Equipment (clean eyes of baked 

anode blocks & transfers materials to 

trucks) 

1979 50023 08 

83044 

150 ton Fresh Alumina Transfer and 

Storage Equipment (store fresh 

alumina and transfer to bake oven dry 

scrubber) 

1979 50024 06 

83045 

50 ton Fluoride Enriched Alumina 

Transfer and Storage Equipment 

(store fluoride enriched alumina and 

transfer to potlines) 

1979 50025 07 

89054 1,080 cfm Housekeeping Equipment 

(vacuum and dust collector) 1986 89054 100 

TABLE 5.5 UNIT ID 03 - Anode Rodding

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

81801 40 tons/hr Bath Removal Station 

(remove bath from spent anode butts) 1979/1982 50032 30 

81802 

110 anodes/hr Butt Blasting 

Equipment (remove remaining bath 

from spent anode butts) 

1979 50007 24 

81002, 

81003 

110 anodes/hr Butt Stripping, 

Conveying, and Crushing Equipment 

(strip spent anode butts from rods, 

crush spent anode butts) 

1979 50008 22 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 25 OF 45

(permit revised 1/30/03, see page 2 for details) 

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

81804 

110 rods/hr Rod and Stub Blasting 

Equipment (clean rods and stubs 

after spent anodes are removed) 

1979 50059 23 

86022 0.5 tons/hr Truck Loading Station 

(load butt blast material to trucks) 1979 50064 26 

80811 

110 anodes/hr Anode Eye Cleaning 

Equipment (clean anode eyes before 

rods are attached) 

1979 50050 27 

73201, 

73202, 

73203 

110 anodes/hr (3) Induction Furnaces 

(melt iron and additives for anode 

rodding process) 

1979 50010 25 

81819 

16 bars/hr Cathode Collector Bar 

Cleaning Equipment (clean cathode 

collector bars) 

1984/1985 50055 101 

TABLE 5.6 UNIT ID 04 - Potlines

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

74711 

200 tons/hr Alumina/Fluoride 

Unloading & Storage - Track Hopper 

(unload from rail cars) 

1980 50053 29 

80015 

200 tons/hr Alumina/Fluoride 

Unloading & Storage - Screening 

Tower (convey alumina and fluoride) 

1980 50026 28 

83026 

35,000 tons Alumina/Fluoride 

Unloading & Storage - Lift Tower 

(convey and store alumina and 

fluoride) 

1980 50029 32 

83024 

200 tons/hr Alumina/Fluoride 

Unloading & Storage - Separator 

Vent (convey and store alumina and 

fluoride) 

1980 50027 33 

83025 

200 tons/hr Alumina/Fluoride 

Unloading & Storage - Separator 

Vent (convey and store alumina and 

fluoride) 

1980 50028 34 

83030 2,000 ton Potline #2 - Fresh Alumina 

& Fluoride Storage Tanks 1980 50031 39 

83027 2,000 ton Potline #1 - Fresh Alumina 

& Fluoride Storage Tanks 1980 50030 40 

70010 

Aluminum Potline #1 - 161E Dry 

Scrubber (electrolytic reduction of 

alumina to elemental aluminum) - 

NSPS

1980 53002 02 

70010 

Aluminum Potline #1 - 161W Dry 

Scrubber (electrolytic reduction of 

alumina to elemental aluminum) - 

NSPS

1980 53003 03 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 26 OF 45

(permit revised 1/30/03, see page 2 for details) 

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

84050 

15 tons/hr Potline #1 - Enriched 

Alumina Conveying System 

“Pneumatic Conveyors” (convey 

enriched alumina from scrubber to 

storage tank) 

1980 50041 41 

83041 

2,000 tons Potline #1 - Enriched 

Alumina Conveying System “Air 

Slides and Tanks” (store enriched 

alumina) 

1980 50039 42 

84040 

15 tons/hr Potline #1 - Enriched 

Alumina Conveying System 

“Pneumatic Conveyors” (convey 

enriched alumina from scrubber to 

storage tank) 

1980 50040 43 

40101 

Potline #1 - #101/#102 East Ridge 

Vent: Emissions to Ambient Plant 

Air - NSPS

1980 N/A 02A 

40102 

Potline #1 - #101/#102 West Ridge 

Vent: Emissions to Ambient Plant 

Air - NSPS

1980 N/A 03A 

70010 

Aluminum Potline #2 - 162E Dry 

Scrubber (electrolytic reduction of 

alumina to elemental aluminum) - 

NSPS

1980 53004 04 

70010 

Aluminum Potline #2 - 162W Dry 

Scrubber (electrolytic reduction of 

alumina to elemental aluminum) - 

NSPS

1980 53005 05 

84060 

15 tons/hr Potline #2 - Enriched 

Alumina Conveying System 

“Pneumatic Conveyors” (convey 

enriched alumina from scrubber to 

storage tank) 

1980 50044 44 

83051 

2,000 tons Potline #2 - Enriched 

Alumina Conveying System “Air 

Slides and Tanks” (store enriched 

alumina) 

1980 50042 45 

84070 

15 tons/hr Potline #2 - Enriched 

Alumina Conveying System 

“Pneumatic Conveyors” (convey 

enriched alumina from scrubber to 

storage tank) 

1980 50043 46 

40103 

Potline #2 - #103/#104 East Ridge 

Vent: Emissions to Ambient Plant 

Air - NSPS

1980 N/A 04A 

40104 

Potline #2 - #103/#104 West Ridge 

Vent: Emissions to Ambient Plant 

Air - NSPS

1980 N/A 05A 

81202 

40 tons/hr Bath Handling and 

Crushing System - Bath Crusher and 

Storage (crush and store bath; clean 

crucibles) 

1980 50032 30 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 27 OF 45

(permit revised 1/30/03, see page 2 for details) 

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

83031-

83036 

40 tons/hr Bath Handling and 

Crushing System - Screens and Bath 

Storage Tanks (classify and store 

bath) 

1980 50052 31 

70026 

22 tons/hr Bath Handling and 

Crushing System - Bath Feed Station 

at Potroom #101 (supply bath for use 

on potline) 

1980/1982 50033 35 

70027 

22 tons/hr Bath Handling and 

Crushing System - Bath Feed Station 

at Potroom #102 (supply bath for use 

on potline) 

1980/1982 50034 36 

70028 

22 tons/hr Bath Handling and 

Crushing System - Bath Feed Station 

at Potroom #103 (supply bath for use 

on potline) 

1980/1982 50035 37 

70029 

22 tons/hr Bath Handling and 

Crushing System - Bath Feed Station 

at Potroom #104 (supply bath for use 

on potline) 

1980/1982 50036 38 

TABLE 5.7 UNIT ID 05 - Pot Repair

Equip ID Equipment Description Installation Date 

Modification Date Control Device ID Stack ID 

40138 

General Operations - Pot Digging, 

Blasting, Loading, and Other Misc. 

Operations 

1980 

1997 50061-50063 21A 

TABLE 5.8 UNIT ID 06 - Cast House

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

73103 & 

71010 

65,000 lbs/batch Hot Side - 

Horizontal Direct Cast (HDC) 

Furnace 103 and HDC In-Line Metal 

Treatment Unit (alloy, treat, and cast 

molten aluminum) - NESHAP

1980/2001 N/A 

51-103 & 

51-103 

MTU 

73104 

65,000 lbs/batch Hot Side -

Horizontal Direct Cast (HDC) 

Furnace 104 (alloy, treat, and cast 

molten aluminum) 

1980 N/A 51-104 

73105 

110,000 lbs/batch Hot Side - Vertical 

Direct Cast (VDC) Furnace 105 

(alloy, treat, and cast molten 

aluminum) 

1980/1992 N/A 51-105 

73106 & 

71001 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 106 and 

Pit #1 In-Line Metal Treatment Unit 

(alloy, treat, and cast molten 

aluminum) - NESHAP

1980/1991/2001 N/A 

51-106 & 

51-106 

MTU 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 28 OF 45

(permit revised 1/30/03, see page 2 for details) 

Equip ID Equipment Description Installation Date Control Device ID Stack ID 

73107 & 

71002 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 107 and 

Pit #2 In-Line Metal Treatment Unit 

(alloy, treat, and cast molten 

aluminum) - NESHAP

1980/1988/2001 N/A 

51-107 & 

51-107 

MTU 

73109 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 109 

(alloy, treat, and cast molten 

aluminum) 

1980/1989 N/A 51-109 

73110 & 

71003 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 110 and 

Pit #3 In-Line Metal Treatment Unit 

(alloy, treat, and cast molten 

aluminum) - NESHAP

1980/1993/2001 N/A 

51-110 & 

51-110 

MTU 

73111 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 111 

(alloy, treat, and cast molten 

aluminum) 

1980/1988 N/A 51-111 

73112 & 

71004 

110,000 lbs/batch Hot Side -Vertical 

Direct Cast (VDC) Furnace 112 and 

Pit #4 In-Line Metal Treatment Unit 

(alloy, treat, and cast molten 

aluminum) - NESHAP - Applicable 

as of March 24, 2003 

1980/1986 N/A 

51-112 & 

51-112 

MTU 

71022 

4,500 tons/yr Dross 

Processing/Remelt - Dross Cooling 

Operations 

1980 50045 47 

71045 2,200 tons/yr Dross 

Processing/Remelt - Ball Mill #1 1980 50046 48 

71046 2,200 tons/yr Dross 

Processing/Remelt - Ball Mill #2 1980 50047 49 

73021 Dross Processing - Dross Pad (store 

dross) also truck loading 1980 50038 50 

73011 

32,500 tons/yr Cold Side (18 x 106

BTU/hr) - Homogenizing Furnace 

#1 (reheat cast aluminum to produce 

uniform grain structure) 

1980 N/A 52-1 

73012 

32,500 tons/yr Cold Side (18 x 106

BTU/hr) - Homogenizing Furnace 

#2 (reheat cast aluminum to produce 

uniform grain structure) 

1980 N/A 52-2 

73115 3.0 x 106 BTU/hr Pre Heat Furnace 2000 N/A 122 

73023 

40,000 tons/yr Cold Side (36 x 106

BTU/hr) - Homogenizing Furnace #3 

(reheat cast aluminum to produce 

uniform grain structure) 

1990 N/A 52-3 

D. EMISSION LIMITS AND STANDARDS

Table 5.9 contains summaries of emission unit emission limits and standards. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 29 OF 45

(permit revised 1/30/03, see page 2 for details) 

TABLE 5.9 EMISSION LIMITS AND STANDARDS

Stack ID Equip ID Control 

ID 

Pollutant/ 

Standard Limit Reference Method Regulation State Only 

Condition 

Number 

ID 01 - GREEN CARBON PLANT

All All All PM 23.85 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 

All 

except 

83-85 

All 

except 

81605, 

73501 & 

73502 

All 

except50

054 

Opacity 10% 9 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.2 

85 81605 50054 Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

85 81605 50054 PM 0.75 lb/hr 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

85 81605 50054 SO2 0.46 lb/hr 6 or 6C 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

83 

84 

73501 

73502 none PM 0.6 lbs/ million 

BTU heat input 5 

SC Regulation 

61-62.5, 

Standard 1, 

Section II 

No 5.E.3 

83 

84 

73501 

73502 none SO2

3.5 lbs/ million 

BTU heat input 6 or 6C 

SC Regulation 

61-62.5, 

Standard 1, 

Section III 

No 5.E.3 

83 

84 

73501 

73502 none Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 1, 

Section I 

No 5.E.4 

09 

09 

10 

11 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

83019 

83055 

81403 

83022 

83003 

80201 

81402 

89004 

81403 

80503 

89005 

80222 

81401 

89056 

50056 

50056 

50057 

50020 

50020 

50058 

50014 

50005 

50013 

50015 

50006 

50016 

50012 

50051 

PM 0.005 gr/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

ID 02 - BAKED CARBON PLANT
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 30 OF 45

(permit revised 1/30/03, see page 2 for details) 

Stack ID Equip ID Control 

ID 

Pollutant/ 

Standard Limit Reference Method Regulation State Only 

Condition 

Number 

All All All PM 29.13 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 

100 

01A 

01A 

89054 

73050-N 

73051-S 

89054 

N/A 

N/A 

Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

01 53001 53001 Opacity 20% 9 40 CFR 60 

Subpart A and S No 5.E.5, 8 

01 53001 53001 POM 0.18 lb/ton 

green anode 

315 or 

approved 

alternative 

40 CFR 63 

Subpart A and 

LL 

No 5.E.5, 9 

01 53001 53001 PM10/PM 4.58/4.91 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

01 53001 53001 SO2 67.4 lbs/hr 6 or 6C 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1, 3 

01 53001 53001 CO 97.7 lb/hr 10 or 10B 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

01 53001 53001 NOX 8.0 lbs/hr 7 or 7E 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

0.04 lbs/ton of 

Al equivalent 

SC Regulation 

61-62.5, 

Standard 7 01 53001 53001 Fluorides 

0.2 lb/ton of 

green anode 

13A or B, or 

approved 

alternative 40CFR63 

Subpart A and 

LL 

No 5.E.1, 7 

06 

07 

08 

08 

83044 

83045 

80912 

80913 

50024 

50025 

50023 

50023 

Opacity 10% 9 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.2 

06 

07 

08 

08 

100 

83044 

83045 

80912 

80913 

89054 

50024 

50025 

50023 

50023 

89054 

PM 0.005 lbs/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

ID 03 - ANODE RODDING

All All All PM 47.4 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 31 OF 45

(permit revised 1/30/03, see page 2 for details) 

Stack ID Equip ID Control 

ID 

Pollutant/ 

Standard Limit Reference Method Regulation State Only 

Condition 

Number 

22 

22 

23 

24 

25 

25 

25 

26 

27 

81002 

81003 

81804 

81802 

73201 

73202 

73203 

86022 

80811 

50008 

50008 

50059 

50007 

50010 

50010 

50010 

50064 

50050 

Opacity 10% 9 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.2 

101 81819 50055 Opacity 40% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

125 89055 89055 Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

22 

22 

23 

24 

25 

25 

25 

26 

27 

101 

125 

81002 

81003 

81804 

81802 

73201 

73202 

73203 

86022 

80811 

81819 

89055 

50008 

50008 

50059 

50007 

50010 

50010 

50010 

50064 

50050 

50055 

89055 

PM 0.005 gr/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

ID 04 - POTLINES

02/02A 

03/03A 

04/04A 

05/05A 

Each Potroom 

Scrubber/baghouse/ 

roof vent group 

PM 28.73 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 

All 

except 

02/02A 

03/03A 

04/04A 

05/05A 

Sources other than 

Scrubber/baghouse 

/roof vent groups 

PM 67.03 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 

All All All Opacity 10% 9 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.2 

02/02A 

03/03A 

04/04A 

05/05A 

Each Potroom 

Scrubber/baghouse/ 

roof vent group 

Opacity 10% 9 40 CFR 60 

Subpart A and S No 5.E.8 

02A 

03A 

04A 

05A 

40101 

40102 

40103 

40104 

N/A 

N/A 

N/A 

N/A 

PM 18.15 lbs/hr 

each 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 32 OF 45

(permit revised 1/30/03, see page 2 for details) 

Stack ID Equip ID Control 

ID 

Pollutant/ 

Standard Limit Reference Method Regulation State Only 

Condition 

Number 

02 

03 

04 

05 

70010 

70010 

70010 

70010 

53002 

53003 

53004 

53005 

PM 1.5 lbs/hr each 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

02 

03 

04 

05 

70010 

70010 

70010 

70010 

53002 

53003 

53004 

53005 

SO2

212.24 lbs/hr 

each 6 or 6B 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

02 

03 

04 

05 

70010 

70010 

70010 

70010 

53002 

53003 

53004 

53005 

CO 3178.3 lbs/hr 

each 10 or 10B 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

02/02A 

03/03A 

04/04A 

05/05A 

Each Potroom 

Scrubber/baghouse/ 

roof vent group 

Fluorides 

1.02 lb/ton of 

Al produced 

per 12 month 

rolling average; 

and 1.34 lb/ton 

of Al produced 

per month 

13A or B or 

approved 

alternative 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1, 6 

28 

29 

31 

31 

31 

31 

31 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

41 

42 

43 

44 

45 

46 

80015 

74711 

83031 

83032 

83033 

83034 

83035 

83036 

83026 

83024 

83025 

70026 

70027 

70028 

70029 

83030 

83027 

84050 

83041 

84040 

84060 

83051 

84070 

50026 

50053 

50052 

50052 

50052 

50052 

50052 

50052 

50029 

50027 

50028 

50033 

50034 

50035 

50036 

50031 

50030 

50041 

50039 

50040 

50044 

50042 

50043 

PM 0.005 lb/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

30 81202 50032 PM 0.0035 lb/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

ID 05 - POT REPAIR

21A 40138 

50061 

50062 

50063 

Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

21A 40138 

50061 

50062 

50063 

PM 0.0035 gr/dscf 5 

SC Regulation 

61-62.5, 

Standard 4 

No 5.E.11 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 33 OF 45

(permit revised 1/30/03, see page 2 for details) 

Stack ID Equip ID Control 

ID 

Pollutant/ 

Standard Limit Reference Method Regulation State Only 

Condition 

Number 

ID 06 - CAST HOUSE

All All All PM 41.71 lbs/hr 5 

SC Regulation 

61-62.5, 

Standard 4, 

Section VIII 

No 5.E.11 

All 

except 

122 

All except 

73115 All Opacity 10% 9 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.2 

122 73115 N/A Opacity 20% 9 

SC Regulation 

61-62.5, 

Standard 4, 

Section IX 

No 5.E.10 

47 

48 

49 

50 

71022 

71045 

71046 

73021 

50045 

50046 

50047 

50038 

PM 0.005 lb/dscf 5 

SC Regulation 

61-62.5, 

Standard 7 

No 5.E.1 

51-103 

MTU 

51-106 

MTU 

51-107 

MTU 

51-110 

MTU 

51-112 

MTU 

71010 

71001 

71002 

71003 

71004 

N/A PM 

0.01 lb/ton of 

Al feed, when 

using reactive 

flux material 

5, or 

approved 

equivalent 

40 CFR 63 

Subpart A and 

RRR 

No 5.E.13 

5.E.14 

51-103 

MTU 

51-106 

MTU 

51-107 

MTU 

51-110 

MTU 

51-112 

MTU 

71010 

71001 

71002 

71003 

71004 

N/A HCl 

0.04 lb/ton of 

Al feed, when 

using reactive 

flux material 

26A 

40 CFR 63 

Subpart A and 

RRR 

No 5.E.12 

5.E.14 

N/A = Not Applicable 

*As Approved by BAQ 

The maximum allowable emission limits above are derived from the various Federal and State 

regulations that govern the operation of this type of source. All applicable facility wide emission 

limits and corresponding regulations are listed above. Additional operating requirements which may 

be more stringent than those above are contained in Part 4.0, Part 6.0, and Part 7.0 of this permit. 

E. EMISSION UNIT CONDITIONS

Condition 

Number Conditions 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 34 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

This is a major facility for PSD and shall comply with all applicable requirements per SC Regulation 

61-62.5, Standard 7, “Prevention of Significant Deterioration (PSD)”. 

These sources are subject to all provisions of SC DHEC Regulation 61-62.5, Standard No. 7, "Prevention 

of Significant Deterioration" for PM, PM10, NOX, CO, Fluorides, and Lead. The Best Available Control 

Technology (BACT) for these pollutants is determined to be as follows: 

POLLUTANT/UNIT CONTROL 

TECHNOLOGY LIMIT

PM/PM10 (Process) Baghouse Controls 

0.005 grains/dry standard cubic foot 

(except 21A and 30) 

0.0035 grains/dry standard cubic foot 

(Sources 21A and 30) 

PM/PM10 (Fuel Combustion) Use of Natural Gas 

(Propane as backup) Use only specified fuel 

PM/PM10 (Fugitives) Best Management Practices Comply with specified practices 

NOx (Process) Good Operating Practices Comply with specified practices 

NOX (Combustion - Holding Furnaces) Good Operating Practices Comply with specified practices 

NOX (Combustion - ABO, RF, HF) Good Operating Practices Comply with specified practices 

CO (Process) Good Operating Practices Comply with specified practices 

CO (Combustion) Good Operating Practices Comply with specified practices 

Fluorides (Bake Oven) Dry Alumina Injection 0.04 lb/ton of Al equivalent 

Fluorides (Process - Uncontrolled) Good Operating Practices Comply with specified practices 

Fluorides (Potline Scrubbers) Dry Alumina Injection - 

Fluorides (Potline Roof Monitors) Good Operating Practices - 

Fluorides (Combined Scrubbers and 

Roof Monitors) - 1.02 lbs/ton per rolling 12 mo avg and 

1.34 lbs/ton single mo avg 

Lead (Process) Baghouse Controls Comply with specified practices 

Lead (Fugitives) Best Management Practices Comply with specified practices 

1.

As established by PSD limits, combined sulfur dioxide emissions from all Potline Roof Monitors and 

Potline Scrubbers shall not exceed 848.96 pounds per hour and 3,718.44 tons per year. Combined carbon 

monoxide emissions from all Potline Scrubbers shall not exceed 12,713.2 pounds per hour and 55,684 tons 

per year. (Source ID04) 

2.

The visible emissions from each source shall not exceed 10% opacity (Method 9) averaged over 4 

consecutive readings taken every 15 seconds. Documented exceedances of the visible emission 

limitations may require source testing for Particulate Matter emissions at the discretion of the Bureau of 

Air Quality. (Sources ID01 except stacks 83-85, ID02 stacks 06-08, ID03 except stack 101 and 125, 

ID04, ID06 except stack 122) 

3.

These fuel combustion sources shall use only natural gas or propane as fuel. The use of any other 

substances as fuel is prohibited without prior written approval from the Bureau of Air Quality. 

(Sources ID01, ID02, and ID06) 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 35 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

4. 

The Hot Oil Heaters shall not discharge into the ambient air smoke which exceeds an opacity of 20%. 

 The twenty (20) percent opacity limit may be exceeded for sootblowing, but may not be exceeded for 

more than six (6) minutes in a one hour period nor be exceeded for more than a total of twenty-four 

(24) minutes in a twenty-four (24) hour period. The owner/operator shall, to the extent practicable, 

maintain and operate any source including associated air pollution control equipment in a manner 

consistent with good air pollution control practices for minimizing emissions. For the opacity 

standards set forth above to not apply during startup or shutdown, the owner/operator shall, for a 

period of at least five (5) years maintain a log of the time, magnitude, duration and any other pertinent 

information to determine periods of startup and shutdown and make these records available to a 

Department representative upon request. (Source ID01 stacks 83 and 84) 

5. 

The potlines and anode bake ovens are subject to New Source Performance Standards (NSPS) 40 CFR 

60 subparts A and S, as applicable. They are also subject to National Emission Standards For 

Hazardous Air Pollutants For Primary Aluminum Reduction Plants 40 CFR 63 subparts A and LL, as 

applicable. The requirements for reporting, testing, instrumentation, etc., will be completed as 

described in these subparts. 

6. 

∋63.843(a)(1) - Emission limits for existing Potlines. The owner or operator shall not discharge or 

cause to be discharged into the atmosphere any emissions of total fluorides (TF) in excess of the 

applicable limits of 0.95 kg/Mg (1.9 lb/ton) of aluminum produced for each CWPB1 potline. 

However, the following limits established under PSD are more restrictive and shall apply. The total 

fluoride emissions from both pot lines (1 and 2) shall not exceed 1.02 pounds per ton of aluminum 

produced as determined by a rolling 12-month average. No single monthly average shall exceed 1.34 

pounds of total fluoride emissions per ton of aluminum produced. (Source ID04) 

7. 

∋63.843(c)(1) - Anode bake furnaces. The owner or operator shall not discharge or cause to be 

discharged into the atmosphere any emissions of total fluorides in excess of 0.10 kg/Mg (0.2 lb/ton) of 

green anode. However, the following limit established under PSD is more restrictive and shall apply. 

The total fluoride emissions from the Anode Bake Plant shall not exceed 0.04 pounds per ton of 

aluminum equivalent as determined by a 12-month rolling average. (Source ID02) 

8. 

∋60.193(a)(1) and (2) - No owner or operator shall cause to be discharged into the atmosphere from 

any potroom group any gases which exhibit 10 percent opacity or greater, or from any anode bake 

plant any gases which exhibit 20 percent opacity or greater. (Sources ID02 stack 01 and ID04 stacks 

02-05 and 02A-05A) 

9. 

∋63.843(c)(2) - The owner or operator shall not discharge or cause to be discharged into the 

atmosphere any emissions of polycyclic organic matter (POM) in excess of 0.09 kg/Mg (0.18 lb/ton) 

of green anode from an anode bake furnace. (Source ID02) 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 36 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

10. 

In accordance with SC Regulations 62.5, Standard No. 4, Section IX - VISIBLE EMISSIONS 

(WHERE NOT SPECIFIED ELSEWHERE), where construction or modification began after 

December 31, 1985, emissions (including fugitive emissions) shall not exhibit an opacity greater than 

20%. (Sources ID01 stack 85, ID02 stacks 100 and 01A, ID03 stack 125, ID05 stack 21A, ID06 stack 

122) [Note Source ID03 stack 101 has an opacity limit of 40%] 

11. 

In accordance with South Carolina Regulation 62.5, Standard No. 4 - EMISSIONS FROM PROCESS 

INDUSTRIES, Section VIII - OTHER MANUFACTURING, particulate matter emissions where not 

specified elsewhere shall be limited to the rate specified by use of the following equations: for process 

weight rates less than 30 tons per hour (E = 4.10P0.67) and for process weight rates greater than 30 tons per 

hour ( E = 55.0P0.11 - 40) where E = the allowable emission rate in pounds per hour and P = process 

weight rate in tons per hour. As such, the limit for each specified source based on its nominal production 

rating is as follows: 

Source Production Rating (tons/hr) PM Emission Limit (lbs/hr) 

ID01 (green carbon plant) 13.85 23.85 

ID02 (baked carbon plant) 18.66 29.13 

ID03 (anode rodding) 67.38 47.40 

ID04 (each potline/scrubber/baghouse/roof vent set) 18.28 28.73 * 

ID04 (dust collectors on equipment other than potlines) 425.00 67.03 

ID06 (cast house) 36.53 41.71

 * For ID04 potlines, the limit of 19.65 lb/hr for each potline scrubber/baghouse and roof vent set 

established under PSD is more restrictive and shall apply.

12. 

∋63.1505(j)(1) - Emission limits for In-Line Metal Treatment Units using reactive flux material. The 

owner or operator shall not discharge or cause to be discharged into the atmosphere any emissions of 

hydrochloric acid (HCl) in excess of the applicable limits of 0.04 lb per ton of feed for each metal 

treatment unit. The compliance date for the metal treatment unit designated as 51-112MTU is March 24, 

2003, unless modified sooner which requires compliance upon completion of the modification. 

 

13. 

∋63.1505(j)(2) - Emission limits for In-Line Metal Treatment Units using reactive flux material. The 

owner or operator shall not discharge or cause to be discharged into the atmosphere any emissions of 

particulate matter (PM) in excess of the applicable limits of 0.01 lb per ton of feed for each metal 

treatment unit. The compliance date for the metal treatment unit designated as 51-112MTU is March 24, 

2003, unless modified sooner which requires compliance upon completion of the modification. 

14. 

∋63.1505(j)(3) - Emission limits for In-Line Metal Treatment Units using no reactive flux material. The 

emission limits in paragraphs (j)(1) and (j)(2) do not apply to an in-line fluxer that uses no reactive flux 

materials. 

 

PART 6.0 MONITORING AND REPORTING REQUIREMENTS [SC Regulation 61-62.1, 

Section II]; [SC Regulation 61-62.70.6(a)(3)(i)(B)] 

A. MONITORING AND REPORTING
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 37 OF 45

(permit revised 1/30/03, see page 2 for details) 

Table 6.1 contains summaries of the monitoring and reporting required of this facility. 

TABLE 6.1 MONITORING AND REPORTING

Unit 

ID 

Pollutant/ 

Parameter Limit Required Monitoring 

Monitoring 

Frequency 

Reporting 

Frequency 

Condition 

Number 

ID 02 AND 04 - ANODE BAKE OVENS AND POTLINES (CONTROL DEVICES) 

02, 04 Refer to 

Conditions N/A Record Keeping 

Refer to 

Conditions 

Refer to 

Conditions 

6.B.1-3, 17-21, 

28-29 

02 POM 0.18 lb/ton 

green anode Source Test Annual Annual 6.B.4-8, 17-21, 23, 28 

02, 04 Total Fluorides Refer to 

Table 5.9 Source Test Annual Annual 6.B.3, 5-8, 17-

21, 23, 28 

02, 04 Alumina Flow 

and Air Flow N/A Record 

Keeping Continuous Refer to 

Conditions 

6.B.9, 17-21, 28-

29 

02, 04 Visual 

Inspections 

Refer to 

Table 5.9 

Record 

Keeping Daily Refer to 

Conditions 

6.B.10, 17-21, 

28-29 

02, 04 Refer to 

Conditions N/A Refer to 

Conditions 

Refer to 

Conditions 

Refer to 

Conditions 

6.B.11, 17-21, 

28-29 

01,02,

04 Sulfur Content 0.85% (pitch) 

2.22% (coke) 

Record 

Keeping Monthly Quarterly 6.B.12 

02, 04 Production 

Rates 

Refer to 

Conditions 

Record 

Keeping Daily Refer to Conditions 

6.B.13, 17-21, 

28-29 

02, 04 Exceedances Refer to 

Conditions 

Refer to 

Conditions 

Refer to 

Conditions 

Refer to 

Conditions 6.B.14-21, 28-29

02 System 

Maintenance 

Refer to 

Conditions 

Refer to 

Conditions 

Refer to 

Conditions 

Refer to 

Conditions 6.B.45 

ID 04 - POTLINES (ROOF VENTS - 40101, 40102, 40103, 40104) 

04 Total Fluorides Refer to 

Table 5.9 Source Test Bi-Monthly Bi-Monthly 6.B.22-23, 28-29

ID 02 AND 04 - ANODE BAKE OVENS AND POTLINES (TOTAL EMISSIONS) 

02, 04 SO2

Refer to 

Table 5.9 

Record 

Keeping 

Refer to 

Conditions 

Refer to 

Conditions 6.B.12, 28-29 

ID 01-06 ALL FUEL BURNING SOURCES 

01-06 PM, SO2, NOX, 

CO, VOC 

Refer to 

Table 5.9 

Record 

Keeping Annual Refer to 

Conditions 6.B.24, 28-29 

ID 01-06 DUST COLLECTORS 

01-06 Pressure Drop/ 

Inspections 

Refer to 

Conditions 

Record 

Keeping Monthly Refer to 

Conditions 6.B.25, 28-29 

01-06 

PM 

(Representative 

Dust Collectors) 

Refer to 

Condition Source Test Initial One-time 6.B.23 

ID 01-02 AND 04 SCRUBBERS 

01-02, 

04 

Air Flow Rate 

and Media Flow 

Rate 

Refer to 

Conditions 

Record 

Keeping Continuous Refer to 

Conditions 6.B.26, 28-29 

ID 01-06 ALL SOURCES 

01-06 Visual 

Inspections 

Refer to 

Table 5.9 

Record 

Keeping Daily Refer to Conditions 6.B.27-29 

ID 06 IN-LINE METAL TREATMENT UNITS (51-106 MTU, 51-107 MTU, 51-110 MTU, 51-103 MTU, 

51-112 MTU)* 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 38 OF 45

(permit revised 1/30/03, see page 2 for details) 

Unit 

ID 

Pollutant/ 

Parameter Limit Required Monitoring 

Monitoring 

Frequency 

Reporting 

Frequency 

Condition 

Number 

06 Refer to 

Conditions N/A Refer to Conditions 

Refer to 

Conditions 

Refer to 

Conditions 

6.B.23, 6.B.30-

44 

N/A = Not Applicable

*The compliance date for in-line metal treatment unit 51-112 MTU is March 24, 2003.

B. MONITORING AND REPORTING CONDITIONS

Condition 

Number Conditions 

1. 

§63.848(j) - The owner or operator of an existing potline or anode bake furnace shall install, operate, and 

maintain a monitoring device to determine the daily weight of aluminum produced and the weight of 

green anode material placed in the anode bake furnace. The weight of green anode material may be 

determined by monitoring the weight of all anodes or by monitoring the number of anodes placed in the 

furnace and determining an average weight from measurements of a representative sample of anodes. 

2. 

§63.848(k) - The owner or operator shall submit recommended accuracy requirements to the regulatory 

authority for review and approval. All monitoring devices required by this section must be certified by 

the owner or operator to meet the accuracy requirements and must be calibrated in accordance with the 

manufacturer’s instructions. 

3. 

§60.194(c) and (d)(2) - The owner or operator shall conduct a performance test on the anode bake plant 

and primary control system once a year during the life of the facility, except when malfunctions prevent 

representative sampling, as provided under 60.8(c). The owner or operator shall give the Bureau at least 

15 days advance notice of each test. The Bureau may require additional testing under section 114 of the 

Clean Air Act. 

4. 

§63.848(c) - POM emissions from anode bake furnaces. Using the procedures in 63.847 and in the 

approved test plan, the owner or operator shall monitor POM emissions from each anode bake furnace on 

an annual basis. The owner or operator shall compute and record the annual average of POM emissions 

from at least three runs to determine compliance with the applicable emission limits. The owner or 

operator must include all valid runs in the annual average. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 39 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

5. 

§63.849(a) - The owner or operator shall use the following reference methods to determine compliance 

with the applicable emission limits for TF and POM emissions: 

 (1) Method 1 in appendix A of 40 CFR 60 for sample and velocity traverses; 

 (2) Method 2 in appendix A of 40 CFR 60 for velocity and volumetric flow rate; 

 (3) Method 3 in appendix A of 40 CFR 60 for gas analysis; 

 (4) Method 13A or Method 13B in appendix A of 40 CFR 60, or an approved alternative, for the 

concentration of TF where stack or duct emissions are sampled; 

 (5) Method 13A or Method 13B and Method 14 or Method 14A in appendix A of 40 CFR 60 or an 

approved alternative method for the concentration of TF where emissions are sampled from roof 

monitors not employing wet roof scrubbers; 

 (6) Method 315 in appendix A of 40 CFR 63 or an approved alternative method for the 

concentration of POM where stack or duct emissions are sampled; and 

 (7) Method 315 in appendix A to this part and Method 14 in appendix A to part 60 of this chapter 

or an approved alternative method for the concentration of POM where emissions are sampled 

from roof monitors not employing wet roof scrubbers. 

6. 

§63.849(d) - For sampling using Method 14 in appendix A of 40 CFR 60, the owner or operator shall 

install one Method 14 manifold per potline in a potroom that is representative of the entire potline, and 

this manifold shall meet the installation requirements specified in section 2.2.1 of Method 14 in appendix 

A of 40 CFR 60. 

7. 

§63.849(e) - The owner or operator may use an alternative test method for TF or POM emissions 

providing: 

(1) The owner or operator has already demonstrated the equivalency of the alternative method for a 

specific plant and has received previous approval from the Administrator or the applicable 

regulatory authority for TF or POM measurements using the alternative method; or 

(2) The owner or operator demonstrates to the satisfaction of the applicable regulatory authority 

that the results from the alternative method meet the criteria specified in 63.848(d)(1) and (d)(3) 

through (d)(6). The results from the alternative method shall be based on simultaneous sampling 

using the alternative method and the following reference methods: 

(i) For TF, Methods 13 and 14 or Method 14A in appendix A of 40 CFR 60; or 

(ii) For POM, Method 315 in appendix A to 40 CFR 63 and Method 14 in appendix A of 

40 CFR 60. 

8. §63.850(b) - Except as provided in 63.850(d), the owner or operator shall submit a summary of all 

subsequent performance tests to the applicable regulatory authority on an annual basis. 

9. 

§63.848(f) - The owner or operator shall install, operate, calibrate, and maintain a continuous parameter 

monitoring system for each emission control device. The owner or operator shall submit for approval a 

description of the parameter(s) to be monitored, the operating limits, and the monitoring frequency to 

ensure that the control device is being properly operated and maintained. An explanation of the criteria 

used for selection of the parameter(s), the operating limits, and the monitoring frequency, including how 

these relate to emission control also shall be submitted. The following monitoring devices shall be 

installed for dry alumina scrubbers; devices for the measurement of alumina flow and air flow. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 40 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

10. 

§63.848(g) - The owner or operator shall visually inspect the exhaust stack(s) of each control device on a 

daily basis for evidence of any visible emissions indicating abnormal operations. 

11. 

§63.850(c) - The owner or operator shall develop and implement a written plan as described in 

§63.6(e)(3) that contains specific procedures to be followed for operating the source and maintaining the 

source during periods of startup, shutdown, and malfunction and a program of corrective action for 

malfunctioning process and control systems used to comply with the standard. The plan does not have to 

be submitted with the permit application or included in the operating permit. The permitting authority 

may review the plan upon request. In addition to the information required in §63.6(e)(3), the plan shall 

include: 

(1) Procedures, including corrective actions, to be followed if a monitoring device measures an 

operating parameter outside the limit(s) established under §63.847(h), if visible emissions from 

an exhaust stack indicating abnormal operation of a control device are observed by the owner or 

operator during the daily inspection required in §63.848(g), or if a problem is detected during 

the daily inspection of a wet roof scrubber for potline secondary emission control required in 

§63.848(f)(5)(ii); and 

(2) The owner or operator shall also keep records of each event as required by 63.10(b) and record 

and report if an action taken during a startup, shutdown, or malfunction is not consistent with 

the procedures in the plan as described in §63.6(e)(3)(iv). 

12. 

The sulfur content of the pitch used in forming the anodes shall not exceed 0.85 % by weight based upon 

a monthly average. The sulfur content of the coke used in forming the anodes shall not exceed 2.22 % by 

weight based upon a monthly average. Records of the monthly average sulfur contents of pitch and coke 

shall be maintained on site for a period of at least five (5) years from the date generated and shall be 

made available to a Department representative upon request. QUARTERLY reports, including all 

recorded parameters and calculated values, shall be submitted to the Manager of the Technical 

Management Section, Bureau of Air Quality postmarked no later than 30 calendar days after the end of 

the reporting period. (Sources ID01, ID02, ID04) 

13. §60.194(b) - The owner or operator shall maintain a record of daily production rates of aluminum and 

anodes, raw material feed rates, and cell or potline voltages. 

14. 

§63.848(h) - If a monitoring device for a primary control device measures an operating parameter outside 

the limit(s) established pursuant to 63.847(h) or if visible emissions indicating abnormal operation are 

observed from the exhaust stack of a control device during a daily inspection, the owner or operator shall 

initiate the corrective action procedures identified in the startup, shutdown, and malfunction plan within 

1 hour. Failure to initiate the corrective action procedures within 1 hour or to take the necessary 

corrective actions to remedy the problem is a violation. 

15. 

§63.848(i) - If the limit for a given operating parameter associated with monitoring a specific control 

device is exceeded six times in any semiannual reporting period, then any subsequent exceedance in that 

reporting period is a violation. For the purpose of determining the number of exceedances, no more than 

one exceedance shall be attributed in any given 24-hour period. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 41 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

16. 

§63.850(d) - As required by 63.10(e)(3), the owner or operator shall submit a report (or a summary 

report) if measured emissions are in excess of the applicable standard. The report shall contain the 

information specified in 63.10(e)(3)(v) and be submitted semiannually unless quarterly reports are 

required as a result of excess emissions. 

17. §63.850(e) - The owner or operator shall maintain files of all information (including all reports and 

notifications) required by 63.10(b) and by 40 CFR 63 Subpart LL. 

18. 

§63.850(e)(1) - The owner or operator must retain each record for at least 5 years following the date of 

each occurrence, measurement, maintenance, corrective action, report, or record. The most recent 2 years 

of records must be retained at the facility. The remaining 3 years of records may be retained offsite. 

19. §63.850(e)(2) - The owner or operator may retain records on microfilm, on a computer, on computer 

disks, on magnetic tape, or on microfiche. 

20. §63.850(e)(3) - The owner or operator may report required information on paper or on a labeled 

computer disc using commonly available and compatible computer software. 

21. 

§63.850(e)(4) - In addition to the general records required by §63.10(b), the owner or operator shall 

maintain records of the following information: 

(1) Daily production rate of aluminum; 

(2) Daily production rate of green anode material placed in the anode bake furnace; 

(3) A copy of the startup, shutdown, and malfunction plan; 

(4) Records of design information for paste production plant capture systems; 

(5) Records supporting the monitoring of similar potlines demonstrating that the performance of 

similar potlines is the same as or better than that of potlines sampled by manual methods; 

(6) Records supporting a request for reduced sampling of potlines; 

(7) Records supporting the correlation of emissions measured by a continuous emission monitoring 

system to emissions measured by manual methods and the derivation of the alternative emission 

limit derived from the measurements; 

(8) The current implementation plan for emission averaging and any subsequent amendments; 

(9) Records, such as a checklist or the equivalent, demonstrating that the daily visual inspection of the 

exhaust stack for each control device has been performed as required in §63.848(g), including the 

results of each inspection; 

(10) Records documenting the corrective actions taken when the limit(s) for an operating parameter 

established under §63.847(h) were exceeded or when visible emissions indicating abnormal 

operation were observed from a control device stack during a daily inspection required under 

§63.848(g), and; 

(11) Records documenting the portion of TF that is measured as particulate matter and the portion that 

is measured as gaseous when the particulate and gaseous fractions are quantified separately using 

an approved test method. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 42 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

22. 

The owner or operator shall conduct a performance test on the roof monitors from the potlines bimonthly during the life of the facility, except when malfunctions prevent representative sampling, as 

provided under §60.8(c). The owner or operator shall give the Bureau at least 15 days advance notice of 

each test. The Bureau may require additional testing under section 114 of the Clean Air Act. 

23. 

All source tests shall be conducted while the facility is operating under permitted conditions. The source 

test should be performed at the expected maximum production rate. A test conducted under any other 

conditions may result in production limitations. The owner or operator shall ensure that source tests are 

conducted in accordance with requirements listed in 40 CFR 60 (Subparts A and S), 40 CFR 63 

(Subparts A and LL), 40 CFR 63 (Subparts A and RRR) and SC Regulation 61-62.1, Section IV, Source 

Tests. This Bureau must be notified at least two weeks prior to any source test so that a Bureau 

representative may be present. Source test methodology must be approved by this Bureau. 

As required by Construction Permit 0420-0015-CR, source tests on representative baghouses of 

controlled sources (four sources consisting of stacks 08, 21A, 29, and 30, or agreed upon substitute 

stacks) will be required within 60 days after achieving maximum production but not later than 180 days 

after initial start-up to determine compliance with PM BACT limits. The Bureau must be notified at least 

two weeks prior to a source test so that a Bureau representative may be present. Source test methodology 

must be approved by the Bureau and comply with Section 60.8 of Subpart A “New Source Performance 

Standards (NSPS)” and SC DHEC Regulation 62.1, Section IV “Source Testing.” This methodology 

shall include the specific baghouses that must be tested. 

24. 

The amount of natural gas and propane combusted by all sources at the facility will be tracked using 

natural gas billing records and records of propane deliveries. Fuel use will be summarized annually. 

These records shall be maintained on site for a period of at least five (5) years from the date generated 

and shall be made available to Department personnel upon request. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 43 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

25. 

The owner/operator shall install, operate and maintain pressure drop gauge(s) on each module of the 

baghouse(s). All pressure drop gauges shall be readily accessible for verification by operating personnel 

and Department personnel (i.e. on ground level or easily accessible roof level). Pressure drop readings 

shall be recorded MONTHLY and shall be made available to Department personnel upon request. The 

readings shall be maintained in logs, along with any corrective action taken when deviations occur. 

Operational ranges for the monitored parameters shall be established to provide a reasonable assurance of 

compliance. These operational ranges for the monitored parameters shall be derived from stack test data, 

vendor certification, operational history, and visual inspections, the combination of which demonstrate 

the proper operation of the equipment in compliance. These ranges, with supporting documentation, 

shall be submitted to the Bureau for approval within 180 days of the issuance of this permit. The 

operating ranges may be updated using this procedure, following Bureau approval. 

Monthly inspections of these sources will be conducted to include the following: 

1) Visually check exhaust from the baghouse to determine if bags are leaking. 

2) Visually check motor and belts to identify any abnormalities. 

3) Visually inspect baghouse (walls, doors, etc.) for holes or leaks. 

4) For Pulse Type Dust Collectors: 

i) Check each pilot valve for proper operation. 

ii) Check header-pipe for air leaks and pressure setting. 

iii) Check pulse timer for proper setting. 

5) For Shaker Type Dust Collectors: 

i) Check each shaker for proper operation. 

ii) Check all shaker belts for wear; check V-blocks. 

iii) Check damper operation on each compartment. 

iv) Check R.V.F. for proper operation. 

v) Check timing mechanism for proper operation. 

6) Check hoppers on each compartment in the dust collector to make sure they are empty. 

7) Visually inspect all ductwork in the inlet and outlet of the Baghouse. 

Anomalous conditions will be noted and corrective action initiated if warranted. Written procedures for 

personnel to follow when performing the monthly inspections will be maintained on file at the facility. 

The owner/operator shall conduct testing of the filter bags used on site in accordance with Alcoa’s Filter 

Bag Quality Assurance Program created on February 4, 1998. 

Baghouse monitoring data shall be maintained on site for a period of at least five (5) years from the date 

generated and shall be made available to Department personnel upon request. Any alternative method 

for monitoring baghouse performance must be approved by the Bureau and shall be incorporated into the 

permit as set forth in S. C. Regulation 61-62.70.7. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 44 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

26. 

The owner/operator shall install, operate, and maintain equipment to monitor air flow and media feed rate 

on each scrubber. All gauges shall be readily accessible for verification by operating personnel and 

Department personnel (i.e., on ground level or easily accessible roof level). Each parameter shall be 

recorded CONTINUOUSLY and shall be made available to Department personnel upon request. The 

readings will be summarized on forms that shall be maintained in logs, along with any corrective action 

taken when deviations occur. Operational ranges for the monitored parameters shall be established to 

provide a reasonable assurance of compliance. These operational ranges for the monitored parameters 

shall be derived from stack test data, vendor certification, operational history, and visual inspections, the 

combination of which demonstrate the proper operation of the equipment in compliance. These ranges, 

with supporting documentation, shall be submitted to the Bureau for approval within 180 days of the 

issuance of this permit. The permit will be revised with a minor permit modification pursuant to South 

Carolina Regulation 61-62.70.7(e)(2) to include the relevant media scrubber and air flow rate to the 

scrubber. The operating ranges may be updated using this procedure, following Bureau approval. 

Written procedures for monitoring scrubber performance will be maintained on file at the facility. 

Scrubber monitoring data shall be maintained on site for a period of at least five (5) years from the date 

generated and shall be made available to Department personnel upon request. Any alternative method 

for monitoring scrubber performance must be approved by the Bureau and shall be incorporated into the 

permit as set forth in S. C. Regulation 61-62.70.7. 

27. 

The facility shall conduct daily visual inspections on all sources for monitoring visual emissions during 

periods of source operation. These visual observations shall be made during daylight hours and consist 

of time of observation and determination of the presence and duration of visible emissions. This 

information shall be maintained in permanent logs, along with any corrective actions taken. Specific 

procedures to be undertaken by the facility upon the observance of visible emissions are as follows:

1) Log the time, date, and dust collector source description in the visible emissions log. 

2) Record the time the equipment is shutdown and the duration of emissions between the 

time of visible emissions detection and the shutdown of equipment for repair. 

3) Make needed repairs and place dust collector back on line. 

4) Inspect dust collector exhaust to ensure problem was effectively corrected by determining 

that the dust collector has no visible emissions. Log the time, date, and dust collector 

source description as repaired in the visible emissions log.

These records shall maintained on site for a period of at least five years from the date of record and 

made available to Department representatives upon request. 

If the daily visual inspection reveals visible emissions, Alcoa - Mt. Holly will take all necessary 

corrective actions to correct the abnormality as expeditiously as possible. All actions taken by Alcoa - 

Mt. Holly will be recorded. A semi-annual report, postmarked no later than 30 days after the end of the 

reporting period, shall be submitted to the Manager of the Technical Management Section, Bureau of 

Air Quality which includes any visible emissions and corrective action taken, or if no visible emissions 

were observed, Alcoa - Mt. Holly will submit a summary of compliance. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 45 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

28. 

This permit contains compliance certification, testing, monitoring, reporting, and record keeping 

requirements sufficient to assure compliance with the terms and conditions of this permit. All submittals 

required by these conditions shall be sent to the South Carolina Department of Health and Environmental 

Control - Bureau of Air Quality (SC DHEC - BAQ) at the following address: 

SC DHEC - BAQ 

Technical Management Section 

2600 Bull Street 

Columbia, SC 29201 

29. 

The owner or operator shall maintain all records for a period of at least five (5) years from the date 

generated and shall make these records available to Department personnel upon request. Unless another 

reporting period is specified under 40 CFR 60, 40 CFR 63, or PSD all reports shall be submitted SEMIANNUALLY. The reports including all recorded parameters and calculated values shall be submitted to 

the Manager of the Technical Management Section, Bureau of Air Quality postmarked no later than 30 

calendar days after the end of the reporting period. 

30. 

§63.1506(b) - The owner or operator must provide and maintain easily visible labels posted at each inline fluxer that identifies the applicable emission limits and means of compliance, including: 

(1) The type of affected source or emission unit; 

(2) The applicable operational standard(s) and control method(s), including, but not limited to, the 

type of charge to be used for a furnace, flux materials and additions practices, and the applicable 

operating parameter ranges and requirements as incorporated in the OM&M plan. 

31. 

§63.1506(d) - The owner or operator of each affected source or emission unit subject to an emission limit 

in kg/Mg (lb/ton) of feed must: 

(1) Install and operate a device that measures and records or otherwise determine the weight of feed 

(or throughput) for each operating cycle or time period used in the performance test; 

(2) Operate each weight measurement system or other weight determination procedure in 

accordance with the OM&M plan. 

32. 

§63.1506(d)(3) - The owner or operator may chose to measure and record aluminum production weight 

from an affected source or emission unit rather than feed/charge weight to an affected source or emission 

unit, provided that: 

(1) The aluminum production weight, rather than feed/charge weight is measured and recorded for 

emission units within a secondary aluminum processing unit (SAPU); and 

(2) All calculations to demonstrate compliance with the emission limits for SAPUs are based on 

aluminum production weight rather than feed/charge weight. 

33. 

§63.1510(b) - The owner or operator must prepare and implement for each new or existing effected 

source and emission unit, a written operation, maintenance, and monitoring (OM&M) plan. This plan 

shall include all the information required by this subpart. The OM&M plan shall be submitted to the 

Manager of the Technical Management Section for review and approval. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 46 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

34. §63.1510(c) - The owner or operator must inspect the labels for each in-line fluxer at least once per 

calendar month to confirm that posted labels as required are intact and legible. 

35. 

§63.1510(e) - The owner or operator must install, calibrate, operate, and maintain a device to measure 

and record the total weight of feed to, or the aluminum production from, the affected source or emission 

unit over the same operating cycle or time period used in the performance test. Feed or aluminum 

production within SAPUs must be measured and recorded on an emission unit-by-emission unit basis. 

36. 

§63.1510(e)(1) - The accuracy of the weight measurement device or procedure must be  1 percent of the 

weight being measured. The owner or operator may apply to the permitting agency for approval to use a 

device of alternative accuracy if the required accuracy cannot be achieved as a result of equipment layout 

or charging practices. A device of alternative accuracy will not be approved unless the owner or operator 

provides assurance through data and information that the affected source will meet the relevant emission 

standard. 

37. 

§63.1510(e)(2) - The owner or operator must verify the calibration of the weight measurement device in 

accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at 

least once every six months. 

38. 

§63.1510(j)(1) - The owner/operator must install, calibrate, operate, and maintain a device to 

continuously measure and record the weight of gaseous or liquid reactive flux injected to each affected 

source or emission unit. 

39. 

§63.1510(j)(1)(I) - The monitoring system must record the weight for each 15 minute block period, 

during which reactive fluxing occurs, over the same operating cycle or time period used in the 

performance test. 

40. §63.1510(j)(1)(ii) - The accuracy of the weight measurement device must be  1 percent of the weight of 

the reactive component of the flux being measured. 

41. 

§63.1510(j)(1)(iii) - The owner/operator must verify the calibration of the weight measurement device in 

accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at 

least once every 6 months. 

42. 

§63.1510(j)(2) - The owner/operator must calculate and record the gaseous or liquid reactive flux 

injection rate (kg/Mg or lb/ton) for each operating cycle or time period used in the performance test using 

the procedure in 63.1512(o). 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 47 OF 45

(permit revised 1/30/03, see page 2 for details) 

Condition 

Number Conditions 

43. 

§63.1511(b) - Following approval of the site-specific test plan, the owner or operator must demonstrate 

initial compliance with each applicable emission, equipment, work practice, or operational standard for 

each affected source and emission unit, and report the results in the notification of compliance status 

report described in §63.1515(b). The owner or operator must conduct each performance test according to 

the requirements of the general provisions in subpart A of the part and this subpart. 

44. 

§63.1516(a) - The owner or operator must develop and implement a written plan as described in 

§63.6(e)(3) that contains specific procedures to be followed for operating and maintaining the source 

during periods of startup, shutdown, and malfunction, and a program of corrective action for 

malfunctioning process and air pollution control equipment used to comply with the standard. The owner 

or operator shall also keep records of each event as required by §63.10(b) and record and report if an 

action taken during a startup, shutdown, or malfunction is not consistent with the procedures in the plan 

as described in §63.6(e)(3). In addition to the information required in §63.6(e)(3), the plan must include: 

(1) Procedures to determine and record the cause of the malfunction and the time the malfunction 

began and ended; and 

(2) Corrective actions to be taken in the event of a malfunction of a process or control device, 

including procedures for recording the actions to be taken to correct the malfunction or 

minimize emissions. 

45. 

In order to prevent excess or uncontrolled emissions from the Bake Oven during planned maintenance 

activity that requires APC system shutdown, the Bake Oven will first be shutdown. This shutdown plan 

must be followed for all planned maintenance shutdowns. A shut-down is defined as the process of 

intentional shut down of the bake ovens for a period of one hour or longer. The shut-down process 

includes the stoppage of fuel to the furnace. The shut-down begins when the fuel system is intentionally 

shut down for a period of one hour or longer. The shut-down concludes when all components of the 

system have been secured in a shutdown mode or a startup is initiated. The APC system shall continue to 

operate for a period of at least one hour after the furnace is in a secure shutdown mode to allow residual 

fumes to be exhausted in a controlled environment. During periods of downtime, the system shall be 

monitored to ensure that adequate ventilation is provided so that flammable toxic gases do not 

accumulate in the furnace, scrubber or associated ducts. The duration of all events must be recorded. 

All planned periods of downtime in excess of one hour shall be reported to SC DHEC at least 24 hours in 

advance to be followed by a written report submitted to the Department within thirty (30) days. The 

written report shall include as a minimum, the following: 

(1) The identity of the stack and/or emission point where the maintenance occurred; 

(2) The magnitude of any excess emissions expressed in the units of the applicable emission 

limitation and the operating data and calculations used in determining the excess emissions; 

(3) The time and duration of the excess emissions; 

(4) The identity of the equipment causing the excess emissions; 

(5) The nature and cause of such excess emissions; 

(6) The steps taken to limit the excess emissions; 

(7) Documentation that the air pollution control equipment, process equipment, or processes were 

at all times maintained and operated, to the maximum extent practicable, in a manner 

consistent with good practice for minimizing emissions. 

Following completion of maintenance performed during furnace down time, the facility’s startup, 

shutdown and malfunction (SSM) plan for “startup” must be followed to prevent excess or uncontrolled 

emissions for the Bake Oven. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 48 OF 45

(permit revised 1/30/03, see page 2 for details) 

PART 7.0 ADDITIONAL CONDITIONS

A. SPECIFIC CONDITIONS

Condition 

Number Conditions 

1. 

These fuel combustion sources shall use only natural gas or propane as fuel. The use of any other 

substances as fuel is prohibited without prior written approval from the Bureau of Air Quality. (Source 

ID01, ID02, and ID06) 

2. 

Alcoa - Mount Holly is subject to the Secondary Aluminum Production MACT (40 CFR 63) that was 

promulgated on March 23, 2000. The facility has three years to comply with the standards outlined in 40 

CFR 63, Subparts A and RRR (March 24, 2003). Should systems be modified then compliance shall be 

demonstrated upon completion of the modification. 

3. There are no Title IV sources at this facility. 

4. 

Any changes to these sources, such as an increase in throughput, changes in the processes, modification 

or removal of equipment, increase in number of hours of operation, etc., which increase emissions 

regulated by the NAAQS, PSD, NSPS, NESHAPS, or Air Toxics Program will require a review of the 

present permit. (All Sources) 

5. 

The facility shall maintain all emission control equipment in a manner that minimizes emissions and that 

is consistent with industry practices for good operation and maintenance of the control devices, including 

periodic maintenance, testing and adjustment of the control equipment in accordance with established 

industry experience or the manufacturers’ recommendations. (All Sources) 

B. OPERATIONAL FLEXIBILITY [SC Regulation 61-62.70.7(e)(5)] 

No proposed reasonably anticipated operating scenarios identified in the permittee’s Part 70 

Application. 

C. COMPLIANCE SCHEDULE [SC Regulation 61-62.70.5(c)(8)] 

Not applicable at this time. 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 49 OF 45

(permit revised 1/30/03, see page 2 for details) 

D. PERMIT SHIELD [SC Regulation 61-62.70.6(f)] (Revised 11/13/98) 

A copy of the “applicability determination” Alcoa - Mt. Holly submitted with its Part 70 permit 

application is included as Attachment C. Compliance with the terms and conditions of this permit 

shall be deemed compliance with any applicable requirements as of the date of permit issuance. The 

permittee shall also be shielded from any non-applicable requirements as agreed upon by the 

Department as specified in Attachment C. 

Nothing in the permit shield or in any Part 70 permit shall alter or affect the provisions of Section 

303 of the Act, Emergency Orders, of the Clean Air Act; the liability of the permittee for any 

violation of applicable requirements prior to or at the time of permit issuance; the applicable 

requirements of the Acid Rain Program, consistent with Section 408(a) of the Clean Air Act; or the 

ability of EPA to obtain information from a source pursuant to Section 114 of the Clean Air Act. In 

addition, the permit shield shall not apply to emission units in noncompliance at the time of permit 

issuance, minor permit modifications (SC Regulation 61-62.70.7(e)(2)), group processing of minor 

permit modifications (SC Regulation 61-62.70.7(e)(3)), or operational flexibility (SC Regulation 61-

62.70.7(e)(5)), except as specified in SC Regulation 61-62.70.7(e)(5)(iii). 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 1 OF 9

(permit revised 1/30/03, see page 2 for details) 

ATTACHMENT A

Modeled Emission Rates 

AMBIENT AIR QUALITY STANDARDS - STANDARD 2 

Modeled Emission Rates (lbs/hr) 

STACK 

TSP PM10 SO2 NOX CO 

01 - Baked Carbon Plant 4.91 4.58 67.412 7.956 97.7 

01A - Baked Carbon Plant 0.554 0.517 - - 3.65 

02 - Potlines 1.5 0.87 212.24 1.60 3178.3 

02A - Potlines 18.15 10.53 - - - 

03 - Potlines 1.5 0.87 212.24 1.60 3178.3 

03A - Potlines 18.15 10.53 - - - 

04 - Potlines 1.5 0.87 212.24 1.60 3178.3 

04A - Potlines 18.15 10.53 - - - 

05 - Potlines 1.5 0.87 212.24 1.60 3178.3 

05A - Potlines 18.15 10.53 - - - 

06 - Baked Carbon Plant 0.176 0.176 - - - 

07 - Baked Carbon Plant 0.034 0.034 - - - 

08 - Baked Carbon Plant 0.223 0.223 - - - 

09 - Green Carbon Plant 0.429 0.429 - - - 

10 - Green Carbon Plant 0.459 0.459 - - - 

11 - Green Carbon Plant 0.154 0.154 - - - 

12 - Green Carbon Plant 0.094 0.094 - - - 

13 - Green Carbon Plant 0.174 0.174 - - - 

14 - Green Carbon Plant 0.137 0.137 - - - 

15 - Green Carbon Plant 0.087 0.087 - - - 

16 - Green Carbon Plant 0.249 0.249 - - - 

17 - Green Carbon Plant 0.043 0.043 - - - 

18 - Green Carbon Plant 0.174 0.174 - - - 

19 - Green Carbon Plant 0.503 0.503 - - - 

20 - Green Carbon Plant 0.026 0.026 - - - 

21A - Pot Repair 2.250 2.250 - - - 

22 - Anode Rodding 0.942 0.942 - - - 

23, 24, 25 - Anode Rodding 0.966 0.966 - - - 

25A - Anode Rodding 0.116 0.058 - - - 

26 - Anode Rodding 0.026 0.026 - - - 

27 - Anode Rodding 0.300 0.300 - - - 

28 - Potlines 0.270 0.270 - - - 

29 - Potlines 0.669 0.669 - - - 

30 - Potlines 4.062 4.062 - - - 

31 - Potlines 0.130 0.130 - - - 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 2 OF 9

(permit revised 1/30/03, see page 2 for details) 

32 - Potlines 0.268 0.268 - - - 

33 - Potlines 0.176 0.176 - - - 

34 - Potlines 0.176 0.176 - - - 

35 - Potlines 0.069 0.069 - - - 

36 - Potlines 0.069 0.069 - - - 

37 - Potlines 0.069 0.069 - - - 

38 - Potlines 0.069 0.069 - - - 

39 - Potlines 0.266 0.266 - - - 

40 - Potlines 0.069 0.069 - - - 

41 - Potlines 0.103 0.103 - - - 

42 - Potlines 0.351 0.351 - - - 

43 - Potlines 0.103 0.103 - - - 

44 - Potlines 0.103 0.103 - - - 

45 - Potlines 0.351 0.351 - - - 

46 - Potlines 0.103 0.103 - - - 

47 - Cast House 0.802 0.802 - - - 

48 - Cast House 0.257 0.257 - - - 

49 - Cast House 0.257 0.257 - - - 

50 - Cast House 1.301 1.301 0.009 3.359 1.318 

51-103 - Cast House 0.77 0.63 0.009 3.359 1.318 

51-104 - Cast House 0.62 0.48 0.009 3.359 1.318 

51-105 - Cast House 0.62 0.48 0.009 3.359 1.318 

51-106 - Cast House 1.12 0.98 0.009 3.359 1.318 

51-107 - Cast House 1.12 0.98 0.009 3.359 1.318 

51-109 - Cast House 0.62 0.48 0.009 3.359 1.318 

51-110 - Cast House 1.12 0.98 0.009 3.359 1.318 

51-111 - Cast House 0.62 0.48 0.009 3.359 1.318 

51-112 - Cast House 1.12 0.98 0.009 3.359 1.318 

52-1 - Cast House 0.134 0.134 0.011 3.779 1.482 

52-2 - Cast House 0.134 0.134 0.011 3.779 1.482 

52-3 - Cast House 0.268 0.268 0.021 7.558 2.965 

64 - Cast House 0.2244 0.2107 0.013 3.403 1.812 

66 - Cast House 0.418 0.323 - - - 

83 - Green Carbon Plant 0.037 0.037 0.003 0.773 0.412 

84 - Green Carbon Plant 0.012 0.012 0.001 0.248 0.132 

85 - Green Carbon Plant 0.75 0.75 0.46 - - 

86 – Potlines 0.596 0.298 - - - 

87 – Potlines 0.50 0.25 - - - 

100 - Baked Carbon Plant 0.046 0.046 - - - 

101 - Anode Rodding 0.030 0.030 - - - 

106 - General Facility 0.56 0.56 0.52 7.91 1.70 

107 - General Facility 0.010 0.010 0.0004 0.334 0.045 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 3 OF 9

(permit revised 1/30/03, see page 2 for details) 

108 - General Facility 0.010 0.010 0.0004 0.334 0.045 

122 - Cast House 0.022 0.022 0.002 0.464 0.247 

125 – Anode Rodding 0.046 0.046 - - - 

AMBIENT AIR QUALITY STANDARDS - STANDARD 2 

Modeled Emission Rates (lbs/hr) STACK 

HF Lead 

01 - Baked Carbon Plant 0.52 0.0052 

01A - Baked Carbon Plant 0.118 3.38E-6 

02 - Potlines 0.63 0.011235 

02A - Potlines 3.36 0.0662 

03 - Potlines 0.63 0.011235 

 03A - Potlines 3.36 0.0662 

04 - Potlines 0.63 0.011235 

04A - Potlines 3.36 0.0662 

05 - Potlines 0.63 0.011235 

05A - Potlines 3.36 0.0662 

21A - Pot Repair 0.00004 0.00008 

25A - Anode Rodding 0.000100 4.86E-6 

47 - Cast House 0.0076 0.00448 

48 - Cast House 0.0024 0.00144 

49 - Cast House 0.0024 0.00144 

50 - Cast House 0.0247 0.00728 

51-103 - Cast House 0.073 0.00001 

51-104 - Cast House 0.073 0.00001 

51-105 - Cast House 0.073 0.00001 

51-106 - Cast House 0.073 0.00001 

51-107 - Cast House 0.073 0.00001 

51-109 - Cast House 0.073 0.00001 

51-110 - Cast House 0.073 0.00001 

51-111 - Cast House 0.073 0.00001 

51-112 - Cast House 0.073 0.00001 

86 - Potlines 0.0249 0.000242 

87 - Potlines 0.00138 3.19E-5 

64 - Cast House 0.01452 0.00001 

30 - Potlines 0.0099 - 

84 - Green Carbon - 0.000001 

52-1 - Cast House - 0.00001 

52-2 - Cast House - 0.00001 

52-3 - Cast House - 0.00002 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 4 OF 9

(permit revised 1/30/03, see page 2 for details) 

83 - Green Carbon - 0.000002 

122 – Cast House - 0.000001 

CLASS II PREVENTION OF SIGNIFICANT DETERIORATION - STANDARD 7 

Modeled Emission Rates (lbs/hr) STACK 

PM10 SO2 NOX 

 01 - Baked Carbon Plant 4.58 67.412 7.956 

01A - Baked Carbon Plant 0.517 - - 

02 - Potlines 0.87 212.24 1.60 

02A - Potlines 10.53 - - 

03 - Potlines 0.87 212.24 1.60 

03A - Potlines 10.53 - - 

04 - Potlines 0.87 212.24 1.60 

04A - Potlines 10.53 - - 

05 - Potlines 0.87 212.24 1.60 

05A - Potlines 10.53 - - 

06 - Baked Carbon Plant 0.176 - - 

07 - Baked Carbon Plant 0.034 - - 

08 - Baked Carbon Plant 0.223 - - 

09 - Green Carbon Plant 0.429 - - 

10 - Green Carbon Plant 0.459 - - 

11 - Green Carbon Plant 0.154 - - 

12 - Green Carbon Plant 0.094 - - 

13 - Green Carbon Plant 0.174 - - 

14 - Green Carbon Plant 0.137 - - 

15 - Green Carbon Plant 0.087 - - 

16 - Green Carbon Plant 0.249 - - 

17 - Green Carbon Plant 0.043 - - 

18 - Green Carbon Plant 0.174 - - 

19 - Green Carbon Plant 0.503 - - 

20 - Green Carbon Plant 0.026 - - 

21A - Pot Repair 2.250 - - 

22 - Anode Rodding 0.942 - - 

23, 24, 25 - Anode Rodding 0.966 - - 

25A - Anode Rodding 0.058 - - 

26 - Anode Rodding 0.026 - - 

27 - Anode Rodding 0.300 - - 

28 - Potlines 0.270 - - 

29 - Potlines 0.669 - - 

30 - Potlines 4.062 - - 

31 - Potlines 0.130 - - 

32 - Potlines 0.268 - - 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 5 OF 9

(permit revised 1/30/03, see page 2 for details) 

33 - Potlines 0.176 - - 

34 - Potlines 0.176 - - 

35 - Potlines 0.069 - - 

36 - Potlines 0.069 - - 

37 - Potlines 0.069 - - 

38 - Potlines 0.069 - - 

39 - Potlines 0.266 - - 

40 - Potlines 0.069 - - 

41 - Potlines 0.103 - - 

42 - Potlines 0.351 - - 

43 - Potlines 0.103 - - 

44 - Potlines 0.103 - - 

45 - Potlines 0.351 - - 

46 - Potlines 0.103 - - 

47 - Cast House 0.802 - - 

48 - Cast House 0.257 - - 

49 - Cast House 0.257 - - 

50 - Cast House 1.301 0.009 3.359 

51-103 - Cast House 0.63 0.009 3.359 

51-104 - Cast House 0.48 0.009 3.359 

51-105 - Cast House 0.48 0.009 3.359 

51-106 - Cast House 0.98 0.009 3.359 

51-107 - Cast House 0.98 0.009 3.359 

51-109 - Cast House 0.48 0.009 3.359 

51-110 - Cast House 0.98 0.009 3.359 

51-111 - Cast House 0.48 0.009 3.359 

51-112 - Cast House 0.98 0.009 3.359 

52-1 - Cast House 0.134 0.011 3.779 

52-2 - Cast House 0.134 0.011 3.779 

52-3 - Cast House 0.268 0.021 7.558 

64 - Cast House 0.2107 0.013 3.403 

66 - Cast House 0.323 - - 

83 - Green Carbon Plant 0.037 0.003 0.773 

84 - Green Carbon Plant 0.012 0.001 0.248 

85 - Green Carbon Plant 0.75 0.46 - 

86 – Potlines 0.298 - - 

87 – Potlines 0.25 - - 

100 - Baked Carbon Plant 0.046 - - 

101 - Anode Rodding 0.030 - - 

106 - General Facility 0.56 0.52 7.91 

107 - General Facility 0.010 0.0004 0.334 

108 - General Facility 0.010 0.0004 0.334 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 6 OF 9

(permit revised 1/30/03, see page 2 for details) 

122 - Cast House 0.022 0.002 0.464 

125 - Anode Rodding 0.046 - - 

TOXIC AIR POLLUTANTS MODELED - STANDARD 8 

Modeled Emission Rates (lbs/hr) 

POLLUTANT 

CAS NUMBER 

STACK Ammonium 

Chloride 

12125029 

Arsenic 

7440382 

Biphenyl 

92524 

Carbonyl 

Sulfide 

463581 

Cadmium Chromium 

01 - Baked Carbon Plant - - 0.055 - - 0.0075 

01A - Baked Carbon Plant - - - - 4.47E-6 5.18E-5 

 02 – Potlines - 0.000236 - 27.93 0.0001123 0.001100 

02A - Potlines - 0.0305 - - - 0.0647 

03 - Potlines - 0.000236 - 27.93 0.0001123 0.001100 

03A - Potlines - 0.0305 - - - 0.0647 

04 - Potlines - 0.000236 - 27.93 0.0001123 0.001100 

04A - Potlines - 0.0305 - - - 0.0647 

05 - Potlines - 0.000236 - 27.93 0.0001123 0.001100 

05A - Potlines - 0.0305 - - - 0.0647 

21A - Pot Repair - 0.00056 - - - 0.00007 

23, 24, 25 - Anode 

Rodding 

- - - - - 0.00162 

25A - Anode Rodding - 2.32E-5 - - 6.03E-7 - 

47 - Cast House 0.03201 - - - 0.000534 0.003522 

48 - Cast House 0.01026 - - - 0.000171 0.001129 

49 - Cast House 0.01026 - - - 0.000171 0.001129 

50 - Cast House 0.05192 - - - 0.000865 0.005711 

51-103 - Cast House - 0.000667 - - 0.000125 0.000422 

51-104 - Cast House - 0.000667 - - 0.000125 0.000422 

51-105 - Cast House - 0.000667 - - 0.000125 0.000422 

51-106 - Cast House - 0.000667 - - 0.000125 0.000422 

51-107 - Cast House - 0.000667 - - 0.000125 0.000422 

51-109 - Cast House - 0.000667 - - 0.000125 0.000422 

51-110 - Cast House - 0.000667 - - 0.000125 0.000422 

51-111 - Cast House - 0.000667 - - 0.000125 0.000422 

51-112 - Cast House - 0.000667 - - 0.000125 0.000422 

64 - Cast House - - - - 4.23E-6 - 

66 - Cast House - - - - 3.48E-5 - 

86 - Potlines - 0.000801 - - 1.18E-4 2.93E-5 

87 -Potlines - 0.000292 - - 6.74E-6 - 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 7 OF 9

(permit revised 1/30/03, see page 2 for details) 

85 - Green Carbon Plant - - 0.0053 - - - 

TOXIC AIR POLLUTANTS MODELED - STANDARD 8 

Modeled Emission Rates (lbs/hr) 

POLLUTANT 

CAS NUMBER 

STACK Chlorine 

7782505 

Cyanide 

57125 

Ethyl Benzene

100414 

Formaldehyde 

50000 

Hydrochloric 

Acid 

7647010 

01 - Baked Carbon Plant - - - - - 

21A - Pot Repair - 0.00506 - - - 

50 - Cast House - - - - - 

51-103 - Cast House 0.60 - - - 0.60 

51-104 - Cast House - - - - - 

51-105 - Cast House - - - - - 

51-106 - Cast House 2.00 - - - 2.00 

51-107 - Cast House 2.00 - - - 2.00 

51-109 - Cast House - - - - - 

51-110 - Cast House 2.00 - - - 2.00 

51-111 - Cast House - - - - - 

51-112 - Cast House 2.00 - - - 2.00 

52-1 - Cast House - - - - - 

52-2 - Cast House - - - - - 

52-3 - Cast House - - - - - 

64 - Cast House - - - - - 

83 - Green Carbon Plant - - - - - 

84 - Green Carbon Plant - - - - - 

77 & 78 - Cast House - - - 0.0004 - 

80 - Green Carbon Plant - - 0.003 - - 

81 - Green Carbon Plant - - 0.003 - - 

82 - Green Carbon Plant - - 0.003 - - 

106 - General Facility - - - - - 

TOXIC AIR POLLUTANTS MODELED - STANDARD 8 

Modeled Emission Rates (lbs/hr) 

STACK POLLUTANT 

CAS NUMBER 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 8 OF 9

(permit revised 1/30/03, see page 2 for details) 

Manganese Naphthalene 

91203 

Nickel 

7440020 

Phenol 

108952 

Phosphorus 

7723140 

01 - Baked Carbon Plant - 1.37 0.0169 0.398 - 

01A - Baked Carbon Plant - - 5.97E-5 - - 

02 – Potlines 0.000599 - 0.00159 - - 

02A – Potlines 0.0216 - 0.0813 - - 

03 – Potlines 0.000599 - 0.00159 - - 

03A – Potlines 0.0216 - 0.0813 - - 

04 – Potlines 0.000599 - 0.00159 - - 

04A – Potlines 0.0216 - 0.0813 - - 

05 – Potlines 0.000599 - 0.00159 - - 

05A – Potlines 0.0216 - 0.0813 - - 

08 - Baked Carbon Plant - - 0.00004 - - 

09 - Green Carbon Plant - - 0.00009 - - 

10 - Green Carbon Plant - - 0.00009 - - 

11 - Green Carbon Plant - - 0.00003 - - 

12 - Green Carbon Plant - - 0.00002 - - 

13 - Green Carbon Plant - - 0.00003 - - 

14 - Green Carbon Plant - - 0.00003 - - 

15 - Green Carbon Plant - - 0.00002 - - 

16 - Green Carbon Plant - - 0.00005 - - 

17 - Green Carbon Plant - - 0.00001 - - 

18 - Green Carbon Plant - - 0.00003 - - 

19 - Green Carbon Plant - - 0.00010 - - 

20 - Green Carbon Plant - - 0.00001 - - 

21A - Pot Repair - - 0.00012 - - 

22 - Anode Rodding - - 0.00019 - - 

23, 24, 25 - Anode Rodding 0.00270 - 0.00277 0.00037 

25A - Anode Rodding 6.08E-5 - 0.000245 - - 

26 - Anode Rodding - - 0.00001 - - 

27 - Anode Rodding - - 0.00006 - - 

30 – Potlines - - - - 0.00008 

31 – Potlines - - - - 3.0E-6 

35 – Potlines - - - - 1.0E-6 

36 – Potlines - - - - 1.0E-6 

37 – Potlines - - - - 1.0E-6 

38 – Potlines - - - - 1.0E-6 

47 - Cast House 0.003522 - 0.002508 - 0.01398 

48 - Cast House 0.001129 - 0.000804 - 0.00448 

49 - Cast House 0.001129 - 0.000804 - 0.00448 

50 - Cast House 0.005711 - 0.004067 - 0.02267 

51-103 - Cast House 0.01019 - 0.000347 - - 

51-104 - Cast House 0.01019 - 0.000347 - - 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 9 OF 9

(permit revised 1/30/03, see page 2 for details) 

51-105 - Cast House 0.01019 - 0.000347 - - 

51-106 - Cast House 0.01019 - 0.000347 - - 

51-107 - Cast House 0.01019 - 0.000347 - - 

51-109 - Cast House 0.01019 - 0.000347 - - 

51-110 - Cast House 0.01019 - 0.000347 - - 

51-111 - Cast House 0.01019 - 0.000347 - - 

51-112 - Cast House 0.01019 - 0.000347 - - 

64 - Cast House 7.19E-5 - 8.27E-6 - - 

66 - Cast House 0.000675 - 3.71E-5 - - 

85 - Green Carbon Plant - 0.0082 0.005 - - 

86 – Potlines - - 0.00133 - - 

87 – Potlines 3.76E-5 - 0.00470 - - 

100 - Baked Carbon Plant - - 0.00001 - - 

101 - Anode Rodding 0.00018 - - - - 

80 - Green Carbon Plant - 0.008 - 0.003 - 

81 - Green Carbon Plant - 0.008 - 0.003 - 

82 - Green Carbon Plant - 0.008 - 0.003 - 

125 – Anode Rodding - - 0.00001 - - 

TOXIC AIR POLLUTANTS MODELED - STANDARD 8 

Modeled Emission Rates (lbs/hr) 

POLLUTANT 

CAS NUMBER STACK 

POM Sulfuric Acid 

7664939 

Hydrogen 

Sulfide 

Carbon 

Disulfide 

Toluene 

108883 

01 - Baked Carbon Plant 3.00 3.58 - - - 

01A - Baked Carbon Plant 0.000335 - - - - 

02- Potlines 0.09977 - 2.91 0.51 - 

03- Potlines 0.09977 - 2.91 0.51 - 

04- Potlines 0.09977 - 2.91 0.51 - 

05- Potlines 0.09977 - 2.91 0.51 - 

85 - Green Carbon Plant 0.340 - - - - 

80 - Green Carbon Plant 0.224 - - - 0.001 

81 - Green Carbon Plant 0.224 - - - 0.001 

82 - Green Carbon Plant 0.224 - - - 0.001 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 10 OF 9

(permit revised 1/30/03, see page 2 for details) 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 1 OF 2

(permit revised 1/30/03, see page 2 for details) 

ATTACHMENT B

Insignificant Activities

The following table contains a list of activities which are considered insignificant pursuant to South 

Carolina Regulation 61-62.70.5(c). Sources listed below are not exempt from any otherwise 

applicable state or federal requirements including, but not limited to, opacity standards, ambient air 

quality standards, and air toxic standards. 

ID General Description Basis 

A (6) Anode Rodding Roof Vents - ambient air monitoring 

conducted 5/17-18/93 criteria <5TPY and HAPs <0.5TPY 

B Anode Assembly Machine Vent criteria <5TPY and HAPs <0.5TPY 

C Spent Anode Cooling Bays Roof Vents (each of the 15 bays 

has 3 roof vents) - stack test conducted 4/27-28/93 criteria <5TPY and HAPs <0.5TPY 

D Bath Handling Area Roof Vents (8 powered exhaust fans) - 

stack test conducted 5/17-18/93 criteria <5TPY and HAPs <0.5TPY 

E (11) Furnace Roof Vents - stack test conducted 5/14/93 criteria <5TPY and HAPs <0.5TPY 

F Hot Side Operations - Ridge Vent - stack test conducted 

5/11-14/93 criteria <5TPY and HAPs <0.5TPY 

G (5) Portable Crucible heaters (total heat rating is 22 million 

BTU/hr - 4.4 million each) criteria <5TPY and HAPs <0.5TPY 

H Hot Side Operations - VDC and HDC Cooling Towers - two criteria <5TPY and HAPs <0.5TPY 

I 1,200 gallon Aboveground Storage Tank for sodium 

hydroxide criteria <5TPY and HAPs <0.5TPY 

J (2) 2,000 gallon Aboveground Storage Tank for water 

treatment chemicals criteria <5TPY and HAPs <0.5TPY 

K Cold Side Ridge Vent criteria <5TPY and HAPs <0.5TPY 

L Casting Pit and Pigger Exhausts (5) criteria <5TPY and HAPs <0.5TPY 

M Cooling Tunnels criteria <5TPY and HAPs <0.5TPY 

N (5) Filter Preheaters - 0.5 million BTU/hr each burns natural 

gas or propane 

criteria <5TPY and HAPs <0.5TPY 

P Gas-Fired Space Heaters criteria <5TPY and HAPs <0.5TPY 

Q Gas-Fired Steam Cleaners criteria <5TPY and HAPs <0.5TPY 

R Diesel Powered Emergency Fire Pump criteria <5TPY and HAPs <0.5TPY 

S (2) Propane Vaporizers criteria <5TPY and HAPs <0.5TPY 

T Propane Flare criteria <5TPY and HAPs <0.5TPY 

U (4) 1,000 gallon AST criteria <5TPY and HAPs <0.5TPY 

V 1,000 gallon AST criteria <5TPY and HAPs <0.5TPY 

W (2) 6,000 gallon AST criteria <5TPY and HAPs <0.5TPY 

X 2,000 gallon AST - Gasoline criteria <5TPY and HAPs <0.5TPY 

Y (1) 2,000, (1) 4,000 and (1) 8,000 gallon ASTs - Diesel criteria <5TPY and HAPs <0.5TPY 

Z (2) 281,400 AST - Fuel Oil (out of service) criteria <5TPY and HAPs <0.5TPY 

AA Waste Oil Fired Heater (out of service) criteria <5TPY and HAPs <0.5TPY 

BB Cooling Tower for contact cooling water from the anode 

cooling baths criteria <5TPY and HAPs <0.5TPY 
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 2 OF 2

(permit revised 1/30/03, see page 2 for details) 

Note the following changes associated with permit modification (1): 

Source ID O (Brick Crusher) has been removed. 

Source ID X: the 4,000 gallon tank is replaced by a 2,000 gallon tank. 

Source ID Y: one 4,000 gallon tank is replaced by a 2,000 gallon tank.
Alcoa - Mt. Holly (operating as Alumax of South Carolina) 

TV-0420-0015 

PAGE 1 OF 9

ATTACHMENT C

Applicable and Non-Applicable Federal and State Regulations

The following contains the Federal and South Carolina air pollution regulations which were 

specified in the Part 70 permit application and determined as applicable and non-applicable by the 

Department as of the date of this permit issuance. This attachment may be revised by the 

Department in the event of a change in the nature or emission of pollutants at the source or 

promulgation of new or revised regulations. 
VIA CERTIFIED MAIL

August 20, 2001 

Alcoa - Mt. Holly 

P.O. Box 1000 

Goose Creek, SC 29445

ATTENTION: Mr. Randy Pulley 

Dear Mr. Pulley: 

Enclosed with this letter is your Part 70 Air Quality (Title V Operating) Permit 

No. TV-0420-0015 that will become effective on October 1, 2001. Please note 

the conditions and limitations imposed. This permit will be valid through 

September 30, 2004, unless otherwise provided for by SC DHEC Regulation 61-

62.70.7(c)(1)(ii). 

Please review this permit carefully. Should you notice any errors or omissions, 

notify your permit engineer, Natalie Loquist, of this office, at (803) 898-3287 

within 15 days of receipt of this letter. 

Sincerely, 

Carl W. Richardson, P.E., Director 

Engineering Services Division 

Bureau of Air Quality 

CWR:NL:pe 

Enclosure 

cc: Bruce Hennessee, Trident EQC District Office 

Scott Miller, EPA Region IV (via e-mail) 

TV-0420-0015 
January 30, 2003 

Alcoa - Mt. Holly 

P.O. Box 1000 

Goose Creek, SC 29445

ATTENTION: Mr. Randy Pulley 

Dear Mr. Pulley: 

The operation of your facility has been evaluated by our technical staff. 

Enclosed please find your revised Title V Operating Permit, permit number 

TV-1140-0005. 

Please note any changes in conditions and limitations imposed. This revised 

permit is being issued as an administrative amendment to add construction 

permit 0420-0015-CR for increased production to the operating permit. 

Expiration date of the Title V permit remain the same. Attachment C is not 

being re-issued. 

Please examine this new permit carefully for errors or omissions and notify 

me at (803) 898-3831, promptly if any are discovered. 

Sincerely, 

Joe Eller 

Engineering Services Division 

Bureau of Air Quality 

JE:pe 

Enclosure 

cc: Bruce Hennessee, Trident EQC District Office 

Scott Miller, EPA Region IV (via e-mail) 

TV-0420-0015