Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 1 of 20 Facility Questionnaire for Primary Aluminum Reductio n Plants 1

, 2

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

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

Part A General Facility Information

Part B Process and Emissions Control Devices

Part C Start

- ups and Shutdowns

Part D Previously Performed Testing and Test Report Data

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

.

Please separate confidential business information (CBI) from non

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

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

Pollutants (HAP).

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

information, as described in t he cover letter from EPA. If possible we would prefer receiving the completed forms
as electronic files in Microsoft® Word format . Please add additional rows to the tables as needed to contain your responses. Blank electronic forms are included on the disc provided with this package.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 2 of 20 PART A : GENERAL FACILITY INFORMA TION (Please fill out a separate form for each of your facilities )

1. Name and address of the PARENT COMPANY that owns the facility: Alcoa (Intalco Aluminum Corporation)

__________________________________________

_________________________________________________________________________

_________________________________________________________________________

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

_________________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

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

a. Address: 4050 Mountain View Road

b

. City: Ferndale

c. State: WA

d. Zip: 98248

e. County: Whatcom

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

a. Address:

_____________________________________________________________ b. City:

________________________________________________________________

c. State:

_______________________________________________________________ d. Zip:

_________________________________________________________________

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

a. Name (First Name, Last Name): Patricia Bilskis

b. Title: Environmental Staff Specialist

c. Telephone number: 360

- 384

- 7267

d. Fax number: 360

- 384

- 7458

e. E

- mail: patricia.bilskis@alcoa.com
6

. Please provide an electronic copy of your current Title V operating permit and any pending
Title V operating permit modification applications (pdf file s are preferred).
Titled Air Operating Permit 000295 0.pdf in requested documents folder

7. Please provide a copy of the facility schematic showing all of the p rimary a luminum operations that are subject to 40 CFR Part 63, Subpart LL . Please i nclud e the control
device ID numbers in the facility schematic. See schematics in requested documents folderEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 3 of 20 PART B: PROCESS ES AND EMISSIONS CONTROL DEVICES

8

. P itch storage tanks :

3 Total number of pitch storage tanks at facility

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

26,647 short tons Total amount of pitch used (tons per year) assuming facility operation at maximum capacity

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

ID No.:

_____ 1

_______ _______ 2

_____ ______ 3

______ Capacity: 485 short tons 485 short tons 485 short tons

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

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

Not practicable economically: Setting a Nationally applicable emission standard for

pitch storage tanks that have no add

- on controls is not technically or economically

feasible because factors affecting emissions vary widel y over time and from site to

site. Tank emissions result from either filling the tank or diurnal temperature

changes. On a short

- term basis (hourly or daily), tank filling emissions will depend

on the size of the tank and how much material is added durin g filling. Both tank size

and delivery volume (or frequency) will vary from one smelter to the next, so

establishing a short

- term emission limit applicable to all tanks is not feasible.

Emissions caused by diurnal temperature variations will vary depend ing on climate.

Not practicable technologically: see above response

9

. A node bake furnaces:

2

_______________ Total n umber of anode bake furnaces at facility

179,840 short tons at maximum Al production Facility

- wide green a node production capacity (tons per year

113,972 short tons at maximum Al production Total a mount of coke used for anode production (tons per year) assuming facility operation at maximum capacity

1 0

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

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

Total potlines ( 3 ) Aluminum capacity ( 306,400 )

Individual potlines (add rows as necessary) and aluminum capacity (tons per year) :

Potline # A Aluminum capacity ( 102,133.3 )

Potline # B Aluminum capacity ( 102,133.3 )Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 4 of 20 Potline # C Aluminum capacity ( 102,133.3 )

1 1

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

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

Potline # A SWPB

_______ 240

____ Potline # B SWPB

_______ 240

____ Potline # C SWPB

_______ 240

____

* Center

- work ed pre

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

Center

- worked pre

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

- worked pre

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

- worked pre

- bake (SWPB)

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

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

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

Side shield (hood) Door (sample

door) Side
shield (hood) Door (sample

door) Side shield (hood) Door (sample

door)

A 10 1 12 1 4.9 2.0

B 10 1 12 1 4.9 2.0

C 9 1 11 1 4.8 3.5

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

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

b The average number of cell openings (i.e. side shields and/or doors removed from

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

.

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

the cited potline is removed

.

1 1 c

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

Potline ID , (Emission Unit) Capture efficiency (%) Evacuation

rate (scfm)

N ote all
evacuation
rates are at full potroom operation

. Damper system? (i.e. to allow high and low flow evacuation rates)

Yes NoEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 5 of 20 Potline A (EU181) 90% 177,000 Yes

Potlne A (EU 182) 90% 176,000 Yes

Potline B (EU183 N) 90% 131,000 Yes

Potline B (EU183 S) 90% 167,000 Yes

Potline B (EU184 N) 90% 154,000 Yes

Potline B (EU184 S) 90% 148,000 Yes

Potline C (EU185 N) 90% 107,000 Yes

Potline C (EU185 S) 90% 129,000 Yes

Potline C (EU186 N) 90% 129,000 Yes

Potline C (EU186 N) 90% 129,000 Yes

1 1 d. Please provide a copy of the method(s) used (e.g. inspection checklist or log) to ensure that the capture efficiencies cited in the table above are achieved.

See the Safe Standard Operating Procedure PL

- 2

- 031 Pot Hood Audits for A,B and
C

- Line.doc in RequestedDocuments \ PotHoodInspections

1 2

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

__ n/a

__ Manifold or

__ n/a

__ Cassette

1 2 a

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

1 3

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

0.5% Typical sulfur content of pitch

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

2.8 Typical sulfur content of coke

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

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

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

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 6 of 20 1 3 b. What company (provide name and contact information) supplies your facility with the raw materials used in paste production? Please submit a copy of the current MSDS for these materials.

Coke:
1 ) Rio Tinto Alcan (Strathcona) Frederic Picard, PH.D. Manager Strathcon Works
Rio Tinto Alcan 910 Petroleum Way Edmonton, AB, Canada T: +1 (780) 467

- 2957 M: +1 (587) 987 2592

2 ) Oxbow Coke
Laura Johnson Technical Manager Oxbow Calcining LLC
11826 N. 30 th St Kremlin, OK 73753
Phone: 580

- 874

- 2201 ext 225

Pitch
1 ) Koppers INC. Gregory P. Traczek
Carbon Materials and Chemicals Koppers Inc. 436 Seventh Ave. Pittsburgh, PA 15219
Phone: 412

- 227

- 2318
1 3 c. Is any coal tar pitch (as opposed to petroleum pitch) used in your facility?
Yes

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

versus pre

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

In 1999 Intalco conducted emission testing to provide detailed COS and SO2 data for modeling purposes and, to improve emission estimates. The sampling and analysis used extractive Fourier Transform Infrared Spectroscopy to analyze potline primary
control device stack emissions. The concl usion of these tests, along with production rates and net carbon consumption, resulted in a site specific COS emission factor that is used in conjunction with a mass balance calculation.

1 4

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

, 2

, 3

, 4 , and/or 5 , as appropriate. Please u se the same ID numbers as were assigned in the schematic provided in response to question 7.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 7 of 20 b. Does your operating permit include limits for emissions of particulate matter from the potlines and/ or limits on the sulfur content of the pitch and/or coke used to produce anodes? If so, what are those limits?
Permit 000295

- 0 condition D3: 3% Sulfur in coke
Permit 000295

- 0 condition D3:0.6% Sulfur in pitch
Permit 000295

- 0 condition D4: Emission of PM from potrooms shall not exceed 0.1 grains /dscf
Permit 000295

- 0 condition D5: The total emissions of PM to the atmosphere from the reduction process (potlines) shall be reduced to the lowest level consistent with reasonably available control technology (RACT). Emissions of PM shall not exceed fifteen (15) pounds of PM per ton of aluminum produced on a dialy basis.
Permit 000295

- 0 condition D6: Emission of PM shall not exceed a combined total of 5050 pounds per day (calculated on a monthly average) from the potlines (primary and second ary control systems) and the bake ovens.
Permit 000295

- 0 condition D7: Emissiosn of PM shall not exceed a combined total of 6.0 pounds per ton of aluminum (calculated on a three month average) produced from the potlines (primary and secondary contr ol systems) and the bake ovens.

c

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

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

( CHECK one) ___________ Yes

______ x _____ No

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

d

. Please indicate below all emission controls that were installed or upgraded AFTER October 7, 1 997 in order to meet the MACT standard s for primary aluminum reduction plants ( add rows as necessary and use the same ID numbers as were assigned in the schematic provided in response to question 7):

Description of new or upgraded control Emission point Emission limit Date the control or upgrade

became operational

Green Mill Coke
Scrubber Emission Unit 316 

### §63.843 (b)(1) The emission capture system shall be installed and operated to meet the generally accepted engineering standards for
minimum exhaust rates as published by the American
Conference of January 15,
2001Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 8 of 20 Governmental Industrial Hygienists in Chapters 3 and 5
of “Industrial Ventilation: A
Handbook
of Recommended Practice” (incorporated by reference in §63.841 of this part); and

(2) Captured emissions shall

be routed through a closed system to a dry coke scrubber

1 5

. Pollution prevention: Describe any procedures

, work practice standards

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

. Alcoa Intalco reduces the evolution of potroom HF by ensuring good cover of the anodes within operating pots are covered w ith sufficient ore.

A coke filled canister is attached to at the final exhaust point of the pitch tanks. Emissions that result from diurnal temperature fluctuations are controlled by the coke filled canister.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 9 of 20 Table 1 Wet Scrubber Description

1

. Control d evice description and ID number ( or numbers, if several identical control devices are used to control a given emission source ) : A line building one wet scrubbers (28 total) identified by EU 22

- 49 A line building two wet scrubbers (27 total)identified by EU 50

- 76 B line building one wet scrubbers (26 total) identified by EU 77

- 102 B line building two wet scrubbers (26 total) identified by EU 103

- 128 C line building one wet scrubbers (26 total) identified by EU 129

- 154 C line building two wet scurbbers (2 6 total)identified by EU 155

- 180

2

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

ID No.: EU 22

- 49 Latitude: 48.848036° Longitude:

- 122.703736°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

ID No.: EU 50

- 76 Latitude: 48.847817° Longitude:

- 122.704786°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

ID No.: EU 77

- 102 Latitude: 48.847603° Longitude:

- 122.70 5836°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

ID No.: EU 103

- 128 Latitude: 48.8473 89° Longitude:

- 122.706894°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

ID No.: EU 12 9

- 154 Latitude: 48.847167° Longitude:

- 122.707931°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

ID No.: EU 155

- 180 Latitude: 48.846953° Longitude:

- 122.708967°

Polygon Fugative Length: 1338 feet Fugative Width: 12 feet Fugative Angle:76°

3

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

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

PM 80 Percent mg/dscf 2

PM10 80 Percent mg/dscf 2

PM2.5 80 Percent mg/dscf 2

Total Fluorides 80 Percent mg/dscf 2

Hydrogen Fluorides 80 Percent mg/dscf 2

POM 80 Percent mg/dscf 2

COS 80 Percent mg/dscf 2Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 10 of 20 Other (specify) 80 Percent mg/dscf 2

Other (specify) 80 Percent mg/dscf 2

Other (specify) 80 Percent mg/dscf 2

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

4

. Device type: V enturi V ertical packed bed

H orizontal packed bed T ray tower spray chamber

x O ther (specify or describe): ambient air is pulled from the potrooms, the air is sprayed with a mist of water that contains soda ash. Solids and gases are scrubbed from the air by the water which returns to the
recirculation tan k.

5

. Pressure mode of operation: x positive pressure negative pressure

6

. Typical gas temperature: inlet °F outlet 55.5 °F

7

. Gas flow rate: acfm (at scrubber outlet) average 111,417 dscfm (each scrubber stack A line has 55, B and C line have 52 each) Plant total ~ 16 million scfm

8

. Pressure drop across scrubber : 0 inches water column (in. H 2 O)

9

. Liquid to gas ratio: gal/1,000 acf

10

. Chemical usage rate (specify chemical and typical usage rate , if applicable )

Chemical added Usage rate Units for usage rate

Soda ash Varies depending on ph of water ph target 9.5Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 11 of 20 11

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

. Source ID No(s). Source description(s)

A line building 1 fugitive
emissions Controlled by Emission Units (EU) 22

- 49

A line building 2 fugitive
emissions Controlled by EU 50

- 76

B line building 1 fugitive
emissions Controlled by EU 77

- 102

B line building 2 fugitive
emissions Controlled by EU 103

- 128

C line building 1 fugitive
emissions Controlled by EU 129

- 154

C line building 2 fugitive
emissions Controlled by EU 155

- 180

12

. Indicate what operational parameters of the control device are monitored to ensure that the
control device is operating properly:

Volumetric flow rate Fan amperage

Pressure drop x Water flow rate

Other (specify):

.

13

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

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

P ressure drop (in. H 2 O)

A line 683,000gpm, B line 639,000 gpm, C line 516,000gpm W ater flow rate (gpm) at full production

O ther (specify):

.

14

. Has the collected sludge been analyzed?

_____ Yes

__ x

___ No
If yes, provide the average and range for each HAP constitue nt analyzed over the past year or last 9 samples, whichever is fewer. Alternatively, attach the results of the analyses. Do not
include results from the Toxicity Characteristic Leaching Procedure (TCLP).

Results will be available in two weeks from June 1.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 12 of 20 15

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 13 of 20 Table 2 Combination Dry Alumina Scrubber /Bag House Description

1

. Control device description and ID number (or numbers, if several identical control devices are used to control a given emission source): A line Center 1, 6 stacks, Emission Unit 181, represented by three dots in google earth info A line Center 2, 6 stack, Emission Unit 182, represented by three dots in google earth info B line Center 3, 26 stacks, Emission Unit 183, represented by three dots in google earth info B line Center 4, 26 stacks, Emission Unit 184, represented by three dots in google earth info
C line Center 5, 22 stacks, Emission Unit 185, represented by three dots in google earth info C line Center 6, 22 stacks, Emission Unit 186, represented by three dots in google earth info Bake Oven Scrubber, 1 stack, Emission unit 187, represented by one dot in google earth info

2

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

ID No.: _EU 181(a)_ Latitude: 48.847433° Longitude:

- 122.703867°

ID No.: ___ (b)

______ Latitude: 48.847297° Longitude:

- 122.703794°

ID No.: ____ (c)

____ Latitude: 48.847144° Longitude:

- 122.703728°

ID No.: __ EU 182_

__ Latitude: 48.845356° Longitude:

- 122.702883°

ID No.: ___(b)______ Latitude: 48.845247° Longitude:

- 122.702844°

ID No.: ____(c)____ Lati tude: 48.845122° Longitude:

- 122.702783°

ID No.: __EU 183

____ Latitude: 48.847147° Longitude:

- 122.706019°

ID No.: ___(b)______ Latitude: 48.846939° Longitude:

- 122.705928°

ID No.: ____(c)____ Latitude: 48.846751° Longitude:

- 122.705839°

ID No .: ___EU 184

___ Latitude: 48.844956° Longitude:

- 122.704969°

ID No.: ___(b)______ Latitude: 48.844772° Longitude:

- 122.704878°

ID No.: ____(c)____ Latitude: 48.844611° Longitude:

- 122.705839°

ID No.: __EU 185

__ Latitude: 48.846692° Longitude:

- 122.708133°

ID No.: ___(b)______ Latitude: 48.846503° Longitude:

- 122.708044°

ID No.: ____(c)____ Latitude: 48.846333° Longitude:

- 122.707953°

ID No.: __EU 186

____ Latitude: 48.844492° Longitude:

- 122.707089°

ID No.: ___(b)______ Latitude: 48. 844286° Longitude:

- 122.706969°

ID No.: ____(c)____ Latitude: 48.844097° Longitude:

- 122.706875°Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 14 of 20 ID No.: __ EU 187

____ Latitude: 48.842903° Longitude:

- 122.710119°

3

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

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

PM 99 Percent mg/dscf 1

PM10 99 Percent mg/dscf 1

PM2.5 99 Percent mg/dscf 1

Total Fluorides 99 Percent mg/dscf 1

Hydrogen Fluorides 99 Percent mg/dscf 1

POM 99 Percent mg/dscf 2

COS 99 Percent mg/dscf 2

Other (specify) Perc ent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________

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

4

. Scrubber device type :

_____ Fluidized bed

___ x

__ Injection

_____ Other (specify or describe): _________________________________________

5

. Bag cleaning method:

__ x

___ Pulse jet (B and C line baghouses EU 183

- 18 7 )

___ x

__ Reverse air (A line baghouses EU 181 and 182)

_____ Other (describe)

_________________________________________________

6

. Pressure mode of operation: positive pressure x negative pressure

7

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

~ 190 ° FEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 15 of 20 8

. Gas flow rate: acfm (at bag house outlet)
1

. 75 million total dscfm (EU’s 181

- 186) 115,000 dscfm (EU 187)

9

. Pressure drop: Across scrubber: 5.5

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

10

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

11

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

Type of Alumina Added Usage rate Units for usage rate

Virgin alumina On at least 1140 minutes a day for EU’ s 183

- 187

On at least 540 minutes a day on EU’s 181

- 182. Minutes per day

Recycled alumina On for less than 300 minutes a day for EU’s
183

- 187 On for less
than 900 minutes for
EU’s 181

- 182. Minutes per day

Other alumina (specify

________________)

12

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

Source ID No(s). Description(s)
A line pots 1

- 30, 91

- 121,
121

- 150, 211

- 240 EU 181,

A line pots 31

- 60, 61

- 90,
151

- 180, 181

- 210 EU 182

B line pots 1

- 30, 91

- 121,
121

- 150, 211

- 240 EU 183

B line pots 31

- 60, 61

- 90,
151

- 180, 181

- 210 EU 184

C line pots 1

- 30, 91

- 121,
121

- 150, 211

- 240 EU 185

C line pots 31

- 60, 61

- 90,
151

- 180, 181

- 210 EU 186

Baking Furnaces EU 187

13

. Indicate what operational parameters of the control device are monitored to ensure that the control device is operating properly:

x Volumetric flow rate Fan amperageEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 16 of 20 x Pressure drop x Visible emissions opacity

Other (specify):

.
14

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

x See operational limits in table below in scfm Volumetric flow rate ( acfm )

Potline Control Device Normal Airflow (1) (ACFM) Operational Lower Limit (SCFM)

A 1 81 177,000 141,000

18 2 176,000 141,000

B 18 3 North 131,000 105,000

18 3 South 167,000 134,000

18 4 North 154,000 123,000

18 4 South 148,000 118,000

C 18 5 North 107,000 85,000

18 5 South 129,000 103,000

18 6 North 129,000 103,000

18 6 South 129,000 103,000
EU 187 Operational Upper Limit 116,000 SCFM

Fan amperage (amps)

Pressure drop (in. H 2 O) 20 Visible emissions opacity (%)

Other (specify):

. 15

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 17 of 20 Table 2 b inserted by Intalco for Dry Coke Scrubber

(Inserted in response to Dave Putneys May 10, 2011 08:30am email)

Control device description and ID number (or numbers, if several identical control devices are used to control a given emission source):

EU 316 Paste Plant Dry Coke Scrubber (Also known as the Pitch Fume Treatment System)

16

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

ID No.: EU 316 Latitude: 48.842861° Longitude:

- 122.709503°

17

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

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

PM 99 Percent mg/dscf 2

PM10 99 Percent mg/dscf 2

PM2.5 99 Percent mg/dscf 2

Total Fluorides 99 Percent mg/dscf 2

Hydrogen Fluorides 99 Percent mg/dscf 2

POM 99 Percent mg/dscf 2

COS 99 Percent mg/dscf 2

Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________

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

18

. Scrubber device type:

_____ Fluidized bed ___x__ Injection

_____ Other (specify or describe): _________________________________________

19

. Bag cleaning method:

__x___ Pulse jet

_____ Reverse air

_____ Other (describe)

_________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 18 of 20 20

. Pressure mode of operation: positive pressure x negative pressure

21

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

22

. Gas flow rate: acfm (at bag house outlet) ~45,000 dscfm

23

. Pressure drop: Across scrubber: 5.5

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

24

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

25

. Coke usage rate ( Table modified to accommodate coke scrubber )

Usage Rate Usage Units

Coke flow from main feed tank Never less than
6.25RPM RPM (4,500 lb/hour)

26

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

Source ID No(s). Description(s)
Anode Forming, Paste Plant EU 181,

27

. Indicate what operational parameters of the control device are monitored to ensure that the control device is operating properly:

x Volumetric flow rate Fan amperage

x Pressure drop x Visible emissions opacity

Other (specify):

.
28

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

46,000 scfm lower limit Volumetric flow rate (acfm)

Fan amperage (amps)

Pressure drop (in. H 2 O) 5 Visible emissions opacity (%)

Parameter Lower
Limit

Coke flow from
main feed tank

SI

- 500 6.25 RPM (RPM at 4,500 lb/hr)

Other (specify):

. 29

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 19 of 20 Table 3 Electrostatic Precipitator (ESP) Description

1

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

2

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

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude:

________________ 3

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

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

PM Percent mg/dscf

_________ PM10 Percent mg/dscf

_________ PM2.5 Percent mg/dscf

_________ Total Fluorides Percent mg/dscf

_________ Hydrogen Fluorides Percent mg/dscf

_________ POM Percent mg/dscf

_________ COS Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________

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

4

. Device type: H igh

- voltage, single

- stage L ow

- voltage, two

- stage

W et D ry

O ther (specify or describe):

5

. Pressure mode of operation: positive pressure negative pressureEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 20 of 20 6

. Typical gas temperature: inlet ° F outlet ° F

7

. Gas flow rate: acfm (at ESP outlet) dscfm

8

. Collection plate surface area: __________ ft 2

9

. Second ary power : _____________ kW

10

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

Source ID No(s). Description

11

. Indicate what operational parameters of the control device are monitored to ensure that the
control device is operating properly:

Visible emissions Volumetric flow Fan amperage opacity rate
Secondary power Secondary voltage

Other (specify):

.

12

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

Visible emissions Volumetric flow Fan amperage opacity (%) rate (acfm) (amps)

Secondary power Secondary voltage (kW) (volts)

Other (specify):

.

13

. Has the collected dust been analyzed?

_____ Yes

_____ No
If yes, provide the average and range for each HAP constituent analyzed over the past year or the last 9 samples, whichever is fewer. Alternatively, attach the results of the analyses. Do
not include results from the Toxicity Characteristic Leaching Procedure (TCLP).

14

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 21 of 20Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 22 of 20 Table 4 Bag House Description ( Only fill out Table 4 for bag houses that are not associated

with a dry alumina scrubber. Do not fill out Table 2 and Table 4 for any one bag house

. )

1

. Control device description and ID number (or numbers, if several identical control devices
are used to con trol a given emission source):

2

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

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _

______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

3

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

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

PM Percent mg/dscf

_________ PM10 Percent mg/dscf

_________ PM2.5 Percent mg/dscf

_________ Total Fluorides Percent mg/dscf

_________ Hydrogen Fluorides Percent mg/dscf

_________ POM Percent mg/dscf

_________ COS Percent mg/dscf

_________ Other (spe cify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________

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

4

. Bag cleaning method:

_____ Pulse jet

_____ Reverse air

_____ Shaker

_____ Other (describe)

_________________________________________________

5

. Pressure mode of operation: positive pressure negative pressure

6

. Typical gas temperature: inlet ° F outlet ° F

7

. Gas flow rate: acfm (at bag house outlet) dscfm

8

. Pressure drop: inches water column (in. H 2 O)Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 23 of 20 9

. Air to cloth ratio: cfm/sf or fpm

10

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

Source ID No(s). Description(s)

11

. Indicate what operational parameters of the control device are monitored to ensure that the control device is operating properly:

_______ Volumetric flow rate

____________ Fan amperage

_______ Visible emissions opacity

____________ Pressure drop

Other (specify):

.

12

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

_______ Volumetric flow rate (acfm)

____________ Fan amperage (amps)

_______ Visible emissions opacity (%)

____________ Pressure drop (in. H 2 O)

Other (specify):

.

13

. Has the collected dust been analyzed?

_____ Yes

_____ No
If yes, provide the average and range for each HAP constituent analyzed over the past year or last 9 samples, whichever is fewer. Alternatively, attach the results of the analyses. Do not include results from the Toxicity Chara cteristic Leaching Procedure (TCLP).

14

. Additional comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 24 of 20 Table 5 Other Air Pollution Control Devices

1

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

2

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

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

ID No.: _________ Latitude: _______________ Longitude: ________________

3

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

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

PM Percent mg/dscf

_________ PM10 Percent mg/dscf

_________ PM2.5 Percent mg/dscf

_________ Total Fluorides Percent mg/dscf

_________ Hydrogen Fluorides Percent mg/dscf

_________ POM Percent mg/dscf

_________ COS Percent mg/dscf

_________ Other (specify) P ercent mg/dscf

_________ Other (specify) Percent mg/dscf

_________ Other (specify) Percent mg/dscf

_________

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

4

. Pressure mode of operation: positive pressure negative pressure

5

. Typical gas temperature: inlet ° F outlet ° F

6

. Gas flow rate: acfm Specify location: _______________________________

dscfm

7

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

Source ID No(s). Source description(s)Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 25 of 20 8

. Indicate what operational parameters of the control device are monitored to ensure that the control device is operating properly :

Visible emissions opacity V olumetric flow rate

P ressure drop

O ther (specify):

.

9

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

Visible emissions opacity (%) Volumetric flow rate (acfm)

Pressure drop (in. H 2 O)

Other (specify):

.

10

. Has the collected dust or sludge been analyzed?

_____ Yes

_____ No

______ Not Applicable

If yes, provide the average and range for each HAP constituent analyzed over the past year or last 9 samples, whichever is fewer. Alternatively, attach the results of the analyses. Do not include results from the Toxicity Characteristic Leaching Procedure (TCLP).

11

. Additi onal comments and information:Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 26 of 20 PART C: START

- UPS AND SHUTDOWNS

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

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

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

1 6

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

a potline during start

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

Not practicable economically : EPA Reference Methods 14 and 14A are designed to

me asure TF roof emissions over only a subset of the smelting pots operating in a pot room

(roughly 10 or 12 pots out of 130 or 150), with the assumption that the pots being sampled

represent the entire potline during steady

- state operation . During potline s tartup, pots
located under a Method 14 or 14A sampling system do not represent the entire potline

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

- steady

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

show compliance with a startup standard using the available EPA Reference Method.

Establishing a standard for startups is further complicated by the fact that startups are rare

and the conditions of a startup (and associated emissi ons) will vary depending on whether a

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

potline was intentionally shut down in a controlled manner. Work practice standards are

the only practicable means of regulating emi ssions during an aluminum potline startup.

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

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

13 separate Reference Method sampli ng systems in each potroom to collect representative
compliance samples. These sampling systems typically cost more than $250,000 each to

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

individual potline.

Not practicable technologically: see response above

1 7

. Do you have test data that show any potline hazardous air pollutant (HAP) emissions during a start

- up or shutdown? (Check one) x Y  N
If yes:

a

. Provide a copy of the test data. Find data in test data folder 2011BLineStartupData.xlsxEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 27 of 20 b

. Describe the operating conditions (e.g. tons of aluminum produced per day) at the time
of the testing. Find data in test data folder 2011BLineStartupData.xlsx

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

1 8

. Do you have an operating plan to minimize emissions during start

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

___ x ___ Yes ____________ No

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

19

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

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

_ A

____ a. Develop a potroom/potline start

- up schedule before start

- up

_ A

____ b

. Perform daily assessment of start

- up pro gress and any schedule changes

_ A

____ c

. Keep records of number of pots started per day

_ A

__ d

. Bring potroom/potline scrubbers and exhaust fans on line prior to energi zing
first cell to be restarted

_ N

____ e

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

If so, how much higher? ____________(percent)

_ S

____ f

. Keep pots covered during start

- up

_ A

____ g

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

_ A

____ h

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

start

- up

_ A

____ i. Monitor pot lines frequently during start

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

__ N

___ Adjust exhaust flow from pots

__ S

___ Adjust cell voltage and feeding levels

_ A

___ Monitor and adjust anode current and liquid level

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

New or restart p ots are monitored daily and adjustments are made

as necessary

2 0

. Please list any additional start

- up activities in the space below.Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 28 of 20 ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 29 of 20 Table 6 Description of most recent potline start

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

Potline ID

(as assigned in
the schematic of question 7) Date(s), duration, and descri ption (e.g. planned shutdown for ..., or emergency shutdown due to ...) of

start

- up or shutdown Was the start

- up or shutdown covered by a

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

A line Shutdown April 2001 ,5yrs 10 months, planned shutdown due to unfavourable market conditions SSM plan followed.

A line Startup R estarted in Feb. 2007

, All Startup, Shutdown, Malfunction (SSM) procedures identified in the facility’s SSM plans were followed to ensure that the start

up of A

- Line was done in a manner that minimized emissions and consistency with good air pollution control practices.

B line Shutdown B line shut down Nov. 2008 , 2 years three months, planned shutdown due to unfavourable market conditions All Startup, Shutdown, Malfunction (SSM) procedures identified in the facility’s SSM plans were followed to ensure that the shutdown of B

- Line was done in a manner that minimized emissions and consistency with good air pollution control practic es.

B line Startup Restarted in Feb. 7, 2011

– Feb. 23, 2011 All Startup, Shutdown, Malfunction (SSM) procedures identified in the facility’s SSM plans were followed to ensure that the start

up of B

- Line was done in a manner that minimized emissions and consistency with good air pollution control practices.

C Line Shutdown April 2001 , one year three months, planned shutdown due to unfavourable market conditions SSM plan followedEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 30 of 20 C Line Startup July 2002 SSM plan followedEnclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1

- April 22 , 2011 Page 31 of 20 PART D : PREVIOUSLY PERFORMED TESTING AND TEST REPORT DATA

2 1

. Submit emission test report result s for calendar year 2010 for polycyclic organic matter (POM) and total fluorides (TF) for any sources that have POM and/or TF emissions standards under Subpar t LL. If available, submit emission test report results for any testing conducted from January 1, 2006 to the present for metal HAP (i.e. antimony, arsenic, beryllium, cadmium, chromium, hexavalent chromium, cobalt, lead, manganese, nickel, and selenium), TF, hydrogen fluoride (HF), particulate matter (PM), POM, speciated organic HAP data, and/or carbonyl sulfide (COS) for primary aluminum sources that currently do not have emission standards for those pollutants under Subpart LL

.

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

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

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

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

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

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

2 2

. If emission con trols were installed or upgraded for primary aluminum sources after October 7, 1997 to control emissions of POM from prebake potlines, emissions of POM from existing pitch storage tanks, and/or emissions of COS , please also include test reports,
if availab le, including the information specified in 2 1 (a) through ( e ), for the most recent emission testing that was performed before these controls were installed or upgraded and identify them as “pre

- MACT test reports.”

2 3

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

, been performed at your facility to measure COS concentration and/or emissions of sulfur
oxides ? If so, please provide the most recent data for a normal operating time period

. Please include a description of the locations of sampling (reference the schematic submitted in response to question 7) , sampling technique, duration of sampling, production rate during sampling, and potroom operations performed during the sampling. Yes, see enclosed report titled:

2 4

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

measure emissions of HF at the same time that TF samples were collected from the roof monitor? If so, please provide the most recent d ata for a normal operating time period. Please include a description of the locations of sampling (reference the schematic submitted in response to question 7), sampling technique, duration of sampling, production rate during sampling, and potroom operatio ns performed during the sampling.
NoEnclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

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

This document provides an overview of approved methods, target pollutant s and units of measure, and reporting requirements for the primary aluminum reduction source category. See Enclosure 3 for details about EPA’s authority under the Clean Air Act (CAA) section 114 (42 U.S.C. 7414) to request source emission test data. All recipients must complete and submit test
results by May 31, 2011

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

1

. 0 Sampling and Chemical Analysis Procedures an d Methods for M etallic HAP (including speciated hexavalent chromium)

2.0 How to Report Data

3.0 How to Submit Data

4.0 Co ntact Information for Questions on Test Plan and Reporting

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

1.1 Sampling

- Bag House and Electrostatic Precipitator (ESP) Particulate Matter

Sample and analyze representative particulate matter (e.g. in the hoppers) collected by each of the bag houses or ESP used to control particulate matter emissions from primary aluminum potlines. In cases where solids from different compartments of a single bag
house or ESP are collected in multiple hoppers or multiple collection sacks, a single composite sample will be adequate. Also, if multiple potlines of the same type (e.g. HSS, SWPB, CWPB1, etc.) are supplied with alumina from the same alumina storage vessel, sampling of representative particulate matter from the bag house or ESP associated with one of those potlines will be adequate. Sampling should be conducted once per day for five consecutive operating days with a clean uncontaminated scoop or similar apparatus

. A ll samples collected should be the approximately the same weight and stored in a clean
air

- tight container.

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

- 95/141), which is available through the following link:

htt p://www.epa.gov/tio/download/char/sf_rep_samp_guid_soil.pdf

1.2 Sampling

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

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

, an d any aqueous blowdown stream discharged from the wet scrubber. If a separate stream of scrubber blowdown is discharged from the scrubber, collect a representative grab sample of this stream. Also, if multiple potlines of the same type (e.g. HSS, SWPB, CWP B1, etc.) are supplied with alumina from the same alumina storage vessel, sampling of representative scrubber sludge, injected slurry (if applicable), and any aqueous blowdown stream from the wet scrubber associated with one of those potlines will be adequ ate. Sampling should be conducted once per day for five consecutiveEnclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

- April 22 , 2011 Page 2 of 3 operating days. All samples collected should be the approximately the same weight or
volume and stored in a clean container.

1.3 Chemical Analysis

Analyze each sample of bag house or electrostatic precipitator particulate matter, scrubber sludge , injected slurry (if any), and scrubber blowdown (if any) for individual
HAP metals as listed in Table 1 .1. Also analyze each sample for hexavalent chromium

. Methods for chemical a nalysis are given in Table 1 .2.

Table 1.1 HAP Metals

Antimony Arsenic Beryllium

Cadmium Chromium Hexavalent Chromium

Cobalt Lead Manganese

Nickel Selenium

Table 1.2 Methods for Analysis of Samples

Analyte Procedure

HAP metals listed
in Table 1.1 EPA Method 3051A digestion followed by ICP

- MS
as detailed in EPA Method 6020

Hexavalent
chromium EPA Method 3060A and EPA Method 218.6:
Extraction and Cr +6 Ion Chromatography

2.0 How to Report Data

2.1 Reporting Bag House or Electrostatic Precipitator Particulate Matter
, Wet Scrubber Sludge, Injected Slurry, and Discharge Water Chemical Analyses

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

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

2.2 Calculating and Reporting Values Measured Below Method Detec tion Levels

See Appendix C

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

.Enclosure 2

Primary Aluminum Reduction Section 114 Enclosure 2

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

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

• E

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

.

• If the files are too large for your e

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

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

If you are submitting CBI, you must mail a separate CD or DVD containing only the CBI

po rtion of your data to the EPA address shown in your Section 114 letter.

4.0 Contact Information for Questions on Test Plan and Reporting

For questions on the primary aluminum source category , contact:

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

- 2016 putney.david@epa.gov

OR

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

- 1390 boyd.rochelle@epa.gov

For questions on the test methods contact:

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

- 2406 garwood.gerri@epa.gov

OR

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

- 5225 merrill.raymond@epa.gov

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

Mark Bahner (RTI, International) (919) 541

- 6016 bahner@rti.orgAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

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

acf actual cubic feet
acfm actual cubic feet per minute

acm actual cubic meters

acmm actual cubic meters per minute
ADL above detection level
APC air pollution control
ASTM American Society for Testing and Materials

atm atmospheres (unit of pressure)
BDL below detection le vel
Btu/hr British thermal units per hour
Btu/scf British thermal units per standard cubic foot
CAA Clean Air Act
CARB California Air Resources Board
CBI confidential business information
CEMS continuous emission monitoring system
CFR Code of Federal Regulations
CO carbon monoxide
COS carbonyl sulfide
Cr chromium
CS 2 carbon disulfide
CTM Conditional Test Method day/yr days per year
°C degrees Celsius
°F degrees Fahrenheit
D/F dioxins and furans
DLL detection level limited
dscf dry standard cubic feet
dscfm dry standard cubic feet per minute
dscm dry standard cubic meters
dscmm dry standard cubic meters per minute
EPA U.S. Environmental Protection Agency
ERT Electronic Reporting Tool
E SP electrostatic precipitator
ft foot or feet
ft 2 square feet
ft 3 cubic feet fpm feet per minute (acfm divided by ft 2 of filter area) fps feet per second gal gallon

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

g gram HAP hazardous air pollutants
HCl hydrogen chloride
HCN hydrogen cyanide
HF hydr ogen fluorideAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

- April 2 2 , 2011 Page 2 of 3 Hg mercury hr hour or hours hr/day hours per day
ICR information collection request
in inch or inches
in

. H 2 O inches of water (pressure drop) kg kilogram
kPa kilopascals
kv kilovolt
kw

- hr kilowatt hour
lb pound lb/day pounds per day lb/gal pounds per U.S. gallon
lb/hr pounds per hour
lb/ton pounds per ton

m meter

m 3 cubic meters
MACT maximum achievable control technology
min minute or minutes Mg megagram
mg milligram mg/kg milligram per kilogram mg/l milligrams per liter
MM btu/hr millions o f British thermal units per hour
MM scf millions of standard cubic feet
MM lb/yr million pounds per year μg/m 3 microgram per cubic meter

μm micrometer
NAICS North American Industry Classification System
NaOH sodium hydroxide
NESHAP National Emission Standards for Hazardous Air Pollutants
NO
x nitrogen oxides OAQPS Office of Air Quality Planning and Standards
OTM Other Test Method
PAH polynuclear aromatic hydrocarbon
PAL primary aluminum reduction facility pdf Image file format produced with Adobe© or s imilar software
PM particulate matter
PM 10 particulate matter that is 10 micrometers or less in diameter
PM 2.5 particulate matter that is 2.5 micrometers or less in diameter
POM polycyclic organic matter

ppmv parts per million by volume

ppmw parts per million by weight
RATA Relative Accuracy Test Audit
% percent

s second or seconds
scf standard cubic feet
scf/hr standard cubic feet per hourAPPENDIX A

Primary Aluminum Reduction Section 114 Appendix A

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

scm standard cubic meters
SO 2 sulfur dioxide
SPPD Sector Policies and Programs Division
SS start

- up or shutdown
TCLP toxicity characteristic leaching procedure
TF total fluorides
THC total hydrocarbons tpd tons (short) per day tph tons (short) per hour tpy tons (short) per year
TSP total suspended particulate vol% volume percent, o r percent by volume
wt% weight percent, or percent by weight

yr year

To convert from To Multiply by
°C °F multiply by 1.8, then add 32

°F °C subtract 32, then multiply by 0.556
ft m 0. 3 048
ft/min m/min 0. 3 048
ft 2 m 2 0.0929
ft 3 m 3 0.028

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

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

. H 2 O mm H 2 O 25.4 kg/hr lb/hr 2.205
lb g 454
lb gr 7000
lb/ft 3 g/m 3 16,000
lb/hr kg/hr 0.454

m ft 3.28
m/min ft/min 3.28

mm H 2 O in H 2 O 0.0394

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

m 3 ft 3 35.31 Mg ton 1.1 ton (short) Mg 0.907APPEND IX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 1 of 5 

### List of Hazardous Air Pollutants (HAP )

CAS
Number Chemical Name

Antimony Compounds Arsenic Compoun ds (inorganic including arsine) Beryllium Compounds Cadmium Compounds Chromium Compounds Cobalt Compounds
Coke Oven Emissions Cyanide Compounds 1 Glycol ethers 2 Lead Compounds Manganese Compounds Mercury Compounds
Fine mineral fibers 3 Nickel Compounds Polycylic Organic Matter 4 (Report individual polycyclic aromatic hydrocarbons by CAS number). Radionuclides (including radon) 5 Selenium Compounds
75

- 07

- 0 Acetaldehyde
60

- 35

- 5 Acetamide
75

- 05

- 8 Acetonitrile
98

- 86

- 2 Acetophenone
53

- 96

- 3 2

- Acetylaminofluorene
107

- 02

- 8 Acrolein

79

- 06

- 1 Acrylamide
79

- 10

- 7 Acrylic acid
107

- 13

- 1 Acrylonitrile
107

- 05

- 1 Allyl chloride

92

- 67

- 1 4

- Aminobiphenyl
62

- 53

- 3 Aniline
90

- 04

- 0 o

- Anisidine
1332

- 21

- 4 Asbestos
71

- 43

- 2 Benzene (including benzene from gasoline)
92

- 87

- 5 Benzidine
98

- 07

- 7 Benzotrichloride
100

- 44

- 7 Benzyl chloride

92

- 52

- 4 Biphenyl
117

- 81

- 7 Bis(2

- ethylhexyl)phthalate (DEHP)
542

- 88

- 1 Bis(chloromethyl)ether

75

- 25

- 2 Bromoform
106

- 99

- 0 1,3

- Butadiene
156

- 62

- 7 Calcium cyanamideAPPEND IX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 2 of 5 CAS
Number Chemical Name

133

- 06

- 2 Captan

63

- 25

- 2 Carbaryl
75

- 15

- 0 Carbon disulfide
56

- 23

- 5 Carbon tetrachloride
463

- 58

- 1 Carbonyl sulfide
120

- 80

- 9 Catechol
133

- 90

- 4 Chloramben

57

- 74

- 9 Chlordane
7782

- 50

- 5 Chlorine
79

- 11

- 8 Chloroacetic acid
532

- 27

- 4 2

- Chloroacetophenone
108

- 90

- 7 Chlorobenzene
510

- 15

- 6 Chlorobenzilate

67

- 66

- 3 Chloroform
107

- 30

- 2 Chloromethyl methyl ether
126

- 99

- 8 Chloroprene
1319

- 77

- 3 Cresols/Cresylic acid (isomers and mixture)
95

- 48

- 7 o

- Cresol
108

- 39

- 4 m

- Cresol
106

- 44

- 5 p

- Cresol

98

- 82

- 8 Cumene
94

- 75

- 7 2,4

- D, salts and esters
3547

- 04

- 4 DDE

334

- 88

- 3 Diazomethane
132

- 64

- 9 Dibenzofurans

96

- 12

- 8 1,2

- Dibromo

- 3

- chloropropane
84

- 74

- 2 Dibutylphthalate
106

- 46

- 7 1,4

- Dichlorobenzene(p)

91

- 94

- 1 3,3

- Dichlorobenzidene
111

- 44

- 4 Dichloroethyl ether (Bis(2

- chloroethyl)ether)
542

- 75

- 6 1,3

- Dichloropropene

62

- 73

- 7 Dichlorvos
111

- 42

- 2 Diethanolamine
121

- 69

- 7 N,N

- Diethyl aniline (N,N

- Dimethylaniline)

64

- 67

- 5 Diethyl sulfate
119

- 90

- 4 3,3

- Dimethoxybenzidine

60

- 11

- 7 Dimethyl aminoazobenzene
119

- 93

- 7 3,3'

- Dimethyl benzidine

79

- 44

- 7 Dimethyl carbamoyl chloride
68

- 12

- 2 Dimethyl formamide
57

- 14

- 7 1,1

- Dimethyl hydrazine
131

- 11

- 3 Dimethyl phthalate

77

- 78

- 1 Dimethyl sulfate
534

- 52

- 1 4,6

- Dinitro

- o

- cresol, and saltsAPPEND IX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 3 of 5 CAS
Number Chemical Name

51

- 28

- 5 2,4

- Dinitrophenol
121

- 14

- 2 2,4

- Dinitrotoluene
123

- 91

- 1 1,4

- Dioxane (1,4

- Diethyleneoxide)
122

- 66

- 7 1,2

- Diphenylhydrazine
106

- 89

- 8 Epichlorohydrin (l

- Chloro

- 2,3

- epoxypropane)
106

- 88

- 7 1,2

- Epoxybutane
140

- 88

- 5 Ethyl acrylate
100

- 41

- 4 Ethyl benzene

51

- 79

- 6 Ethyl carbamate (Urethane)
75

- 00

- 3 Ethyl chloride (Chloroethane)
106

- 93

- 4 Ethylene dibromide (Dibromoethane)
107

- 06

- 2 Ethylene dichloride (1,2

- Dichloroethane)
107

- 21

- 1 Ethylene glycol
151

- 56

- 4 Ethylene imine (Aziridine)

75

- 21

- 8 Ethylene oxide
96

- 45

- 7 Ethylene thiourea
75

- 34

- 3 Ethylidene dichloride (1,1

- Dichloroethane)
50

- 00

- 0 Formaldehyde
76

- 44

- 8 Heptachlor
118

- 74

- 1 Hexachlorobenzene

87

- 68

- 3 Hexachlorobutadiene

77

- 47

- 4 Hexachlorocyclopentadiene
67

- 72

- 1 Hexachloroethane
822

- 06

- 0 Hexamethylene

- 1,6

- diisocyanate
680

- 31

- 9 Hexamethylphosphoramide
110

- 54

- 3 Hexane
18540

- 29

- 9 Hexavalent chromium
302

- 01

- 2 Hydrazine
7647

- 01

- 0 Hydrochloric acid
7664

- 39

- 3 Hydrogen fluoride (Hydrofluoric acid)

123

- 31

- 9 Hydroquinone

78

- 59

- 1 Isophorone
58

- 89

- 9 Lindane (all isomers)
108

- 31

- 6 Maleic anhydride

67

- 56

- 1 Methanol
72

- 43

- 5 Methoxychlor
74

- 83

- 9 Methyl bromide (Bromomethane)
74

- 87

- 3 Methyl chloride (Chloromethane)
71

- 55

- 6 Methyl chloroform (1,1,1

- Trichloroethane)
60

- 34

- 4 Methyl hydrazine
74

- 88

- 4 Methyl iodide (Iodomethane)
108

- 10

- 1 Methyl isobutyl ketone (Hexone)
624

- 83

- 9 Methyl isocyanate

80

- 62

- 6 Methyl methacrylateAPPEND IX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 4 of 5 CAS
Number Chemical Name

1634

- 04

- 4 Methyl tert butyl ether

101

- 14

- 4 4,4

- Methylene bis(2

- chloroaniline)

75

- 09

- 2 Methylene chloride (Dichloromethane)
101

- 68

- 8 Methylene diphenyl diisocyanate (MDI)
101

- 77

- 9 4,4'¬

- Methylenedianiline

91

- 20

- 3 Naphthalene
98

- 95

- 3 Nitrobenzene
92

- 93

- 3 4

- Nitrobiphenyl
100

- 02

- 7 4

- Nitrophenol

79

- 46

- 9 2

- Nitropropane
684

- 93

- 5 N

- Nitroso

- N

- methylurea

62

- 75

- 9 N

- Nitrosodimethylamine
59

- 89

- 2 N

- Nitrosomorpholine
56

- 38

- 2 Parathion
82

- 68

- 8 Pentachloronitrobenzene (Quintobenzene)
87

- 86

- 5 Pentachlorophenol
108

- 95

- 2 Phenol
106

- 50

- 3 p

- Phenylenediamine

75

- 44

- 5 Phosgene
7803

- 51

- 2 Phosphine
7723

- 14

- 0 Phosphorus
85

- 44

- 9 Phthalic anhydride
1336

- 36

- 3 Polychlorinated biphenyls (Aroclors)
1 120

- 71

- 4 1,3

- Propane sultone
57

- 57

- 8 beta

- Propiolactone
123

- 38

- 6 Propionaldehyde
114

- 26

- 1 Propoxur (Baygon)

78

- 87

- 5 Propylene dichloride (1,2

- Dichloropropane)
75

- 56

- 9 Propylene oxide
75

- 55

- 8 1,2

- Propylenimine (2

- Methyl aziridine)
91

- 22

- 5 Quinoline
106

- 51

- 4 Quinone
100

- 42

- 5 Styrene

96

- 09

- 3 Styrene oxide
1746

- 01

- 6 2,3,7,8

- Tetrachlorodibenzo

- p

- dioxin
79

- 34

- 5 1,1,2,2

- Tetrachloroethane
127

- 18

- 4 Tetrachloroethylene (Perchloroethylene)
7550

- 45

- 0 Titanium tetrachloride

108

- 88

- 3 Toluene

95

- 80

- 7 2,4

- Toluene diamine
584

- 84

- 9 2,4

- Toluene diisocyanate

95

- 53

- 4 o

- Toluidine
8001

- 35

- 2 Toxaphene (chlorinated camphene)

120

- 82

- 1 1,2,4

- TrichlorobenzeneAPPEND IX B

Primary Aluminum Reduction Section 114 Appendix B

- April 2 2 , 2011 Page 5 of 5 CAS
Number Chemical Name

79

- 00

- 5 1,1,2

- Trichloroethane
79

- 01

- 6 Trichloroethylene
95

- 95

- 4 2,4,5

- Trichlorophenol
88

- 06

- 2 2,4,6

- Trichlorophenol
121

- 44

- 8 Triethylamine
1582

- 09

- 8 Trifluralin

540

- 84

- 1 2,2,4

- Trimethylpentane
108

- 05

- 4 Vinyl acetate
593

- 60

- 2 Vinyl bromide

75

- 01

- 4 Vinyl chloride
75

- 35

- 4 Vinylidene chloride (1,1

- Dichloroethylene)
1330

- 20

- 7 Xylenes (isomers and mixture)
95

- 47

- 6 o

- Xylenes
108

- 38

- 3 m

- Xylenes
106

- 42

- 3 p

- Xylenes

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

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

2: Includes mono

- and di

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

- (OCH2CH2)n

- OR' where :

n = 1, 2, or 3

R = alkyl or aryl groups

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

R

- (OCH2CH)n

- OH. Polymers are excluded from the glycol category. Also excludes ethylene glycol monobutyl ether (EGBE) (2

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

- 76

- 2) and s urfactant alcohol ethoxylates and their derivatives (SAED).

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

micrometer or less.

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

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

Primary Aluminum Reduction Section 114 Appendix C

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

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

• BDL (below detection level)

– all analytical values used to calculate and report a fabric filter particulate matter, electrostatic precipitator particulate matter, sludge, or scrubber blowdown metal analysis are less than the laboratory’s reported detection le vel(s);

• DLL (detection level limited)

– at least one

, but not all

, values used to calculate and report a fabric filter particulate matter, electrostatic precipitator particulate matter, sludge, or scrubber blowdown metal analysis are less than the laboratory’s reported detection level(s); or

• ADL (above detection level)

– all analytical values used to calculate and report a fabric filter particulate matter, electrostatic precipitator particulate matter, sludge, or scrubber blowdown metal analysis are greater than the laboratory’s reported detection level(s).

For each reported emissions value, insert the appropriate flag (i.e. BDL, DLL, or ADL) in
the Note line of the Microsoft® Excel emission test spreadsheet template.

When reporting and calculating individual test run data:

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

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

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

− Report the calculated emissions concentration or rate result as a bracket ed “less than” detection level value (e.g., [<0.0105]) in the Microsoft® Excel emission test spreadsheet template

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

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