Final December 2010

STAH OF WASI-IINGTON 

## DEPARTMENT OF ECOLOGY PO lJox 47600 o Olympia, WA 911504-760() o 3MJ-,W7-GOOO 711 fur Wasllinglou /lelify Service o Persons 

### with ,, speech 

### clis,,bi/ity c,m ca/11177-1133-63·11



### November 9, 2010



## Mr. 

## BatTy Hullett Alcoa Intalco Works 4050 Mountain View Road Ferndale, 

## WA 98248-0937
Dear Mr. Hullett: 

### Regionnl Haze Best Avnilnble RetrofitTechnology (BART) Detcrrnination Best Available Retrofit Technology (BART) is required to reduce the regional haze hnpacts of emissions ofyour facility. The enclosed Order#7837, Revision 1, contains our BART determination for your facility including a schedule for compliance. This revision is in response to a request by the company to repeat the emission limitation, monitoring, recordkeeping, and reporting requirements contained in OrderNo. DE02AQIS-3967 rather than incorporating them by reference. Ifyou have questions or requests relating to this order, please contact Alan Newman at (360) 407-6810 or alan.ne\vman@ecy.wa.gov. Sincerely,

# ~bb JeffJohnston, 

## Ph.D. Manager, Science and Engineering Section Air Quality Program JJ/lb Enclosure

cc: Kathym Mitchell, Intalco Ferndale Alan Newman, Ecology Rick Graw, USFS Portland James Jones, EHS Services North America Judy Schwieters, Industrial Section John Bunyak, National Park Service

### _ STATEOFWASI-lTNGTON

. DEPARTMENT OFECOLOGY Final December 2010



### IN EMATTEROFAN ] ADM STRA**TIV~** 

### ORDERAGAINST: ] 

### ] ] 

# ---------T------------------] TO: Mr. Barry Alcoa Intalco orks 4050 Mountain 'ewRoad Ferndale, WA 982 -0937 This is an Administrative Orde equiring your company comply with WAC**173-400~** 

### 151 by taking the actions that are describ below. Chapter 70 4 RCW authorizes the Washington State Department ofEcology's Air ality Progran1 cology) to issue Administrative Orders to require compliance**~th** 

### the requireme is ofChapt 70.94 RCW and regulations issued to itnplement it. · Ecology has determined that portions ofyou cility are subject to the provisions ofthe federal and state visibility protection program (W C 1 -400-151 and 40 CFR Part 51, Subpart**P)~** 

### The rules require that the State determine w t techno

### I ies and level ofemission control constitutes Best Available Retrofit Techilology ( T) 

### for the ·gible emissionunits at your facility.
FINDINGS
A. 

### elter facility subject to BART. 

## B. The BART-eligible e ission units at Intalco are the three potlin , anode bake furnace, 13 aluminum holding aces, material handling and**trru~~fer** 

### operatl s, and a number ofsmall miscellaneous

. C. Emissions fr m 

### existing BART units are· controlled by:

a. Use six existing primary control systems each consisting ofa dry almnin injection sy em**follow~d** 

### by a baghouse for the prin1ary control ofPM and fluoride em· sions from

epotline buildings

.

. Use ofa series of 159 wet roofscrubbers to control secondary PM and fluoride ernlss

from the potline buildings.

c. Use ofa dry alwnina injection syste1n followed by a baghouse for control ofPM and fluoride emissions from the Anode Bake Furnace.

L- 89

## Alcoa Intalco Works BART Compliance Order#7837, Revision 1 J ly 7, 2010

fsulfur content limitations to limit 

# so2 emissions due to th tion ofanodes. Final December201 0



## Page 2 of4

e. Use ofbaghou s and fabric filters to control PM en1is · ns fr01n various Material Handling and Trm er Operations throughout the f ity. D. Ecology has determined that requirementsofBART. currently installed at Intalco meet the



## E.

F. On July 29,2010 Intalco re ested the original BA a. Incorporate the speci emission limitations, tnonito · g and reporting requirements contained in Orde E02AQIS-3967 rather than incorpo e that order and its requirements reterence as done in the original version of ·s order, and ecific NOx emission rates, especially a revised N

. emission rate for the used on recent source test information. Additio Iinformation and analysis is available in the BART Determination Supp Document for coa lntalco Works, Ferndale, Washington, prepared by the Washington State De ment**~cology,** 

## and the BART Determination for Alcoa Intalco Works Ferndale, Washington, prepared by ENVIRON Corporatioh on behalfofAlcoa Intalco Works, November 2007. YOU ARE ORDERED: To operate existing emission control equipment in accordance with the following conditions: 1. BART Emission Litnitations are contained in the tables contained in Attaclunent Ato this Order.

2. Schedule for Compliance 2.1. Compliance with the emissionlin1itations for particulate n1atter, nitrogen oxides, and sulfur dioxide is required upon the effective date ofthis Order. 3. Monitoring and Rccordkeeping, Requirements are contained in Attachn1ent A to this Order 4. Recordkeeping Requirements

L- 90

### Alcoa Intalco Works BART Compliance Order #7837, Revision 1 July7,2010 Final December 2010



### Page 3 of4

4.1. Intalco shall submit a monthly air monitoring report which contains the respective results ofthe monitoring required in the conditions ofthis order. The report shall be submitted within 30 days ofthe end ofeach calendar month. Intalco shall report the data in a format that will allow a comparison ofall the data to the respective emission limits. The fonnat shall include a table which summarizes the required source tests conducted during that tnonth and the dates when they were completed. Intalco shall submit the results ofsource tests to Ecology in the air monitoring report tor the month that the results are received by Intalco. This reporting requirement applies to all Conditions in Attachment A ofthis Order.

·ailure to comply with this Order may result in the issuance ofcivil penalties or other acf wfi 1er administrative orjudicial, to enforce the tem1s ofthis Order. ight to appeal this Order. To appeal you must:

• File your a eal with the Pollution Control Hearing Board with' 30 days ofthe "date of receipt" ofthi ocument. Filing means actual receipt by th oard during regular office hours.

• Serve your appeal on the mtment ofEcology 1thin 30 days ofthe "date ofreceipt" ofthis document. Service rna be accomplis by any ofthe procedures identified in WAC 371-08-305(10). "Date o · eipt" · defined at RCW 43.218.001(2). Ifyou appeal, you must:

• Include a copy ofthis docu ent with your Notic 

### f Appeal. • Serve and file your apR**~** 

### in paper form; electronic

e Pollution Control Hearing Board:

The P ution Control Hearings Board P

..Box 40903 OR

lympia, W A 98504-0903 The Pollution Control Hearing 4224-6th Avenue SE Rowe Six, Lacey, WA 98503 To serve your appeal on the Department ofEcology:

·l- 91

### Alcoa Intalco Works BART Compliance Order #7837, Revision 1 July 7, 2010

Depart nt ofEcology Appeals C rdinator P.O. Box47 Olympia, WA 9 04-7608 And send a copy ofyou AlanNewman Department ofEcology Air Quality Progran1 P.O. Box 47600 Olympia, W A 98504-7600
For additional infonnation, go to the Enviro http://www.eho.wa.gov. OR Final December 2010



### Page 4 of4

Deliver your appeal in person to· Department ofEcology Appeals Coordinator 300 Desmond Drive Lacey, WA 98503

e Legislator website at

Your appeal alone will not st the effectiveness ofthis Order. ay requests must be submitted in accordance with RCW 4 .21B.320. These procedures are consi nt with Chapter 43.218 RCW.
y of

## Nove~r, 20 

# 1'0 at Olyn1pia, Washington.

Ma ger, Science and Engineering Section partment ofEcology Air Quality Program

L- 92r-



## . co w 

### AttachmentA BARTEmission limitations, Monitoring, Recordkeeping and Reporting Requirements Approval Process Area Pollutant Emission limit l\1onitoring and Recordkeeping Condition requirements 

### PlantWide Limitations AI Plantwide Natural Nitrogen oxides 341 lb/day, calendar Intalco shall demonstrate compliance by gas Usage (not (NOx month average using the following equation: including Bake furnace) Natural gas NOx from sources excluding the Bake Ovens and the Remelt Furnace

### = Plantwide natural gas - bake oven natural gas - remelt natural gas 

### Intalco shall maintain a record ofnatural

# 

### gas usage at the plant. Records maintained shall be sufficiently complete to quantify natural gas used in the bake furnace and remelt furnace. Natural gas usage shall be converted to a calendar month average NOx emission rate through the use ofan Ecology specified emission factor of 140 lb/I.Ox1 06scfof natural gas. A2 Plantw.ide 

## so2 Sulfur dioxide Comply with the emission a. Intalco shall conduct source tests upon Emissions (S0

## 2 ) limitation contained in Ecology'srequest using EPA RM 6 per40 WAC 173-415-030(5); CFRPart 60, Appendix A, or another EPA Total emissions ofS02 approved method. from all emissions units b. Intalco shall determine total facilityshall not exceed thirty wide S02 emissions by summingthe S02 grams ofsulfur dioxide genez:ated from the potlines, the anode perkilogram ofaluminum bake**~lVens** and natural gas usage. lntalco produced on a shall calculate S02 emissions from the monthly average (sixty potlines, anode bake ovens, and paste plant pounds perton of by using the following mass balance aluminum produced). equations and information: Reporting requirements

30 days after the end ofeach calendar month

30 days afterthe end ofeach calendarmonth or, for source tests, 30 days afterthe end of the month the source test report is received by Jntalco



### --- ·--·--- ------·----<--------r 

### Alcoa lntalco Works BART Compliance Order#7837, Revision 1 July 7, 2010

Approval Process Area Pollutant Condition



### Miscellaneous Materials Handling systems A3 Unspecified PM emission units Emission limit

Meet the more restrictive applicable emission. limitation contained in 

## • WAC 173-400-060, or 

## • WAC 173-415- 

### Page2 of4

Monitoring and Recordkeeping Reporting requirements requirements Total S0

## 2 =RawMaterial S0

## 2 (Coke and Pitch) +Natural Gas 

## so2 Raw material 

## so2 (coke and pitch) will be determined by using the following mass balance equation: Coke and Pitch S0

## 2 = (total Pet coke weight %S) + (total pitch weight %S) + (total packing coke weight %S)- (COS x 64/60) Carbon consumption ratio is pounds of carbon consumed perpounds ofAluminum produced. Intalco shall assume 95% ofthe sulfur in green anodes is converted to

## so2 and 5% is converted to COS (Carbonyl Sulfide). Intalco shall calculatethe 

## so2 generated bynatural gas combustion using an Ecology approved emission factor.

Intalco shall conduct source tests upon 30 days after the end ofthe Ecology'srequest usingEPA RM 5 per40 month the sourcetestreport CFR60, Appendix A, The test**m~thod** is received by Intalco. required to demonstrate compliance with an applicable particulate mattercontrol requirement of40 CFRPart 63 SubpartI 

### Alcoa 

### In talco Works BART Compliance Order#7837, Revision 1 July 7, 2010

Approval Process Area Pollutant Condition

A4 Autogenous Mill PM -Unit#209



### Aluminum Production A5 Aluminum Production Limit

A6 Potline Primary Operational and Secondary limits Control Systems Emission limit 030(2), or 

## • 40 CFR Part 63, Subpart RRR Emissions ofPM shall not exceed 5.0 tons ofPM per year AND Emissions ofPM shall not exceed 0.01 grains per dscf.

Net potline production of Aluminum shall be**l~mited** to**~307,000** tons ofaluminum per calendar year.

The following limits shall not be exceeded : Operating 

### < 720 pots/day 

### S 3.0 % sulfur in coke 

### S 0.6% sulfur in pitch 

### :S 150,000 amps ofcurrent 

### S 0.4250 carbon consumption ratio (pounds ofcarbon consumed per pound of Aluminum produced) 

### Page 3 of4

Monitoring and Recordkeeping Reporting requirements requirements RRR, or another EPA approved method.

Intalco shall conduct source tests once 30 days after the end ofthe every 5 years and upon Ecology's request month the source test report using EPA RM 5 per40 CFR 60, is received by Intalco. Appendix A, or another EPA approved method.

Intalco shall maintain a record ofthe daily 30 days afterthe end ofeach net production ofaluminum and report the calendar month average daily net aluminum production in the monthly air monitoring. Net production ofaluminum is the total mass ofmolten metal produced from tapping all pots in all operating potlines, measured at the casthouse scales and the rod shop scales 

### Intalco shall maintain a record ofthe data 30 days after the end ofeach co1lected for the parameters listed below, calendar month compute the monthly average, and report the monthly average (unless another average is noted below) for each parameter in the monthly air monitoring report submitted to Ecology: 

## • Number ofpots operated per day (potdays) 

## • Percent sulfur in pitch (Intalco shall

### ·Alcoa Intalco \Vorks BART Compliance Order #7837, Revision I 

## July 7, 2010

Approval Process Area Pollutant ·condition



# I A7 Particulate (PM) Emission limit

Emissions ofPM shall not exceed a combined total of5050 pounds per day (calculated on a monthly average) from the potlines (primary and secondary control systems) and the bake ovens AND Emissions ofPM shall not exceed a combined total of6.0 pounds perton of aluminum (calculated on a three month average) produced from the potlines (primary and secondarycontrol systems) and the bake ovens 

### Page 4 of4

Monitoring and Recordkeeping Reporting requirements requirements analyze each incoming load orbatch ofpitch for sulfur content using the proce4ures in ASTM D4239 or other ASTM sulfur methods) 

## • Percent sulfur in coke (Intalco sha11 analyze each incoming load orbatch ofcoke for sulfur content using the procedures in ASTM D4239 or other ASTM sulfur methods) 

## •**Carb~n** consumption ratio as a daily average computed monthly 

## • Amperes ofcurrent Unless a different testing schedule is 30 days after the end ofeach 

# I contained in an Ecology approved Air calendar month Monitoring Plan, Intalco shall.determine PM emissions by testing the primary and secondary control systems and the bake furnace using the following methodology: Primary control system: Intalco shall test 4 cells (J run/cell) per month per potline (2 cells from each ofthe 2 baghouse centers) for a minimum of5 hours using EPA RM 5 per40 CFR Part 60 Appendix A, Alcoa method B-54, oranother EPA approved method. Secondary control system: lntalco shall test three roofscrubbers simultaneously (I run/test) three times permonth per potline using EPA RM 5 per40 CFR Part 60 Appendix A, Alcoa method B-54b, or

### Alcoa Intalco Works BART Compliance Order#7837, Revision I July 7, 2010

Approval Process Area Pollutant Condition

A8 Sulfur dioxide (S02) Emission limit

Emissions ofS0

## 2 shan not exceed 37, 780 pounds perday 

### Page 5 of4

Monitoring and Recordkeeping Reporting requirements requirements another EPA approved method. Bake Ovens: lntalco shall conduct a source test (3 runs/source test) once peryear and upon Ecology's request using EPA 

### RM 5 per40 CFR Part 60 Appendix A Intalco shall determine the 

## so2 emitted Intalco shan report the

by using the following formula: 3monthly average ofpounds



## so2 emissions in lbs. /day 

### = of

## so2 per day in each month .30 days afterthe end ofeach (carbon consumption ratio) calendar month (2000 pounds Aluminum per ton) x (% sulfur in baked anodes/I00) x (% S converted to S021100) x (2 lb sulfur dioxide per lb sulfur)x (Tons ofAluminum permonth)/ days permonth. Carbon consumption ratio is pounds of carbon consumed perpoW1d ofAluminum. Percent sulfurin baked anode material (Jntalco shall analyze baked anode material for sulfur content using the procedures in ASTM D4239 or other ASTM sulfur methods). %S converted to S02 is 95% Intalco shall report the monthly average of pounds ofS02 per day. Intalco shall maintain records ·ofr I <0 (X) 

### Alcoa Intalco Works BART Compliance Order#7837, Revision 1 July 7, 2010

Approval Process Area Pollutant Condition

A9 Sulfur dioxide (S0

## 2 )

AIO Nitrogen oxides (NOx) Emission limit

Emissions ofS0

## 2 shall not exceed 44.8 pounds perton ofaluminum produced (calculated on a three month average).

Emissions ofNOx shall not exceed 219 pounds per day (calculated on a one month average). 

### Page 6 of4

Monitoring and Recordkeeping Reporting requirements requirements production data used to develop carbon consumption ratio and tons ofaluminum produced. Intalco shall provide the records to Ecology upon request

Intalco shall determine the S02 lntalco shall report the 3 emitted by using the following month average ofpounds of fonnula: 

## so2 perton ofaluminum 

## so2 emissions 

### in Jbs. /month = produced 30 days after the end ofeach calendarmonth (carbon consumption ratio) (2000 pounds Aluminum per ton) x (% sulfur in baked anodes/100) 

## * (% S converted to S02/1 00) x (2 lb sulfur dioxide per lb sulfur)x(Tons of Aluminum permonth) Carbon consumption ratio is pounds ofcarbon consumed per pound ofAluminum. Percent sulfur inbaked anode material (Intalco shall analyze baked anode material for sulfur contentusing the procedures 

### in ASTM 04239 orother ASTM sulfur methods)

.. %S converted to S0

## 2 is 95% Intalco shall determine plant wide 30 days afterthe end ofeach emissions ofNOxbyusing the plant calendarmonth specific emission factor ofD.26 lb NOx/ton ofAluminum produced.r I co co 

### Alcoa Intalco \Vorks BART Compliance Order#7837, Revision 1 July 7, 2010

Approval Process Area Pollutant Condition 

### Anode Production and Baking All Green Carbon PMJO Pitch Fume Treatment System

Al2 Anode Baking Nitrogen oxides (NOx) Emission limit

Emissions ofPM 1 0 shall riot exceed 2.36 lb/hour

933 lb/calendar day, 30 day average 

### Page 7 

### of4

Monitoring and Recordkeeping Reporting requirements requirements
lntalco shall conduct a source test once 30 days after the end ofthe every two years and upon Ecology's month the source testreport request using EPA RM 5 per40 CFR Part is received by Intalco. 60, Appendix A, or another EPA approved method. Intalco can reduce monitoring frequencies ifeach ofthree consecutive source tests demonstrates that the emission rate is< 75% ofthe applicable limit. lntalco shall resume the original source testing frequency any time a source test demonstrates emissions have increased above 75% ofthe applicable limit. Intalco shall submit a letter notifying Ecology that the monitoring frequency will be reduced. The notification shall demonstrate the justification for the reduced monitoring frequencv and schedule. lntalco shall determine NOx 30 days afterthe end ofthe emissions from its anode baking month the source test report furnace operation by multiplying is received by Intalco. the Ecology approved sitespecific emission factor of2.02 lbs ofNOx perton ofbaked anodes times the tons ofbaked anodes produced during the month divided by the number of operating days during the month. Intalco shall report the monthly average ofpounds ofBaking

### .... 0 0 

### AlcoaIntalco \Vorks BART Compliance Order#7837, Revision 1 July 7, 2010

Approval Process Area Pollutant Condition

I 

# I

Metal Products Area A13 Remelt Furnace Nitrogen oxides (NOx)

\ Emission limit

NOx emissions shall not exceed: 5.72 tons for the most 

### I recent 12-monthperiod or

0.48 tons for any single month or 32 lb/calendar day, 30 day average. Remelt furnace NOx is , also included in plantwide natural gas NOx emission limit 

### Page 8 of4

MonitoriJJ.g and Recordkeeping Reportingreq**uir~ments** requirements FurnaceNOx per day. 

# I

Baking Furnace NOx Equation: PoundsNOx 

## = day tons of Aluminum x 2.02lbNox month tonAL month x dayspermonth

Intalco shall detennine Remelt 30 days after the end ofeach Furnace NOx emission by the calendar month following method: Natural gas usage shall be converted to a calendar month average NOx emission rate through the use ofan Ecology specified emission factor of 0.048 tons NOx /l.OxI06scfofnatural gas. For each month Intalco shall report:



## • The volume ofnatural gas consumed during the month (l.Oxl06scf) 

## • The volume ofnatural gas consumed (I.OxI06scf) 

### in the most recent 12-month period 

## • The tons ofNOx emittedr 

### Alcoa Intalco Works BART Compliance Order#7837, Revision 1 

### July 7, 2010

Approval Process Area Pollutant Condition

Al4 Homogenization NOx 

# I Furnace

- Unit

#314 

## I

I Emission limit

Emissions ofNOx shall not exceed 83 ppm corrected to 3% oxygen. 

### Page 9 of4

Monitoring and Recordkeeping Reporting requirements requirements during the month, The total tons ofNOx emitted for the most recent 12-month period Intalco shall conduct an annual source test 30 days after the end ofthe on the furnace dUring full operation using month the source test report EPA RM 7E forNOx and RM 3A for is received by Intalco. Oxygen as per40 CFR Part 60, Appendix A, or another EPA approved method. lntalco can reduce the frequency ofsource testing to once every 5 years ifeach of three consecutive source tests demonstrates that the emission rate is < 75% ofthe applicable limit. Intalco shall resume the original source testing frequency any time a source test demonstrates emissions have increased above 75% ofthe applicable limit. Intalco shaiJ submit a letter notifYing Ecology that the monitoring frequency will be reduced. The notification shall demonstrate the justification for the reduced monitoring frequency andschedule. Intalco shall submit the notification to Ecology within 60 days after the last source test used to make the demonstration.