# Instructions The EPA secondary aluminum production test program requires emissions and other test data for several pollutants. EPA understands that you own one or more secondary aluminum production facilities. For at least one thermal chip dryer and at least one scrap dryer/delacquering kiln/decoating kiln that you own, you must perform a stack test for volatile and semi-volatile organic HAPs as specified in the letter and instructions accompanying this file. You should collect emissions samples for the identified pollutants downstream of the last relevant emissions control device (i.e., stack or other point representing the composition of the flue gases at the exit to the atmosphere), unless otherwise indicated. (Contact the EPA project lead for situations with multiple stacks or other complex emissions points for the unit.) Sample and analyze the particulate matter collected in the hopper from at least one bag house used to control particulate matter from each type of affected source subject to 40 CFR 63, subpart RRR at your secondary aluminum production facilities. Choose bag houses that are used to control particulate matter from each of the six different types of affected sources (i.e.group 1 furnaces, scrap shredders, chip dryers, scrap dryers/delacquering kilns/decoating kilns, dross only furnaces, and rotary dross coolers) if you have these controlled affected sources at your facilities. Where more than one bag house discharges solids to a common hopper, a single sample will be adequate. In cases where solids from different compartments of a single bag house are collected in multiple hoppers or multiple collection sacks, a single composite sample will be adequate. If you have a total of three or fewer bag houses at all of your facilities, sample and analyze particulate matter from all of them, even if they are controlling the same type of affected source. It is not necessary to conduct a stack test for multi-metals analysis.
Sample and analyze the lime used for injection to any of the lime-injected bag houses from which particulate matter samples were collected. If lime of the same type, obtained from the same supplier, is used for more than one lime injected bag house, a single sample will be adequate to represent the lime used in these bag houses.

You must report the results of these tests and chemical analyses in this Microsoft® Excel Emission Test Template. The Excel templates are specific to each type of pollutant. You must report the results of each test on the appropriately labeled worksheet corresponding to the specific tests and analyses conducted at your facilities. If more than one source was tested, you must make a copy of the worksheet and update the source ID in order to distinguish between each separate test of a chip dryer or scrap dryer/ delacquering kiln/decoating kiln at each facility and each different source of particulate matter. After completing the worksheet, you must also submit an electronic copy of the emission test report and the chemical analyses. (PDF format preferred).
Please refer to the cover letter of this packet (CAA section 114 letter) for additional testing information. Please note that you do not have to submit a test plan to EPA for approval prior to testing; however, we recommend that you prepare a test plan for your own use to assist in the planning and to verify that you address all of the testing and reporting requirements. You must follow all of the procedures as specified in the test methods, including the quality assurance and quality control measures, and document the results in any test report provided to EPA.**Facility Name and Address Unit Description**  **Process Unit ID Control Device ID** 

Custom Alloy, 13329 Ector Street, City of Industry, CA 91746 Scrap Dryer 1 (D9) Afterburner 1 (C9); Baghouse 3 (C23)

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **10/13/2010 10/13/2010**  **10/14/2010** Feed/Charge Rate 0.96 0.99 1.66 Mg/hr Afterburner Operating Temperature 1638 1640 1640 degree F

Type of Charge:Mixed Aluminum Borings

**Compound Volatile Organic HAP**  **Emission Rate Sample 1**

**(kg/hr) Volatile Organic HAP**  **Emission Rate Sample 1 (kg/Mg of feed/charge)** **Volatile Organic HAP Emission Rate Sample**  **2 (kg/hr) Volatile Organic HAP** 

**Emission Rate Sample 2 (kg/Mg of**  **feed/charge) Volatile Organic HAP** 

**Emission Rate Sample 3**

**(kg/hr) Volatile Organic HAP** 

**Emission Rate Sample 3 (kg/Mg of**  **feed/charge) Test Method**  **Used Detection Limit** 

**Information (BDL,DLL,ADL)** **Other Supporting Information**  Acry lonitrile 107-13-1 4.30E-06 4.49E-06 3.50E-05 3.53E-05 3.85E-06 2.33E-06SW-846 0031 DLL 1) Since condensate Benzene 71-43-2 2.75E-03 2.88E-03 3.09E-03 3.12E-03 3.37E-03 2.04E-03SW-846 0031 ADL samples were mostly Bromodichloromethane 75-27-4 8.29E-07 8.66E-07 7.95E-07 8.04E-07 7.42E-07 4.48E-07SW-846 0031 BDL ND, these samples Carbon disulfide 75-15-0 6.71E-07 7.00E-07 6.43E-07 6.50E-07 2.10E-05 1.27E-05SW-846 0031 DDL were not included Carbon tetrachloride 56-23-5 7.43E-06 7.75E-06 1.87E-05 1.89E-05 1.47E-05 8.90E-06SW-846 0031 DDL in the assessment Chlorodibromomethane 124-48-1 6.95E-07 7.26E-07 6.67E-07 6.74E-07 6.22E-07 3.76E-07SW-846 0031 BDL BDL, DLL, ADL terms. Chloroform 67-66-3 5.98E-05 6.25E-05 1.32E-04 1.33E-04 1.03E-04 6.23E-05SW-846 0031 ADL 2) All Benzene results Chloroprene 126-99-8 n/a n/a n/a n/a n/a n/a SW-846 0031 n/a from saturated lab Dibromomethane 74-95-3 9.27E-07 9.68E-07 8.89E-07 8.98E-07 8.29E-07 5.01E-07SW-846 0031 BDL peaks, thus results are 1,1-Dichloroethane 75-34-3 1.04E-06 1.08E-06 9.94E-07 1.00E-06 9.27E-07 5.60E-07SW-846 0031 BDL represented as ">". 1,2-Dichloroethane 107-06-2 8.40E-06 8.77E-06 2.08E-05 2.10E-05 1.03E-05 6.20E-06SW-846 0031 DDL 3) Toulene results for 1,1-Dichloroethene 75-35-4 1.46E-06 1.53E-06 1.40E-06 1.42E-06 1.31E-06 7.91E-07SW-846 0031 BDL Run3, Test2 also from trans-1,2-Dichloroethene 156-60-5 1.44E-06 1.50E-06 1.38E-06 1.39E-06 1.29E-06 7.77E-07SW-846 0031 BDL saturated peak, thus 1,2-Dichloropropane 78-87-5 9.75E-07 1.02E-06 9.36E-07 9.46E-07 8.72E-07 5.27E-07SW-846 0031 BDL results are as ">". cis-1,3-Dichloropropene 10061-01-5 7.68E-07 8.02E-07 7.37E-07 7.45E-07 6.87E-07 4.15E-07SW-846 0031 BDL 4) Since the FB had trans-1,3-Dichloropropene 10061-02-6 1.30E-06 1.36E-06 1.25E-06 1.26E-06 1.17E-06 7.05E-07SW-846 0031 BDL MeCl2hits and MeCl2 Methy lene chloride 75-09-2 3.51E-03 3.66E-03 1.67E-03 1.69E-03 8.26E-04 4.99E-04SW-846 0031 ADL solvent was on-site for Tetrachloroethene 127-18-4 1.28E-05 1.34E-05 5.96E-05 6.03E-05 2.95E-05 1.78E-05SW-846 0031 DDL CARB 429 recovery, Toluene 108-88-3 1.47E-03 1.54E-03 2.13E-03 2.16E-03 2.55E-03 1.54E-03SW-846 0031 ADL the MeCl2emissions 1,1,1-Trichloroethane 71-55-6 1.10E-06 1.15E-06 1.05E-06 1.06E-06 9.81E-07 5.93E-07SW-846 0031 BDL may be biased 1,1,2-Trichloroethane 79-00-5 1.93E-06 2.01E-06 1.85E-06 1.87E-06 1.72E-06 1.04E-06SW-846 0031 BDL Trichloroethene 79-01-6 1.15E-06 1.20E-06 3.22E-05 3.25E-05 1.55E-05 9.36E-06SW-846 0031 DDL Trichlorofluoromethane 75-69-4 3.50E-05 3.66E-05 3.06E-05 3.09E-05 3.41E-05 2.06E-05SW-846 0031 ADL **Speciated Volatile Organic HAP Emission Data Facility Name and Address**  **Unit Description Process Unit ID**  **Control Device ID**

Custom Alloy, 13329 Ector Street, City of Industry, CA 91746 Scrap Dryer 1 (D9) Afterburner 1 (C9); Baghouse 3 (C23)

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **10/13/2010 10/13/2010**  **10/14/2010** Feed/Charge Rate 0.96 0.99 1.66 Mg/hr Afterburner Operating Temperature 1638 1640 1640 degree F

Type of Charge:Mixed Aluminum Borings

**Compound Semi-volatile Organic HAP**  **Emission Rate Sample 1**

**(kg/hr) Semi-volatile Organic HAP** 

**Emission Rate Sample 1 (kg/Mg of feed/charge)** **Semi-volatile Organic HAP Emission Rate**  **Sample 2 (kg/hr) Semi-volatile Organic HAP**  **Emission Rate Sample 2 (kg/Mg of feed/charge)** **Semi-volatile Organic HAP Emission Rate**  **Sample 3 (kg/hr) Semi-volatile Organic**  **HAP Emission Rate Sample 3 (kg/Mg of**  **feed/charge) Test Method Used** **Detection Limit Information**  **(BDL,DLL,ADL) Other Supporting**  **Information** Acenaphthene 83-32-9 6.42E-06 6.70E-06 8.94E-06 9.04E-06 1.33E-05 8.04E-06 CARB 429 ADL Acenaphthylene 208-96-8 2.41E-05 2.52E-05 5.15E-05 5.21E-05 1.87E-04 1.13E-04 CARB 429 ADL Anthracene 120-12-7 9.32E-06 9.74E-06 1.15E-05 1.16E-05 4.53E-05 2.73E-05 CARB 429 ADL Benz[a]anthracene 56-55-3 1.97E-07 2.06E-07 5.29E-07 5.34E-07 3.87E-07 2.34E-07 CARB 429 ADL Benzo[a]pyrene 50-32-8 5.33E-08 5.57E-08 5.34E-08 5.40E-08 5.30E-08 3.20E-08 CARB 429 BDL Benzo[b]fluoranthene 205-99-2 1.56E-08 1.63E-08 1.26E-07 1.27E-07 1.55E-08 9.37E-09 CARB 429 DLL Benzo[g,h,i]perylene 191-24-2 2.15E-08 2.24E-08 2.15E-08 2.18E-08 2.14E-08 1.29E-08 CARB 429 BDL Benzo[k]fluoranthene 207-08-9 1.60E-08 1.67E-08 1.60E-08 1.62E-08 1.59E-08 9.62E-09 CARB 429 BDL Chrysene 218-01-9 1.06E-06 1.11E-06 2.25E-06 2.27E-06 1.66E-06 1.00E-06 CARB 429 ADL Dibenz[a,h]anthracene 53-70-3 1.77E-08 1.85E-08 1.77E-08 1.79E-08 1.76E-08 1.06E-08 CARB 429 BDL Fluoranthene 206-44-0 4.28E-05 4.47E-05 4.42E-05 4.47E-05 4.99E-05 3.01E-05 CARB 429 ADL Fluorene 86-73-7 1.41E-05 1.47E-05 2.28E-05 2.30E-05 3.70E-05 2.23E-05 CARB 429 ADL Indeno(1,2,3-cd)pyrene 193-39-5 3.77E-08 3.94E-08 3.78E-08 3.82E-08 3.75E-08 2.27E-08 CARB 429 BDL Naphthalene 91-20-3 2.91E-04 3.04E-04 6.84E-04 6.91E-04 1.35E-03 8.17E-04 CARB 429 ADL Phenanthrene 85-01-8 1.12E-04 1.17E-04 1.46E-04 1.47E-04 3.39E-04 2.05E-04 CARB 429 ADL Pyrene 129-00-0 3.17E-05 3.31E-05 3.54E-05 3.57E-05 3.91E-05 2.36E-05 CARB 429 ADL **Speciated Volatile Organic HAP Emission Data**

### Facility Name and Address **Unit ID Unit Type (Chip dryer or scrap** 

**dryer /delacq /decoating kiln)**



### Custom Alloy, 13329 Ector Street, City of Industry, CA 91746 Scrap Dryer 1 (D9) Afterburner 1 (C9); Baghouse 3 (C23)

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information Date of Testing**  **10/13/2010 10/13/2010**  **10/14/2010** Feed/Charge Rate 

### 0.96 0.99 1.66 Mg/hr Afterburner residence time 

### 1.4 1.4 1.4 sec Afterburner Operating Temperature 1638 1640 1640 degree F



### 1 10/13/2010 8:50 10/13/2010 11:19 2 10/13/2010 14:00 10/13/2010 16:20 3 10/14/2010 8:30 10/14/2010 10:59

**Run Number THC Emission Rate (kg/hr)**  **THC Emission Rate (kg/Mg of feed/charge)**  **Data Flag (ADL, BDL, DDL)*******Detection Limit (ng/dscm)**  

### 1 0.25 0.259 ADL n/a 2 0.24 0.247 ADL n/a 3 0.32 0.191 ADL n/a *** See Appendix A to Enclosure 1 

### NOTE: THC results are "as propane". **Test End Time**

**Run Number Test Start Date**  **Test Start Time Test End Date** 

### Facility Name and A**ddress Unit Description**  **Process Unit ID Control Device ID** 



### Custom Alloy, 13329 Ector Street, City of Industry, CA 91746 Scrap Dryer 1 (D9) Afterburner 1 (C9); Baghouse 3 (C23)

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **10/13/2010 10/13/2010**  **10/14/2010** Feed/Charge Rate 

### 0.96 0.99 1.66 Mg/hr Afterburner Operating Temperature 1638 1640 1640 degree F Flow Rate 

### 392.52 414.63 388.96 actual M3

### /min Flow Rate 

### 375.15 395.42 370.20 dry sM3

### /min

**Emission Test Results Constituent**  **Composition Sample 1**  **(%) Composition** 

**Sample 2 (%)**  **Composition**

**Sample 3 (%)**  **Test Method Used**

**(ex. U.S. EPA**

**Method 3B) Other Supporting Information**  O2 

### 19.77 19.68 19.47 CO2 

### 0.61 0.65 0.79 H2

### O 

### 4.4 4.6 4.8

# Facility Name and A**ddress Unit Description**  **Process Unit ID Control Device ID** *



# Custom Alloy, 13329 Ector Street, City of Industry, CA 91746 Scrap Dryer 1 (D9) Afterburner 1 (C9); Baghouse 3 (C23)
**Sample ID No.:**BH - 1/2 BH - 3 BH -6 **Type of Sample (Lime or Particulate):**Particulate Particulate Particulate **Date Sampled:**9/23/2010 9/23/2010 9/23/2010 **Date(s) Analyzed:**10/18-10/26/2010 10/18-10/26/2010 10/18-10/26/2010

**HA P Metal**  **mg/kg mg/kg**  **mg/kg** Antimony 

# 33 11 73 Beryllium 

# 3.3 3.2 2.5 Chromium 

# 120 170 18 Hexavalent chromium 

# ND (0.12) ND (0.12) ND (0.12) Lead 

# 470 1100 320 Mercury 

# 1.5 0.6 2.5 Selenium 

# 9.1 11 7.7 Arsenic 

# ND (4.0) ND (4.0) ND (4.0) Cadmium 

# 27 22 24 Cobalt 

# 14 14 1.7 Manganese 

# 230 380 48 Nickel 

# 110 180 9.4
*** Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.**