Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 1 of 20

Facility Questionnaire for Primary Aluminum Reduction 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 the 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 INFORMATION

(Please fill out a separate form for each of your facilities)

1. Name and address of the PARENT COMPANY that owns the facility:

Alcoa, Inc. ________________________________________________________________

201 Isabella Street __________________________________________________________

Pittsburgh, PA 15212-5858 ___________________________________________________

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

Alcoa, Inc. ________________________________________________________________

PO Box 472 _______________________________________________________________

Rockdale, Texas 76567 ______________________________________________________

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

a. Address: 4069 Charles Martin Hall Road____________________________________

b. City: Rockdale ________________________________________________________

c. State: Texas___________________________________________________________

d. Zip: 76567____________________________________________________________

e. County: USA__________________________________________________________

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): Terry, Blodgett ______________________________

b. Title: Environmental Supervisor___________________________________________

c. Telephone number: ____512-446-8379_______________ ext. _________________

d. Fax number: 512-446-8441_______________________________________________

e. E-mail: terry.blodgett@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 files are preferred).

7. Please provide a copy of the facility schematic showing all of the primary aluminum 

operations that are subject to 40 CFR Part 63, Subpart LL. Please include the control 

device ID numbers in the facility schematic.

Refer to Emission Point Diagram which shows all control equipment
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 3 of 20

PART B: PROCESSES AND EMISSIONS CONTROL DEVICES

8. Pitch storage tanks:

0 _______________ Total number of pitch storage tanks at facility

0 _______________ Is at least one of the pitch storage tanks empty at all times?

0 _______________ Total amount of pitch used (tons per year) assuming facility 

operation at maximum capacity

8a. Please provide the capacity (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 necessary):

ID No.: _na_________ ____________ ____________ ____________

Capacity: __na________ ____________ ____________ ____________

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

to the pitch storage tank(s) is not practicable economically or technologically

Not practicable economically: _Rockdale uses dry pencil pitch___________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Not practicable technologically: __________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

9. Anode bake furnaces:

3 _______________ Total number of anode bake furnaces at facility

>186,000 ________ Facility-wide green anode production capacity (tons per year)

101,000__________ Total amount of coke used for anode production (tons per year) 

assuming facility operation at maximum capacity

10. Aluminum production, by potline(s) (use the same potline ID numbers as were assigned in 

the schematic provided in response to question 7):

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

Total potlines (6) Aluminum capacity (294,300 US Short tons per year)

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

Potline # _3___ Aluminum capacity (42,875 US short tons per year)

Potline # _4___ Aluminum capacity (42,875 US short tons per year)

Potline # _5___ Aluminum capacity (42,875 US short tons per year)
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 4 of 20

Potline # _6___ Aluminum capacity (42,875 US short tons per year)

Potline # _7___ Aluminum capacity (61,400 US short tons per year)

Potline # _8___ Aluminum capacity (61,400 US short tons per year)

11. 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):

11a. Potline ID No. Potline Type * Total No. of Pots

Potline # ___3_____ _CWPB2____ _144______

Potline # ___4_____ _CWPB2___ _144_______

Potline # ___5_____ _CWPB2___ _144_______

Potline # ___6 ____ _ CWPB2__ _144_______

Potline # ___7_____ _CWPB2__ _160_______

Potline # ___8_____ _ CWPB2___ _160_______

* Center-worked 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)

11b. 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 Door Side shield Door Side shield Door

3 3 6 3 1 9 10

4 3 6 3 1 9 10

5 3 6 3 1 9 10

6 3 6 3 1 9 10

7 3 6 3 1 9 10

8 3 6 3 1 9 10

a

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

the cited potline is opened 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.
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 5 of 20

c

The average length of time, in minutes, that a given side shield or door of a cell of 

the cited potline is removed.

11c. Describe the exhaust capture/hooding system for each potline including the capture 

efficiency (if known), evacuation rate, and damper system.

Potline ID

Capture 

efficiency

(%)

Evacuation 

rate

(scfm)

Damper system? (i.e. to allow high 

and low flow evacuation rates)

Yes No

3 No valid data ~1,800 X

4 No valid data ~1,800 X

5 No valid data ~1,800 X

6 No valid data ~1,800 X

7 No valid data ~2,100 X

8 No valid data ~2,100 X

11d. 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.

12. Is total fluoride emitted from the roof vents measured with a sampling manifold or a 

cassette system? (CHECK one) _4, 6, 8____ Manifold or _3, 5, 7________ Cassette

Three potrooms are equipped with cassettes and three potroom are equipped with manifolds.

12a. What is the total typical exhaust rate from the roof vents of each potroom (scfm)?

Potline 3 1,800,000 SCFM T51 Pot Design

Potline 4 1,900,000 SCFM T51 Pot Design

Potline 5 1,800,000 SCFM T51 Pot Design

Potline 6 2,300,000 SCFM T51 Pot Design

Potline 7 4,000,000 SCFM P100 Pot Design

Potline 8 3,600,000 SCFM P100 Pot Design

These values represent the total flow out of a potline (two potrooms).

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

Unavailable due to time Typical sulfur content of pitch

Unavailable due to time Maximum sulfur content of pitch cited in specifications 

provided to pitch suppliers, if applicable

1.9 % by weight ___ Typical sulfur content of coke

1.9 % by weight ___ Maximum sulfur content of coke cited in specifications provided to 

coke suppliers, if applicable
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 6 of 20

13a. What is the availability and cost of coke and pitch with lower sulfur contents for your 

facility? What is the lowest sulfur 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.

13b. 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.

Unavailable. Rockdale is a temporarily curtailed facility.

13c. 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.

Alcoa Rockdale utilized wet scrubbers on three of the six potlines which achieve some 

level of COS removal. Of the incoming sulfur in petroleum coke it is assumed 10% 

forms COS and 90% forms SO2. Of the COS that forms and makes it to the 

scrubbers it is assumed 10% is removed. Hooding efficiency is also considered when 

estimating how much COS is routed to the wet scrubbers. On non-wet scrubbed 

potlines it is assumed all COS is released uncontrolled.

14. 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 use the 

same ID numbers as were assigned in the schematic provided in response to question 7.

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?

State of Texas NSR permit 56300 includes limits for particulate matter as well as sulfur emission 

limits that relate back to sulfur content in new petroleum coke. The limits are in Permit 

56300 that was submitted in this package.

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
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 7 of 20

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, 1997 in order to meet the MACT standards 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

15. 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).

_The use of “cover material” or “anode cover material” or “cover bath” is used to form a 

layer over the top of carbon anode cover within the pots. This cover reduces the formation 

of hydrogen fluoride (HF) gas by reducing the hydrogen molecules in the presents of 

fluoride 

molecules.________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

Numerous. Please refer to 

submitted file: MactPlan.pdf
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 8 of 20

Table 1a Wet Scrubber Description

1. Control device description and ID number (or numbers, if several identical control devices 

are used to control a given emission source): Pot fumes are routed through ESPs then wet 

scrubbers before being released to the atmosphere

2. Stack or vent location of each control device (use NAD83 and include six decimal places and 

add rows as necessary):

ID No.: _10C1 __ Latitude: _ 30.565447___ Longitude: _-97.070207_____

ID No.: _10C2 ____ Latitude: _30.565393__ Longitude: _-97.070185_____

ID No.: _10C3 _____ Latitude: _ 30.565079____ Longitude: _-97.071289_____

ID No.: _10C4 __ Latitude: _ 30.565028____ Longitude: _-97.071273_____

ID No.: _10C5 ____ Latitude: __ 30.564977____ Longitude: _-97.071619_____

ID No.: _10C6_____ Latitude: __ 30.564922___ Longitude: _-97.071592_____

ID No.: _10C7 __ Latitude: _ 30.565380_____ Longitude: _-97.070433_____

ID No.: _10C8 __ Latitude: _ 30.565322_____ Longitude: _-97.070402_____

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 0.57 mg/dscf __1______

Hydrogen Fluorides Percent 0.15 mg/dscf __1______

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: Venturi Vertical packed bed

 Horizontal packed bed Tray tower spray chamber

 X Other (specify or describe): Open spray tower.
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 9 of 20

5. Pressure mode of operation: X positive pressure negative pressure

6. Typical gas temperature: inlet ~300 °F outlet ~105 °F

7. Gas flow rate: ~45,000 acfm (at scrubber outlet) ~40,000 dscfm

8. Pressure drop across scrubber: unknown inches water column (in. H2O)

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

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

Chemical added Usage rate Units for usage rate

LIME

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

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

Potline 3 Potline 3 pots

12. Indicate what operational parameters of the control device are monitored to ensure that the 

control device is operating properly:

 Volumetric flow rate X Fan amperage

 Pressure drop X Water flow rate

Other (specify): .

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

 Volumetric flow rate (acfm) X Fan amperage (amps)

 Pressure drop (in. H2O) X Water flow rate (gpm)

Other (specify): .
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 10 of 20

14. Has the collected sludge been analyzed?

_____ Yes __X___ 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 Characteristic Leaching Procedure (TCLP).

Lab report included in attachments.

15. Additional comments and information:

Scrubber sludge is kept in a closed-loop system.

Table 1b Wet Scrubber Description

1. Control device description and ID number (or numbers, if several identical control 

devices are used to control a given emission source): Pot fumes are routed through ESPs 

then wet scrubbers before being released to the atmosphere

2. Stack or vent location of each control device (use NAD83 and include six decimal places

and add rows as necessary):

ID No.: _10D1_ Latitude: _ 30.566162_____ Longitude: _-97.069940______

ID No.: _10D2 _ Latitude: _ 30.566102_____ Longitude: _-97.069915______

ID No.: _10D3 _ Latitude: _ 30.565633_____ Longitude: _ -97.071535______

ID No.: _10D4 _ Latitude: _ 30.565574_____ Longitude: _ -97.071508______

ID No.: _10D5 _ Latitude: _ 30.565353_____ Longitude: _ -97.072427______

ID No.: _10D6_ Latitude: _ 30.565285_____ Longitude: _ -97.072395______

ID No.: _10D7_ Latitude: _ 30.565338_____ Longitude: _ -97.072347______

ID No.: _10D8 _ Latitude: _ 30.565989_____ Longitude: _-97.070443______

ID No.: _10D9_ Latitude: _ 30.565934_____ Longitude: _ -97.070417______

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 0.39 mg/dscf __1______

Hydrogen Fluorides Percent 0.14 mg/dscf __1______

POM Percent mg/dscf _________

COS Percent mg/dscf _________
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 11 of 20

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: Venturi Vertical packed bed

 Horizontal packed bed Tray tower spray chamber

 X Other (specify or describe): Open spray tower.

5. Pressure mode of operation: X positive pressure negative pressure

6. Typical gas temperature: inlet ~300 °F outlet ~105 °F

7. Gas flow rate: ~48,000 acfm (at scrubber outlet) ~45,500 dscfm

8. Pressure drop across scrubber: unknown inches water column (in. H2O)

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

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

Chemical added Usage rate Units for usage rate

LIME

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

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

Potline 4 Potline 4 pots

12. Indicate what operational parameters of the control device are monitored to ensure that 

the control device is operating properly:

 Volumetric flow rate X Fan amperage

 Pressure drop X Water flow rate

Other (specify): .
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 12 of 20

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

 Volumetric flow rate (acfm) X Fan amperage (amps)

 Pressure drop (in. H2O) X Water flow rate (gpm)

Other (specify): .

14. Has the collected sludge been analyzed?

_____ Yes __X___ 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 Characteristic Leaching Procedure (TCLP).

Lab report included in attachments.

15. Additional comments and information:

Scrubber sludge is kept in a closed-loop system.

Table 1c Wet Scrubber Description

1. Control device description and ID number (or numbers, if several identical control 

devices are used to control a given emission source): Pot fumes are routed through ESPs 

then wet scrubbers before being released to the atmosphere
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 13 of 20

2. Stack or vent location of each control device (use NAD83 and include six decimal places

and add rows as necessary):

ID No.: _10F1__ Latitude: _ 30.565864___ Longitude: _ -97.071782____

ID No.: _10F2____ Latitude: _ 30.565913__ Longitude: _ -97.071849___

ID No.: __10F3____ Latitude: _ 30.565838 ____ Longitude: _ -97.071872____

ID No.: _10F4__ Latitude: _ 30.565873 ____ Longitude: __ -97.071936___

ID No.: __10F5___ Latitude: _ 30.565806_ ____ Longitude: _ -97.071970____

ID No.: _10F6_____ Latitude: _ 30.565843__ Longitude: _ -97.072015____

ID No.: _10F7__ Latitude: _ 30.565789 _____ Longitude: _ -97.072207____

ID No.: _10F8__ Latitude: _ 30.565722_____ Longitude: _ -97.072217___

ID No.: __10F9___ Latitude: _ 30.565762 ____ Longitude: _ -97.072290____

ID No.: _10F10_____ Latitude: __ 30.565685 ___ Longitude: _ -97.072295___

ID No.: _10F11__ Latitude: _ 30.565724 _____ Longitude: _ -97.072375___

ID No.: _10F12__ Latitude: _ 30.565665_____ Longitude: __ -97.072397___

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 0.44 mg/dscf __1______

Hydrogen Fluorides Percent 0.09 mg/dscf __1______

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) _______________________
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 14 of 20

4. Device type: Venturi Vertical packed bed

 Horizontal packed bed Tray tower spray chamber

 X Other (specify or describe): Open spray tower.

5. Pressure mode of operation: X positive pressure negative pressure

6. Typical gas temperature: inlet ~300 °F outlet ~105 °F

7. Gas flow rate: ~32,000 acfm (at scrubber outlet) ~29,000 dscfm

8. Pressure drop across scrubber: unknown inches water column (in. H2O)

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

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

Chemical added Usage rate Units for usage rate

LIME

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

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

Potline 6 Potline 6 pots

12. Indicate what operational parameters of the control device are monitored to ensure that 

the control device is operating properly:

 Volumetric flow rate X Fan amperage

 Pressure drop X Water flow rate

Other (specify): .

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

 Volumetric flow rate (acfm) X Fan amperage (amps)

 Pressure drop (in. H2O) X Water flow rate (gpm)
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 15 of 20

Other (specify): .

14. Has the collected sludge been analyzed?

_____ Yes __X___ 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 Characteristic Leaching Procedure (TCLP).

Lab report included in attachments.

15. Additional comments and information:

Scrubber sludge is kept in a closed-loop system.
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 16 of 20

Table 2a 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): Control device is a series of Alcoa 398 dry 

alumina scrubbers followed by an integral fabric filter baghouse 398s are very effective at 

fluoride removal. 

2. Stack or vent location of each control device (use NAD83 and include six decimal places and 

add rows as necessary):

ID No.: _10E1____ Latitude: _ 30.566060_____ Longitude: _ -97.071440_____

ID No.: _10E2____ Latitude: _ 30.566048_____ Longitude: _ -97.071489_____

ID No.: _10E3____ Latitude: _ 30.566034_____ Longitude: _ -97.071539_____

ID No.: _10E4____ Latitude: _ 30.566018_____ Longitude: _-97.071589_____

ID No.: _10E5____ Latitude: _ 30.565889_____ Longitude: _ -97.071538_____

ID No.: _10E6____ Latitude: _ 30.565907_____ Longitude: _ -97.071484_____

ID No.: _10E7____ Latitude: _ 30.565921_____ Longitude: _ -97.071435_____

ID No.: _10E8____ Latitude: _ 30.565940_____ Longitude: _ -97.071385_____

ID No.: _10E9____ Latitude: _ 30.565956_____ Longitude: _ -97.071337_____

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 648 mg/dscf ___2_____

PM10 Percent mg/dscf _________

PM2.5 Percent mg/dscf _________

Total Fluorides Percent 0.017 mg/dscf ___1_____

Hydrogen Fluorides Percent 0.007 mg/dscf ___1_____

POM Percent mg/dscf _________

COS 0 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) _______________________

4. Scrubber device type:

__ _ Fluidized bed _____ Injection

__X___ Other (specify or describe): _Integrated fluidized bed and baghouse_____
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 17 of 20

5. Bag cleaning method:

__X__ Pulse jet _____ Reverse air _____ Shaker

_____ Other (describe) _________________________________________________

6. Pressure mode of operation: X positive pressure negative pressure

7. Typical gas temperature: inlet to scrubber 250 °F outlet from bag house 200 °F

8. Gas flow rate: 39,600 acfm (at bag house outlet) 31,700 dscfm

9. Pressure drop: Across scrubber: unknown inches water column (in. H2O)

Across bag house: unknown inches water column (in. H2O)

10. Solid to gas ratio: unknown 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

Recycled alumina

Other alumina (specify ________________)

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

Source ID No(s). Description(s)

Potline 5 Potline 5

13. Indicate what operational parameters of the control device are monitored to ensure that the 

control device is operating properly:

 Volumetric flow rate X Fan amperage

 Pressure drop X Visible emissions opacity

Other (specify): .

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

 Volumetric flow rate (acfm) X Fan amperage (amps)

 Pressure drop (in. H2O) X Visible emissions opacity (%)
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 18 of 20

Other (specify): .

15. Additional comments and information:

Table 2b 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): Control device is a series of Alcoa 

398 dry alumina scrubbers followed by an integral fabric filter baghouse 398s are very 

effective at fluoride removal. 

2. Stack or vent location of each control device (use NAD83 and include six decimal places and 

add rows as necessary):

Potline 7

ID No.: _10G1____ Latitude: _30.568259____ Longitude: _-97.071573____

ID No.: _10G2____ Latitude: _ 30.568283_____ Longitude: _ -97.071525_____

ID No.: _10G3____ Latitude: _ 30.568298_____ Longitude: _ -97.071479_____

ID No.: _10G4____ Latitude: _ 30.568313_____ Longitude: _ -97.071429_____

ID No.: _10G5____ Latitude: _ 30.568335_____ Longitude: _ -97.071380_____

ID No.: _10G6____ Latitude: _ 30.568353_____ Longitude: _ -97.071321_____

ID No.: _10G7____ Latitude: _ 30.567939_____ Longitude: _ -97.072576_____

ID No.: _10G8____ Latitude: _ 30.567924_____ Longitude: _ -97.072628_____

ID No.: _10G9____ Latitude: _ 30.567908_____ Longitude: _ -97.072680_____

ID No.: _10G10____ Latitude: _ 30.567888_____ Longitude: _ -97.072731_____

ID No.: _10G11____ Latitude: _ 30.567872_____ Longitude: _ -97.072777_____

ID No.: _10G12____ Latitude: _ 30.567858_____ Longitude: _ -97.072824_____

Potline 8

ID No.: _10H1____ Latitude: _ 30.568905 _____ Longitude: _ -97.071842 _____

ID No.: _10H2____ Latitude: _ 30.568922 _____ Longitude: _ -97.071791 _____

ID No.: _10H3____ Latitude: _ 30.568944 _____ Longitude: _ -97.071745 _____

ID No.: _10H4____ Latitude: _ 30.568958 _____ Longitude: _ -97.071692 _____

ID No.: _10H5____ Latitude: _ 30.568972 _____ Longitude: _ -97.071644 _____

ID No.: _10H6____ Latitude: _ 30.568993 ____ Longitude: _ -97.071594 ____

ID No.: _10H7____ Latitude: _ 30.568578 _____ Longitude: _ -97.072850 _____

ID No.: _10H8____ Latitude: _ 30.568563 _____ Longitude: _ -97.072895 _____

ID No.: _10H9____ Latitude: _ 30.568550 _____ Longitude: _ -97.072946_____

ID No.: _10H10____ Latitude: _ 30.568533 _____ Longitude: _ -97.072994 _____

ID No.: _10H11____ Latitude: _ 30.568515 _____ Longitude: _ -97.073041 _____

ID No.: _10H12____ Latitude: _ 30.568498_____ Longitude: _ -97.073088_____
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 19 of 20

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 648 mg/dscf ___2_____

PM10 Percent mg/dscf _________

PM2.5 Percent mg/dscf _________

Total Fluorides Percent 0.04 mg/dscf ___1_____

Hydrogen Fluorides Percent 0.02 mg/dscf ___1_____

POM Percent mg/dscf _________

COS 0 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) _______________________

4. Scrubber device type:

__ _ Fluidized bed _____ Injection

__X___ Other (specify or describe): _Integrated fluidized bed and baghouse_____

5. Bag cleaning method:

__X__ Pulse jet _____ Reverse air _____ Shaker

_____ Other (describe) _________________________________________________

6. Pressure mode of operation: X positive pressure negative pressure

7. Typical gas temperature: inlet to scrubber 250 °F outlet from bag house 200 °F

8. Gas flow rate: 39,600 acfm (at bag house outlet) 31,700 dscfm

9. Pressure drop: Across scrubber: unknown inches water column (in. H2O)

Across bag house: unknown inches water column (in. H2O)

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
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 20 of 20

Virgin alumina

Recycled alumina

Other alumina (specify ________________)

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

Source ID No(s). Description(s)

Potline 7

Potline 8

Potline 7

Potline 8

13. Indicate what operational parameters of the control device are monitored to ensure that the 

control device is operating properly:

 Volumetric flow rate X Fan amperage

 Pressure drop X Visible emissions opacity

Other (specify): .

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

 Volumetric flow rate (acfm) X Fan amperage (amps)

 Pressure drop (in. H2O) X Visible emissions opacity (%)

Other (specify): .

15. Additional comments and information:
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 21 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):

ESPs are used upstream of six of the eight wet scrubbers in Potline 3 and upstream from all 

the Potline 6 wet scrubbers. These are shown in the file “Control_Equipment_Diagrams.pdf” 

submitted with this document. No lats or longs are being shown below as these vent through 

the wet scrubbers identified in the Table 1a and 1c above.

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: High-voltage, single-stage Low-voltage, two-stage

 Wet Dry

 X Other (specify or describe): The primary voltage which feeds 

the ESP’s is single phase 480 volts. The secondary voltage is DC and the 

target voltage was 40,000 volts. Primary voltage and secondary current 

was monitored for MACT reporting.
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 22 of 20

5. Pressure mode of operation: positive pressure negative pressure

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

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

8. Collection plate surface area: __________ ft2

9. Secondary 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 23 of 20
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 24 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 control a given emission source):

1 baghouse is in operation on Potline 3 prior to the wet scrubber and upstream from all the 

wet scrubbers in Potline 4. VE readings and stack testing are associated with the exit of the 

wet scrubbers.

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. Bag cleaning method:

__X__ Pulse jet _____ Reverse air _____ Shaker

_____ Other (describe) _________________________________________________

5. Pressure mode of operation: X positive pressure negative pressure

6. Typical gas temperature: inlet 250 °F outlet 200 °F
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 25 of 20

7. Gas flow rate: ~90,000 acfm (at bag house outlet) ~70,000 dscfm

8. Pressure drop: unknown inches water column (in. H2O)

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)

Part of Potline 3 and Potline 4 

control trains

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. H2O)

Other (specify): .

13. Has the collected dust been analyzed?

_____ Yes __X__ 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 Characteristic Leaching Procedure (TCLP).

14. Additional comments and information:

Please refer to Table 1 for wet scrubbers as that is the location for VE readings and stack testing. 

These are upstream from those controls and emission points.
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 26 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 * 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. 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 27 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 Volumetric flow rate

 Pressure drop

Other (specify): .

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

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

 Pressure drop (in. H2O)

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. Additional comments and information:
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 28 of 20

PART C: START-UPS AND SHUTDOWNS

Please provide the information in Table 6 and questions below for each Subpart LL potline 

during start-up (the commencement of operation for any purpose) and shutdown (the cessation of

operation for any purpose) operations. 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).

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

a potline during start-up or shutdown is not practicable economically or technologically

not practicable economically: Not practicable economically: EPA Reference Methods 14 

and 14A are designed to measure 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 startup, 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 nonsteady-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 emissions) 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 emissions 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 sampling 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. Additionally, a large team of staff or contract resources necessary to 

collect the required 48-hours three sampling runs.

Not practicable technologically: _______________________________________________
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 29 of 20

_________________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

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

during a start-up or shutdown? (Check one) Y N

If yes:

a. Provide a copy of the test data.

b. Describe the operating conditions (e.g. tons of aluminum produced per day) at the time 

of the testing.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

18. 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. See file “Potline_SSM_Plan.pdf”

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 Always, Sometimes, or Never.

__A__ a. Develop a potroom/potline start-up schedule before start-up

__A__ b. Perform daily assessment of start-up progress 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 energizing 

first cell to be restarted

__N__ e. Supply alumina at a higher rate than during normal pot operation

If so, how much higher? ____________(percent)

__A__ 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 use the following methods to manage a “sick” or unstable pot

__N__ Adjust exhaust flow from pots

__S__ Adjust cell voltage and feeding levels

__S__ Monitor and adjust anode current and liquid level

_____ Other corrective procedures. Please describe the corrective 

procedures applied (use additional pages if needed):
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 30 of 20

_______________________________________________________

_______________________________________________________

_______________________________________________________

_______________________________________________________

_______________________________________________________

20. Please list any additional start-up activities in the space below.

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 31 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 description 

(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?

Potline 3 June 19, 2008 Start

June 21, 2008 End (48 hrs)

Planned Shutdown

Followed SSM Plan Followed SSM Plan which was submitted along with this 

questionnaire. It provides details that are best read directly from 

the plan.

Potline 4 June 19, 2008

June 21, 2008 End (48 hrs)

Planned Shutdown

 “ “ “ “ “ “ “ “

Potline 5 June 19, 2008

June 21, 2008 End (48 hrs)

Planned Shutdown

 “ “ “ “ “ “ “ “

Potline 6 October 3, 2008 Start

October 5, 2008 End (48 hrs)

Planned Shutdown

 “ “ “ “ “ “ “ “

Potline 8 October 17, 2008 Start

October 19, 2008 End (48 hrs)

Planned Shutdown

 “ “ “ “ “ “ “ “
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 32 of 20

Potline 7 November 7, 2008 Start

November 9, 2008 End (48 hrs)

Planned Shutdown

 “ “ “ “ “ “ “ “
Enclosure 1

Primary Aluminum Reduction Section 114 Enclosure 1 - April 22, 2011

Page 33 of 20

PART D: PREVIOUSLY PERFORMED TESTING AND TEST REPORT DATA

21. Submit emission test report results 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 Subpart 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) Pollutants and emission rates measured (e.g., lb/hr, gr/dscf, lb/ton),

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

(c) Information on actual production or processing 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.

22. If emission controls 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 available, including the information specified in 21(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.”

23. Has any air monitoring, such as Fourier Transform Infrared (FTIR) spectroscopy, 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.

24. Has any air monitoring, such as FTIR spectroscopy, 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 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.
Enclosure 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 pollutants 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 document is organized as follows:

1.0 Sampling and Chemical Analysis Procedures and Methods for Metallic HAP 

(including speciated hexavalent chromium)

2.0 How to Report Data

3.0 How to Submit Data

4.0 Contact 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. 

All 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:

http://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), and 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, CWPB1, 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 adequate. Sampling should be conducted once per day for five consecutive 
Enclosure 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 analysis 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 analysis 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 Detection 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 

portion 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.org
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 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 level

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

CS2 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

ESP electrostatic precipitator

ft foot or feet

ft2square feet

ft3cubic feet

fpm feet per minute (acfm divided by ft2of 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 hydrogen fluoride
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 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. H2O 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 of British thermal units per hour

MM scf millions of standard cubic feet

MM lb/yr million pounds per year

μg/m3 microgram per cubic meter

μm micrometer

NAICS North American Industry Classification System

NaOH sodium hydroxide

NESHAP National Emission Standards for Hazardous Air Pollutants

NOx 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 similar software

PM particulate matter

PM10 particulate matter that is 10 micrometers or less in diameter

PM2.5 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 hour
APPENDIX A

Primary Aluminum Reduction Section 114 Appendix A - April 22, 2011

Page 3 of 3

scfm standard cubic feet per minute

scm standard cubic meters

SO2 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, or 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 0.3048

ft/min m/min 0.3048

ft2m

2

0.0929

ft3 m

3

0.028

g lb 0.0022

g/m3lb/ft30.0000624

gr lb 0.000143

gr/dscf mg/dscm 2,290

in. H2O mm H2O 25.4

kg/hr lb/hr 2.205

lb g 454

lb gr 7000

lb/ft3g/m316,000

lb/hr kg/hr 0.454

m ft 3.28

m/min ft/min 3.28

mm H2O in H2O 0.0394

m

2

ft210.76

mg/dscm gr/dscf 0.00044

m

3

ft335.31

Mg ton 1.1

ton (short) Mg 0.907
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 2011

Page 1 of 5

List of Hazardous Air Pollutants (HAP)

CAS 

Number Chemical Name

Antimony Compounds

Arsenic Compounds (inorganic including arsine)

Beryllium Compounds

Cadmium Compounds

Chromium Compounds

Cobalt Compounds

Coke Oven Emissions

Cyanide Compounds1

Glycol ethers2

Lead Compounds

Manganese Compounds

Mercury Compounds

Fine mineral fibers3

Nickel Compounds

Polycylic Organic Matter4(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 cyanamide
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 salts
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 methacrylate
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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)

1120-71-4 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-Trichlorobenzene
APPENDIX B

Primary Aluminum Reduction Section 114 Appendix B - April 22, 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 surfactant 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 22, 2011

Page 1 of 1

Guidance For Calculating And Reporting Measurements Less Than

Method Detection Levels For Test Data Submitted in Response

to Information Collection 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 level(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 bracketed “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 the analytical 

detection level and a laboratory-specific reporting or quantification level (i.e., flag 

as ADL).