### Report on the Shredder B aghouse Air Emissions Test Program

Conducted for Nichols Aluminum Casting at their Facility Located in Davenport, Iowa

Iowa Plant Number 82

- 01

- 089

Report No. 3592

- Shredder

N

ovember 1 , 2012Nichols Aluminum Casting Report No. 3592

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### Table o f Contents

PROJECT OVERVIEW

................................ ................................ ................................ .............................. 2

General

................................ ................................ ................................ ................................ ................... 2 Methodology

................................ ................................ ................................ ................................ ........... 2

Parameters

................................ ................................ ................................ ................................ ............. 3

Results

................................ ................................ ................................ ................................ .................... 3

SUMMARY OF RESULTS

................................ ................................ ................................ ......................... 4

Table 1

– Summar y of Particulate Matter Results, Shredder Outlet

................................ ...................... 4

TEST PROCEDURES

................................ ................................ ................................ ................................ .. 5

Method Listing

................................ ................................ ................................ ................................ ........ 5

Method 1

................................ ................................ ................................ ................................ ............. 5

Method 2

................................ ................................ ................................ ................................ ............. 5

Method 4

................................ ................................ ................................ ................................ ............. 6

Method 5

................................ ................................ ................................ ................................ ............. 6

Method 9

................................ ................................ ................................ ................................ ............. 7

DESCRIPTION OF PROCE SS

................................ ................................ ................................ ................... 9

APPENDIX

Figures Sample Calculations

Parameters

Fi eld Data Printouts

Field D ata Laboratory Data

Calibration Data

Process DataNichols Aluminum Casting Report No. 3592

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### Project Overview

General

Airtech Environmental Services Inc. (Airtech) was contracted by Nichols Aluminum Casting (Nichols) to perform an air emissions test program at their facility located in Davenport , Iowa. The objective of the test program was to satisfy the requirements of 40 CFR Part 63, Subpart RRR (National Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Smelters). Testing in this document was conducted a t the

exhaust of the Shredder baghouse.

Testing was performed on August 16 and August 17 , 20 12 . Coordinating the field portion of the test program were:

Brian McCabe

- Nichols Aluminum Casting

Jeff K aput

- Airtech Environmental Services Inc. Kurt Wepprecht

- Airtech Environmental Services Inc.

Methodology

EPA Method 5 was used to determine the emissions of filterable particulate matter ( F PM ) at the Shredder baghouse exhaust

. A sample of the gas strea m was withdrawn isokinetically from the exhaust duct and the PM in the sample gas was collected in a glass probe and on a glass fiber filter . The weight of particulate collected with the sample train combined with the volume of dry gas withdrawn from the stack wa s used to calculate the particulate concentration.

To convert the concentrations of particulate to mass emission rates, the volumetric gas flow rate was determined using EPA Methods 1 , 2 and 4 . In addition, the opacity of the

emissions at the baghouse exhaust was determined using EPA Method 9. Opacity observations were conducted by a certified observer from Airtech

.Nichols Aluminum Casting Report No. 3592

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Parameters
The following specific parameters were determined at the test location:

• gas velocity

• gas temperature

• moisture conten t

• filterable particulate matter concentration

• opacity of emissions

Results
A summary of results is presented in Table 1 on page 4.

Because the test location emitted essentially ambient air, the dry molecular weight of 29.00 was used in lieu of performing Method 3 as allowed by Method 2, Section 8.6.

Prepared by: Reviewed by:

Cathy Busse Jeff KaputNichols Aluminum Casting Report No. 3592

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### Summary of Results

Table 1

– Summary of Particulate Matter Results, Shredder Outlet

**Test Parameters** Run 1 Run 2 Run 3 Average

Date 8/16/2012 8/16/2012 8/17/2012

Start Time 14:31 16:00 8:32
Stop Time 15:40 17:09 9:40

**Production Rate**
Throughput (tons/hr) 43.19 49.93 45.54 46.22

**Gas Conditions**

Temperature ( o F) 104 104 96.9 102
Volumetric Flow Rate (acfm) 73,700 73,600 73,200 73,500

Vol umetric Flow Rate (scfm) 67,200 67,000 68,100 67,400
Volumetric Flow Rate (dscfm) 66,200 66,000 67,100 66,500
Moisture (%) 1.44 1.61 1.42 1.49

**Particulate Results**
Concentration (grains/dscf) 0.0000719 0.000145 0.0000785 0.0000985

Emission Ra te (lb/hr) 0.0408 0.0820 0.0452 0.0560

**Opacity Results**
Average Opacity (%)* 0.00 0.00 0.00 0.00
Minimum Opacity (%) 0 0 0
Maximum Opacity (%) 0 0 0

* The average opacity is base d on the highest six

- minute reading.Nichols Aluminum Casting Report No. 3592

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### Test Procedures

Method Listing
The following test methods were referenced for the test program. These methods can be found in 40 CFR, part 60, Appendix A.

Method 1 Sample and Velocity Traverse for Stationary Sourc es

Method 2 Determination of Stack Gas Velocity and Volumetric Flow Rate (Type S pitot tube)

Method 4 Determination of Moisture Content in Stack Gases

Method 5 Determination of Particulate Matter Emissions from Stationary

Sources

Method 9 Visual Determin ation of the Opacity of Emissions from Stationary

Sources

Method 1
EPA Method 1 was used to determine the suitability of the test location and to determine the sample points used for the particulate and volumetric flow determinations. The test

location co nformed to the minimum requirements of being located at least two diameters downstream and at least 0.5 diameters upstream from the nearest flow disturbance.

The Shredder Baghouse exhaust test location was a round, vertical stack with a diameter

of 4 5 .0 i nches. Two ports were sampled with twelve sample points per port. The test location was located approximately 3.5 diameters downstream and greater than 3.3 diameters upstream from the nearest flow disturbance. A cross section of the sampling

location is shown in Figure 1 in the Appendix.

Method 2
EPA Method 2 was used to determine the gas velocity through the test location using a Type S pitot tube and an incline plane oil manometer. The manometer was leveled and “zeroed” prior to each test run

. The sa mple train was leak checked before and after each run by pressurizing the positive side, or “high” side, of the pitot tube and creating a

deflection on the manometer of at least three inches of H 2 O. The leak check was

considered valid if the manometer rem ained stable for 15 seconds. This procedure was repeated on the negative side by generating a vacuum of at least three inches of H 2 O. The velocity head pressure and gas temperature were then determined at each point specified in Method 1. The static pre ssure of the duct was measured using a water filled U

- tube manometer. In addition, the barometric pressure was measured and recorded.

The values measured in Method 2 were used to calculate the volumetric flow rate through

each test location. The Method 2 sampling apparatus is shown in Figure 2 as part of the Method 5 sample train.Nichols Aluminum Casting Report No. 3592

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Method 4
The moisture content at the test location was determined using Method 4. A known volume of sample gas was withdrawn from the source and the moisture was condensed

an d measured. The dry standard volume of the sample gas was then compared to the volume of moisture collected to determine the moisture content of the sample gas. A diagram of the Method 4 apparatus is shown as part of the Method 5 sampling train in Figure 2 of the Appendix.

To condense the water vapor, the gas sample was passed through a series of 4 impingers. The first and second impingers each contained 100 ml of de

- ionized ultra filtered water (DIUF). The third impinger was empty and the fourth contai ned a known weight of silica gel to absorb any remaining water vapor. Sample train operations followed the procedures outlined in EPA Method 5.

After the test run, the amount of water collected in the condenser system was measured gravimetrically. The net weight gain of water was converted to a volume of wet gas and then compared to the amount of dry gas sampled to determine the moisture content.

Method 5

EPA Method 5 was used to determine the FPM concentration at the test location. A diagram showing the major components of the Method 5 sample train is shown in Figure 2 of the Appendix. A sample of the gas stream was withdrawn isokinetically from the stack and the particulate matter in the sample gas stream was collected in a glass probe and on a glas s fiber filter. The weight of particulate collected combined with the volume of dry gas withdrawn from the stack was used to calculate the particulate concentration.

To prevent contamination, all components of the sample train were constructed of gla ss with no metal connections. Prior to testing, the components were washed using detergent and rinsed with tap water, deionized water and lastly with acetone. After drying, all components were sealed with parafilm or Teflon tape.

The sample probe consis ted of a glass liner and glass nozzle. Sample gas passed through the nozzle and probe assembly and then through a glass fiber filter heated to 250 o F (+/

- 25 o F). After exiting the filter, the sample gas passed through the condenser system

described in Meth od 4. The dry gas exiting the moisture condenser system then passed through a sample pump and a dry gas meter to measure the gas volume. After leaving the dry gas meter, the sample stream passed through an orifice used to meter the flow rate through the sample train. The pressure drop across the orifice was measured with an incline plane, oil manometer.

85mm Whatman glass fiber filters were used as the substrate for the particulate sampling. The filter was loaded into a glass filter holder with a Teflo n support screen that was prepared in the same manner as the other components of the sample train. Prior to the test run, the filter was desiccated for at least 24 hours and then weighed to the nearestNichols Aluminum Casting Report No. 3592

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0.0001g until a constant weight was achieved. The we ight of the filter was considered constant only when two consecutive weights taken at least six hours apart were within 0.0005g of each other.

The probe was thoroughly pre

- cleaned with acetone and the probe wash saved as a quality

assurance check. The co ndenser system was then prepared as outlined in Method 4. The sample train was leak checked prior to the test run by capping the probe tip and pulling a vacuum of at least 15 in. Hg. A leak check was considered valid if the leak rate was less

than 0.02 c ubic feet per minute or four percent of the average sample rate. When not in operation in the stack the nozzle was sealed with Teflon tape.

The probe tip was then placed at each of the sample points determined in Method 1. The velocity at the sample poi nt was determined using Method 2 by reading the velocity pressure from the manometer. Sample gas was withdrawn from the source at a rate such that the velocity at the opening of the nozzle matched the velocity of the stack gas at the sample point (isokine tically). The gas velocity pressure ( ∆ P), gas meter reading, gas meter inlet and outlet temperatures, gas meter orifice pressure ( ∆ H) and pump vacuum were recorded for each sample point.

After the test run, the train was leak checked at the highest vacuum encountered during

the test run. The condensate net gain of the impinger contents was determined as outlined in Method 4 and discarded. The probe liner and nozzle were washed with acetone. The rinse was saved in a 250 ml glass jar equipped with a Teflon lined lid. Teflon tape was

used to seal the filter assembly. The filter was removed from the filter holder and sealed in a plastic petri dish once testing was completed.

Analysis of the samples for particulate matter was performed at the Airtech Laboratory in Elk Grove Village, Illino is. Each probe rinse was transferred to a tared beaker, evaporated to dryness under ambient temperature and pressure conditions, desiccated for 2 hours and weighed to a constant weight. Each filter was desiccated for 24 hours and weighed to a constant we ight. The weight

- gain of the probe rinse and filter from a test run yield the total weight of particulate collected. To eliminate interference in establishing a constant weight, both the analytical balance and the desiccators were equipped with an ion ge nerating polonium strip designed to eliminate static electricity that may have collected on the samples.

Method 9
The opacity of emissions from the test location was determined according to Method 9. A certified observer positioned with a line of sight pe rpendicular to the plume direction determined the opacity. The observer viewed the plume with the sun oriented in the 140 o sector of the observer’s back. A minimum distance equal to three times the height of the

stack was maintained between the observer and the smoke plume. The observer’s line of sight did not include more than one plume.Nichols Aluminum Casting Report No. 3592

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Readings were taken at 15

- second intervals. Observations were recorded concurrently with the particulate testing. Between readings, the observer looked away from t he plume to rest his eyes. Wind speed and direction were recorded as well as descriptions of the plume.Nichols Aluminum Casting Report No. 3592

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### Description of Process

Nichols Aluminum operates a casting facility on JM Morris Blvd in Davenport Iowa (Iowa Plant Number 82

- 01

- 089 ). Testing in t his document was conducted on the Shredder baghouse. The Shredder baghouse is a Howden HF Dust Filter.