## ) I



# ) •. ....

/



# ) 2011 PrimaryAluminum Potline and Anode BakeFurnace MACT Test Program Report Certification I certify that to thebest ofmyknowledge: o Testing data and all correspondinginformation havebeen checked for accuracy and completeness. o Samplingand analysis havebeen conducted in accordance with the approved protocol and applicable referencemethods (as applicable). o All deviations, method modincations, or sampling and analytical anomalies are summarized in the appropriatereportp.arrative(s). 

# 1:2

**~;2-** 

# /l Date TRC was operatinginconformance withtherequirements ofASTM D7036-04during this testprogram. 

# 9.v0Bp.:i Jeffrey . Burdette · TRC

## Air Measurements Technical Director

# ( 

# )

---- TABLE 1-2 TEST 

## RUN TIMES- POM TEST 

## RUNS ALCOA WARRICK OPERATIONS Date Anode Baking Ring Furnace (A-446) Reactor# 1 Run 1 24-0ct Run 2 24-0ct Run 

## 3 24-0ct Anode Baking Ring Furnace (A-446) Reactor# 3 Run 1 24-0ct Run 2 24-0ct Run 3 24-0ct · Start Stop 10:30 13:24 14:30 17:25. 19:35 21:44 10:30 12:59 14:30 17:25 19:35 22:26

### Alcoa- iFarrick Operations Ne1vburs;h, 

## LN - 

## SECTION2.0 

## SUMMARY OF TESTRESULTS Table 2-1 summarizes the POM results for the reactors. The mass emission.rate ofPOM from each reactor and the combined mass emission rate from both reactors are shown as lb/hr values as well as on the basis oflbs/ton ofgreen anode throughput. The average POM emission rate from the A-446 Reactor# 1was 0.0515 lbs/ton ofgreen anode. The average POM emission rate from the A-446 Reactor # 3 was 0.0377 lbs/ton of green anode (after adjustment for: low isokinetic rates). As

**di~cussed** 

## further in Section 7, the POM emission rates for Reactor#.3 for· Run 1 and Run2 

## were adjusted (increased) to correct for the low isokinetic sampling rates for these two ljlillS. 

## The combiried POM emission rate for the A-446 Reactors was 0.0893 lb/ton of·· green anode (adjustedvalues).. Table 

## 2-2 summarizes the 

# PM

**r~sults** derived from Method 315 for the reactors. The .mass emission rate ofPM from e!lch reactor and

**th~** 

## combined mass emission rate from both reactors are shown as lb/h! values as well as on the basis of lbs/ton of green anode throughput. ·The average PM emission rate from the A-446 Reactor# 1 was 0.0179 lbs/ton ofgreen anode. The average PM emission rate from the A-446 Reactor# 3 was 0.0628 lbs/ton ofgreen anode (after adjustmenyfor low isokineticrates). As discussed further in Section 7, the PM emissionrates for Reactor # 3 for Run 1 and Run 2 were adjusted (increased) to correct for the low isokinetic sampling rates for these two runs. The combined PM emission rate for the A-446 Reactorswas 0.0808 lb/tpn ofgreen.anode (adjusted values). ! . . . . 

## The stack test data and te.st results for each test method and eachtestrun conducted are provided .. inmoredetailedtablesthroughthis report.

. ·•·· ·-·-·-.-··-· '•·•··•·•· .r--'7-'

C:\ALCOA PROJECTS\186567-WarrickPMACT 2011\Repom\Test Repon-Potlines & BakeFurnace Rpl-Rev.doc 

## 2-1 i 

### I··- tons/hr lblhr Ibs/ton of Green Anode ( ---..___./ TABLE 2-1 POM TEST RESULTS A-446 REACTORS ALCOA-WARRICK OPERATIONS NEWBURGH, IN A-446 REACTOR# 1 Green Anode Throughput Reactor Emission Rate Emission Rate Run#1 19.85 1.111 0.0560 Run#2 19.85 0.896 0.0451 Run#3 Average 19.85 19.85 1.062 1.023 0.0535

!

0.0515

I I I I

---------------------------------------------------------------------------------------------------------'-----:---------------------------------1-------------------l
tons/hr lb/hr lbs/ton of Green Anode lblhr lbs/ton of Green Anode A-446 REACTOR# 3 Green Anode Throughput Reactor Emission Rate Emission Rate Reactor Emission Rate, iso adjusted Emission Rate, iso adjusted 19.85 0.665 0.0335 0.759 0.0382 19.85 0.785 0.0395 0.913. 0.0460 I I I I I I I I I I I 19.85 l 0.576 0.0290 0.576 0.0290

. '

. 19.85 0.675 0.0340 0.749 0.0377 --------------------------------------------.-----------------------=------------------------------------------------:-----------;,..- ________________ ,_ _________________ _
tonslhr lb/hr lbs/ton of Green Anode NOTE: COMBINED A-446· REACTORS # 1 & # 3 Green Anode Throughput 19.85 19.85 19.85 Reactor Emission Rate 1.776 1.681 1.638 Emission

Rate 0.0895 0.0847 0.0825 Reactor

Emission Rate, iso adjusted 1.870 1.809 1.638 Emission Rate, -iso adjusted 0.0942 0.0911 0.0825
The Run 1 and Run 2 POM emission results for Reactor# 3 were adjusted (increased)

to correct' for the low isoki.netic sampling rate during those two test runs. 19.85 1.698 0.0856 1.772 0.0893 .,_..-·;

' . ---+ ---- -T·-- **---~-**tons/hr lb/hr lbs/ton of Green Anode TABLE2-2 PM TEST RESULTS A-446 REACTORS ALCOA- WARRICK OPERATIONS NEWBURGH, IN A-446 REACTOR# 1 Green Anode Throughput Reactor Emission Rate Emission Rate Run#1 19.85 0.281 0.0141 Run#2 19.85 0.356 0.0179 Run#3 19.85 0.432 0.0218 Average 19.85 0.356 0.0179 **~~---------------------------------------------------------------------------------------------------------------------------------------------------------t-----------**
tons/hr lb/hr lbs/ton of Green Anode lb/hr lbs/ton of Green Anode 1 I I A-446 REACTOR# 3 ! Green Anode Throughput 19.85 Reactor Emission Rate 0.822 Emission Rate 0.0414 Reactor Emission Rate, iso adjusted 0.939 Emission Rate, iso adjusted 0.0473 19.85 1.166 0.0587 1.355 0.0683 19.85 1.446 0.0729 1.446 0.0729 I I I 19.85 1.145 0.0577 1.247 0.0628 **1~---------------------------------------------------------------------------------------------------------------------------------------------------------t-----------** ·tons/hr lb/hr lbs/ton of Green Anode lb/hr. lbs/ton of Green Anode NOTE COMBINED A-446 :REACTORS # 1 & # 3 Green Anode Throughput

. **~9.85** 19.85 19.85 Reactor Emission Rate 1.103 1.522 1.878 Emission Rate 0.0556 0.0767 0.0946 Reactor Emission Rate, iso adjusted 1.219 1.712 1.878 Emission Rate, isb adjusted 0.0614 0.0862 0.0946

The Rtm 1 and Run 2 PM emisison results for Reactor # 3 were adj1.1sted (increased)

to correct for the low isokinetic sampling rate during those two test runs 19.85 1.501 0.0756 1.603 0.9808

# )

·._ 

# ) Alcoa- Warrick Operations Newburgh, IN 

## SECTION 3.0 DESCRIPTION OF SOURCES AND SAMPLINGLOCATIONS 

# . 3.1 DESCRIPTION OFPROCESS**---~---------------------------·** 

### ·--=------------------- ---- 

## The anode baking furnace is comprised ofone green anode ring baking furnace controlled by a common Alcoa designed A-446 emission control device. The baking furnace structureis a series of interconnected refractory flues connected to side main exhaust manifolds. Ptoducts of combustion and other**~missions** 

## created .in the baking fumace are drawn into therefractory flues_· and exhausted to the- common control equipment through a se1ies ofducts. The furnace is fueled with natural gas. In 

## the baking furnace, green anodes are stacked into sub-surface pits foim-ed by -the interconnecting flue. structures. After being placed in the pits, the green anode material is surrounded and covered with petroleum coke referred to as "packing material". The baking process is operated toallow recently filled pits to be preheated for aperiod oftime bef0rebeing actively fired. Likewise, after firing, baked anodes are allowed to cool in thepits before they are removed and used in the smelting process. Natural gas burners supply heat to the furnace and promote the combustion oforganic constituents drawn into the flues during the baking,process. The preheating, heating, and cooling processes are sequenced around the fumace im.either a clockwise or counter clockwise direction. Emissions from the anode bake furnace are collected and treated by an integrated system of ducting and a-pollution control system. The control system employed at the Warrick Operation anode baking furnace is a multi-unit, fluid-bed reactor type system with fabric :filtration downstrean1 ofthe

## re~ctor beds. Smelting grade alumina is introduced into one

## -enctoftb:~,Alcoa.. ·· designed A-446 reactors. -The alumina is fluidized by an auxiliary**fluid~zing** 

## fan blowing. ambient air through a s·eries ofperforated plates in the bottom ofthe reactor .Chamber. A.p.ode· · baking_furnace emissions are introduced into ,tlie fluidized bed through exhaust gas map.i,iqlds > 

## along each side ofthe reactor. The fluid bed provides a site for fluoride to**rea~t** 

## withthe alm$ina · and for the gas stream to be cooled. The fabric filtration devices are positimied atop .ofthe

## ~uid beds to collect entrained alumina particlesand-otherparticulatematterpresentinthe·gas**stre~.** J:\180000-209999_Job#\186567 • Warrick PMACT 2011\Repons\Test Repm1-Potlines & Bake Furnace Rpt.doc ':t 1 

# I I I 

# I I .i

# I I ; 

# i'

## Alcoa- Warrick Operations Newburo-Jz, IN "·-·-··-····--· ----······-···----..,..------------- 

## 3.2 SAMPLINGLOCATIONS Metho.d 

## 1 datasheets and traverse point locations are provided in Appendix 

## A for each ofthe samplinglocations.
----
) ..' 

## The anode bake furnace primary system consists ofa single dry 

## alumina scrubber .control.device. with three (3) reactor sections or compartments. Two compartments (ReactorNo. 1 and Reactor No.2) on the anode furnace control device have three stacks and one compartment (Reactor No. 3) has only one stack. The Green Anode Baking Ring Furnace exhausts through seven (7) 

## separate stacks. Three stacks 

# - . 

## for ReactorNo. 

## 1 and three stacksfor ReactorNo.2 and one stack for Reactor No.3. The stacks for Reactor No. 

## 1 and Reactor No. 2 are identical. These vertical stacks have 

## an internal

diameter of26.25-inches. The location ofthe two test ports (90° apart) are 60-inches (2.3 duct diameters) do,wnstream from the nearest
**d~sturbance,** 

## and 232-inc.hes (8.8 duct diameters) upstream from the exhaust. "For Reactor No. 3, the inside diameter ofthe stack is 46-inches, and it has two test ports (90° apart). The ports are Q2.5-inches 

## (2 duct diameters) downstream frorri the nearest disturbance, and 192-inches (4.2 duct diameters) upstream from the exhaust. For

**particulat~** 

## measurements conforming to Method 5 (as referenced in Method 13A and Method 315) a total of 24 traverse points were used at each stack for the velocity and TF and POM measurements, 12 traversepoints perport.

:.·:0 __ _ C:\Documents and Settings\bruntsh\Local Settings\ Temporary InternetFiles\Content.Outlook\69ZUN3HF\Test
**Report~Potlines** BakeFurnaceRpt-Revl2-6·1 !.doc 

## 3-2 1 i

## ( 

# )

**·~.**___/

1._ )

,

### ___...,. 

## Alcoa- Warrick Operations Newburgh, IN

.• 

# ·.c 26.25inches .SamplePorts 

# 0 FLOW ' 

## . 

# . , 

## 232 inches

**6.0~ches**



## Figure 3-3. A-446 ReactorNo. 1 StackSamplingLocations C:IALCOA PROJECTS\186567-Warrick PMACT 2011\Reports\Test Report-Potlines & Bake Furnace Rpt.doc I



# ~ I

# ( 

# ) Alcoa- Warrick Operations Newburgh, IN



## 46 · :inches SamplePorts 

# -0

FLOW ,.. .. 

## 192 inches

92.5 inches Roof Figure3-4. A-446 ReactorNo. 3 Stack SamplingLocation C:\ALCOA PROJECTS\186567-Wanick PMACT 201 1\ReportsiTest Report-Potlines & BakeFurnace Rpt.doc I I



# ~

# )

' 

## ) '-._____./ 

## Alcoa- Warrick Operations Newburgh, IN 

## SECTION4.0 SAMPLING AND ANALYTICAL PROCEDURES The sampling and analytical procedures that were used in this test program are described below. The referenced EPA sampling and analytical procedures are available from the EPA TTN EMTIC electronicbulletin board. 4.1 SAMPLING TRAVERSE POINTS The number and location of the sampling traverse points were detem1ined according to the procedures outlined in EPA Method 1. 

## Priorto conductingthe emission tests, TRCmeasured the stack dimensions and distances to gas flow disturbances. The actual number and location ofthe traversepoints were dete1mined using EPA Method 1. 4.2 VOLUMETRIC FLOW 4.2.1 Flue Gas Velocity The velocity was determined according to the procedures outlined in EPA Method 2. Velocity head (delta P) measurements were made using TypeS Pitot tubes conforming to the geometric specifications outlined in EPA Method 2 and having a coefficient of 0.84. The differential pressures were measured using a fluid manometer. The exhaust gas temperatures were measured using chromel-alumel thermocouples and associated digital readouts. 4.2.2 Exhaust Gas Composition The potline flue gas contains ambient air that is drawn from hoods above the pots inside ofthe smeltin·g building. The oxygen content was assumed to be 20.9% and the carbon dioxide was assumed to be 0%. The anode furnace A-446 reactor flue gas composition was measured by collecting integrated Tedlar bag samples during each test run. Thesebag samples were analyzed onsite with an Orsat. J:\180000-209999_Job#\186567 • Wanick PMACT 2011\Repons\Tcsl Report-Pollines & Bake Furnace Rpl.doc 

## 4-1

### Alcoa- Warrick Operations 

### Newburalz, IN 

## 4.4 POLYCYCLIC ORGANICMATTER Method 315 

## "Determination ofPatiiculate and Methylene Chloride Extractable Matter (MCEM) from Selected Sources at Primary Aluminum Production Facilities" was used to measure the polycyclic organic matter (POM) emissions. This method uses aMethod 5 style sampling train. 4.4.1 SampleCollection Samples were collected isokinetically (90% to 110%) from the stack using an EPA Method 5 · style sampling train. The sampling train consisted of a glass nozzle, connected to a glass-lined probe with a Type S Pitot tube attached. The sample was passed through a heated filter maintained at 248 °F (within 25 °F) provided by Alcoa. After passing through the filter, the sample stream was connected to the Method 5 style back-halfwhich consisted offour impingers. The first two impingers each contained 

## 1 00-ml of deionized distilled (DI) water, the third impinger was empty and the fourth impinger contained silica gel. Each impinge!'was weighed ( ) prior to sample train assembly. The sample train was connected to a standard Method 5 metering ··..._./ 

## console. 4.4.2 SampleRecovery After the completion ofthe test run and following the post..:test leak check, the filter was removed from the filter holder and placed in a glass samplejar orpetri dish. Following the test run, each of the impingers was weighed to determine the post-test weight. The ·weight ofwater vapor condensed in the impingers and the weight ofwater vapor collected in the silica gel was summed and subsequently entered into moisture content calculations. The nozzle, probe, and front.;..halfof the filter holder were rinsed with acetone into a glass samplejar. Following the acetone rinses the front half ofthe satnple train was rinsed with methylene chloride· which was collected in· another glass jar. The impinger catch was poured into a glass samplejar and then tl1e sample train back-halfglassware was 1insed first with water, acetone and then with methylene chloride. The waterrinse was added to the impinger catch samplejar. The two solvent rinses were placed in a separate glass samplejar. The filter, impinger catch and DI and solventrinses were analyzed by Alcoa laboratory personnel per Method 315 

## procedures to determine the polycyclic organic matter (POM) content. J:\180000-209999_Job#\186567 ·Warrick PMACT 2011\Reports\Test Report-Potlines & Bake FurnaceRpt.doc

# _) Alcoa- Warrick Operations Newburgh, IN 

## SECTION 5.0 QA/QC PROCEDURES AND RESULTS • As a guide, TRC uses the EPA do.cument 

## Quality Assurance Handbook for Air Pollution Measurement System, Volume III. TRC's QA/QC plan has incorporated certain considerations to the production ofquality data in all ofits sampling workregardless ofthe scope and purpose ofthe testing. These considerations include: • Planningthe testingprogram; • Use ofreliable andwell-maintained equipment; • Use ofappropriate fmms for recording sampling data; • Establishing .a sample coding system to ensure proper chain of custody (i.e., sample identification, laboratorytracing and storage, analysis and reporting); e 

## Use of calibration and audit gases traceable to the National Institute of Standards and Technology (NIST); • Control errors bychecking data inputs and perfonningredundant calculations; • Adherenceto established protocol. 

## 5.1 BAROMETER Barometric pressure values for the testing period were recorded fi:om a calibrated digital barometer on-site and verified by side by side comparison to a mercurial barometer located in the TRC Field Officein Raleigh, NC. 

## 5.2 PITOTTUBES '\"-) Each Pitot tube used in this samplingprogram met the design specifications for Type S Pitottubes in EPA Method 2. Therefore in accordance with Method 2 procedures, a baseline coefficient (Cp) J:\180000-209999_Job#•l86567 -Warrick PMACT 2011\Repo11siTest Report-Potlines & Bake Fumncc Rpt.doc

### Alcoa- Warrick Operations Newburaft, IN 

## of 0.84 was assigned to each Pitot tube. Calibration at the manufacturer for Pitot face-opening alignment included measuring the extemal tubing diameter (dimension D 1 ), 

## the base-to-opening

**~ ~**  . 

## misalignment angles, with all tenns as described in Figures 2-2 and 2-3 ofEPA Method 2. Pitot tubes werevisuallyinspectedpriorto and at the completion ofthetest to insure structural integrity. 

## 5.3 CALIBRATION METERAND METERING SYSTEM TRC calibrates meter boxes at least once per year. The calibration set-up for the dry gas metering system using the secondary reference meter in lieu ofthe wet test meter is given in Figure 5.5 of EPA Method 5. A leak check ofthemetering system before calibration was performed as shown in Figure 

## 5.4 ofEPA Method 

## 5. Themetering system's pump was operated for5 minutes at

# an orifice manometer setting of

## 0.5 inches H2

## 0 

## to heat up the pump and system to stabilize the meter. inlet and outlet temperatures. Values for the orifice setting (delta H), wet test meter volume 

## (V 

## w), conesponding 

## dry test meter volume 

## (V ct), dty test meter inlet and outlet gas temperatures (tcti and tctn), and time wererecorded for the initial calibration. Theratio ofthe wet testmeterto the drytest meter (y or gamma) and the orifice pressure differential that equates to the desired sampling rate at· standard conditions (delta H@) was then calculated. A copy of the pre-test metering system calibration is included in Appendix Cto this TestReport. 

## 5.4 POST-TEST METER CALIBRATION As an altemative to performing post-test meter calibration checks, TRC follows EPA Altemative009. This procedure is performed on-site using the data collected for each ofthe test runs. It is prefen·ed byEPA because it eliminates the questions aboutpossiblemeter damage during transport 

## after the emission test and, because the calibration data is available in the field immediately following the test, it eliminates the costly travel, remobilization, and scheduling ofa retest should the meter fail the post-test calibration. These calibration checks are included with ·the field datasheets in Appendix A ofthis.Test Report. 

## 5.5 THERMOCOUPLES AND DIGITALINDICATORS Them1ocouples were calibrated by comparing them against an ASTM-3F mercury-in-glass thennometer at approximately 32°F (ice water), ambient temperature and approximately 212°F (boiling water). Each thermocouple was calibrated against temperatureranges to which itwas to be typically exposed during test conditions, and they must agree within 1.5 percent (expressed in °R) of the reference thermometer throughout the entire calibration range. A post calibration was J:\1 80000-209999_Job#\186567 - Warrick PMACT20Il\Repm1s\Test Rep011-Potlines & Bake Fumnce Rpt.doc---
**·--~--** - ---·--···-- --- 

# (J

(

_

# _) Alcoa- Warrick Operations Newburgh, IN 

## perfonned in accordance with EPA ALT-OII using a single point calibration against an ASTM ;nercury-in-glass

**thern101~eter** 

## in addition to a contin,.nity check of the the1mocouple. The continuity check involves verifying that the thennocouple read-out trends in the appropriate direction when exposed to atemperature change. Digital indicators were checked byintroducing a series ofmillivolt signal strengths to the input and comparing the indicator reading with the actual signal strength. Acceptable calibration error does not exceed 0.5 percentwhen temperatures are expressed in °R. 5.6 ANALYTICAL BALANCE The analytical- balance was calibrated by comparing readings from its own internal calibration weight against a I00 gram NIST (formerly NBS) Class-SI standard weight. Linearity ofthe balance was demonstrated by further comparison ofits readings against other selected (0.5g, lg, lOg, 50g) NIST Class S-I weights. The NIST class S-1 weights were calibrated by the NC Department ofAgricultural Standards LaboratoryinRaleigh, NC. 

# 5.7 REAGENTBLANKS AND FIELD BLANKS TRC collected reagent blank samples for Methods 13A and 3I5. These reagent blanks were analyzed along with the field samples. 5.8 CHAIN OFCUSTODY A list or log of all samples was prepared and used to maintain the chain of custody of the san1ples. Copies ofeach "sample log" or chain ofcustody form are included with the laboratory report. The field team leader·prepared the satnple log onsite during or at the conclusion of sample recovery activities. Samples were carefully packed for transport .to the analytical laborato1y. .The samples were transp01ied to the laboratorybyTRC.

J:\1 80000-209999_Job#\1 86567- Wanick PMACT 201 1 \Reports\ Test Repo11-Potlines & BHke Fumace Rpl.docI I 

## Alcoa- Warrick Operations Newburalt, IN 

## SECTION:6.0 

## CALCULATION OF.RESULTS ·

.

# .,. ... 

## Emission rates interms ofpounds per hour (lbs/lu·) were calculated using the pollutant emission concentration expressed in ternis of grruns per 

## dry standard cubicfeet and ·milligrams p(:)J:·c1;1bic, metertimesthe volumetric gas flow rate expi·essed in terms of

## dry standard cubicfeetpermin:ute ... · . · Emission rates in terms of.powds per hour {lbs/hr).were calculated using the. pollutant emission rate in terms of micrograms per dry standard cubic foot (ug/dscf), flowrate ·"" dsc:fi:n (Qs), .60 minutes/hour, dividedby**453,~00,000**

## ug/lb. lbs/hr = 

## (ug/dscf) X ·Qs X 60 453.6 

## X 106 

## Emission ratesin terms ofpounds per hour (lbs/hr) were calculated using the pollutant emission rate in terms of parts per million (ppm/dry), flowrate - dscfm (Qs), molecular weight of the pollutant (MW), 

## 60 minutes/hour, dividedby385.3 X 

## 106

## dscf/lb-mole@ 68°F (20°C). lbs/hr = 

## ppm 

## X Qs 

## X MW X 60 385.3 

## X 106 

## Fortestruns which had isokinetic samplingrates below 90%the emissionrates were adjusted (increased) by dividingthe emissionrate bythe lowisokinetic rate. Forexample, ifthe isokineticrate was 86%, thenthe emissionrate was dividedby0.86. Fortestruns whichhad isokinetic san1pling rates above 110% the emissionrates were adjusted (increased) by multiplyingthe emissionrate bythe highisokineticrate. Forexample, ifthe isokineticrate was 114%,thenthe emissionrate was multipliedby 1.14.

C:\Documents and Settings\bruntsh\Local Settings\TemporaryInternetFiles\Content.Outlook\69ZUN3HF\Test Report·Potlines BakeFurnaceRpt-Revl2-6-ll.doc 

## 6-1 ·"': •; 'i.' 

## )

··...__/ 

### Alcoa- Warrick Operations Newburalz, IN 

## : SECTION 7.0 DISCUSSION'OF TESTRESULTS Table 7-7 provides the 

## POM test data and resul.t's for the A-446 Reactor.. No. 1 stacks. The POM 

# .. emission rate averaged 1.023 lb/hr with arange from 0.896 to l.llllb/hr. Table 7-8 provides the 

## POM test data and results for the A-446 Reactor No. 3 stack. The POM emission·rate averaged 0.675 lb/hr with a range from 0.576 to 0.785 lb/hr. The isolcinetic rate for Run 1 was 87.6% and the isolcinetic rate for Run 2 was 86.0%. In Table 2-3 the POM test results for Run 1 and Run 2 were adjusted for these low isolcinetic sampling rates by dividing the Run I··· 

## POM mass emission rate by the 0.876 and by dividing the Run 2 POM mass emissionrate by 0.860. This adjustment increases the

## POM emission rates for thesetwo test runs. The field datasheets, laboratory analytical report and procedures, along with the equipment calibration documentation are provided in the appendices to thisreport.

J:\180000-209999_Job#\186567 -Warrick PMACT 2011\Repons\Test Repon-Potlines & Bake Furnace Rpt.doc .· 

### .. : ·,,;



# ...

# i TABLE 7-7 i-



### -- "· 

### l METHOD 315 POM TESTRESULTS ALCOA- WARRICK OPERATIONS A-446 REACTOR# 1 (Three Stacks) ' NEWBURGH, IN 

### ' ·' •' RUN NUMBER ' M315-BH#1-1 M315-BH#1-2 M315-BH#1-3 

# I AV.ERAGE RlUN DATE ·' 10/24/2011 10/24/2011 10/24/2011 

### ! •' RUNTIME 1030-1324 1430-1725 1935-2144 

### ! ! MEASURED DATA 

# i (Y) Meter BoxY 0.9912 0.9912 0.9912 : (DeltaH) · AvgDelta H, inches H2 0 1.11 1.19 1.17 

# I (Pbar) Barometric Pressure, inches Hg 29.60 29.60 29.60 (Vm) Meter Volume, 

### ft3 85.201 88.809 85.757 

# I (Tm) Avg Meter Temp, deg F 73 80 57 (Pg) Static Pressure, inches H2 0 -0.22 -0.25 -0.22 I .. 

### ! (Ts) Avg Stack Temp, deg F 173 172 176 

## ! (Vlc) Water Collected, mL 199.8 159.5 188.9 

# I (%C02) Carbon Dioxide; % 3.0 2.6 2.6 2.7 (%02) Oxygen,% 17.0 17.7 17.0 

### ! 17.2 (%N2) Nitrogen,% 80.0 79.7 80.4 

### ! 80.0 

### ! (Cp) Pitot Tube Coefficient 0.84 0.84 0.84 

### : 

### ! (DeltaP) Avg Sqrt Delta P, (inches H20)Y, 0.756 0.787 0.800 : (Theta) SampleTime, min 144 144 144 

# i· : (Dn) Nozzle Diameter, inches 0.216 0.216 0.214 

# I CALCULATED DATA 

# } (An) Nozzle Area, square feet 0.000254469 0.000254469 0.000249778 (Vmstd) Standard Meter Volume, ft3 82.895 85.302 86_052 

# !
...... : (Ps) Stack Pressure, inches Hg 29.58 29.58 29.58 

### ! (%H20) Moisture,% 10.2 8.1 9.4 

### ! 9.2 

### ! (Vwstd) Standard Water Vapor Volume, ft3 9.421 7.520 8.907 

### ! (Mfd) Dry MoleFraction 0.898 0.919 0.906 j (Md) Molecular Weight-dry, lbllb-mole 29.16 29.12 29.10 

# I (Ms) Molecular Weight-wet, lb/lb-mole 28.02 28.22 28.06 

# ! (Vs) Velocity, ft/s 47.5 49.2 50.3 49.0 (A) Stack Area ofThree Stacks, ft2 11.27 11.27 11.27 

## j (Qa) VolumetTic flow, acfm 32,102 33,271 34,032 : 33;135 : (Qs) Volumetric flow, dscfm 23,767 25,233 25,310 

# I 24,770 

### (I) Isokinetic Rate, % 107.3 104.0 106.6 EMISSIONS DATA 

# ! : 

### ! POLYCYCLIC ORGANIC MATTER (POM) 

# ! 

# I. (grams) Total POM Catch, g 0:0293 0.0229 0.0273 0.0265 (mg/dscm) Concen., mg/dscm 12.5 9.5 11.2 

# I 11.1 (mg/acm) Concen., mg/actual m3 9.2 7.2 8.3 

# I 8.3 . (gridscf) . Concen., gr/dscf 0.00545 0.00414 0:00490 

### !' 0.00483 (gr/acf) Concen., gr/actual cf 0.00404 0.00314 0.00364 

### ! 0;00361 

### ! (lb/hr) Emission Rate, lb/hr 1.111 0,896 1.062 : 1.-023 !( 

# ' I· f I PARTICULATEMATTER (PM) I I I I I I I (grams) Total PM Catch, g 0.00740001 0.0091 0.01109999 I 0.0092 I I I Concen., mg/dscm (mg/dscm) 3.2 3.8 4.6 I 3.8 ' I ' I Concen., mg/ actual m3 ·' I •' (mg/acm) 2.3 2.9 3.4 I .2.9 I I (gr/dscf) Concen., gr/dscf 0.00138 0.00165 0.00199 I .6':00167 I I I ;;,:.::·· (gr/acf) Concen., gr/actual cf 0.00102 0.00125 0.00148 I 

# ·.

**·1w~t~,~:~ 5**  I· I I (lblhr) EmissionRate, lb/hr 0.281 0.356 0.432 I. 

## ' C:!t¥rfi/i

### TABLE 7-8 METHOD 315 POM TEST RESULTS ALCOA- WARRICK OPERATIONS

A-446 REACTOR# 3 (One Stack) NEWBURGH, IN 

# . . .. I' 

### RUN NUMBER M315-BH#3-1 M315-BH#3-2 M315-BH#3-3 

### I AVERAGE RUN DATE ' 

### 10/24/2011 10/24/2011 10/24/2011

**~** •' .•I 

### RUNTIME 1030- 1259 1430 - 1725 1935- 2226 I I l 

### MEASURED DATA 

# I (Y) Meter BoxY 0.9874 0.9874 0.9874· (DeltaH). Avg Delta H, inches H 2 0 1.76 1.80 2.25 (Pbar) Barometric Pressure, inches Hg 29.60 29.60 29.60 

# I (Vm) MeterVolume, 

### ftl 103.111 103.366 111.978 I 

# '! (Tm) Avg Meter Temp, deg F 72 73 59 

### j (Pg) ' 

### Static Pressure, inches H20 

### -0.31 -0.30 .-0.32 

# ! (Ts) Avg Stack Temp, deg F 170 170 169 

# I (VIc) Water Collected, mL 235.6 201.0 239.7 

### . I. (%C02) Carbon Dioxide, % 1.7 2.6 2.4 

### j 2.2 (%02) Oxygen,% 18.6 17.3 18.1 

# i 18.0 

### i (%N2) Nitrogen,% 79.7 80.1 79.5 

### I 79.8 (Cp) Pitot Tube Coefficient 0.84 0.84 0.84 

## ! (DeltaP) Avg Sqrt Delta P, (inches H20)Yz 

### 0.775 0.781 0.829. I 

### (Theta) Sample Time, min 144 144 144 

# !

(Dn) Nozzle Diameter, inches 0.259 0.259 0.259 I 

# I CALCULATED DATA (An) Nozzle Area, square feet 0.00036587 0.00036587 0.00036587 

### I (Vmstd) Standard Meter Volume, ft3 

### 100.293 100.399 111.814 

# !

(Ps) Stack Pressure, inches Hg 29.58 29.58 29.58 

### I (%H20) Moisture,% 10.0 8.6 9.2 

### I 9.3 (Vwstd) Standard Water Vapor Volume, ft3 

### 11.109 9.477 11.302 

# i (Mfd) Dry Mole Fraction 0.900 0.914 0.908 

# I (Md) Molecular Weight-dry, lb/lb-rnole 29.02 29.11 29.11 I 

### I (Ms) Molecular Weight-wet; lbllb-mole 27.92 28.15 28.09 

# I (Vs) Velocity, ft/s 48.6 48.8 51.8 -49.7 (A) Stack Area, ff 11.54 11.54 11.54 

# I (Qa) Volumetric flow, acfm 33,630 33,785 35,885 34,433 (Qs) Volumetric flow, dscfm 25,092 25,582 27,034 

### l. 25,903 (I) Isokinetic Rate, % 87.6 86.0 90.6 

## \j I 

### EMISSIONS DATA 

# I I POLYCYCLIC ORGANIC MATTER (POM) 

# !: 0.0233 

### " (grams) Total POM Catch, g 0.0201 0.0180 

### " 0.0205 

### J; (mg/dscm) Concen., mg/dscm 7.1 8.2 5.7 

### !-: 7.0 (mg/acm) Concen., mg/actualm3 

### 5.3 6.2 . 4.3 

# L· 5.3 (gr/dsct) Concen., gr/dscf 0.00309 0.00358 0.00248 

### 1:.. 0.00305 (gr/act) Concen., ,ir/actual cf 0.00231 0.00271 0.00187 1 

### 0.00230 I 

### (lb/hr) Emission Rate, lb/hr 0.665 0.785 0.576 I 

### 0.675 

### I ! 

### PARTICULATEMATTER (PM) (grams) Total PM Catch, g 0.02485787 0.0346 0.04519998 0.0349 (mg/dscm) Concen., mg/dscm 8.8 12.2 14.3 11.8 (mg/acm) Concen., mg/ actual m3 

### 6.6 9.2 10.8 8.9 (gr/dsct) Concen., gr/dscf 0.00382 0.00532 0.00623 0.00512 (gr/act) Concen., gr/actual cf 0.00286 0.00402 . 0.00470 0.00386 (lb/hr) Emission Rate, lb/hr 0.822 1.166 1.446. 1.145

# (--, -.__

# )


# C_J METHOD 1WORKSHEET Summary of Location Setup 

### COMPANY NAME: FACILiTY LOCATION (City, State)·. SAMPLING LOCATION: Circumference Far Wall to Outside of Port Inside Wall to Outside of Port DIAMETER OF STACK DIAMETER OF STACK Nearest Upstream Disturbance Nearest Dowstream Disturbance Nearest Upstream Disturbance Nearest Dowstream Disturbance Enter Information Below: ALCOA- WARRICK OPERATIONS Newburgh, IN A-446 REACTOR# 1 or 

### #2 (Each of 3 Stacks) Inches· 30 Inches · 3.75 Inches 26.25 Inches 2.19 Feet 60 Inches 232 Inches 2.3 Diameters. 

## 8.8 Diameters . USE 12 TRAVERSE POINTS PER PORT TOTAL TRAVERSE POINTS EXPECTED RUN DURATION TIME PER TRAVERSE POINT READINGS EVERY EXPECTED READINGS 24 144



### 6 6 24 24 ptX 3 Stacks minutes minutes minutes

### METHOD 1 TRAVERSE POINTS ALCOA· WARRICK OPERATIONS 

### Newburgh, IN A-446 REACTOR# 1 or# 2 (Each of 3 Stacks) Far Wall to Outside of Port 30 Inches Inside Wall to Outside of Port 3.75 Inches DIAMETER OF STACK 26.25 Inches Nearest Upstream Disturbance 60 Inches Nearest Dowstream Disturbance 232 Inches NUMBER of Traverse Points per Port. 12 POINT %of Depth Diameter ··Distance Distance from Inside w/ Nipple 1 0.021 26.25 0.551 4.301 2 0.067 26.25 1.759 5.509 3 0.118 26.25 3.098 6.848 4 0.177 26.25 . 4.646 8.396 5 0.25 26.25 6.563 10.313 6 0.356 26.25 9.345 13.095 7 0.644 26.25 16.905 20.655 8 0.75 26.25 19.688 23.438 9 0.823 26.25 21.604 25.354 10 0.882 ; 26.25 23.153 26.903 11 0.933 26.25 24.491 28.241 12 0.979 26.25 25.699 29.449 All measurements were verified in the ·field. Two Available Ports with 12 Traverse Points per Port Expecting 3 to 4 hour runs SAMPLE EACH POINT FOR 6 READINGS EVERY· 6 

### AREA OF STACK: 3.7583 ft.l\2

REACTOR#1 or #2-M1 Diameters 2.3 8.8

. 4 2/8

54/8 6 7/8 8 3/8 10 3/8 13 1/8 20 5/8· 23 4/8 25 3/8 26 7/8 28 2/8 29 4/8 Minutes Minutes I I 

# I I

**~** 

# I I 

# I

# C)·

l_) MeterBox PostTest Calibration Check ALCOA- WARRICK OPERATIONS NEWBURGH, IN
.A-446 REACTOR # 

### 1 (Three Stacks)

... MeterBox#: M-12 

# ---- Calibrated by: 5-Pt CalDate: 

### Richey Lowe 10/12/2011 DeltaH @ ---=-1::-:.9,_,.4..,..6 Gamma, initial 0.9934 CalculateYqa for each testrunusing thefolloviing equation: where: Yqa q Vm Tm Pb 0.0319 DHavg DH@ Md 29 13.6 dry gas metercalibration checkvalue, dimensionless. total runtime, min. total samplevolumemeasuredby dry gas meter, dcf. · absolute average dry gas metertemp., 0

### R.

barometricpressure, in. Hg. = 

### (29.92/528)(0.75)2 (in. Hg/0

### /R) cfm2. average orificemeterdifferential, in. H20. orificemetercalibrationcoefficient, in. H20. drymolecularweight ofstackgas, lb/lb-mole. 

### dry molecularweight ofair, Ib/lb-mole. specific gravity ofmercury. After eachtestrun series, do the following: Averagethethree ormore Yqa's obtained from the test run series and comparethis average with the dry gas meter calibrationfactor, Y. The average Yqamustbewithin 5 percent ofY. Ifthe average Yqa does notmeetthe+5 percent criterion, recalibrate the meter over the full range oforifice settings, as detailed in Section 5.3.1 of Method 5. Then follow the procedure in Section 5:3.3 ofMethod 5. Test I Test 2 time. •' 

### 144 144 Vm- total 101.619 106.257 Tmavg 78.1 80.9 Tm-R 538 541 Barometric 29.6 29.6 DHavg 1.514 1.804 DH@ 1.9460 1.9460 Md stackgas 29.16 29.12 MdAir 29.00 29.00 MeterBox Gamma 0;9934 0.9934 QAGamma 0.9295 0.9839 Difference: 6.4% 1.0% within 5%? FAIL PASS AVERAGEDIFFERENCE 2.8% 

# ----

Test3 144 103.784 60.7 521 29.6 1.779 1.9460 29.10 29.00 0.9934 0.9821

1.1% PASS 

### . I

..) I. 

### ISOKINETIC FIELD DATA SHEET METHOD 

# 1031>

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# 0TRC

Date:

## _/'-'-(~_5:::....__~-'--'-1/--

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## --...,.,;:=;;.<;,0-<~=.,_.....,=-----:---­ (ProJect:}''t;;Q'erorQA Manager ) RAI

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# / J METHOD4· MOISTUREANALYSISDATASHEET 

# 0TRC
Run Number Test Date RecoveryDate Recovered By 

### lmpinger 1 Dl Water Final Weight, g Initial Weight, g 

# 1- Net weight, g lmpinger 2 Dl Water Final Weight, 

## g Initial Weight, g 

# () Net wei lmpinger 3 Empty Final Weight, g initial Weight, g Net ht, g · lmpinger 4 Silica Gel Final Weight, g Initial Weight, g Netweight, g . lmpinger 5 Final Weight, g

**~e** 

### lnitiaiWeight, g Netweight, g lmpinger 6 Final Weight, g



### Checked By: tn__,__

# ,.,.:;2~.M()fl**u~nanor\ Date:___,/__,_/_-~']_-_{_{----** 

## METHOD 3 • ORSAT ANALYSIS FIELD DATA 

# (JTRC

. Run No.

. Start 

## Run Time . Chk 

# i=o___ _ Run No. Run Time Leak Chk 

# F

0



## . Run No. Run Time ·Leak Chk



# Fo

Checked By: RAI .M::\

**XI~** 

## Avg 

## --3 ;·.·

## Avg 

## ALCOA 

## 186567 WARRICK OPERATIONS

Avg

**~--~--~------~** QC Validation 

### Fa= (20.9- %02) I %C02 Distillate Oil 1.260 - 1.413 Residual Oil 1.210 - 1.370 Natural Gas 1.600 - 1.836 Wood/Bark 1.000-1.130 Expected 

### Fa Ranges

. Anthracite/Lignite Coal 1.015 - 1.130 Bituminous Coal 1.083 - 1.230 Municipal Solid Waste 1.043- 1.177



# ~S Date: 

## __,_,_/1_-s+-,...__,-t+-r __ _ (Project

**~anager** or QA Manager)C' **•LCOA-W~A~R=nl=cK~o=p=e=RA,.!:~~~~~~LlTY** NAME SAMPLING LOCATION-

,-446 REACTOR #1 IThreo Stacks) CITY AND STATE

IEWBURGH.IN STACK DIMENSIONS

lote Calc is for 3 sta' StnckiO Lenath

" ENTER IN INCHES 26.25 RUN SPECIFICS DATA

Runt Run2

EST DATE 10/2412011 1012412011

·EsrnMes 1030-1324 1430-1725 'EST DURATION 144 144 'EST RUN ID'$ M315-BH1t1-1 M315-9Hfl.1·2 NOZZLE INSIDE DIAMETER

G-4-144 Ruu I Run2

JOZZLE DIAMETER 0.216 0.216 DRY GAS METER DATA

M-10 Run I Rnn3

Aeterbox# M-10 M-10

JGM Gamma (Y) 0.9912 0.9912

lGMDeltafH) 1.815 1.915 VOLUME METERED

l\h:lerRendin!!'l Run I R11n2

tunS1nrt 131.440 217.290

t\mllirl 216.641 306.089
..e.1k Check I Stnn 0.000 0.000

. e.1k Check l EOO. o.nno 0.000

..cnkChcck2Start 0.000 O.ooo

.cnkChcck:!f:n:J 0.000 0.000

Volume Metered. 85.201 88.809

OK PRESSURE DATA

Run! Run:!

3aromelric Pressure 29.60 29.60 3tatlc PressU're ·0.22 MOLECULAR WEJGIIT DATA

Runt RlDI1

:lXVQen 17.0 17.7 :arbon Oio>dde 3.0 2.6 MOISTURE DATA

Runt Runl

3rams/mls Collected 199.8 159.5 Width Ruu

10/24/2011

1935-2144 144 M315-BH#1-3 Run3

0.214 Run

M-10

0.9912

1.815 Run

306.430

392.187 o.noo

o.oon o.ooo

0.000

85.757

OK "'"' 17.0 2.6 Run

188.9 POLYCYCLIC ORGANIC l\IATITERCPOM)

I RunlD.02931 :;rnms Collected Run:! 0.02191 Rm•

0.0273 TOTAL FLUORIDES LAB DATA

Rnnl Rnn2 R•m

\olitllornms Conected IN/A N/A N/A

I R1m I j R1!!!1__j Rlut /

K- Facio• ( I j 2 I . . /--'-\···

. **DornEnl~)** ·,;._,,· NUMBER OF TRAVERSE POINTS= l72j 12j nl DELTA P ----

RUN III RUNHl 'RUNII3 RUN/II

I 0.47 0.(,8G I 0.41 0.(>40 I

**·~·** 0.762 I 0.89

2 **0~2** 0.721 2 052 0.721 2 058 0.761 ' 0.98

J 056 0.748 J 0.45 0.671 ' 0.72 O.lW9 J t.on

4 0.72 0.849 4 050 0.707 4 0,78 0.8SJ 4 138

5 0.65 0.806 5 052 0.711 5 0.85 0.922 5 1.25

6 0.79 0.889 6 0.78 0,883 6 0.80 0.894 ' 1.49

7 0.81 0.900 7 ·0.78 0.88) 7 0.78 O.RRJ 7 !53

• 0.64 0.800 R 0.70 0.837 • 0.69 0,8.11 R 1.25

9 **0~9** 0.768 9 0..42 0.648 9 0.40 0.632 9 1.10

10 032 0.566 10 0.48 0.69) 10 0.40 0.632 10 0.60

II 0.40 O,Ci;\2 II 0.42 0.648 II 035 0.592 II 0.78

" 036 0.600 " 0.40 0.6.12 12 030 0.548 " 058

13 0.60 0.175 " 0.63 0.794 13 0.61: 0,787 13 1.20

" 0.65 0.806 14 0.72 0.849 " 0.75 0.8(11i 14 1.25

IS **0~6 n.~t2**  IS 0.85 0.922 IS 0.85 0.922 IS 1.25

16 D;74 0.860 16 us 0.9.22 16 0.88 0.938 16 1.40

11 0.81 0.9011 17 **0~1** 0.900 17 0.91 . 0.954 17 153

18 0.83 0.911 IR 0.70 0.8J7 18 0.87 0.9)) IR 1.60

: 19 0.84 (1,9\7 19 052 0.721 19 0.76 0.872 19 1.60

20 f!.6& 0.812 .20 0.40 0.6.12 20 0.60 0.715 20 1.26

" o ..... 0.663 " 0.40 ll.liJ2 " 0.48 0.693 " **·~I**

" 033 0.574 22 0.45 0.671 22 0.41 0.640 22 0.60

2.1 033 0.574 2.1. 0.41 0.640 2.1 037 0.608 2:\ O.fiO

24 0.30 0.548 ,. 032 o.sr.r. 24 0.38 0.616 24 058

" 0.47 o.6sr; " 0.61 0.781 " 0.48 0.693 " O.fl9

26 0.47 0.681i 26 058 0.762 2!i 0.62 0.787 2 26 0.89

27 058 0.7!i2 " 0.78 0.883 27 0.78 0.883 27 I.JO

'" 0.60 0.775 28 **0~5** 0.922 " 0,90 .0.949 '" uo

29 O.fiO 0.775 29 **o~s** 0.922 29 0.85 0.922 " 1.20

JO 0.83 0.911 30 **0~5** 0.912 30 0.88 0.938 JO 1.60

31 0.72 0,849 31 0.8! 0.900 31 **0~5** 0.922 31 132

32 050 0.707 J2 0.78 0.8Rl 32 0.78 0.8113 32 035

33 050 0.707 33 0.46 fl.!i78 33' 0.75 0.866 33 0.95

.34 ·0.48 ll.fi9J'• J4 033 0.574 . . 14· . o.fit 0.781 " 0.92

)5 031 0.5116 JS 0.33 0574 )5 **0~7** . 0.608 35 0.60

36 0.29 0.539 36 035 . 0.592 J6 035 0.592 36 055

37 0.48 0.69) )7 0.7 0.8)7 37 0.43 0.656 J7 0.92

JS 050 0.707 38 0.72 0.849' JS O.fi2 0,787 )8 035

39 0_"6 0.7411 39" 0.85 0.9.!2 39 0.69 0.8)1 )9 1.10

40

**·~'** 0.787 40 0.85 0.922 40 **0~5** 0.922 40 1.25

•t· 0.64 . 0.800 " 0.72 0.849 " 0.89 0.943 41 uo

" 0.75 0.8r.!i 42 0.8 0.1194 42 0.91 0.954 " us

43 0.68 0.825 .43 o.ti8 0.825 41 0.86 0.927 43 130

44 0.65 0,806 44 0.7 0.837 44 **0~3** 0.911 44 i.30

45 0.45 0.671 45 0.7 0.837 45 0.70 0.837 45 0.85

46 0.45 0,671 ... o.sa 0.762 46 051 0.714 46 **0~5**

47 0.46 0.678 " 05 0.707 " 050 0.707 " ... ,

48 052 0.721 48 05 0.707 4R. 0.41 **0.~40** 4R 038

49 0.60. 0.775 49 0,6[ 0.781 .,. 0.4fl . o.r.93 " 1.20

50 o.ss· 0.762 50 0.71 0.843 50 057 0.755 50 J.IS

5I 0.68 0.825 5I ·0.89 0.943 5I 0.71 0.849 5I 1.30

52 D.li5 0.806 52 031 0.95<1 52· 0.84 0.917 52 130

5J 0.84 o9i7" · .,·53 0.95 0.975 53 0.84 0.917 53 1.60

54 **0~2** 0,906 54 0.83 0.911 ... 031 0.95<1 54 t.fiO

ss· 0.60 0.175 55

**·~·** 0.900 55 0.87 0.9JJ 55 1.20

sr. **0~0** 0,775 56 0.68 0.825 56 0.80 0.894 56 1.20

57 0.43 0,656 57 **0~1** 0.787 57 0.75 0.866 51 0.85

5R 0,46 0:,678 .... 58 05 0.707 .58 0.85 0.922 5R

**~.as**

S9 0.50 0,707 S9 0.41 0.(>40 S9 **O~l** 0,906 3 S9 035

, .. "·"' 11.632 , .. 035 0.592 G<i 056 0.748 GO 0.76

61 054 0.735 61 059 0.7!i8 61 0.46 0.678 61 1.00

62 057 O.iSS .62 0.73 0.854 62 0.46 0.678 62 1.05

(,1 **0~3** 0.794 "' 0.75 0JIIi6 "' 056 0.748 6) 1.25

64 0.63 0.794 64 **0~5** 0.922 **(~** 0.65 0.806 **(~** 1.25

65 0.12 0.849 65 0.83 0.911 65 0.70 o.s.n 65 1.32

66 0.75 0,8GG 66 0.91 0.954 66 0.82 0.906 66 135

67 0.83 0.911 67 o.ss 0.922 67 0.72 0.849 67 1.60

.. 0.65 o:so6 68 0.7 OJU7 68 n.Gs 0.806 68 1.25

'" 0.70 0.837 69 052 0.721 " 05Z 0.721 69 138

70 0.70 0.8J7 70 o.s 0.707 70 0.4Z 0.648 70 1.3R

71 0.43 O.GSii 71 0.41 0.640 71 OJ6 Cl.600 71 0.86

12 0.43 0.6Sii 12 0.35 0.592 72 0.30 0.548 12 0.86

7) 0.000 7) 0.000 73 0.000 7)

74 0.000 74 0.000 74 0.000 74

75 0.(1{10 75 0.000 15 o.ono 75.

76 o.ono 76 11.000 76 0,000 76

77 0.000 77 0.000 77 0.1100 77

78 0.000 78 0.000 78 0.000 78

79 11.000 79 0.000 79 0.000 79

80 0.000 80 0.000 '" 0.000 80 54.450 56.662 57,(125 c:JJI AvgSq11

**~** L..l!:Z!l.!!. **~** -·-:-. ... **~)**
ELTA D ....... n.u FLUE GAS TEMP METER TEMP

RUN/12 RUN#3 ' RUN/II RONII2 RUNfl3 RUN#! RUN Ill RUNfl3

I 0.77 I t.n5 1 169 I 170 I 172 I· " I 78 I ..

2 us 2 I. OS ., l7l 2 In 2 In ,. " 2 78 2 58

J 0.80 J 1.28 ' 171. J 172 ' 173 J .. 3 78 J 57

4 0.95 4• 135 4 171 4 172 4 173 4 . 70 4 78 4 57

5 1.00 5 !53 5 172 5 172 5 173 5 70 5 78 5 5R

·6 1.47 6 ,15 6 172 ' 172 ' 173 ' " 6 77 6 58

7 1.47 7 135 7 172 7 171 7 173 7 71 1 .17 7 "

R 1.40 8 1.25 R m R 173 .R 173" R 71 8 77 R 5R

9 0.80 9 0.72 9 171 9 173 9- 113 9 71 9 77 . 58

10 **0~5** 10 0.72 10 "' 10 173 10 173 10 71 10 17 1(1 5R

II **0~0** II 0.62 II 166 II 174 II 't73 II 71 II 77 II 58

" 0.78 " 0.6 12 164 " 171 " -·173 " 7l p 77 " sa

" 1.19 13 1.1 13 172 13 175 IJ 172 13 72 ·IJ 79 IJ "

14 1.36 14 13 14 m 14 175 " 173 " .72 .14 79 14 "

IS 1.60 IS 1.6 IS 173 .IS 173 IS m IS ., IS. 19 IS 58

16 1.60 16 ..• 16 173 16 173 16 173 ·16 73 16 79 16 58

11 1.60 17 1.61 17 173 11 173 11 173 17 73 17 79 17 58

18 1.40 IR 1.6 '18 113 18 173. 18 173 IR " IR 79 IR "

19 t.oo 19 13 19 172 19 173 19 . 173" 19 '.14 19 19 19 ,.

20 **0~0** 20 1.06 20 172 20 173 20 172 20 73 20 80 20 58

" 0.78 21 0.85 " 171 21 171 " ·173 21 " 21 80 21 "

" 0.90 " 0.73 '22 164 22 172 " l7l 22·:··' .14 .22 81 " 58

2.1 0.80 23 0.65 2.1 164 2.1 171 2.i •170 2.1 73 2.1 81 2.1 58

,. **o~o** 24 0.65 24 160 24 172 24. 'i6B ,. 72 .14 .. 82 . 24 58

" 1.18 " **0~5** .2S 11S 25 174 25 179 2S· 73 " "' 25 "

21i 1.15 26 1.1 2 26 176 . :!G 175 26 179 2 26 73 21i 85 26 58

27 135 27 13R " 177 27 178 27 179 27 72 27 .. 27 5R

28 uo 2B 159 28 17R 28 178 28 179 28 73 2R 85 2R 58

,. L60 " 155 ,. 178 29 178 29 178 29 12 29 R5 29 5R

30 l.fiO JO 159 JO 179 JO 178 30 179 )0" ;· 73 30 RS ;Ill 5R

31 **1~0** 31 I.SS 31 177 " 177 " ·179 " 12 " 85 " 57

32 1.35 n 15 ·)2 177 )2 177 32 179 32 .12 32 R5 32 ,.

33 us 33 1.48 33 176 3) 111 33 179 :n· 73 33. 85 33 58

" 0.60 34 1.1 " 176 )4 nii J4 t79 :l4. 12 )4 R5 34 58

35. **0~0** .35 0.65 J5 112 35 176 JS 179 35 73 J5 85 J5 58

36 **0~0** 36 · **~** o.6s **-~6** 172 36 175 )6 175. . )6 73 36 85 )6 $7

37 1.30 ')7 0.83 J7 176 37 174 "37. 180 37 74 37 84 37 57

JS 1.35 38 i.J JR 175 J8 174 .18 179- 3R 74 38 81 J8 51

39 1.60 39 1.23 39 178. J9 174 )9 179. 39 ·'.74. 39 ss )9 51

40 MD 40 155 40 178 40 174 40 179 40 .' 74 40 85 40 51

" us 41 1.6 41 178 41 174 41 179 41 75 41 8S 41 . 57

42 155 42 1.6 42 17R 42 175 42 179 **~** 42 75 . 42 R4 42· 57

43 130 43 155 . ., 117 43 175 43 179 ,4) 75 43 R5 43 57

44 130 44 15 44 117 44 175 44 ISO· 44. ·. 15. .... 85 44 57

45 130 45 _1.24 45 176 1> 113 45 180. 45."-- 75 . .45 85 45 57

46 036 46 0.9 46 175 4(,_ ·173 ·46 180 46 75 4(, R5 46 $7

" 0.95 " ·o3 47 175 4i '" " 179 47 " 47 86 " 57

4R 035 48 ri:fi8 '" 176 48 166 ·48 **17~** 4R 75 4R 86 48 57

49 1.18 49 0.85 49 174 49 170 .. 174 -· 49 . 7S

**~9;** 83 49 57

50 135 so t.o8 50 174 50 170 50. 176 50 75 50 R4 sn 57

51 1.65 5I 1.25· 5I 176 51 171 5I 176 .51 15 5I 84 5I 57

52 1.68 ·52 1.55 . 51 176 52 170 52 176 52 75 52 83 52 57

5J t:70 SJ 155 5J 175 5J 170 ·SJ 176 5J 75 53 R3 5J 57

54 . uo .54 1.6 54 175 54. 170 54 175 54 75 54 R1 54 57

55 1.60 55 155 55 172 55 170 55 175 55 75 55 81 55 57

56 130 56 1.4 56 172 ·SG. 170 56 176 " 75 5(1. 78 56 57

57 1.:20 57 1.25. 57 171" ·st 168 57 175 57 75 57 78 57 57

58 0.95 5R 15 58 170 ·,58 168 58 174 58 75 5R 7R SR 57

S9 uo S9 1.45 3 S9 170 S9 "" S9 174 3 59 75 S9 " 59 57

r.n 0.60 GO 0.99 , .. 170 60 "' 60 112 r.n 75 (<I 76 r.n 57

61 1.07 61 0.81 61 '172 61 '" 61 178 61 74 61 74 61 "

62 1.33 62 0.85 62 113 62" l7l 62 178 62 74 62 75 62 "

6) us 6) 0.99 6) 173**~1** 171 6) • 178 6) 75 6) 15 (,1 "

64 155 64 1.15 64 113 64. 171 64 180 **(~.** 75 ( ... 75 **(~** "

65 155 65 1.25 65 173 65 170 65 180 65 75 65 75 r.s "

66 1.60 66 1.45 (,6 173 lili 171 66 180 66 15 66 75 llli "

67 1.55 67 1.25 67 113 67 1;1 67 180 67 75· 67 76 67 S6

68 **1~0** 68 1.15· 68 174 68 17t" 68 179 68 75 (,8 75 68 S6

69 1.00 69 032 " 174 69 l7l 69 179 69. 75 (8 76 69 56

70 1,00 70 0.74 70 "i70 70 '" 70 177 70 15 711 75 70 S6

71 0.75 71 0.65 71 172 71 '" 71 173· 11 75 71 75 71 56

12 0.63 72 '0.53· 71 172 ·72 168 12 173 12 75 12 76 12 56

7) 13 7) 7) 13 7) 7) 73

74 74 74 74 74 ·74 74 74

75 75 75 15 75 75 15 75

76 76 76 76 76 76 " 76

77 11 .11 17 11 it 17 11

78 78 78 78 78 78 78 78

79 79 79 " 79 79 79 79

80 80 80 80 80 80 80 Sll L____ld2. L.___ill L...ill.2. **~** L...!m L..:....:lli **~**

**~**

### Meter Box Post Test Calibt·ation Check ALCOA- WARRICK OPERATIONS NEWBURGH, IN
. A-446 REACTOR # 1 (Three Stacks) MeterBox#: M-10 • · Calibratedby:

5-PtCalDate: · Greg Byrd 6/6/2011 Delta H ®_--,..:1:,:.:.8o-::17 

### 5
.Gamma, initia1_--"0-'-'.9....:.9....:.12:o:... Calculate Yqa for each testrun using the following equation: where: . .Yqa q 

### Vm
. Tm



## Pb 0.0319 DHavg
.DH@ Md 29 13.6 

# .__ =

**~** 

# _ 0.0319 Tm 29 (-JMi) Yqa H al'g 

# Vm1/ b.

# H (P 

# +

**il·~-)** 

# M d 

## v @ b 

## 13.6 dry gas meter calibration check value, dimensionless. · .totalrun time, min. · total sample volume measured by drygas meter, dcf.

absolute average dry gas metertemp., 0

### R. barometric pressure, in. Hg. 

## =(29.92/528)(0.75)2 (in. Hg/0

### /R) cfm2. average orifice meter differential, in. H20. orifice meter calibrationcoefficient, in. H20. dry molecular weight ofstack gas, lb/lb-mo1e. dry molecularweight ofair, lb/lb-mole. specific gravity ofmercury. After each testrun series, do the following: Average the three or more Yqa's obtained from the test run series and compare this average.with the dry gas meter calibration factor, Y. The average Yqa mustbe within 5percerit ofY. Ifthe average Yqa does not meet the +5 percent criterion, recalibrate the meter overthe full range oforifice settings, as detailed in Section 5.3.1 of Method 5. Then follow the procedure in Section 5.3.3 ofMethod 5.

.. 

### Test 1 Test2 time 144 144 Vm

**~total** 

### 85.201 88.809 Tm avg 73.4 80.4 Tm-R 533 540 Barometric ... 29.6 29.6 DHavg 1.115 1.187 DH@. 1.8150 1.8150 Md stackgas 29.16 29.12 MdAir 29.00 29.00 Meter Box Gamma 0.9912 0.9912 QAGamma 0.9904 0.9852 Difference: 0.1% 0.6% within 5%? PASS PASS AVERAGE DIFFERENCE 0.3% Test 3 144 85.757

57.3 517 29.6 1.174 1.8150 29.10 29.00 0.9912 0.9929

0.2% PASS

# ()

( ·. 

# ,'-._) COMPANY NAME: METHOD 1WORKSHEET Summary of Location Setup 

### Enter Information Below: ALCOA- WARRICK OPERATIONS FACILITY LOCATION (City, State) Newburgh, IN SAMPLING LOCATION: A-446 REACTOR# 3 Stack Circumference ·Far Wall to Outside of Port 56.5 Inside Wall to Outside of Port .10.5 DIAMETER OF STACK 46
. DIAMETER OF,STACK 3.83 ·Nearest Upstream Disturbance 92.5 · Nearest Dowstream Disturbance 192

Nearest Upstream Disturbance 2.0 Nearest Dowstream Disturbance 4.2 USE 12 TRAVERSE POINTS PER PORT rnches Inches Inches Inches. Feet Inches Inches Diameters· Diameters TOTAL TRAVERSE POINTS EXPECTED RUN DURATION TIME PER TRAVERSE POINT 24 144



### 6 6 24 .24 pt X 

### 3 Stacks minutes READINGS EVERY EXPECTED READINGS

,.-' 

### minutes minutes

### METHOD 1 TRAVERSE POINTS ALCOA· WARRICK OPERATIONS NewburQ,h, IN :A-446REACTOR

## # 3 Stack Far Wall to Outside of Port 56.5 Inside Wall to Outsideof Port 10.5 DIAMETER OF STACK . 46 Nearest Upstream Disturbance 92.5 Nearest Dowstream Disturbance 192 NUMBER of Traverse Points per Port 12 POINT %of Depth Diameter Distance Distance from Inside w/ Nipple - 

### 1 0.021 46 0.966 11.466 2 0.067 46 3.082 13.582 3 0.118 46 5.428 15.928 4 . 0.177 46 8.142 18.642 5 0.25 46 11.500 22.000 6 0.356 46 16.376 26.876 7 0.644 46 29.624 40.124 8 0.75 46 34.500 45.000 9 0.823 46 37.858 48.358 10 0.882 46 40.572 51.072 11 0.933 46 42.918 53.418 12 0.979 46 45.034 55.534 All measurements were verified in the field. Inches Inches Inches Inches Inches

Two Available Ports with 12 Traverse Points per Port Expecting 3 to 4 hour runs SAMPLE EACH POINT FOR 6 READINGS EVERY 6 

### AREA OF STACK: 11.5410 

### ftA2

REACTOR#3-M1 Diameters 2.0 4.2 11 4/8 13 5/8 15 7/8 18 5/8 22 26 7/8 40 1/8 45 48 3/8 51 1/8 53 3/8 55 4/8 Minutes Minutes

### (]··~ 

## --


# u METHOD 1- TRAVERSE POINT LOCATIONS 

# CTRC

3 4 5 .6



### 7 

### 8 9 10 11 

### 12 13 14 15 16 Note: When using 4 ports in a circular duct, the probe is marked with onI the points for the first halfofthe full diameter traverse. 

# r TestPort . If more than 8 and 2'diameters.and Ifduct diameter is less than.24", use 8 or 9 points
. . .

**~** -! '· :DIAMETERS Velocity UP DOWN Particulate

24 or25 2 0.5


### ~-~---...J · Disturbance DRAW HORIZONTAL LINES THROUGH UPSTREAM AND-DOWNSTREAM DIAMETERS AND USE THE HIGHER NUMBER OF POINTS•. 

### Equivalent Diameter (for rectangular ducts): De=2 *Depth *Width I (Depth+ Width) De 

## = 2 * ( )



## ~ )I ( ) + ( )= 

# I LOCATION OFPOINTS IN CIRCULAR STACKS OR DUCTS

(Fraction of

**st~!ameter** from inside wall to traverse point)

2 4 ""!!"' 8 10 \,12_) 14 16 18 20 1 .146 .067 .044 .032 .026 .021 .018 .016 .014 .013 2 .854 .250 .146 .105 .082 .067 .057 .049 .044 .039 3 .750 .296 .194 .146 .118 .099 .085 .075 .067 4 .933 .704 .323 .226 .177 .146 .125 .109 .097 5 .854 .677 .342 .250 .201 .169 .146 .129 6 .956 .806 .658 .356 .269 .220 .188 ..165 7 .895 .774 .644 .366 .283 .236 .204 8 .968 .854 . 750 .634 .375 .296 .250 9 .918 .823 .731 .625

**.~82** .306 10 .974 .882 .799 .717 .618 .388 11 .933 .854 .780 .704 .612 12 .979 .991 .831.. 764 .694 13 

# --- .943 ..875 ..812 .750 14 For 22 or24 testpoints, ·.982 .915 ..854 .796 15 .951 .891 .835 16 see Method 1table in .984 .925 .871 17 CFR .956 .903' 18 .986 .933 19 .961 20 .:: .. 987 LOCATION OFPOINTS IN RECTANGULAR STACKS ORDUCTS(

(F 

### r nofstackdiam te f m·ns·d II t t rse point)

rae 10 e r ro I 1 ewa o rave 2 3 4 5 6 7 8 9. .10 11 12 1 .250 .167 .125 .100 .083 .071 .063 .056 .050 .045 .042 2 .750 .500 .375 .300 .250 .214 .188 .167 .150 .136 .125 3 .833 .625 .500 .417 .357 .313 .278 .250 .227 .208 4 .875 .700 .583 .500 .438 .389 .350 .318 .292 5 .900 .750 .643 .563 .. 500 .450 .409 .375 6 .917 .786 .688 .611 .550 .500 .458 7 .929 .813 .722 .650 .591 .542 8 .938 .833 .750 .682 .625 9 .944 .850 .773 .708 10 .950 .864 .792 11 .955 .875 12 .958 I I 

### I**~·**...

.....

**~·.** 

# TEST LOCATION SCHEMATIC DIAGRAMS 1 . Make a separate drawing for each Method 1 Sheet 2. Show distances to upstream and downstream disturbances. Show ornote what the disturbances are. 3. All ports must be shown and labeled. Note which ports were used and for what type oftesting. 4. Indicate the number of points per port and the total points that were sampled .5. Be sure to indicate the air flow direction. Plant 

# "' Test Location . 

# k 4t{

# G Date .

## I

# o/z'fIll Initials 

## Ao

**~~~~----~-** ' I 

## CROSS SECTION

DIMENSIONS EXAMPLE 62"Dinmolor1V: ..**~r·** 8·



### 40.. -JI 12• 0 \1

**~**

. ..._....



# ~..



# ~..:... A 

# fm+·++.. : : . 1oo

# ""!"'T"T"" c 

## "T"T"j'"' _o 

# 1 From 

# i' Jl Boohouso -

. TRAVERSE POINTS

4 Ports 

### Indicate View (top, side, etc.} 4 Points perPort 16 polnls Tolal 03" 

### _L TolD Fen·. ........ / 

# CJ CYCLONIC FLOWDETERMINATION DATA SHEET (WITH 

### PRELIMIN~RY VELOCITY AND MOISTURE)
. . 

# CTRC

'----"'"'-· -----------"-----' Gas·Parameters 

### Balance No. ___ _ ·Total Catch 

# ...._ 

# _____... Fyrite Orsat GEM Meter Pre Post 02% in. 

## Hg C02% 

### cfm Pitot Delta Pavgis square ofthe average ofthe individualsquare roots Location is acceptable ifavg ofABS(Yaw)

**~** 20° Checked 

### By: ,.,__, __, ..___

# ,g_,~- 

# "''"------, / Date: 

## _--....J(u...j-_")_-"'-1 \,___ '.·**(~' ~·**  **LCOA~-~W~A~R~R~IC~K~O~P"'ERA~;~I~!l;~;!,!~LITY** NAME **-44S"'R~EA"'c=r~o~R~#~ ~IO"nS"'**  **0 A~St;,!.'.t:!;'~'!.!l**  I""NG LOCATION EWBURGH. IN CITY AND STATE ==:::1 STACK DIMENSIONS

· ENTER IN INCHES I St::lck ID 461 lenath I Width I
EST DATE EST TIMES EST DURATION EST RUN ID'S 7F·1

IOZZLE DIAMETER IYJ Mt:terRcftd[ne,

:tatStnrt

**~tnt** Eni

.cak Check I S1o1r1

.cnk Check 1 Etxl .en k **Clu~ck** 1 S1art .cnkChcck:?Etd

**~** larametrlc **Pr~ure** 31atic Pressure )xvaen ;arbon Dlo)lide RUN SPECIFICS DATA Runt Run2

10/24/2011 10124/2011

.. 1030-1259 1430 -1725 144 144

M13A-1 M13A-2 NOZZLE INSIDE DIAMETER

I **Ru~:~l0.2471** Runl

0.247 DRY GAS ?o.IETER DATA

Runl

M1

0.9965

1.713 VOLUME METERED 0.000

n.ooo 0,000

0.000 'ffi:7o7

OK Run3 M1

0.9965

1.713 Rnn2

919.400

1044.176 0.000

0.000 0.000

....!!&QQ.

124.776 PRESSURE DATA

Rtntl

**~**

-0.31 Run2 ----=-29.60 -<>.30 MOLECULAR WEIGHT DATA

Rtml RID12

18.6 17.3 1.7 2.6 MOISTURE DATA Run 10/24/2011 1935·2226 144

M13A..J Run3

0.24.7 Run

M1

0.9965

1.713 Run CITE(K 44.78fl 160.719 0.000

0.0110 0.000

0.000

115.939 Rtm

-----zg:eo -0.32 R•m

18.1

2.4 3ramslmlsCollecled I Rn1lll93.91 Ru1l 2 zso.zl Ru1l 258.61 FILTERABLE PARTICULATE DATA

Rtml Run2 RtDl

3rams Collected 0.0000 o.onno 0.0000 TOTAL FLUORIDES LAB DATA

Rtml Run:! Rtm

WlliQrams Colleclcd 0.34 0.21 0.30

I "'·- 1 I **~h!!!..L____I_** Run I K-Faclo, I ..... I I **~** ' ,,....-·-........ . i \ **DataEnt~**

. ·NUMBER OF TRAVERSE POINTS : I >4 I ,. I ,.I

DELTAP .....................

RUNHI RVNIIZ RUN//3

I 0.34 0.583 I 0.38 0.616 I 0.46 0.678 I

2 0.43 0.(,56 2 0.50 0.707 2 o.so 0.707 .,

J 0.49 0.700 J o.so 0.707 3 0.54 0.735 3

4 0.57 0.755 4 0.56 0.748 ' 0.66 0.812 4

5 0.73 0.854 5 0.64 0.800 5 0.74 0.8(10 5

6 0.75 0.866 6 0.72 0.849 6 **0~4** 0.917 6

7 uo O.fl94 7 us 0.922 7 0.89 0.943 7

• 0.76 0,872 • **0~0** 0.894 • 0.80 0.894 8

9 0.61 0.781 9 0.70 o.a:n 9 0.63 0.794 '

10 0.66 0.812 10 . 0,60 0.775 10 0.63 0.794 10

II 0.57 0.755 II 0.57 0.755 II 0.57 0.75!i II

12 0.54 0.735 " 0.53 0.728 12 0.55 0.742 12

13 .0.38 0.616 13 . 0.41 O.ft48 13 0,40 **o:6~2** 13

14 0.43 0.656 14 0.42 O.f..tR 14 0.47 .O.GRii 14

IS 0.60 0.775 15 051 0.714 IS 0.61 0.781 IS

16 0.61 0.781 " 0.62 0.787 " 0.63 0.794 16

17 0.70 0.837 17 0.73 0.854 17 0.68 0.825 17

·18 **0~4** 0.917 ... **0~6** 0.927 '" **0~5** 0.921 18

19 0 ... 0.943 19 **0~6** 0.927 19 **0~0** 0.894 19

20 **0~78** 0.883 20 **0~3** 0.911 20 0.7R . 0.883 '"

21 0.62 0.787 21' 0.73 0,854 21 0.61 0.781 21

" **0~60** '0.775 :u **~66** 0.812 " 0.60 0.775 "

**~·** 0.54 0.735 23 0.63 0.794 23 0.56 0,748 **~·**

24 0.54 0.735 24 058 0.762 24 053 0.729 24

25 0.000 2S 0.000 2S 0.000 2S

26 0.000 26 0,000 26 0.000 2 26

27 0.\'100 27 0.01'10 27 0,000 27

28 0.000 28 0.000 28 0,000 2R

29 .. 0.000 29 0.000 29 0.000 29

30 0.000 )0 0,000 30 0,000 30

31 0.000 31 0.000 31 0.000 31

32 o.ooo. '32" 0.000 n 0.000 32

• 33 0.000 33 0,000 .-J,l 0.000 .1;1

34 0.000 .34 0,0\'10 34 0.000 34

35 0.000 35 ·0.000 3S 0.000 3S

36 0.000. 36 0.000 ·36 0.000 36

37 0.000 :31 ·o.ooo. 37.· 0.000 37

'" 0.000 38 .' 0.000 38 0.000 38

39 0.000 . 39 0.000 39 0.000 39

. 40 ,0,000 ·'" 0.000 40 0.000 40

41 0.000 41 0.000 41 . o.ouo 41

42 0.000 42 0.000 42 0.000 42

**~)** 0.000 4) 0.000 4) 0.000 4)

.. .0.000 .. O.ooo 44 0.000 ,44

45 0.000 45 0.000 45. o.ooo. 45

46 0.000 46 0.000 46 0.000 46

47' 0,000 47 0.000 47 0.000 47

48 0.000 4R 0.000 48 . 0.000 48

49 0.000 . 49" 0.000 49 0.000 49

50 0,000 50 0.000 sn 0.000 so

51 0.000 5I 0.000 51 0.000 5I

52 o.ooo- 52 0.000 52 . 0.000 52

53 0.000 ·5J fl.ODO 53 . 0.000 53

54 ·o.ooo 54 0.000 54 0.000 54

55 ·o.ooo 55 0.000 55 0.000 55

56 0.000 56 0.000 56 0.000 56

57 0.000 57 0.000 57 ' 0.000 57

58 0,000 ·58 0.000 '58 0.000 58

59 0.000 59 0,0011 59 0.000 3 59

(,0 0.000 60 0.000 60 0,000 60

61 0.000 61 0.000 61 0.000 61

62 . 0,000 "62 0.000 62 0,000 62

63 o.uoo 63 0.000 63 0.0011 63

(>4 0,000 (>4 0.000 (o4 0.000 64

65 0.000 65 0.000 liS· 0.000 65

66 o.noo 66 0.000 66 0.000 66

67 0.000 G7 0.000 67 0.000 67

68 0.000 '" 0.000 68 0.000 '"

•• ri.ooo 69 0.0(10 69 0,0110 69

70 o.ooo 70 0,000 70 0.000 70

71 0,000 71 0.000 71 0.000 71

n 0.000 7' 0.000 n OJ)()() 72

73 0.00{} 73 0.000 73 0.000 73

74 0.000 74 0.000 74 0.000 . 74

75 0.000 75 0.000 75 Q.OOO 75

76 o.ooo 76 0,000 76 0.000 76

77 0.000 77 0,000 77 0.000 77

78 0.000 '78 0.000 78 0.000 78

i9 - 0.000 79 0.000 79 0.000 79

80 o.ono 80 0,000 80 0.0110 80 18.70J 1R.978 19.080

Al:gSqrt LQ.lliL L.!1ll!!!!

**~ ltt.'\Cf'OI\•Jo~U>,\.~1•**  ,_) ..,a:....,an.n ' ···-

RUNHl RUNIIZ RUNif3 RUNI#1 RUN liZ RUNII3 RUN III RUN liZ RtiNif3

1.35 I I .SO I

**·~·** I 171 I "' I 171 I 67 I 73 I 61

1.70 2 **2~0** 2 2 ., m 2 171 2 "171 2 68 2 73 2 "

1.95 3 l.OO 3 2.15 3 m· 3 171 3 m 3 " 3 73 ' 61

2.30 4 2.25 4 1.65 4 173 4 ·17Z 4 172 4 ., 4 73 4 60

**2~0** 5 255 5 2.05 5 174 5 173·. 5.· 172 5 70 5 73 5 60

**~no** 6 2.90 6 2.35 6 174 ' 173 6 . 173 ·- • 70 • 73 6 '"

3.20 7 3.40 7 '2.5 7 173 7 173 7

**·~.** til 7' 71 [' J, 73 7 60

3.05 8. 3.20 • 2.25 8 173 a·.·. 173 .. 172 • 72 73 8 S9

2.45 9 2.80 9 '1.75 9 171 9 173 9 171 9 72 .. 73 9 S9

2.65 10 2.40 10 1.15 10 171 IO 172 10 171 10 72 10 73 10 S9

2.30 II 230 II 1.6. u 170 II 1.73 · II 170 it 72 II 72 II S9

1.15 12 1.10 12 :t.ss 12 170 12 .111 12 170 12 72 12 ri " S9

I .SO 13 1.70 13 1.6 13 170 13 171 13. 168 IJ 71 13 71 13 57

1.70 14 1.70 14 1.85 14 170 ·14 111 14 '169 14 71 14 72 14 57

2.40 15 2.05 IS 2,45 IS 171 IS:· 172 15 170 IS 71 IS 72 15 57

2.45 16 2.50 16 2.5 " 172 16 172 16 171 ·" ii •• 72 " 57

**z~o** 17 2.110 " 2.7 17 173 17 172 17 172 17 71 17 72 17 58

335 18 3.45 18 3.4 '" 173 18 172 18' 171 ·ts 7l .IR 73 lR 59

3.55 19 3.45 19 3.2 19 173 19 171 19

**.t~** .. 19· n 19 72 19 59

3.10 20 3.30 20 3.1 20 173 2CI 171 20 173 20 7J ,. 72 20 58

2.50 21 2.110 21 :z;45 21 i73 21 170 21 l7Z 21 73 21 72 21 58

2.40 22 2.65 22 2,4 22 173 22 "' 22 172. " i3 22 72 58

2.15

**~·** 2.50 23 2.25 23 173 .?J 168 :z.i 172 **~1** 73 23 72 **~1** 57

2.15 24 230 24 2.1 24 172 24 168 24 170 24 73 24 '72 24 "

25 2S 25 25 2S 2S 25 25

26 26 2 26 26 26 2 26 21i 21i

27 27 27 27 27 -27 27 ·27

28 28 28 '28 '28 ., . 28 2R 28

29 29 29 " 29 29 29 "

30 30 30 30 30 )0 30 30

31 31 Jl. 31 31 3t" 31 31

32 32 32 32 32 J2 32 J2

33 33 33 33 33 33 33. 33

34 34 34 34 34 34 34 34

35 35 · .. . : 35 35 35 35 3!i 3S

36 )li 36 36 36 . 36 36 .16

37 37 )7 37 37''

**~7** .. 37 37

38 '" )8 )8 '" 38

.. '" 3R

39 39 ,. 39 39 : 39 J9 39

40 40 40 40 40 40 40 40

41 41 41 41 41 41 41 41

**4~·** 42 42 42 42 ·42 . 42 42

43 43 .· I 43 43 43 . 43 43 "

" 44. 44 44, .. , 44 44 44

45 45: .. ·' 45 45. 45 45" '45 45

46 46 • 46 '461 46 46 46 46

47 47 . **-~** .. 47 47 47 47:. **·.~** 47 47

48 48. 48 48 48. .. 48 48

49 49

**-:~9** 49 49 :·. **~9'** 49 49

sn 50 50 so 50 50 50 sn

51 5I 51 5I 5.1 51 5I 51

'52 52 52 52 52 52 52 52

5) 53 53 53 53 53 53 53

54 54 54 54 54 54 54 54

55 55 55 55 5S 55 55 55

56 56 '56 .56 56 · 56 sr.·· 56

57 57 57 57 57 57 ).7' 57

58 58 58 ·sa 58 58' 58 58

S9 59 3 59 59 59 3 59 59 59

60 60 611 GO (,0 GO 611 (,0

61 61 61 61 61 61 61 61

., ., ., ., ., ., ., 62

63 63 63 63 63 G3 63 li1

64 64 64 (o4 64 (,4 (o4 64

65 65 ., 65 65 65 r.s 6S

66 66 66 66 (,0 66 ,.. 66

G7 G7 G7 67 67 G7 67 G7

'" 68 6R 68 68 68 r.s 68

.. 69 .. 69 69 m· .. , 69

70 70 70 70 70 70 70 711

71 71 71 71 71 71 71 71

72 n n n 72 n n 7'

73 73 73 73 73 7.l 73 73

74 74 74 74'· 74 74 74. 74

75 75 75 75 75 75 75 75

76 ! 76 76 76 76 .76 76 76

77 77 77 77 77 ' 77 77 77

78 78 78 78 78 78 78 78

79 79 .79 79 79 79 79 79

.. 80 80 811 80 80 80 ..

DEL TAB METER TEMP FLUE GAS **TE~tr ~**  L....,lJL L....bti l.._11b! L.Jill. L..__!11l L__Z!.d. **~ ~** . ' ' 

### MeterBox Post Test Calibration Check ALCOA- WARRICK OPERATIONS NEWBURGH, IN 

### A-446 REACTOR#3 (One Stack) MeterBox#;..:cM..::.l __ _ 

### · Calibrated by: 5-Pt Cal Date: Chris Abbott 4/15/2011 DeltaH @ 

### ---::-=1=.:::-:. 7::-::17 

### 3 Gamma, initial 0.9965 ·. Calculate 

### Yqa for each testrun using the following equation: where: 

### Yqa q 

### Vm Tm Pb 0.0319 DHavg DH@ Md 29 13.6 dry.gas meter caJibration checkvalue, dimensionless. ·

**.~**

### tot<il run.time, min.

total sample volume measured by dry gas meter, dcf. absolute average dry gas myter temp., 0

### R. 

### barometric pressure, in. Hg. = 

### (29.92/528)(0.75)2 (in. Hg/0

### /R) cfm2. average orifice meter differential, in. H20. orifice meter calibration coefficient, in. H20. dry molecular weight ofstackgas, lbllb-mole. ciry molecular weight ofair, lbllb-mole. specific gravity ofmercury. After each testrun series, do the following: Average the three ormore Y qa's obtained from the test run series and comparethis average with the dry gas meter calibration factor, Y. The average Yqa mustbe within 5percent ofY. Ifthe average Yqa does not meet the +5 percent criterion, recalibrate the meter over the full range oforifice settings, as detailed in Section 5.3.1 of Method 5. Then follow the procedure in Section 5.3.3 ofMethod 5. Test 1 Test 2 time· 144 144 Vm- total 123.707 124.776 Tmavg 71.2 72.4 Tm-R· 531 . 532 Barometric 29.6 29.6 DHavg' 2.460 2.533 DH@· .• 

### 1.7130 1.7130 Md stackgas 29.02 29.11 MdAir 29.00 29.00 Meter Box Gamma 0.9965 0.9965 QAGamma 1.0455 1.0412 Difference: 4.9% 4.5% within 5%? PASS PASS AVERAGE DIFFERENCE 

### 4.7% Test 3 144 115.939 58.7
. 519 29.6 2.269 1.7130

**~9.11** 

### 29.00 0.9965 1.0436

4.7% PASS I 

# I

### ISOKINETIC FIELD DATA SHEET ·; METHOD(S} 

### ~t"tt 

## 1/s- Page ____ 1 __

## ot__jl__

. / 

# -----------------



# (j 

# _CTRC • 

# ,

## •

**·~** 

## ISOKINETIC FIELD DATA SHEET METHOD(S) __ **1:::...~1:.:..r** 

### _____ _

RAL-IS01.xls 

# erR.C I 

### I I I .I'\ ' 

## ISOKINf:TIC FIELD DATA SHEET 

# METH ____ **1~/~r~----~-----** Page_1_-_of_l_. 

# C'TRC



# ()....., : 

## METHOD 4- MOISTURE ANALYSIS DATA SHEET

lmpirigei" 1 Dl Water ·

· Final Weight,

# g ··l!iltial Weight, 

# g Netweight, g lmplnger 2 Dl WatEir Final Weight, g Initial weight•.g Net weight, lmpinger 3 Empty Final Weight, g Initial Weight, g Netwe ht, g lmpinger 4 Silica Gel Final Weight, g Initial Weight, g Net weight, 

## ALCOA WARRICK OPERATIONS. 

# (JTRC

lmpinger 5 ____ 

## 1-~--.--......:::~--t--:---:-----r-----;---_.:....-+--------l

. Final Weight, g

Initial Weight, g Net weight, lmpinger 6 __ _ Final Weight, g InitialWeight, g Netweight, Filter ID 

## # Final Weight, g **1-----~--+------~-------r-----~~**



### .~ Checked 

### By: 

# Q

**~** Date: 

# If-£- {I



### ----(P-ro-je-ct-M-an-ag+~+o~r-QA_M_a-na-g-er) CAl f.AAI\J..JI\1 VI C'o . ! ·.• I 

### I 

### I**·~ ~.**  

# (-) ''----'

.- 

## r\___) METHOD 3 • ORSAT ANALYSIS FIELD DATA
Run Time Leak Chk 

## Fo Run No.

**.M~Jr-2-** 

## Run Time of Time Leak Chk 

## Fo __ _

. Run No.

**~3/S"'-3** 

## Run Time Leak Chk 

## Fo

Checked By:



# ~-< Avg ; 

## ,:(-:- 

# - .. 

### · AV[j Reading Reading


# y Avg Distillate Oil Residual Oil Natural Gas Wood/Bark Date: 

## 186567

..·

**~,**

·,.: 

# /F, -- 

## -Avg Value Reading Value Value 

# I I 

## Avg QC Validation F0 

## =(20.9- %02) 

### I%C02 ExQected F0 Ranges 

### 1.260-1.413 Anthracite/Lignite Coal 

### 1.015-1.130 1.210-1.370 Bituminous Coal 

### 1.083 - :1 

### .230 1.600- 1.836 Municipal Solid Waste 

### 1.043- 1'177 1.000 - 1.130



## ff-s-~llFACILITY NAME IALCOA-WARRJCKOPERATIONS I SAMPLING LOCATION )A-446

REACTOR# 3 (One Stack) ) CITY AND STATE

I NEWBURGH. IN I STACK DIMENSIONS

I

.O::::f!:!r:k ID I I anath I Width I

,

•• ENTER IN INCHES I 46 I I I TEST DATE TEsT TIMES TEST DURATION TEST

RUN ID'S G-S-61 NOZZLE DIAMETER (Yl Leak Check I Stan leak

Check I Ea1 Leak Check 2 St:an l..cakChc..:k2F

... nl **~ered** Barometric Pressure Static Pressure OXVQen Carbon Dio»de Grams/mls Conected RUN SPECIFICS DATA Runt

Rnn2 10124/2011

10/2412011 1030-1259 1430 -1725 144 144 M315-BHII3-1 M315-BH#3-2 NOZZLE

INSIDE DIAJ\IF.TF.R

I

Ruu **~.2591** Run2 0.259 DRY GAS METER DATA Run

1 Run3 M-16

M-16 0.9874

0.9874 1.952

1.952 VOLUME METERED 0.000 0.000 0.000 0.000 IOJ.lll OK

Ruu2 142.400 245.766 0.000 0.000 0.000 0.000 103.366 PRESSURE DATA Run

I. 29.60 .0.31 Rtol2 **~9.60** -0.30 MOLECULAR WEIGHT DATA Runt ----:;a:eo

Run2 -----:r7:3o Ron 10/24/2011 1sJs-··.u.Za 1 ... '-M31S·BHII3-3 OK Run3 0.259 Ron M-16 Q,g874 Us2 Rnn 246.208 358.18& 0.000 o.ono 0.000 0.000 111.978 Rtm "29.60 ·0.32 B!.!!L 18.10 1.70 2.60 " 2.40 MOISTURE

DATA Run

I Run:Z Rnn **235~**

201.0 239.7 POLYCYCLIC

ORGANIC MA TITER (POI\1 Runt I Run2 I Run Grams

conected I 0.02011 0.02331 0.0180 TOTAL FLUORIDES LAB DATA

j

Rom I I **D·~2** I Run I l11.1illiarams

CoDected INIA INJA .. , ,jN/A · I

I R•n•l ) D·m2 I Run· I

I K-Faolor I I I I Data Entry **NU~IBER** OF TRAVERSE POINTS = I

,. I ul ,.1 DEL TAP DELTAH

..,."" ..... '"" 14 L.......... ... u- r.tt.lER TEZ\IP

RUNI#l

RUN;'12 RUN§3 R1JNI'l RL'Nfl . RtlND RUS.Il **Rt:X._~** Rt.!Nn: . . Rt.!XI'I RL%"2 **RLX~**

I .0.54 0.135 I 051 0.714 I 0.53 0.718 I I.SS 1 1.50 I LSS I. 170 I ·170 I L;a I fiT I 7l I S7

2

o..s6 o.748 2 o.s6 0.748 2 o..s& o.748 2 uo 2 -!.60 2 u 2 . 111 2 tn 2 1711 2 or 2 n 2

3

o.so o.748 3 o.tio o.11s 3 o.o 0.7'14· J uo 3 us 3 us 3 , 111 3 112· . 3 11n 3 0 J n J s'

4

0.66 o.s12 4 0.67 0.819 4 o.n om 4 1.90 4 us 4 2.25 4 111 :"' ··: · .-l7I · . .; 1"67 _. · ;e ..: ;z 4 ''

s 0.74 · 0.860 s 0.16 o.s12 · s o.90 0.949 s 1.16 s uo s 3.6 s tn s 111 s 10 s · 11 5 n s 61

6

0.89 0.943 6 Q.BO 0.894 6 **0~** .0.9j1J 6 1.60 6 2.:30 6 . 3.55 6 i10 6 -IJZ . -6 • t69 Jl ' 73 6 73 6 . &2

1

0.88 • . 0.938 7 0.76 0.8?2 7 032 0.959 7 .;5S ' 1 l.lO 7 -- 3.55 ·7 liD 7 171 · .7 liO 7 74 7 73 7 &J

8

-- · ·o.73 ; 0..854 8 D.ti6 o.su 8 o.16 o.S11 8 uo · 8 ·uo 8 u s 110 s tn s no 8 76 s 74 s &J

9

o.sz o.nr 9 o.s& o.74& 9 0.16 o.m 9 t.so : 9 1.60 9 u 9 16! 9 1n 9 , 110 9 11 9 74 9 &J

io

O.Sl . 0.714 10 0..4& O.G78 10 0..68 0.825 10 I.SO 10 1..35 10 2..6 10 10' 10. i7D 10 168 10 76 10 74 10 62

II

0.42 . 0.648 II MJ 0.640 II 0.60 0.715 II ·t.lO ·.II l.lO 'II .!.3 II 167 11 169 II ' '167 II' 76 II 74 11 61

12

0..34 o..58J 12 0.37 o.608 . 12 o.s1 0.714 12 o.99 12 J.OS 12 · :; us 12 165 . 12 167 12 165 12 75 12. 73 12

13

0.53 0.728 13 0.55. 0.742 13 0..56 0.748 IJ 1.55 13 1..60 13 . LS5 I) liO 13 1&9 13 169 1J 72 13 70 l:t SS

14

· · o".SS o)42 14 o.57 o.755 14 o.ss 0.162 14 1.6o 14 us ).; · 1..1 14 169 .,4 169 14 t&s 14 73 1.; n 14 .56

15

0.59 0.768 I.S 0.64 · 0.800 15 0.64 0.800 IS 1.70 IS 1.85 :15 US 15 171 IS 170 ·IS 169 . IS 73 IS 73 T.S 58

16 0.59 . 0.768 16 0.67 0.819 16 0.78 0.883 16 1.70 lfi . 1..95 . 16 2.2S 16 169 16 170 16 169 16 72 16 74 16 60

17 0.72 OJI49 17 0.79 0.889 17 0..!7 0.933 17 2.10 17 2.30 17 2.5 17 171 17 170 .17 170 17 72 17 74 17 5'

18

0.85 0.922 18 0.88 0.938 18 0.89 0.943 18 2.45 18 ' 2.5S 18 2.6 18 1i0 18 liO 18 171 18 72 18 74 18 S9

19

0.81 0.900 19 0.88 0.938 19 O.B-t 0.917 19 2.35 19 2.55 19 2..45 19 170 19 169 19 171 19 72 19 74 19 58

20

0.11 o.s-o 20 0.79 0.889 .20 0.78 o.sRJ 20 z.os 20 2.30 2.25 . 20 111 20 169 20 no 20 12 20 74 :zn sn

21

0.62 0.787 21 0.64 0.800 21 0.7U 0.837 21 1.80 21 1.85 21 2JtS 21 liD 21 168 21 170 21 72 21 74 21 58

22 0.52 0.121 .,., 0.52 O.P-1 .,., 0.62 0.787 .,., 1.50 22 150 i2 I.& .,., 170 il 167 21 170 .,., 72 .,., 74 SU

23

0.44 0.66.1 2.1 0.44 0.663 13 0.49 0,700 2.1 1.30 23 1.30 23 u 23 168 23 166 "23 166 2.1 72 2.1 74 2.1 51

24 o.Js · 0.592 24 o.Js o.616 24 OAt o.64o 24 t.Oo 24 1.10 24 1.2 2.; 1&7 24 l&s 24 165 24 n 24 74 24 51

25

0.000 2S 0.000 2S 0.000 25 15 2.5 25 2S 25 25 2S 25

2

26 0.000 26 0.000 26 0.000 2 26 26 26 2. u. 26 26 2. "26 26 26

21

o.ooo 21 o.ooo 21 o.ooo 21 21 n n n . 21. 21 11 2;

28

0.000 28 0.000 28 0.000 28 28 18 18 !.8 • . 28 . . 28 28 28

29

·0.000 19 . 0.000 19 0.000 29 29 29 29 ':!9 2.9 29 29 29

30

0.000 30 0.000 JO 0.000 JO 30 JO 30 JO JO JO JO 10

31

o.poo 31 0.000 31 o.ooo 31 31 31 31 31 Jl 31 j1 Jl

J2

0.000 )2 0.000 32 0.000 32 32 32 32 32 32 ' 32 32 32

33

0.000 J3 . 0.000 JJ 0.000 J] 33 JJ :o - JJ . JJ 33 33 J3

34 0.000 34 0.000 H 0.000 34 34 34 34 }4 34 .:14 .:14 :t4

J5

0.000 35 0.000 35 0.000 35 35 35 35 JS 35 3S 35 35

36

0.000 36 0.000 J6 0.000 36 36 J6 36 36 )6 36 36 311

37

11.000 37 0.000 )7 0.000 37 37 37 37 37 37 37 37 17

38

0.000 38 0.000 38 0.000 38 38 J8 )S 38 JK ' 38 38 18

39

0.000 39 0.000 39 0.000 J9 39 39 ]9 39 39 ).9 39 39

40 0.000 0.000 40 0.000 40 40 40 40 40 .;o· 40 . 40 40

41

0.000 -U 0.000 41 0.000 41 41 41 -U 41 41 -41 41 41

42

· 0.000 .(! O.OOtJ 42 0.000 42 42 42 4:? 42 . '4i 41 42 42

-D

0.000 43 0.000 43 0.000 43 43 -(1 43 -o 43 43 43 43

44

0.000 -14 0.000 -14 0.000 44 44 44 44 44 • . 44 . 44 44 44

45

- : o.ooo 45 o.ooo 45 O.ooo 4S · 45 4S 45 45 '45 45 45 -'5

46

0.000 46 0.000 46 0.000 46 46 46 46 46 • -46 46 46 46

47

. 0.000 47 0.000 47 0.000 47 47 47 47 4i 47 47 47 47

48

0.000 48 0.000 48. 0.000 48 48 48 .;g 48 48 48 48 48

49

0.000 49 0.000 49 0.000 49 49 49 49 49 49 . 49 49 -'9

50 0.000 0.000 so 0.000 50 so 50 so so 50 so so so

51

0.000 Sl 0.000 51 !1.000 51 51 51 51 51 51 Sl 51 51

52 0.000 52 ' 0.000 52 0.000 52 52 52 - 52 52 52 52 52 52

53 0.000 53 0.000 53 0.000 53 53 53 53 53 53 5l 53 53

54

. 0.000 S4 0.000 s..: 0.000 54 54 54 . .s..: S4. 54 54 54 54

55

0.000 SS 0.000 -'S 0.000 55 55 55. S.S SS 55 55 55 5S

56

• o.ooo 56 -o.ooo 56 o.ooo 56 ·sG : · 56 56 S6 56 se. 56 56

.

57 . 0.000 57 0.000 S7 0.000 57 57 57 57 57 57 57 57 57

58

0.000 58 0.000 58 0.000 58 58 58 58 58 58 58 58 58

159

·o.ooo 59 o.ooo 59 o.ooo 3.59 59· 59 35!1 S9 59 359 59 59

60

· o.ooo 60 o.ooo 60 o.ooo 60 oo w ro 60 60 60 ro oo

61

0.000 61 0.000 GJ 0.000 61 61 61 61 61 61 61 61 61

62

. 0.000 62 0.000 62 0.000 62 62 62 62 6:2 62 6:? 62 62

63

0.000 63 0.000 63 0.000 6J 63 63 63 &3 . 6.1 63 63 63

64

0.000 64 0.000 64 0.000 64 G4 . I 6.-t 64 64 64 .M 64 64

65

0.000 6S 0.000 6S 0.000 6S 65.' 6S 6S 6S 65 6S 6S 65

66 0.000 66 0.000 (lfi 0.000 66 Ci5 ·66 65 ·66 66 66. 6l.i 66

67.

0.000 67 0.000 67 0.000 67 67 : 67 G7 67 67 67 G7 67

68

0.000 68 0.000 68 IJ.OOO 68 68 '• 68 68 68 68 . (,S G8 li8

69

0.000 69. 0.000 69 0.000 69 69 69 69 f/1 . : f>9 69 69 (fJ

70 0.000 70 0.000 70 0.000 70 70 70 • : iD iD . 70 . 70" 70 70

71

0.000 71 0.000 71 0.000 71 71 - 71 71 71 71 71 71 71

71 0.000 71 0.000 72 O.OCIO 72 72 7' 72 72 . 72 72 72 72

7J

0.000 13 0.000 73 0.000 73 73 . 73 73 73 73 . 7J 73 73

74

0.000 74 0.000 74 0.000 74 74 74' 74 74 74 -74. 74 7..:

15

0.000 15 0.000 75 0.000 1S 75 7S 75 15 15 15· 1S 1S

76

0.000 76 0.000 76 0.000 76 76 76 76 76 76 76 76 71)

11

o.ooo 77 o.ooo n· o..ooo n , 11 n 11 n· n ·· 11 n 77

78

0.000 18 0.000 78 0.000 78 ·. 78 78 7& 78 78 78 78 78

'79

0.000 79 0.000 79 0.000 ?9 79 19 19 19 19 19 ·. 19 19

80

0.000 80 0.000 SO 0.000 HO 80 80 SO 80 80 80 80 FLUE GAS TEll

18.589 18.151 19.905 **~____!_]§_** L..J&Q.

**~ ~**  **~** . L...!.§2B t.::.:::lli '-1ll.

**~**

Al-gSqrt **~** 1__QJ!Q_ **~** . -**'~** ' 

# ) 

# (j·- .. '··


# (_) MeterBox PostTest Calibration.Check ALCOA- WARRICK OPERATIONS NEWBURGH, IN A-446 REACTOR#3 (0\}e Stack)

**~** 

### MeterBox#: 

### M-16 _..:.;....:..._--,- 

### CaJibrated by: ·. 5-Pt Cal :bate: 

### Richey Lowe 10/12/2011 DeltaH **@_--::-'1~.9::-;:5,:;;:-2** 

### Gamma, initial 0.9874 CalculateYqa for each testrunusing the following equation: where: Yqa q· 

### Vm Tm Pb 0.0319 DHavg DH@ Md 29 13.6 dry gas meter calibration checkvalue, dimensionless. total runtime,

# min. total sample volume measured by dry gas meter, dcf. absolute average dry gas metertemp., 0

### R. barometricpressure, in. Hg. = 

### (29.92/528)(0.75)2 (in. Hg/0

### /R) cfm2. average orificemeter differential, in. H20. ·orificemeter calibration coefficient, in: H20. drymolecular weight ofstack gas, lb/lb-mole. drymolecular weight ofair, lb/lb-mole. specific-gravity ofmercury. After eachtestrun series, do the following: Averagethe three ormore Yqa's obtained from the testrun series and compare this average with the dry gas meter calibrationfactor, Y. The average Yqamustbewithin 5percent ofY. Ifthe average Yqa does notmeetthe +5 percent criterion, recalibrate the meter overthe full range oforifice settings, as detailed·in Section 5.3.1 of · Method 5. Then follow theprocedure in Section 5.3.3 ofMethod 5. Test 1 Test2 time 144 144 Vm- total. 103.111 103.366 Tmavg .. 

### 72.4 73.2 Tm-R 532 533 Barometric 29.6 29.6 DHava 1.765 1.796 DH@ 1.9520 1.9520 Md stack gas 29.02 29.11 MdAir 29.00 29.00 MeterBox Gamma 0.9874 0.9874 QAGamma 0.9950 1.0011 Difference: 0.8% 1.4% within 5%? PASS PASS AVERAGEDIFFERENCE 1.8% 

# _ **____.::,.;.:,..,:.~**



### Test 3 144 111.978 59.2 519 29.6 2.252 1.9520 29.11 29.00 0.9874 1.0183

3.1% PASSPOM CONCENTRATION. MILLIGRAMS PER DRY STANDARD CUBIC METER mgldscm = mgldscnz = grams * Vmstd 1,000 * 35.314 0.0293 * 1,000 * 35.314 82.895 POM EMISSION RATE. POUNDS PER HOUR /blltr = 60 * grams * Qs 453.592

Vmstd /b/111' = .60 * 0.0293 * 23.767 453.59

82.89544 12.5 mgldscm 1.111 lblhr Example Equations Page 3 of3 ..... .... . REACTOR#!-· · ·.IsSAMPLE LOG and CHAIN OF CUSTODY RECORD ·- --········- --·-----;· ··--c------ ·--- ·- . ·------------------------ ---··--· **Clien~:---~~~-~ -=-~==~--=-~-~=-~~-**  ]TR.c **Environme~tal C~!Jloi"atio-n**  **~ ~-r-==·**  **-=~-=~- -=-~=~**  == **~~- ~~**  **-~~ --~---q**  **-~ -=~~~**  .. l'RCPro}ectMariager

:· ·- . - -- - --·--;--·Jim seme- -.- Alcoa Lab **~<?_~atlon:** _____ -·------- ·-·--·----j554g_ **Centervi~~~uite ~**  **--~** --·- **--~--------** -----·-
- --· -- . - 'Telephone No. ··--- ----W919) **25~~~.!.·~-=~**

n **~~=-~=-- r:::~~~--~~**  **---==--==-~-;~;;.~~=~~:~_ t~-~~!-**  **~ :~**  **-~:=_~~~~~--~=~~~-:=__==-==~~= ~~:=~·I"'** 
1 **~** : 1

'

'

· • Carrier or Delivery: ;TRC to lab Sam lei.D.No.andDescri tion Date Delivered to La&:···

.. **---~-·** ··· **-~--·----** ·-· -·- **-==~--=--=t-------** ---±- **---~** -----·- : _____ **i=-=~=---_---------t** Sample s::ple ;-- **~;P~~-~~~i~n~l~~;s-~e~~e_:;~eiC [=~A~446R:::t::e~1**  -r# ____

. **::~:::-~-L_-:_** __ **T_:-~;:~=-----.,--_:_~1:~-T-----~-----F:F;;r~~----. ----h-:~-e~_--=_-=_-_-=_=T:-~-t:r~--~---:---C-on-:~~~:~+-.-_-_:_** 
___ **P~iv(_-:-·~- ---~146**  Reactor __:1_ o 2 t' 3 Stacks **~--** M315 ---·---;-· ··-1 ·; ----- ... FHAcetone Rinse

:· 24-0ct Acetone Rinse

; 250 ml Amber.,.!

- POM ___ ---- __ A:'!46 Reactor __:1_ or z-::-·- **--3&aeks~- ·--~f5**  **--~~~ ::.::::~T~---=----**  FH Meth:YierleChiOiideRiriS_e ___ **l_~4-0c(** Methylene Chloride RinseT_-255-rrifAmber. ·t -· **~_§M-= -~**  **:~~:.:** _ ____ .. **~:<\46** Reactor 1 _ :_____]__ __ 3 **Stack~_--~~!?.______**

. ____ 1___ . _; ____ lmpinger Catch **~.Q!_~nse**

'I 24-0ct

' Water

\ 500 ml Amber __ **~~---** _ _£OM .. __ _ .. ____ A-446 Reactor __:1_ r # + 3 **Stac~=~~---~~1.§__**

_ _;__ _ '!_ __ . __ : ----· **~f::!.~cetone** & Hexane Rinse _______ _:___24-0ct

: Acetone & Hexane Rinses ! 250 ml Amber _j _____ **...!:_Q~---** __ .. . .. - -· **-~~!!~ ~==~~~**  : **~- :rr=t=·;~:~~!-~-1=___**  **~;~~ ~~~~~---**  r==· **~- ~=:·=~~~~~:~~Tnse**  **~-=--i-~tg~-=~=::et:~!f~in:~**

**~ ~--**  **~~~:~~~~~~e~r~= -~-**  **~-~-g~** =-:. **--~-­ ::_---~-**  **~~:;~~==~~~~** # **~ ~**  **z---t--·11!:~:-±~=_:-·=~~;** _-:: **~-** ==-; **~~~~= F::n~~::~e~=t3,h~~~~~::e**  --T **~tg~~** • **Methylene~:t~:de Rinse-~=:~=~** 

! **--~=~~g~** · **-~** _. ____ A-446 Reacto # 1 #_r--l-_ 4 __ **-·3stacks-_-_c·:_:::~31·i:=_-=:::_~-:_-~=?** ---- BH AceiOne& Hexane Rinse 24-0ct Acetone_&_H_e-xa_n_e-Rin-se_s_,_2_5_0_ml **~~rj-:_:_-** ___ **:~_-=:£og~_----**
·· · A-446 Reactor__!_ # w--3Stacks- ---M315 ___ -- -- -T-:
' **====-~=ilt~--==-~-~-:-+24-oct...l** ----Riter _____ -'-!_- .. Petri _____ **~** -·- ---···p-aM:=::...::.
- **--~446Reactor!.!_** __ # ___ ,. **3Sta<!_~·-f---- M31~-----~---~----·-**  FHAcetoneRinse . \ 24-0ct AcetoneRinse

; 250ri11Amber .L.:. ___ **______EQ~---** _A-446 Reacto !.!_ r 2..,__BStacks ____ **M3~-----** _ **~----** FH Methylene Chloride Rinse 24-0ct-
.. Methylene Chloride Rinse

;. 250 ml Amber L.- ___ POM ... _ .. A-446 Reacto # 1 r. 2 · 3 Stacks M315 ' 3 . lmpinger Catch & Dl Rinse

. 24-0ct Water 500 ml Amber _L__ POM **---A~eact0#1-#** -:_·-·---3Stacks M315 **---~---"3---~** BHAcetone&HexaneRinse **~~t--fACetOne&HexaneRiilses:** 250m1Amber

I ____ **POM-~~=-·** ------------------------------------------1--------------------------------------------:---------'------------------------------t·-----

: ---------------+------------·------- **--==:~~:~~==~~~~=; _±~:~f-·** 

**1 ~~-~~~r-··=-~~:~-**  **--~~~-=~-~---~::::~=~---**

! **~tg~**
: **Acet:;~e~inse ~~f~::;.:f------{g~-~~=~~-~**  **-~46** Reactor #_3 _ __j_ _ _! **Stac~----1----**

. **M31~---** ____ _!____ FH Methylene Chloride Rinse

I 24-0ct
· ·Methylene Chloride Rinse
. 250 ml Amber **L__-~-**

. __ A-446 Reactor# 3

! 1 Stack

I M315
1 lmpinger Catch & Dl Rinse 24-0ct Water

! 500 ml Amber j ______ POM __ . A-446 Reactor# 3
1 Stack __ _=t= **M31~-=-.:_·** ____ **i.-=.·=~-=** B!:f.Acetone & Hexane Rinse 24-0ct Acetone & **He~ne** Rinses: 250 **~~Amber ~---·---!'.Q.I\i!..**  A-446Re8ctor#Y____

1 stack j---- M315----;·-·-2··------ **----~ilter** _______

i 24-0ct **-~-~--** ·t-··- - Petri-· ·- .1 ___ ··-·· F>orvc· · A-446Reactor#3 ····--- --1-s-tack--+- ..... -----M-3-15-···- **~--** ·z-: ··• · -- · **-FHAceton_e_R_irise·--~-·**

i 24-0ct Aceto_n_e_Ri ___ **n_se----~~2-5-o-~-,A-m-ber** ····· __ P_O_M_ A-446 Reactor# 3
1 Stack _ _ _____ **M315_~~:=·~-**
2 · **-=~--** _FH.Methylene Chloride Rinse

I 24-0ct

. Methylene Chloride Rinse i 250 ml Ambe':_
1 ___ POM --·· ______ A-446 Reactor# 3 --·---·· _____ 1 Stack 1 ___ **-~~-** ___ .L __ . **-~--.:_** __ **~pinger** Catch & Dl Rinse

. 24-0ct Water

: .500 ml Amber -+-- ···- **PO~** ______ _ ___ A-446 **Reacto~_ ~~.,:--i--·-**  M315 ---·f ___ 2_ __ ; ___ . ___ BH Acetone & Hexane Rinse I 24-0ct r Acetone & Hexane Rinses 250 ml Amber f--·· __ POM __ . A-446 Reactor# 3 --

· 1 Stack --.-; -. -M315- ----: ····-3 __ ; _______ ·- Filter --·-----:---t 24-0ct Riter Petri ·---r--Pcirv1 ____ - . **-····--·-f-------··----·---------·~-** -·-··--- ·-·-···-···--·-------·- ------1-

I ·---·- -·- A-446 Reactor# 3
1 Stack **~-~~!?** ____ . .)_. ___ 3 __ .__ FH Acetone Rinse _J_. 24-0ct Acetone Rinse --,-! 250 ml Amber ·"1 **~** ___ POfl!_ _____ c A-446 Reactor#3 t- 1 Stack. --J ___ M315 ____ _-__L ____ }__ _ FH Methylene Chloride Rinse ___J_. 24-0ct Methylene Chloride Rinse·. 250 ml Amber __1___ ____ **..!:~.** ---.- A-446Reactor#3

1 Stack
I M315

. · 3 . lmpingerCatch&DIRinse

J 24-0ct Water 500m1Amber

! ___ POM ________ _ **[~-~==-=~~=~~~::~~~~-~----~----~t-~~=-~-~~~:~-----~-~~=~---~~-~~~=~=--~~=?~~~-~~---~-**
_ **--~~-~~~-=-=~~~-~~-:~~:~---------~-** 24-0ct

. Acetone & Hexane **Rins:--~~~-=~~=~-~:---t-~~=-==~~~~~=~~~-== ~------·---·------------**  **···------~------+----===t===~~~~~~-=-==~~==~~-=~-~~--~-~:~.--~~~=~~==--~------**

.. ------ - ___..1,... _______ -- **--~-~--=-------** -- ·-- -- ----· M315 Reagent Blank
! 100 ml

, RB Acetone

i 24-0ct Acetone Blank 250 ml Glass
. POM ===--·M315 ___ **~--- Reagent8i~inrZ-t---1oorill**  ___ r- .. RB **.J...:::=·=---=:-MEithyleneChiortd-~** ___ __j_ 24-0ct or Water Blank 250 ml Glass
. L _- ==POM **-~** ... M315 Reagent Blank

' 100 ml/ ! RB i

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! 24-0ct Hexane Blank 250 ml Glass _j____ __ POM __ ·---------

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. _ . _!)'!_te ..... .. . ...... + __ ---,---- ---·--·--- '· TRC Environmental
Chain of Custody-M315 10/1;j/2011.... •':

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# Method 

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## 1 mgffilter. ·. ·• Acetone

# wa:sn 8eagentBlank must not exceed 1 

### mg/L.


# .• -Methylene:cJiloride Reageri(Biank

## ·musfticit exoeeo 

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### exceed 1 mg/L 

### ·• **Methyle.ne~Cnlorfd'e·** 

## ReagerifBlahk musftiot exc·eed 

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## Amount liquid lost

durinq **tran~ort** 

## Acetone Blank

Volume (ml) 

## Acetone blank c.oncentratlon (Eq. ··315-4) **(m~/mg)**



### Acetone wash blank (Eq. 315·5) 

# (mm Container No. ·1 Container No..2 

# rA Total 

# Method·315 Particulate 

# and. MCEM Ana/ysJs .
. . 

# . ·

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## Partioulate Analysis·· 11 1 1

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# I.

Room Humidity 

## (%RH1 

## ./ Date; J "'·

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# lmpingers 

# Note 1 Note 1 Silica Gel 

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## tG.weight 

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# \~- 1

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# . Date:·/.. ..··.. '' 

# .. Time: 

# . .

# . 

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## Aluminum Gain Volume(mL) ChlorideWash (%RH) 

## Dish (g) (mg) 

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# L3:f" 1 

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### Methylene Chloride

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### (notto 

# -cc>,.o) -:- 

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## = Zmtotsl- Wa- 

## Wr-Fb Notes: 

## ~ '" Blankanalysts must

### be completed before 

### sample analysis ls started. 

### ·• Filter

## ~reparation Blank must not 

## e~c:;eed.1 mgffllter. · • Acetone Wash ReagentBlank must not exceed 1mgfL. ·• **Methylsn~** 

### Chloride Reagent Bh:mk musi: 

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### Room Relative Humidity mustbe below 50% when samples are bsln,g weighed.



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during transport 

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# Final Volume (mg) 

# Initial Volume (mg) Liquid 

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## weight

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# Q.f.WE;!ter . 

## 1g/mf), 

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### No. · Humidity . Weight 

### (g) 

### Aluminum Gain Volume(mq 

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### (%RH) 

## Dish (g)· 

## (rng) **Vol~me** 

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## 1 

# . 28



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# . .. 

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## .. Less Filter Blank 

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## MCEM Welght 

## (mg) mMDI:DM-:::::

## Zmtwer- We- Wt

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## F.b 

# (~:iR) Notes: 

## ~ ·• Blankanalysis 

## must be completed before sample 

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## i mg/L. ·• Methylene Chloride Reagent 

### Blank must 

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### 1.5 

### mg/L. .e 

### lmpingerW~ter 

### Reagent.Biank must not exceed 1.5 mg/L. 

### ..., Room Relative Humidity 

## must be 

## below 50% when samples are being weighed.



# ---------- --· 

# --- .....

# Method 315 Particulate and. MCEM 

# Analysis

. '.. 

### ... . . 

## . . 

## P.artlc::ulate Analysis 

# A. **~-Ltl_** .. 

## Plant: 

## . {Date: {

## ,Q 

# ~'2.'f.-d



# 1 · Run No.· 

# .**R-e~Jr)~~**

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# ·~ 6D CAA.-•

# I ..

Volume 

## (ml2 ' 

# . 

# . Acetone 

## blank oonoentratlon (Eq. 

# ,{) 0A 

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# .. Acetone wash 

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# .. :·. 

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# M..v : 

## ·Room·. \\. 

## Humidity Final Weight 

## (g) 'Tare Weight(g) 

### Weight Gain (mg) • 

## (%RH).



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# ~r**o~o**

# 'J Weight of Particulate. matter. 

# J.l:'., Moisture **An~lysis** " 

## Liquid..Collected ,. 

# Final Volume (mg) initial 

# Volume (mg) .. 

## (ing) . .··.·. 

# Jmpingers 

# Note 1 

# Note 1 Si

## fica Gel 

# Total 

# ·u/ .·-.. .. Note .1 ;- Convert

# volume·ofwater-to·weight-

# by-multiplying 

## bythe density G>fwater. .....· 1 

## /mf, '



# ..

## . . . 

# . . 

# .

·. 

### .. **.I\!IC~M** 

### Analysis Date:

# J '

# . '' 

## ...

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## .. '' 

## Time: Room Container· 

### Final 

## No.· Humidity Welght(g) 

### (%RH) 

## '1 

# '-fo(stf· **J<~rM** 

# '.**4?/o~**

**2~2M** 

# '33}t;Rg_ **&/1~(,)~** !..-."?.

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# ~:.P/s~ **~** 0

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### Less Ac::atefle Wash Blank (mg) (notto exceed 1mg/L of

## acetone used) Ws::: **o~P,J:Vaw** " ·' 

### Tare of 

### Aluminum

.. 

### Dish (g) ''' 

## . ' 

### (,, **t-{~1,3** •'



## -~ 

# tffLJ-P 

# r;. 'f"t...'o·
Less Methylene ChlorideWash Blank (mg) (notto exceed 1.5 mg/L ofmsthyleme chloride used) · ·· 

# Wr··= **o,P~Vtw** 

### Lass Filter Blank (mg) (notto exoesa 1·

## m,g/filter) 

## · Fb

MCEM Weight (mg) mMCSDM

## =Imtolal- Wa.-

# w,-Fb Notes: 

## Weight Gain


### .(mg) 

# ,3

·. 

# ·§)f

:3,3, 

# .. AcetoneWash 

### Volume (mq

oe 

### Blankarialysls must l:ie complsted 

# beforesample analysis 

### is started.



### .. Filter

## Preparation Blank must not excee£1 mg/filter. 

### ·• Acetone Wash Reagent Blank must not exceed 

### 1mg/L. 

## ·• Methylene Chloride Reagent 

## Bla.nk

# must not 

## exceed. 1.5

## m.g/L • lmpingerWater Reagent-Blank must not exoeed 1.5 mg/L ... ·• Room 

## Relative Humidity mustbe below 50%.

## when **sampl~s** 

### are.bslng 

### weighed. 

## MethY,Iens Chloride .Wash

**Vo!t-~me** 

### (mL)

# Method 315PartlcuJate atJd. MCEM Analysis . . 

# . . . .. . 

### . ..:· . **P~rtlculate**

### Analysis 

## .4.. t._n I 

### I 

## Plant:. 

## ./Date: { 1

### o...

# 2..'1~il Run 

## No. 

# . . **"~!I**

# (( y 

# PI

**1P~a ~-**  6 

## r


# ~ tA'"" 

# :::1-. P:i/ter

## No. 

# GA . .., 

### Amount liquid Jost
. 

## '() ()

durinqtransport ' 

## '·· Acetone 

## Blank •. 

# ·s O(Jfr\ .} · 

# .. .. Volume (ml) 

## ... . 

### Acetone 

## blank concentration 

## (Eq. I. ()

# 0 

# M.J_M' ·. 315·4) (mg/m.rJ) . Acetone wash u 

## . 0 

# .. . i ! ·I 

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# -

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# .. ': ,• 

## (mal 

# ,.60 J>V} I 

### Room l .. 

## Humidity ·· Final Weight (g) · Tare Weight (g) Weight Gain 

## (mg) I " 

## Jo/oRHl 

# JJ!rJ7 **.~~.Usr·** (!

### .Z.. I 

## 7'7 

# '7 

# CJ Container No.1 · 

# 2-t/)3



# 5~ **2~./.hl** 

# fz_. I 

### o/7:Z-- 

# Jrh_'-f·

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# .//nJ!i/ !$").., I 

## '177 / 

# t3,7 2.!'"/9'1 lj$'7 

# LjqQ_~ 137·'1-612../ ContainerNo:2 

## :~'+ **1.~** 

# 7 l.f73/,/ 

# ·fief" CA ' . l· 

## Total **~l,** .. 

## LessAcetone blank 

# ~ro 

# :e)

.. . 

## . 

## Welght of **Particulat~** 

## matter . 

# ,!JS.'h ·· Moisture **An~Jysis** ' 

## Liquid Collected Final Volume (mg) Initial 

## Volume (mg) (mg) 

# Jmpingers Note 1 

# Note 1 SiIlea Gel 

# Total · r · ·-- · 

## Note·1;· Gonverf·vo)ume-

# GJf.water.to-welghtby 

# multip.lyingJJ.)!

# .tbe_de.nsJty. **C?LWf3t~L**

# _. _:_ 

# \J· (1 

## g/ml)..- 

# ·. " 

### .... ... 

### .MCEM Anai.Y.sls 

## • 

## Pate:j 0 0 0 0

**~** 

## .Time.: 0. ' 

# . ' • 0 ' 

## .. • 0 0 "' 

### Container' 

### Room 

## Flrial . Tare 

## of Weight AcstoneWash 

### Humidity 

## Aluminum Gain 

## No. (%RH) WeibJht(r;l) Dish 

### (g) 

### (mg) Volume (mL)

.. : 

## 1 

# ·s3/33 o I • o \ 

# .'3-1 I#!

**~** 

# 41.. 

# !"F **~./i~ rz~**  **I~** • I 

# .. 

# So, '3

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.· 2+2M


# J~/lf/(1

# 1/ .. 4'1(/!d 

# 4 ., Lft.f 55" 

# 3!5/ g,.....f **~'M**



## . 3W 

# W 

# s w( 

## J 

# ?.S/3'1 

# t/tltt9 t.t.ftJ"o



# 3.~ 3 S· 

# zr/Jt.f'(,,ff35 

# t .'1.

# e'(') ·. n::o .. ,AI() 1/

# tA:..J. S!?i 0

# "t: 0 

## '3 

# -r 3S. 

## f~.~ "*" t 1'; t't' [! **:,t;~,.}-** r , . 

## Total 

# '&.~'$ **I~'['**

# nvl-5 ·rmcolsl 

## LV 11w 

### Less 

### AoetCJne 

## Wash Blank (mg).


# -(a,~). (notto exceed 1mg/L ofacetone used) Ws :;; 

### ofP s'ZVaw 

### Less Methylene 

### Chloride Wash 

## Blank (mg) 

### (not to

**~·** 

### exceed 1.5 

## mg/L:ofmethylene chloride used) · ,. 

# ·- (o:.o).·. Wt

# = o,PiZVtw Lass Filter Blank (mg} (notto exceed 

### 1mgffllter)



# ~ 

# (b ."7J · Fb

MCEM Weight (mr;i) 

# (~ mMCEOM

# = Zmlolsl- 

### Ws- Wt r 

### Fb 

# J-.01,

# 'f ' -..... 

# -- Notes; 

### ,., Blank·analysls·must be 

### completed before 

### sample analysis is started. 

### • Filter

### J:reparation Blank must not ex('}eed.1 mg/fiiter, •• Acetone

## Wash Reagent 

### Blank must 

## not exceed 

## 1mgfL. ·• Methylene Chloride 

## Reagent Blank must not

## exceed 1.5 mgfL. ·• JmpingerV\fater Re13gent-Blank.must not exoaed 

### 1 .5 

## rng/L. 

## ..

-



# - '

• 0 ' '. 

### Metl:wlene Chloride

## .Wash . Volt.une (mL) 

# '1'35 . 0 • '



### ~,.~'2.!"" 

# qs- !C?O

.. **~0-z..r.;** 

# ..

0 • 

### .( r''



# SLJG""-1.5 1'Vtw
0 0 

# ... '



### ..



### • ·Room Relative Humidity must be 

## below 50% 

## when samples are being 

## weighed.


## -. -·.. 

# - -·· .........

## -..... 

## - ..... 

## -- ............ 

## - ...........

# --- .. 

## -- 

# - .... 

## -

# -- .

# - - 

### .. 

# ----------·-·-·· ,I

. i

# f)' / 

## •



# , ·Method315 Particulate and.MCEM Analysis· I . 

## FilterNo.

Amount liquid

## lost during

## transport Acetone Blank

Volume (ml) · 

### Acetone 

## blank ooncentration (Eq. 

## . 315-4) **(mr~lmr:J)**

Acetone 

## wash blank(Eq. 

## 315-5) (mQ) 

# A I . Room . · Humidity



## (%RH) 

# ·"' .Particulate Analysis ·

# .4-LI_U./:. ·· 

# ·.on .. SCI6M/ " Final Wsfght (g) Tare Weight 

### (g) :. 

### .. . 

## ..

, 

### ,"··::. ; 

### Weight 

## Gain (mg) .. ··



# ~(=) 

# ---
**··~ cC>ntainei'-No~;;r--il?/33**  

# -1 **Tf.~-ot-l.fl:/- --!;&t-.~.fl.s-s**  1r·'3:.r r's'i. **3~5'7**/ 

# Total Less Acetone blank WeightofParticulate matter 

## Moisture **An~Jysis** 

# Final Volume 

# (mg) Initial Volume (1}19) Liquid Collected {mg) . 

# lmpingers Note 1 

# Notei Silica 

## Gel 

# Total 

# (j- **~ote**

## ..1: Convert

## volume of

## water·to weightby.multiplyJng by.the 

## density.r.:>f

# water. .. '- 1 

## /mf. 

# . .

., 

### .

# ·. Date:·

# f. ·,. f •·. 

### . 

# .' •· 

### .li.me.: 

# . "I! 

### Container· 

## Room ' 

### Final 

### ·. **T~re** 

### of 

## No. Humidity \1\leit;Jht (g) Aluminum 

### (%RH) Dish 

## (g)

'( ' I 

### 3W

**j~Z...** 

## J

# w 

# zr--j3Y **~/1tr93 ~~**  ¥¥ 1./

# '> iota! Less Acetr:me Wash Blank (mg) 

### (nptto exoeed 1

## mg/Lofacetone **.use~)** 

### We·= CePsZVaw · · ·. · · 

### Less lvlathyle'ne Chloride Wash .Blank (mg) (not

### to 

### -exceed 1.5 mg/Lofmethylene 

### chloride used) '· 

## Wt=

## o1 

## P;Zvrw J..ess Filter Blank (mg) {notfo 

### exoeBd

## '1 mgffllter) 

## · Fb . ·

IIIICEM Weight

## (mg) mMO!EDM

# = ImtwsrWa- Wt



### ~

## F.b Notes: . We.ight Galn (mg) I 

# :t· 

# s AoatoneWash 

### Volume{mq 

# f'/6' Vc·(: ., "'{r.•.r,•· t 

# r

l-f. 1 M 

# l_;;

.· 

# -(o,q)·· ...

·• Blank analysis mustbe 

### completed before 

### sample analysis Is started. · . 

### ·• **Fllter'~rsparation** 

### Blank musl notexcesd:1 

### mg/fllter. • Acetone Wash Reagant 

### Blank must 

### not exceed 1

### mg/L 

### ·• Me1hylene Chloride Reagent Blank must

### not exceed 1.5 mg/L. 

## ·• lmp!ngarWater Reagent.Biank must not exceed 1.5 mr;1/L 

### Metb>t.lene Chloride

## ·Wash
.·**Vol~rne·**

## (mL)

. I 

### l 

### r::; 

## '!I

# 7 M.(.:S

··:oJ 

### Room 

## RE!Iative Humiditymust

**~e** 

## below 50% when samples are .being 

## weighed.



## .

## -....

# - ............ 

## - .....

# Method 315 

# Particulate and. 

# MCEM Analysis 

# , .. ' 

### PartlouJate Analysis 

# Auu_i· "· 

## Plant . J

## Date; 

## {t£)

# -'2..~~ 1(. Run No. 

# _fRe_cu.t-~;3·:_ 

# !<u:·,., 3 ' 

## ..
.Filter No.. 

# "J'A .

# . .. Amount liquid lost 

# 6() durinG **tran~Q_ort** 

### . .; . 

### . :

## . Acetone Blank 

# '3_/)tJ M 

# I .. **~** ., .



## Volume (ml) · 

## . ; 

### Acetone 

## blank concentration (Eq. 

## ...-LJ {j

# fVLJ-1M I_ 

# . 315-4) 

### (mq/mg) 

### Acetone wash 

## . **~** {j 

### -- ., 

# . ' . **~-** 

### blank. (Eq. 315-5) 

## .. .. /'•

### ::·

## . 

## ·.(mal 

# . **otJ,~** 

# ... Room 

# u Humidity Final Weight (9) Tare Wei_ght {9) Weight Gain (mg) ·' 4: 

## (%RHl 

# '"31

# /,o']_ **X?t-~m3** 

# s- trj;' 

## tf. Q? 

## ::-s-o



# (~) 

# '/!:. " Container No. 1 

## 'i..B 

# 3 -**~**

## If 

## _l/7 

# _3__'d--_./ 'ft¥._, 'S''SP- 

# ,q: G- I 

## '3.r· 

# .€'f •.



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# 4 

# ?,r.!J'f 

# 133. (rC{ 

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# 34- **133.~9** 

# 5"'7 / 

# . **~-7.8.**



## ~A 

## Total 

# . **tf5',~** 

## .LessAcetone blank 

# -(_a,o) Weight ofParticulate m,atter 

# ·4k., d-; . Moisture **An~lysis** 

# Final Volume (mg) lnttial Volume (mg) 

## Liquid Collected

.. 

## (mg) 

# lmplngers 

# Note 1 Note·1 Sl

# lica Gel 

# Total 

# () Note :1·;-Convert-volume ofwater-to-weight.by multiplyln,g-by

# the .densriy. 

# Gf.water.____ :_ 1 

# /mi... 

### .M.CE:M Analysis 

## Date:·/. 

# .. Time,:_ 

# ·• .. **~** 

## .. 

# , Container' Room Final Tare

# of Weight AcetoneW

### ash Metby.lene . 

## No: Humidity Weight (g) 

### Aluminum Gain Volume 

## (mq · Chloride

## .Wash (%RHJ Dish (g) 

## ...(mg) Vol4me(ml) I ; 

## t5fJ 1 

# '4-t& . , 

# .... J ...

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# lilA /,.., 4 7&t'J 

# G, l.f1j

# h 0 

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# t;,''(4> 'fS" 

# Lf, - ' 0 

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# s' ., -,o +'Lr· 

### 3 S· ·:



# ~iJi u.J73'B 0' 

# 1/ry ;/•; '/[' I ·( I {.I • •, 

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# . $-'3 

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# 3/Ml5 706 ttA{S Total r Imtchll 

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### Blank (mg) 

### (not to exceed 1mg/L ofacetone_used) 

# - **{o,~)·.**

**w~**

# = **c,.P,.rv~w** 

## Less Methylene Chloride Wash Blank 

### (mg) 

## (notto 

# -(0,;·)
**~·** 

### exaaed 1.5 

## mg/L of

### methylene chloride used) ·' 0. 

### W, ::: 

## GtPtZVtw Less Filter Blank (mg) .. 

### (not

## to exceed 1 mg/fllter) 

# - (cL7) · Fb

MCEM Weight (mg). 

# (tl ..

# a) · mMcEOM-=

## Imto1ar We- Wt



### ~ Fb 

## Notes: .e 

### Blank analysis must be 

### compfeted before sample **a~alysls** 

### Is 

### started.
..· Filterpreparation Blank must not excreect: 1mg/fllter. • Acetone Wash Reagent Blank must not exceed 1mgfL. 

### ·• Mathylene Chloride Reagent B)ank must not 

### exceed 1.5 mg/L, 

### ·• ·lmplngerWater Reagent

## -Blank.must not.exceed 

### 1.5 mg/L. 

# -

0.



### ,, Room Relative Humidity must 

### be 

### below 50% 

### when samples are baing weigh'ed.


## -.. 

## ..... .. 

## . ... 

## .. 

## -.. .. .. 

## ... . 

### . '' 

## - 

# .. .. •'

## 10 Minute Pretest Audit Form



# .... 

# --· I • • '

·•· 

## .......:."· . · 

### ..· 

# -- . i

. I


### . ' .... 

# Yq a ( 

# E>J *



# ~ 0.03 19*

# (r 772 

# + 460) · VTn- . Pbar 0.5 

# [ 14 + 

### (0.0 /60 )

# J [ 0.0319. ( 73.5 +

### 460}

# J min sec 

### * Tmeter 

### = 

# I 0.9868 

# I 10.713 . 29.85 . Volume Metered Pbar 

## 0.97 

## * 0.9874 

# =I 0.9578 Y gamma 

## 1.03 * 

## 0.9874 

# =I 1.0170 Y gamma 

# TRC Environmental Corporation

## 10 Minute Pretest Audit Form


# . .**~** '! ' ' 

### M-10 

## -··' 

# '-·

, t •I' "', ' t**~-** -- -

### -- - -**~** 

### -- - 

## 1.815**0~9912** 

## . ·;.._ ... ·.
..... •...
·...... ,.;. 

# -- ; ' ' ' ' '

# ~a . ( 

# E>J *

# ~ 0.03 19"'

# (rnz + 46<?} Vln . Pbar · 0.5 [ -16_m_in_+

## _(_a_. a

# s-~6-

# 0o_)-] *[ 0.0319 

### * ( 69.0 T

# :e:~o )

# J =

# l._ __ 

# o_.s_s_ 42

_ 

# __.1. 12.151 . 29.60 

### Volume Metered Pbar 

### 0.97 

## * 0.9912 

# =I 0.9615 Y gamma 

### 1.03 

## * 0.9912 

# =I 1.0209 . Y gamma 

# TRC Environmental CorporationC' MeterBoxiD Gas Meter Number Calibrated By Orifice lD Orifice Coefficient K' Ambient Temperature Vacuum t:':l4.1" Hg) Delta H Initial Volume Ft 3 Final Volume Fe Total (;::5 Fe) Initial DGM Temperature °F Final DGM Temperature °F Average Temperature °F Time Minutes Time Seconds DeltaH@ Gamma(Y) Average Gamma (Y) Delta H@ tolerance **~~. RC~·~:~.**  : ..... - ... **~-·**

.. -. '. **-~** .. - '.- . **~~** M10 6839401 .G. Byrd Run#l Run#2 Pass !,-,, u Dry Gas Meter 5-Point Full Test

I Run#l Run#2 Pass Calibration Date Barometric Pressure Orifice Set Calibration Date Run#l Pass Run #2 · Run #1 Gamma(Y) DeltaH@ Pass **.,.~** 6/6/2011 29.47 2/16/2011 Run#2 Run#l Pass
1 -- 0.9912 I 1.815 .. QA/QCCheck: SignandDate. **~'l** u **06-07~11-**

I .... **~ ~\**  J Run#2I Dry Gas Meter Temperature Display Calibration MeterBoxiD Date Calibrated By Input Temperature M10 6/6/2011 G. Byrd

1 - Channel temperatures must agree with+/- 5 °F or 3 °C

2 - Acceptable temperature difference is less than 1.5 % -J Reference Calibrator Serial Number Reference Calibration Date Temperature Reading from Individual Thermocouple Inpu.t 1 Dry Gas Meter Thermocouple Calibration 3 Reference Thermometer·
75 . 75 .... & Omega...;CL23A T-235647 8/16/2010' Pass

3 - Dry gas meter thermicouple is compared to an ASTM type mercury in:glass reference thermometer

QA I QC Check: Sign and Date **·{U·)-~** 06-07-11 .... &--·-···----·---·-------cMeterBoxiDGasMeterNumberCalibratedByOrificeIDOrificeCoefficientK'AmbientTemperatureVacuum(2_14.1"Hg)DeltaHInitialVolumeFeFinalVolumeFt3Total(:::5Ft3)InitialDGMTemperature°FFinalDGMTemperature°FAverageTemperature°FTimeMinutesTimeSecondsDeltaH@Gamma(Y)AverageGamrria(Y)DeltaH@tolerance·TRQ···-,.·-.---.,-...·...::'-.__:-......_M1614435277.G.ByrdRun#lRun#2Pass0DryGasMeter5-PointFullTest:··lRun#lRun#2PassCalibrationDate.,BarometricPressureOrificeSetCalibrationDateRun#lPassRun#2Run#lGamnia(Y)DeltaH@Pass8/5/201129.482/16/2011Run#2.Run#lPassI-QAIQCCheck:andDate08-05-11......._,)"-'../Run#2Dry Gas Meter Temperature Display Calibration Meter BoxiD Date Calibrated By Input Temperature M16 8/5i2011 G. Byrd Pass Pass 1 - Channel temperatures must agree with +/- 5 °F or 3 °C 2 - Acceptable temperature difference is less than 1.5 % .-.·---- ... 1\Ti-- **-~~--,RC- ~~** 

) - -- **r-----~-**

l Reference Calibrator ---Serial Number Reference Calibration Date Temperature Reading from Individual Thermocouple Input? Pass Pass Pass Pass Pass Pass Dry Gas Meter Thermocouple CalibratiQn
3 Reference Thermometer 73 74 _ Omega-CL23A **~T-235647** 8/16/2010 Pass Pass Pass 3 - Dry gas meter thermicouple is compared to an ASTM type mercury in glassreference thermometer QA I QC Check: Sign and Date (2e)_U 08-05-11 -.· .. ·

# () 

# ()

**(~)** Pitot Tube Inspection Sheet _ 

# i!'·TRC

**:.~** .· 

# ·.~--- PitotNumber: Inspection :O'ate: 

## .RPT-AO ·. 01/04/2011 Calibrated By: __ ·. **------=0~·-=B~y_rd:--------** 

## ReviewedBy:._ 

## -'""'------...:C:....:.':....:.F:....:.in:..:.:k:..:.:__;..._ __ _ Pit?tType: . Detachable TiJl



# ~..I__ 

## X-'--...J Fixed

# L..'------l PMlO 

# I

.. l---'--_ __,..,-'

. . .



## Wind Tunnel Calibration?
I I 

## Diagram 1



# -~a1

.

# a; ./ 

# .· . Degree indicating
**le~el** position for**deten'ni~ing** a 1 and Cl:!. ' 

## Diagram 2 Degree indicating level position for determining 

### P 1 and 

### P 2• Degree-Indicating level position fcir determining ythen ca}culate z.

. 

### . . 

# ~"' **~---** 

## -~"!--~- 

# . t/ Degree indicating level position for determining 

## ethen calculate w. 

# _No[KJ

Comments: Installed on ProbeRP-4B TC: RT-4B Yes L-1 

# ----~ 

# ==,._ ·Coefficient:_ A 

# s~dec=]
.. Bstdec=J Level? ·YES 

## Obstructions? NO Damaged? NO " 

### Diagram 1 

## - -10° < a 1

## <+10° = 

## 2 -10° < a2

## < +10° = 

### 1 Diagram 2 

## -50<

**~1** 

## <+50= ,2 -5°<

**~2** 

## < +5° = 0 

### Diagram3 

## y= 1 0= 

## 1 A= 

## 0.949 Pa:::: pb = 

## A/2= 0.475 0.188 11 _:::: 

## D1 _::: 

## 0.375 11 

### = 

## 0.375 1.05 D1

## < A/2 < 1.5 D1

## = .. 

### YES 

## z=A

## tan 

## y< 0.125 11 

### = 

## 0.0166 w=A

## tan

# e < 0.03125 11 

### = 

## 0.0166 w and zmeet specs? " 

### YES 

## Thepitottube/probe meets or exceeds all specifications criteria and/or applicable design features and is hereby assigned apitottube coefficientfactor of0.84, unless a specific wind tunnel calibration· coefficienthas been detennined. 40 CFR 60, Appendix A, Method 2. Verify theminimum 3/4 inch separationbetween thepitottube and thenozzle and minimum 2inch setback ofthethermocouple (or3/4" separation) in the assembled probe.

# Pitot Tube Inspection Sheet Probe **Configuratio~** 

## Pitot Number: RPT-40 

## Inspection Date: 1/ 

## 01/04/2011 A. 

## B. c. OR D. 

# CTlRC Calibrated By: ____ G_._B.:...yr_d ___ _ Reviewed By: 

# C. Fink 

# ----------- Dt=l 0.375 

## Dn=l 0.500



## a=I 1.500 p 

## =I

a . 

### 0.475. 

## Pb=l 0.475 

## b=l 1.000 

## c=l 4.500 

## d=l 4.000 

## e=l 2.000 OR 

## c=l f=l Specifications (EPA Method2) · .. 

## Dt = 

### 3/16"

## to 3/8" 

## Dn= 112" a 

## 2: 3/4" b 

## 2: 0 

## c 

## 2: 3" d 

## 2: 3" 

## e

## 2: 3/4" 

### f 

## 2: 2" 

## Pa=Pb 1.05 

## Dt:S P

## :S 1.50 

## Dt IDOES PITOTCONFIGURATION MEET SPECIFICATIONS? YES

### (



# ~) 

# PitotTube Inspection Sheet PitotNumber: Inspection Date: 

# , RPT-78 ·. 01/04/2011 Calibrated By: ______ J._L_o;_w_e _____ __ Reviewed

**By~** 

## C. Fink 

# , **~----------~-----------------** 

## Pitot Type: Detachable Tip 

# I . X Fixed ._I __ __. 

## PM10.,__1_ ___. Wind Tunnel Calibration? 

## Diagram 1

·Degree'indicating.level position fordetermining a; ·and a2. 

## Diagram 2 Degree indicating level position for determining 

### P 1 and 

### P 2•
Degree Indicating level position for determining r then calculate z. Degree Indicating level position for · determining 

### ethen calculate w. 

## No[TI

Comments: Installed on M5 probe RP-3K TC: RT-3K Yes 

## I._ __ _. 

## ===I~ Coefficient: A

# side~ Bsidec=J Level? YES 

## Obstructions? NO Damaged? NO Diagram 1 -10° < a 1

## < +10° = •1 -10° < Uz 

## < + 1 0° = 0 Diagram 2 -5°<

**~I** 

## <+5°= 0 -50 <

**~2** 

## <+50= 0 

## Diagram 3 

## y= 0 

## ®= 0 A= 0,906 Pa = pb 

## =A/2 = .0.453 0.188":::;Dt:::; 0.375" = 0.375 1.05 Dt<A/2 < 1.5 D1

## = YES 

## z=A tan 

## y<0.125" = 0.0000 w=A tan

# e <0.03125" = 0.0000 w and zmeet specs? YES 

## The pitottube/probe meets or exceeds all specifications criteria and/or applicable design features and is hereby assigned apitottube coefficientfactor of0.84, unless a specific wind tunnel calibration coefficienthas been detennined. 40 CFR 60, Appendix A, Method 2. Verify the minimum 3/4 inch separation between the pitottube and the nozzle and minimum 2 inch setback ofthe thermocouple (or 3/4" separation) in the assembled probe. 

# .I i

# Pitot Tube Inspection Sheet Probe Configuration Pitot Number: RPT-78 Inspection Date: . 01/04/2011**----------~~~~-----------** 

### A. 

## B. 

## c. OR 

## D. 

# CTrc. Calibrated 

## By: J. Lowe**---------------~~~------------** 

## Reviewed 

## By: 

# C. 

# Fink 

# , ---------------------------------------- D1

# =j 0.375 

# Dn=l 0.500



# a=l 0.875 

# Pa=j 0.453 

# Pb=j 0.453 

# b=l 0.375 

# c=l 4.750 d

# =I 5.000 

# e=L 2.000 

## OR 

# c=I f=l Specificatiqns (EPA**M~tltod**

### 2) ·. 

## Dt = 

## 3/16" to 3/8" 

## Dn = 

## 1/2" a ?:3/4" 

### b ?: 

### 0 

### c ?:3" 

## d ?: 

## 3" e?:3/4" f?: 2" 

# Pa=Pb 1.05 

## Dt

## .:SP

## .:S 1.50 

## Dt 

# I DOES PITOTCONFIGURATION MEET SPECIFICATIONS? YESlnA-?!l-11) GlassMasterfor printinQ.xlsx 11/5/2011 

# ,. 

# I ' : .I(09-29-11) GlassMasterfor printing.xlsx 11/5/2011 . I I 

# .I •I

.·Y

i 

### I I