APPENDIX VIII 

FACILITY AND PROCESS DATA 
CENTURY ALUMINUM 

ANODE PROCESSING DATA 

NOTE: 

Numbers in green represent cell of Line 4. 

Numbers in red represent number of anodes changed during the night shift, during testing. 

Line 

4 

7-

May 

8-

May 

9-

May 

29 15 8 16 

30 15 8 16 

31 15 8 16 

32 15 8 16 

33 15 8 16 

34 15 8 16 

35 15 8 16 

36 15 8 16 

37 15 8 16 

38 15 8 16 

39 15 8 16 

40 15 8 16 

41 15 8 16 

42 15 8 16 

43 16 7 17 

44 16 7 17 

45 16 7 17 

46 16 7 17 

47 16 7 17 

48 16 7 17 

49 16 7 17 

50 16 7 17 

51 16 7 17 

52 16 7 17 

53 16 7 17 

54 16 7 17 

55 16 7 17 

56 16 7 17 

Line 

4 

12-

Apr 

13-

Apr 

14-

Apr 

29 14 9 

30 14 9 

31 14 9 

32 14 9 

33 14 9 

34 14 9 

35 14 9 

36 14 9 

37 14 9 

38 14 9 

39 14 9 

40 14 9 

41 14 9 

42 14 9 

43 9 15 8 

44 9 15 8 

45 9 15 8 

46 9 15 8 

47 9 15 8 

48 9 15 8 

49 9 15 8 

50 9 15 8 

51 9 15 8 

52 9 15 8 

53 9 15 8 

54 9 15 8 

55 9 15 8 

56 9 15 8 








1 of 4 

Table 3 Wet Scrubber Description

1. Control device description: 

Potline 1-4 Wet Scrubber 

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

ID No.: ___84______ Latitude: 37.943250__________Longitude: -86.786596____ 

3. Design collection efficiency and outlet concentration (add rows as necessary): 

Pollutant Collection Outlet Source of 

 Efficiency * concentration Estimation * 

 (if known) 

HF 90 Percent mg/dscf _3________ 

So2 50 Percent mg/dscf __3_______ 

 Percent mg/dscf _________ 

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 

 4 = Title V permit application 5 = Other (specify) _______________________ 

4. Device type: Venturi Vertical packed bed 

 Horizontal packed bed X Tray tower spray chamber 

 Other (specify or describe): 

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

6. Typical gas temperature: inlet 200 °F outlet 79 °F 

7. Gas flow rate: 1,640,000 acfm (at scrubber outlet) 1,415,980 dscfm 

8. Pressure drop across scrubber: 2-12 inches water column (in. H2O) 

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

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

Chemical added Usage rate Units for usage rate 

Lime 100 Tons/week 

 
2 of 4 

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

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

EP (84) Equip 4200 Potline #1 CWPB3 

EP (84) Equip 4220 Potline #2 CWPB3 

EP (84) Equip 4230 Potline #3 CWPB3 

EP (84) Equip 4240 Potline #4 CWPB3 

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

control device is operating properly: 

 Volumetric flow rate X Fan amperage 

 Pressure drop X Water flow rate 

Other (specify): . 

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

 Volumetric flow rate (acfm) 170-210 Fan amperage (amps) 

 Pressure drop (in. H2O) 3,000 Water flow rate (gpm) 

Other (specify): . 

14. Additional comments and information: 
3 of 4 

Table 4 Combination Dry Alumina Scrubber/Bag House Description

1. Control device description: 

Carbon Bake Scrubber 

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

ID No.: 41_________ Latitude: 37.948694___________ Longitude: -86.787524_____

3. Design collection efficiency and outlet concentration (add rows as necessary): 

Pollutant Collection Outlet Source of 

 efficiency * concentration Estimation * 

 (if known) 

POM 90 Percent mg/dscf ____3_____ 

PM 90 Percent mg/dscf ____3_____ 

HF 90 Percent mg/dscf ___3______ 

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 

 4 = Title V permit application 5 = Other (specify) _______________________ 

4. Scrubber device type: 

__X___ Fluidized bed ___X__ Injection 

___X__ Other (specify or describe): _____cooling tower_____________________ 

5. Bag cleaning method: 

__X___ Pulse jet _____ Reverse air _____ Shaker 

_____ Other (describe) _________________________________________________ 

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

7. Typical gas temperature: inlet to scrubber 254 °F outlet from bag house 185 °F 

8. Gas flow rate: 174,150 acfm (at bag house outlet) 136,040 dscfm 

9. Pressure drop: Across scrubber: Bed pressure 0.53 inches water column (in. H2O) 

Across bag house: 8.0 inches water column (in. H2O) 

10. Solid to gas ratio: ND lb/1,000 acf 
4 of 4 

11. Alumina usage rate (differentiate between virgin and recycled alumina from potlines) 

Type of Alumina Added Usage rate Units for usage rate 

Virgin alumina 3475 Lbs/hr 

Recycled alumina 

Other alumina (specify ________________) 

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

Source ID No(s). Description(s)

EP (41) Anode Bake Furnaces 1,2 &3 

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

control device is operating properly: 

 X Volumetric flow rate Fan amperage 

 Pressure drop X Visible emissions opacity 

Other (specify): Gas temp at cooling tower, Alumina Feed rate 

. 

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

 119,232 SCFM Volumetric flow rate (acfm) Fan amperage (amps) 

 Pressure drop (in. H2O) 20 Visible emissions opacity 

(%) 

Other (specify): Gas Temp-170/-208 F 

Alumina Flow rate- 3475 lbs/hr . 

15. Additional comments and information: 
5 of 4 

Table 5 Electrostatic Precipitator (ESP) Description 

1. Control device description: 

Potlines 1-4 ESP 

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

ID No.: _84________ Latitude: 37.943250_____ Longitude: -86.786596__________ 

3. Design collection efficiency and outlet concentration (add rows as necessary): 

Pollutant Collection Outlet Source of 

 efficiency * concentration Estimation * 

 (if known) 

PM 94.5 Percent mg/dscf ___3______ 

 Percent mg/dscf _________ 

 Percent mg/dscf _________ 

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 

 4 = Title V permit application 5 = Other (specify) _______________________ 

4. Device type: X High-voltage, single-stage Low-voltage, two-stage 

 Wet Dry 

 Other (specify or describe): 

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

6. Typical gas temperature: inlet 200 °F outlet °F 

7. Gas flow rate: 1,640,000 acfm (at ESP outlet) 1,415,980 dscfm 

8. Collection plate surface area: _1800 per ESP (8 total)_____ ft2

9. Secondary power: _____________ kW 

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

Source ID No(s). Description 
6 of 4 

EP (84) Equip 4200 Potline #1 CWPB3 

EP (84) Equip 4220 Potline #2 CWPB3 

EP (84) Equip 4230 

EP(84)Equip 4240 

Potline #3 CWPB3 

Potline #4 CWPB3 

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

control device is operating properly: 

 X Visible emissions Volumetric flow X Fan amperage 

opacity rate 

 Secondary power X Secondary voltage 

 X Other (specify): Secondary current 

. 

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

 20 Visible emissions Volumetric flow 170-210 Fan amperage 

opacity (%) rate (acfm) (amps) 

 Secondary power 20-29 mVSecondary voltage 

(kW) (volts) 

 80-156 mA Other (specify): Secondary Current 

. 

13. Additional comments and information: 
7 of 4 

Table 6 Combination Dry Coke Scrubber and Bag House Description

1. Control device description: 

NA 

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

ID No.: _________ Latitude: _______________ Longitude: ________________ 

3. Design collection efficiency and outlet concentration (add rows as necessary): 

Pollutant Collection Outlet Source of 

 efficiency * concentration Estimation * 

 (if known) 

 Percent mg/dscf _________ 

 Percent mg/dscf _________ 

 Percent mg/dscf _________ 

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 

 4 = Title V permit application 5 = Other (specify) _______________________ 

4. Scrubber device type: 

_____ Fluidized bed _____ Injection 

_____ Other (specify or describe): _________________________________________ 

5. Bag cleaning method: 

_____ Pulse jet _____ Reverse air _____ Shaker 

_____ Other (describe) _________________________________________________ 

6. Pressure mode of operation: positive pressure negative pressure

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

8. Gas flow rate: acfm (at bag house outlet) dscfm 

9. Pressure drop: Across scrubber: inches water 

column (in. H2O) 

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

10. Solid to gas ratio: lb/1,000 acf 
8 of 4 

11. Dry coke usage rate: 

NA 

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

Source ID No(s). Description(s) 

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

control device is operating properly: 

_______ Volumetric flow rate ____________ Fan amperage 

_______ Visible emissions opacity ____________ Pressure drop 

Other (specify): . 

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

_______ Volumetric flow rate (acfm) ____________ Fan amperage (amps) 

_______ Visible emissions opacity (%) ____________ Pressure drop (in. H2O) 

Other (specify): . 

15. Additional comments and information: 
9 of 4 

Table 7 Other Air Pollution Control Devices

1. Control device description: 

Potline 1-4 Wet Scrubber Cyclone 

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

ID No.: _84________ Latitude: 37.943250______ Longitude: -86.786596_________ 

3. Design collection efficiency and outlet concentration (add rows as necessary): 

Pollutant Collection Outlet Source of 

 efficiency * concentration Estimation * 

 (if known) 

PM 80 Percent mg/dscf ___3______ 

 Percent mg/dscf _________ 

 Percent mg/dscf _________ 

* 1 = Performance testing 2 = Engineering judgment 3 = Manufacturer specs. 

 4 = Title V permit application 5 = Other (specify) _______________________ 

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

5. Typical gas temperature: inlet 65 °F outlet °F 

6. Gas flow rate: 5000 acfm Specify location: _______________________________ 

 Dscfm 

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

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

EP (84) Equip 4200 Potline #1 CWPB3 

EP (84) Equip 4220 Potline #2 CWPB3 

EP (84) Equip 4230 Potline #3 CWPB3 

EP (84) Equip 4240 Potline #4 CWPB3 

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

control device is operating properly: 

 Visible emissions opacity Volumetric flow rate 

 Pressure drop 

Other (specify): . 
10 of 4 

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

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

 Pressure drop (in. H2O) 

Other (specify): . 

10. Additional comments and information: