### 2010 PRIMARY ALUMINUM MACT
TEST RESULTS FOR THE AN ODE BAKING RING FURNACE

Performed for:



### ALCOA INC. – WARRI CK OPERATIONS Highway 66 Newburgh, IN 47629

December 1, 2010

Submitted by:

Air Quality Services, LLC
425 Main Street Evansville, Indiana 47708

Phone: (812) 452-4785

Fax: (812) 452-4786

AQS Project# 10736-11-001

## SOURCE TESTING REPORT CERTIFICATION

Air Quality Services, LLC

425 Main Street Evansville, Indiana 47708

Phone: (812) 452-4785

Fax: (812) 452-4786

I have reviewed this report and found the informat ion accurate and complete to the best of my ability.

Report Writer

_________________________________ Date____________________

Leslie J. Ashley Project Scientist Air Quality Services, LLC

Reviewer

_________________________________ Date____________________

Daniel L. Todd, QEP, CHMM
President Air Quality Services, LLCTABLE OF CONTENTS

Page

SECTION 1 EXECUTIVE SUMMARY .............................................................1

SECTION 2 INTRODUCTION ...........................................................................2

SECTION 3 SUMMARY OF TEST RESULTS..................................................3

SECTION 4 PROCESS DESCRIPTION .............................................................6

SECTION 5 SAMPLING AND ANALYTICAL PROCEDURES......................7

Location of Measurement Sites ...................................................7 Stack Gas Velocity and Volumetric Flow Rate ...........................9
Stack Diluent Content................................................................10
Stack Gas Moisture Content ......................................................10
Total Fluorides – Method 13A...................................................10 Polycyclic Organic Matter – Method 315..................................12

SECTION 6 QUALITY ASSURANCE/QUALITY CONTROL .....................14

Performance Specifications .......................................................14

APPENDIX A - EXAMPLE CALCULATIONS
APPENDIX B - SUMMARY OF STACK GA S PARAMETE RS AN D TEST RESULTS
APPENDIX C - FIELD DATA
APPENDIX D - LABORATORY DATA APPENDIX E - QUALITY ASSURANCE / QUALITY CONTROL

iii LIST OF TABLES

Table Page

1.1 Test Results Reactor #2 ...............................................................................1

1.2 Test Results Reactor #3 ...............................................................................1

1.3 Test Results – Combined Reactor #2 and Reactor #3..................................1

2.1 Test Program Contacts.................................................................................2

3.1 Summary of React or #2 TF Test Results.....................................................4

3.2 Summary of React or #2 POM Test Results.................................................4

3.3 Summary of React or #3 TF Test Results.....................................................5

3.4 Summary of React or #3 POM Test Results.................................................5

3.5 Summary of Combined Reactor #2 and Reactor #3 Test Results................5

6.1 Field Equipment Calibration Summary .....................................................14

LIST OF FIGURES Figure Page

5.1 Schematic of Sample Location – Reactor #2...............................................8

5.2 Schematic of Sample Location – Reactor #3...............................................9

5.3 Method 13A Stack Sampling Train Diagram ............................................12

LIST OF ABBREVIATIONS

acfm actual cubic feet per minute dscfm dry standard cubic feet per minute gr/dscf grains per dry standard cubic foot lb/dscf pound(s) per dry standard cubic foot lb/hr pound(s) per hour fps feet per secondSECTION 1

EXE CUTIVE SUMMARY

On December 1, 2010, stack testing for total fluorides (TF) and polycyclic organic matter (POM) measured as Methylene Chloride Extractable Matter, was perform ed on the exhaust of the Anode Baking Furnace Ring (A446), Reactor #2 and Reactor #3, located at Alcoa Inc. – Warrick Operations (Alcoa) located near Newburgh, Indiana. This tes ting was pursuant to the Part 70 Operating Permit #T173-6627- 00007 and 40 CFR Part 63.

The results of the emissions tests are summarized below:

TABLE 1.1
Reactor #2 TF and POM

Emissions Emission

Parameter Green Anode Throughput,
tons/hr lb/hr lbs/ton green

anode

TF 19.94 0.014 0.0007

POM 19.94 0.609 0.031

TABLE 1.2
Reactor #3 TF and POM

Emissions Emission

Parameter Green Anode Throughput,
tons/hr lb/hr lbs/ton green

anode

TF 19.94 0.016 0.0008

POM 19.94 0.548 0.027

TABLE 1.3
Combined Reactor #2 and Reactor #3 TF and POM

Emissions Emission

Parameter Green Anode Throughput,
tons/hr lb/hr lbs/ton green

anode

TF 19.94 0.030 0.0015

POM 19.94 1.157 0.058

1SECTION 2

INTRODUCTION

Alcoa retain ed Air Quality Services, LLC (AQS) to plan and conduct a testing program that determined total fluorides and polycyclic or ganic matter (POM) from A-446 Reactor #2 and Reactor #3. These were tested simultaneously.

The sampling was conducted using EPA Methods 1, 2, 3, 4, 13A, and 315 to determine sample traverse locations, velocity and volumetric flow rates, molecular weights, moisture content, and
total fluoride concentrations a nd methylene chloride extractable matter (MCEM) concentrations, respectively. For the purposes of this test program, the MCEM determined by Method 315 is considered to be POM by USEPA.

Messrs. Paul Siegel, David Oligher, Chip Mulz er, and Marshall Peters, of AQS, performed the sampling procedures on December 1, 2010. Ms. Ch ris Allen and Mr. Sam Bruntz, of Alcoa, coordinated the test program.

The contacts for this test program are as follows:

TABLE 2.1
TEST PROGRAM CONTACTS

Alcoa Inc. – Warrick Operations:
Ms. Chris Allen 4700 Darlington Road Newburgh, IN 47630 Phone: (812) 853-4639 E-mail: Chris.Allen@alcoa.com Air Quality Services, LLC: Mr. Dan Todd / Mr. Paul Siegel
425 Main Street Evansville, IN 47708 Phone: (812) 452-4785 Fax: (812) 452-4786 E-mail: dtodd@aqsllc.net psiegel@aqsllc.net

2SECTION 3

SUMMARY OF TEST RESULTS

On Dece mber 1, 2010, Reactors #2 and #3 of A-446 were tested for TF and POM. All of the test
runs were 2 hours and 24 minutes in duration. Method 13A was us ed to determine the TF and
Method 315 was used to determine POM. All rins es and filters from th is test program were delivered to Alcoa’s on-site laboratory.

The green anode baking ring furnace consists of three (3) reactor sections. Reactor #1 was not tested in the program because it was not in operation. Reactor #2 has three emission stacks, identical in size, with a diamet er of 26.25 inches. All three stack s were tested during each of the three test runs. Reactor #3 has a single emi ssion stack with a diameter of 46.25 inches.

The process rate during this testing program wa s 19.94 tons of green anod e input per hour.

Complete tabulations of measured parameters an d calculated results are included as Appendix B.

GAS FLOW AND COMPOSITION

Gas characteristics were determined by the us e of EPA Method 2 (velocity and flow rate), Method 3 (CO and oxygen content), and Method 4 (moisture). The sampling equipment was associated with POM testing, and the results applied to both test methods.

Based upon the data recorded during the testing, the Reactor #2 stack gas composition averaged approximately 2.5% carbon dioxide (CO 2 )

, 17.5% oxygen (O 2 )

, and 80.0% nitrogen (N 2 ); the effluent gas temperature averaged 177oF; the moisture content averaged 7.3%; and the velocity averaged 60.2 feet per second (fps ). The measured volumetric fl ow rate averaged 40,696 actual cubic feet per minute (acfm). Converting the measured volumetric flow rate to standard conditions, the exhaust averaged 31,358 dry stan dard cubic feet per minute (dscfm).

Based upon the data recorded during the testing, the Reactor #3 stack gas composition averaged approximately 0.2% CO 2, 20.2% O 2, and 79.7% N 2 ; the effluent gas temperature averaged 172oF; the moisture content averaged 7.3%; and the velocity averaged 61.6fps. The measured volumetric flow rate averaged 43,066acfm. Conve rting the measured volum etric flow rate to standard conditions, the exhaust averaged 33,432dscfm.

TOTAL FLUORIDES

Total fluoride concentrations were measured in the exhaust gases of Reactor #2 and Reactor #3 according to the procedures prescribed in EPA Method 13A.

Reactor #2 average total fluoride emissions were 0.014lbTF/hr; which calculates to be 0.0007lbTF/ton of green anode.

3Reactor #3 average total fluoride emissions were 0.016lbTF/hr; which calculates to be 0.0009lbTF/ton of green anode.

Combining the emissions of the two reactors, the average total fluoride emissions were 0.029lbTF/hr; which calculates to be 0.0015lbTF/ton of green anode.

POLYCYCLIC ORGANIC MATTER

POM concentrations were measured in the exha ust gases of Reactor #2 and Reactor #3 according to the procedures prescribed in EPA Method 315.

Reactor #2 average POM emissions were 0.609lbPOM/hr; which calculates to be 0.031lbPOM/ton of green anode.

Reactor #3 average POM emissions were 0.548lbPOM/hr; which calculates to be 0.027lbPOM/ton of green anode.

Combining the emissions of the two reactors, the average POM emissions were 1.157lbPOM/hr;
which calculates to be 0. 0058lbPOM/ton of green anode.

Tables 3.1, 3.2, 3.3, and 3.4 summarize the test results for the individual me thods and individual reactors; Table 3.5 combines all test results.

Table 3.1
SUMMARY OF REACTOR #2 RESULTS – TF December 1, 2010

Run Time Velocity acfm dscfm % H2O O2 CO2 lb/hr lb/ton

1 09:46-12:27 60.4 40,887 31,657 7.1 17.5 2.5 0.020 0.0010
2 13:13-15:55 56.8 38,437 29,345 8.1 17.5 2.5 0.009 0.0004
3 16:52-19:41 60.4 40,889 31,773 6.8 17.5 2.5 0.012 0.0006 Average 59.2 40,071 30,925 7.3 17.5 2.5 0.014 0.0007

Table 3.2
SUMMARY OF REACTOR #2 RESULTS – POM December 1, 2010

Run Time Velocity acfm dscfm % H2O O2 CO2 lb/hr lb/ton

1 09:46-12:27 61.3 41,477 32,021 7.1 17.5 2.5 0.736 0.037
2 13:13-15:55 59.8 40,460 30,795 8.1 17.5 2.5 0.583 0.029
3 16:52-19:41 62.1 42,024 32,554 6.8 17.5 2.5 0.507 0.025 Average 61.1 41,320 31,790 7.3 17.5 2.5 0.609 0.031

4Table 3.3
SUMMARY OF REACTOR #3 RESULTS – TF
December 1 , 2010

Run Time Velocity acfm dscfm % H2O O2 CO2 lb/hr lb/ton

1 09:45-12:24 60.9 42,645 33,175 7.2 20.0 0.0 0.023 0.0011
2 13:13-15:50 61.5 43,016 33,121 7.9 20.0 0.5 0.013 0.0007
3 16:52-19:38 62.7 43,869 34,190 6.8 20.5 0.0 0.011 0.0006 Average 61.7 43,176 33,495 7.3 20.2 0.2 0.016 0.0008

Table 3.4
SUMMARY OF REACTOR #3 RESULTS – POM December 1, 2010

Run Time V elocit y acfm dscfm % H2O O2 CO2 lb/h r lb/ton

1 09:46-12:25 61.7 43,196 33,687 7.2 20.0 0.0 0.609 0.031
2 13:14-15:51 60.5 42,331 32,640 7.9 20.0 0.5 0.508 0.025
3 16:53-19:39 61.9 43,336 33,777 6.8 20.5 0.0 0.527 0.026 Average 61.4 42,955 33,368 7.3 20.2 0.2 0.548 0.027

Table 3.5
SUMMARY OF REACTOR #2 and REACTOR #3 RESULTS December 1, 2010

Reactor Velocity acfm dscfm % H2 O O2 CO2 lb/hr lb/ton lb/hr lb/ton

2 60.2 40,696 31,357 7.3 17.5 2.5 0.014 0.0007 0.609 0.031

3 61.5 43,065 33,432 7.3 20.2 0.2 0.016 0.0008 0.548 0.027

60.8 83,761 64,789 7.3 18.8 1.3 0.029 0.0015 1.157 0.058 TF POM

5SECTION 4

PROCESS DESCRIPT ION

The anode baking furnace is comprised of one (1) above-ground, green anode ring baking furnace controlled by a common Alcoa designed A-446 emission control device. The baking
furnace structure is a series of interconnected refractory flues c onnected to side main exhaust
manifolds. Products of combustion and other emi ssions created in the baking furnaces are drawn into the refractory flues and exhausted to the emission control equipment through a series of ducts. The furnace is fueled with natural gas.

In the baking furnace, green anodes are stack ed into sub-surface pits formed by the interconnecting flue structures. After being pl aced in the pits, the green anode material is surrounded and covered with petroleum coke refe rred to as “packing material”. The baking process is operated to allow recently filled pits to be preheated for a period of time before being actively fired. Likewise, after firing, baked anodes are allowed to co ol in the pits before they are removed and used in the smelting process. The “packing material” is reclaimed and reused in the baking process. Natural gas burners supply heat to the furnace and promote the combustion of organic constituents drawn into the flues duri ng the baking process. The preheating, heating, and cooling progresses are sequenced around the furnace in 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 anode baking furnace is a multi-unit, fluid-bed reactor type system with fabric filtration down stream of the reactor beds. Smelting grade alumina is in troduced into one end of the Alcoa designed A446 reactors. The alumina is fluidized by an a uxiliary fluidizing fan blowing ambient air through a series of perforated plates in the bottom of the reactor chamber. Anode baking furnace emissions are introduced into the fluidized bed through exhaust gas manifolds along each side of
the reactor. A car efully metered amount of water is spra yed into the fluidi zed bed to control temperature. The fluid bed provi des a site for fluoride to react with the alumina and for the gas
stream to be cooled. The fabric filtration devices are positioned at op of the fluid beds to collect entrained alumina particles and other partic ulate matter present in the gas stream.

The anode bake furnace primary system consists of a single dry alumina scrubber control device with three (3) reactor sections or compartm ents. Two compartments on the anode furnace
control device have thre e stacks and one compartment has only one stack.

6SECTION 5

SAMPLING AND ANALYTICAL PROCE DURES

The sampling and analytical procedures used in this test program conformed to EPA Reference Methods 1, 2, 3, 4, 13A and 315, as published in th e Code of Federal Regula tions, Title 40, Part 60, (40 CFR 60) Appendix A and Title 40, Part 63, Appendix A.

LOCATION OF MEASUREMENT SITES

EPA Method 1, “Sample and Velocity Traverses fo r Stationary Sources”, was used to select representative measurement points. Measur ements listed are by AQS and also provided by
Alcoa for measurements not able to be determined due to obstructions.

The Green Anode Baking Ring Furnace exhausts th rough seven (7) separate vertical circular stacks; three stacks for Reactor #1, three stacks fo r Reactor #2, and a single stack for Reactor #3.
The three stacks for Reactor #2 ar e identical, with an inside diameter of 26.25 inches. The location of the two test ports (9 0o apart) are 60 inches (2.3 stack diameters) downstream from the nearest disturbance, and 232 inches (8.8 duct diameters) upstream from the exhaust. For Reactor #3, the inside diameter of the st ack is 46.25 inches, and it has tw o test ports (90o apart). The ports are 92.5 inches (two stack diameters) downstream from the nearest disturbance, and 192 inches (4.2 duct diameters) upstre am from the exhaust. For par ticulate measurements conforming to Method 5 (as indicated in Method 315), a total of 24 traverse points were used at each stack for the velocity and particulate measurem ents, 12 points per test port.

Copies of the field work sheet s are included in Appendix C.

7FLOW

60 inches

Roof 26.25inches

232 inches

Sa mple Ports

FIGURE 5.1
STACK DI AGRAM FOR REACTOR #2
three identical stacks (not to scale)

8FLOW

92.5 inches

Roof 46.25inches

192 inches

Sam p le Ports

FIGURE 5.2
STACK DI AGRAM FOR REACTOR #3 (not to scale)

STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE

EPA Method 2, “Stack Gas Velocity and Volume tric Flow Rate”, was used to determine volumetric flow rate. A Type “S” Pitot tube, with a standard coefficient of 0.84, and an inclined manometer were used to measure velocity pressure. A calibrated Type “K” thermocouple, attached directly to the Pitot t ube, was used to measure stack gas temperature, which was displayed on a digital temperature indicator. The average st ack gas velocity was calculated from the average velocity pressure, the average stack gas temperat ure, stack gas molecular weight and absolute static pressure. The volumetric fl ow rate is the product of stack gas velocity and the stack cross sectional area. See Appendix C fo r field worksheets and calculated values based on the field data.

9STACK G AS DILUENT CONTENT

EPA Reference Method 3, “Gas Analysis for the Determination of Dry Molecular Weight”, was
used to measure the O 2 and CO 2 concentrations of the stack gas. An integrated sample was
collected in a Tedlar ® bag for each test run. The collected sample was analyzed using a Fyrite analyzer. Each sample was measured in triplica te until a reading was repeated within 0.3%. This testing was performed in conjunction with the POM testing. The results can be found in Appendix B.

STACK GAS MOISTURE CONTENT

Concurrent with the Method 315 testing, EPA Re ference Method 4, “Determination of Moisture Content in Stack Gases”, was utilized. A Method 315 impinger train was used in place of the standard Method 4 condenser train, however both impinger systems are identical in glassware and impinger contents. The moisture train consisted of a total of four (4) impingers, with the first two each containing approximately 100 milliliters of de -ionized water, followed by a third empty impinger, with the first and third impingers be ing the modified Greenburg-Smith design, and the second impinger having the standard design. Th e final impinger contained approximately 300 grams of indicating silica gel. Each of the im pingers was weighed prior to use then reweighed after the test run to quantify the moisture gained. Following the leak check, the impingers were separated, the moisture on the exterior was remove d, and they were prepared for transport to laboratory. Upon receipt, each impinger was reweighed to the nearest one-tenth gram. The
totaled differences between the initial and final weights represented the moisture content of the stack gas during each test run. The results we re also utilized in the Method 13A (TF)
determinations. Moisture content wo rksheets are included in Appendix C.

TOTAL FLUORIDES

EPA Reference Method 13A, “Determination of Total Fluoride Em issions from Stationary Sources”, was employed for this testing. Method 13 A is similar to EPA Method 5, is published at 40 CFR 60, Appendix A, except that the filte r position is interchangeabl e. For the purposes of this test, the filter was placed between the last two impingers.

AQS used a glass nozzle and probe assembly. Th e stack gases passed through three of the moisture trains before entering the filter and pa ssing through the fourth impinger. The im pingers were placed in an ice bath during the sampling process.

When the sampling train was completely assemble d, a leak check was performed before the start of the test run. Stack gas volumes and sampling ra tes were controlled using a dry gas meter with calibrated orifice and a rotary va ne vacuum pump. Meter temper ature, stack temperature, and differential pressure were record ed at regular intervals during each test run. The sampling
scheme:

 At Reactor #2, each point was sampled for two (2) minutes, and with 24 sample points per stack for each of the three stacks, this provided a total of 144 mi nutes of sampling. For Run #1, the sampling commenced on the south stack, moving to the cent er stack after all 24 points were

10 At Reactor #3, each point was sa mpled for six (6) minutes, provid ing a total of 144 minutes of sampling, simultaneous with the Reactor #2 testing

Upon completion of each test run, the system was post-leak checked at a vacuum greater than that achieved during the sample test run. Following the leak check, the impingers were separated, the moisture on the exterior was re moved, and each impinger was reweighed to the nearest one-tenth gram. The totaled differences between the initial and final weights represented
the moisture content of the st ack gas during each test run.

The particulate matter was recovered from the te st equipment by removing the nozzle, probe, and
front half of the filter ho lder then rinsing and brus hing each component with water, in triplicate.
The water rinses from each test run were collected in amber glass bottles. The glass fiber filters were removed with forceps, placed in Petri di shes, and sealed for transport to the Alcoa laboratory.

Laboratory data are included in Appendix D.

11Figure 5.3 Method 13A Sample Train

POLYCYCLIC ORGANIC MATTER

EPA Reference Method 315, “Determination of Part iculate and Methylene Chloride Extractable Matter (MCEM) from Selected Sources at Primary Aluminum Production Facilities”, was employed for this testing. AQS used a glass no zzle and glass probe assembly connected to a glass filter bell containing a three-inch glass-fi ber filter with a glass frit filter support and a silicone rubber gasket. The st ack gases passed through the filter before entering the moisture train. The impingers were placed in an ice bath during the sampling process.

When each sampling train was completely assembled, a leak ch eck was performed before the start of the test run. Stack gas volum es and sampling rates were controlled using a dry gas meter with calibrated orifice and a rotary va ne vacuum pump. Meter temperature, stack temperature, and differential pressure were recorded at regular intervals during each test run. The sampling strategy was identical to the plan used in the TF testing.

Upon completion of each test run, the system wa s post-leak checked at a vacuum greater than that achieved during the sample test run.

12The parti culate matter was recovered from the te st equipment by removing the nozzle, probe, and front half of the filter holder then rinsing a nd brushing each glass com ponent with acetone, in triplicate. The acetone rinses from each test run were collected in amber glass bottles. The glass
fiber filters were removed with fo rceps, placed in Petri dishes, and sealed for transport to the inhouse laboratory.

After the acetone rinse, the en tire procedure was repeated us ing methylene chloride as the reagent and the rinse was collect ed in a separate container.

The impingers were recovered and rinsed according to the proce dures of Method 315 and sealed for transport to the Alcoa laboratory.

Laboratory analytical worksheets are included in Appendix D.

13SECTION 6

QUALITY ASSURANCE/QUALITY CONTROL

All m anual stack gas sampling equipment was calibra ted before the test program in accordance with the procedures outlined in the Quality Assurance Handbook for Air Pollution Measurement Systems, Volume III , EPA-600/4-72-027B. The stack gas sa mpling equipment calibrations that were performed in preparation for this project are summarized in Table 5.1. The dry gas meter system was calibrated after the test. Ca libration data are included in Appendix E.

TABLE 6.1

FIELD EQUIPMENT CALIBRATION SUMMARY

Field Equipment Calibrated Against Allowable Error

Method 5 Dry Gas

Meter Stainless Steel Critical Orifice

Set Y + 0.02 Y

Δ H @ + 0.15

Post Test Y + 0.05 Y

Pitot Tube Geometric Specifications

Wind Tunnel Calibration See EPA Method 2

Probe nozzles Calipers Max. Difference 0.004
in. between two

measurements

Thermocouple ASTM – 3F thermometer + 1.5%

Condenser Thermometer ASTM – 3F thermometer + 2°F

Dry Gas Thermometer ASTM – 3F thermometer + 5°F

Barometer NBS Traceable Barometer + 0.01 in. Hg

PERFORMANCE SPECIFICATIONS

The preparation and calibration of source sampli ng equipment are essential to maintain data quality. AQS strictly follows referenced calibr ation procedures and doc uments all results. Appendix H contains the quality assurance/quality control (QA/QC) limits and the results of the QA checks that were performed for this test program. All QA checks were within the allowable
limits.

14

### APPENDIX A
EXAMPLE CALCULATIONS

15

### APPENDIX B
SUMMARY OF STACK GAS PARAMETERS
AND TEST RESULTS

16

### APPENDIX C

FIELD DATA

17

### APPENDIX D
LABORATORY DATA

1819 

### APPENDIX E QUALITY ASSURANCE / QUALITY CONTROL