2010 PRIMARY ALUMINUM MACT 

 TEST RESULTS FOR THE ANODE BAKING RING FURNACE 

Performed for: 

ALCOA INC. – WARRICK 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 information 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, LLC 
TABLE 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 GAS PARAMETERS AND TEST RESULTS 

APPENDIX C - FIELD DATA 

APPENDIX D - LABORATORY DATA 

APPENDIX E - QUALITY ASSURANCE / QUALITY CONTROL 

i
ii

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 Reactor #2 TF Test Results.....................................................4 

 3.2 Summary of Reactor #2 POM Test Results.................................................4 

 3.3 Summary of Reactor #3 TF Test Results.....................................................5 

 3.4 Summary of Reactor #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 second 
SECTION 1 

EXECUTIVE SUMMARY 

On December 1, 2010, stack testing for total fluorides (TF) and polycyclic organic matter (POM) 

measured as Methylene Chloride Extractable Matter, was performed 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 testing 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 

1
SECTION 2 

INTRODUCTION 

Alcoa retained Air Quality Services, LLC (AQS) to plan and conduct a testing program that 

determined total fluorides and polycyclic organic 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 and 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 Mulzer, and Marshall Peters, of AQS, performed the 

sampling procedures on December 1, 2010. Ms. Chris 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 

2
SECTION 3 

SUMMARY OF TEST RESULTS 

On December 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 used to determine the TF and 

Method 315 was used to determine POM. All rinses and filters from this 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 diameter of 26.25 inches. All three stacks were tested during each of the 

three test runs. Reactor #3 has a single emission stack with a diameter of 46.25 inches. 

The process rate during this testing program was 19.94 tons of green anode input per hour. 

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

GAS FLOW AND COMPOSITION 

Gas characteristics were determined by the use 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 (CO2), 17.5% oxygen (O2), and 80.0% nitrogen (N2); 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 flow 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 standard cubic feet per minute (dscfm). 

Based upon the data recorded during the testing, the Reactor #3 stack gas composition averaged 

approximately 0.2% CO2, 20.2% O2, and 79.7% N2; 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. Converting the measured volumetric 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. 

3
Reactor #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 exhaust 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 methods 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

4
Table 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 Velocity acfm dscfm % H2O O2 CO2 lb/hr 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 % H2O 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

5
SECTION 4 

PROCESS DESCRIPTION 

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 connected to side main exhaust 

manifolds. Products of combustion and other emissions 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 stacked into sub-surface pits formed 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 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 cool 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 during 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 introduced into one end of the Alcoa designed A446 reactors. The alumina is fluidized by an auxiliary 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 carefully metered amount of water is sprayed into the fluidized bed to control 

temperature. The fluid bed provides a site for fluoride to react with the alumina and for the gas 

stream to be cooled. The fabric filtration devices are positioned atop of the fluid beds to collect 

entrained alumina particles and other particulate 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 compartments. Two compartments on the anode furnace 

control device have three stacks and one compartment has only one stack. 

6
SECTION 5 

SAMPLING AND ANALYTICAL PROCEDURES 

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 the Code of Federal Regulations, 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 for Stationary Sources”, was used to select 

representative measurement points. Measurements 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 through seven (7) separate vertical circular 

stacks; three stacks for Reactor #1, three stacks for Reactor #2, and a single stack for Reactor #3. 

The three stacks for Reactor #2 are identical, with an inside diameter of 26.25 inches. The 

location of the two test ports (90o 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 stack is 46.25 inches, and it has two 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) upstream from the exhaust. For particulate 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 measurements, 12 points per test port. 

Copies of the field work sheets are included in Appendix C. 

7
FLOW

60 inches

Roof 

26.25inches

232 inches 

Sample Ports 

FIGURE 5.1 

STACK DIAGRAM FOR REACTOR #2

three identical stacks 

(not to scale) 

8
FLOW

92.5 inches

Roof 

46.25inches

192 inches 

Sample Ports

FIGURE 5.2 

STACK DIAGRAM FOR REACTOR #3

(not to scale) 

STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE 

EPA Method 2, “Stack Gas Velocity and Volumetric 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 tube, was used to measure stack gas temperature, which was displayed 

on a digital temperature indicator. The average stack gas velocity was calculated from the average 

velocity pressure, the average stack gas temperature, stack gas molecular weight and absolute 

static pressure. The volumetric flow rate is the product of stack gas velocity and the stack cross 

sectional area. See Appendix C for field worksheets and calculated values based on the field data. 

9
STACK GAS DILUENT CONTENT 

EPA Reference Method 3, “Gas Analysis for the Determination of Dry Molecular Weight”, was 

used to measure the O2 and CO2 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 triplicate 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 Reference 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 being the modified Greenburg-Smith design, and the 

second impinger having the standard design. The final impinger contained approximately 300 

grams of indicating silica gel. Each of the impingers 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 removed, 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 were also utilized in the Method 13A (TF) 

determinations. Moisture content worksheets are included in Appendix C. 

TOTAL FLUORIDES 

EPA Reference Method 13A, “Determination of Total Fluoride Emissions 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 filter position is interchangeable. For the purposes of 

this test, the filter was placed between the last two impingers. 

AQS used a glass nozzle and probe assembly. The stack gases passed through three of the 

moisture trains before entering the filter and passing through the fourth impinger. The impingers 

were placed in an ice bath during the sampling process. 

When the sampling train was completely assembled, a leak check was performed before the start 

of the test run. Stack gas volumes and sampling rates were controlled using a dry gas meter with 

calibrated orifice and a rotary vane vacuum pump. Meter temperature, stack temperature, and 

differential pressure were recorded 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 minutes of sampling. For Run #1, 

the sampling commenced on the south stack, moving to the center stack after all 24 points were 

10
 At Reactor #3, each point was sampled for six (6) minutes, providing 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 removed, 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 stack gas during each test run. 

The particulate matter was recovered from the test equipment by removing the nozzle, probe, and 

front half of the filter holder then rinsing and brushing 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 dishes, and sealed for transport to the Alcoa 

laboratory. 

Laboratory data are included in Appendix D. 

11
Figure 5.3 

Method 13A Sample Train 

POLYCYCLIC ORGANIC MATTER 

EPA Reference Method 315, “Determination of Particulate and Methylene Chloride Extractable 

Matter (MCEM) from Selected Sources at Primary Aluminum Production Facilities”, was 

employed for this testing. AQS used a glass nozzle and glass probe assembly connected to a 

glass filter bell containing a three-inch glass-fiber filter with a glass frit filter support and a 

silicone rubber gasket. The stack 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 check was performed before the start 

of the test run. Stack gas volumes and sampling rates were controlled using a dry gas meter with 

calibrated orifice and a rotary vane 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 was post-leak checked at a vacuum greater than 

that achieved during the sample test run. 

12
The particulate matter was recovered from the test equipment by removing the nozzle, probe, and 

front half of the filter holder then rinsing and brushing each glass component with acetone, in 

triplicate. The acetone rinses from each test run were collected in amber glass bottles. The glass 

fiber filters were removed with forceps, placed in Petri dishes, and sealed for transport to the inhouse laboratory. 

After the acetone rinse, the entire procedure was repeated using methylene chloride as the 

reagent and the rinse was collected in a separate container. 

The impingers were recovered and rinsed according to the procedures of Method 315 and sealed 

for transport to the Alcoa laboratory. 

Laboratory analytical worksheets are included in Appendix D. 

13
SECTION 6 

QUALITY ASSURANCE/QUALITY CONTROL 

All manual stack gas sampling equipment was calibrated 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 sampling 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. Calibration 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 

ΔH @ + 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 sampling equipment are essential to maintain data 

quality. AQS strictly follows referenced calibration procedures and documents 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 

18
19

APPENDIX E 

QUALITY ASSURANCE / QUALITY CONTROL