# Instructions The EPA secondary aluminum production test program requires emissions and other test data for several pollutants. EPA understands that you own one or more secondary aluminum production facilities. For at least one thermal chip dryer and at least one scrap dryer/delacquering kiln/decoating kiln that you own, you must perform a stack test for volatile and semi-volatile organic HAPs as specified in the letter and instructions accompanying this file. You should collect emissions samples for the identified pollutants downstream of the last relevant emissions control device (i.e., stack or other point representing the composition of the flue gases at the exit to the atmosphere), unless otherwise indicated. (Contact the EPA project lead for situations with multiple stacks or other complex emissions points for the unit.) Sample and analyze the particulate matter collected in the hopper from at least one bag house used to control particulate matter from each type of affected source subject to 40 CFR 63, subpart RRR at your secondary aluminum production facilities. Choose bag houses that are used to control particulate matter from each of the six different types of affected sources (i.e.group 1 furnaces, scrap shredders, chip dryers, scrap dryers/delacquering kilns/decoating kilns, dross only furnaces, and rotary dross coolers) if you have these controlled affected sources at your facilities. Where more than one bag house discharges solids to a common hopper, a single sample will be adequate. In cases where solids from different compartments of a single bag house are collected in multiple hoppers or multiple collection sacks, a single composite sample will be adequate. If you have a total of three or fewer bag houses at all of your facilities, sample and analyze particulate matter from all of them, even if they are controlling the same type of affected source. It is not necessary to conduct a stack test for multi-metals analysis.
Sample and analyze the lime used for injection to any of the lime-injected bag houses from which particulate matter samples were collected. If lime of the same type, obtained from the same supplier, is used for more than one lime injected bag house, a single sample will be adequate to represent the lime used in these bag houses.
You must report the results of these tests and chemical analyses in this Microsoft® Excel Emission Test Template. The Excel templates are specific to each type of pollutant. You must report the results of each test on the appropriately labeled worksheet corresponding to the specific tests and analyses conducted at your facilities. If more than one source was tested, you must make a copy of the worksheet and update the source ID in order to distinguish between each separate test of a chip dryer or scrap dryer/ delacquering kiln/decoating kiln at each facility and each different source of particulate matter. After completing the worksheet, you must also submit an electronic copy of the emission test report and the chemical analyses. (PDF format preferred). Please refer to the cover letter of this packet (CAA section 114 letter) for additional testing information. Please note that you do not have to submit a test plan to EPA for approval prior to testing; however, we recommend that you prepare a test plan for your own use to assist in the planning and to verify that you address all of the testing and reporting requirements. You must follow all of the procedures as specified in the test methods, including the quality assurance and quality control measures, and document the results in any test report provided to EPA.**Facility Name and Address Unit Description**  **Process Unit ID Control Device ID** 

Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/24/2010 8/25/2010**  **8/25/2010** Feed/Charge Rate 0.66 0.31 0.31 Mg/hr Afterburner Operating Temperature Not Applicable Not Applicable Not Applicable degree F

Type of Charge:__**Aluminum Plate Milling Chips**

____

**Compound Volatile Organic HAP**  **Emission Rate Sample 1**

**(kg/hr) Volatile Organic HAP**  **Emission Rate Sample 1 (kg/Mg of feed/charge)**  **Volatile Organic HAP Emission Rate Sample**  **2 (kg/hr) Volatile Organic HAP** 

**Emission Rate Sample 2 (kg/Mg of**  **feed/charge) Volatile Organic HAP** 

**Emission Rate Sample 3**

**(kg/hr) Volatile Organic HAP** 

**Emission Rate Sample 3 (kg/Mg of**  **feed/charge) Test Method Used** **Detection Limit Information**  **(BDL,DLL,ADL) Other Supporting**  **Information** Acry lonitrile 107-13-1 [< 1.82E-05] [< 2.75E-05] [< 2.21E-05] [< 7.14E-05] [< 2.01E-05] [< 6.49E-05]SW 846 M-0031 DLL Benzene 71-43-2 [< 2.93E-06] [< 4.43E-06] [< 3.31E-06] [< 1.07E-05] [< 3.38E-06] [< 1.09E-05]SW 846 M-0031 DLL Bromodichloromethane 75-27-4 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL Carbon disulfide 75-15-0 [< 2.83E-06] [< 4.28E-06] [< 3.38E-06] [< 1.09E-05] [< 3.62E-06] [< 1.17E-05]SW 846 M-0031 DLL Carbon tetrachloride 56-23-5 [< 3.72E-06] [< 5.64E-06] [< 4.57E-06] [< 1.47E-05] [< 4.25E-06] [< 1.37E-05]SW 846 M-0031 DLL Chlorodibromomethane 124-48-1 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL Chloroform 67-66-3 [< 1.65E-06] [< 2.51E-06] [< 1.97E-06] [< 6.37E-06] [< 1.89E-06] [< 6.09E-06]SW 846 M-0031 DLL Chloroprene 126-99-8 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL Dibromomethane 74-95-3 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL 1,1-Dichloroethane 75-34-3 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL 1,2-Dichloroethane 107-06-2 [< 3.00E-06] [< 4.54E-06] [< 3.67E-06] [< 1.18E-05] [< 3.25E-06] [< 1.05E-05]SW 846 M-0031 DLL 1,1-Dichloroethene 75-35-4 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL trans-1,2-Dichloroethene 156-60-5 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL 1,2-Dichloropropane 78-87-5 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL 1,3-Dichloropropene 542-75-6 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL Methy lene chloride 75-09-2 6.69E-06 1.01E-05 8.06E-06 2.60E-05 5.20E-06 1.68E-05SW 846 M-0031 DLL Tetrachloroethene 127-18-4 [< 1.50E-06] [< 2.27E-06] [< 2.02E-06] [< 6.53E-06] [< 2.20E-06] [< 7.11E-06]SW 846 M-0031 DLL Toluene 108-88-3 [< 7.17E-06] [< 1.09E-05] [< 8.33E-06] [< 2.69E-05] [< 9.11E-06] [< 2.94E-05]SW 846 M-0031 DLL 1,1,1-Trichloroethane 71-55-6 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL 1,1,2-Trichloroethane 79-00-5 [< 3.63E-06] [< 5.50E-06] [< 4.43E-06] [< 1.43E-05] [< 4.22E-06] [< 1.36E-05]SW 846 M-0031 BDL Trichloroethene 79-01-6 [< 3.63E-06] [< 5.50E-06] [< 3.68E-06] [< 1.19E-05] [< 3.57E-06] [< 1.15E-05]SW 846 M-0031 DLL Trichlorofluoromethane 75-69-4 [< 3.96E-06] [< 6.00E-06] [< 4.74E-06] [< 1.53E-05] [< 4.59E-06] [< 1.48E-05]SW 846 M-0031 DLL **Speciated Volatile Organic HAP Emission Data Facility Name and Address**  **Unit Description Process Unit ID**  **Control Device ID**

Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/24/2010 8/25/2010**  **8/25/2010** Feed/Charge Rate 0.66 0.31 0.31 Mg/hr Afterburner Operating Temperature Not Applicable Not Applicable Not Applicable degree F

Type of Charge:__**Aluminum Plate Milling Chips**

____

**Compound Semi-volatile Organic HAP**  **Emission Rate Sample 1**

**(kg/hr) Semi-volatile Organic HAP** 

**Emission Rate Sample 1 (kg/Mg of feed/charge)**  **Semi-volatile Organic HAP Emission Rate**  **Sample 2 (kg/hr) Semi-volatile Organic HAP**  **Emission Rate Sample 2 (kg/Mg of feed/charge)**  **Semi-volatile Organic HAP Emission Rate**  **Sample 3 (kg/hr) Semi-volatile Organic**  **HAP Emission Rate Sample 3 (kg/Mg of**  **feed/charge) Test Method Used**  **Detection Limit Information**  **(BDL,DLL,ADL) Other Supporting**  **Information** Acenaphthene 83-32-9 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Acenaphthylene 208-96-8 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Anthracene 120-12-7 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Benz[a]anthracene 56-55-3 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Benzo[a]pyrene 50-32-8 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Benzo[b]fluoranthene 205-99-2 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Benzo[g,h,i]perylene 191-24-2 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Benzo[k]fluoranthene 207-08-9 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Chrysene 218-01-9 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Dibenz[a,h]anthracene 53-70-3 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Fluoranthene 206-44-0 [< 4.61E-08] [< 6.98E-08] 5.91E-08 1.91E-07 6.82E-08 2.20E-07SW 846 M-0010 DLL Fluorene 86-73-7 [< 4.61E-08] [< 6.98E-08] 4.16E-08 1.34E-07 3.76E-08 1.21E-07SW 846 M-0010 DLL Indeno(1,2,3-cd)pyrene 193-39-5 [< 4.61E-08] [< 6.98E-08] [< 1.94E-08] [< 6.27E-08] [< 1.95E-08] [< 6.28E-08] SW 846 M-0010 BDL Naphthalene 91-20-3 1.07E-06 1.62E-06 5.16E-07 1.66E-06 2.36E-07 7.61E-07SW 846 M-0010 ADL Phenanthrene 85-01-8 1.14E-07 1.72E-07 1.49E-07 4.80E-07 1.57E-07 5.05E-07SW 846 M-0010 ADL Pyrene 129-00-0 [< 4.61E-08] [< 6.98E-08] 3.24E-08 1.04E-07 3.24E-08 1.05E-07SW 846 M-0010 DLL **Speciated Volatile Organic HAP Emission Data**

### Facility Name and Address **Unit Description Process Unit ID**  **Control Device ID**



### Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/24/2010 8/25/2010**  **8/25/2010** Feed/Charge Rate 

### 0.66 0.31 0.31 Mg/hr Afterburner Operating Temperature Not Applicable 

### Not Applicable Not Applicable degree F Flow Rate 

### 32.28 40.41 38.60 actual M3

### /min Flow Rate 

### 29.22 35.91 34.01 dry sM3

### /min

**Emission Test Results Constituent**  **Composition Sample 1**  **(% )**  **Composition Sample 2**  **(% )**  **Composition**

**Sample 3 (%** **) Test Method Used** 

**(ex. U.S. EPA Method 3B) Other Supporting Information**  O2 

### 20.77 20.86 20.82 US EPA Method 3A CO2 

### 0.09 0.01 0.02 US EPA Method 3A H2

### O 

### 1.8 1.9 2.0 US EPA Method 4

### Facility Name and A **ddress Unit Description**  **Process Unit ID Control Device ID**  

## Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility Not Applicable

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information Date of Testing**  **8/24/2010 8/25/2010**  **8/25/2010** Feed/Charge Rate 

## 0.66 0.31 0.31 Mg/hr Afterburner residence time 

## Not Applicable Not Applicable Not Appliacble sec Afterburner Operating Temperature Not Applicable 

## Not Applicable Not Appliacble degree F



## 1 8/24/2010 12:50 8/24/2010 17:04 2 8/25/2010 7:50 8/25/2010 11:55 3 8/25/2010 12:27 8/25/2010 16:30

**Run Number THC Emission Rate (kg/hr)**  **THC Emission Rate (kg/Mg of feed/charge)**  **Data Flag (A DL, BDL, DDL)** *** **Detection Limit (ng/dscm)**  

## 1 0.00202 0.00306 ADL N/A 2 0.00278 0.00897 ADL N/A 3 0.00236 0.00761 ADL N/A *** See Appendix A to Enclosure 1

**Run Number Test Start Date**  **Test Start Time Test End Date**  **Test End Time**

## Facility **Name and A ddress**  **Unit Description Process Unit ID**  **Control Device ID*** 

## Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility
**Sample ID No._ Lancaster BH # 1 Dust** 

**___________________ Ty** **pe of Sample (Lime or Particulate):_ BH Dust** 

**____________________________ Date Sampled**  **Date(s) Analyzed**

25-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

**HAP Metal mg/kg**  Antimony 

## 21.7 Beryllium 

## 0.203 Chromium 

## 16.1 Hexavalent chromium 

## 1.5 Lead 

## 3.52 Mercury 

## 0.0078 Selenium 

## < 1.0 Arsenic 

## 1.23 Cadmium 

## 1.05 Cobalt 

## 5.16 Manganese 

## 53.8 Nickel 

## 20.1
*** Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.**

## Facility **Name and A ddress**  **Unit Description Process Unit ID**  **Control Device ID*** 

## Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility
**Sample ID No._ Lancaster BH # 3 Dust** 

**___________________ Ty** **pe of Sample (Lime or Particulate):_ BH Dust** 

**____________________________ Date Sampled**  **Date(s) Analyzed**

24-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

**HAP Metal mg/kg**  Antimony 

## 10.4 Beryllium 

## 1.02 Chromium 

## 348 Hexavalent chromium 

## < 1.0 Lead 

## 10.1 Mercury 

## 0.0048 Selenium 

## 91.9 Arsenic 

## 0.86 Cadmium 

## 0.682 Cobalt 

## 15.0 Manganese 

## 2370 Nickel 

## 31.7
*** Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.**

## Facility **Name and A ddress**  **Unit Description Process Unit ID**  **Control Device ID*** 

## Alcoa Mill Products, Lancaster, PA Chip Dryer Chip Dryer at Plate Facility
**Sample ID No._ Lancaster Lime Feed** 

**___________________ Ty** **pe of Sample (Lime or Particulate):_ Lime** 

**____________ Date Sampled**  **Date(s) Analyzed**

25-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

**HAP Metal mg/kg**  Antimony 

## 0.23 Beryllium 

## 0.126 Chromium 

## 2.46 Hexavalent chromium 

## < 1.0 Lead 

## < 0.5 Mercury 

## 0.0019 Selenium 

## < 1.0 Arsenic 

## 0.55 Cadmium 

## < 0.05 Cobalt 

## 1.91 Manganese 

## 26.4 Nickel 

## 13.5
*** Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.**