POLYCYCLIC ORGANIC MATTER (POM) TEST REPORT 

(as determined by methylene chloride extractable matter – EPA Method 315) 

ANODE BAKING FURNACE (A-446) 

Performed for: 

ALCAN PRIMARY PRODUCTS CORPORATION 

SEBREE WORKS 

9404 State Route 2096 

Robards, KY 42452

June 5 – 7, 2012 

Submitted by: 

Air Quality Services, LLC 

425 Main Street 

Evansville, IN 47708 

Phone: (812) 452-4785 

Fax: (812) 452-4786 

AQS Project# 12662-21-001 
ii 

SOURCE TESTING REPORT CERTIFICATION 

Air Quality Services, LLC 

425 Main Street 

Evansville, Indiana 47708 

Phone: (812) 452-4785 

Fax: (812) 452-4786 

Reproducing portions of this test report may omit critical substantiating documentation 

or be taken out of context and due care should be exercised in this regard. 

I have prepared and reviewed this report and found the information accurate and 

complete to the best of my ability. 

Report Writer 

_________________________________ Date____________________ 

Stephen R. Endress 

Air Quality Services, LLC 

Report Reviewer 

_________________________________ Date____________________ 

Daniel L. Todd, QEP, CHMM 

Air Quality Services, LLC 

 July 24, 2012 

 July 24, 2012 
iii 

TABLE OF CONTENTS

Page

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

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

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

SECTION 4 PROCESS DESCRIPTION .............................................................5 

SECTION 5 SAMPLING AND ANALYTICAL PROCEDURES......................6 

 

 Location of Measurement Sites ...................................................6 

 Stack Gas Velocity and Volumetric Flow Rate ...........................6 

 Stack Gas Oxygen and Carbon Dioxide Content.........................6 

 Stack Gas Moisture Content ........................................................7 

 Methylene Chloride Extractable Matter.......................................7 

 Performance Audits .....................................................................7 

SECTION 6 QUALITY ASSURANCE / QUALITY CONTROL ...................10 

 

APPENDIX A - EXAMPLE CALCULATIONS 

APPENDIX B - DATA SUMMARY 

APPENDIX C - FIELD DATA 

APPENDIX D - LABORATORY DATA 

APPENDIX E - QUALITY ASSURANCE / QUALITY CONTROL 
iv 

LIST OF TABLES

Table Page

 1.1 Test Results..................................................................................................1 

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

 3.1 Summary of Stack Gas Parameters and Test Results ..................................4 

 6.1 Field Equipment Calibration Summary .....................................................10 

LIST OF FIGURES

Figure Page

 5.1 Method 5/13B Stack Sampling Train ..........................................................8 

 5.2 Schematic of Sample Locations...................................................................9 

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 
Page 1 of 11 

AQS Project# 12662-21-001 

SECTION 1 

EXECUTIVE SUMMARY 

On June 5 – 7, 2012, stack testing for polycyclic organic matter (POM) was performed on the 

three reactor stacks which exhaust the scrubber of the Anode Baking Furnace (also known as 

A-446). Testing was conducted at Alcan Primary Products Corporation, Sebree Works in 

Robards, Kentucky (Source ID # 21-101-00029). 

These tests followed the procedures for EPA Methods 1, 2, 3, and 4 (as specified in 40 CFR 

60, Appendix A), and EPA Method 315 (as specified in 40 CFR 63, Appendix A). 

The results of the emissions tests are summarized below: 

TABLE 1.1 

TEST RESULTS 

Location 

POM Controlled 

Emission Rate, 

lbs/ton of green anode 

POM Controlled 

Emission Limit1

, 

lbs/ton of green anode 

A-446 0.0196 0.18 

The green anode throughput during the month of June was 10,674 tons, which averages 

14.825 tons per hour. 

 

1

 Permit # V-05-088 § B, Subject Item 6, Condition 2.d 
Page 2 of 11 

AQS Project# 12662-21-001 

SECTION 2 

INTRODUCTION 

Alcan Primary Products Corporation retained Air Quality Services, LLC (AQS) to plan and 

conduct a testing program to determine POM on the baking furnace exhausts that are 

connected to the carbon bake dry alumina scrubber at the Sebree, Kentucky facility, which is 

part of the Anode Baking Furnace A-446. The tests were conducted on June 5 – 7, 2012. 

Testing was conducted to fulfill the permit required testing under Permit Number V-05-088 

R1, Section B, Subject Item 6 Requirements, Condition 3 Testing Requirements: b. 

 

The sampling was conducted using EPA Methods 1, 2, 3, 4, and 315 to determine stack 

sample traverse locations, velocity and volumetric flow rates, molecular weight, moisture 

content, and methylene chloride extractable matter (MCEM) concentrations, respectively. 

For the purposes of this test program, the MCEM determined by Method 315 is represented 

as POM. Mr. Neal Stewart, of AQS, performed the sampling procedures. Mr. Brandon 

Coomes, of Alcan Primary Products Corporation, coordinated the production rate with the 

testing schedule. There were no agency observers at this testing program. 

The contacts for this test program were as follows:

TABLE 2.1 

TEST PROGRAM CONTACTS 

Alcan Primary Products Corporation 

Sebree Works: 

Mr. Brandon Coomes 

9404 State Route 2096 

Robards, KY 42452 

Phone: (270) 521-7454 

Fax: (270) 521-7455 

E-mail: brandon.coomes@riotinto.com 

Air Quality Services, LLC: 

Mr. Dan Todd / Neal Stewart 

425 Main Street 

Evansville, IN 47708 

Phone: (812) 452-4785 

Fax: (812) 452-4786 

E-mail: dtodd@aqsllc.net 

 nstewart@aqsllc.net 
Page 3 of 11 

AQS Project# 12662-21-001 

SECTION 3 

SUMMARY OF TEST RESULTS 

The testing program at Alcan Primary Products Corporation was performed on June 5 – 7, 

2012. POM was collected by EPA Test Method 315, a procedure in which MCEM is 

collected and recovered in a sampling train. For the purposes of this test program, the 

MCEM determined by Method 315 is represented as POM. Sample collection and laboratory 

analyses utilized the applicable procedures as published in the Code of Federal Regulations, 

Title 40, Part 60, (40 CFR 60) Appendix A and 40 CFR 63, Appendix A.

There are a total of three stacks – one stack per scrubber reactor – that comprise the emission 

points of the Anode Baking Furnace dry scrubber/baghouse system. Testing was conducted 

above the baghouse in three identical, vertical, circular stacks with an inside diameter of 50.5 

inches each. This test program consisted of three (3) four-hour test runs, one per stack. 

During June, the bake furnace had 10,674 tons of green anode throughput, which averages 

14.825 tons of green anode per hour. The emissions were determined in unit of pounds of 

POM per hour. The overall emissions were determined by calculating the sum of the three 

stacks (lb/hr) and dividing by the process throughput (ton/hr), resulting in pounds of POM 

per ton green anode throughput. 

The sum of the emissions from Reactors #1, #2, and #3 represent the Anode Baking Furnace 

emissions. The A-446 POM emissions totaled 0.0196 lbs/ton. 

The POM results are summarized in Table 3.1. More detailed calculations are included in 

Appendix A. The individual test results and the field data sheets from each test location are 

located in Appendices B and C, respectively. Appendix D contains the laboratory data and 

analysis. 
AQS P

TABLE 3.1 

SUMMARY OF STACK GAS PARAMETERS AND TEST RESULTS 

Flow PO

Run 

No. Time Date 

Stack 

Temp. 

°F 

O2

% 

CO2

% 

H2O 

% 

Velocity

ft/s acfm dscfm lbs/hr 

C-1 8:12-12:14 06/05/12 175.5 17.0 3.0 9.5 27.9 23,269 17,419 0.057 C-2 5:59-10:06 06/06/12 178.5 17.5 3.0 9.3 35.4 29,524 22,168 0.085 C-3 6:00-10:02 06/07/12 177.5 17.5 3.0 9.7 33.1 27,634 20,705 0.149 

Averages 177.2 17.3 3.0 9.5 32.1 26,809 20,097 0.097 

(June average) Tons green anode throughput

Total POM Emissions, lb/ton green a
Page 5 of 11 

AQS Project# 12662-21-001 

SECTION 4 

PROCESS DESCRIPTION 

The Anode Baking Furnace, also referred to as A-446, is the oven process from the 

production of carbon anodes which are used on-site in the potlines. The carbon anodes are a 

mixture of carbon coke and tar pitch, which is formed into green anodes in the Green Mill. 

The green anodes are placed in a ring furnace for a bake cycle, which consists of pre-heating, 

baking, and cooling. The furnace operates continuously with a production rate of 

approximately 400 anodes per day. After cooling, the baked anodes are supplied to the 

potlines for the use in the production process. The emissions from the baking furnace are 

ducted to a dry aluminum scrubber, which cleans the gases emitted by the baking process. 

The scrubber employs a baghouse to control the particulate emissions. 
Page 6 of 11 

AQS Project# 12662-21-001 

SECTION 5 

SAMPLING AND ANALYTICAL PROCEDURES 

The sampling and analytical procedures used in this test program were in accordance with 

EPA Reference Methods 1, 2, 3, 4, 5 and 315, as published in the Code of Federal 

Regulations, Title 40, Part 60, (40 CFR 60) Appendix A and 40 CFR 63, Appendix A. 

LOCATION OF MEASUREMENT SITES

EPA Method 1, “Sample and Velocity Traverses for Stationary Sources”, was used to select 

representative measurement points at both test locations. 

The Anode Baking Furnace exhausts through three vertical, circular stacks (#1, #2, and #3), 

each with an inside diameter of 50.5 inches. The two test ports (90o apart) are located 118 

inches (2.3 stack diameters) downstream from a disturbance and 222 inches (4.3 stack 

diameters) upstream from the exhaust for each stack. For velocity measurements conforming 

to Method 315, a total of 24 traverse points were used for the measurements, 12 per test port. 

A copy of the field work sheet is included in Appendix C. 

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 at both test locations. 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 A for 

calculated values based on the field data and Appendix C for field data sheets. 

STACK GAS OXYGEN AND CARBON DIOXIDE CONTENT 

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

was used to measure the oxygen (O2) and carbon dioxide (CO2) concentrations of the stack gas 

at the test locations. The integrated samples were collected at the exhaust of the dry gas 

meter and were analyzed using a Fyrite® analyzer. Each sample was measured in triplicate 

until a reading was repeated within 0.3%. The results of this testing can be found in 

Appendix B. 
Page 7 of 11 

AQS Project# 12662-21-001 

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 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. 

METHYLENE CHLORIDE EXTRACTABLE MATTER 

EPA Reference Method 315 (40 CFR 63, Appendix A), “Determination of Particulate and 

Methylene Chloride Extractable Matter from Stationary Sources”, was employed for this test. 

The collected samples and blanks were sent to a contract laboratory for analysis. 

Method 315 specifies the use of the standard particulate sampling train described in Method 

5 (40 CFR 60, Appendix A). In Method 5, the gas sample is pulled though a sampling 

nozzle, probe, and a filter – all are heated to 250°F. At the point the gas leaves the filter 

holder, it is no longer heated. Downstream of the filter, the gas is cooled in a condenser 

consisting of a train of impingers. Following each test run, the front half of the sample train 

(nozzle, probe liner, front of filter holder) is brushed and acetone-rinsed, then brushed and 

rinsed with methylene chloride. The water in the condenser is recovered, and then the back 

half of the sample train (back of filter holder, all impingers, and all connecting lines) is rinsed 

with water, then acetone, then methylene chloride. These preparation, sampling, and 

recovery procedures were followed without deviation. 

PERFORMANCE AUDITS 

Testing commenced on June 5, 2012. In accordance with the applicable requirements 

specified in 40 CFR 63.7(c)(2)(iii), the USEPA Web site was accessed at least 60-days prior 

to the test date (calculates to be April 6, 2012). At that time, there were commercially 

available performance audit samples for POM from one supplier. EPA rules do not require 

the use of performance audit samples unless there are at least two suppliers. No audit 

samples were utilized in this test program. 
Page 8 of 11 

AQS Project# 12662-21-001 

FIGURE 5.1 

METHOD 5 STACK SAMPLING TRAIN

(as specified in Method 315) 
Page 9 of 11 

AQS Project# 12662-21-001 

FLOW 118 inches 

222 inches 

Top of stack = 70 feet above grade 

Sample Ports 

50.5 inches 

Top of baghouse 

FIGURE 5.2 

SCHEMATIC OF SAMPLE LOCATIONS 

A-446 Reactors #1, #2, and #3 (Identical Stacks) 

(not to scale) 
Page 10 of 11 

AQS Project# 12662-21-001 

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 6.1. 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 

∆H @ + 0.15 

Post Test Y + 0.05 Y 

Pitot Tube Geometric Specifications 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 

AQS’ stack testing policies and practices conform to ASTM D7036-04 “Standard Practice 

for Competence of Air Emission Testing Bodies” for emission testing programs affected by 

the requirements of 40 CFR 75.21(f), as performed on Part 72 sources and Part 75 sources. 

ASTM D7036-04 notwithstanding, it is our mission to be a trusted provider of air-related 

environmental services. We aspire to exceed client expectations by imparting exceptional 

quality and value in meeting corporate needs and fulfilling regulatory requirements. 

The AQS Quality Objectives are: 

• to continually monitor and improve our ability to deliver the scope of services 

• to assign qualified test personnel to satisfy the needs of our clients 
Page 11 of 11 

AQS Project# 12662-21-001 

• to comply with quality control procedures established in test methods, in the AQS 

Quality Manual, and by regulatory agencies that have jurisdiction over test programs 

• to prepare reports that clearly communicate test program results 

• to utilize recordkeeping systems that allow for data retrieval and reconstruction 

• to keep clients apprised of project progress and promptly respond to concerns 
APPENDIX A 

EXAMPLE CALCULATIONS 
APPENDIX B 

DATA SUMMARY 
APPENDIX C 

FIELD DATA 
APPENDIX D 

LABORATORY DATA 
APPENDIX E 

QUALITY ASSURANCE / QUALITY CONTROL