# 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.**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/23/2010 8/24/2010**  **8/24/2010** Feed/Charge Rate 5.37 5.39 5.15Mg/hr Afterburner Operating Temperature 1405 1405 1409degree F Average

Type of Charge:Aluminum 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**  Acrylonitrile 107-13-1 4.44661E-05 8.27322E-06 4.47445E-05 8.30679E-06 4.30241E-05 8.3495E-06Method 0031 BDL Benzene 71-43-2 5.18052E-06 9.6387E-07 5.03239E-06 9.34261E-07 4.8389E-06 9.39064E-07Method 0031 BDL Bromodichloromethane 75-27-4 3.88539E-06 7.22902E-07 3.829E-06 7.1085E-07 3.68177E-06 7.14505E-07Method 0031 BDL Carbon disulfide 75-15-0 8.60182E-05 1.60043E-05 3.282E-05 6.093E-06 1.56738E-05 3.04175E-06Method 0031 DLL Carbon tetrachloride 56-23-5 7.07464E-05 1.31628E-05 2.2602E-05 4.19605E-06 3.25889E-05 6.32439E-06Method 0031 BDL Chlorodibromomethane 124-48-1 6.25979E-06 1.16468E-06 4.48539E-06 8.3271E-07 5.47006E-06 1.06155E-06Method 0031 DLL Chloroform 67-66-3 3.75587E-06 6.98806E-07 3.73054E-06 6.92571E-07 3.5871E-06 6.96132E-07Method 0031 BDL Chloroprene 126-99-8 8.6342E-06 1.60645E-06 8.75199E-06 1.6248E-06 8.41548E-06 1.63315E-06Method 0031 BDL Dibromomethane 74-95-3 6.6915E-06 1.245E-06 6.23579E-06 1.15767E-06 5.68045E-06 1.10238E-06Method 0031 BDL 1,1-Dichloroethane 75-34-3 3.88539E-06 7.22902E-07 3.829E-06 7.1085E-07 3.68177E-06 7.14505E-07Method 0031 BDL 1,2-Dichloroethane 107-06-2 4.74881E-06 8.83547E-07 4.70419E-06 8.7333E-07 4.52332E-06 8.77821E-07Method 0031 BDL 1,1-Dichloroethene 75-35-4 9.92932E-06 1.84742E-06 9.73659E-06 1.80759E-06 9.36222E-06 1.81688E-06Method 0031 BDL trans-1,2-Dichloroethene 156-60-5 1.80239E-05 3.35346E-06 1.45502E-05 2.70123E-06 1.33596E-05 2.59263E-06Method 0031 BDL 1,2-Dichloropropane 78-87-5 4.96466E-06 9.23709E-07 4.70419E-06 8.7333E-07 4.52332E-06 8.77821E-07Method 0031 BDL 1,3-Dichloropropene 542-75-6

9.79981E-06 1.82332E-06 9.75847E-06 1.81165E-06 9.19391E-06 1.78422E-06Method 0031 BDL Lab analysis includes the cis- and trans- isomers separately. Results have been combined for this worksheet Methylene chloride 75-09-2 0.000863851 0.000160725 0.000831767 0.000154417 0.000715631 0.000138879Method 0031 DLL Tetrachloroethene 127-18-4 1.41385E-05 2.63056E-06 8.75199E-06 1.6248E-06 9.15183E-06 1.77606E-06Method 0031 BDL Toluene 108-88-3 9.92932E-06 1.84742E-06 1.55348E-05 2.88402E-06 1.45167E-05 2.81719E-06Method 0031 BDL 1,1,1-Trichloroethane 71-55-6 5.18052E-06 9.6387E-07 5.03239E-06 9.34261E-07 4.8389E-06 9.39064E-07Method 0031 BDL 1,1,2-Trichloroethane 79-00-5 4.74881E-06 8.83547E-07 4.70419E-06 8.7333E-07 4.52332E-06 8.77821E-07Method 0031 BDL Trichloroethene 79-01-6 4.74881E-06 8.83547E-07 4.70419E-06 8.7333E-07 4.52332E-06 8.77821E-07Method 0031 BDL Trichlorofluoromethane 75-69-4 1.77001E-05 3.29322E-06 1.78322E-05 3.31053E-06 1.71465E-05 3.32755E-06Method 0031 BDL Miscellaneous Organics 8.6342E-07 1.60645E-07 7.65799E-07 1.4217E-07 7.36354E-07 1.42901E-07Method 0031 BDL **Speciated Volatile Organic HAP Emission Data (Method 0031) Facility Name and Address**  **Unit Description Process Unit ID**  **Control Device ID**

General Motors LLC 105 GM Drive, Bedford, IN 47421 Natural Gas-Fired Aluminum Thermal Chip Dryer CHIP-2 AB-1

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/23/2010 8/24/2010**  **8/24/2010** Feed/Charge Rate 5.38 5.39 5.15Mg/hr Afterburner Operating Temperature 1405 1405 1409degree F Average

Type of Charge:Aluminum 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) 1**  **Other Supporting Information**  Acenaphthene 83-32-9 1.77803E-06 3.30786E-07 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (ADL, BDL, BDL) Acenaphthylene 208-96-8 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (ADL, BDL, BDL) Anthracene 120-12-7 1.48169E-06 2.75655E-07 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (ADL, BDL, BDL) Benz[a]anthracene 56-55-3 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Benzo[a]pyrene 50-32-8 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Benzo[b]fluoranthene 205-99-2 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Benzo[g,h,i]perylene 191-24-2 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Benzo[k]fluoranthene 207-08-9 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Chrysene 218-01-9 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Dibenz[a,h]anthracene 53-70-3 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Fluoranthene 206-44-0 1.87681E-06 3.49163E-07 1.11902E-06 2.07711E-07 4.90264E-07 9.52273E-08Method 0010 (ADL, ADL, BDL) Fluorene 86-73-7 8.39625E-06 1.56205E-06 1.02172E-06 1.89649E-07 4.90264E-07 9.52273E-08Method 0010 (ADL, ADL, BDL) Indeno(1,2,3-cd)pyrene 193-39-5 4.93897E-07 9.18851E-08 4.86532E-07 9.03092E-08 4.90264E-07 9.52273E-08Method 0010 (BDL, BDL, BDL) Naphthalene 91-20-3 9.1371E-05 1.69987E-05 1.51798E-05 2.81765E-06 3.54951E-05 6.89445E-06Method 0010 (ADL, ADL, ADL) Phenanthrene 85-01-8 2.16821E-05 4.03376E-06 3.16246E-06 5.8701E-07 2.15716E-06 4.19E-07 Method 0010 (ADL, ADL, ADL) Pyrene 129-00-0 4.93897E-07 9.18851E-08 1.50825E-06 2.79959E-07 4.90264E-07 9.52273E-08Method 0010 (BDL, ADL, BDL) 1. Acronyms are listed in order corresponding to Samples 1-3. **Speciated Volatile Organic HAP Emission Data (Method 0010)**

## Facility

**Name and A**

**ddress Unit ID**  **Unit Ty pe (Chip dry**  **er or scrap**
**dry er /delacq /decoating kiln)** 



## General Motors LLC 105 GM Drive, Bedford, IN 47421 CHIP-2 Natural Gas-Fired Aluminum Thermal Chip Dryer

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information Date of Testing**  **8/23/2010 8/24/2010**  **8/24/2010** Feed/Charge Rate 

## 5.38 5.39 5.15Mg/hr Afterburner residence time 

## Unkown Unkown Unkown sec Afterburner Operating Temperature 

## 1405 1405 1409degree F 

## Average

1 8/23/2010 16:49 8/23/2010 20:10 2 8/24/2010 7:47 8/24/2010 10:56 3 8/24/2010 11:52 8/24/2010 15:06

**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 0.667 0.124ADL Used online analyzer to get ppm reading on wet basis.

2 0.631 0.117ADL Used online analyzer to get ppm reading on wet basis.

3 0.122 0.024ADL Used online analyzer to get ppm reading on wet basis. *** See Appendix A to Enclosure 1 **Test End Time**

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

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

### General Motors LLC 105 GM Drive, Bedford, IN 47421 Natural Gas-Fired Aluminum Thermal Chip Dryer CHIP-2 AB-1

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/23/2010 8/24/2010**  **8/24/2010** Feed/Charge Rate 

### 5.38 5.39 5.15Mg/hr Afterburner Operating Temperature 

### 1405 1405 1409degree F 

### Average Flow Rate 

### 663.2 654.9 646.6actual M3

### /min Flow Rate 

### 364.7 363.5 365.0dry 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 

### 16.2 16.2 16.6 3A CO2 

### 2.5 3.1 2.4 3A

H2

### O 

### 18.87 20.61 19.89 4 Moistures from Method 0031 train give results of (0.59%, 0.67%, and 0.64%) which are not accurate. Results reported here are from Method 0010 samping train.

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



## General Motors LLC 105 GM Drive, Bedford, IN 47421 Natural Gas-Fired Aluminum Thermal Chip Dryer CHIP-2 AB-1 (Baghouse)
**Sample ID No.____CHIP BH DUST COMP 1 - 3_________________ Typ** **e of Sample (Lime or Particulate):____Particulate_______________**
**Date Sampled Date(s) Analyzed**  8/25/2010 9/2/10 and 9/3/10

**HAP Metal mg/kg**  **mg/kg mg/kg**  **Average (mg/kg)** Antimony 

## <20.0 <20.0 <20.0 <20.0 Beryllium 

## <0.967 <0.915 <0.949 <0.944 Chromium 

## 643 446 556 548 Hexavalent chromium 

## <10.0 <10.0 <10.0 <10.0 Lead 

## 4710 3260 3990 3987 Mercury 

## <0.05 <0.05 <0.05 <0.05 Selenium 

## <20.0 <20.0 <20.0 <20.0 Arsenic 

## 1370 959 1240 1190 Cadmium 

## 42.1 29.5 36.9 36 Cobalt 

## 34.1 24.5 30.3 30 Manganese 

## 4030 2730 3420 3393 Nickel 

## 506 354 443 434
*** Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.**