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 5.15 Mg/hr

Afterburner Operating Temperature 1405 1405 1409 degree 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-06 Method 0031 BDL

Benzene 71-43-2 5.18052E-06 9.6387E-07 5.03239E-06 9.34261E-07 4.8389E-06 9.39064E-07 Method 0031 BDL

Bromodichloromethane 75-27-4 3.88539E-06 7.22902E-07 3.829E-06 7.1085E-07 3.68177E-06 7.14505E-07 Method 0031 BDL

Carbon disulfide 75-15-0 8.60182E-05 1.60043E-05 3.282E-05 6.093E-06 1.56738E-05 3.04175E-06 Method 0031 DLL

Carbon tetrachloride 56-23-5 7.07464E-05 1.31628E-05 2.2602E-05 4.19605E-06 3.25889E-05 6.32439E-06 Method 0031 BDL

Chlorodibromomethane 124-48-1 6.25979E-06 1.16468E-06 4.48539E-06 8.3271E-07 5.47006E-06 1.06155E-06 Method 0031 DLL

Chloroform 67-66-3 3.75587E-06 6.98806E-07 3.73054E-06 6.92571E-07 3.5871E-06 6.96132E-07 Method 0031 BDL

Chloroprene 126-99-8 8.6342E-06 1.60645E-06 8.75199E-06 1.6248E-06 8.41548E-06 1.63315E-06 Method 0031 BDL

Dibromomethane 74-95-3 6.6915E-06 1.245E-06 6.23579E-06 1.15767E-06 5.68045E-06 1.10238E-06 Method 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-07 Method 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-07 Method 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-06 Method 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-06 Method 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-07 Method 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-06 Method 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 0.000138879 Method 0031 DLL

Tetrachloroethene 127-18-4 1.41385E-05 2.63056E-06 8.75199E-06 1.6248E-06 9.15183E-06 1.77606E-06 Method 0031 BDL

Toluene 108-88-3 9.92932E-06 1.84742E-06 1.55348E-05 2.88402E-06 1.45167E-05 2.81719E-06 Method 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-07 Method 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-07 Method 0031 BDL

Trichloroethene 79-01-6 4.74881E-06 8.83547E-07 4.70419E-06 8.7333E-07 4.52332E-06 8.77821E-07 Method 0031 BDL

Trichlorofluoromethane 75-69-4 1.77001E-05 3.29322E-06 1.78322E-05 3.31053E-06 1.71465E-05 3.32755E-06 Method 0031 BDL

Miscellaneous Organics 8.6342E-07 1.60645E-07 7.65799E-07 1.4217E-07 7.36354E-07 1.42901E-07 Method 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 5.15 Mg/hr

Afterburner Operating Temperature 1405 1405 1409 degree 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-08 Method 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-06 Method 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-08 Method 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 Address Unit ID 

Unit Type (Chip dryer or scrap 

dryer /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 5.15 Mg/hr

Afterburner residence time Unkown Unkown Unkown sec

Afterburner Operating Temperature 1405 1405 1409 degree 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 (ADL, BDL, DDL)*** Detection Limit 

(ng/dscm)

1 0.667 0.124 ADL

Used online analyzer to 

get ppm reading on wet 

basis. 

2 0.631 0.117 ADL

Used online analyzer to 

get ppm reading on wet 

basis. 

3 0.122 0.024 ADL

Used online analyzer to 

get ppm reading on wet 

basis. 

*** See Appendix A to Enclosure 1

Run Number Test Start Date Test Start Time Test End Date Test End Time
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 5.15 Mg/hr

Afterburner Operating Temperature 1405 1405 1409 degree F Average

Flow Rate 663.2 654.9 646.6 actual M3/min

Flow Rate 364.7 363.5 365.0 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 16.2 16.2 16.6 3A

CO2 2.5 3.1 2.4 3A

H2O 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_________________

Type 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.