U.S. EPA Information Collection Request Emission 

Test Report 

Particulate Matter, Polycyclic Organic Matter, and 

Metals 

Hazardous Air Pollutant Emissions 

Fugitive Roof Line Emissions – Pot Lines 2 and 3 

Ormet Primary Aluminum Corporation 

Hannibal, Ohio 

Permit-to-Operate No. 0656000001 

Prepared for Ormet Primary Aluminum Corporation 

Hannibal Reduction Division 

P.O. Box 176 

State Route 7 

Hannibal, Ohio 43931 

Prepared by 

Shaw Environmental & Infrastructure, Inc., a CB&I company 

5050 Section Avenue 

Cincinnati, Ohio 45212 

PN 150125-01 

July 2013

A World of SolutionsTM
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Table of Contents

Page 

List of Tables ................................................................................................................................. iii 

List of Figures ................................................................................................................................ iii 

1.0 Introduction ..........................................................................................................................1 

2.0 Summary of Results .............................................................................................................2 

 2.1 Flue Gas Flow Rate ..................................................................................................2 

 2.2 HAP Metals Emissions Data ....................................................................................2 

 2.3 PM/MCEM Emissions Data ....................................................................................2 

3.0 Process and Sampling Location Descriptions ......................................................................6 

 3.1 Process Description ..................................................................................................6 

 3.2 Sampling Location Description ...............................................................................6 

4.0 Sampling and Analytical Methods .......................................................................................8 

5.0 Quality Assurance ..............................................................................................................10 

Appendices 

 A Calculations .................................................................................................................... A-1 

 B Field Data .........................................................................................................................B-1 

 C Laboratory Data ...............................................................................................................C-1 

 D Sampling and Analytical Procedures .............................................................................. D-1 

 E Calibration Results ........................................................................................................... E-1 

 F Process Data ..................................................................................................................... F-1 
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List of Tables ________________________________________ 

Page

2-1 Summary of Roof Monitor Exhaust Conditions ..................................................................2 

2-2 Summary of Hazardous Air Pollutant Metals Emissions Data – Pot Line 2 Roof 

 Fugitive Emissions ...............................................................................................................3 

2-3 Summary of Hazardous Air Pollutant Metals Emissions Data – Pot Line 3 Roof 

 Fugitive Emissions ...............................................................................................................4 

2-4 Pot Line 2 Roof Fugitive Emissions ....................................................................................5 

2-5 Pot Line 3 Roof Fugitive Emissions ....................................................................................5 

3-1 Production Data ...................................................................................................................6 

List of Figures _______________________________________ 

Page 

3-1 Roof Monitor Outlet Discharge Location Schematic ..........................................................7 
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1.0 Introduction

Shaw Environmental & Infrastructure, Inc., a CB&I company, was retained by Ormet Primary 

Aluminum Corporation (Ormet) to provide professional services to prepare a pot line fugitive 

emissions report to satisfy U.S. Environmental Protection Agency (EPA) Information Collection 

Request (ICR) requirements for primary the Aluminum Reduction Source Category. The information is being collected by EPA’s Office of Air and Radiation to develop National Emission 

Standards for Hazardous Air Pollutants (NESHAP) for Primary Aluminum Reduction Facilities 

under Section 112 of the Clean Air Act. Testing was conducted by Ormet personnel on the roof 

monitor outlets for Pot Lines 2 and 3 at their facility located in Hannibal, Ohio. The measurements were conducted on April 4 and 5, April 10 and 11, and April 24 and 25, 2013. Each 

measurement period was 32 hours in duration. 

Testing was conducted for the following hazardous air pollutant (HAP) categories: particulate 

matter (PM), methylene chloride extractable matter (MCEM), mercury, and non-mercury 

metallic HAPs. Mr. Brian Ashbrook of Ormet coordinated the Ormet sampling team and plant 

personnel, who collected the emission samples and monitored pot line operations and aluminum 

production rates during each sampling run. 
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2.0 Summary of Results

2.1 Flue Gas Flow Rate

Table 2-1 presents a summary of measured flue gas conditions for each of the roof monitor 

exhaust outlets during the test program. 

Table 2-1

Summary of Roof Monitor Exhaust Conditions

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01)

Date 

(2013) 

Roof Monitor 

No. 

Run 

No. 

Average Flue Gas Flow Rate 

Average 

Temperature (°F) 

Average 

Moisture 

(%)c acfma

 dscfmb

April 4-5 2 1 3,106,172 3,021,046 81 1.5 

April 10-11 2 2 2,882,852 2,521,100 108 5.9 

April 24-25 2 3 3,106,172 2,963,965 81 2.2 

Averages 3,031,732 2,835,370 90 3.2 

April 4-5 3 1 3,776,130 3,664,029 82 1.5 

April 10-11 3 2 3,776,130 3,302,286 108 5.9 

April 24-25 3 3 4,216,002 3,948,839 88 2.8 

Averages 3,922,754 3,638,385 93 3.4 

a

 acfm = Actual cubic feet per minute at roof monitor conditions from all 4 sections of pot line exhausts. 

b

 dscfm = Dry standard cubic feet per minute; standard conditions are 68°F and 29.92 in.Hg from all 

4 sections of pot line exhausts. 

c

 Moisture % = Average of moisture saturation at monitor temperature and average relative humidity. 

2.2 HAP Metals Emissions Data

Tables 2-2 and 2-3, respectively, present Pot Line 2 and 3 HAP metals emissions concentrations 

in micrograms per cubic meter and emission rates in pounds per hour and pounds per ton of 

aluminum produced. 

2.3 PM/MCEM Emissions Data

Table 2-4 and 2-5, respectively, present Pot Line 2 and 3 PM/MCEM emissions concentrations 

in grains per dry standard cubic foot and emission rates in pounds per hour and pounds per ton of 

aluminum produced. 
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Table 2-2 

Summary of Hazardous Air Pollutant Metals Emissions Data 

Pot Line 2 Roof Fugitive Emissions 

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01) 

Parameters Metals Metals Metals 

Pot Line No. 2 2 2 

Test Date (2013) 4/4-4/5 4/10-4/11 4/24-4/25 

Run Number 1 2 3 Average 

Antimony 

Concentration, μg/m3 a 5.510E+00 6.890E+00 3.117E+00 5.172E+00 

Mass emission rate, lb/hb 6.23E-02 6.51E-02 3.46E-02 5.40E-02 

Mass emission rate, lb/tonc 1.01E-02 1.30E-02 6.29E-03 9.79E-03 

Arsenic 

Concentration, μg/m3

 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/h 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/ton 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Beryllium 

Concentration, μg/m3

 1.185E-02 2.422E-02 3.864E-02 2.490E-02 

Mass emission rate, lb/h 1.341E-04 2.287E-04 4.289E-04 2.639E-04 

Mass emission rate, lb/ton 2.163E-05 4.574E-05 7.799E-05 4.845E-05 

Cadmium 

Concentration, μg/m3

 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/h 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/ton 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Chromium 

Concentration, μg/m3

 7.228E-01 7.629E-01 9.144E-01 8.000E-01 

Mass emission rate, lb/h 8.179E-03 7.204E-03 1.015E-02 8.511E-03 

Mass emission rate, lb/ton 1.319E-03 1.441E-03 1.846E-03 1.535E-03 

Cobalt 

Concentration, μg/m3

 0.000E+00 0.000E+00 3.992E-01 1.331E-01 

Mass emission rate, lb/h 0.000E+00 0.000E+00 1.773E-02 5.910E-03 

Mass emission rate, lb/ton 0.000E+00 0.000E+00 3.223E-03 1.074E-03 

Lead 

Concentration, μg/m3

 1.627E+01 2.269E+01 1.118E+01 1.671E+01 

Mass emission rate, lb/h 1.84E-01 2.04E-01 1.24E-01 1.71E-01 

Mass emission rate, lb/ton 2.97E-02 4.08E-02 2.26E-02 3.102E-02 

Manganese 

Concentration, μg/m3

 0.000E+00 4.359E-01 0.000E+00 1.453E-01 

Mass emission rate, lb/h 0.000E+00 4.116E-03 0.000E+00 1.372E-03 

Mass emission rate, lb/ton 0 8.23E-04 0 2.744E-04 

Mercury 

Concentration, μg/m3

 5.000E-04 4.153E-04 3.078E-04 4.077E-04 

Mass emission rate, lb/h 5.658E-06 3.922E-06 3.417E-06 4.332E-06 

Mass emission rate, lb/ton 9.126E-07 7.844E-07 6.213E-07 7.728E-07 

Nickel 

Concentration, μg/m3

 2.346E+00 4.202E+00 4.173E+00 3.574E+00 

Mass emission rate, lb/h 2.655E-02 3.968E-02 4.632E-02 3.752E-02 

Mass emission rate, lb/ton 4.28E-03 7.94E-03 8.42E-03 6.880E-03 

Selenium 

Concentration, μg/m3

 3.578E+00 7.750E+00 2.524E+00 4.617E+00 

Mass emission rate, lb/h 4.049E-02 7.318E-02 2.802E-02 4.723E-02 

Mass emission rate, lb/ton 6.531E-03 1.464E-02 5.095E-03 8.754E-03 

a μg/m3

 = Micrograms per cubic meter. 

b lb/h = Pounds per hour. 

c lb/ton = Pounds per ton of aluminum produced per hour. 
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Table 2-3 

Summary of Hazardous Air Pollutant Metals Emissions Data 

Pot Line 3 Roof Fugitive Emissions 

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01) 

Parameters Metals Metals Metals 

Pot Line No. 3 3 3 

Test Date (2013) 4/4-4/5 4/10-4/11 4/24-4/25 

Run Number 1 2 3 Average 

Antimony 

Concentration, μg/m3 a 4.960E+00 7.027E+00 4.219E+00 5.402E+00 

Mass emission rate, lb/hb 6.807E-02 8.692E-02 6.240E-02 7.246E-02 

Mass emission rate, lb/tonc 1.216E-02 1.774E-02 1.114E-02 1.368E-02 

Arsenic 

Concentration, μg/m3

 1.958E-01 6.166E-01 0.000E+00 2.708E-01 

Mass emission rate, lb/h 2.687E-03 7.627E-03 0.000E+00 3.438E-03 

Mass emission rate, lb/ton 4.80E-04 1.56E-03 0.00E+00 6.788E-04 

Beryllium 

Concentration, μg/m3

 3.263E-02 2.126E-02 6.717E-02 4.036E-02 

Mass emission rate, lb/h 4.478E-04 2.630E-04 9.936E-04 5.681E-04 

Mass emission rate, lb/ton 8.00E-05 5.37E-05 1.77E-04 1.037E-04 

Cadmium 

Concentration, μg/m3

 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/h 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Mass emission rate, lb/ton 0.000E+00 0.000E+00 0.000E+00 0.000E+00 

Chromium 

Concentration, μg/m3

 7.070E-01 6.804E-01 9.942E-01 7.939E-01 

Mass emission rate, lb/h 9.703E-03 8.416E-03 1.470E-02 1.094E-02 

Mass emission rate, lb/ton 1.73E-03 1.72E-03 2.63E-03 2.025E-03 

Cobalt 

Concentration, μg/m3

 0.000E+00 0.000E+00 1.115E+00 3.717E-01 

Mass emission rate, lb/h 0.000E+00 0.000E+00 6.597E-02 2.199E-02 

Mass emission rate, lb/ton 0.00E+00 0.00E+00 1.18E-02 3.927E-03 

Lead 

Concentration, μg/m3

 1.385E+01 1.952E+01 1.334E+01 1.557E+01 

Mass emission rate, lb/h 1.900E-01 2.414E-01 1.973E-01 2.096E-01 

Mass emission rate, lb/ton 3.393E-02 4.927E-02 3.524E-02 3.948E-02 

Manganese 

Concentration, μg/m3

 9.137E-01 3.934E-01 1.061E+00 7.895E-01 

Mass emission rate, lb/h 1.254E-02 4.866E-03 1.570E-02 1.103E-02 

Mass emission rate, lb/ton 2.239E-03 9.930E-04 2.803E-03 2.012E-03 

Mercury 

Concentration, μg/m3

 5.079E-04 1.892E-04 3.681E-04 3.551E-04 

Mass emission rate, lb/h 6.971E-06 2.341E-06 5.445E-06 4.919E-06 

Mass emission rate, lb/ton 1.245E-06 4.777E-07 9.723E-07 8.983E-07 

Nickel 

Concentration, μg/m3

 5.362E+00 5.209E+00 9.190E+00 6.587E+00 

Mass emission rate, lb/h 7.359E-02 6.444E-02 1.359E-01 9.132E-02 

Mass emission rate, lb/ton 1.314E-02 1.315E-02 2.427E-02 1.685E-02 

Selenium 

Concentration, μg/m3

 3.589E+00 4.221E+00 4.299E+00 4.036E+00 

Mass emission rate, lb/h 4.926E-02 5.221E-02 6.359E-02 5.502E-02 

Mass emission rate, lb/ton 8.797E-03 1.065E-02 1.136E-02 1.027E-02 

a 

μg/m3

 = Micrograms per cubic meter. 

b lb/h = Pounds per hour. 

c lb/ton = Pounds per ton of aluminum produced per hour.
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Table 2-4 

Pot Line 2 Roof Fugitive Emissions 

Particulate Matter (PM) and Methylene Chloride Extractable Matter (MCEM) 

Emissions Concentrations 

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01) 

Date 

(2013) 

Pot Line 

No. 

Run 

No. 

Concentration (gr/dscf)a

PM/MCEM Emissions 

lb/hb lb/ton c

PM MCEM PM MCEM PM MCEM 

April 4-5 2 1 3.935E-04 1.004E-03 10.19 26.01 1.64 4.19 

April 10-11 2 2 2.540E-04 3.386E-04 5.49 7.32 1.10 1.46 

April 24-25 2 3 6.415E-04 7.596E-04 16.30 19.30 2.96 3.51 

 Averages 4.296E-04 7.009E-04 10.66 17.54 1.90 3.06 

a 

gr/dscf = Grains per dry standard cubic feet at standard conditions 68°F and 29.92 in.Hg. 

b lb/h = Pounds per hour. 

c lb/ton = Pounds per ton of aluminum produced per hour.

Table 2-5 

Pot Line 3 Roof Fugitive Emissions 

Particulate Matter (PM) and Methylene Chloride Extractable Matter (MCEM) 

Emissions Concentrations 

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01) 

Date 

(2013) 

Pot Line 

No. 

Run 

No. 

Concentration (gr/dscf)a

PM/MCEM Emissions 

lb/hb lb/ton c

PM MCEM PM MCEM PM MCEM 

April 4-5 3 1 1.217E-03 6.558E-04 38.2 20.6 6.82 3.7 

April 10-11 3 2 6.643E-04 1.342E-03 18.80 38.0 3.84 7.8 

April 24-25 3 3 1.209E-03 1.239E-03 40.9 41.9 7.31 7.5 

 Averages 1.030E-03 1.079E-03 32.6 33.5 5.99 6.3 

a 

gr/dscf = Grains per dry standard cubic feet at standard conditions 68°F and 29.92 in.Hg. 

b lb/h = Pounds per hour. 

c lb/ton = Pounds per ton of aluminum produced per hour. 
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3.0 Process and Sampling Location Descriptions

3.1 Process Description 

Ormet uses crystalline aluminum oxide (Al2O3) in the Hall-Heroult process to produce aluminum 

metal. Electrolytic reduction of alumina occurs in shallow rectangular cells or “pots,” which are 

steel shells lined with carbon. Carbon electrodes extending into the pot serve as the anodes, and 

the carbon lining serves as the cathode. Molten cryolite functions as both the electrolyte and the 

solvent for the alumina. The electrolytic reduction of Al2O3 by the carbon from the electrode 

occurs as follows: 

2Al2O3 + 3Carbon 4Aluminum + 3Carbon dioxide 

Aluminum is deposited at the cathode, where it remains molten metal below the surface of the 

cryolite bath. The carbon anodes are continuously depleted by the reaction. The aluminum 

product is tapped every 24 to 48 hours beneath the cryolite cover using a vacuum siphon. Emissions from the pot lines are controlled by alumina-injected dry scrubber systems. Table 3-1 

summarizes the process production rates. Additional process data are provided in Appendix F. 

Table 3-1 

Production Dataa

Pot Lines 2 and 3 April 2013 

Ormet Primary Aluminum Corporation 

(CB&I PN 150125-01) 

Date 

(2013) 

Line 

No. 

Aluminum 

Production 

(pounds/day) 

Aluminum 

Production 

(tons/day) 

Aluminum 

Production 

(tons/hour) 

2-Day Average 

Aluminum Production 

(tons/hour) 

4/4 2 301,474 150.74 6.3 

4/5 2 289,123 144.56 6.0 6.2 

4/4 3 285,521 142.76 5.9 

4/5 3 249,647 124.82 5.2 5.6 

4/10 2 236,070 118.04 4.9 

4/11 2 247,220 123.61 5.2 5.0 

4/10 3 249,242 124.62 5.2 

4/11 3 224,220 112.11 4.7 4.9 

4/24 2 271,638 135.82 5.7 

4/25 2 258,166 129.08 5.4 5.5 

4/24 3 276,544 138.27 5.8 

4/25 3 263,626 131.81 5.5 5.6 

a Data provided by plant personnel. 

3.2 Sampling Location Description 

The emissions from pot line Roof Monitors 2 and 3 are exhausted through each unit's corresponding pot line roof discharges. Each pot line has four sectional discharges (i.e., Pot Line 2 has 
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sections: A and B), further divided by east and west sections. Each sectional discharge has a 

rectangular size of 5.67-feet x 497.3-feet . All four outlet discharge exhausts on each pot line 

have the same dimensions. The sampling was conducted in Section 2A West for Pot Line 2 and 

Section 3B East for Pot Line 3. A schematic of the typical roof discharge monitor locations is 

shown in Figure 3-1. 

Figure 3-1. Roof monitor outlet discharge location schematic. 
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4.0 Sampling and Analytical Methods

The sampling and analytical procedures used in this test program conformed to EPA Reference 

Method 14A criteria, as published in the Federal Register. The modified procedures of EPA 

Method 14A, “Determination of Hydrogen Fluoride Emissions From Selected Sources At 

Primary Aluminum Production Facilities,” were used to measure PM, MCEM, mercury, and 

non-mercury metallic HAPs. This method was developed by consensus with the Aluminum 

Association and U.S. EPA for the determination of total fluoride emissions from primary 

aluminum production facilities. The method was modified using specific media for the collection 

of PM, MCEM, and HAP metals. PM, MCEM, and HAP metals were withdrawn from the 

ascending air stream inside the aluminum reduction pot room and, prior to exiting the pot room 

roof monitor, into a specific cassette arrangement. The cassettes were connected by tubing to 

flow meters and a manifold system that allowed for the equal distribution of volume pulled 

through each cassette, and finally to a dry gas meter. The cassettes had a pre-tared SKC 225-

1827 (filter, quartz, 37-millimeter, Type R-100) filter and support pad in the first section of the 

cassette for solid particulate retention. A minimum of eight cassettes were used for each pot line 

and were strategically located at equal intervals across the pot room roof so as to encompass a 

minimum of 8 percent of the total length of the pot room. The mass flow rate of pollutants was 

determined with anemometers and temperature-sensing devices located immediately below the 

opening of the roof monitor and spaced evenly within the cassette group. After collection, the 

samples were recovered and sent to DAT Laboratories for analyses. The samples were analyzed 

in the following manner: 

PM: The filters were removed from the cartridge and desiccated overnight to a constant weight, 

weighing to the nearest 0.1 mg. 

MCEM: Each filter and PM was transferred to a 250-milliliter (mL) beaker; 100 mL of methylene chloride (EMD 53011) was added, covered with foil, and soniccated for 3 minutes and 

allowed to stand for 20 minutes. The methylene chloride was carefully decanted through a filter 

into second beaker. The filter was rinsed with 20 mL of methylene chloride. The methylene 

chloride rinse was evaporated under cover to less than 25 mL, then transferred to a tarred 50-mL 

beaker and taken to dryness. The residue was desiccated and then measured to a constant weight. 

The method blank consisted of 100 mL of methylene chloride. The filter and PM were 

transferred to a flat dish and allowed to dry. 

Metals Determination: Each filter and PM was transferred to a Teflon beaker; 4 mL of hydrofluoric acid (GFS C255634) was pipetted to a digest filter. Upon cessation of fuming 6 mL of 

nitric acid (EMD#51264) was added and digested at 120°C for 30 minutes; 10 mL of nitric acid 

was added to the corresponding MCEM residue and heated for 10 minutes. Digested MCEM 

residue was added to the Teflon beaker, cooled, and transferred to a hot block with filtering. 

Took to 50 mL final volume. 
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The method blank and LCS used filters from the same lot (SKC 225-1827, Lot 13099-7DC-324. 

The metals of interest were determined using inductively-coupled argon plasma emission 

spectroscopy. 
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5.0 Quality Assurance

Routine standard reference method quality control procedures were followed throughout this test 

series. These included, but were not limited to, the following:

• Calibration of field sampling equipment. Sampling equipment was calibrated in accordance 

with the procedures of the “Quality Assurance Handbook for Air Pollution Measurement 

Systems, Volume III,” EPA 600/R-94-038c, September 1994. The equipment calibration data 

are presented in Appendix E. 

Sampling equipment, reagents, and analytical procedures used in this test series followed and 

met all necessary guidelines set forth for obtaining accurate test results. All sampling equipment 

was calibrated within the limits described in U.S. EPA Method 14A.