## 2010 PRIMARYALUMINUM MACl' l'ESl'RESULTS·'FOR THE ANODE BAKINGRING FURNACE Performed for: 

# eALt:OA ALCOA INC.-WARRICK OPERATIONS Highway 66 Newbti!gh, IN47629 December 1, 2010 Submitted by:



# Air~auality

# services Air Quality Services, LLC 425 Main Street Evansville, Indiana47708

Phone: (812) 452-4785

FaX.: (812) 452-4786 AQS Project# 10736-11-001



# ·-~~.--J

### ) ---

**------~-·---** --- -- --·- -·- --·- -------- ---------- 

# SOURCE TESTING REPORT CERTIFICATION

Air Quality Services, LLC 425 Main Street Evansville, fudiana 47708

Phone': (812) 452-4785

Fax: (8l2) 452-4786 

### I have reviewed this report and found the information accurate and complete to the best of my ability. ReportWriter Leslie J. Ashley Project Scientist Air Quality Services, LLC 

### Reviewer DanielL. Todd, QEP, CHMM 

### President Air Quality Services, LLC 

### Date 

# /-/3-//

Date

# _ZJ--1-/_;_(_3+,/_t_r __ _ I

. I

### TABLE OF CONTENTS
,---- 

### SECTION 1 .. ---·. c. . --·-· --- __.......,..- **-~** -- -, - 

### EXECUTIVE S8MMARY .::............................::............:::..

### ,.,~';,;-.-;;;;'1 .:••, -- ·• ·

....... **··-·-:'·=-:-~--"'"· ~--**  

### SECTION 2 INTRODUCTION ...................................................................-...-.-....2 SECTION 3 SUMMARY OF TEST RESULTS .............................:........:;.......::::.3 SECTION 4 PROCESS DESCRIPTION ............................................................ 6 SECTION 5 SAMPLING AND ANALYTICAL PROCEDURES......................

### ? Location ofMeasurement Sites ...................................................

### ? Stack.Gas Velocity and Volumetric FlowRate ...........................9 Stack Gas Diluent Content......................................................... 10 Stack Gas ·Moisture Content ...................................................... 10

.Particulate Matter and Polycyclic Organic Matter - Method 315 : ................................................................... 1 0 SECTION 6 QUALITY ASSURANCE/QUALITY CONTROL .....................12 Performance Specifications ....................................................... 12

1

### 1.2 1.3 2.1 3.1 3.2 3.3 3.4 

## 3.5 6.1 5.1 

### LIST OF TABLES Test Results 

## Re~ctor #2 .......................................:'....................................

## ::~.. 1 Test Results Reactor #3 ................................:..........................· ....................

### 1 Test Results- CombinedReactor #2 and Reactor #3 ..................................

## 1 Test Program Contacts.................................................................................2 Summary ofReactor #2 PM Test Results....................................................

### 4 Summary ofReactor#2 POM TestResults.................................................4 Summary ofReactor #3 PM·Test Results.................:.................................. 

### 5 Summary ofReactor#3 POM TestResults.................................................

### 5 Summary ofCombinedReactor #2 and Reactor #3 Test Results................5 FieldEquipment Calibration Summary .....................................................12 

### LIST OF FIGURES Schematic ofSample Location- Reactor #2 ...............................................

## 8 Schematic ofSample Location- Reactor #3 ................................:........:.....9
acfm dscfm gr/dscf lb/dscf lb/hr fps 

### LIST OF ABBREVIATIONS actual cubic feet perminute dry standard cubic feet perminute grains per dry standard cubic foot pound(s) per dry standard cubic foot pound(s) perhour feet per second

11



# ···------·---~

### SECTION 1 EXECUTIVE SUMMARY 

# .:on December 1, 2010, stack testmg for particulate-organic matter-(PM)

# -and pc)lyc]Clic organic

matter (POM) measured as Methylene Chloride Extractable Matter, was perfoJ1!1JUed on the · exhaust ofthe Anode Baking Furnace Ring (A446), Reactor#2 and Reactor #3 **,Joc~t·ed** 

### at Alcoa Inc.- Warrick Operations (Alcoa) located near Newburgh, Indiana. Thistesting V'Va=tS 

### pursuant to the Part 70 Operating Permit #T173-6627-00007 and 40 CFRPart 63. The results ofthe emissions tests are summarized below: Emission Parameter PM POM Emission Parameter PM 'i'

**~** ' . 

### POM TABLE 1.1 Reactor #2 PM and POM Green Anode Emissions Throughput, lblhr tons/hr

19.94 0.014 19.94 0.609 TABLE 1.2 Reactor#3 PM and POM lbs/ton grec11 anode 0.0007 0.034 GreenAnode Emissions Throughput, lblhr lbs/ton gree11 tons/hr anode

19.94 0.016 0.0009 19.94 0.548 0.031 TABLE 1.3 Combined Reactor#2 and Reactor#3 PM and POM Emission Green Anode Emissions Throughput, lbs/ton green Parameter lb/hr tons/hr anode PM 19.94 0.030 0.0017 POM 19.94 1.157 0.065 

### 1 

# I I

### SECTION2 INTRODUCTION 

### Alcoa retained Air Quality Services, LLC (AQS) to plan and ..Conduct a testing--pro-g;amlliat - - ' deterni.ined particulate matter (PM) and polycyclic organic matter (POM) fromA-446 Reactor #2 and Reactor #3. These were tested simultaneously. The sampling was conducted using EPA Methods 1, 2, 3, 4, and 315 to determine sample traverse locations, velocity and volumetric flow rates, molecular weights, moisture content, and particulate matter and methylene chloride extractable matter (MCEM) concentrations, respectively. For the purposes ofthis test program, the MCEM determined by Method 315 is considered to be POM by USEPA. 

### Messrs. Paul Siegel, David Oligher, Chip Mulzer, and Marshall Peters, ofAQS, performed the sampling procedures on December 1, 2010. Ms. Chris Allen and 

## Mr. Sam Bruntz, of Alcoa, coordinated the test program. The contacts for this test program are as follows: TABLE2.1 TEST PROGRAM CONTACTS Alcoa Inc.- Warrick Operations: 

### Ms. Chris Allen 4700 Darlington Road Newburgh, IN 47630 Phone: (812) 853-4639 E-mail: Chris.Allen@alcoa.com

2 

### Air Quality Services, LLC: 

### Mr. Dan Todd 

### I

## Mr. Paul Siegel 425 Main Street Evansville, IN 47708 Phone: (812) 452-4785 Fax; (812) 452-4786. E-mail: dtodd@aqsllc.net psiegel@aqsllc.net

### SECTION3 

### SUM'iV.IARY OF TESTRESULTS On December 1, 2010, Reactors #2 and #3 ofA-446 were tested for PM and POM. All ofthe test runs were 2 hours and 24 minutes in duration. Method 315 was used to determine PM and POM. All rinses and filters fromthis.test program were delivered to Alcoa's on-site laboratory.· The green anode baking ring furnace consists ofthree (3) reactor sections. Reactor #1 was not tested in the program. Reactor #2 has three emission stacks, identical in size, with a diameter of 26.25 inches. All three stacks were tested during each ofthe three test runs. Reactor #3 has a single emission stack with a diameter of46.25 inches. ·The process rate during this testing program was 19.94 tons ofgreen
**anod~** 

### input per hour. Complete tabulations ofmeasured parameters and calculated results are included as Appendix B. GAS FLOWAND COMPOSITION Gas characteristics were determined by the use of EPA Method 2 (velocity and flow rate), Method 3 (CO and oxygen content), and Method 4 (moisture). The sampling equipment was associated withPM and POMtesting. Based upon the data recordec1 during the testing, the Reactor #2 stack gas composition averaged approximately 2.5% carbon dioxide (C02), 

### 17.5% oxygen (02), 

### and 80.0% nitrogen (N2); 

### the effluent gas temperature averaged 177°F; the moisture content averaged 7.3%; and the velocity averaged 60.2 feet per second (:fps)., The measured volumetric flow rate averaged -40,696 actual cubic feet per minute (ac:fm). Converting the. measured volumetric flow rate to standard conditions, the exhaust averaged 31,358 

### dry standard cubic feet per minute (dsc:fm). Based :upon the data recorded during the testing, the Reactor #3 stack gas composition averaged approximately 0.2% C02, 

### 20.2% 0 2, 

### and 79.7% 

### N 2 ; 

### the effluent gas temperature averaged 172°F; the moisture content averaged 7.3%; and the velocity averaged 61.6 :fps. The measured. volumetric flow rate averaged 43,066 acfm. Converting the measured volumetric flow rate to standard conditions, the exhaust averaged 33,432 dsc:fm. POLYCYCLIC ORGANIC MATTER PM and POM concentrations were measured in the exhaust gases ofReactor #2 and Reactor #3 according to the procedures prescribed inEPA Method 315. Reactor #2 average PM.emissions were 0.609lbPOM/hr; which calculates to be· 0.031 lb PM/ton of green anode. Reactor #2 average POM emissions were 0.609 lbPOM/hr; which calculates to be 0.031lb POM/ton ofgreen anode. 3
**-------·----···-------~**

### Reactor #3 average PM emissions were 0.548lbPOM/hr; which calculates to be 0.027 lb PM/ton of green anode. Reactor #3 average POM emissions were 0.548 lbPOM!hr; which calculates to be 0.027lb POM/ton ofgreen anode.



## Combini~g the emissions of



## the~~ reactors, the average PM erissions were 1-.157--lbPOMfh.r; which calculates to be 0.0058 lb PM/ton of green anode. The average POM emissions were 1.157lbPOM/hr; which calculates to be 0.0058 lb POM/ton ofgreen anode. Tables 3.1, 3.2, 3.3, and 3.4 summarize the test results for the individual methods and individual reactors; Table 3.5 combines all test results.
Run Time

1 09:46-12:27 2 13:13-15:55 3 16:52-19:41 Average
Run Time

1 09:46-12:27 2 _ **)3:U~~.s.:5~.** % 

### "'']_ **-~I6::s2::t9:4'1** Average 

### Table 3.1 SUMMARY OF REACTOR#2 RESULTS- PM 

### ·December 1, 2010 Velocity acfm dscfm 

### %H20 02 C02

61.3 41,477 32,012 7.1 17.5 2.5 59.8 40,460 30,796 8.1 17.5 2.5 61.1 42,024 31,790 6.8 17.5 2.5 61.1 41,320 31,790 7.3 17.5 2.5 

### Table 3.2 SUMMARY OFREACTOR #2 RESULTS- POM 

### December 1, 2010 Velocity acfm dscfm 

### %H20 02 C02

61.3 41,477 32,012 7.1 17.5 2.5

.5Q,8 40,460 30,796 8.1 17.5 2.5 '61.1 42,024 . 31,790 6.8 17.5 2.5 61.1 41,320 31,790 7.3 17.5 2.5



### 4 lb/hr lb/ton- · 0.601 0.031 0.083 0.004 0.258 0.013 0.317 0.016
lb/hr lb/ton 0.736 0.037 0.583 0.029 0.507 0.025 0.609 0.031

### Table 3.3 Run

1 2 3

Run

1 2 3

Reactor 

### 2 3 ...... Time 09:46-12:25 13:14-15:51 16:53-19:39 ·Average
Time 09:46-12:25 13:14-15:51 16:53-19:39 Average 

## SUMMARY OF REACTOR#3 

## RESULTS- PM December 1, 2010

........ ·-·--·- - Velocity

**acfm~** dscfm 

### %H20 02 C02

61.7 43,196 33,687 7.2 20.0 0.0 60.5 42,331 32,640 7.9 20.0 0.5 61.9 43,336 33,777 6.8 20.0 0.0 61.4 42,955 33.368 7.3 20.2 0.2 

### Table 3.4 

## SUMMARY OF REACTOR#3 

## RESULTS- POM December 1, 2010 Velocity acfm dscfm 

### %H20 02 C02

61.7 43,196 33,687 7.2 20.0 0.0 60.5 42,331 32,640 7.9 . 20.0 0.5 61.9 43,336 '33,777 6.8 20.0 0.0 61.4 42,955 33.368 7.3 20.2 0.2 

### Table 3.5 .. - - 

### lb/hr 1.309 0.691 1.087 1.029


### lb/hr 0.609 0.508 0.548 ·0.548 

## SUMMARY OF REACTOR#2 and REACTOR#3 RESULTS December 1, 2010 

### PM Velocity acfm dscfm %H20 02 C02 lb!hr lb/ton lblbr

60.2 40,696 31,357 7.3 17.5 2.5 0.317 0.016 0.609 61.5 43,065 33,432 7.3 . 20.2 0.2 1.029 0.052. 0.548 60.8 83,761 64,789 7.3 18.8 1.3 1.346 0.068 1.157 ,.,.



### 5 Ill/ton

**~** 0.066· O.D35 0;055 0.052
liJ/ton 0.031 0.025• 0.026 .0.027


### POM lb/ton 0.031 0.047 0.058

### SECTION 4 PROCESS DESCRIPTION 

# . ' 

## " •' 

### The anode baking furnace is comprised of one (1) 

### .above-ground, green anode ring baking furnace controlled by a common Alcoa designed A-446 emission control device. The baking furnace strUcture is a series ofinterconnected refractory flues connected to side main exhaust manifolds. Products ofcombustion and other emissions created in the baking furnaces are drawn into the refractory flues and exhausted to the emission control equipment through a s_eries of ducts. The furnace is fueled withnatural gas. 

### In the baking furnace, green anodes are stacked into sub-surface pits. fonried by the interconnecting flue structures. After being placed in the pits, the green anode material is surrounded and covered with petroleum coke referred to as "packing material". The balcing process is operated to allow recently filled·pits to be preheated for a period of.time

**be~ore** 

### being actively fired. Likewise, after frring, baked anodes are allowed to cool 

### inthe pits before they are removed and used in the.smelting process. The "paclcing material" is reclaimed and reused in the baking process. Natural gas burners supply heat to the furnace and promote the combustion oforganic constituents drawn into the flues during the balcing process. The preheating, heating, and cooling progresses are sequenced around the furnace in either a .clockwise or counter clockwise direction. Emissions from the anode bake furnace are collected and treated by an i:ritegrated system of ducting and a pollution control system. The control system employed at the Warrick anode baking furnace is a multi-unit, fluid-bed reactor type system with fabric filtratiop down stream of the reactor beds.. Smelting grade alumina is introduced into one end ofthe Alcoa designed A446 reactors. The alumina is fluidized by an auxiliary fluidizing fan blowing ambient airthrough



## ~-"-~.~~~'~'~'':·~·f;,,l?,~Jf~~~!,~.i",\B,l,f:l,:t5rffi. 

# p tpe bottom of the reactor chamber.· Anody baking furnace 

### -····:······· **';"·"j'''.''?_,t:·:;\ehTI~~lli(:)nst: iit'e\•miotfuceU-'intcdhe**  

### fluidized bed through- exhaust gas manifolds along each side of the Teactor. 

### A carefully metered amount of water is sprayed into the fluidized bed to control temperature. Thefluid bed provides a site for fluoride to react with the alumina and for the gas stream to be cooled. The fabric filtration devices are positioned atop ofthe-fluid beds to collect entrained aluminaparticles and otherparticulate matter present inthe gas stream. The anode bake furnace primary system consists ofa single dry alumina scrubber control device with three (3) reactor sections or compmiments. Two compartments on the anode furnace control device have three stacks and one compmimenthas only one stack.

6

. --------- ----------------------

### SECTIONS •' 

## SAMPLING 

## AN)) ANALYTICAL PRQCEDURES The sampling and analytical procedures used in this test program conformed to EPA Reference Methods 1, 2, 3, 4, and 315, as published in the Code ofF ederal Regulations, Title40, Part 60, (40 CFR 60) AppendixA and Title40, Part 63, Appendix 

## A. 

## LOCATION OF MEASUREMENT SITES EPA Method 1, "Sample and Velocity Traverses for Stationary Sources'', was used to select representative measurement points. Measurements listed are by AQS and also provided 

### by Alcoa for measurements not able to be determined due to obstructions. The Green Anode Baking Ring Furnace exhausts through seven (7) separate vertical circular stacks; three stacks for Reactor #1, three. stacks for Reactor #2, and.a single stack for Reactor #3. the three stacks for Reactor #2 are identical, with an inside diameter of 26.25 inches. The location ofthe two test ports (90° apart) are 60 inches (2.3 stack diameters) downstream from the nearest disturbance, and 232 inches (8.8 duct diameters) upstream from the exhaust. For Reactor #3, the inside diameter ofthe stack is 46.25 inches, and it has two test ports (90° apart). 

## The ports are 92.5 inches (two stack diameters) downstream from the nearest disturbance, and 192 inches (4.2 duct diameters) upstream from the exhaust. For particulate measurements conforming to Method 5 (as indicated in Method 315), a total of24 traverse points were used at each stack for the velocity and particulate measurements, 12 points per testport. Copies ofthe field work sheets are included in Appendix C.



### 7

### 26.25inches 232 inches. Sample Ports 

# .C 

# 0

.

**~** .

# - FLOW.·

**~**



### FIGURES.l 60 inches
Roof 

### STACK DIAGRAM FOR REACTOR #2 three identical stacks (not to scale)



### 8

# I r 46.25inches
Sample Ports 

# 0 FLOW r 

### 192 inches

92.5 inches



# ~ 

# I Roof FIGURE 5.2 STACKDIAGRAMFORREACTOR#3 (not to scale) STACKGAS VELOCITYAND VOLUMETRIC FLOWRATE EPA Method 2, "Stack Gas Velocity and Volumetric Flow Rate", was used to detennine volumetric flow rate. A Type

**"S'~** 

### Pitot tube, with a standard coefficient of0.84, and an inclined manometer were used to measure velocity pressure. 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 C for field worksheets and calculatedvalues based on the field data. 9

### STACK GAS DILUENT CONTENT EPA Reference Method 3, "Gas Analysis for the Determination ofDry Molecular Weight", was used to measure the_ 1

### 02 and C02

**cpn~entrations** 

# o.f the stac:!< gas. 

## An.

**int~grate4** 

### sap1_ple,WfiS 

### collected 

## in a Tedlar® bag for each·test run. The collected sample was analyzed using a Fyr:ite analyzer. Each sample was measured in triplicate until a reading was repeated within 0.3%. This testing was performed in conjunction with the POM testing. The results can be found in Appendix 

## B. STACK GAS MOISTURE CONTENT Concurrent with the Method 315 testing, EPA Reference Method 

## 4, "Determination ofMoisture 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 ofa total offour (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 ofthe impingers was weighed prior to use thim reweighed after the test run to quantify the moisture gained. Fallowing the leak check, the impingers were separated, the moisture on the exterior was removed, and they were prepared for transport to laboratory. Upon receipt, each impinger was reweighed to the nearest one-tenth gram. The totaled differences between the initial and fmal weights represented the moisture content ofthe stack gas during each test run. The results were also utilized in the Method 13A (TF) determinations. Moisture content worksheets are included inAppendix C. PARTICULATE MATTER and POLYCYCLIC ORGANIC MATTER ··'EPJ\:'''Rererence Method 315, "Determination ofParticulate and Methylene Chloride Extractable

Matter (MCEM) from Selected Sources at Primary Aluminum Production Facilities", was employed for this testing..AQS used a glass nozzle and glass probe assembly connected to a glass filter bell containing a three-inch glass-fiber filter with a glass frit 

### filter support and a silicone rubber gasket. The stack gases passed through the filter before entering the moisture train. 

### The impingers were placed in an ice bath during the sampling process. When each sampling train was completely assembled, a lealc checkwas performed before the start ofthe test run. Stack gas volumes and sampling rates were controlled using a dry 

### gas meter with calibrated orifice and a rotary vane vacuum pump. Meter temperature, stack temperature, and differential pressure were recorded at regular intervals during each test run. 

### The· sampling strategy was identical to the plan used inthe TF testing. Upon completion of each test run, the system was post-lealc checked at a vacuum greater than that achieved during tlie sample test run. . . 10

### The particulate matter was recovered from the test equipment by removing the. nozzle, probe, and front half of the filter holder then rinsing and brushing each glass component with acetone, 

### in · triplicate. The acetone rinses from each test run were collected in amber glass bottles. The glass fiber filters were removed wit4 forceps, placed in Petri

**di~hes,** 

### and sealed for
**transport.~o_** 

### t4e inhouse laboratory. ·

**.~** 

### · . . ; -.-

**~** 

### -- · After the. acetone .rinse, the entire procedure was repeated using methylene chl.oride as the reagent and the rinse was collected in a separate container. The impingers were recovered and rinsed according to the procedures ofMethod 315 and sealed for transport to the Alcoa laboratory. Laboratory analytical worksheetsare included in Appendix D.

11

### SECTION6 9UALITY

**ASS~CE/QUALITY CONT_~OL**  

### 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 5.1. 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 Y± 0.02 Y Method 5 Dry Gas Stainless Steel Critical Orifice 6.H @± 0.15 Meter Set Post TestY±0.05 Y Pitot Tube Geometric Specifications SeeEPA Method 2 Wind Tunnel Calibration Max. Difference 0.004 Probe nozzles Calipers 

### in. between,,tw,o.,",.,.,

**'""""~""'!'** ',1 

### 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 PERFORMANCE SPECIFICATIONS The preparation and calibration of source san1pling equipment are essential to maintain data quality. AQS strictly follows referenced calibration procedures and documents all results. Appendix H contains the quality assurance/quality control (QA/QC) limits and the results ofthe QA checks that were performed for this test program. All QA checks were within the allowable limits. 12

**---~--------- ~~~--~~~~~~-~~--** .,.,-:. 

## APPENDIX

## A EXAMPLE CALCULATIONS

-----------------------'

# I

I 

# I Example Calculation Project# 10736-11 

### ALCOA Warrick Operations US EPA Test Method-315 Polycyclic Organic Matter (POM) A-44-GReactor-2 · 

# .. Run# 

### One 

## Calculated Concentrations - 1 ( 

### lb ) - 7 ,000 

### (grains 

## ) Km 

## Km 

## = 1.43E-04 

## CMCEII?(MCElv£ramsx

## l,OOQ

## I(

**(T~,** X 

## r)

## I (l-

## Bws))I0.02832 CMCEM: = (( 

### 0.0246 X 

### 1,000 ) 

### I (( 135.685 X 

### 0.9947 )) 

## I 0.929 ) 

## I 0.02832 C MCEM-2 = 

### 5.977

CMCEM-1 = 

### 0.0246 X 7,000 453.6 

# ---------------- 141.612 C MCEM-1 = 

### 2.68E-03 

## CMCEM -2 

### = 

## C MCEM -1 X 

### f{m 

### C MCEM-2: = 

### 2.68E-03 X 

### 1.43E-04 C MCEM-2 = 

### 3.83E-07 Page 1 of7

- **--------~~~~-** 

# --------_tl

# 1:

I 

# .I 

# r II Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA TestMethod-315 Polycyclic Organic Matter (POM) A:.446 Reactor 2



# ..Run# One 

## Calculated Parameters 

# %N 2 

# =100.0- (%C02 

# +%02 ) 

### %N2 

## = 100.0 - ( 2.5 

## + 17.5 ) %N2 

## = 80

r 

## !1Hpbar 

## + -- 13.6 V

m (std) 

### = 

## V m X 

## y X 

## 17 .64 X 

### V

m(stdJ = 

### 135.69 X 

### 0.9947 X 

### 17.64 X V

m(std) 

## = 141.612 

# p 

# =P, 

# +



# ~tatic

s bar 

# 13 .6

p s = 

### 30.04 

### +



# ~~--~ **4** 

### p s = 

### 30.02 Vw(std) 

# =

# w;c X 

### 0.04715 Vw(std) 

## = 231 X 

### 0.04715 vw(std) = 

### 10.873 

## Page 2 of7 2.960 30.04 

## +--- 13.6 48.90 

### + 460 

# . I **--~**

# I

fi 

# r Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA TestMethod-315 Polycyclic Organic Matter (POM) A-446 Reactor 2

Run# One 

## Calculated Parameters (Continued) 

# ·vw (std 

### >. 

## BWS =------X 

## 100% 

## Vw ( std ) 

# + V m (sld ) 

### B = 

### 10.8728 X 

### 100

### %

ws 

### 10.873 . 

### + 141.61 Bws = 

### 7.1% ( 6.691 - 3144 

# J 10 T., +390 .86 

## B - -------X 

## 100 % ws (sat) - 

## ·p s 6.691 177 + 390.86 [ 3144 

### B ws(sat) = 

### 10 X 

### 100% 

# --------------------- B ws(sat) ;;;: 

### -47.5%



### 1-Bws = 

### 1 - 7.1% 1-B ws 

## = 0.929 30.02



## 11{ =(0.44x% 

# cq(d,J+(0.32x% q(drJ+(0.28x%



## ~d,J 

# :I
:I

M d = ( 

### 0.44 X 

### 2.5 ) 

## + ( 0.32 X 

### 17.5 ) 

## + ( 0.28 X 

### 80 ) 

## Md = 

### 29.1 

### Page 3

**o~7**

# I li II

**~·** 

### I !



## ~· 

## II Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA TestMethod-315 Polycyclic Organic Matter (POM) · A-446 Reactor 2 Run# One 

## Calculated Parameters (Continued) Ms 

## = 29.1 X 

### 0.929 

## + 18 X 

### 7.1% 

## Ms = 

### 28.31 

# (r:-;:;) Ts(avg) 

# +460 Vs 

### = K p X C p X '\j M avg X '\/ 

## p X 

## M v s s 

# vs = 85.49 

# A= 1rr 2 

### 177.00 

### + 460 X 

### 0.84 X 

### 0.9861 X

**~I** V 

### 30.02 X 

### 28.31
A = 

### 3.1416 X 

### 13.125 2 

### A = 

### 3.76 Reactor #2 exhausts via three identically-sizedstacks simultaneously. Thus, to derive the effective cross-sectional area of the emissions source, it is necessary to multiply the cross-sectional area of a single stackby three 

### A = 

### 11.27

# fi

II I! 

### Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA TestMethod-315 Polycyclic Organic Matter (POM) A-446 

### Reactor 2 

### " Run# One 

## Calculated Parameters (Continued) 

# I....··.···. :;:

**_:~:** .. . . ·. ·. 

## Qa
**=Ax60x~.** 

### Qa = 

### 11.27 X 

### 60 X 

### 61.3 

### Q a 

## = 41,478 Qs(std) 

## =17.647xQax( 

## Ps Jx(l-BwJ 

# lI:(avgy 

## +460 

# I 30.02 Qs(std) = 

### 17.647 X 

### 41,478 X ----- 

### 177 

## + 460 X 

### 0.929 Q s(std) 

## = 32,030



### Page 5 of7 

# 1-

### Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA Test Method-315 Polycyclic Organic Matter {POM) A-446 Reactor2 ,.. 

### Run# One 

## Calculated Concentrations 

## V.:.···· ..

# IGz.: :Gonversicm

## •Factor, gr/dscf•to lbs/dscf 

### K 

## = 1 ( 

### lb ) m 

### 7 ' 000 

### (grains ) 

### Km = 

### 1.43E-04 

### CMCEM: = (( 

### 0.0246 X 

### 1,000 ) 

### I (( 135.685 X 

### 0.9947 )) 

### I 0.929 ) 

### I 0.02832 CMCEM-2 = 

### 5.977 

### 7,000grains MCEMgrams X 

### S 

## 4 3.6grams **CuaM-1=----~--------~­** 

### Vm(std) 0.0246 X 

### 7,000 CMCEM-1 

## = 453.6 

# ---------------- 141.612 

### CMCEM-1 = 

### 2.68E-03 

## CMCEM -2 

### = 

## C MCEM -1 X 

## K m 

### CMCEM-2 : = 

### 2.68E-03 X 

### 1.43E-04 

## CMCEM-2 = 

### 3.83E-07 

## Page 6 of7 

# 'I

# I

I 

# I 

# r Example Calculation Project# 10736-11 ALCOA Warrick Operations US EPA Test Method-315 Polycyclic Organic Matter (POM) A-446 Reacto:r-2

Run# One 

## Calculated Emission Rates 

# r.

**'J!McEli~M!** 

# ,ivJe·CI :Extractable MatterEmiss'ion 'Rate, 

### ·Jb/hr EMcEM-J 

### = CMCEM-' 

### x 

## Qs (std)x 60 (



# ~:

# J E MCEM-1 = 

### 3.83E-07 X 

### 32,030 X 

### 60 EMCEM-1 

## = 0.736 EMCEM-2 =EMCEM-1 

# IPR E MCEM-2 

## = 0.736 

### I 19.940 EMCEM-2 = 

### 0.0369



### Page 7 of7

**~------------·** , 

# I i



### ------------

# __I

# I···



# i

.. APPENDIXB SUMMARY OF STACK GAS PARAMETERS AND TEST RESULTS 

# . ..Sn.nmmary of Sta!ck Gas !Parameters and! lest ResiU!Its Project # 10736-11 AlCOA Warli"ick Ope;aftions US EPA Test Meti'iodl-315

**IPo!ycyc~ic** Organic Matter (P>OM) A-446 Reactor 2 ' Page 1 o1f2 ' ·' Reactor#2 Reactor#2 Reactor#2 

## .. MB#1311 RUN NUMBER R2-0ne R2-Two R2-Three RUN DATE 1211/2010 121112010 12/112010 Avera!Je RUNTIME 09:46-12:27 13:13-15:55 16:52-19:41 MEASURED DATA DH@ Orifice Meter Calibration Coef., in. H2 0 1.7406 1.7406 1.7406 1.7406 Pstatic Stack Static Pressure, inches H20 . -0.34 -0.34 -0.34 -0.34

y Meter Box Correction Factor 0.9947 0.9947 0.9947 0.9947 Pbar Barometric Pressure, inches Hg 30.04 30.04 30.06 30.05 Vm Sample Volume, ft3 135.685 133.097 137.908 135.563 Dp112 Average Square Root Dp, (in. H20) 112 0.9861 0.9583 0.9997 0.9814 DH Avg Meter Orifice Pressure, in. H2 0 2.960 2.790 3.050 2.933 Tm Average Meter Temperature, oF 48.90 53.50 50.60 . 51 Ts Average Stack Temperature, oF 177.00 179.40 177.50 178 VIc Condensate Collected, ml 230.6 257.2 222.2 236.7 C02 Carbon Dioxide content, % by volume 2.5 2.5 2.5 2.5 02 Oxygen content, 

### % by volume 17.5 17.5 17.5 1T5 N2 Nitrogen content, 

### % by volume 80.0 80.0 80.0 80.0 CP Pitot Tube Coefficient 0.84 0.84 0.84 0.84 Circular Stack? 1=Y,O=N: 1 1 1 As Diameter or Dimensions, inches: 26.250 26.250 26.250 26.25 Q Sample Run Duration, minutes 144.0 144.0 144.0 144 Dn Nozzle Diameter, inches 0.251 0.251 0.251 0.251 CALCULATED DATA An Nbzile"Area, 

### tf 0.000344 0.000344 0.000344 0.000344 Vm(std) Standard Meter Volume, ft3 141.611 137.609 143.578 140.933 Vm(std) Standard Meter Volume, m 3 4.010 3.897 4:066 3.991

Om Average Sampling Rate, dscfm 0.983 0.956' 0.997 0:979 Ps Stack Pressure, inches Hg . 30.02 30.02 30.04 30.02 Bws Moisture, 

### % byvolume 7.1 8.1 6.8 7.3 Bws(sat) Moisture (at saturation), % by volume 47.5 50.2 48.0 48 ..6 Vwsld Standard WaterVapor Volume, ft3 10.854 12.106 10.459 11.140 1-Bws Dry Mole Fraction 0.929 0.919 . 0.932 0.927

Md Molecular Weight (d.b.), lb/lb•mole 29.10 29.10 29.10 29.10 Ms Molecular Weight (w.b.), lb/lb•mole 28.31 28.20 28.35 28.29 Vs Stack Gas Velocity, ft/s 61.3 59.8 62.1 61.1 A Stack Area, 

## ff(x 3 stacks) 11.27 11.27 11.27 11.27 Oa Stack Gas Volumetric flow, acfm 41,477 40,460 42,024 41,320 Os Stack Gas Volumetric flow, dscfm 32,021 30,795 32,554 31,790 Os Stack Gas Volumetric flow, dscmm 907 872 922 900

I lsokinetic Sampling Ratio, % 100.8 101.8 100.5 101.1

**---~~~~~~~~~~~~~~~-~-~~~~~~-'**Summary of Staclk Gas Paramef!:errs and Tes1t

**ResiL!I~irs** Pmject

### # 101736-11

**~.LCOA** Wa;rock Operaf!noD'lls US EPA Test Method-315 Poiycycik: Org;al!'lnc M<Bliicer

**{P'O~Jl}** A-446 ReSJctor 2' RUN NUMBER RUN DATE RUNTIME PRODUCTION DATA 

### Page 2 of2 R2-0ne 1211/2010 09:46-12:27 R2-Two 121112010 13:13-15:55 Tons carbon anodes input per hour 19.94 19.94 MCEM MCEM MCEI\Il MCEM MCEM MCEM MCEM MCEM CMcem CMCEM CMCEM EMCEM EMCEM EMISSIONSDATA Methylene Chloride Extractable Matter Filter Weight Gain, mg Front-half Weight Gain, mg lmpinger Weight Gain, mg Back-half Weight Gain, mg Filter Blank Correction, mg Acetone Blank Correction, mg Methylene Chloride Blank Correction, m! Total Catch, g Concentration, mg/acm Concentration, gr/dscf



### C¢Qi:!eili~tion, Jb/dscf 

### Emission Rate, lb/hr Emission Rate, lb/ton carbon anode

**;&mi(';JmfuaJtr~•ail!tr&".!!1·** 

### PM PM PM PM ·· :: ,. **'~:** !::: ::-,;:o:,**~:l."!~~;;:;;,s~;,;,s-:~"'''l'l'l~:.,,~~""~~~':'""** 

### Filter Weight Gain, mg Front-h,alfWeight Gain, mg Acetone Blank Correction mer ' b 

### Total Catch, g 0.5 6.9 

### 3.8 13.5

0.1 0.0 0.0 0.0246 5.978 2.68E-03 3.83E-07 0.736 0.0369 

### 6.4 

### 14.0

0.0 0.0204 Cpm 

### Concentration, mg/acm 4.957 Cpm 

### Concentration, gr/dscf 2.22E-03 Cpm 

### Concentration, Ib/dscf 3.18E-07 Epm 

### Em,.ission Rate, lb/hr 0.610 Epm 

### Emission Rate, Ib/ton_carbon anode 0.0306 0.2 

### 3.5 4.4 1i .7

0.1 0.0 0.0 0.0197 4.829 2.21E-03 3.16E-07 0.583 0.0292 

### -2.6



### 5.4 0.0 ,, 

### 0.0028 0.686 3.14E-04 4.49E-08 0.083 0.0042 R2-Three 1211/2010 16:52-19:41 19.94



### 2.4 9.8 

### 2.6

. 2.2

0.1 

### 0.0 0.0 0.0169 4.1J55 1.82E..03 2.59E-07 0.507 0.{)254



### 0.3 8.3 0.0 0.0086 2.063 9.23E-04 1.32E-07 0.258 0.0129 .Ave.--age I I 

## i 

# I I I I 19.94' ! ! . 1.03 6.73 I 3.60 

# I 9.13. 

# r 0.10 

# I 0.00 0.00 0.0204 4..954 

# J 2.24E-03 3.19E-07 0.609 If 0.031 ·J 

# I' 4.10 9.23 0.0 

# 0.01061 2.569 

### 1.15E-04 1.65E-67 0.317 ; 0.015'9 'MB # 1314 DH@ Pstatic

y Pbar

. Vm Dp112 DH Tm Ts Vic C02 02 Nz 

## c·

p As Q Dn An Vm(std) Vm(std)

Om Ps Bws Bw;(sat) Vwstd 1-B;,...s

Md Ms Vs A Oa Os Os



### I Summary of Stadt Gas IP'a;ameterrs and

**res~** IResn.dts !Project # 11017315-11 ALCOA Warrick Ope;atnoiTlls US !EPA rest Metll1od-315 IP'o!ycycDic 011'9Jatllllic Matter (IPOM} A-446 Reacto; #3 ' !Page 

### 1 of

### 2 ' 

# .. ·' Reactor#3 Reactor#3 . Reactor#3 RUN NUMBER R3-0ne R3-Two R3-Three RUN DATE 1211/2010 121112010 1211/2010 RUNTIME 09:46-12:25 13:14-15:51 16:53-19:39 MEASURED DATA Orifice Meter Calibration Coef., in. H2 0 1.7760 1.7760 1.7760 Stack Static Pressure, inches H20 -0.60 -0.60 -0.60 Meter Box Correction Factor 0.9941 0.9941 0.9941 Barometric Pressure, inches Hg 30.04 30.04 30.04 Sample Volume, ft3 132.618 132.436 133.161 Average Square Root Dp, (in. H20) 112 . 0.9928 0.9710 0.9949 Avg Meter Orifice Pressure, in. H20 2.875 2.790 2.920 Average MeterTemperature, oF 54.20 63.20 "61.40 Average Stack Temperature, oF 169.80 172.25 172.40 Condensate Collected, ml 224.8 243.6 211.6 Carbon Dioxide content, 

### % by volume 

### 0.0 0.5 0.0 Oxygen content, 

### % by volume 20.0 20.0 20.5 Nitrogen content, 

### % by volume 80.0 79.5 79.5 Pitot Tube Coefficient 0.84 0.84 0.84 Circular Stack? 1=Y,O=N: 1 1 1 Diameter or Dimensions, inches: 46.250 46.250 46.250 Sample Run Duration, minutes 144.0 144.0 144.0 Nozzle Diameter, inches 0.246 0.246 0.246 CALCULATED DATA 

## NozzleFJ!.:rea,

# te 0.000330 0.000330 0.000330 Standard Meter Volume, ft3 136.873 134.306 135.550 Standard Meter Volume, m 3

**3~876** 3.803 3.838 Average Sampling Rate, dscfm 0.951 0.933 . 0.941 Stack Pressure, inches Hg 30.00 30:00 30.00 Moisture, 

### % by volume 7.2 7.9 6.8 Moisture (at saturation), 

### % by volume 40.4 42.7 ·42.9 Standard Water Vapor Volume, 

### ft3 10.581 11.466 9.960 Dry Mole Fraction 0.928 0.921 0.932 Molecular Weight (d.b.), lb/lb·mole 28.80 28.88 . . 28.82 Molecular Weight (w.b.), lb/lb•mole 28.02 28.02 28.08 Stack Gas Velocity, ft/s 61.7 60.5 61.9 Stack Area, ft2 ( x 3 stacks) 11.7 11.7 11.7 Stack Gas Volumetric flow, acfm 43,196 42,331 43,336 Stack Gas Volumetric flow, dscfm 33,687 32,640 33,777 Stack Gas Volumetric flow, dscmm 954 924 .956 lsokinetic Sampling Ratio, 

### % 99.8 101.0 98.5 Average 1.7760

-0.60 0.9941

30.04 132.738

0.9862

2,862 60 

### 111 226.7 0.2 20.2 79.7 0.84 46.25

144 0.246 0.000330 135.576

3.839 0.942 30.00

7.3

. 42.0 10.669.

0.927 28.83 28.04

61.4 11.67 42,955 33,368 945- 99.8
.•.....1 f,Summar}' of Staclk Gas Pau<nmeters am11d! Test

**Resn.n~trs** Project# 10736-11 AlCOA Warrick Opemfrions US EPA Test Me11:hodl-3'i5 Po!ycyclnc Orrganic Matter (POMp A-446 Reauc:toll" #3 /Page 2 of 2 I· RUN NUMBER R3-0ne R3-Two R3-Three ' RUN DATE 121112010 121112010 121112010 Average RUNTIME 09:46-12:25 13:14-15:51 16:53-19:39 I PRODUCTION DATA Tons carbon anodes input per hour 19.94 19.94 19.94 19.94


# .. EMISSIONS DATA Methylene Chloride Extractable Matter ! MCEM Filter Weight Gain, mg 0.9 0.5 0.7 0.70 MCEM Front-halfWeight Gain, mg 4.8 5.6 4.9 5.10 MCEM lmpinger Weight Gain, mg 2.8 2.8 1.6 2.40 MCEM Back-halfWeight Gain, mg 10.3 7.0 8.9 8.73 MCEM Filter Blank Correction, mg 0.1 0. i 0.1 0.10 MCEM Acetone Blank Correction, mg 0.0 0.0 0.0 0.00 MCEM Methylene Chloride Blank Correction, rr 0.0 0.0 0.0 0.00 MCEM Total Catch, g 0.0187 0.0158 0.0160 0.0168 CMcem Concentration, mg/acm 4.649 3.904 3.976 4.176 CMCEM Concentration, gr/dscf 2.11E-03 1.82E-03 1.82E-03

**1;92E~a:r** 

## ·qMdeM
**··t$~'i1~~(~t'f~1i'~n~·:·tt>Jctscf** 3.01E-07 2.59E-07 2.60E-07 2.74E-07 · EMCEM Emission Rate, lb/hr 0.609 0.508 0.527 0.548 EMCEM Emission Rate, lb/ton carbon anode 0.0305 0.0255 0.0264 0.027 \ " 

### Particulate Matter I 

### PM Filter Weight Gain, mg 21.1 1.5 12.9 11.83 PM F;ront-halfWeight Gain, mg 19.1 20.0 20.1' 19.73 PM Acetone Blank Correction, mg ' 

### 0.0 0.0 0.0 0.0 PM Total Catch, g 0.0402 0.0215 0.033 0.0316 

### Cpm Concentration, mg/acm 9.994 6.312 8.201 8.169 Cpm Concentration, gr/dscf 4.54E-03 2.48E-03 3.75E-03 3.59E-03 Cpm Concentration, lb/dscf 6.47E-07 4.52E-07 5.36E-07 5.45E-07 Epm Emission Rate, lb/hr 1.309 0.691 ' 1.087 1.029 Epm Emission Rate, lb/ton carbon anode 0.0657 0.0347 0.0545 0.0516

**···~**•' 

## APPENDIXC FIELD DATA**[.!__l:~** Air Quality services FIELD OAT A SHEET

Plant: , ......... Sampling

Location: a3,t.G.d of d,

**~** \h/t-h Pbar: ,,0. 01 _

Ps:**_.....:·~-...!..·----**

Run Nurnber: 0(\Je-- Date:**\~-** \- )U C02: **J.~?** 02: 17. £

Pretest

Leak

**.~ate:.~** cfm@ __j£ in.Hg Probe Length!Type: t <Z

**~** \ I\ Pilot#: fa

3. A r

Pretest Leak Ck: Pitot: / Orsat: Stack Diameter: As:
Travers e Point Number Vm= t:. H= Ts= **~J;J** Air ouality Services Tm= 4 ?

**-~I** q

_. t **~** •

# I 

# •

**'~·'** '-'; 

# Jl 'iii 0. ::J 0 0 0 

### f <ll 

### F

cci 0 

### c a:;

**~** 0 

### z 1- 

## w 

# w ;_;

**~ ~-**  Q) 

## <e8



# ~ Cl 

### 0 ..J 

# w u. Ol ::z:; .!: ©l :r: 

### <l ro 1!! ©l 0 'i§ .§ 0

**~** Li: ;;..: :§ Qi 0: iii .i.i 0::: u



### ~ -"' ro



### ~ Q) !Il _J "0 0 Ul Q) !Il Q) E

**~** f- ::J 2 ..!. C{J C{J (/) Q) 0 

### -<

**~** a.

**~**



## ~ 

# 8

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### I~

II



### I~

II :r: 

### l<l 0 If'

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### 6 

### v.



## .I

# I[;_J:l;j

··<·e?''';f'LJ
Air Quality services

FIELD DATA SHEET
Sampling Location:

, - **-~-** .., - • • · ,
Run

Number:**~** Date:____

_ Pbar: ---------------------- C02: **----------~----------**
Pretest Leak .Rate: cfm@

___ in.Hg I

Probe Lengthfrype:

---------
Pretest Leak Ck: Pilot: Orsat: Stack Diameter: Travers e Point Number Sample Time (Min)

Clock Time (24-hr

clock) Gas Meter Reading (Vm)

ft3 Operator: Ps: 02:**--~----------­** Pitot#: --------- As: **~ ~**  -

.1·

A **r~~** .::a **~** ..... .J;;;,J

Air Qul!lity services Nozzelln. Dia.: ------- -.. - - Assumed Bws: _____ Filter#:

_______ _ Meter

Box#: ----'- Y: --,-------- llH@

____ _ Post-Test

Leak Rate: ,cf,!ll@ in.H Post-Test

Leak Ck: Pilot: Orsat: Tm= **V(~,q ~**  s:-z **.:l·~** q u-;tL

# I

I 

# I I I 

# II

# t f

**~** SAlviPLE RECOVERY DATA PLA.NT 

# A I c. 0 

## q - 

# Wwc!.a.-k D·'9q \J (.'L 1'1 

### Run No. 

# R. :1- \ DATE I

### ;z..- 

## t - l 0 

### Sample Box No. 

# -=-b __ JobNo. !D73(o-\\-o<01 

### SAlvlPLE LOCATION 

## 'j2. g.o,e..

## J:or if_ 

## 2 TRAIN PREPARER**_......:fl',__:~~L_2_·. -~-·**  

### _..

_______________ _ SAMPLE RECOVERY PERSON 

## _/ff'-..,2..., 

## ...,..5;"""'/'-"'~=- =ez_::...=...----------- CL}[\1lVlENTS 

## Me-Vd 3\5 :FRONT HALF Acetone C

### onraincr Nl). 

### Filrer 

### Conuin¢r

## No. Dc$CripTion ofFilre-r Liqu.id Level lviark.ed 

# ------- ------- 

# filte.r 2 A. Samples Swrcd 'md Lacked Sealed 

# ----- Scaled ___ _

**~7,o~**

**~'Z.-** l.;.'-f1../-.(o 

## !./tf3. 

## 3 BACK **B.~1.,/l\10lSTURE** 

### C

### omainer No.



## '9~S 

# j5J.,:? 

# "!J Liquid Leve-l Sealed 

# ---- INITAfL IMP. NO. CONTENTS VOL WEIGHT (grams) (mil INITIAL FINAL NET 

# ., 

# 0

**-~** ' 

# . 

# "'- (. )

# ,, rr,-r.1 87:3.2 I {

# b. 1 2 

# o.J. /J() 

# l '3 1: '2.- 

## Bote. 

# .7
**~9.5** 

### ,, ,.e_ 

### M.?



### ~~, 

### () 

### ~~3\-S' 

### f>L./'7, 

## 2 !S."l ,) 4



# ~~ f



# :r~ 

# d-:;zrr . **~** 

## D'l,7 

# £137-0 2'1·3 5 

### 6 

### TOTAL 

## 2'1'33 

# .s :?I!.P"+.l **2~·6** 

### De.scriprion,oflmpinger Cacch: __ __;_ ______________ _ . )

## EPA METHOD 4 MOISTURE CALCULATIONS PLANT: Alcoa Warrick Operations DATE: 12/01/10 SOURCE: A-446 Reactor 2 (POM train) RUN#: one 1. Leakage Correction for Volume Metered: Vme= Vm-(Lp-La)XOYme= Vm-(Lp-0.02)x0 - Vme = ( ) - ( -0.02) X ( Vme= 

# J 135.685lcu. Ft. 2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) Vm_std 

### = ( Pbar 

### +( .L±i/13.6) ) 17.64 XVme X Y X (460 + Tm) 2380.797938



# .(--~3=0·=~5~:8~~:~7~0_6__ )


### · Vm_•d

# =

# l 141.555 

# I dsc! 3. Volume Water Vapor Collected, Standard Conditions: lmpingers & Silica Gel =

.4. Percent Moisture, 

### by Volume Vw std Vw_std = 0.04715 X (Wt-Wi) Vw_std 

# = 0.04715 X 230.6 Vw_std = 10.87279 

### X 100 Bws= Vw_std 

### + Vm_std Bws = 10.87279 

### X 100 152.4277983 Bws = 7.13 

# '%**~~<::.c: ';0-~.f-'**  q .;;fl!jt:"O;Ii

**~:;·::;'-** "' Ul:8 LIFd

Air Quality senrice-j

FIELD DATA SHEET **_,~** . AirOIIalityServices

Sample Type: =--

- **Operator:~** Nozzelln. Dia: Therrnocouole#___ 1

Pbar·

Ps: Assumed Bws: Filter#:._'-_•

------

C02: (IV

.. - **~ J..~**  s Mf on{

**~I** 1 **~**

Meter Boldt: Y: l'.H@

__ _

r-pj'8nt: ltf<""M\ , Sampling Location: t\

**-e.r..~..tac** J.-.{fi\ ilk
Run Number. '\\JJ

o Date: ____

_ Pretest

Leak Rate: cfm@

__ in.Hg I

Prabe Lengthrrype:

Pita!#: --------- Post-Test Leak Rate: cfm@ in.Hg

Pretest Leak Ck: Pilot: Orsat___ 1 Stack Diameter: **-~**

As. Post- Test Leak Clc Pitot. Orsat: **F~ra:~~J~,~~;m.~~-y=~:~if~,~~.-~~<~~~--:~'f~2t~:~~%Y-f~'i>~'~t~~~;~~!::!~~!~~~7~;;~~::.:ft;;_%~S£5'.'-~~~·;~~Slt!0«-**

01 .

Dry Gas Meter ; Pump --\

P . t r· Clock Time Gas Meter Reachng Velocity Head (£\p) ( II). H

2 0 Stack Temp. Temperature "F lmpmger T t [T J I V (' 1

e otn **l~e** (24-hr clock) (Vm) ft3 in H20 . t.:.· m (Ts)

Temp. "F empera ure m I accum ln. \

Number (Mm)

.p" Desired Actual Prabe Filter Inlet ·'F \ Outlet "F Hg)

1 **~~~t,;~[~~~~~~l.~~ :~~~~~~Eji** **l~~~~f.~ Jg:~:~~~~~~~f**  **~.:j~~:~~~ ~~~l1:~},~~~** **·~~~~~~:;i~~~~~~· ;~1;~~~~~~**  **¥.f~;~~~~ ~Z~@~1r.~~t~);,(**  **-----~-----!--------~--------------:~~~~~~~~~=**

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____ **~:L_k** et .FJ SJ- **_££-hL--~-~** f_ **---~-J..'::.a+---- _3__~.1.:..U** 

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## SA.lviPLE RECOVERY DATA PLANT 

### .b_r,..~OA.- **kkr~Jo** Opu<4t;,O>\$. Run No. 

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# I

I I I I EPA METHOD 4 MOISTURE CALCULATIONS PLANT: Alcoa Warrick Operations DATE: 12/01/10 SOURCE: A-446 Reactor 2 (POM train) RUN#: two 1. Leakage Correction for Volume Metered: Vmc= Vm-(Lp-La)XOVmc= Vm-(Lp-0.02)x0_- Vmc= ( )-( -0.02)X( Vmc = 133.097lcu. 

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# I EPA METHOD 4 MOISTURE CALCULATIONS PLANT: Alcoa Warrick Operations DATE: 12/01/10 SOURCE:·A-446 Reactor 3 (POM train) RUN#: one 1. Leakage Correction for Volume Metered: Vmc= Vm-(Lp-La)XOVmc = Vm- (Lp- 0.02) x 0 - Vmc= ( )-( -0.02)x( Vmc = 132.618fcu. Ft. 2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) Vm_std = 17.64 XVmc XYx 

### ( P,., + ( 

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# ( 30.25139706 514.2 

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### & Silica Gel = 4. Percent Moisture, by Volume Vw std Vw_std = 0.04715 X 

### (wf-W;) Vw_std = 0.04715 X 224.8 Vw_std = 10.59932 

### X 100 Bws = Vw_std 

### + Vm_std Bws = 10.59932 

### X 100 147.4177152 Bws 

### = 7.19 

# 1% 

# ) )

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FIELD DATA SHEET

Plant: Alce4

--- --- - Sample Type:

**A~** - - - - -- Operator:

___.N,__,- -'--'-t-""3'------
Sampling Location: _Rf!At,'\Il( tt;3

**A-"l~!v** Pbar· 3Q.Oz.J

Ps: **-~~**

Run Number: **)~o** Date: \J-\-\0

C02: 0.6 _

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Assumed Bws: Ca9'o Fi:ter#:._J.{t!A::L..

______ _ Meter Boxlt:**~** Post-Test Leak Rate: Y: **~** '• llH@ \,1J!J,D **~** cfm@ 5

in.Hg

Pretest Leak Rate: -00"":1 cfm@ $

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### :( 

## SAMPLE RECOVERY DATA PL\NT



## ~~**~tcu;~,.** - 

## LdArc~ ,_k_ 

## DD~a-a~ Run 

## No._Ii~W=C""------ 1

**~.v** ,(\1\ 

### A DATE **\a~1~10** 

### Samplc:BoxNo. 1:7 JobNo. (o73fo-}l.-oD( SAlviPLE LOCATION 

### 'ReuJor .i:!

## 3 A..**J.~'illl** 

### TRi\.IN PREPARER /), 

## .5/a,4CL **--~.~~==~--------------------------** 

### SA1v1PLE 

### HECOVERY PERSON__ 

## ,/2___.__:);~~"-""-"-/:!.=~=-----------­ COMlVlENTS 

# 1/e.liod 5!5:

..FRONT HALf Acewnc ContainerNo. Liquid 

### Level !\.-larked 

# ------ ------ Sealed ___ _ Filter 

## Conminc:rNo. Description ofFilter Samples Stored and Locked 

## BACK H.ALF/MOlSTURE 

### Comainer No. Liquid 

### Level IMP. NO. CONTENTS .I 

### <j) 

## ,1. 2 

# D.·J:., ,,



## ~ vi\?L, ,) INlTAfL VOL (ml) 

## l"'u \VD

0 4



### ~ **~ \}c~**  

# :t.§"o·t 5 6 TOTAL 

### Sealed ____ _
Sealed

# ---- WEIGHT (grams) INITIAL FINAL NET 

# '7 z;

# 0 I 

# '1 &5'?.& 

# 9&.1 

# l

**&~** 

# ,y !'lb.

# I 

# 11.7

**do6~**

# .. 

# 3 tb33,8 

# 2'9 ..5

**~10,** 

# '3 t:jo5. 

# B 35.5

**2~4'1.9** 

## 32'+3.5' 

# 2<-1-3.6 **~:Description** oflmpinger Catch: ---------------------------- **Ac.~** 

### ll:,,z_ l 

### z.8. ( 

# '/5". t (}

**r.~··** 

# I 

# t 

# r I' li 

# r

# f r " 

## EPA METHOD 4 MOISTURE CALCULATIONS PLANT: Alcoa Warrick Operations DATE: 12/01/10 SOURCE: A-446 Reactor 3 (POM train) RUN#: two 1. Leakage Correction for Volume Metered: Vme = V m - (Lp - La) X

### 0 - Vmc= · Vm-(Lp-0.02)x0 Vmc= ( )-( -0.02)x( Vmc= 132.436Jcu. Ft. 2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) Vm_std = 17.64 X 

### Vme X 

### Y X 

# e.., + ( L'fl/13.6) (460 + 

### Tm) Vm_std = 2322.387631 

# ( 30.24514706 523.2 

# Vm_"'"8 ·dscf 3. Volume Water Vapor Collected, Standard Conditions: lmpingers & Silica Gel= Vw_std = 0.04715 X (wr-Wi) 

### Vw_std = 0.04715 X 

### 243.6 Vw_std = 11.4857 4 4. Percent Moisture, by Volume Bws 

# = Vw std X 

### 100 Vw_std + 

### Vm_std Bws 

# = 11.48574 

### X 100 145.7383306 Bws 

# = 7.88 

# 1% 

# ) )FIELD DATA SHEET **r~·r~-** -=j **(..,;_~~** Air Quality Services

Plant: .:dJ(@-

Sample Type: __Ak_ru£

Operator:

**~** Noz:zelln. Dia : ·cil"'lo Ti1ermocouole#:

___ J

Sampling Location: _R.fM.dot

**~** 3 A-AI%,) Pbar· 30.(1&.\

Ps: -.Lc Assumed Bws: **~--** Filter#:__,(o""AQ._

_____ _

Run Number: **~Date ~\..:lQ..._** 

C02: • C

02:_ Cl\).S' Meter Bm:#: ) 31!{ Y: • G9"1l 11H@ )./J{p{> PretestLeakRate:**~cfrn@ ~in.Hg** 

Pmlielenglhrfype: ,}ll:t-SL

Pilot#: **9\7.~SL~T** Post-TestLeakRate: .QO(o. cfm@ f.£

in.Hg

Pretest Leal< Ck:

**P~ot:** / Orsat:

___ Stack Diameter.

As: Post-Test Leak Ck: Pilot:

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1

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. H

2 0 Stack Temp. Temperature °F • !mplf1Qer T t [T ) V (. 1

r P:ml lmO (2·1-hl """' (Vm) 113 '" H20 . 6 '" (T•J

T•mp. "F •mP"'""

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## SAlviPLE RECOVERY DATA PLANT __ 

## .fl1eoa - Wacc.'.:k. tjAera4a::S · Run No.--!Jb-4-ll-rce"'""------- D_,\TE 

### t "2-/1 / 2Dto 

### Sample Box No. 

## ?1111A- 8 · Job No. **lo131o~** 

### I\- 

## oD1 

## • .S.-\l\lPLE Ll)CATION 

# tk.ot:.±or 1=t

# 3 

# A·L11.14> TRAIN PRI:JlARE'_R /1 .,.--? 

### ----~~~~~~Ad~~~~~~~----------~~-----~----- 

### :SA1vil'LE RECOVERY PERSON __ 

## __.,_/.--'-,_,_5;=.w(,~e-'""'/ ______________ 7

### f

_ **C0~'\1lvJENTS ,£k~,k/**  

# ?;;,£

FRONT HALF Acc:wnc 

### Cumn.inc:r Nu. 

### Liquid Level 1vfarked Sealed --------- 

# ------- 

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## Conuin.;.:r No. Dc.scriprion 

### offilrer 

### Samples Srored

**~illd** 

### Locked BACK H.ALF/MOlSTURE Conrainer No. 

### Liquid Lt\'d IMP. NO. CONTENTS



# ~it DI kz_o 1 

### D:r:. /-1.2-o 2 /· 

### ., 

## &;¢'r

I ,) 4 

## .5'/~/~trz 5 6 !/If



### ~I TOTAL



### r~; '• INITAfL VOL (mil /00 /PtP



# -

**~52),._** 

# I of**~mpinger** 

### Catch: 

# l\ Scaled ____ _
Sealed 

# ------ WEIGHT (grams) INITIAL FINAL NET 

# 1'-/CJ,S g3tJ.8 

# 8l.3 

# 762.3 833-b ?/.3

**f,~o.9** 

### ~!o3.:3 

## 2.2.4 

# &3/./ 

# 81P 7. 7 30

# .Ia 1t:.J

# 83.8 31'15.4 

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r,- t."'"**~··** .:;_ 

## EPA METHOD 4 MOISTURE CALCULATIONS PLANT: Alcoa Warrick Operations DATE: 12/01/10 SOURCE: A-446 Reactor 3 (POM train) RUN#: three 1. Leakage Correction for Volume Metered: Vmc= Vm-(Lp-La)xO - Vmc= Vm-(Lp-0.02)x0 - Vmc= ( )-( -0.02)x( Vmc= 133.161fcu.Ft. 2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) Vm_std = 17.64xVmcXYX 

### ( Pb., + ( 

# & /13.6 

## I 

# ) (460+Tm) 

# ( 30.25470588 Vm_std = 2335.101176 521.4 

### vm_ ••

# =B dsct 3. Volume Water Vapor Collected, Standard Conditions: lmpingers & Silica Gel = Vw_std = 0.04715 X 

### (Wt-W) Vw_std = 0.04715 X 211.6 Vw_std = 9.97694 4. Percent Moisture, by Volume Bws = Vw_std Vw_std + Vm_std 

### X 100 Bws =. 9.97694 

### X 100 145.4732946 Bws = 

# I 6.86 

# '% 

# )

# r 

# I

w····· 

## APPENDIXD LABORATORYDATA .. **_.:.~.---**

# I JAN/03/2011/MON 02:02PM P. 001 i>. .,; 

# I 

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### Date: ·

**~-** ·. 

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### (g) (g) 

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# .4:!1# tJv/ 

# N/ft- .. 

## 1fQ5 

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### • Acetone Wash 'Reage'nt Blank must not exceed 1 mg/L. 

### · -•· Meth91ene Chloride Reagent Blank must not exceed 1.5 mg/L.

·eP 

### ·lmpinger Water Raagent Blank must not exceed 1.5 mg/L. . 

## (mg!L:7

It 

# I ·o.o 1).0



## ·/~ ..



### • Room. Relative Humidity must be below 50% when samples are being 

### weighe.d. . •' 

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# .- '

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02-FORM-074 

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### Data: 20·1 0/03/31 I



# .~f;-:· 

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## l~itial Volume (mg) l.,.iq1:.1id Collected (mg) 

### Note ·1 Note 1: Convert volume ofwater to weight by 

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### exceed 1.5 .mg/1... • Room Relative 

### Humidity must be 

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### when samples 

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### 02-FORM-074 

### Revision Date: 2010/03/31 

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### Revision Date: 201 0/03/31 • 0' ; 

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## Calibration Procedures and 

## Results Pitot tubes and thermocouples are calibrated in accordance with the procedures outlined in USEPA MetJ1od 2 - Determination of Stack Gas Velocity and Volumetric Flow Rate (TypeS Pitot Tube), Sections 

### 10.1-10.4, "Sampling Equipment Calibration", as follows: 

### Pitot Tube Calibration Each pitot tube used in sampling is carefully inspected to ensure that all aligmnent specifications ofEPA Method 2, Section 

### 1 0.1. are met. Upon passing the inspection, a baseline coefficient of 0.84 is assigned to each pitot tube. The aligmnent speCifications ofMethod 2 and the Pitot Tube Inspection Data Sheet(s) for each pitot tube used during the test program are presented herein.
Transverse Tube Axis



## ~ A Face

--- Dpenng Planes

(a)

(b) 8 .. 

## -------

(a) erd Yew, !lee openir(l """"'perperr:>:m-

totralsver.;eiDris;



### --~----Aor"B----(-7-----. (c)stlo*'<r,lxllhiogsof"''J'iiergllii<KI cerl!lOOesiDhci:lerl.\\hen-tan lxllhsi:les. Basei1ecoo..fii;iertvailesof 0.64 rrnybe assi;Toe:f I> pl.ollubesoon- slucledtllisway (c)

### Thermocouple(s) Calibration- Approved Alternate Method (ALT-011) 

### In EPA Method 2, EPA recommended the use of an extrapolation technique for a siinplified, post-test, them1ocouple calibratiou procedure using a two point calibration: (1) 

### ice bath and (2) boiling water. Because ofthe inherent accuracy and precision ofthe thermocouple within ±1.3°F in the range of -32°F to 2500°F, the two-point post-test calibration procedure may be. replaced with a single-point check. A single-point calibration procedure that checks the operation of a thermocouple system withii1 ±1.0 percent ofthe absolute measured temperature is all that is necessary to check the system for the presence of discmmected wire junctions, other loose cmmections, or a potential miscalibrated emf readout. A system that performs accurately at one temperature is expected to behave similarly at other temperatures. Therefore, an alternative to the Method 2, two-point, thermocouple calibration can be used and the procedure is as follows: After each test run series, the accuracy (and, hence, the calibration) ofeach thermocouple system at ambient temperature, or any other temperature, is checked within the range specified by the manufacture, using a reference thermometer (either ASTM reference thermometer or a thermometer that has been calibrated against an ASTM reference themiometer). The temperatures ofthe them1ocouple and reference thermometers shall agree to within ±2°F. Results of the thermocouple calibration(s) are shov.m on the "Temperature Sensor Calibration Data Form".Pitot Tube Number: PR-3A Effective Length (in.): 36" Pitot Tube Openings Damaged? YES Pitot Tube Assembly Level? 

## j· YES 

### a 1 = 1.8 °(< 10°)


## -----------**~** 1 = 0.5 0(< 50) 

# ------------- y = 1.3 

## ------------- 0 

# e = 1.2 

### ------'-------- 

### z=Asiny= 0.02160 in. ( < .125 in.)


## ------------ w= A sine= 0.01994 in. ( < 0.03125 in.) 

## ------------- 0.375 

# -------------------- 1.27 

# ---------------------**~** ' I 

# lh!**~--** 1 I : i ! (a) j (b)
(d) (e) 

# ;yz 

# I;

..,

__**~.--** ....

-4

.. - .......

- ...._-_- ..._-_- ___

-____

-__**-_-:;:;_~--** ..**-:--~"'l ~--·--·--·**  B (f) 

### Air Quality Services, LLC 425 Main Street Evansville, Indiana 47708 Phone: (812)452-4785 Fax: (812)452-4786 Date: 10/06/10 .,**----------------~--** Calibrated By: DLO NO 

## NO a2 1.8 0(< 100)


### ------------**~** 2 0.6 0(<50)


### ------------- A= 0.952 in. 

### ------------- 0.476 in. 0.476 in. in. ( 0.1875 in.**~D S,0.375**  in.) in. ( 1.05 in.*D1**~** A/2/D1**~** 1.50 in.*D1 )

# ::::i-X~ ...

# f!~.--========~F~Io~vD~t_ ......._____**_.h'-"A"'-----~ ~** ........:. ,_..____.......,_,.::,.,,=-·-·-·-....

### ~c-f" (c)

(g) The types of face-opening misalignment shown above·will not afuct the baseline value of Cp(s) so long as a, and a2 is less than or equal to 10°, B 1 and B 2 is less than or equal to 5°, z is less than or equal to 0.32 em (1/8 in.), and w is less than or equal to 0.08 cm(1 /32 in.) (reference11.0 in Section 1B.m. 

# ACCEPT 

# I Pitot Tube Calibration Form 2001 Yearly CalibrationPitot Tube Number: PR-5C 

# .. Effective Length (in.): 60 Pitot Tube Openings Damaged? 

### YES Pitot TubeAssembly Level? 

### YES 

### a 1 = _____ 0_._1___0(< 10°)

**~** I = 0.6 o(< 5o) 

# ---------- y = 0.5 0 

# e 0.8 

# -------- z= Asiny = 0.00820 in. ( < .125 in.) 

# ---------- w= A 

### sine= 0.01312 in. ( < 0.03125 in.) 

# -------- 0.375 

# -------------- 1.25 

# ------------- jA.; ! f 

# --88- ! (a) 

# l (b)
(d) (e) 

# ;yz 

# I;

**----------~r-** 

### ____

-4_-_- ___

-_____



### .,---~----------------------------" __ 

### -:::_E3>~-------·--! **~----------··** 8 (f) 

### Air Quality Services, LLC 425 Main Street Evansville, Indiana 47708 Phone: {812)452-4785 Fax: (812)452-4786 Date: 09/09/10 

# -------------------- Calibrated By: DLO NO NO 0.1 0(<100) 

## ------------- 0.7 0 (<50) 

# ------------ A= 0.94 in. 

## ------------ 0.47 in. 0.47 in. in. ( 0.1875

**in.~** D1S.0.375 in.) in. ( 1.05

**in.*D** **~A/2/D ~**  1.50 in.*D1 )



# :::::;X~s~-=-=·=-··=···**::::--~F-~I:?_~V::.::::t** __________________ 

# 1A -......_

- - 

### '--.\----

**-----------------..:::,_·~"-·-····----·**



### 13j(~ (c)

(g) The types of face-opening misalignment shown abovewill not arect the baseline value of Cp(s) so long as a,anda 2 islessthanorequalto 10°,l1 1 and 11 2 islessthan orequalto 5°, zis lessthan or equal to 0.32 em (1/8 in.), andw is less than or equal to 0.08 cm(1/32 in.) (reference11.0 in SA,-,tinn 1

**F'l~O).** 

# [ ACCEPT 

# I PitotTube Calibration Form 2001 Yearly Calibration

### Air Quality Services, LLC 425 Main **Stre~t** Evansville, Indiana 

### 47708

Phone: 

### (812)452-4785

Fax: 

### (812)452-4786 

### TEMPERATURE SENSOR CALIBRATION DATA FORM 

### (Flow) DATE:

Equipment Name Probe Probe Probe 

### 12-Jan-11 Identification

Number PR-3A-T Pitot P-3A Meter In 1311 Meter Out 

### 1311 Sa'rrlple Head . UMA-4 Sample Head
a Allowable tolerance 1.0% Calibrator: Calibrator: Reference Thermocouple Thermometer Potentiometer Temperature,°F Temperature,°F 

### 67 66 67 66 63 65 63 65 65 67 66 65 Temperature Difference,a Absolute R,% 

### .0.2% 0.0% 

## ·o.o% 0.2% 0.4% 0.4% 0.4% 0.2% 0.0% b Referes to Table 5-1 of Method-S 

# IACCEPT ] DLO Continuity Temperature

Check Difference,b Yes/No Absolute °F 

### y 1 

### y 0 

### y 0 

### y 1 .Y 2



### y 2 

### y 2 

### y 1 

### y 0 

# IACCEPT 

# I
"A single-point calibration procedure that checks the operation ofa thermocouple system within plus or minus 

### 1.0% ofthe absolute measured temperature is all that is necessary to check the system for the presence ofa disconnected wire junctions, other loose connections, or a potential miscalibrated emf readout. A system that performs accurately at one temperature is expected to behave similarly at other temperatures."

### Air Quality Services, LLC ' 425 Main Street

Evansville, Indiana 47708

Phone: (812)452-4785

Fax: (812)452-4786 

### TEMPERATURE SENSOR CALIBRATION DATA FORM DATE: 12-Jan-11 Calibrator: Calibrator: DLO

Equipment Identification Reference Thermocouple Temperature Continuity· Temperature Name Number Thermometer Potentiometer Difference,a Check· Difference, 0 Temperature,°F Temperature,°F Absolute R,% Yes/No Absolute °F Probe PR-5C 62 61 0.2% y 1 Probe 0.0% 

### y 0 Probe 0.0% 0 Pitot 0.0% y 0 Meter In 1314 62 62 0.0% y 0 Meter Out 1314 62 62 0.0% y 0 Sample Head UMA-2 

### 61 59 0.4% y 2 · Samplec;Ffea<;l·

**\)i;~(!UJI\ilJI,\.-6** 61 59 0.4% 

### y 2

sample Head 0.0% 0

.a Allowable tolerance 1.0% b Referes to Table 5-1 of Method-5
"A single-point calibration procedure that checks the operation ofa thermocouple system within plus or minus 1.0% ofthe absolute measured temperature is all that is necessary to check the system for the presence of a disconnected wire junctions, other loose connections, or a potential miscalibrated emf readout. A system that performs accurately at one temperature is expected to behave similarly at other temperatures."

### Pre-TestMeter Calibration - Critical Orifice Calibration 

### The calibration set-up for the dry gas metering system using the calibrated critical orifices in lieu of the wet te.;:;t meter is given in Section 16.2 of EPA Method .§.' 

### A 

# .. minimum ofthree critical orifices were selected that are appropriately sized to cover the range of flow rates between 10 and 34 liters/min (0.35 and 1.2 cfm) or the expected operating range. Two of the critical orifices bracket the expected operating range. Before calibrating, the system was warmed up for a period of 15 minutes to equilibrate the temperatme conditions through the DGM before a leak check of the system was conducted After determining that the meter box is lealdess, the barometric pressure and temperatures ofthe inlet and outlet ofthe DGM were noted. A minimum voluri1e of0.14 m3 

### (5 ft3) 

### was used at all orifice settings. All the data was recorded on a form similar to, that presented in Figure 5-5 ofEPA Method 5. The DGM calibration factor (y) 

### and the orifice calibration factor (.t.H@) was calculated at each orifice setting. ·The average ofthe y values was used in the calculations.. Post Test Meter Calibration Check- Approved Alternative Method (ALT-009) 

### PosHest meter calibrations were conducted on the dry gas meters after the test to check their accuracy against the original pretest calibration. Post-test meter calibrations to detennine the Yqa 

### were conducted on the dry gas meters to check their accuracy against the original pretest calibration. This post-test calibration was made using the alternative procedure defined by EPA as ALT-009. This procedure was performed on-site using the data collected for each ofthe test runs. It 

### is preferred by EPA because it eliminates the questions about possible . meter damage during transport 

## after the emission test ·and, because the calibration data is available in the field immediately following the test, 

## it eliminates the costly travel, remobilization, and scheduling of a retest should the meter fail the post-test calibration. Additionally, the metering system was subjected to the leak check procedure defined in Method 5 Item 5.6. A complete copy of EPA ALT-009 is available from EPA from the EPA website at 

## http://wee. epa.gov/ttn/emc/.

i: i i.

### Digital Indicators for Thermocouple Readout A digital indicator 

## is calibrated by feeding a series of millivolt signals to the input and · comparing the indicator reading with the reading the st'gnal should have generated. EIT6rs did not exceed 0.5 percent (%) 

### when the temperatures were expressed in degrees Rankine. Calibration data are included in the following Thermocouple Digital Indicator Calibration Data Sheet(s).



# I :·1...

. **et:-~::-::.~~--.::-:-~~~~?Z"1~--«o::j;~i.t~r-** METHOD 5 DRY GAS METER CALIBRATION USING CRITICAL ORIFICES **~ ~~~~W&@~·~OOF~mOOWffllmi~'~&!Mmm~m~~~·~®i~i~~~~~~~~~~**  - or&

1) Select three critical orifices to calibrate the dry gas meter which bracket the expected operating range.

2) Record barometric pressure before and after calibration procedure.

3)

Run at tested vacuum (from Orifice Calibration Report), for a period of time necessary

to achieve a minimum total volume of 5 cubic feet.

4)

Record readings in oullined boxes below, other columns are automatically calculated. INITIAL FINAL METERSERIAL#:l **·-·~** I

BAROMETRIC PRESSURE (In Hg)c;:;:;J I

29.84 I
CRITICAL ORIFICE SET SERIAL# 1367s

K' TESTED FACTOR I

VACUUM RUN# I

· (AVG) (In Hg) n t_;j n w3 n w 0.8306 0.8306 0.8306 0.6444 0.6444 0.6444 0.501 0.501 0.501 15 15 15 17 17 17 18 18 18 994.400 1,005.20 1,016.010 1026,822 1,035.225 1,043.635 1,052.043 1,058.590 1,065.140 USING THE CRITICAL ORIFICES AS CALIBRATION STANDARDS: 1,005.20 1,016.010 1026.822 **1~035.225** 1,043.635 1,052.043 1,058.590 1,065.140 1,071.702 10.80 10.810 10.812 8.403 8.410 8.408 6.547 6.550 6.562 64 62 62 63
65 62 64 65 66 64 65 69
66 65 65 71 67 65 67 71
65 66 67 72
66 67 68 72 67 68 69. 72 **_6_~--** L ____ **~9**_ ___ 69_ t______l_2_ 65 69 71 71 72 72 72 72 **~** DGM AVG 63 65 67.25 68 68.75 69.25 69.75 70.25 70.75 ELAPSED TIME(MIN) 8 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 AVG(Pb") 29.84 § 8 8 E§ 2 2 § 3 3 10.9780 10.9463 10.9016 8.4275 8.4226 8.4126 6.530 6.5268 6.5326 IF Y VARIATION EXCEEDS 2.00%, ORIFICE SHOULD BE RECAUBRATED 10.8306 10.8203 10.810 AVG= 8.3867 8.3787 8.3947 AVG= 6.5204 6.5142 6.5080 AVG= 0.9866 0.9885 0.9916 1 0.9889 -0.53 0.9952 0.9948 0.9979

'1. • 0.9959 0.18 0,9985 0.9981 0.9962 0.9976 0.35

The

f911owing equations are used to calculate the standard volumes of air passed through the DGM, Vm (std), and the critical orifice.

V" (std), and tl1e DGM calibration factor, Y. These equations are automatically calculated in the spreadsheet above. AVERAGE DRY GAS METER CALIBRATION FACTOR, Y = **c~**

(1) Vm (std)= (2j I V"(std)=

' (3)1 Y= ::-:-=:_:--:J:.:::. :.:..:.::;::;:_;.:..-;:;:.:.=-:, **-.-::-~** K, V m Pbar + (nH/13.6) = Net volume of gas sample passed through DGM, corrected to standard conditions

K,

= 17.64 'Rfln. Hg (English).0.3858 'Kimm Hg (Meine) · .

T. m p· e **K'~** T m = Absolute DGM avg. temperature ('R- English, 'K- Meine)

= Volume of gas sample passed through the critical orifice, corrected to standard conditions

T.mb

= Absolute ambient temperature ("R- English, "K- Metric)

K'

= Average K' factor from Critical Orifice Calibration Yer(std)

= DGM calibration factor
Vm

(std) **·---....,..-~----"---~~--__:_.;..:_.**_____ **--..;._..;.__--'c:--'-......C·-~~--~~------·---------·-** .. AVERAGEAH@= 1.7760 nH@= . . 2 . .

( 0.75 e ) <.\H {Y.m(std)) Yc,(std)

\ Vm '1. • 1.8523 1.8487 1.8443 1.7645 1.7654 1.7570 1.7155 1.7171 1.7188

### Alternative Method 5 Post-Test Calibration

ApprovedAlternative Method (ALT-0009} Calculation utilizes the following: 0.0319 = (29.92/528)(0.075f (in. Hg/ 0/R) cfm2

29 = dry molecular

### wt. ofair, lb/lb-mole 13.6 =specific gravity of mercury· G Total run time (minutes): Vm Total sample Volume (dcf): T m Ave. Dry Gas Meter Temp(deg F): in Rankin= Pbar Barometric Pressure (in.Hg) DH@ Oriface meter calibration coeficient (in.H20) DHave Ave. Oriface meter differential (in.H20)



### Md dry molecular 

### wt. ofstack gas (lb/lb-mole) DH 112 Ave. Sq. Root DH (in. H20)1/2

y Meter Box Correction Factor (gamma)

Yqa = dry,gasmeter calibration check value Yqa 

### = Average 

# Pass or Fail(+/-) 5% ·-· ..... **~k** 

### v 

# =- •q.. , 

# ----------· t: • 'I ...

**~·~..,,** \ 

# M. c

**~~~-·I** 

# l: .! MB# 1314 9/5/2008 9/5/2008 9/5/2008

. Run 1. Run 2 Run 3 144 144 144 132.618 132.436 133.161 54.2 63.2 61.4 514.2 523.2 521.4 30.04 30.04 30.04 1.8490 1.8490 1.8490 2.875 2.79 2.92 28.96 28.96 28.96

1.70 1.67 1.71 0.9941 0.9941 0.9941 Run 1 Run 2 Run 3 0.9977 0.9929 1.0083 0.9996 

## ·I 

# 0.56%1 

# Result:! Pass FORM ID#

.· FY;· 

## 'v-•·' .l .'!"I'J

### Alternative Method5 Post- Test Calibration ApprovedAlternative Method (AL T-0009) Calculation utilizes the following: 0.0319 = (29.92/528)(0.075) 2 (in. Hg/ 0/R) cfm 2

29 = dry molecular

### wt. of air, lb/lb-mole 13.6 =specific gravity of mercury Total run time (minutes): Total sample Volume (dcf): Ave. Dry Gas Meter Temp(deg F): in Rankin= Barometric Pressure (in.Hg) DH@ Orifice meter calibration coeficient (in. H20) DHave Ave. Orifice meter differential (in.H20)

Md dry molecular 

### wt. ofstack gas (lb/lb-mole) DH 112 Ave. Sq. Root DH (in. H20)112

y Meter Box Correction Factor (gamma)

Yqa = dry g'as'meter

**c~llbration** check value Yqa 

### = Average



# .Pass or F?Iil (+/-) 

# 5% 12/1/2010 Run 1 144

131.357

49.02 509.02

30.04 1.8690

3.09 29.1 1.76 1.0036 Run 1 1.0307 M81647 12/1/2010

Run 2 144 125.526 56.4 516.4 30.06 1.8690

2.78 29.1 1.67 1.0036 Run 2 1.0304 FORM 10#5-0009



## ,.

12/1/2010

Run 3 

## I 144 133.594 ' . !

. t 52.6 512.6 

### i. 30.06 1.8690

3.14 29.1 1.77 1.0036 Run 3 1.0247 1.0286 

# 2.49%

# I Result:

# I Pass



# .I

. fi ' '

:
---------------------'{;">" METHOD 5 DRY GAS METER CALIBRATION USING CRITICAL ORIFICES

1) Select three critical orifices to calibrate the dry gas meter which bracket the expected operating range.

2) Record barometric pressure before and after calibration procedure. ..

3) Run at tested vacuum (from Orifice Calibration Report}, for a period of time necessary

to achieve a minimum total volume of 5 cubic feel

4)

Record readings in outlined boxes below, other columns are **automaticall~** calculated. INITIAL FINAL BAROMETRIC PRESSURE (In

**Hg)~** J 30 J CRITICALORIFICESETSERIAl1tC

1v"''"" 1

K' TESTED FACTOR I VACUUM **RU~**

(AVG) (in Hg) GJ, s 0.8306 16 0.8306 16 0.8306 16 GJ 3 0.501 19.5 0.501 19.5 0.501 19.5 Gl s 0.6444 18 0.6444 18 0.6444 18 530.166 541.320 552.542 563.7230 570.451 577.166 583.885 592.485 601.075 541.320 552.542 563.723 570.451 577.166 583,885 592.485 601.075 609.669 ' 11.154 11.222 11.181 6.728 6.715 6.719 8.60 8.590 8.594 • 100 w w
• 00 M **~**
• M M **~** 90 95 94 96
90 94 94 95 90

94 94 95 90 93 93 94 90 94 94 94 90 94 94 94 • **~** 00 95 95 94 94 94 94 DGM AVG 98.25 96.5 95.75 95 94.5 94.25 93.5 94 94 ELAPSED TIME(MIN) a 10.00 10.00 10.00 10,00 10,00 10.00 10.00 10.00 10.00 **~11~~** ENVIRONMENTAL

SUPPLY COMPANY
AVG (P 0 .,) 30 § 7 7 § 3 3 § 2 2 10.6754 10.7743 10.7494 6.4393 6.4326 6.4394 8.2714 8.2543 8.2582 IF Y VARIATION EXCEEDS 2.00%, ORIFICE SHOULD BE RECALl BRA TED 1 10.6281 0.9956 10.6281 0.9864 10.6281 0.9887 AVG=

0.9902 -0.45 6.4106 0.9955 '1. • 6.4106

0.9966 6.4106 0.9955 AVG=

0.9959 0.12 8.2455 0.9969 8.2455 0.9989 8.2455 0.9985 AVG=

0.9981 0.34

USING

THE CRITICAL ORIFICES AS CAUBRATION STANDARDS:

The

following equations are used to calculate U1e standard volumes of air passed through the DGM, Vm (std), and the critical orifice,

V 0 (std), and the DGM calibration factor, Y. These equations are automatically calculated in the spreadsheet above. AVERAGE DRY GAS METER CALIBRATION FACTOR, y =[--o:9947_]

(1) Vm (std) = (2) v" (std) = (3) Y= K, Vm Pb,.+ (AH/13.6) = Net volume of gas sample passed through DGM, corrected to standard conditions

K,

= 17.64 'R/in. Hg (English), 0.3858 'Kimm Hg (Metric)

Tm P e **K'·~** T m ::: Absolute

**~GM** avg. temperature ( 0 R **~** English, 0 1( - Metric)

= Volume of gas sample passed through the critical orifice, corrected to standard conditions
Tamb:::

Absolute ambient temperature ( 0 R- English, °K- Metric)

K'

= . Average K' factor from Critical Orifice Calibration

Vee

(std) = DGM calibration factor

Vm

(std) AVERAGE AH@ = 1.7406 LIH@= ( 0.75 8 ) 2 LIH

{Jm(std)) **V~,(std)**

· · \ Vm · " . 1.7635 1.7690 1.7714 1.7030 1.7045 1.7053 1.7506 1.7490 1.7490

### Alternative Method 5 Post-Test Calibration ApprovedAlternative Method (AL T-0009) Calculation utilizes the following: 0.0319 = (29.92/528)(0.075Y (in. Hg/ 0/R) cfm2

29 = dry molecular wt. of air, lb/lb-mole 13.6 = specific gravity of mercury G Total run time (minutes): Vm Total sample Volume (dcf): Pbar 

## DH® DHave

Md DH1t2

y Ave. Dry Gas Meter Temp(deg F): in Rankin= Barometric Pressure (in.Hg) Oriface meter cali.bration coeficient (in.H20) Ave. Oriface meter differential (in. H20) dry molecular wt. of stack gas (lb/lb-mole) Ave. Sq. Root DH (in. H20)1/2 Meter Box Correction Factor (gamma) Yqa = dry gas meter calibration check value Yqa = Average 

# Pass or Fail(+/-) 5% ' .... 

# --

**;:~** T o• 

### ,. 11' MB# 1311 9/5/2008 9/5/2008

Run 1 144 135.685 48.9 508.9 30.04 1.8490

2.96 28.96

1.72 0.9947 0.9842 Run 2 144 133.097 53.5 513.5 30.04 1.8490

2.79 28.96

1.67 0.9947 0.9787 9/5/2008 Run 3 144 137.908 50.6 510.6 30.06 1.8490

3.05 28.96

1.75 0.9947 0.9842 0.9824 

# I -1.24%1 Result:! 

# Pass FORM /0#