# 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 Solutions TMM:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## ii 

# 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-1M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## iii 

# 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 ..........................................................7M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 1 

# 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 Ai r 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 roofmonitor 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.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 2 

# 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 

### acfm a 

### dscfm b 

### 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 monito r 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 em ission rates in pounds per hour and pounds per ton of aluminum produced.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 3 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, μ g/m 3 a 5.510E+00 6.890E+00 3.117E+00 5.172E+00 Mass emission rate, lb/h b 6.23E-02 6.51E-02 3.46E-02 5.40E-02 Mass emission rate, lb/ton c 1.01E-02 1.30E-02 6.29E-03 9.79E-03
Arsenic

Concentration, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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 μ g/m 3 = Micrograms per cubic meter. b lb/h = Pounds per hour.

c lb/ton = Pounds per ton of aluminum produced per hour.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 4 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, μ g/m 3 a 4.960E+00 7.027E+00 4.219E+00 5.402E+00 Mass emission rate, lb/h b 6.807E-02 8.692E-02 6.240E-02 7.246E-02 Mass emission rate, lb/ton c 1.216E-02 1.774E-02 1.114E-02 1.368E-02
Arsenic

Concentration, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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, μ g/m 3 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 μ g/m 3 = Micrograms per cubic meter. b lb/h = Pounds per hour.

c lb/ton = Pounds per ton of aluminum produced per hour.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 5 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/h b 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 c ubic 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/h b 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.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 6 

# 3.0 Process and Sampling Location Descriptions

3.1 Process Description Ormet uses crystalline aluminum oxide (Al 2 

## O 3 

## ) 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 Al 2 

## O 3 

## by the carbon from the electrode
occurs as follows:

2Al 2 

## O 3 

## + 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 aluminumproduct is tapped every 24 to 48 hours beneath the cryolite cover using a vacuum siphon. Emissions from the pot lines are controlled by alum ina-injected dry scrubber systems. Table 3-1 summarizes the process production rates. Additional process data are provided in Appendix F.

Table 3-1 Production Data a 

## 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 DescriptionThe 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 hasM:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 7 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 f our 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.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 8 

# 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 Federa l Register. The modified procedures of EPA Method 14A, “Determination of Hydrogen Fluorid e 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 modi fied 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 dige st 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.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 9 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.M:\150125-01\ICP Fug Mtls HAP Rep - 7-13.doc\sm 

## 10 

# 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 A ssurance 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.