2010 PRIMARY ALUMINUM MACl' 

l'ESl' RESULTS·'FOR THE ANODE BAKING RING FURNACE 

Performed for: 

eALt:OA 

ALCOA INC.-WARRICK OPERATIONS 

Highway 66 

Newbti!gh, IN 47629 

December 1, 2010 

Submitted by: 

Air~auality services 

Air Quality Services, LLC 

425 Main Street 

Evansville, Indiana 47708 

Phone: (812) 452-4785 

FaX.: (812) 452-4 786 

AQS Project# 10736-11-001 
) 

--- -- --·- ------~-·--- --- ---------- -·- --·- --------

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. 

Report Writer 

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 Flow Rate ........................... 9 

Stack Gas Diluent Content ......................................................... 1 0 

Stack Gas ·Moisture Content ...................................................... 1 0 

. 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- Combined Reactor #2 and Reactor #3 .................................. 1 

Test Program Contacts ................................................................................. 2 

Summary of Reactor #2 PM Test Results .................................................... 4 

Summary of Reactor #2 POM Test Results ................................................ .4 

Summary of Reactor #3 PM·Test Results ................. : .................................. 5 

Summary of Reactor #3 POM Test Results ................................................. 5 

Summary of Combined Reactor #2 and Reactor #3 Test Results ................ 5 

Field Equipment Calibration Summary ..................................................... 12 

LIST OF FIGURES 

Schematic of Sample Location- Reactor #2 ............................................... 8 

Schematic of Sample Location- Reactor #3 ................................ : ........ : ..... 9 

acfm 

dscfm 

gr/dscf 

lb/dscf 

lb/hr 

fps 

LIST OF ABBREVIATIONS 

actual cubic feet per minute 

dry standard cubic feet per minute 

grains per dry standard cubic foot 

pound(s) per dry standard cubic foot 

pound(s) per hour 

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 of the Anode Baking Furnace Ring (A446), Reactor #2 and Reactor #3 ,Joc~t·ed at Alcoa 

Inc.- Warrick Operations (Alcoa) located near Newburgh, Indiana. This testing V'Va=tS pursuant to 

the Part 70 Operating Permit #T173-6627 -00007 and 40 CFR Part 63. 

The results of the 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 

Green Anode 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;am lliat -- ' 

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 of this test program, the MCEM determined by Method 315 is 

considered to be POM by USEP A. 

Messrs. Paul Siegel, David Oligher, Chip Mulzer, and Marshall Peters, of AQS, 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 TEST RESULTS 

On December 1, 2010, Reactors #2 and #3 of A-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 from this .test program were delivered to Alcoa's on-site laboratory.· 

The green anode baking ring furnace consists of three (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 of the three test runs. Reactor #3 has a 

single emission stack with a diameter of 46.25 inches. 

·The process rate during this testing program was 19.94 tons of green anod~ input per hour. 

Complete tabulations of measured parameters and calculated results are included as Appendix B. 

GAS FLOW AND 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 with PM and POM testing. 

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% N2 ; 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 of Reactor #2 and Reactor #3 

according to the procedures prescribed in EPA 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 of green 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 of green 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 of green 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 OF REACTOR #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 of interconnected refractory flues connected to side main exhaust 

manifolds. Products of combustion 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 with natural 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 in the 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 

of organic 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 of the Alcoa designed A446 reactors. The alumina is fluidized by an auxiliary fluidizing fan blowing ambient air through 

~-"-~.~~~'~'~'':·~·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. The fluid 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 of the-fluid beds to collect 

entrained alumina particles and other particulate matter present in the gas stream. 

The anode bake furnace primary system consists of a 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 compmiment has 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, Title 40, Part 60, ( 40 

CFR 60) Appendix A 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 of the 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 of the 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 of 24 traverse points were used at each stack for 

the velocity and particulate measurements, 12 points per test port. 

Copies of the 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 

STACK DIAGRAM FOR REACTOR #3 

(not to scale) 

STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE 

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 of 0.84, 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 calculated values based on the field data. 

9 
STACK GAS DILUENT CONTENT 

EPA Reference Method 3, "Gas Analysis for the Determination of Dry 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 of Moisture 

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 of a total of four ( 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 of the 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 of the 

stack gas during each test run. The results were also utilized in the Method 13A (TF) 

determinations. Moisture content worksheets are included in Appendix C. 

PARTICULATE MATTER and POLYCYCLIC ORGANIC MATTER 

· ·'EPJ\:'''Rererence Method 315, "Determination of Particulate 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 check was performed before the start 

of the 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 in the 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 of Method 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, EP A-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 See EPA 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 

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.,.,-:. 

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) )I 0.02832 

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 

C MCEM -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 

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r 

II 

Example Calculation 

Project# 10736-11 

ALCOA Warrick Operations 

US EPA Test Method-315 Polycyclic Organic Matter (POM) 

A :.446 Reactor 2 .. 

Run# One 

Calculated Parameters 

%N2 = 100.0- (%C02 + %02 ) 

%N2 = 100.0 - ( 2.5 + 17.5 ) 

%N2 = 80 

r !1Hpbar + --

V m 13.6 (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 Test Method-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 ws - -------X 100 % (sat) - ·p s 

6.691 

177 + 390.86 [ 

3144 

B ws(sat) = 10 X 1 00% ---------------------

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 

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II 

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I 

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~· 

II 

Example Calculation 

Project# 10736-11 

ALCOA Warrick Operations 

US EPA Test Method-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-sized stacks 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 stack by three 

A = 11.27 
fi 

II 

I! 

Example Calculation 

Project# 10736-11 

ALCOA Warrick Operations 

US EPA Test Method-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 l I:(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 Reactor 2 ,.. 

Run# One 

Calculated Concentrations 

V.:.···· .. IGz.: :Gonversicm •Factor, gr/dscf•to lbs/dscf 

K = 1 ( lb ) 

m 7 ' 000 (grains ) 

K m = 1.43E-04 

C MCEM: = (( 0.0246 X 1,000 ) I (( 135.685 X 0.9947 )) 

I 0.929 ) I 0.02832 

C MCEM-2 = 5.977 

7,000grains MCEMgrams X S 

4 3.6grams CuaM-1=----~--------~­

Vm(std) 

0.0246 X 7,000 C MCEM-1 = 453.6 ---------------- 141.612 

C MCEM-1 = 2.68E-03 

C MCEM -2 = C MCEM -1 X K m 

C MCEM-2 : = 2.68E-03 X 1.43E-04 

C MCEM-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 I PR 

E MCEM-2 = 0.736 I 19.940 

E MCEM-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. H20 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. H20 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, m3 

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, % by volume 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 Water Vapor 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 of 2 

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 

1 i .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. H20 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 Meter Temperature, 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-half Weight 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-half Weight 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

Air ou
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 ~ ~ 

II 

I~ 

II 

I~ 

II 

:r: 

l<l 

0 

If' 

~ 

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 

~ .

Air Qu

Nozzelln. Dia.: ---

Assumed Bws: ___

Meter Box#: ----'

Post-Test Leak Rate: 

Post-Test Leak Ck: Pilo
I 

I 

I 

I 

I 

I 

It 

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 N l). 

Filrer 

Conuin¢r No. 

Dc$CripTion of Filre-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. 

Liquid Leve-l 

'9~S j5J.,:? "!J 

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, of lmpinger 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 -

V me = ( ) - ( -0. 02) X ( 

V me= J 135.685lcu. Ft. 

2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) 

Vm_std = (

Pbar +( .L±i/13.6) ) 17.64 X Vme 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 

Bws= X 100 

V w_std + V m_std 

Bws = 10.87279 X 100 

152.4277983 

Bws = 7.13 '% 

~~<::.c: 

';0-~.f-' q .;;fl!jt:"O;Ii ~:;·::;'- "' 

Ul:8 Air Quality senrice-j FIELD DATA LIF

SHEET 

_,~ . AirOIIalit

Sample Type: =--

-

Operator:~ Nozzelln. Dia: 

Pbar· 

Ps: Assumed Bws: C02: (IV .. - ~ 

J..~ s Mf 

on{ ~I 1 

~ Meter Boldt: 

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: 

Pretest Leak Ck: Pilot: Orsat ___ 1 Stack Diameter: -~ As. 

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

Post-Test Leak Clc Pitot. 

01 

. 

P . t r· Clock Time Gas Meter Reachng Velocity Head (£\p) ( II). H20 Stack Temp. Temperature "F lmpmger 

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

Number (Mm) .p" Desired Actual Prabe Filter I

~~~t,;~[~~~~~~l.~~ :~~~~~~Eji 

l~~~~f.~ 

Jg:~:~~~~~~~f 

~.:j~~:~~~ 

~~~l1:~},~~~ 

·~~~~~~:;i~~~~~~· 

;~1

-----~-----!--------~--------------:~~~~~~~~~= , s-o /lto1 ,5t,{q.),J- ~l 

.:'·1-~Lf I-t 16'1 ;}...5] ~SJ 

~PI j_

),., (f 2. .511 . l .l - • ~ I I . g 1 I . fi _L8' I A 5 D /.. > 0 

~ 

~- "

j_ ~~ __£] q . J-1 , ~ '-1 I · q o I · q J ff3 ;!,. s-v J.. Yo 't _,_,_ S

_:l H ,t)tfo.ff{ 11 1.1'-\ 1.\ 115':1 )...51.1 A"J'i LIS" S

~±== !l-44 SS' l tl 'h·11 "!! .'0 I 

~(.. _;..So l.s J '-1 C.. 5

_l) tt. t . ~3:._ \ , \ 3 · 7-.1 1 · 1 · I 

1/~ 

~ 4 q J... '5' (} '-I ~ . 5

I 1, L<-!d_ --~-\.{l). S"D ~. () 2_.'11 'A f) .J 

~(.. A-'1 

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q \~A_ . S'J~V. lJ )-. q 5' 7, ,gJ J,.. 8" l 

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~ 

l~oCf S L; ~. J.l j ~ 5" '-. ~ )j A" .5 ___!___ff_L_ 'J..:> I A ,.r~ 'i 9 5" 

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r\:..ll._l'i3/ 6'""5'S'.i;.G>f5 .It> 

~ 

?._,D<J 1sl a"t'i J-.41 J.SV SJ 5-

t ~ 1 ~..J- J '-1.~ s- ~ , 'l-~ . 1 ' .:L • 1 ~-I J.. , 1 _ 1 7 '-~ 'J .n .z s 1 'i t.. :5

~~" 1·"\\ 1 _5)[(. 'i'/ , 1 c ;c.;. '-1 l-. ~ I lfo ;L ~ 1 ;t_ ~~ LJq ___.

1§. 1 - ~·.\~ I . ___ _j3_e...._1_1~ __ ._j_L __ J...:l!2_ __ l__!__~ ___ J ~'j ____ 'J..'Hf ____ U!!_ ___ _j_i_· _ _5

. \ ·~ '),..1) s' "-~- ___ .__iL_-J:..-!k__ J.. 7 I f'f ;>. 'i 8' :J.. .5" t) j-{/ j""/

_e-l:1-1.. 5t.'{~_§L_ _ '.LD... ________ .;L.:L1._ .. L-.J_:._Y ___ _j_§_h__ ____ ~:L_k et .FJ SJ-

_££

---~-J..'::.a+---- _3__~.1.:..U _____ t_':2 ____ _ ]_J.J,' __ ,..3~-- _Lfi ___ .l:._!i_J -L-L'LL_-r!-?- S 

l----.. 2._ }_~-~--~- ------- .. 5 ~I() ,_[_l--- - ____ L _ _l_, -----~--•-,[ ~ . 3 . ~ ---- ___ !_:[ "']____ __ _l__'i_2-____ ·V 'L9_L_.f_!J_ ____ -f_

_

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~ 

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: 

______ .,i.lP._!..i.fL 

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~~0-----L,-9~g'--f--·l_:.~;-~ 

_____ L.·.~------~~u. --f---]_d 

1 0 

.. _______ LY.f___ -~'::U ___ -:~J,..(_"~-.SS 

______ [_

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Air Quality services FIELD DATA SHEET lant: Sample Type: Operator: ....J-:"-"-.-""---'---- Sampling Location: lle.t.c..-hc ;).. Sovt\-, Pbar: Ps: 

Run Number: {W Q Date: C02: 02: -------- Pretest Leak Rate: cfm@ __ in.Hg Probe Lenglhffype: .Pitol#: -------- Pretest Leak Ck: Pitot Orsat: ___ Stack Diameter: As: 

Travers 

e Point 

Number 

Sample 

Time 

Min) 

Clock Time 

.(24-hr clock) 

Gas Meter Reading 

(Vm) ft3 

vm= 

\~~-; 

f:!

Air Qual

Noz.zelln. Dia.: ---

Assumed Bws: ___

Meter Box#: ____ _ 

Post-Test Leak Rate: 

Post-Test Leak Ck: Pilot: 

T
SA.lviPLE RECOVERY DATA 

PLANT .b_r,..~OA.- kkr~Jo Opu<4t;,O>\$. Run No. K 2... ~ Z. 

DATE n ... /i/

I I 1o Samplc:BoxNo. WfAA IB JobNo. lt>I3Lr.-\l-oOI 

SAl\ 1PLE LOCA. TI 

ON_--!:{Z::....!M~L::.c-~h::lll...c_f:J-~2.~----.!.A::::::::..;:<-t-EY.::L!.I:k2...-_____ _ 

,. 

I"RAIN,.l.".)REPARER --+e_..!.._S-dJ.,'e.,~Tr::;t.· :s:.:l~--------------

1{R0NT HALF 

AcciOnc: 

Cuntn.:incr N..:.1. 

Filter 

Cont::liner No. 

Dc-scriprion of filter 

Liquid 

_____ Level Iv!arked ___ _ 

San.J.pks StOred ~md Locked 

Sealtd ----

S ca.led -----'--

N.e.~ :z 74. 7 

2 zo. '-1 

___:._.---:: 

o3. 7 o- BACK HALF/MOISTURE 

C omqiner N u. JI(eC-!2 '"357. o 

Jo?}.B 

Liquid Level .. Sealed ___ _ tlf?.z.. I 

INITAfL 

IMP. NO. CONTENTS VOL WEIGHT (grams) 

(ml) INITIAL FINAL NET 

"] DI 1.-\.2-D too 7-53. 8 tJD2./ ;¥8.3 

2 It> ::r: 14 0=' toe 7 '-f'-f'-, 813.fo .b8.9 

3 e~b.t - lo 571 ·~ b[pB ,3 I L '2... 

4 :SIL.Ic:.4,-~!Sl. 250""" 885,7 1JJ/,5'. 2S>. B 

5 

6 

TOTAL 30~1.3 .'~298.5 2.5{.'L 

· Description Df Jmpinger Catch:------------------

.~-----------··---

-----~ 
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. Ft. 

2. Volume Metered, S~andard Conditions (68 F, 29.92 in.Hg) 

Vm_;;td = 17.64 XV me X Y X ( P,, + ( f'!-l I 13.6) 

(460 + T m) 

Vm_std = 2335.387575 ( 30.24514706 

513.5 

Vrn_« ~ EJ dscf 

3. Volume Water Vapor Collected, Standard Conditions: 

Impingers & Silica Gel = 

4. Perce11t Moisture, by Volume 

Vw std 

Vw.;.std = 0.04715 X (Wt-Wi) 

Vw_std = 0.04715 X 257.2 

Vw_std = 12.12698 

Bws = X 100 

V w_std + V m_std 

· Bws = 12.12698 X 100 149.6812948 

Bws = 8.10 '% 

) 

) 

··-~ 
~J.:.U· Air Quality services Plant: 

Sampling Location: 

, -,..-~, 

~· -" 

Run Number: '!h{ve, Date: I'J.. -1-11) Pretest Leak Rate: t fl& 0 Afm@ {IJ in.Hg Pretest Leak Ck: Pitot: / Orsat: 

Travers 

e Point 

Number 

Vm= 

""""''~·f,;c-if.~Q;?" 

FIELD OAT A SHEET 

i 0 .. ()(, 

C02: IN .:!. ' 5 

Probe Length/Type: ·f (lJ A 

fi H= Ts = 

- - - 

Assumed Bws: 

_ _,.,

Meter Box#: 11 II 

T
I Ol 

~ 

.s 

I :if 

©) (]) 

0. :c ::l 

0 <I 0 ro 0 f!1 

I E .@) 0 (]) 

.c .§ I- 'i! 0 

~·~ ~ 

I e 

w: II 

lli~ ;;..: 

2 

I~ 

I e iii 0:: 

'a: a; -"" 0::: () 

oi ~ -"" 

ro ~ 0 ~ (]) (]) 

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o. 1/) 0 0 

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I 

I 1-

w II 

w L: I~ ::r;: .8 

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1- II 

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Sampling Location.1, ,. !1\ ~, v , v , , · • • · 

Run Number: tb ( f {..Date: _____ _ 

··~,·~r~~-;f:f01 

FIELD OAT A SHEET 

----------- Operator: , v~- u 

-------------- Ps: C02: 

02: ------------- Pretest Leak Rate: cfm@ _. _ in.Hg I Probe Length!Type: Pitot#: Orsat: Stack Diameter: As: 

Clock Time I Gas Meter Reading (24-hr clock) (Vm) ft3 

-

-

Nozzelln. Dia.: 

Air Q

Assumed Bws: 

Meter Box#: 

Post-Test Leak Rate: 

l
I 

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SAlvf.PLE RECOVERY DATA 

PLANT AJ~_.damc~ op¢/'d~/16 Run No. R 2 ... 3 

DATE ~potD SampltBoxNo.tiJiiA-/5 JobNo. \o"]3(,..-\\-ool· 

S_'\i\lPLE LOC A Tl ON _ __.}<...!:~==::..or-_2.._,.____--'--_ _._A~-_Y.:_'-\-_;_\o=---------

TRAIN PREPARER -+-£_,_ ..... S~,c:r;.::::..=-=e:L-'---"------'-------------

S"'\.MPLE RECOVERY PERSON _ _,_p~· ~5"""-'-'ta==--"'---.-=-e:L-=--------'----

FRONT HALF 

J\.cciOnc 

Cunr<lincr Nu. 

Liquid 

Level h'farked Staled ------- ----- ----

Filter 

Conuintr Nu. 

Dc.scriprion of filrer 

Sampks Srored ~Uld Locked 

BACK HAlF/MOiSTURE 

Conrtlin.::r No. 

Liquid Le:vd 

IIV1P. NO. CONTENTS 

bi H-2-0 

'I 

"t>"' .Wz..O 2 

. , 

,.) EM_Pb~ 

4 ~ll..tCA Gte:l. 

5 

6 

TOTAL 

INITAfL 

VOL 

(mil 

loo 

IDO , .. 

..-. 

250 -/;-' 

Sealed ___ _ 

Sealed· ----

WEIGHT (grams2 

INITIAL FINAL NET 

1'7 1./, z &,82,8 /OB.b 

156. 2 B!SI5 b5./ 

lo 5S", 2 b 68. 1

-l /3.2 

,!t/b. 'I 881.7 35'.3 

302.6.0 

~ . 

t32't8. '2- 1. z:z ''Z-

. . 

~. Dc:.s.:rip1ion uf ~mpinger Catch: _ 

J . 

-·-

Ac.e..b 3~Z · 2-

3.e> ::3 ' "7 

~0 m~~t- · 33&. 1 

/'12. 7 

Ttf b.; d 
I 

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EPA METHOD 4 MOISTURE CALCULATIONS 

PLANT: Alcoa Warrick Operations DATE: 12/01/10 

SOURCE: A-446 Reactor 2 (POM train) RUN#: three 

1. Leakage Correction for Volume Metered: 

Vmc= Vm-(Lp-La)xOV me = V m - (Lp - 0.02) X 0 -

Vmc= ( )-( -0.02)x( 

V me= 137.908fcu. Ft. 

2. Volume Metered, Standard Conditions (68 F, 29.92 in.Hg) 

Vm_std = 17.64 X Vmc X Y X ( P," + ( ,1\tJ /13.6) 

(460 + T m) 

2419.803825 ( 30.28426471 

510.6 

Vm_std = 

vm_""=B dscf 

3. Volume Water Vapor Collected, Standard Conditions: 

lmpingers & Silica Gel = 

4. Percent Moisture, by Volume 

Vw std 

Vw_std = 0.04715 X (Wt-WD 

Vw_stct = 0.04715 X 222.2 

Vw_std = 10.47673 

Bws = X tOO 

Vw_stct + Vm_stct 

Bws = 10.47673 X 100 153.998037 4 

Bws = I 6.80 1% 

) 

) 
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rPi~;;:;T-

-~--------- I S9rnple Typ<:!·:--~:.ru£-- ----- Opf:ralor· 11f~----=---- Nr;zzel ln. Dia ~- _._a.~~up _

Sa1npilng Location __jk_Q..~t__ 'f%.3 A-4::.\lo I Pbar· __'5C>.o&__ __ Ps· __ :_.1r1___ Assumed 8ws: 

_____!dl

Run Number _j)l).f...__ O~te . ..Ja::....\..::.._\1)__ C02: _c,._Q_______ 02 

__ .;{__o_._Q__ Meier Bo>.-lt: 

-~.1_ Y

I Pretest Leak·Rale: ......oo_:i cfrn@ __tcCin Hg I P1nbe LengthrType:__E\l:...SL ____ Pilol# ~C.-I Post-Test Leak Rate: _.(.!_

F'1etesl Leak Ck. P1io!. ____ 7 ___ 01sat. _____ I Slack Doameh;:r. ------------ As. ------- Posi-.Tssl Le.al< Ck· Pilot· 

-

l~'U'-::·:"8~~f:5T--?f:;'¥£.~t,~p1::-¥.~''"-"';·,~~~~iE-

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; fravers 0ample I . . t 

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Differential~ 1 i . 

1 p . l - I Clor:k T1ms Gas Meier Readong Veloc11y Head (rep) · ( H)_ -l Star:k Temp. Temperature "F J lmponger T 

~ 

Din Time ; (2> h ' •k) (V I [13 - . H20 {', tn I 20 {Ts) T "F e

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J),\_·i·f · __ ta_:,J_:_lQ __ S::m1pk Box No. u.MA-t 

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l 

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INITA(L 

VOL WEIGHT (grams) 

(ml) INITIAL FINAL 

\ 'C ~ Lo(\~.5 78S.L/ 

\OQ _'7 ~ '3 '_Lj &3?.0 

b ~?, dk-7 t'/1. 6 

d- )()i' ~ ~ ~ .d- 1~~~ (:, 

I 

2462..& .317?.1., 

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c,t:>~ript.iLHl odmp.ingr:r Ca[ch: -----------------------

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I : 
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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 X Vmc X Yx ( P,., + ( L'!J /13.6) 

(460 + Tm) 

Vm_std =· 2325.579169 ( 30.25139706 

514.2 

vm_..,=B dscf 

3. Volume Water Vapor Collected, Standard Conditions: 

lmpingers & 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 

Bws = X 100 

Vw_std + Vm_std 

Bws = 10.59932 X 100 147.4177152 

Bws = 7.19 1% 

) 

) 

,, 

., 

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Air Quality senrices 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 Run Number: 

)~o Date: \J-\-\0 Ps: -~~ C02: 0.6 

_ 02 -~«=0.'-'-'0~-

t:J?

Air Onality 

Nozzelln. Dia : ~-

Assumed Bws: Ca9'o 

Meter Boxlt: 

~ 

Post-Test Leak Rate: 

~ 

Pretest Leak Rate: -00"":1 cfm@ $ in.Hg Probe LenglhfType: PrA- 5C.. 

@F;~;~:;;~~;~~;j,;~;i~:i!,"t!~~~~:~P.;;~~)}~~{:?~~;;~;,;;~;:~~~~~~~~~:~~~~:f~~~~;;~it~~i~,~;;~t~V;;;:~~~¥.!*;~~k::::::~;;st 

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Leak 

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1 

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. 

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1 

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e Pain\ 

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Numher (Mm) 

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____ as.L_~~f---:5_L-r--Lb.

f-J.L __ w._~c r--

_ J.l_f:i3_.J.S_ ___ ---L~o__ _ _2.0.0 __ _______;~._.__r;__r-___1]£ 

__ -~-c--_;z-~~£5"_ 1 lnL 

__ 5 _____ ~~t>-_1 ______________ &~~~~ . _____ /_.._2_ __ ___3cLIL ___.3,,;>:_ ___ __1~$__---~+-;s-~-Lt._L~~

1_lP __ ~'W..t----c-- _____ S.c__S_Jg _____ ____ .. _l,_Q>. __ ~..$0 _ ____ 2>~S __ - ___ J_1~-- __ ___;;t;:)__.L -~---~---1-_!J,lo -----1---lM

~ __ 1_ __ 

1\. s~.o 1 c----SJ.Ol~ClJ_r--------l}:l_ -~~<fL _'"W___c __ l]jL- ,---~'1--~-:S:{ I JD't-+--l.s

1 __ :L _i2,w_&L--------r----..2~1-"!L_- ________ J.,3 ____ 1---'5.$Q ____ 3___,_L _ _ n_~---~---a-~?:1-

___ 2.5__ ~1---~c---lo3-

~-'L_~~Q_L 

_ ______.5~~l!L--r-----t!1.--~---o~-r----.1L.aL_ _L{3___r---__a_s_ci__ ~:t---1 __ t __ Lo;,t ___ r---_J.o3. 

f---16 ___ J_~_._L~U--~-------.~· !£-1----------W-. ~-'-1------_:3~- _ _l1,,3_1-_a~ __ (_.L __ H5.!L _tp_g ______ (Q!-

; ____ \LJ_Di.·l"'6.:.~+-------

___ 5__~S:~JlQ 

___________ .!l't__ ----~c.__ 

r-----;(1.,3~-

_ __jl~--r-

~~---~~_,?_5_l--r---~l-.. --

-~~--

' 

__ .\a-_ _1_¢,~~.o_LJ.S..:SL. 

'-"1P·~~-· r----.-:.li-1--«-.d<j__ 

~~:;2~~3~

4 =~~'7j!!._ 

~~~ 

2S 11.6__ --o?S~-- 1_ __ .,7__~~---j_ 

__ ~_3____ 

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_ T'n:= ~

/ 

. v 

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i-; 

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:( 

SAMPLE RECOVERY DATA 

PL\NT ~~ ~tcu;~,. - LdArc~ ,_k_ DD~a-a~ Run No._Ii~W=C""------

DATE 

1 ~.v ,(\1\ A 

\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 HE COVER Y PERSON __ ,/2___.__:);~~"-""-"-/:!.=~=-----------­

COMlVlENTS 1/e.liod 5!5: 

.. FRONT HALf 

Acewnc 

Container No. 

Liquid 

------Level !\.-larked ------ Sealed ___ _ 

Filter 

Conminc:r No. 

Description of Filter 

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 of lmpinger 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: 

V me = 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 V me 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 

V w_std = 11.4857 4 

4. Percent Moisture, by Volume 

Bws = Vw std X 100 

V w_std + V m_std 

Bws = 11.48574 X 100 145.7383306 

Bws = 7.88 1% 

) 

) 
FIELD DATA SHEET 

r~·r~

(..,;

Air Quality 

Plant: .:dJ(@- Sample Type: __Ak_ru£ Operator: ~ Noz:zelln. Dia : ·cil"'lo 

Sampling Location: _R.fM.dot ~ 3 A-AI%,) Pbar· 30.(1&.\ Ps: -.Lc Assumed Bws: 

~-- 

Run Number: ~Date ~\..:lQ..._ C02: • C 02: 

_ Cl\).S' Meter Bm:#: ) 31!{ Y

PretestLeakRate: ~cfrn@ ~in.Hg Pmlielenglhrfype: ,}ll:t-SL Pilot#: 

9\7.~SL~T Post-TestLeakRate: .QO

Pretest Leal< Ck: P~ot: / Orsat: ___ Stack Diameter. As: Post-Test Leak Ck: Pilot: 

r~ra:~?;.';!:~:~·'f:i~·~,'i~':£'i~"~fiJ.<:<~-'~~,~~~~;~~~]~.'~~~:lff~~~~~;!:~~~~!!~~~"~;~i~:~;TJ;t:5~';:;;;_::;~~';£~~:~~;:,:;:~K= 

« ;to• j :_") :;, :~ DS~

1 . T Clock Time Gas Meter Read1ng Velocity Head (lip) ( H) . H20 Stack Temp. Temperature °F • !mplf1Qer T 

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

her (Mm) · Desired Actual Probe Filter Inl

_Q 

.it 

_r~.o 

f~D \ ~ ~ !{ 3_ ~~(~~!~ 

~}~~:r:~;:~¥.~@~ 

J¥fl!.~1~1;~f\~ 

tf~;:JJl 

~.::~~;:~ 

,~~:;~~ 

·~~}~y~~l~~· 

~f.;

5SL Jt/to Lj . ~'2.. .;:>. ?J"b 2.1-l 11\ ~5.1.1_ a~~ I _ ~\..Q _5

L "}.{) 

_5_ o.o 

'0~.0 

-

Ll I 

. .'tlO 

.v - -

~;;;·,;·,;~;;-...,--:::~~·-··- -- --·-· .-----.-. 
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:Jl ARE'_R 

----~~~~~~Ad~~~~~~~----------~~-----~-----

/1 .,.--? 

: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 ------- -------

Filter 

Conuin.;.:r No. 

Dc.scriprion of filrer 

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 2 { l.b 

-----

f>-c.J2-~€. . 3D 3. 9 

z4L/. I 

-
[i 

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 

LABORATORY DATA 

.. _.:.~.---
I JAN/03/2011/MON 02:02PM P. 001 

i>. .,; 

I 

I 

" 

I 

I ·. :. : 

f 

... ,, :.. 

-· •.· .. 

•': •:..'·,· .. ·. .. 

: M~thod 315 Blank Analysis . ·.··· . 

... Blank Analysis - Particulate . 

''"'''·· . .•'. ·' 

Date: · ;ot.Z~'lO j Time: } ~- ·. .· J------'-----1--'---"'<...:.---'-----'-...... ____,.-.,---,-----,-----,--,,.--;:,,-, ..,.,...,,....,., -.,.-, ---,,,.--, ,-, -+.. .....,..j. . . .. • • 

Filter No. 

. :" .. ~. 

·. 7~ 

Room· 

.·. Humldity 

.WoRI-i) 

•'' 0 .................. . . /•. 

Final W,alght (gj ,: · · :··Tare Weight (g) 

;· · .. ·' 

.... 

.... Blank Analysis - MCEM 

bate: I . ... ,. , .. 

Time: ::· ... _-:.: 

Room " - . 

Final 'Humidity Tare of · ,Weight Gaif'il· ~~ :: Wash cbntainer Weilght (g)' •. :Blank · (%RH). Alum1r:ium· .volum~··· ·No. Dish (g) (g) (mg) (L) , .. 

Eilter.Bik .% ~- ~1ir1 .4:!1# tJv/ N/ft- .. 

1fQ5 ;?if f.ltlffl Acetone Bfk ' 4-- )16" j) o .. ·(J !·J~S" 

" .. Methylene 

Chloride Blk )%1 &.#aq &.~4t]o o.o '2..-5-o, ·. . 

Water Blk 

~ f.l.ulf- ··/f. /:2-8 I 0-~ ) vo ' . 

~~- A. ~ ·~ ~ . .,....,.. . £51)' . .' Notes: t1~ rg~l {jJ .JtY~q fJ · fft/f7 t).O 

,. Blank analysis must be·oompleted·before sample analysis ·is started. 

·• Pllter Preparation Blank must not exceed 1 mgf.fllter. 

• 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. 

. •' 

-: ... ·-. , ,. 

: .Pass/Fail 

r 

? 

? 

? 

" .· 

'i>. 

.-

' 

·i 

I 

I 

02-FORM-074 Revision Data: 20·1 0/03/31 

I 

.~f 
;-:· 

JAN/03/2011/MON 02:02PM P. 002 

< ' 

. · •' "' . 

:~ , .. :. 

• ~- •: ': -'"·. • ' \1. 

. :.: ;' ,· . .... · 

............ Method 315 .Particulate and MCEM Analysis 

:-: ·· .. , . 

... " ParticuiateAnalysls ·· "' .... 

. ~ , .. , 

Filter. :N_a:·;· ::_.·,.:,·: .::i-i : 2· . . · '. , · : .- I ''' 

. . ~-~ 

j ,1:, .......... ,,,•:.; 

Acetone Blank . . . 

Volume (.ml) .:2-.~ · " ' · ·· ' ' ' ·· ··· '· · 1--A.,...:.c-=et=on=e~b~Ja:.~.:-nk~J-~----~-r-/-:-. _ ___,;... ______ ~..,., .. ....:...:;_-'--:----,.:.. -:-:: _.....,.;,....,.:..; '~'. 

concentration (Eq.. 0 ., () 11J f 4 · · .. 315-4).(mg/mg) . . . .. · . . · . : ..... - .. .. · · ·· 

Acetone wash .. . . ... . ... 

blank ~~~)315-5) () • 0 ~' . ... • •• . .. ·: ' :· ~. _.... ::. ! 

Room 

Humidity Tare Weight (g) .Weight Gain (m.fl) • ~·. , .... 

··J-~--~··-~~(=(%~R~H~)~----~~_,~~-----~~~~--~~ 

.~ /J?J.:4-1_i)!J ,. 15o.+89~ .. .. .. 

· F.lnaf W~i~ht (g) 

Container No.1 ~·-;-#f.-~~~ .. .)go.lf8 14-

.. · · ·: · .. ·.v« ·rvr &· ~ ke · · 1111. t 1sa; } 4-.0 

.Container No.2 r-·~~ .. ·r=~~· :::::::/M-~11 ·:=:.i r;q::::::· z...~·~¥-··~-·· ~-----:---t.__··_·· ----J·· 

Total 

,. ·:•·: ., ...... : '· .• ·:v::·· .,.... ··~·,·,.~,. 

Cess.Ac.etone blank ·O .. D ., 

Weight of Particulate matter 

lmpihger$ 

Silica Geh 

Total 

...... . , 

Note 1 

Moisture.Analysis 

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

(mg) 

Note ·1 

Note 1: Convert volume of water to weight by multiplying by the density of water.. · 

(1 g/ml). 

02-FORM~074 Revision Date: 2010/03/31 . 

.· .. 

• ... : 

... ,., ' 

.· . 

. :' .:.·. 
, 

I 

JAN/03/2011/MON 02:02PM P. 003 

I .··· • : •' , . ·~ I. ~·. 

I '•'; .. · .·. 

I 

.. ·:··"." .. : ·:· . ' ...• ! 

•• •.••· .... ''1 ' •••• 

~. . . 

''r • ,, 

. . .. · .•. . . ,.. ··~ 

': .... ~ . 

. ····· 

p--1 

. . . ... M.CEM Anal~sis < ......... 

1--P_at_e;_.L / ... 1:....,2--~j·~..,--j....:...}~\:o_·.,~· .. _·.·-~-· _ ..... _ .. ·T_· i_rn_e:_..:..__+--=-0-=-./t~~-·"-· ·-=..··~__....,·;..:...:·. __ ·:..__· _·· .,··-.,..-----,--··,.,.,.··r_,.'·:_...,..,....,.......,-e--·'·_·.: _ __,..,.,,.......,..j·.:. ,-.,. , .. 

·' ···· :_ Roqm . .. : .. : . .. Tare pf Weight .... · ... j. · .. ·Metbylen~ .... 

Cpntalner · .HLimidfty' · Final. Aluminum Gain .AVcelt~~eW( ·~Ls)h. ,j · ·cnlor:ide.W.ash ·· ·· 

.. ...NO.· . ... · · [.%RH) .. :r.sJg_ht ~~)... Dls.h (~) .·.. ..(mg) .. , o ume m_ -::_. V:c!iu.t:r;~::(r.n~): .... · 

- . .. .. . .... 

J· .• ·: 

. ,,. 

Total Vt~11 -;,~~.. .. 17 ° 

Zmrotal !'v,., . ..r~ 

Less Acet~:.me Wash· Blank (nig) 

(not to exceed 1 mg/L of acetpne used) (_o.v~/JbB~)(, iff~):·~-~:::_¢~-~~:;·: · 

Ws = CaParvaw . ··· ., ... ····, .•. 

Less Methylene Chloride Wash Blank (mg)(not to · 

exceed 1.5 mg/L 'of methylene .. chforlde used) .... 

WI= c1

P1

LVrw · · 

{J-O~j.1~~t>t-)(~·?'f?~)~i; .t>:_' .. ~-~j~:: ....... ·: ... ·· .. . . : .:. :. :, : ··• . . . 

Less Filter Blank (mg) 

.. (not to exceed 1 mgffilter) 

Fb 

MGEMWeight (mg) 

mMcEoM := fm_~t~r- w~- Wt- Fb 

·Notes: ·. ·· 

0·.1 

- ·• ·Blank analysis must be completed before sample analysis Is started . 

. . ·· .•.. Filter.Pr~paratlon Blank must not !;}X~eed·'1.m.g/filter .. ' . 

·• · Aceto~e Wash Reag~rit·Bil3r.ik must n9t exceed 1 mg/L . 

• Methylf;lne.9hloride Reagent Bla.nk must not exoeed 1,5 mg/L. 

• lmplnger Water Reagent -Blank must not exceed 1.5 mg/L 

·• Room Relative Humidity must be below 50% IJVhen samples are being weighed. 

·.' 

02-FORM-074 Revision Date: 2010/03/31 

··.· 

.. · .. ; . . ... . . · .. . 

.· .. 

. ...... 
I 

I 

I 

JAN/03/2011/MON 02:03PM P. 004 

I ·-·. ' ... .. ~: , .... :..... ' 

. : .... ·:":-'·:. :; ' 

I ....... ··.-·· .... 

.. Method 3.15 .Particulate .anq MCEM Analysis 

< .. .•• . 

;,. .. .. ... .... Particulate Analysis . .. 

... 

Plant : W~~fl.k./ P!3te: ~/li/1. JO . "·/. -Run N~,"_, .· ./ ¢-2- ~ i . {i~~Jor#·z. . .. . ... . . . ... .. .... 

. Filter,No·:. · ·.$A-. . ~·· ·.•:, .. . . .. . ·' ~ .;' ·.·· . ,.·· .... ., 

· · : Amount ll(:luid·lost .. · . .. .. . .. . .... 

A/;#~·· . ·- .. ··:::···· .• .. .. ··,····· ;: ~·· . .. ~- . . durinr.l_transport ,•;." : . ·:·; Ji;···· 

Acetone Blank .... ... . . ·: ~ '•·-~- . ' : :.~ .. -:. 

~STJ .. ·. ·.: ·, 

Volume (ml) .. t·· : .... .. ·:.:: .. ·· . .. ... .. Acetone blank .. 

. ;, : .. '; ... ' .. : 

concentration (Eq. 0-0 '· .. 315-4) (i:ng/m.g). rJ. ~-- .. 

. ··. . . . .. 

Aceton(? wash .. . .. . . . . .. ·: .... :.·~. ;' ... : .. . · .. 

blank (Eq. 315-5) ~o~; • :,.1 . .. ·. -~·.:·:: () ··:.:;., .. ~ .. 

(mg) ., 

' .. .. Room 

Humidity Fir:iar Weight (g) : Tare Weight (g) Weight Gain ·(mg) 

... .' (%RH) 

~. ~S.t57 8. 1s 15~4 

. . 

Container No. 1 ~~r I~ s-.+0-3) .. ... .3r:. 4i11 ..-.z_ ::(o ·: . . ,. · . ... 

-~· . : .. 

/.tj. r; i51" /s3 -irlk!IE_ ' 5: 4- .. .. . . 

.. ' 0 •• ~ 

. Container No.2 

-~' m.~ . Lus-~: ' -. 

/ 

Total z_.a } 

(~~s Acetone blank .· 0 .. 0 

Weight of Particulate matter .. 

.·· .. 2-"B .. • '1;\_., . 

fv1oisture Analysis ...) 

.. . . ., : .. Liquid Collected Final \io:l~n;J_e (mg.) lnrtial Volume (mg) (mg) 

lmpingers Note 1"" '·· Note 1 

,Silica Gel. .. '·: . ,. .. • . ·- '. 

Total 

Note 1: Convert volume of water to weight by multiplying by the density of water. · . 

(1 g/ml). · 

0?-'FORM-07 4 Revision ·oate: 201 0/03/31 

... 

: 

' ' 

.. 

.. 

' .. ·. . ..... 

. ; . 

;.·'.· .. 

-... = .. . ·· 

.. '. .· 

••• I' 

. ,· . ' 
JAN/03/2011/MON 02:03 PM P. 005 

. . ~· .. ..... 

. . .· ·,, 

··· ... ·· .. , · .. 

... 

.. · .. , 

·· ...... 

' .. ··: 

. .. ·. 

.· .: .. 

... ' .. 

,..._..__,....__:____;.~··"-''-"-" ---'-'-----------:--------~=-... ..,.,-, -....,...---,,.....,.,..,---, " ..... . MC!;tyl ,An<;~IY.sls '. 

.·· · · · Room .. · < ·-

· Container., ... · .. - · : · ... ~·· .. Final Tqre of Weight 

;• ... ·····.:· 

. Metbyleme . '• 

No.. . . H~mldlty .Wel(;!ht (Q) · .. . ... . ... ...(.%RH) .. . . 

Aluminum .. Gain 

Di~b (g) . . · · (m~) 

Aceto_ns\IY?~h- ,. :· Chlor:l'ds .w .. ash : 

Volurl_l~ (ml.:~.. Yolt.~mtf(rnLL '.: .> .. 

~:· s .. qq1e·· s··:q.·97/.P<.:·:o.~· .-··· 

· ... 

2-80 

Total ;\~,to 

Less Acsteme Wash Blank (mg) · .. 

(not to· exceed 1 mg/L of ac;etone used) 

Wa = CsP_~Vaw · · , -· Less Methylene Chloride Wash Blank (mg) (not to 

exceed 1.5 mg/L of·rhethylehe chloiii:le used) ·· ........ 

Wt-= orP7vJ.W 

· ·(_ r;.·o~{.z,s-uL)(l~:~l~~).~ :._o.·:, '~-~~: ·:_::-

Less Filter Blank (mg) 

(not to exceed .1 mg/filter) _ .. 

Fb 

Notes: 

:. 

0- I 

. . .. ~ . 

·• Blank analysis must be completed before sample amilysis is started. 

. •· ~ · ··Filter Pr~paration Blank must. ncif'~C;eed~1 ·mg/filter. 

. . . • .. Aceton~Wash Re~gent:Biank mu.st not exceed 1 mg/L. 

• · ·. Methylene ChloMe Reagent Blan~ :must. not exceed .1.5 mg/L. 

. •. lmplnger Water Reagent-Blank must not exceed 1.5 mg/L. .. '· 

" ·Room Relative Humidity must be below 50% when samples are being weighed. 

n?-I=ORM-074 

·- ·. ..... 

Revision Date: 2010/03/31 

. ·'·· . ... 

. ~~ -:.·. 

., . 

•'-

~~ 

i! 

It 

I" 

J; 

I! 

li 

I' 

il II 

li 

il 

:· 

:r 

!J 

., 

,, 

.. ;i 

:I 

ih 
JAN/03/2011/MON 02:03PM P. 006 

.... : ........ Method 315 Particulate and MCEM Analysis 

'. 

· · ... ·.- Particulate Analysis . . " 

~~-~-~~ .. ~--r-~-~---~--~~--~--------.-----~~~~~~. 

' .. : . _. :/ _ .. . Plant: ... ·; .-~, vJmZ.iiii / pate: ./1 :z,h_ i D · J.- ~un No. .-J.k- 2-- ~- :. :. -fz~~ r#-a.. . , . ,. ·;--:"-·. _;Filter·~~:·:~·-';,. ,3ft. ., ·, .. _·.. . ·. · i ··:: ··::·. , ... 

... • · A:u~~~\~i~!~-~~t·· )1/ /jrj;r:· · · · 

Acetone Blank . 

. '·.:;:-.• 

, • 0. o, 

! .·-:: • •• '··· ........ • .. :: 

.. .. . .· ·.·· ·: ... : ';:·."· 

·.·•· 

.... · ... ~. .. 

... V.oiwme (mil . . .. ... . z_~o. .. ._...;~_ :- .. . :·. 

f...-;-~~~~""'i----'---'-,~~:;._------.:..._.......---------,.,-.. -;--;--'--;, .. =--,.-;; ......:....::.:,.~----::-J.. .. ... _, ... , ''. . . ·.· Acetone blank · 

.. ·. 

J--::c~:..l.l~~:::...:~":::L~)t..l:!.r (~I:::.;:;~Z!:!..!'~IT.l~.~;""-)q_.L•' ~-. _:_"...:..· ....:'..::.----.:f!:_·_;__· ()---.:··;;...~--~ •• ~b.;_. M1---;il-. ---=-----'---------,--:'--:---:-.-,--. :c-'-··.::..:- .. -':-·:·,_,_ ... ,..;-.. ---.-'J _ ..... 

Acetone .wash · · · 

. ,·. . • .... 

blank (Eq. 315-5) ·· .. , . (mg) 

.. .. ;.",•jo I o • :): '(;·~~! 

Room 

Humidity Final Weight (g) Tare Weight (g) 

.:. ·.-. 

Wejght Gain. (mg) ..... ,- ,· · :~ .. 

.... J%RH) 

Container hole. :1. 

.. .. ,. ~ IS~41-ot.· ·. . · .... ·;: . ,..,..-;"' .· A.~" 

.. .c~_nta1ner No.2 ~ /51- ·1'"~ 

' 

--

Total 

Le~s Acetone blank 

Weight of Particulate matter 

13 7,'fg/C, -

·""' .? . (/ ., _::) ' 

.. . . 

o. 0. .-: .. 

.... ·~ :(j7 ~li: . 

Moisture Analysis, 

lmpingers 

.. ... . Silica Gel· 

Total 

.. 

·, .. 

· · FiJ1.al Volume (mg) 

·'· Note 1' 

I. 

-.---· -····--·- .................. ____ , _____ ,. 

Initial Volume (mg) Liquid Collected 

(mg) 

Note.1 

• .. -· . 

··--·-- -·--· .. -·--·-- ... ___ , ... ___ ... ····-····--- --·-----·-- .. -··---·· -· ..... 

Note 1: Convert volume· of water to weight by multiplying by the density 0f ~ater ~;--:--· --~ .. -- :: .... -. ------ (1 g/ml). .. .. · · 

Revision Date: 2010/03/31 

}' h 
JAN/03/2011/MON 02:03PM P. 007 

:' 

I' .;•••• .-. ••, 

'·' 

....... ':-·." 

,, ....... 

··· .... ·r-·.' , ..... • :. 

· .. ;· 

, .· .. , :·. 

~ ....... . .... . , ... 

,.'i~ :• I '• o : ·.: .. ·;, 

: ,._,. •'. 

~ ... :. . 

;i. ' .... ; ... _ ~ . 

: .. -· . . .... 

. . . MC~M .. AnaiY,si~ . . ... " .. . . '• .. ... '. .. 

. Date: ./... t.0Ji,tj!i::. ·.:~· .: : : 

T!m~: .. .0-&6o .. , .. :.··· .. ... .. ··: . . . ... . .. . •' . . -. . . .. . ~ .. ... _,R.oRr:n. -Tar19 of Weight, .. · ·Matbylene . ·Container· .· Finai AcetoneWash · Aluminl.n-Ti Gain Chlorlde .. wash No. Humidity Weight (g) veiu~e (mq~ ::. t%RH) .... ' .. ·. Dish _(g) ..... ' (mg) ···.· Vol4me;_(J)1Lr· .. .. 1~9! ·' y)~lt). 

%- -. .. .. ........... . . "'' ..... ·' 

4-~o~:e·~- ... ·er .·, ·;!- j () '• ,. 1'. ,. ·f.or· 13 . . . . .. . ... . . .. ~--: ' , 

·I .. ·-. ... . .. . ' . .. ,. . . . . .. .. ... .. . 

I~ .. ( : 

2+2M /f:P~l-fl 4-- o J;.:B· ·q.s ,1 \~£' ·~ 

.. j1 .. .. .. .:{ '· .. : .. 

3W ;.~/73 g .q1Jr;:7' '1/_.',J r ')· i:.: 'I ro .. ... J : '. 

3s:··.::·.::: ~· 5:~·19·:;-n·--· ·-?,~, q 4'1 · ·- ·r;;/1-· ,~- ·:~ '5" ,: ;.:~ .. ,.-~1-r.~ ... ... . . . 

;l1·@ .. 1 .. Total • . -~·-t.t' 94'Z.. : Xmtotal Zv~w --~ l'Vtw 

Less Acekme Wash Blank (nig)· {t&f:>: (0--'~-1-1z..<;~)~~t-):-=>~_--.".:J ';. ~ . (not to exceed 1 mg/L of acetone used) 

Wa = CePal:'Vaw " -\fi}I.DttMil· -{Q.-O""'\/.i-SIJ~\(. 1.-:ii.L\::···;·.OYk-~ 

Less Mathytene Chlo~ide Wash Slank(mg) (not to 

exceed 1.5 rng/L of methylene chloride used) ..... •tD~l~~)C~i:i~)~ 1;>~:4"!: .. 

Wr = CtP,!Vtw 

Less Filler Blank (mg) .. ·. : : . ' 

(not to exceed 1 mg/filter) -{}' I ... 

Fb - MCEMWeight (mg) (jw.q9. __ l1.J·~~ ... tJ.Ij- o~o~j -. ~·~~).:: [l(p.q~ mMpBOM :::: Xmwsr- Wa- Wr - Fb 

... 

Notes: · · · 

. • Blank analysis·must be completed before sample analysis is started. 

• F_lltar Preparatio0 B!ank must not ~xG.asd.'j :mglffiter.. 

·• Acetonr;i'Wasti' Reagen't'Blahk must not exceed 1 mg/L 

.• Methyl~ne Chloride ReageFJt Blank must not exceed 1.5 mg/L. 

• lrripiriger Water Reagent-Blank must not exceed 1.5mg1L. 

• Room Relative Humidity must be below 50% when samples are being weighed, 

: ... · .... ~ 

n?.F()RM-07 4 Revision Date: 2010/03/31 

----------- -----

.. 

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·< 

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JAN/03/2011/MON 02:03PM P. 008 

Method 315 Particulate and MCEM Analysis 

"' Particulate Analysis '' 

Plant: WAf;!.tl\ak./ Date: I rl:/r /t D I Run No. I 12-g -I fZ-ec;..J~-..+1- 3 . -

Filter No. lk .. ·.· 

Amount liquid lost 

durinq transport ll/t!lf~ '• ;.:·· . •'' 

Acetone Blank ~~() .. . .. . : . 

Volume (ml) .· .. · .. · I I 

Acetone blank 

c:oncentration ()~0 Mj /MIJ (Eq. -' 

315~41. (mg/mg) 

Acetone wash "" 

blank (Eq. 315·5) ~ .. ~~ ... :·. :: ... 

(mg) 

Room 

Humidity Final Weight (g) Tare Weight (g) Weight Gain (mg) .· 

(%RH) .. 

~ !'#-. 5 Cf!LIJ ·- ;gf.'S71'E 

.J Container No. 1 ~ -::JJ/:51~ !51:37&8 J-:1 . I I 

/:if /32-7.?ttf l~Z--"12-04 {q, I 

.Container No.2 ~( ~--~ /~Z · /3.~··- ' 

--- Total lfi;.~ .2.,._· 

Less Acetone blank f). 0 . 

Weight of Particulate matter · ..;lf/)IZ.~·, 

Moist~re Analysis 

Final Volume (mg) Initial Volume (mg) Liquid Collected 

(mq) 

lmpingers . Note 1 Note 1 

Sillca Gel 

Total 

Note 1: Convert volume of water to weight by multiplying by the density of water. 

(1 g/ml), , 

Revision Pate: 201 D/03/31 

. i., 
J/03/2011/MON 02:03PM P. 009 

.....-----·----..:__--------------:----------··~-....., 

)0CEM AnaiY,sis 

Date: j .. !;/~1/l~ ... · Time: 

.. 

Container Room Final 

No. Humidity Weight (g) (o/o.RH). 

Tare of 

Aluminum 

Dis.h (g) .. 

Weight 

Gain 

(mg) 

AcetoneW ash 

Volume (mq 

3W , ;;i .q-, oo4/t; 

Total 

Less Aceteme W,ash Blank (nig) 

(noi to exceed i mg/L of ac;etone used) 

Ws = CsP e'rVaw -

4. 0409 : 

4-. c?O 18 

Less Methylene Chloride Wash Blank (mg). (not to 

exceed 1.5 mg/L of methylene c;hlorlde used) · · 

W, = c,P,Lvrw 

Less Fllt~r Blank (mg) 

{not to exceed 1 mg!filter) 

· Fb 

MCEM Weight (mg) 

mw~EOM::::: Zmtolar- We- We- Fb 

Notes: 

o.9 ·. 

flo· 

~5:r-;£'·· 

~~0 .. 

0. I 

,. Blank analysis must be completed before sample analysis is started. 

:e Fllter Preparation Blank must not exqeed: 1 'mg/fl!tsr. 

·• Acetone Wash Reagent-Blank must not exceed 1 mg!L. 

·e Methylene Ch.loride Reagent Blank must not exceed 1.5 mg/L. 

• lmplnger Water Reagent-Blank must not exoeed 1.5 mg/L. 

•·. 

Metbylene 

Chloride .Wash 

VOIL!me· (r'nL) 

a(J 

10!" 

/80 

qD';) 

- .. 

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

Revision Date: 2010/03/31 

. ~ 

L: .. 

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. JAN/03/2011/MON 02:03PM P. 010 

Method 315 Particulate and MCEM Analysis. · .. ··:.: .-... . : ~ . .. . 

.· .. · ·· ·.. .: r~:uiioulate.'Analysis · · 

·· .: ,: ... · .. \:.. ....... PJ.~nt: ::.'. ~-~~cli) .. ~~te: .. /1~/r J;r;_: / ·~u'n'N9. 

"'.~. : ...->·· :·.:'· ··Fllt~;:No .. :·., .. ~-.· }4: ···':. . . . ': · ... 

'· ' · · · · ":'·'·. Amount .. liquid lost·· ·:· ·• ·~£ · · ... · · ·.. · ... , .·, · 

: · .. ;:. .. -; .. ·~ ~. 

• I 0' • :':,:•, ",•, o ,: •,i.'': < •',:?:' ' 

t o,! : o o o' ,•:', :~,: ''o I I' ~~ ',• ol : 

, . . . :. 

. ' · during transport. .. /l/!t?Y!!:':_ 

Acetone Blank I I ~ o ' 0 o\ I o oo ~•.•' o ol ''• I ' .... , ........ . .··.; r~j <· ,"; _; :~ ! '•' 

: .•· VoilJRJe :(mil · · i, ·,: •.• -.:;. :. •••· 

'• • •• oo • o •• ' o I '• " ~.,' o o 

Acetone· blank 

: c:oncentrotion (Eq. . . ··, .. ·,'• . ..:,,' .. 

· .......... · · . 315·4J,(m.g/mg.) .. 1 I ••: 

0 

~:' 

\ 0 ...... 

. · ... 

· .. · 

. ; Acetone wash -. . ... ''' :~'. \ o o • ••! -~: I:, ,'~ .,:·., 

· . blank (Eq'. 315·5) 

. . (mg) 

Ro0m " ... · ...... : 

Humidity Fin.al Weight (g) T-are Weight (g) · Weight Gain (mg) .. ,..-.· . ··,.· 

.... -f---"'---"----+-(~~%::..:..,R!...!H'--)t----:---...;__~-t------..,...:.._t----:,.--.,..,...-,-:--;-;~ .. 

A_·. 0-b ~ ,(p ~~ . /21/_lf; g 9! "" ..... , .. . ' 

contair.~er No.1 . ~ :, j;,~···.IR4f~~r-£ · . /Jiv'!fl-· · · ... 

•· . ?ii: ~ f.o ·'---=> . . .· , 

Total 2-/ -s- . t) •. o. . 

Weight of Particulate matter 

lmpingt?rs. 

·Silica GeL 

Total 

Moisture Analysis . 

·~inal Volume (mg) 

Note 1 .. · 

·. 

Initial Volume (mg) l.,:iquid Collected. 

(mg) 

Note 1 -·.··· 

:. : ':.' 

Note 1'-: Convert volume of water to weight by multiplying by the. density 0f water .. ·. 

(1 g/ml). 

02~FORM~07 4 Revision Date: 2010/03/31 

· .... 

i 

I. 

i i 

i 

j j 
JAN/03/2011/MON 02:03PM P. 011 

. ~ ..... '· . 

....... :· .. '\·· 

·.; . 

I • t',' ,:,, • • '' 

. .. . ... 

: ..,·. 

. ·. ~ 

·'· .. .. .. .... ... 

. MC~M. .Analysi~ .. . '. .. ' .. / .. ~~::·~·; /i.IL.-. " .. . ' 

Qflt!7: .. ·· .. , TirJ1e.: . ou~"--·· .· . . " .. .. ··. i•,: 

. ,:•: , ... ....... ., . " 

R_oqm_. .. .... ' . . T~re of Weig~t ·Metbyl~oe 9c:>ntairier -·:. . , ... F.lt;H":ll .. . .. .. AcetoneW,.as.h ., 

No. ., Humidi!Y Weight (g) Aluminum Gain . Voll1r'ne. (mL) . ; CbJori~eWas~ 

(.%RH) ..... .DJsh (g) .. (tng) . V_o!t.u:n:e:·(rt;~q: .. .. .. ... "' ... : .. .. .. ... . . . .. 

·~ f •' .. : : .. 1'• 5'-8'19-.ti . . ·g·~'f1~ ··.·:.- ·.: ...... 5" .. . '·:t:>O: ' . .. ... . . . :. 0-· . ,.. · ... .. 

J~ .. '' ... ..... . . .. : . ... Jq_·o 241,) 2+2M ~--1Bn 5-971-{: ~.lo 

.. .. 

.P11 .... .. . .. 

: .. .. 

s,.q~~+ 'i}J ( q 6 3W rtr ~/19/z, .. ! .. .. ·. 

h .. 

)/: G#~Jf~· ,4-. tift .{"-":•· .. 

: 3 s· ,.;-.:: : .. ·'1'0 .. 4-0.· ... . . l·~ ' .. 

Total . . .. .. r5;q ~3M;, q _or;;-· 

Zmtotsl L'Vaw .. .!v~w 

Less· Acetcme Wash Blank .(mg~ · · .. . ( (J. (}~:) ,p(i) ~r)( ~~ D~ ~.: . ·t?. -~~r . . 

(notio exceed 1 mg/L of acetone used) ·, .. 

Wa = GePerVaw ..... . .. . . . 

Less Methylene Chloride Wash Blank (mg) (not to . . ·{o·a~} 1-~~,..-Y. 4o~L)···-::. ·.~· o ~-<· .. ,. . ·:· 

eXceed 1 :s· mg!L of methylene chloride' used). . .. . . 

. '·.:··· ...... ·. ·:~)·· ......... Wt = OtPtLVJW . .' · . ~· ;. ~ . l • · ..... Less Filter Blank (mg) .. . ... .. 

(not to exceed 1 mglfilter) .• op I 

Fb 

'MCEMWslghl"(mg). 

fnMCE!OM = Zf!itclll/- Ws.,... Wt :- Fb aH. It-~~ o.l "1·-.v .o~ ·~ o .oJ. ~ )§:B~J 

Notes: 

·• Blank.analysis must be completed before sample analysis Is started .. 

. .. 

.. , 

: ~ .··. ,. .. , 

.. .... 

' 

·· ,; · Filter P.r~p~ratio~)3!ank _must ncif ~X~E!~d;1 ·mg/filter. · ·,· : . ~ .. ·.' : ~. , . . :. 

• ·Acetone· Wash Re~gent Blank m1:1st not exc~d 1 mg/L .· ;'. ':· 

.e Methylene'Chloride Reagent Blank must not exceed 1.5 mg/L. . . . . 

....•. lmplnger Water Reagent-Blank must.not exceed 1.5 .mg/1... 

• Room Relative Humidity must be below 50% when samples are being weighed. , ·.: ,.• 

. '· ol, , , 0 ° 0 

! 

02-FORM-074 Revision Date: 2010/03/31 

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JAN/03/2011/MON 02:04PM P. 012 

. .. .,. .. 

• ., :· •• 0 

.. ' ~- . ,. . .• . : .· ·· .. ·:·: 

• .. ·1-:. .. · .. · 

.. . ·.· 

...... , ... Method 315 Particulat.e and fVICEM Analysis 0 ••• , •••••••• 

,---~---· ...:.:...::..._' ._,:....:. .. ::.....:.· ·..:...· ......;" '--------------........,...---..,...--,....,.. .. .' 

· · · .. Particulate A~~lysis 

Plant: 

. .. .. . .. . . . .' Amount liqu. id lost· ·: ·•:'·,-L .:, .... • I '•:~ ','J, ::,: .~ 

... · ., ..... : durimJt~ansport. ..MtJJ( · 

f,:' •.' .. ,, t, I o ~ j 

.. • .. J'' ......... ,. 

_,·.. .,. 7'-:· : 

.. ..; :~.l 

/ .. Room 

Final Weight (9) Tare Weight (g) . Weight G~ln (mg) ·.· · . . . 'Humidity 

(%RH) 1----"'-'" . ._____-.J---->..::..::.:...:.:...:.L-+--.:....,--__,...----,j--...,-------:;.---,,:;-, ~__,....,----:""'--1 .. '·'· 

~3 82. /S:9(P. ~2..14-s-sContainer No. 1 

.. 

. Container No. 2 

. •, 

..... 

· .. :· ... 

Total 

Less Acetbhe·.blank .{)./) 

Weight of Particulate·· matter . .. . 

Moisture Analysis I ~ )?in.a].Volume (mg) initial Volume (mg) ~~d Collected· ·. .. 

: 

lmpingerS" · · · Note 1 Note 1 

Silica Gel. :· · : ·:··. "'·· ··.· 

Total 

~------------------------~--~--~------~ .. 

Note 1: Convert volume of water to weight by multiplying by the density G>f wate.r. .· . .' .. · .. · . · .. · 

(1 g/ml). · 

Revision Pate: 201 0/03!31 

. 

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I JAN/03/20 11/MON 02: 04 PM P. 013 

I 

I ... .. '•;' 

. ···.· •', .... 

( 0 

I 

.-;.,:···.·.·.·.·-··.· ','' . .. . . ' 

,:.·• ' ·.,.: .. ··.: ... ··.: 

r. 

I ,, 

·: · ...... :.· .. 

. · .. 

·· ... · 

''• 

12{(.6.o ·~ 00 0 •• 

. .... · 

.. ...... 

Container. · · .·R.o_~m ·. :. : Fjn8J ·· Hum1dlty . .. . N~ .. ~.. !.%RH) 00 • w.~~g~~ (g)._ 

Ti:!rB of.. .. 

Aluminum 

.Dls.h. (g) .... 

Wei(1ht " 1 . W k. Met~ylene. G 1 mce one .. asr;a.. .. Chi 'd W h · ·. ,:: 

( artn) ''""yolume (.nil:~.··... v ofn· e.~··( .aL). 1 ... ·. '· .m::~ ... I Rl,l..f:;, . , ~'f. o L!.~~ n:] ' .. 

TotE!,! 

Less Acetcme Wash BJaok (rrig) · _ 

(not to exceed 1 mg!L of acetone used) /ttl5= f:P.~>w.;/,17,9 ·:~~~~ ,··:~··~,;~ ·~,: ::" 

W,9·== CePe'ZV~w · · . ·- .. ' .~~et!.~(~,o,...1 I ,;z.51J.zXtt6ll:·.w . .:;... o.~""'"" Less Methylene Chloride Wash Blank (mg) (not to 

exceed 1.5 mg/L of ri'H~thylene· chloride used) · · · · · · 

Wt ::: c,P,?Vtw . (!? ,{P ~ /.~iik)t13gi). ~ ':~~~~ ~ ' '' 'I" ., ' 

Less Fllter Blank (mg) 

(oot to exceed 1 r.nglfilter) 

Fb 

MCE'MWVeight {mg) 

mMCEDM = ?_mtoJ~r-. !'I'~- Wt ~ Fb 

Notes: 

'- - . • . Blank·analysis mustbe.c:ompleted before sample analysis is started. 

. 'i' Filter ~reparation B!ank m.ust not eiceed:{m(11fllter. 0 0 0 

· •' 'Acetone Wash Reagent-Blank must not exceed 1 mg/L 

' ·Methylen.e Chfor.ide.Reagent Blank must not exceed 1.5 mg/L 

0 0 0 • e 0 .(mpinger Water Reagerit·BiaRk must not exceed 1.5 mg/L. 

· .e. Room Relative Humidity must be below 50% when samples are being weighed. 

02-FORM-074 Revision Date: 201 0/03/31 

• 0' 

; ...... 

·. -. 

. ~ .. : , . 

'' . 

.I 

Calibration Procedures and Results 

Pitot tubes and thermocouples are calibrated in accordance with the procedures outlined 

in USEP A 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 of EPA 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 

of Method 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 rrny be assi;Toe:f I> pl.ollubes oon- 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 of the inherent accuracy and precision of the 

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 of the 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) of each 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 of the 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 Calibration 
Pitot Tube Number: PR-5C .. 

Effective Length (in.): 60 

Pitot Tube Openings Damaged? YES 

Pitot Tube Assembly 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 above will not arect the baseline value of Cp(s) so 

long as a,anda2 islessthanorequalto 10°,l11 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 

Pitot Tube 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 I ACCEPT ] 

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 

I ACCEPT I 

"A single-point calibration procedure that checks the operation of a thermocouple system within plus or minus 

1.0% of the 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." 
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 of a thermocouple system within plus or minus 

1.0% of the 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-Test Meter 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 of three 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 of EPA Method 5. The DGM calibration factor (y) and the 

orifice calibration factor (.t.H@) was calculated at each orifice setting. ·The average of the 

y values was used in the calculations .. 

Post Test Meter Calibration Check- Approved Alternative Method (AL T -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 of the 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~~~

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 

ORI

10.8306 

10.8203 

10.810 

AV

8.3867 

8.3787 

8.3947 

AV

6.5204 

6.5142 

6.5080 

AV

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 

(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

nH@= 

. . 

( 

0.75 e 

Yc,(std) 
Alternative Method 5 Post-Test Calibration 

Approved Alternative Method (ALT-0009} 

Calculation utilizes the following: 

0.0319 = (29.92/528)(0.075f (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): 

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. of stack gas (lb/lb-mole) 

DH112 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 Method 5 Post-Test Calibration 

Approved Alternative Method (AL T-0009) 

Calculation utilizes the following: 

0.0319 = (29.92/528)(0.075) 2 (in. Hg/ 0

/R) cfm2 

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. of stack gas (lb/lb-mole) 

DH112 Ave. Sq. Root DH (in. H 20) 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 

AVG (P0 .,) 

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 

OR

10.62

10.62

10.62

A

6.41

6.41

6.41

A

8.245

8.245

8.24

A

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, V0 (std), and the DGM calibration factor, Y. These equations are automatically calculated in the spreadsheet above. AVERAGE DRY GAS METER CALIBRATION FACTOR

(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 (0R ~ English, 0 1( - Metric) 

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

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

K' = . Average K' factor from Critical Orifice Calibration 

Vee (std) = DGM calibration factor 

Vm (std) 

AVERAGE A

LIH@= 

( 

0.75 

V~,(st
Alternative Method 5 Post-Test Calibration 

Approved Alternative 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#