Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 1 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Start-Up of Bake Oven

To prevent excess or uncontrolled emissions from the Bake Oven, this startup plan must be 

followed for all startups. In the event that a start-up of bake ovens served by this emission 

control system creates or leads to a situation that causes operation outside of appropriate 

parametric ranges for process gas flow or alumina flow, the following Start-Up plan must be reinitiated within one hour of first becoming aware of the situation. 

A start-up is defined as the process of baking green anodes in a ring furnace using natural gas or 

propane as a fuel. The start-up begins when fuel and ignition are introduced to a furnace 

containing green anodes. The start-up concludes when baked anode production begins. 

Appropriate limits for parametric ranges during a start-up are those typical ranges that have 

previously been established for this emission control device. 

1. The Operator(s) is to assure that prior to start-up of the furnaces that the emission control 

system is on line and operating within normal parametric limits. The sonic tower low 

temperature setpoint should be reduced to ambient until the tower is conditioned (warmed 

up) by hot process gas. This prevents the system from shutting down on low temperature 

during attempted startups.

2. When the emission control system is on-line and operating within normal parametric limits, 

the Environmental Control Shift Technician will notify the Bake Oven Supervisor that the 

start-up of the furnaces can begin.

3. In the event of operation outside of acceptable parametric limits, the Operator is to assure 

that the emission control system is still on line. If this is not the case, a shut down of the 

bake oven is to be initiated.

4. The start-up concludes when production of baked anodes begins.

5. The Start-Up is to be logged. Include the time, date, duration of event, extraordinary actions 

taken beyond the scope of this plan, and initials or a signature. Records of the start-up are to 

be retained for five (5) years. Should non-conformance with an applicable requirement 

occur, it is to be entered into the semi-annual reporting period log kept by the Environmental 

Department.

Note: All revisions to this plan are to be retained for five (5) years from their date of issue.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 2 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Shut-Down of Bake Oven

To prevent excess or uncontrolled emissions from the Bake Oven, this shutdown plan must be 

followed for all shutdowns. In the event that a shut-down of bake ovens served by this emission 

control system creates or leads to a situation that causes operation outside of appropriate 

parametric ranges for process gas flow or alumina flow, the following Shut-Down plan must be 

re-initiated within one hour of first becoming aware of the situation.

A shut-down is defined as the process of intentional shut down of the bake oven furnaces for a 

period of an hour or longer. The shut-down begins when the flow of fuel to the furnaces is 

intentionally cut off. The shut-down concludes when the components of the furnaces have been 

secured in a shutdown mode or a startup is initiated. Appropriate limits for parametric ranges 

during a shut-down are those typical ranges that have previously been established for this 

emission control device. 

1. In the event of operation outside of approved parametric limits the Emission Control Shift 

Technician is to assure that the emission control system is still on line. If this is not the case, 

the shut down of bake oven is to proceed immediately and efforts to re-start the emission 

control system are to be initiated immediately.

2. The shutdown begins when the fuel to the furnace is intentionally cut off.

3. The shut-down concludes when the system components have been secured in a shutdown 

mode. This includes removal of the exhaust manifolds from the furnaces and removal of the 

end covers of the furnaces side-mains. Appropriate barricades must be in place around the 

open side mains.

4. The Bake Oven supervisor will notify the Environmental Control Shift Technician that the 

furnaces have been secured. The Environmental Control Shift Technician will verify that the 

exhaust manifolds and side-main end covers have been removed.

5. Following verification that the exhaust manifolds and side-main end covers have been 

removed, the emission control device will continue to operate for a minimum 1-hour period 

to purge the side-mains

6. After the minimum 1-hour purging, the emission control device can be shutdown.

7. The Shut-Down is to be logged. Include the time, date, duration of event, extraordinary 

actions taken beyond the scope of this plan, and initials or a signature. Records of the shutdown are to be retained for five (5) years. Should non-conformance with an applicable 

requirement occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department.

Note: All revisions to this plan are to be retained for five (5) years from their date of issue.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 3 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Catastrophic Failure of Fume Control Equipment

In the event of catastrophic failure of fume control equipment or components in this emission 

control system (device) the following malfunction and corrective action plan must be initiated 

within one hour of first becoming aware of a malfunction

Examples of catastrophic failure include, but are not limited to; collapse of a Dry Injection Fume 

Control Device or inlet duct, a direct lightning strike, a loss of electrical power, a hurricane, an 

earthquake, a tornado or a system fire that results in uncontrolled emissions.

1. As soon as the situation has become stable and hazards have been cleared, the operator or 

proxy is to confirm the system status, noting which equipment on the unit is down or 

otherwise impaired. The operator is to log the time that the condition was first noticed or 

reported and also log the time at which he/she first began to respond to check the system 

status.

2. Following this initial response, the operator is to restart all operational equipment, notify 

appropriate maintenance (for necessary repairs), engineering and support personnel.

3. Personnel responding to the malfunction are to make repair(s), equipment replacement(s) or 

process change(s) to remedy the situation in a safe, efficient, and timely manner.

4. The system operator or proxy will be responsible for logging the time, date, duration and 

cause of the malfunction, extraordinary actions taken beyond the scope of this plan, and 

initials or a signature. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5. Records of the malfunction and maintenance activity are to be retained for five (5) years. 

Should non-conformance with an applicable requirement occur, it is to be entered into the 

semi-annual reporting period log kept by the Environmental Department.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 4 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Visible Emissions – Dusting Stack(s)

In the event that emissions outside the normal operating range are visibly being emitted from the 

exhaust(s) of the emission control system (device) the following malfunction and corrective 

action plan must be implemented within one hour of the initial observation of the malfunction.

Examples of visible emissions or dusting stack(s) include, but are not limited to; continuous 

emissions observed by the operator (or reported to him) from the stack on the fume control 

system(s).

1. The operator is to report the dusting stack(s) from any source including, but not limited to the 

daily visual checks made by the Operator. The operator is to log the time that the condition 

was first noticed or reported and also log the time at which he/she confirmed reported 

emissions or has initiated this plan.

2. Following this initial response, the operator is to initiate corrective action within one hour by 

having the appropriate compartment(s) shut down to make repairs.

3. Personnel responding to the malfunction are to make repair(s) to remedy the situation in a 

safe, efficient, and timely manner.

4. The system operator will be responsible for logging the time, date, duration and cause of the 

malfunction, extraordinary actions taken beyond the scope of this plan, and initials or a 

signature in the visible emission log. If required, maintenance personnel will be responsible 

for making appropriate entries into any maintenance logs.

5. Records of the event and maintenance activity are to be retained for five (5) years. Should 

non-conformance with an applicable requirement occur, it is to be entered into the semiannual reporting period log kept by the Environmental Department.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 5 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Loss of Parametric Monitoring – Fresh Alumina Feeder Signal

In the event of a loss of the fresh alumina feeder signal(s) for the emission control systems, the 

following malfunction and corrective action plan must be initiated within one hour of first 

becoming aware of a malfunction. Examples of loss of signal include, but are not limited to; 

unexpected failure of the programmable logic controller (PLC) and Wonderware (Data logging) 

central monitoring system for more than one (1) hours in any twenty-four (24) hour period. This 

also includes loss of a measurement device (signal) component that results in a daily cumulative 

fresh alumina feeder tph (tons per hour) parametric that is below established limits of 0.5 tons 

per hour.

1. The operator is to confirm the system status, noting if the Control room PLC is off line or if 

the Wonderware (data logging) central monitoring system is not recording data. The 

operator is to log the time that the condition was first noticed or reported and also log the 

time at which he/she first began to respond to check the system status.

2. Following this initial response, the operator or proxy is to notify appropriate maintenance 

personnel and/or contact outside contractor or restart the PLC or Wonderware system.

3. Personnel responding to the malfunction are to make repair(s), equipment replacement(s) or 

process change(s) to remedy the situation in a safe, efficient, and timely manner.

4. The system operator or proxy will be responsible for logging the time, date, duration and 

cause of the malfunction, extraordinary actions taken beyond the scope of this plan, and 

initials or a signature. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5. Records of the malfunction and maintenance activity are to be retained for five (5) years. 

Should non-conformance with an applicable requirement occur, it is to be entered into the 

semi-annual reporting period log, kept by the Environmental Department.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 6 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Loss of Parametric Monitoring – Static Pressure Signal

In the event of a loss of the static pressure signal for the emission control systems, the following 

malfunction and corrective action plan must be initiated within one hour of first becoming aware 

of a malfunction. Examples of loss of signal include, but are not limited to; unexpected failure 

of the programmable logic controller (PLC) and Wonderware (Data logging) central monitoring 

system for more than one (1) hour in any twenty-four (24) hour period. This also includes loss 

of a measurement device (signal) component that results in a daily cumulative static pressure 

parametric that is below established limits. 

1. The operator is to confirm the system status, noting if the Control room PLC is off line or if 

the Wonderware (data logging) central monitoring system is not recording data. The 

operator is to log the time that the condition was first noticed or reported and also log the 

time at which he/she first began to respond to check the system status.

2. Following this initial response, the operator or proxy is to notify appropriate maintenance 

personnel and/or restart the PLC or Wonderware system.

3. Personnel responding to the malfunction are to make repair(s), equipment replacement(s) or 

process change(s) to remedy the situation in a safe, efficient, and timely manner.

4. The system operator or proxy will be responsible for logging the time, date, duration and 

cause of the malfunction, extraordinary actions taken beyond the scope of this plan, and 

initials or a signature. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5. Records of the malfunction and maintenance activity are to be retained for five (5) years. 

Should non-conformance with an applicable requirement occur, it is to be entered into the 

semi-annual reporting period log, kept by the Environmental Department.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 7 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Low Flow of Alumina 

In the event of low flow of alumina through this emission control system (less than 0.5 tons per 

hour) the following malfunction and corrective action plan must be initiated within one hour of 

first becoming aware of a malfunction. Examples of low alumina flow conditions include, but 

are not limited to; unexpected failure of the primary air gravity conveyor (air slide) or one of its 

components, (such as the media cloth membrane or the primary, air float, blowers), excessive 

downtime and /or failure (malfunction) of Dense phase material transfer units, fresh alumina 

storage tank low (or empty) levels and excessive (or full) reacted alumina storage tanks. Also 

included are reductions in alumina flow due to excessive compartments out of service due to 

various reasons. 

1. The operator is to confirm the system status and/or problems with air float blowers, material 

transfer (removal) systems as well as confirm levels in the fresh and reacted storage tanks. 

The operator is to then log the time that the condition was first noticed or reported and also 

log the time at which he/she first began to respond to check the system status and notify 

proper appropriate personnel to initiate repairs and/or conditions.

2. Following this initial response, the operator or proxy is to notify appropriate maintenance 

personnel and/or initiate a maintenance work order, or restart the unit(s).

3. Personnel responding to the malfunction are to make repair(s), equipment replacement(s) or 

process change(s) to remedy the situation in a safe, efficient, and timely manner.

4. The system operator or proxy will be responsible for logging the time, date, duration and 

cause of the malfunction, extraordinary actions taken beyond the scope of this plan, and 

initials or a signature. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5. Records of the malfunction and maintenance activity are to be retained for five (5) years. 

Should non-conformance with an applicable requirement occur, it is to be entered into the 

semi-annual reporting period log kept by the Environmental Department.
Anode Bake Oven Startup, Shutdown and Malfunction Plan Page 8 of 8

Alcoa – Mt. Holly

TV-0420-0015

Condition: Low Flow of Process Gas

In the event of low flow of process gas (low air flow) through this emission control system as 

indicated by a common static pressure of less than 8.0"w.g., the following malfunction and 

corrective action plan must be initiated within one hour of first becoming aware of a 

malfunction.

Examples of low flow conditions include, but are not limited to; a failure or malfunction of a fan, 

an unexpected loss of electrical power and/or problems with multiple compartment downtime 

which reduce the static pressure parametric value below established limits. 

1. The operator is to confirm the system status, noting if compartments (cells) are either off line 

or otherwise impaired. The static pressure set point on the main fan controller needs to be 

checked to insure proper setting. Operator needs to insure that all fans are operating properly 

and that compartment (cells) differential pressures are within control. The operator is to log 

the time that the condition was first noticed or reported and also log the time at which he/she 

first began to respond to check the system status.

2. Following this initial response, the operator or proxy is to notify appropriate maintenance 

personnel and/or initiate a maintenance work order, or restart the unit(s).

3. Personnel responding to the malfunction are to make repair(s), equipment replacement(s) or 

process change(s) to remedy the situation in a safe, efficient, and timely manner.

4. The system operator or proxy will be responsible for logging the time, date, duration and 

cause of the malfunction, extraordinary actions taken beyond the scope of this plan, and 

initials or a signature. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5. Records of the malfunction and maintenance activity are to be retained for five (5) years. 

Should non-conformance with an applicable requirement occur, it is to be entered into the 

semi-annual reporting period log kept by the Environmental Department.