Instructions

 The EPA secondary aluminum production test program requires emissions and other test data for several pollutants. EPA understands that you own one or 

more secondary aluminum production facilities. 

 For at least one thermal chip dryer and at least one scrap dryer/delacquering kiln/decoating kiln that you own, you must perform a stack test for volatile and 

semi-volatile organic HAPs as specified in the letter and instructions accompanying this file. You should collect emissions samples for the identified pollutants 

downstream of the last relevant emissions control device (i.e., stack or other point representing the composition of the flue gases at the exit to the 

atmosphere), unless otherwise indicated. (Contact the EPA project lead for situations with multiple stacks or other complex emissions points for the unit.)

Sample and analyze the particulate matter collected in the hopper from at least one bag house used to control particulate matter from each type of affected 

source subject to 40 CFR 63, subpart RRR at your secondary aluminum production facilities. Choose bag houses that are used to control particulate matter 

from each of the six different types of affected sources (i.e.group 1 furnaces, scrap shredders, chip dryers, scrap dryers/delacquering kilns/decoating kilns, 

dross only furnaces, and rotary dross coolers) if you have these controlled affected sources at your facilities. Where more than one bag house discharges 

solids to a common hopper, a single sample will be adequate. In cases where solids from different compartments of a single bag house are collected in 

multiple hoppers or multiple collection sacks, a single composite sample will be adequate. If you have a total of three or fewer bag houses at all of your 

facilities, sample and analyze particulate matter from all of them, even if they are controlling the same type of affected source. It is not necessary to conduct 

a stack test for multi-metals analysis. 

Sample and analyze the lime used for injection to any of the lime-injected bag houses from which particulate matter samples were collected. If lime of the 

same type, obtained from the same supplier, is used for more than one lime injected bag house, a single sample will be adequate to represent the lime used 

in these bag houses.

You must report the results of these tests and chemical analyses in this Microsoft® Excel Emission Test Template. The Excel templates are specific to each 

type of pollutant. You must report the results of each test on the appropriately labeled worksheet corresponding to the specific tests and analyses conducted 

at your facilities. If more than one source was tested, you must make a copy of the worksheet and update the source ID in order to distinguish between each 

separate test of a chip dryer or scrap dryer/ delacquering kiln/decoating kiln at each facility and each different source of particulate matter. After completing 

the worksheet, you must also submit an electronic copy of the emission test report and the chemical analyses. (PDF format preferred).

Please refer to the cover letter of this packet (CAA section 114 letter) for additional testing information. Please note that you do not have to submit a test 

plan to EPA for approval prior to testing; however, we recommend that you prepare a test plan for your own use to assist in the planning and to verify that 

you address all of the testing and reporting requirements. You must follow all of the procedures as specified in the test methods, including the quality 

assurance and quality control measures, and document the results in any test report provided to EPA. 
Facility Name and Address Unit Description Process Unit ID Control Device ID

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2 Afterburner

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/18/2010 8/19/2010 8/19/2010

Feed/Charge Rate 16.093 18.775 16.652 Mg/hr

Afterburner Operating Temperature 1410 1410 1410 degree F

Type of Charge:__ Recycled Aluminum - Used Beverage Cans _________

Compound

Volatile Organic HAP 

Emission Rate Sample 1 

(kg/hr) 

Volatile Organic HAP 

Emission Rate Sample 1 

(kg/Mg of feed/charge) 

Volatile Organic HAP 

Emission Rate Sample 

2 (kg/hr) 

Volatile Organic HAP 

Emission Rate 

Sample 2 (kg/Mg of 

feed/charge) 

Volatile Organic HAP 

Emission Rate Sample 3 

(kg/hr) 

Volatile Organic HAP 

Emission Rate 

Sample 3 (kg/Mg of 

feed/charge) Test Method Used

Detection Limit 

Information 

(BDL,DLL,ADL)

Other Supporting 

Information

Acrylonitrile 107-13-1 [< 2.03E-04] [< 1.26E-05] [< 2.16E-04] [< 1.15E-05] [< 2.32E-04] [< 1.39E-05] SW 846 M-0031 DLL

Benzene 71-43-2 [< 9.17E-05] [< 5.70E-06] [< 1.17E-04] [< 6.21E-06] [< 1.30E-04] [< 7.82E-06] SW 846 M-0031 DLL

Bromodichloromethane 75-27-4 [< 4.00E-05] [< 2.49E-06] [< 3.85E-05] [< 2.05E-06] [< 4.18E-05] [< 2.51E-06] SW 846 M-0031 DLL

Carbon disulfide 75-15-0 [< 3.40E-05] [< 2.11E-06] [< 4.20E-05] [< 2.24E-06] [< 5.28E-05] [< 3.17E-06] SW 846 M-0031 DLL

Carbon tetrachloride 56-23-5 [< 4.77E-05] [< 2.96E-06] [< 4.02E-05] [< 2.14E-06] [< 5.30E-05] [< 3.19E-06] SW 846 M-0031 DLL

Chlorodibromomethane 124-48-1 [< 3.48E-05] [< 2.16E-06] [< 3.64E-05] [< 1.94E-06] [< 3.91E-05] [< 2.35E-06] SW 846 M-0031 DLL

Chloroform 67-66-3 [< 4.57E-05] [< 2.84E-06] [< 3.85E-05] [< 2.05E-06] [< 4.86E-05] [< 2.92E-06] SW 846 M-0031 DLL

Chloroprene 126-99-8 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

Dibromomethane 74-95-3 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

1,1-Dichloroethane 75-34-3 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

1,2-Dichloroethane 107-06-2 [< 3.42E-05] [< 2.13E-06] [< 3.54E-05] [< 1.89E-06] [< 3.51E-05] [< 2.11E-06] SW 846 M-0031 DLL

1,1-Dichloroethene 75-35-4 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

trans-1,2-Dichloroethene 156-60-5 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

1,2-Dichloropropane 78-87-5 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

1,3-Dichloropropene 542-75-6 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

Methylene chloride 75-09-2 6.82E-05 4.24E-06 8.73E-05 4.65E-06 6.57E-05 3.94E-06 SW 846 M-0031 ADL

Tetrachloroethene 127-18-4 [< 1.74E-05] [< 1.08E-06] [< 1.89E-05] [< 1.01E-06] [< 2.12E-05] [< 1.28E-06] SW 846 M-0031 DLL

Toluene 108-88-3 [< 8.87E-05] [< 5.51E-06] [< 7.33E-05] [< 3.90E-06] [< 6.93E-05] [< 4.16E-06] SW 846 M-0031 DLL

1,1,1-Trichloroethane 71-55-6 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

1,1,2-Trichloroethane 79-00-5 [< 4.07E-05] [< 2.53E-06] [< 3.98E-05] [< 2.12E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 BDL

Trichloroethene 79-01-6 [< 3.85E-05] [< 2.39E-06] [< 3.87E-05] [< 2.06E-06] [< 4.25E-05] [< 2.55E-06] SW 846 M-0031 DLL

Trichlorofluoromethane 75-69-4 [< 3.00E-05] [< 1.86E-06] [< 2.76E-05] [< 1.47E-06] [< 3.15E-05] [< 1.89E-06] SW 846 M-0031 DLL

Speciated Volatile Organic HAP Emission Data
Facility Name and Address Unit Description Process Unit ID Control Device ID

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2 Afterburner

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/18/2010 8/19/2010 8/19/2010

Feed/Charge Rate 16.093 18.775 16.652 Mg/hr

Afterburner Operating Temperature 1410 1410 1410 degree F

Type of Charge:__ Recycled Aluminum - Used Beverage Cans _________

Compound

Semi-volatile Organic HAP 

Emission Rate Sample 1 

(kg/hr) 

Semi-volatile Organic HAP 

Emission Rate Sample 1 

(kg/Mg of feed/charge) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 2 (kg/hr) 

Semi-volatile Organic HAP 

Emission Rate Sample 2 

(kg/Mg of feed/charge) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 3 (kg/hr) 

Semi-volatile Organic 

HAP Emission Rate 

Sample 3 (kg/Mg of 

feed/charge) Test Method Used

Detection Limit 

Information 

(BDL,DLL,ADL)

Other Supporting 

Information

Acenaphthene 83-32-9 [< 2.05E-06] [< 1.27E-07] 2.79E-07 1.49E-08 [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 DLL

Acenaphthylene 208-96-8 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Anthracene 120-12-7 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Benz[a]anthracene 56-55-3 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Benzo[a]pyrene 50-32-8 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Benzo[b]fluoranthene 205-99-2 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Benzo[g,h,i]perylene 191-24-2 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Benzo[k]fluoranthene 207-08-9 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Chrysene 218-01-9 [< 2.05E-06] [< 1.27E-07] 2.80E-07 1.49E-08 [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 DLL

Dibenz[a,h]anthracene 53-70-3 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Fluoranthene 206-44-0 [< 2.05E-06] [< 1.27E-07] 1.09E-06 5.81E-08 2.52E-06 1.51E-07 SW 846 M-0010 DLL

Fluorene 86-73-7 [< 2.05E-06] [< 1.27E-07] 8.52E-07 4.54E-08 [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 DLL

Indeno(1,2,3-cd)pyrene 193-39-5 [< 2.05E-06] [< 1.27E-07] [< 2.01E-07] [< 1.07E-08] [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 BDL

Naphthalene 91-20-3 7.64E-06 4.75E-07 2.19E-06 1.17E-07 1.10E-05 6.61E-07 SW 846 M-0010 ADL

Phenanthrene 85-01-8 4.73E-06 2.94E-07 3.49E-06 1.86E-07 5.59E-06 3.36E-07 SW 846 M-0010 ADL

Pyrene 129-00-0 [< 2.05E-06] [< 1.27E-07] 5.43E-07 2.89E-08 [< 2.04E-06] [< 1.23E-07] SW 846 M-0010 DLL

Speciated Volatile Organic HAP Emission Data
Facility Name and Address Unit Description Process Unit ID Control Device ID

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2 Afterburner

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 8/18/2010 8/19/2010 8/19/2010

Feed/Charge Rate 16.093 18.775 16.652 Mg/hr

Afterburner Operating Temperature 1410 1410 1410 degree F

Flow Rate 1,119.7 1,134.6 1,213.2 actual M3

/min

Flow Rate 311.3 307.8 328.6 dry sM3

/min

Emission Test Results Constituent

Composition 

Sample 1

 (%)

Composition 

Sample 2

 (%)

Composition 

Sample 3

 (%)

Test Method Used

(ex. U.S. EPA Method 3B) Other Supporting Information

O2 11.43 10.96 11.36 US EPA Method 3A

CO2 6.31 6.65 6.25 US EPA Method 3A

H2O 10.4 11.5 11.2 US EPA Method 4
Facility Name and Address Unit Description Process Unit ID Control Device ID

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2 Afterburner

Parameter Sample 1 Sample 2 Sample 3 Unit of Measure

Other Supporting 

Information

Date of Testing 

Feed/Charge Rate 16.093 18.775 16.652 Mg/hr

Afterburner residence time 1 1 1 sec

Afterburner Operating Temperature 1410 1410 1410 degree F

1 8/18/2010 14:30 8/18/2010 18:32

2 8/19/2010 9:25 8/19/2010 13:33

3 8/19/2010 14:15 8/19/2010 18:54

Run Number THC Emission Rate (kg/hr) 

THC Emission Rate (kg/Mg 

of feed/charge) Data Flag (ADL, BDL, DDL)*** Detection Limit 

(ng/dscm)

1 0.0199 0.00124 ADL N/A

2 0.0214 0.00114 ADL N/A

3 0.0191 0.00115 ADL N/A

*** See Appendix A to Enclosure 1

Run Number Test Start Date Test Start Time Test End Date Test End Time
Facility Name and Address Unit Description Process Unit ID Control Device ID*

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2

Sample ID No._TN BH # 5 (Delac Fce # 3)____________________

Type of Sample (Lime or Particulate):_BH Dust_______________

Date Sampled Date(s) Analyzed

18-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

HAP Metal mg/kg

Antimony 16.6

Beryllium 0.428

Chromium 121

Hexavalent chromium < 1.0

Lead 1530

Mercury 0.87

Selenium 2.1

Arsenic 7.04

Cadmium 11.5

Cobalt 37.1

Manganese 1200

Nickel 46.7

* Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.
Facility Name and Address Unit Description Process Unit ID Control Device ID*

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2

Sample ID No._TN BH # 4 (Crusher # 2)____________________

Type of Sample (Lime or Particulate):_BH Dust_______________

Date Sampled Date(s) Analyzed

18-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

HAP Metal mg/kg

Antimony 2.36

Beryllium 0.111

Chromium 69.2

Hexavalent chromium < 1.0

Lead 179

Mercury 0.67

Selenium < 1.0

Arsenic 1.66

Cadmium 5.39

Cobalt 8.23

Manganese 1370

Nickel 39.6

* Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.
Facility Name and Address Unit Description Process Unit ID Control Device ID*

Alcoa - Tennessee Operations Delacquering Furnace Delac Furnace No. 2

Sample ID No._TN Lime for BH # 5____________________

Type of Sample (Lime or Particulate):_Lime__________

Date Sampled Date(s) Analyzed

18-Aug ICPMS on 9/9, Hg on 9/2, Hex Cr on 9/13

HAP Metal mg/kg

Antimony 0.1

Beryllium 0.067

Chromium 13.5

Hexavalent chromium 5.7

Lead < 0.5

Mercury 0.0018

Selenium < 1.0

Arsenic 0.52

Cadmium 0.109

Cobalt 1.76

Manganese 18.8

Nickel 18.2

* Enter multiple control device ID Nos. if the lime results apply to mulitiple control devices.