# 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** 

Wise Alloys, LLC 1009 Ford Road Muscle Shoals, AL 35661 Delacquering kiln 2, controlled by baghouse 6 Delacquering Kiln 2 Baghouse 6

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/17/2010 8/18/2010**  **8/18/2010** Feed/Charge Rate 11.43 11.13 11.35 Mg/hr Hot Gas Generator Operating Temperature 1,412 1,410 1,410degree F

Type of Charge:_______________________________________________________________________ Used Beverage Cans (UBCs)

**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 0.00168 0.0001470 0.00242 0.0002174 0.00239 0.0002106 31DLL, DLL, BDL Benzene 71-43-2 0.00538 0.0004708 0.00977 0.0008779 0.00328 0.0002890 31DLL Bromodichloromethane 75-27-4 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31BDL Carbon disulfide 75-15-0 0.01631 0.0014272 0.02424 0.0021780 0.00817 0.0007198 31DLL Carbon tetrachloride 56-23-5 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31BDL Chlorodibromomethane 124-48-1 0.0001 0.0000088 0.00015 0.0000135 0.00015 0.0000132 31BDL Chloroform 67-66-3 0.00011 0.0000096 0.00018 0.0000162 0.00016 0.0000141 31BDL, DLL, BDL Chloroprene 126-99-8 0.00015 0.0000131 0.00022 0.0000198 0.00023 0.0000203 31BDL Dibromomethane 74-95-3 0.0002 0.0000175 0.00028 0.0000252 0.00029 0.0000255 31BDL 1,1-Dichloroethane 75-34-3 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31BDL 1,2-Dichloroethane 107-06-2 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31BDL Run 1 Tube set 3ABC, surrogate recovery for D4-1, 2-Dichloroethane outside control limits. Overall QC for this analysis meets acceptability criteria. 1,1-Dichloroethene 75-35-4 0.0002 0.0000175 0.00028 0.0000252 0.00029 0.0000255 31BDL trans-1,2-Dichloroethene 156-60-5 0.0002 0.0000175 0.00028 0.0000252 0.00029 0.0000255 31BDL 1,2-Dichloropropane 78-87-5 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31BDL 1,3-Dichloropropene 542-75-6 0.00023 0.0000201 0.00033 0.0000297 0.00034 0.0000300 31BDL Methylene chloride 75-09-2 0.00049 0.0000429 0.00084 0.0000755 0.00067 0.0000590 31DLL Tetrachloroethene 127-18-4 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31BDL Toluene 108-88-3 0.00227 0.0001986 0.00427 0.0003837 0.00222 0.0001956 31ADL, ADL, DLL 1,1,1-Trichloroethane 71-55-6 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31BDL 1,1,2-Trichloroethane 79-00-5 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31BDL Trichloroethene 79-01-6 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31BDL Trichlorofluoromethane 75-69-4 0.00044 0.0000385 0.00063 0.0000566 0.00056 0.0000493 31DLL **Speciated Volatile Organic HAP Emission Data Facility Name and Address**  **Unit Description Process Unit ID**  **Control Device ID** Wise Alloys, LLC 1009 Ford Road Muscle Shoals, AL 35661 Delacquering kiln 2, controlled by baghouse 6 Delacquering Kiln 2 Baghouse 6

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/17/2010 8/18/2010**  **8/18/2010** Feed/Charge Rate 11.43 11.13 11.35 Mg/hr Hot Gas Generator Operating Temperature 1,412 1,410 1,410degree F

Type of Charge:_______________________________________________________________________ Used Beverage Cans (UBCs)

**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 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018CARB429Mod ADL Acenaphthylene 208-96-8 0.000808 0.0000707 0.000885 0.0000795 0.000392 0.0000346CARB429Mod ADL Anthracene 120-12-7 0.000649 0.0000568 0.000418 0.0000375 0.000194 0.0000171CARB429Mod ADL Recovery of D10-Anthracene is outside control limits. The overall quality control for this analysis meets acceptability criteria. Benz[a]anthracene 56-55-3 0.000066 0.0000058 0.000047 0.0000042 0.000040 0.0000035CARB429Mod ADL Benzo[a]pyrene 50-32-8 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018CARB429Mod BDL Benzo[b]fluoranthene 205-99-2 0.000008 0.0000007 0.000005 0.0000005 0.000005 0.0000004CARB429Mod ADL Benzo[g,h,i]perylene 191-24-2 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003CARB429Mod BDL Benzo[k]fluoranthene 207-08-9 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003CARB429Mod **BDL** Chrysene 218-01-9 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018CARB429Mod ADL Dibenz[a,h]anthracene 53-70-3 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003CARB429Mod BDL Fluoranthene 206-44-0 0.002056 0.0001799 0.001495 0.0001344 0.000975 0.0000859CARB429Mod ADL Fluorene 86-73-7 0.000231 0.0000202 0.000321 0.0000288 0.000138 0.0000121CARB429Mod ADL Indeno(1,2,3-cd)pyrene 193-39-5 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018CARB429Mod BDL Naphthalene 91-20-3 0.001491 0.0001304 0.001311 0.0001178 0.001062 0.0000935CARB429Mod ADL Phenanthrene 85-01-8 0.003525 0.0003084 0.003323 0.0002986 0.001359 0.0001197CARB429Mod ADL Pyrene 129-00-0 0.001540 0.0001347 0.001132 0.0001017 0.000767 0.0000676CARB429Mod ADL **Speciated Volatile Organic HAP Emission Data**

# Facility Name and A **ddress Unit Description**  **Process Unit ID Control Device ID**  

# Wise Alloys, LLC 1009 Ford Road Muscle Shoals, AL 35661 Delacquering kiln 2, controlled by baghouse 6 Delacquering Kiln 2 Baghouse 6

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information Date of Testing**  Feed/Charge Rate 

# 11.43 11.13 11.35Mg/hr Afterburner residence time 

# NA NA NA sec Hot Gas Generator Operating Temperature 

# 1,412 1,410 1,410degree F



# 1 8/17/2010 914 8/17/2010 1555 2 8/18/2010 719 8/18/2010 1243 3 8/18/2010 1408 8/18/2010 1802

**Run Number THC Emission Rate (kg/hr)**  **THC Emission Rate (kg/Mg of feed/charge)**  **Data Flag (A DL, BDL, DDL)** *** **Detection Limit (ng/dscm)**  

# 1 0.52 0.046ADL 2 0.65 0.058ADL 3 0.65 0.057ADL *** See Appendix A to Enclosure 1

**Run Number Test Start Date**  **Test Start Time Test End Date**  **Test End Time**

EPA-HQ-OAR-2010-0544-DRAFT-0164.xlsx: M25A_THC

# Facility Name and A**ddress Unit Description**  **Process Unit ID Control Device ID** 



# Wise Alloys, LLC 1009 Ford Road Muscle Shoals, AL 35661 Delacquering kiln 2, controlled by baghouse 6 Delacquering Kiln 2 Baghouse 6

**Parameter Sample 1**  **Sample 2 Sample 3**  **Unit of Measure Other Supporting**  **Information** Date of Testing **8/17/2010 8/18/2010**  **8/18/2010** Feed/Charge Rate 

# 11.43 11.13 11.35Mg/hr Hot Gas Generator Operating Temperature 1,412 

# 1,410 1,410degree F Flow Rate 

# 1,830 2,576 2,603actual M3

# /min
Flow Rate 

# 1,605 2,255 2,341dry 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 

# 20.85 20.82 20.77U.S. EPA Method 3A CO2 

# 0 0.13 0.14U.S. EPA Method 3A H2

# O 

# 2.93 3.09 3.17U.S. EPA Method 4

## Facility Name and Address **Unit Description Process Unit ID**  **Control Device ID***



# Wise Alloys, LLC 1009 Ford Road Muscle Shoals, AL 35661 Delacquering kiln 2, controlled by baghouse 6 Delacquering Kiln 2 Baghouse 6

**Sample ID No. Lime Sample, Maxxam ID GX0868**  **Type of Sample (Lime or Particulate): Lime** 

**Date Sampled Date(s) Analyzed**  8/18/2010 9/24/2010

**HAP Metal mg/kg**  Antimony 

# 0.4 Beryllium 

# 1.5 Chromium 

# 14 Hexavalent chromium 

# 3.1 Lead 

# 9 Mercury 

# 0.0075 Selenium 

# 4.3 Arsenic 

# 33 Cadmium 

# 0.2 Cobalt 

# 8.1 Manganese 

# 63 Nickel 

# 14
**Sample ID No. Baghouse 6 A**  **sh Sample, Maxxam ID GX0870 Type of Sample (Lime or Particulate):** **Particulate**

**Date Sampled Date(s) Analyzed**  8/18/2010 9/24/2010

**HAP Metal mg/kg**  Antimony 

# 6 Beryllium 

# 2.4 Chromium 

# 36 Hexavalent chromium 

# <0.2 Lead 

# 110 Mercury 

# 0.24 Selenium 

# 26 Arsenic 

# 44 Cadmium 

# 6.7 Cobalt 

# 11 Manganese 

# 260 Nickel 

# 21

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

EPA-HQ-OAR-2010-0544-DRAFT-0164.xlsx: PM_and_lime_HAPmetals