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 1,410 degree 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 31 DLL, DLL, BDL

Benzene 71-43-2 0.00538 0.0004708 0.00977 0.0008779 0.00328 0.0002890 31 DLL

Bromodichloromethane 75-27-4 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31 BDL

Carbon disulfide 75-15-0 0.01631 0.0014272 0.02424 0.0021780 0.00817 0.0007198 31 DLL

Carbon tetrachloride 56-23-5 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31 BDL

Chlorodibromomethane 124-48-1 0.0001 0.0000088 0.00015 0.0000135 0.00015 0.0000132 31 BDL

Chloroform 67-66-3 0.00011 0.0000096 0.00018 0.0000162 0.00016 0.0000141 31 BDL, DLL, BDL

Chloroprene 126-99-8 0.00015 0.0000131 0.00022 0.0000198 0.00023 0.0000203 31 BDL

Dibromomethane 74-95-3 0.0002 0.0000175 0.00028 0.0000252 0.00029 0.0000255 31 BDL

1,1-Dichloroethane 75-34-3 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31 BDL

1,2-Dichloroethane 107-06-2 0.00011 0.0000096 0.00015 0.0000135 0.00016 0.0000141 31 BDL 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 31 BDL

trans-1,2-Dichloroethene 156-60-5 0.0002 0.0000175 0.00028 0.0000252 0.00029 0.0000255 31 BDL

1,2-Dichloropropane 78-87-5 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31 BDL

1,3-Dichloropropene 542-75-6 0.00023 0.0000201 0.00033 0.0000297 0.00034 0.0000300 31 BDL

Methylene chloride 75-09-2 0.00049 0.0000429 0.00084 0.0000755 0.00067 0.0000590 31 DLL

Tetrachloroethene 127-18-4 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31 BDL

Toluene 108-88-3 0.00227 0.0001986 0.00427 0.0003837 0.00222 0.0001956 31 ADL, ADL, DLL

1,1,1-Trichloroethane 71-55-6 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31 BDL

1,1,2-Trichloroethane 79-00-5 0.00017 0.0000149 0.00025 0.0000225 0.00026 0.0000229 31 BDL

Trichloroethene 79-01-6 0.00012 0.0000105 0.00018 0.0000162 0.00018 0.0000159 31 BDL

Trichlorofluoromethane 75-69-4 0.00044 0.0000385 0.00063 0.0000566 0.00056 0.0000493 31 DLL

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 1,410 degree 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 0.0000018 CARB429Mod ADL

Acenaphthylene 208-96-8 0.000808 0.0000707 0.000885 0.0000795 0.000392 0.0000346 CARB429Mod ADL

Anthracene 120-12-7 0.000649 0.0000568 0.000418 0.0000375 0.000194 0.0000171 CARB429Mod 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 0.0000035 CARB429Mod ADL

Benzo[a]pyrene 50-32-8 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018 CARB429Mod BDL

Benzo[b]fluoranthene 205-99-2 0.000008 0.0000007 0.000005 0.0000005 0.000005 0.0000004 CARB429Mod ADL

Benzo[g,h,i]perylene 191-24-2 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003 CARB429Mod BDL

Benzo[k]fluoranthene 207-08-9 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003 CARB429Mod BDL

Chrysene 218-01-9 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018 CARB429Mod ADL

Dibenz[a,h]anthracene 53-70-3 0.000002 0.0000002 0.000002 0.0000002 0.000003 0.0000003 CARB429Mod BDL

Fluoranthene 206-44-0 0.002056 0.0001799 0.001495 0.0001344 0.000975 0.0000859 CARB429Mod ADL

Fluorene 86-73-7 0.000231 0.0000202 0.000321 0.0000288 0.000138 0.0000121 CARB429Mod ADL

Indeno(1,2,3-cd)pyrene 193-39-5 0.000021 0.0000018 0.000022 0.0000020 0.000020 0.0000018 CARB429Mod BDL

Naphthalene 91-20-3 0.001491 0.0001304 0.001311 0.0001178 0.001062 0.0000935 CARB429Mod ADL

Phenanthrene 85-01-8 0.003525 0.0003084 0.003323 0.0002986 0.001359 0.0001197 CARB429Mod ADL

Pyrene 129-00-0 0.001540 0.0001347 0.001132 0.0001017 0.000767 0.0000676 CARB429Mod ADL

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 

Feed/Charge Rate 11.43 11.13 11.35 Mg/hr

Afterburner residence time NA NA NA sec

Hot Gas Generator Operating Temperature 1,412 1,410 1,410 degree 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 (ADL, BDL, DDL)*** Detection Limit 

(ng/dscm)

1 0.52 0.046 ADL

2 0.65 0.058 ADL

3 0.65 0.057 ADL

*** 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 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 1,410 degree F

Flow Rate 1,830 2,576 2,603 actual M3

/min

Flow Rate 1,605 2,255 2,341 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 20.85 20.82 20.77 U.S. EPA Method 3A

CO2 0 0.13 0.14 U.S. EPA Method 3A

H2O 2.93 3.09 3.17 U.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 Ash 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