From: Bo Quick [mailto:Bo.Quick@southwire.com] 

Sent: Thursday, September 19, 2013 2:49 PM

To: Boyd, Rochelle

Subject: RE: Additional Questions 

Rochelle:

Please see the attached.

Thanks...Bo

From: Boyd, Rochelle [mailto:Boyd.Rochelle@epa.gov] 

Sent: Wednesday, September 18, 2013 1:25 PM

To: Bo Quick

Subject: Additional Questions 

We have additional questions regarding the test data. See attached. Thanks

Rochelle Boyd, Environmental Engineer

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

Sector Policies and Programs Division

109 T.W. Alexander Drive, RTP, NC 27711

Mail Drop D243-02

Ph: (919) 541-1390 Fax: (919) 541-3207

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Questions about Southwire Emissions Data. Southwire responses are provided in red.

1) This is Table 35.a from your ICR response.

D/F emissions from Melter #1, Melter #2, Melter/Holder #5 and Melter/Holder #6 are shown as 2.10E04 grain/ton for each. This equates to 15 ug/Mg, which is also the D/F emission limit. We interpreted 

the D/F values in Table 35.a to not be your actual emissions measured during 2007 testing. Is this 

interpretation correct? No. 2.10E-04 is the limit. We mistakenly entered the wrong information here. 

Calculated emissions are given in Table 39.

35.a. Please list all regulated pollutant emissions from equipment subject to 40 CFR 63, subpart RRR.

Unit ID No.

Emissions Unit 

Name

Emissions of Regulated RRR Pollutants Based on 

Performance Tests

Control Device (from 

Part C or D above)

List Dates of 

the 

Applicable 

Compliance 

Tests*

PM 

(lbs/ton)

D/F** 

(grain/ton)

HCl 

(lbs/ton)

Total 

Hydrocarbons 

(THC) 

(lbs/ton)

Device 

Type*

Unit ID 

No.

S1 (001), S2 

(002), S8 

(021), S9 

(021), S23 

(023)

SAPU1 0.19 N/A 0.21 N/A N/A N/A April/May/July 

2007

S1 (001) Melter #1 0.4 2.10E-04 0.4 N/A N/A N/A July 2007

S2 (002) Melter #2 0.4 2.10E-04 0.4 N/A N/A N/A N/A

S3 (014) Melter #3 3.4 lb/hr N/A N/A N/A N/A N/A N/A

S4 (003) Holder #1 N/A N/A N/A N/A N/A N/A N/A

S5 (004) Holder #2 N/A N/A N/A N/A N/A N/A N/A

S6 & S7 

(013)

Holders #3 & #4 3.4 lb/hr N/A N/A N/A N/A N/A N/A

S8 (021) Melter/Holder #5 0.4 2.10E-04 0.4 N/A N/A N/A April-May 

2007

S9 (021) Melter/Holder #6 0.4 2.10E-04 0.4 N/A N/A N/A N/A

S23 (023) In-Line Fluxers 1, 2, 

& 3

0.01 N/A 0.04 N/A N/A N/A July 2007

2) This is Table 39 from your ICR response.

D/F emissions from Melter #1 are 3.23E-06 gr/ton; D/F emissions from Melter/Holder #5 are 1.88E-04 

gr/ton. Do these emissions include fugitive emissions? Yes

39. For each affected source listed in [Section B, above], identify the date(s) of latest NESHAP compliance testing. 

Date Tested

Emission Unit

Test Method Used

Pollutant(s) 

Tested

Emissions 

(specify 

Unit Name Unit ID No. units)

July 2007 Melter #1 S1 M5 PM 0.09 lb/ton

M26A HCl 0.10 lb/ton

M23 D/F 3.23E-06 gr/ton

April-May 2007 Melter/Holder #5 S8 M5 PM 0.310 lb/ton

M26A HCl 0.197 lb/ton

M23 D/F 1.88E-04 gr/ton

July 2007 In-Line Fluxer (Rod Mill 1) S23 M5 PM 0.07 lb/ton

M26A HCl 0.03 lb/ton

July 2007 In-Line Fluxer (Rod Mill 2) S23 M5 PM 0.010 lb/ton

M26A HCl 0.02 lb/ton

July 2007 In-Line Fluxer (Rod Mill 3) S23 M5 PM 0.016 lb/ton

M26A HCl 0.092 lb/ton
3) At the time that you submitted your ICR response, Melter #3 was identified as a Group 2 

furnace. In your 2011 testing, you operated and tested Melter #3 as a Group 1 furnace. For the 

foreseeable future, will Melter #3 be continuously operated as a Group 1 furnace? Yes. Melter 

3 began operating as a Group 1 furnace on 4/2/12 and will continue as such going forward.

4) In the Section 4 – Test Results sent to EPA on September 13, 2013, you estimated fugitive 

emissions based on 2007 testing. The description of how fugitive emissions were estimated are 

“...discussed in Section 2.3 and demonstrated in Appendix H.” Can we obtain a copy of these 

sections? Yes. See attached.

5) Also according to Section – Test Results, fugitive emissions are estimated to be greater for 

Melter #3 due to the differences in the sizes of the charge door. Fugitive emissions from Melter 

3 are increased by a factor of 25% to account for the larger charge doors. Is this correct? Yes. 

See Appendix H attached.

6) The Technical Supporting Document (TSD) for the Secondary Aluminum Risk and Technology 

Review Proposal of 2011 contains tables presenting results of testing at Southwire in 2007. The 

tables from that TSD are included in Appendix A to this document. We compared our TSD 

information in Appendix A with the information in the document (Section 4 - Test Results) that 

you sent to Rochelle Boyd, EPA, in an email on September 13, 2013. The tables from the TSD 

seem incompatible with the following results presented for Furnace M1 and M3, which seem to 

show over 99% of emissions escaping as fugitives. (Note: The following results for Furnace M5, 

which seems to show 32% of the emissions escaping as fugtives, is very compatible with the 

tables in the TSD.) Can you explain why the results for Furnace M1 and M3 seem so different 

from the results for Furnace M5 and the tables in the TSD?

Good point. We recognize that fugitive emissions for M1 and M3 are overestimated using our 

approach, particularly since flux is no longer used on M1 (as it was in 2007). 2011 stack D/F 

emissions are significantly lower as a result (2.27E-9 lb TEQ/hr in 2007 versus 7.94E-11 lb TEQ/hr 

in 2011 for M1). However, the 2007 test results were the fugitive emissions data we have, and 

it was decided that a conservative estimate was better than attempting to test fugitive 

emissions again from these units (the agency required us to ‘account’ for fugitives in some way). 

We tested fugitives on M1 in 2007, but it was expensive, difficult, and disruptive. We have no 

safe, practical way of testing fugitives on M3. In reality, D/F fugitive emissions should be much 

lower than we reported since flux is not used on M1 or M3. By using 2007 fugitive emissions 

data to estimate emissions under 2011 conditions, the percent of fugitive emissions is 

overinflated. However, we had little choice if we wanted to avoid testing. 
Furnace M1 Results: D/F TEQ Emissions

Parameter Value Reported Fraction of Total Emissions

Mass of Stack Emissions (grains TEQ) 1.77E-06 0.01

Mass of Fugitive Emissions (grains TEQ) 3.01E-04 0.99

Total Mass of D/F (grains TEQ) 3.03E-04 1.00

Stack Emission Rate (grains/ton charged) 4.05E-08 0.01

Fugitive Emission Rate (grains/ton charged) 6.89E-06 0.99

Total Emission Rate (grains/ton charged) 6.93E-06 1.00

Stack Emission Rate (ug/Mg charged) 0.00289 0.01

Fugitive Emission Rate (ug/Mg charged) 0.49211 0.99

Total Emission Rate (ug/Mg charged) 0.49500 1.00

Furnace M3 Results: D/F TEQ Emissions

Parameter Value Reported Fraction of Total Emissions

Mass of Stack Emissions (grains TEQ) 3.11E-06 0.01

Mass of Fugitive Emissions (grains TEQ) 3.60E-04 0.99

Total Mass of D/F (grains TEQ) 3.63E-04 1.00

Stack Emission Rate (grains/ton charged) 7.72E-08 0.01

Fugitive Emission Rate (grains/ton charged) 8.93E-06 0.99

Total Emission Rate (grains/ton charged) 9.01E-06 1.00

Stack Emission Rate (ug/Mg charged) 0.00551 0.01

Fugitive Emission Rate (ug/Mg charged) 0.63806 0.99

Total Emission Rate (ug/Mg charged) 0.64358 1.00

Furnace H5 Results: D/F TEQ Emissions

Parameter Value Reported Fraction of Total Emissions

Mass of Stack Emissions (grains TEQ) 2.43E-04 0.68

Mass of Fugitive Emissions (grains TEQ) 1.15E-04 0.32

Total Mass of D/F (grains TEQ) 3.58E-04 1.00

Stack Emission Rate (grains/ton charged) 1.21E-05 0.68

Fugitive Emission Rate (grains/ton charged) 5.72E-06 0.32

Total Emission Rate (grains/ton charged) 1.78E-05 1.00

Stack Emission Rate (ug/Mg charged) 0.86301 0.68

Fugitive Emission Rate (ug/Mg charged) 0.40842 0.32

Total Emission Rate (ug/Mg charged) 1.27144 1.00
Appendix A

Southwire Test Results from

Technical Support Document (TSD) for

Secondary Aluminum Risk and Technology Review Proposal of 2011

(TSD available here: http://www.regulations.gov/#!documentDetail;D=EPA-HQ-OAR-2010-0544-0152)

Table 1. Southwire Test Results Summary

Test Report Date Pollutant

Three-run Average

Fraction in Furnace Stack

Three-run Average

Fraction in Canopy Hood Stack

June 26, 2007 PM 0.78 0.22

June 26, 2007 HCl 0.81 0.19

June 26, 2007 D/F 0.97 0.03

Sept. 5, 2007 PM 0.49 0.51

Sept. 5, 2007 HCl 0.77 0.23

Sept. 5, 2007 D/F 0.42 0.58

Average for all All 0.71 0.29
Table A1. Southwire Testing Reported June 26, 2007: Complete Test Results 

* reported as 2378-TCDD equivalent

Southwire Testing Reported on June 26, 2007

PM PM HCl HCl TOTAL D/F* TOTAL D/F*

Duration(hr) furnace stack

Run 1 7.70 0.56 #/hr 4.31 lb 0.71 #/hr 5.47 lb 8.69E-08 #/hr 6.69E-07 lb

Run 2 8.00 0.75 6.00 lb 0.7 5.60 lb 7.72E-08 #/hr 6.18E-07 lb

Run 3 7.70 0.57 4.39 lb 0.69 5.31 lb 2.18E-08 #/hr 1.68E-07 lb

Duration(hr) canopy hood

Run 1 3.00 0.32 #/hr 0.96 lb 0.51 #/hr 1.53 lb 3.87E-09 #/hr 1.16E-08 lb

Run 2 3.33 0.58 1.93 lb 0.41 1.37 lb 4.92E-09 #/hr 1.64E-08 lb

Run 3 3.00 0.41 1.23 lb 0.28 0.84 lb 2.95E-09 #/hr 8.85E-09 lb

Total

Run 1 5.27 lb 7.00 lb 6.81E-07 lb

Run 2 7.93 lb 6.97 lb 6.34E-07 lb

Run 3 5.62 lb 6.15 lb 1.77E-07 lb

average 6.27 lb 6.71 lb 4.97E-07 lb
Table A2. Southwire Testing Reported on June 26, 2007: Results in Pounds

Southwire Testing Reported on June 26, 2007

Pollutant Location Units Run 1 Run 2 Run 3 Average

PM Furnace stack lb 4.31 6.00 4.39 4.90

PM Canopy hood lb 0.96 1.93 1.23 1.37

PM Total lb 5.27 7.93 5.62 6.27

PM Furnace stack fraction of total 0.82 0.76 0.78 0.78

PM Canopy hood fraction of total 0.18 0.24 0.22 0.22 22% Avg

PM Total fraction of total 1.00 1.00 1.00 1.00

HCl Furnace stack lb 5.47 5.60 5.31 5.46

HCl Canopy hood lb 1.53 1.37 0.84 1.25

HCl Total lb 7.00 6.97 6.15 6.71

HCl Furnace stack fraction of total 0.78 0.80 0.86 0.81

HCl Canopy hood fraction of total 0.22 0.20 0.14 0.19 19% Avg

HCl Total fraction of total 1.00 1.00 1.00 1.00

Total D/F Furnace stack lb 6.69E-07 6.18E-07 1.68E-07 6.35E-07

Total D/F Canopy hood lb 1.16E-08 1.64E-08 8.85E-09 1.48E-08

Total D/F Total lb 6.81E-07 6.34E-07 1.77E-07 4.97E-07

Total D/F Furnace stack fraction of total 0.98 0.97 0.95 0.97

Total D/F Canopy hood fraction of total 0.02 0.03 0.05 0.03 3% Avg

Total D/F Total fraction of total 1.00 1.00 1.00 1.00
Table A3. Southwire Testing Reported September 5, 2007: Complete Test Results

Southwire Testing Reported on September 5, 2007

PM PM HCl HCl TOTAL D/F* TOTAL D/F*

Duration(hr) furnace stack

Run 1 3.20 0.61 #/hr 1.95 lb 1.38 #/hr 4.42 lb 2.02E-09 #/hr 6.46E-09 lb

Run 2 3.20 0.49 1.57 lb 0.81 2.59 lb 3.97E-09 #/hr 1.27E-08 lb

Run 3 3.20 0.49 1.57 lb 0.68 2.18 lb 8.31E-10 #/hr 2.66E-09 lb

Duration(hr) canopy hood

Run 1 3.00 0.86 #/hr 2.58 lb 0.38 #/hr 1.14 lb 8.31E-09 #/hr 2.49E-08 lb

Run 2 3.00 0.36 1.08 lb 0.25 0.75 lb 2.20E-09 #/hr 6.60E-09 lb

Run 3 3.00 0.53 1.59 lb 0.28 0.84 lb 1.35E-09 #/hr 4.05E-09 lb

Total

Run 1 4.53 lb 5.56 lb 3.14E-08 lb

Run 2 2.65 lb 3.34 lb 1.93E-08 lb

Run 3 3.16 lb 3.02 lb 6.71E-09 lb

average 3.45 lb 3.97 lb 1.91E-08 lb
Table A4. Southwire Testing Reported on September 5, 2007: Results in Pounds

Southwire Testing Reported on September 5, 2007

Pollutant Location Units Run 1 Run 2 Run 3 Average

PM Furnace stack lb 1.95 1.57 1.57 1.70

PM Canopy hood lb 2.58 1.08 1.59 1.75

PM Total lb 4.53 2.65 3.16 3.45

PM Furnace stack fraction of total 0.43 0.59 0.50 0.49

PM Canopy hood fraction of total 0.57 0.41 0.50 0.51 51% Avg

PM Total fraction of total 1.00 1.00 1.00 1.00

HCl Furnace stack lb 4.42 2.59 2.18 3.06

HCl Canopy hood lb 1.14 0.75 0.84 0.91

HCl Total lb 5.56 3.34 3.02 3.97

HCl Furnace stack fraction of total 0.79 0.78 0.72 0.77

HCl Canopy hood fraction of total 0.21 0.22 0.28 0.23 23% Avg

HCl Total fraction of total 1.00 1.00 1.00 1.00

Total D/F Furnace stack lb 6.46E-09 1.27E-08 2.66E-09 1.06E-08

Total D/F Canopy hood lb 2.49E-08 6.60E-09 4.05E-09 1.27E-08

Total D/F Total lb 3.14E-08 1.93E-08 6.71E-09 1.91E-08

Total D/F Furnace stack fraction of total 0.21 0.66 0.40 0.42

Total D/F Canopy hood fraction of total 0.79 0.34 0.60 0.58 58% Avg

Total D/F Total fraction of total 1.00 1.00 1.00 1.00