### 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

- 32 07

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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 2.10E

04 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 wro ng 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 Performa nce 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 units) Unit Name Unit ID No. 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
M elter #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 D ocument (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 A ppendix 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 pre sented 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 yo u 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 repo rted 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://ww w.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 A 1. 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