MACT Compliance Plan – 2001 Q2 Update. Doc 30 July 2001

ATTACHMENT 1 –MACT COMPLIANCE PLAN

ROCKDALE OPERATIONS

EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED 

COST FOR 

UPGRADE

COMPLIANCE SCHEDULE INTERIM 

PARAMETRICS

CONTRACT 

AWARDED:

CONSTRUCTION 

INITIATED:

CONSTRUCTION 

COMPLETED:

COMPLIANCE 

TO BE 

ACHIEVED BY:

LINE 1 POTLINE IDLE

LINE 2 POTLINE IDLE

LINE 3 Fume Control Equipment Flexible 

Permit Limit

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections 

Rebuild/ upgrade electrostatic precipitators $300,000 COMPLETED 3/00 3/01

Option to modify multiclones and install flow baffles in 

electrostatic precipitators

$350,000 COMPLETED 4/01 10/01

Option to install conveying system for precipitator/baghouse 

hopper dust transport

$1,200,000 COMPLETED 10/01 10/01

Option to install additional fans/additional ductwork for 

redundancy.

$2 Million COMPLETED 10/01 10/01

Option to install three additional FRP scrubber towers for 

redundancy or purchase portable baghouse and scrubber for 

precipitator maintenance outages

$3 Million 12/00 6/01 11/01 10/01

Install lower nozzle configuration on six existing wet scrubbers. $200,000 COMPLETED 4/00 10/00

Install redundant sump and sump pumps for scrubber forced 

drain system.

$250,000 11/00 3/01 12/01 10/01

Operations and Maintenance

Replace existing PLC with SLC 504 system to begin tracking 

parametric data.

$ 50,000 COMPLETED 4/00 12/00
MACT Compliance Plan – 2001 Q2 Update. Doc 30 July 2001

EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED 

COST FOR 

UPGRADE

COMPLIANCE SCHEDULE INTERIM 

PARAMETRICS

CONTRACT 

AWARDED:

CONSTRUCTION 

INITIATED:

CONSTRUCTION 

COMPLETED:

COMPLIANCE 

TO BE 

ACHIEVED BY:

LINE 4 Fume Control Equipment Flexible 

Permit Limit

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections 

Install baghouses to replace precipitators

Install new fans for higher pot draft

Replace #10 and 12 scrubber systems with FRP towers and 

lower nozzle configuration along with two extra towers for 

redundancy.

Install instrumentation to monitor water flow. Fan amps are 

currently logged.

Install conveying system on baghouse hoppers for dust 

transport

Install PLC system for operational control of new system

$13 Million COMPLETED 2/01 3/01

Install redundant sumps and sump pumps for forced drain 

system.

$300,000 11/00 3/01 12/01 10/01

LINE 5 Fume Control Equipment Flexible 

Permit Limit

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections

Install variable frequency drives on the rotary vane feeders to 

improve scrubber efficiency.

$ 50,000 COMPLETED 6/01

Install instrumentation to monitor alumina flow. $ 20,000 COMPLETED 6/01
MACT Compliance Plan – 2001 Q2 Update. Doc 30 July 2001

EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED 

COST FOR 

UPGRADE

COMPLIANCE SCHEDULE INTERIM 

PARAMETRICS

CONTRACT 

AWARDED:

CONSTRUCTION 

INITIATED:

CONSTRUCTION 

COMPLETED:

COMPLIANCE 

TO BE 

ACHIEVED BY:

LINE 6 Fume Control Equipment Flexible 

Permit Limit

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections

Upgrade/rebuild electrostatic precipitators $600,000 COMPLETED 3/00 3/01

Option to intall flow baffles in electrostatic precipitators $300,000 COMPLETED 7/01 10/01

Install lower nozzle configuration on twelve existing wet 

scrubbers

$600,000 COMPLETED 3/00 12/00

Install duct sprays to towers $200,000 COMPLETED 12/00 3/01

Install instrumentation to monitor water flow. Fan amps are 

currently logged.

$100,000 COMPLETED 3/00 12/00

Install fume duct flowmeters to monitor potdraft. $ 15,000 COMPLETED 6/00 12/00

Install redundant sump and sump pumps for forced drain 

system.

$250,000 8/00 6/01 12/01 6/01

Operations and Maintenance

Install SLC 504 for control of electrostatic precipitators.

Modify PI system for datalogging.

Complete computer programming for WonderWare control.

$100,000 COMPLETED 7/00 12/00
MACT Compliance Plan – 2001 Q2 Update. Doc 30 July 2001

EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED 

COST FOR 

UPGRADE

COMPLIANCE SCHEDULE INTERIM 

PARAMETRICS

CONTRACT 

AWARDED:

CONSTRUCTION 

INITIATED:

CONSTRUCTION 

COMPLETED:

COMPLIANCE 

TO BE 

ACHIEVED BY:

LINE 7 Fume Control Equipment Flexible 

Permit Limit 

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections

Replace existing baghouses with new baghouses improve 

particulate emissions.

$2.8 million COMPLETED

8/99

Install fume duct flowmeters to monitor potdraft. $ 15,000 COMPLETED 6/00 12/00

Replace inlet fan dampers to scrubbers to improve potdraft. $ 75,000 COMPLETED

3/99

Install variable frequency drives on the rotary vane feeders to 

improve scrubber efficiency.

$ 50,000 COMPLETED 3/00 12/00

Install instrumentation to monitor alumina flow. $ 20,000 COMPLETED 7/00 12/00

Option to install cross-over duct between reactor banks to 

improve scrubbing redundancy

$ 180,000 COMPLETED 7/01 3/01

Operations and Maintenance

Modify PLC system for monitoring new instrumentation.

Modify PI system for datalogging.

Complete computer programming for WonderWare control.

$ 30,000 COMPLETED 3/01 3/01

LINE 8 Fume Control Equipment Flexible 

Permit Limit 

Standard 

monthly 

emissions 

testing for 

outlet and 

roof monitor

Daily visual 

inspections

Install fume duct flowmeters to monitor potdraft. $ 15,000 COMPLETED 6/00 12/00

Replace inlet fan dampers to scrubbers to improve potdraft. $ 75,000 COMPLETED

3/99

Install variable frequency drives on the rotary vane feeders to 

improve scrubber efficiency.

$ 50,000 COMPLETED 4/00 12/00

Install instrumentation to monitor alumina flow. $ 20,000 COMPLETED 7/00 12/00

Option to install cross-over duct between reactor banks to 

improve scrubbing redundancy

$ 180,000 COMPLETED 6/01
MACT Compliance Plan – 2001 Q2 Update. Doc 30 July 2001

EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED 

COST FOR 

UPGRADE

COMPLIANCE SCHEDULE INTERIM 

PARAMETRICS

CONTRACT 

AWARDED:

CONSTRUCTION 

INITIATED:

CONSTRUCTION 

COMPLETED:

COMPLIANCE 

TO BE 

ACHIEVED BY:

Bldg. 

76/77

Scrubber Water Supply System N/A

Install PLC system for automated control of scrubber water 

system

$130,000 COMPLETED 4/00 N/A

Convert quicklime system to hydrated lime system for 

improved scrubber efficiency

$ 75,000 COMPLETED 9/00 N/A