### M ACT 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: CONSTRUC

TION

INITIATED: CONSTRUC

TION

COMPLETED: COMPLIANCE

TO BE

ACHI EVED 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 COMPL ETED 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

p recipitator 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

### M ACT Compliance Plan

– 2001 Q2 Update. Doc 30 July 2001 EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED

COST FOR

UPGR ADE COMPLIANCE SCHEDULE INTERIM

PARAMETRICS CONTRACT

AWARDED: CONSTRUC

TION

INITIATED: CONSTRUC

TION

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 inst rumentation 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

in spections Install variable frequency drives on t he rotary vane feeders to improve scrubber efficiency. $ 50,000 COMPLETED 6/01

Install instrumentation to monitor alumina flow. $ 20,000 COMPLETED 6/01

### M ACT Compliance Plan

– 2001 Q2 Update. Doc 30 July 2001 EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMAT ED

COST FOR

UPGRADE COMPLIANCE SCHEDULE INTERIM

PARAMETRICS CONTRACT

AWARDED: CONSTRUC

TION

INITIATED: CONSTRUC

TION

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 existi ng 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

### M ACT Compliance Plan

– 2001 Q2 Update. Doc 30 July 2001

EQUIPMENT/OPERATIONAL CHAN GES REQUIRED ESTIMATED

COST FOR

UPGRADE COMPLIANCE SCHEDULE INTERIM

PARAMETRICS

CONTRACT

AWARDED: CONSTRUC

TION

INITIATED: CONSTRUC

TION

COMPLETED: COMPLIANCE

TO BE

ACHIEVED BY:

LINE 7 Fume Control Equipment Flexible

Permit Limit

Standard

mont hly

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 van e 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 $ 180,00 0 COMPLETED 7/01 3/01

Operations and Mainte nance
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

monthl y 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

### M ACT Compliance Plan

– 2001 Q2 Update. Doc 30 July 2001 EQUIPMENT/OPERATIONAL CHANGES REQUIRED ESTIMATED

COST FOR

UPGRADE COMPLIANCE SCHEDULE INTERIM

PARAMETRICS CONTRACT

AWARDED: CONSTRUC

TION

INITIATED: CONSTRUC

TION

COMPLETED: COMPLIANCE

TO BE

AC HIEVED 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 l ime system for improved scrubber efficiency $ 75,000 COMPLETED 9/00 N/A