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Meter temperature___________ Pressure drop
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TYPE OF CONTAMINANT CONTROL
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INSTRUMENTATION NOTES
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ARCH 18783
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DATE
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ARCH 18784
HLiuH hi ft bMnKL 1 i'jij uATA SHEET
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TYPE OF CONTAMINANT C0NTR0L_
ENVIRONMENTAL AND OPERATING CONDITIONS
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ARCH 18785
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TYPE OF CONTAMINANT CONTROL ENVIRONMENTAL AM) OPERATING CONDITIONS
INSTRUMENTATION NOTES
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ARCH 18786
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BUILDING NO. ANALYSIS FORf) SfifTSTO `rS
DATE 17- >2- O (3
OPERATION
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EMPLOYEE NAMEJ$
______________ CLOCK NO. 327^ SOC.SEC.NO.
Sampling position_ Method of Sanpling_
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TYPE OF CONTAMINANT CONTROL ENVIRONMENTAL AND OPERATING CONDITIONS
INSTRUMENTATION NOTES
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ANALYTICAL DATA AND CALCULATIONS
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` ARCH 18787-
At f'OA AIR SA.'-'PLIfiG SATA SHEET
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TYPE OF CONTAMINANT CONTROL
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INSTRUMENTATION NOTES
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ARCH 18788
AtCQA AiR SAfiPLIi!G DATA, SHEET
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Meter temperature______ 1
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IYPE OF CONTAMINANT CONTROL
ENVIRONMENTAL ANT) OPERATING CONDITIONS
No. sampling strokes *
"Hg
Volume
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INSTRUMENTATION NOTES
l'0`
NALYTICAL DATA AND CALCULATIONS
'CENTRA! ION arks:
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ARCH 18789
V.*0roC3_ 'h'ocKQglz: _3L'ildc;c :;o.______________________
date 11- IZ-OG
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____
Volume, ml_
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Time of Sampling 12 32- to
Duration
min.
Cal.Rate 2,
"Stroke counter start_
_stroke counter end_
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Meter temperature____
Pressure droo
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Volume__________
TYPE OF CONTAMINANT CONTROL
ENVIRONMENTAL AND OPERATING CONDITIONS
INSTRUMENTATION NOTES
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ANALYTICAL DATA AND CALCULATIONS
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ARCH 18790
morns P>cKC)PrLET' building no._
sample no. P-Ol'Oi
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ANALYSIS FOR
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Volume, ml______
68Cal.Rate___ [
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Volume
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TYPE OF CONTAMINANT CONTROL
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TYPE Or CONTAMINANT CONTROL
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INSTRUMENTATION NOTES
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ANALYTICAL DATA AND CALCULATIONS
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ARCH 18792
\
E. B. PARKER ROCKDALE WORKS
THIS COPY FOR MR. T. B. BONNEY, PITTSBURGH
1978 November 03
RE: MONTHLY ENVIRONMENTAL REPORT - 1978 OCTOBER
Government Agency Contacts
An application was submitted to the Texas Department of Water Resources requesting that additional outfalls for the discharge of mine water be added to the existing permit.
An application was submitted to the Texas Air Control Board for a construction
permit to install a new lignite primary crusher in the south mining area and
to refurbish and extend an existing conveyor from the new crusher to the
power plant area.
.
A modification to the Construction Permit for Bldg. 160, the new anode baking furnace, was received from the Texas Air Control Board. The modification allows firing the new furnace on a 40-hour cycle provided any increase in carbon produced as a result is offset by an equivalent reduction in carbon produced in the existing furnaces.
Mr. Gary Naler, Texas Air Control Board staff, telephoned to inquire about Alcoa's progress in coiipleting the testing of No.2 boiler in the power plant.
He indicated that the staff is anxious to resolve the question of ETU deter mination during emissions testing and asked that we schedule a meeting with them as soon as possible. The meeting has been scheduled for 1978 Decenber 7.
An Industrial Surface Impoundment Assessment questionnaire was completed and sent to the Texas Department of Water Resources.
A letter was received from the Austin Area OSHA office granting a three-month extension to the abatement date for the Bath crusher dust exposure problem.
The Texas Air Control Board was advised of the following emissions incidents:
1. Dusting from the Carbon Plant precipitator stack 2. High opacity of emissions when No. 3 boiler in the power plant
was shut down to repair a tube leak
ALCOA
p h'> . *
ARCH 18793
s
MR. G. H. LANTZ 1978 Novenber 03 Page TVro
Other Environmental Activity
Another series of limestone injection tests were conducted on No.3 power plant boiler. Again, no SO2 reduction was observed. Additional laboratory work is planned in order to define and optimize the variables in the process. Once this has been done, further testing at Rockdale may be warranted.
A Continuous Monitoring Compliance questionnaire was received from an organi zation called Research Triangle Institute. The questionnaire dealt with the continuous monitoring requirements for the new anode baking fumade. It was filled out and returned to Dr. P. R. Atkins for review before being submitted to RTI. The questionnaire reflected Alcoa's belief the continuous monitoring requirements do not apply in this case.
The original Class I waste disposal pit was levelled in order to determine its remaining capacity. It appeared that enough volume remained to last perhaps six months.
Contact was made with Mr. Jim Boyt, Pittsburgh Environmental Control, concerning a proposed study of the waste water streams being discharged into Alcoa Lake. The study will provide direction in developing plans to control these discharges and preserve the quality of the lake.
In Septenber, a Research-Cottrell service representative visited Rockdale in connection with Carbon Plant precipitator problems. He made several recommen dations to improve the unit's performance, all of which were completed in October. In spite of this, the precipitator still performs erratically. Conse quently, arrangements have been made for Research-Cottrell's most knowledgeable * precipitator expert to visit Rockdale in early-Novenber. Meanwhile, Engineering is proceeding with preparation of an RFA to replace the precipitator.
Requisitions were placed for "sound control walls" to be installed at the crusher and at the stripping press hydraulic unit in the Rodding Room.
The electrical package for the project to replace batch cars in the anode mixing area with screw conveyors was released to Construction.
Evaluation of the 2M whitecap helmet and powered air purifier for use on bath crushing vehicles continued to look good. A decision is expected in early Novenber concerning the acceptance of this equipment as the abatement strategy to control employee exposure to dust in the bath crushing area.
Respiratory protection program audits were conducted in the Potlining, Utility, Environmental Control,Ingot and Properzi, Mechanical Maintenance, and Atomizer areas. In general, the audits were satisfactory. However, it was found that plans to insure periodic refresher training were needed.
ARCH 18794
MR. G. H. LANTZ 1978 November 03
Page Three
Emissions Testing Results
Source
Date
Pollutant
Actual Emissions
Allowable Emissions
Carbon Plant Prec.
78-09-29 (1)
TSP
78-10-13 (2)
TSP
78-10-13-
Opacity
78-10-27 (13 Observations)
B79 Dust Collector 78-09-29
L6 Roof Monitor
78-08-17
78-09-12
L8 Roof Monitor
78-07-31
78-09-14
TSP TSP Total F" SOTSP Total F-
S02 TSP Total F" S02 TSP Total F'
SO2
118.2 lbs/hr 87.8 lbs/hr
Max. 30% Avg. 24% Min. 19% 13.1 lbs/hr
3.9 lbs/ton A1 2.21 lbs/ton A1 1.09 lbs/ton A1 2.62 lbs/ton A1 4.30 lbs/ton A1 1.79 lbs/ton A1 7.56 lbs/ton A1 9.79 lbs/ton A1 4.66 lbs/ton A1 2.59 lbs/ton A1 3.96 lbs/ton A1 1.92 lbs/ton A1
28.5 lbs/hr 27.7 lbs/hr 30%
-
-
19.4 lbs/hr
-
-
-
-
-
-
- -
-
-
(1) Test run before installation of new rappers (2) Test run after installation and adjustment of new rappers and alignment
of frame
General
E. B. Parker and Ken Allison (Engineering Science, Inc.) met in Pittsburgh with Dr. P. R. Atkins and Mr. R. H. Carwile to discuss SC>2 dispersion modeling.
E. B. Parker participated in a meeting in Pittsburgh concerned with a timetable for installation of Alcoa 398 systems to replace scrubbers at Wenatchee and Rockdale.
E. B. Parker, C. L. Green, W. E. Michalke, John Barnett, and K. K. Adams met in Dallas with Messrs. V. W. Rieke, M. W. Wei, Dr. P. R. Atkins, and represen tatives of Texas Power and Light to discuss SO2 emissions from the Sandow Generating Station.
Mr. Dick Shakelford, Hearing Conservation Noise Control, paid a routine visit to Rockdale in connection with the Hearing Conservation Program.
EBP:cw Copy -
P. R. Atkins, Pittsburgh V. W. Rieke, Pittsburgh
T. B. Bonney, Pittsburgh J. C. Mayfield, Pt. Comfort R. C. Hinkle, Ebdin
C. L. Green, Rockdale
ARCH 18795
J. W. Havins, Rockdale
W. D. Essary, Rockdale
A. G. Clayton, Rockdale
.
J. J. Congleton, Rockdale W. J. Drake, Rockdale
-
FROM E. B. PARKER ROCKDALE WORKS
THIS COPY FOR MR. T. B. BONNEY, PITTSBURGH
TO MR. G. H. LANTZ ROCKDALE WORKS
1978 October 04
RE: MONTHLY ENVIRONMENTAL REPORT - 1978 SEPTEMBER
Government Agency Contacts
Mr. Steve Blackhurst, Texas Air Control Board regional staff, conducted a routine inspection of Rockdale Works. He was particularly interested in the l-ignite handling and drying operations, the new dust collection facilities in the Rodding Room and the Building 160 carbon cleaning machines.
An application for a permit to operate the new anode baking furnace was submitted to the Texas Air Control Board. The application was accompanied by a report detailing the results of NSPS testing of the furnace's emissions. The same report was submitted to the EPA.
Both the EPA and the Texas Air Control Board were advised that the firing schedule of the new anode baking furnace was being changed from 48 hours to 40 hours for performance evaluation purposes. Additional testing at the new rate may be required.
An application was submitted for amendments to Rockdale's Texas Department of Water Resources discharge permit. The amendments will add a number of outfalls in the surface mining area. Previously, the TDWR had disclaimed jurisdiction over surface mining discharges, saying that such discharges were regulated by the Surface Mining Division of the Railroad Commission. Recently, this responsibility was given to the TDWR, thus permit amendments to Rockdale's permit became necessary.
The Texas Air Control Board was advised of the following emissions incidents:
1. Excessive dusting from the carbon plant precipitator - this appeared to be the result of a smoldering fire in the unit.
2. High opacity during the restart of No.3 Boiler in the power plant.
3. Excessive dusting from the lignite dryer shuttle house rotoclone corrosion and resulting leaks in the water pan beneath, the rotoclone made it necessary to run the unit without water. The pan will be replaced.
4. Excessive dusting from an Alcoa 446 reactor dust collector caused by bad bags.
5. High opacity when No.l Boiler in the power plant was shut down.
6. High opacity from lignite dryers when the No.2 scrubber fan was shut down for excessive vibration.
arCH 18796
ALCOA
se-4s*3 i>cv n-6>
MR. G. H. LANTZ
1978 OCTOBER 04
PAGE TWO
A quarterly progress report was submitted to OSHA describing progress made in abating violations cited during an industrial hygiene inspection in 1977 November. Requests for extensions in abatement dates were requested as follows:
Poot Front-end loader operator overexposed to dust in the bath crushing
f*n<) ,'y^r
corV^ce^oSaorelua ti-onA.irstAresakemd
helmets were not for an extension
accepted by OSHA as until 1978 December
a permanent 31 to complete
evaluation and selection of acceptable powered air purifying systems.
t'pC
Employees overexposed to coal tar pitch volatiles in anode mixer area - The initial abatement plan which includes mixer modifications and fume exhaust, improvements will be complete by the abatement date. However, an extension until 1979 July 31 to permit completion of the batch car replacement project was requested. The batch car project was not included in the initial abatement plan.
3. An employee was overexposed to noise in the rodding room - The original abatement plan depended on noise reduction associated with rodding room modernization. After modernization was complete, overexposure was still found. Asked for an extension of abatement until 1979 June 30 to complete additional noise control projects.
Other Environmental Activity
A representative of Research-Cottrell, manufacturer of the carbon plant precipitator, spent several days at Rockdale trouble-shooting the unit. He made several recommendations aimed at improving the unit's performance. These will be completed in early October. If performance is still unsatisfactory, replacement of the unit will be considered.
Rockdale enlisted the services of a consulting firm. Engineering Science,Inc., to perform an SO^ dispersion modeling study aimed at predicting the effect of increased SO2 emissions from the power plant boiler stacks. Results of the study indicated that SO2 emissions could increase significantly without causing a violation of national ambient air quality standards or without using up the available P.S.D. increment. The study is part of a plan to seek relief in the form of a standards change from the Texas Air Control Board.
Another segment of the study predicted that SO2 emissions from the smelter alone would result in violation of the annual average SO2 concentration in an
area on Alcoa property about one mile north of the plant. Mr. Ken Allison, Engineering Science, and Mr. E. B. Parker will review the study results with Dr. P. R. Atkins' group in Pittsburgh on October 9.
A third limestone injection test for SO2 removal from power plant boiler effluent is planned for October 13.
On Labor Day, 1978 September 04, a complaint was received from a local resident concerned about excessive dusting from the carbon plant precipitator. Investigation revealed a smoldering fire in the unit. Apparently a similar complaint had been lodged with the TACB earlier.
ARCH 18797
MR. G. H. LANTZ
1978 OCTOBER 04
PAGE THREE
Subsequent to OSHA's determination that Airstream helmets did not constitute a permanent solution to dust exposure experienced by bath crusher front-end loader operators, a 3M powered air purifier to be used with a 3M white cap helmet was obtained for trial. Initial response from the operators was favorable.
Construction of the potroom roof monitor sampling station in Room 10 continued. At month's end, the ductwork had been balanced and was ready for installation.
The fall urinary survey is scheduled to begin October 16.
Emissions Testing Results
Source
Date
Pollutant
Actual Emissions
Allowable Emissions
L6 Roof Monitor
78-07-10
TSP Gas F" Part F" Total F" SO2
3.95 lbs/ton A1 1.95 lbs/ton A1 1.60 lbs/ton A1 3.54 Ibs/ton A1
.36 ppm
L8 Roof Monitor
78-07-18
IGC Boiler #2
78-08-29 thru 78-09-01
TSP Gas F" Part F` Total F~ S02
7.79 lbs/ton A1 4.37 Ibs/ton A1 2.45 lbs/ton A1 6.82 lbs/ton A1
.97 ppm
TSP (F Factor) .23 lbs/10 BTU S02 (F Factor) 3.67 lbs/10 BTU S02 (Lignite 3.19 lbs/106 BTU
Analysis)
.3 lbs/106 BTU 3.0 lbs/106 BTU 3.0 lbs/106 BTU
E. B. PARKER
EBP:cw
Copy -
P. R. Atkins, Pittsburgh V. W. Rleke, Pittsburgh T. B. Bonney, Pittsburgh J. C. Mayfield, Pt. Comfort R. C. Hinkle, Badln C. L. Green, Rockdale J. W. Havins, Rockdale D. L. Smith, Rockdale A. G. Clayton, Rockdale J. J. Congleton, Rockdale
W. J. Drake, Rockdale
ARCH 18798
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0 ALCOA
1501 Alcoa Building Pittsburgh, Pennsylvania 15219
ARCH -18799