Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 92
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146 Introduction
PRIMARY ALUMINUM REDUCTION PLANTS -SUBPART S
§60.l90 - 60.195
(Amendments to the NSPS for this category will be promulgated shortly;
the requirements detailed here incorporate these amendments.)
The NSPS for this category applies to potroom groups and anode bake plants,
regardless of size, which are located at primary aluminum reduction plants.
Performan~e
tests are required at least once each month during the life of the
affected facility, but the owner or operator may petition the EPA administrator
to establish an alternative requiring less frequent testing' for a primary con-
trol system or an anode bake plant.
Performance standards have been established for fluorides and opacity.
Fluoride emissions are limited to:
(1) 1.0 kg/Mg (2.0 lb/ton) of aluminum
produced for potroom groups at Soderberg plants; (2) 0.95 kg/Mg (1.9 lb/ton)
of aluminum produced for potroom groups at prebake plants; and (3) 0.05 kg/Mg
CO.l 1b/ton) of aluminum equivalent for anode bake plants.
Potroom emissions
could exceed the applicable Soderberg or prebake plant standard, but could
never exceed 1.30 kg/Mg (2.6 lb/ton) , if an owner or
op~rator
could establish
that the emission control system was
prop~rly
operated and maintained at the
time the excursion above the standard occurred.
Opacity must be less than
10 percent for potroom groups and less than 20 percent for anode bake plants.
Sources constructed, modified, or reconstructed after October 23, 1974 are
subject to the regulations.
Process Description
All aluminum produced in the United States is by electrolytic reductiori of
alumina (A1203)'
Alumina is itself a product produced from Bauxite ore.
Fig-
ure 17 presents a flow diagram of the aluminum reduction process.
The
process
is carried out in shallow rectangular cells (Pots) constructed of carbon coated
steel shells (cathodes) utilizing consumable carbon blocks (anodes) which are
suspended above and extend down into the pot.
A series of these cells, when
connected to a common electrical supply, is considered a potline.
Potlines are
normally constructed as two adjacent buildings approximately 1,200 ft long.
Cryolite, a double fluoride salt of sodium and aluminum (Na3AlFs), serves
as both an electrolyte and a solvent for alumina.
The resistance of the cells
causes them to be heated and operate between 950
0
and 980
0
C (1,740
0
to 1,830
0
F).
During the reduction process, aluminum ions are reduced to aluminum.
The
oxygen released reacts with the anode to form carbon dioxide and carbon mon-
oxide.
Molten aluminum is periodically tapped from beneath the cryolite bath
and moved to holding furnaces prior to being cast into ingots.
PO
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