Bo•EA-1-7 

V 

PARTICULATE, HCL, HF 

and VISUAL EMISSIONS TESTING 

ON THE DRY INJECTION FABRIC FILTER BAGHOUSE (DIFF) 

BRICKS 

700 South Long Street 

EAST SPENCER (ROWAN COUNTY), NC 28039 

(704) 636-1031 Plant Contact Telephone Number 

(704) 636-7865 Plant Facsimile Number 

Source Testing Conducted: 

February 13, 2007 

ATC Project Number 

P-07021 

ANALYTICAL TESTING CONSULTANTS, INC. 

301 Brookdale Street 

Kannapolis, N. C. 28083 

(704) 932-3193 telephone 

(800) 733-3193 toll-free 

(704) 932-0570 facsimile 

•et.net e-mail 

www.atc-net,net Web site 

Distribution: 

Mr. Frank Porter 

(Four copies) 

Mr. Barry Schenk 

(One copy) 

Issue Date: 

Febmary 28, 2006 
TABLE OF CONTENTS 

Introduction 3 

Certification of Results 3 

Source Description 4 

Results Summary 5 

Results, Conclusions and Comments 6 

Sampling and Analytical Procedures 7 

References 9 

Emission Calculations 

Particulate Emission Rate Calculation 11 

Isokinetie Data and Calculations 16 

Moisture Data 14 

Isokinetie Sampling Rate Equation 25 

Sample Calculations 28 

Nomenclature 30 

Calculation Formulae 32 

Appendix 35 

Isokinetie Sampling Data Sheets AI 

Impinger Data Records A10 

Portable Oxygen/Carbon Dioxide Measurements A12 

Visible Emissions Obsereations A18 

Source Surveys/Equal Areas A21 

G-ravimetrie Lab Report A28 

HF/HC1 Laboratory Report :. A42 

Process Data ,.'. A50 

Process Flow Diagram A53 

Protocol Approval Letter A54 

Calibration Data A55 

LELAP Certification A102 

Page 2 of 30 
INTRODUCTION 

This report presents the results of particulate, hydrogen chloride, hydrogen fluoride and visible 

emissions testing performed on the inlet/outlet of the new dry injection fabric filter baghouse recently installed on Brick Kiln #6 at Boral Bricks, Inc in East Spencer, North Carolina. 

Emissions testing were conducted while the kiln was fired at a rate of 20.3 t•tas fired product per 

hour. 

The following table outlines the methodology utilized. 

US EPA 

Methodology 

2 

Inlet/Outlet 

3a 

InleffOuflet 

4 

Inlet/Outlet 

5 

Outlet Only 

9 

26a 

Inlet/Outlet 

Description 

Determination of Volumetric Flow 

rates 

Oxygen/Carbon dioxide concentration 

determinations 

Determination of Stack Moisture 

Content 

Determination of TSP particulate 

Determination of Opacity 

Determination of Hydrogen Halide and 

Halogen Emissions from Stationary 

Sources 

Isokinetic 

Sampling? 

No 

No 

Yes 

Yes 

No 

Yes 

Notes 

S-type pitot tube 

Semi-continuous 

analyzers 

Combined with USEPA 

M5 outlet/26A inlet 

3 1-hr runs 

Combined with M5 on 

Outlet/M4 on Inlet 

Testing was conducted by ANALYTICAL TESTING CONSULTANTS, INC., Karmapolis, North Carolina. Members of the test team were Dan McCombs, Bill Kissel, Jason Treutel, Matt 

Hamilton and Tom Lange. Mr. Frank Porter of Boral Bricks performed the visual emissions 

observations. 

CERTIFICATION OF RESULTS BY TEST FIRM 

"By our signature we certify that the testing and the reporting of the test results contained herein are 

prepared to the best of our abilities and that, to our knowledge, the data have been ealculated and reported correctly, No data or information has knowingly been omitted." 

Technical Director/Test Report Author 

W. Keith Poole 

President/Quality Manager 

C. Daniel MeCombs 

Page 3 of 30 
SOURCE DESCRIPTION 

Testing was conducted on the inlet/outlet of the new dry injection fabric filter (DIFF) baghouse 

that controls acid gas (HC1 and HF) and particulate emissions released from the wood-waste 

fired Brick Kiln #6 at Boral Bricks, located in East Spencer, North Carolina. The DIFF system 

injects hydrated lime into the brick kiln extmust stream which reacts with HF and HC1 to form 

calcium fluoride and calcium chloride. The spent lime (CaF and CaC1) is removed from the 

exhaust air stream by bagfllters and is transported offsite for disposal. The baghouse exhaust 

gas contains un-reacted pollutants and partietdate matter. 

"Green" brick are stacked on drying racks and placed in a warming room, where initial drying 

occurs. The warming room is supplied with waste heat from the cooling section of the kiln. 

From the warming room, bricks enter the dryer where the temperature is raised and most of the 

process water is removed before entering the kiln. In the kiln, f'mal evaporation of the process 

water takes place as well as oxidation, vitrification, and the cooling process. All heat used in this 

process is formed in the kiln and waste heat is used for the dryer and warming room with no 

other supplementary heat. After exiting the kiln, bricks are packaged and stored on site for sale. 

The brick production rate during testing was 20.3 tons per hour. 

Page 4 of 30 
SYSTEM 

RESULTS SUMMARY 

Boral Bricks 

DIFF Baghouse 

GENERAL 

TEST DATE 

PARAMETER 

QS, FLOW, AP, I:M 

Q STD DRY, FI.OW SCFM 

Vm STD (ft3) 

QS, FLOW, ACFM 

Q STD DRY, FI.OWSCFM 

Vm STD (ft3) 

%1 

Production Rate, tons/hr 

Particulate Emission Rates 

PMRc (Ibs/hr) Particulate 

Emission Rate Ibs PM•ton fired product 

Allowable, Ibs PM/ton fired product 

40CFR63, Subpart JJJJJ 

02/13107 

Run #1 Run #2 Run #3 

83,291 84,026 85;608 

46,746 46,959 47,315 

42.76 42.91 43.85 

95.33 95.24 96.59 

88,309 86,627 90,989 

50,073 48,855 51,405 

41.44 40.79 42,62 

96.25 97.10 96.43 

2.302 0.840 0.479 

AVERAGE 

84,308 

47,007 

88,642 

50,1tt 

20,3 

1.207 

0.• 

Page =5 of 30 
SYSTEM 

HF Mass Rates 

TEST DATE 

PARAMETER 

PMRc (Ibs/h• HF 

PMRc (Ibs/hr) HF 

Emissions, Ibs HF/ton fired product 

HF Removal Efficiency, % 

Allowable, Ibs HF/ton fired product 

40CFR63, Subpart JJJJJ 

HCI Mass Rates 

PMRc (Ibs/hr) HC! 

PMRc (Ibs/hr) HC! << 

Emissions, Ibs HCl/ton fired product 

HCI Removal Efficiency, % >> 

Allowable, Ibs HCI/ton fired product 

40CFR63, Subpart JJJJJ 

RESULTS SUMMARY 

Boral Bricks 

DIFF Baghouse 

2/13/2007 

Run #t Run #2 Run #3 

11,962 12,017 12,820 

0.144 0.143 0.160 

0,0071 0.0070 0.0079 

98.80% 98,81% 98.76% 

1.996 2.012 2,084 

0. 096 0.111 0,096 

0.0047 0.0055 0.0047 

95.19% 94.49% 95,41% 

AVERAGE 

12.267 

0.149 

0.0073 

98.79% 

0.057 

2.031 

0.101 

96.03% 

0.26 

Page 6 of 30 
RESULTS, CONCLUSIONS AND COMMENTS 

Results are presented in the preceding Summary. Additional information may be reviewed in the 

Calculations and Appendices sections of this report. 

Emissions Results-Inlet 

Mean measured stack velocities on the seventy inch (70") horizontal inlet duct were 52.58 feet 

per second yielding an actual volumetric flow rate of 84,308 cubic feet per minute. The 

volumetric air flow rate was standardized to a mean 47,007 cubic feet per minute based upon 

stack conditions (moisture, temperature, static pressure and station pressure). 

Inlet loading mass rates of hydrogen fluoride were a mean 12.27 pounds per hour; HC1 averaged 2.03 lbs/hr. Results were compared to the calculated emission levels of these constituents to 

effect a control removal efficiency. 

The mean measured stack velocity of the seventy-five inch (75") outlet duet was 48.15 feet per 

second yielding an actual volumetric flow rate of 88,642 cubic feet per minute. Standardized 

flow rates (mean=50,111) were utilized in calculations of mass emissions ofPM, HCI and HF. 

Particulate emissions from the exhaust of the dry injection fabric filter baghouse (DIFF) averaged 1.207 lbs/hr and 0.059 lbs PM per ton of fired product, well in compliance with 40 

CFR 63 Subpart JJJJJ, table 1 emission limitations of 0.42 lbs/ton. 

Hydrogen fluoride emissions average 0.149 Ibs/hr and 0.0073 lbs/ton fired product yielding a 

removal efficiency of 98.8%. The DIFF Baghouse was shown to be in compliance with the 

emission limitation of 0.057 lbs/ton. 

Hydrogen chloride was not detected in any of the outlet samples or the blank. Estimated 

emissions, based on the in-stack detection limit, are no greater than 0.101 lbs per hour yielding a 

process-related emission rate of 0.0050, well in compliance with the Subpart JJJJJ standard of 

0.26 lbs/ton. Removal efficiency of hydrogen chloride is greater than 95.03%. 

No visible emissions were observed. 

Sampling and Analysis Notes 

Sampling and analyses were accomplished according to the site-speeific test plan submitted to 

NCDENR on December 21, 2006. An approval letter was received on February 6, 2007. 

Post test calibrations of the outlet isokinetic sampling module (ATC #6) did not agree with pretest meter coefficients within the required +5%. A full primary calibration was repeated and the 

results that yielded the higher emission limits (lowest sample volume) were utilized. All 

calibration records are included in the Appendix to this report. 

Page 7 of 30 
SAMPLING AND ANALYTICAL PROCEDURES 

TSP particulate emission testing and analysis were performed according to procedures developed 

by the U. S. Environmental Protection Agency (USEPA) and referred to as Method 5. Sampling 

port locations and number of test points to be used were determined according to Method 1. The 

above federal test methods appear in the Code of Federal Regulations (Reference 1). 

TSP measurements were combined with US EPA method 26a for determinations of hydrogen 

ha]ides and halogens; only the halide and PM portion of the sampling train was of concern. A 

standard US EPA method 5/26a all-glass sampling train was utilized that employed pyrex or 

quartz glass nozzles and probe liners, pre-tared 3" round Pallflex quartz filters (lot #55356), and 

Teflon filter supports. The condenser train consisted of five glass impingers connected 

sequentially. The ftrst two impingers were each charged with 100 ml of 0.1 N H2SO4; the third 

and fourth were filled with 100 ml of 0.1 N NaOH. The final impinger was initially charged 

with 300 grams of silica gel. All sample recovery was conducted in the on-site field trailer. 

Condenser train acid collections were measured and transferred to 500 ml Nalgene samples 

bottles. The sodium hydroxide fractions were measured and discarded since no further analysis 

was required. The front half of the sampling train (nozzle, probe and front half of the filter bell) 

was rinsed with reagent grade acetone and stored in 500 ml Nalgene® bottles until analysis. 

Liquid levels were marked on the sampling bottles with a grease pencil. 

Test point locations and sampling port placement for velocity traverses are shown in the data 

sheets. Test point locations were ea]culated based upon an outlet stack diameter of 75" and inlet 

stack diameter of 70". Upstreams/downstreams on the exhaust dictated maximum sampling 

points (24) while twelve total test points were measured on the inlet. 

Laboratory equipment that was utilized for the gravimetric sample analysis included the 

following: 

1) Precisa 303A Analytical Lab Ba]ance-certifieation and annual maintenance by Applied 

Weight Technologies, Inc. (completed 3/2/2006). 

2) Prior to each use, the balance is calibrated with NIST Traceable weights-0.5000, 5.0000, 

50.0000, and 100.0000 grams, and 

3) a Nalgene® 5317-0180 Desiccator cabinet with indicating desiccant. 

Prior to the field test, filter media were prepared by sequentially numbering Pallfiex quartz filters 

with a non-bleeding marker and oven drying. Duplicate weights were then performed on the 

filters to reach a constant weight. Additionally, sufficient quantities of numbered 150ml Griffin 

beakers were thoroughly washed with warm, soapy water and oven-dried. Once cooled, the 

beakers were also weighed to a constant weight and stored in the dessieator cabinet until needed. 

Page 8 of 30 
SAMPLING AND ANALYTICAL PROCEDURES 

(continued) 

After recovery, each filter was stored individually in petri dishes until transferred to the 

desiccator for a period of no less than twenty-four hours at room temperature and constant 

relative humidity; filters were then weighed to a constant weight (to the nearest 0.1 mgweighings over minimum of six hour period). 

A blank of the acetone reagent was collected in the field, along with the samples and analyzed side by side. An appropriate portion of acetone (density 0.788 me/l) was evaporated. The 

maximum allowable residue according to US EPA QA/QC documentation is 0.0001% grams. 

The net gain of the acetone blank was applied based upon this and a ratio of the volume of the 

sample to the volume of the blank according to the following example. 

A filter blank was processed in conjunction with the samples and is recorded in the gravimetdc lab report. This was for QA/QC purposes only. 

Page 9 of 30 

F 

Calo•tion Form•ae 
HCI/HF Inlet Loading Calculation 

LOCATION: Boral Bricks 

SOURCE: DIFF Baghouse Inlet 

DATA Run #1 Run #2 Run #3 

DATE 02113/07 02113/07 02/13/07 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0,280 0.280 0.280 

An (ft2) 4.28E-04 4.28E-04 4.28E-04 

AVG DH (in H20) 1.63 1.69 1.74 

P A TM (in Hg) 28.90 28.90 28.90 

Pm (in Hg) 29.02 29.02 29.03 

Ps (GAUGE) -0.48 -0.48 -0.48 

Ps (IN HG) 28.86 28.86 28.86 

Tm (F) 58.67 62.50 63.83 

Tm (R) 518.36 522.19 523.52 

Vm (ft3) 43.98 44.46 45.54 

Vm STD (ft3) 42.76 42.91 43.85 

VLQ (ml) 41.70 43.70 51.30 

WSTD (ft3) 1.97 2.06 2.42 

V STD (ft3) 44.72 44.97 46.27 

%M 4.40 4.58 5.23 

% SVP 100.00 100.00 100.00 

MD 0.956 0.954 0.948 

MWD 29.17 29.14 29.14 

M 28.67 28.63 28.56 

Ts (F) 408.00 410.00 413.75 

Ts (R) 867.69 869.69 873.44 

SUM SQRT DP 8.48 8.54 8.67 

N DP 12.00 12,00 12.00 

AVG SQRTDP 0.71 0.71 0.72 

CP 0.84 0.84 0.84 

Vs (if/s) 51.94 52.40 53.39 

Ds (in) 70.00 70.00 70.00 

As (ft2) 26.73 26.73 26.73 

QS, FLOW, ACFM 83,291 84,026 85,608 

Q STD (ft3/min) 48,896 49,214 49,925 

Q STD DRY, FLOWSCFM 46,746 46,959 47,315 

WT(gm) HCI 0.0138 0.0139 0.0146 

WT(gm) HF 0.0827 0.0830 0.0898 

%1 95.33 95.24 96.59 

%C02 2.75 2.56 2.50 

%02 18.14 18.35 18.50 

%C0 0.00 0.00 0.00 

%N2 79.11 79.09 79.00 

AVERAGE 

4.74 

4t0.68 

870.27 

62,68 

84,308 

49,34• 

47,007 

2.60 

18,33 

Theoretical amount of moiatum that Ts can hold. 

If %M>%SVP, %SVP will be utilized in calcula•ona. 

Page 12 of 30 
HCI/HF Emission Rate Calculation 

LOCATION: Boral Bricks 

SOURCE: DIFF Baghouse Exhaust 

DATA Run #t Run #2 Run #3 

DATE 02/13/07 02113107 02/13/07 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0.284 0.284 0.284 

An (ft2) 4.40E-04 4.40E-04 4.40E-04 

AVG DN (In H20) 1.69 1.62 1.80 

P ATM (in Hg) 28.90 28.90 28.90 

Pm (In Hg) 29.02 29.02 29.03 

Ps (GAUGE) -0,24 -0.24 -0.24 

Ps (IN HG) 28.88 28.88 28.88 

Tm (F) 67.75 74.71 76.58 

Tm (R) 527.44 534.40 536.27 

Vm (ft3) 42,46 42.35 44,39 

Vm STD (ft3) 41.44 40.79 42.62 

VLQ (ml) 43,60 44.60 43.30 

W STD (ft3) 2.06 2.10 2.04 

V $TD (ft3) 43.50 42.89 44.66 

%M 4.73 4.90 4.57 

% SVP 100.00 100.00 100.00 

MD 0.953 0.951 0.954 

MWD 29.08 29.10 29.09 

M 28.56 28.56 28.58 

Ts (F) 396.71 399.75 401.25 

Ts (R) 856.40 859.44 860.94 

SUM SQRTDP 15.73 15.41 16.18 

N DP 24.00 24.00 24.00 

A VG SQRT DP 0.66 0.64 0.67 

CP 0.84 0.84 0.84 

Vs (rds) 47.97 47.06 49.43 

Ds (in) 75.00 75.00 75,00 

As (ft2) 30.68 30.68 30.68 

QS, FLOW, ACFM 88,309 86,627 90,989 

Q STD (ft3/min) 52,557 51.374 53.867 

Q STD DRY, FLOW SCFM 50,073 48,855 51,408 

Wr(gm) NCl < 0.0006 0.0007 0.0006 

WT(gm) HF 0.0009 0.0009 0.0010 

%1 96.25 97.10 96.43 

%C02 2.29 2.45 2.38 

%02 17.83 17.71 17.72 

%C0 0,00 0.00 0.00 

%N2 79.88 79.84 79.90 

TheoreUcal emount ofmoisture that Ts can hold. 

If %M>%SVP, %SVP will be utilized In calculations, 

AVERAGE 

4.73 

399.24 

858.93 

48,15 

88,642 

52,599 

50,1tl 

2,37 

17,75 

Page 13 of 30 
PARTICULATE EMISSION RATE CALCULATION 

LOCATION: Boral Brfcks 

SOURCE: DIFF Baghouse Exhaust 

DATA Run #1 Run #2 Run #3 

DATE 02/13/07 02/13/07 02/13/07 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (In) 0,284 0.284 0,284 

An (ft2) 4.40E-04 4.40E-04 4.40E-04 

A VG DH (in N20) 1.69 1.62 1.80 

P ATM (in Hg) 28.90 28.90 28.90 

Pm (in Hg) 29.02 29.02 29.03 

Ps (GAUGE) -0.24 -0.24 -0.24 

Ps (IN HG) 28.88 28.88 28.88 

Tm (F) 67.75 74.71 76.58 

Tm (R) 527.44 534.40 536,27 

Vm (ft3) 42.46 42.35 44.39 

Vm STD (ft3) 41.44 40.79 42.62 

VLQ (ml) 43.60 44.60 43.30 

VV STD (ft3) 2,06 2.10 2.04 

VSTD (ft3) 43.50 42.89 44,66 

%M 4.73 4.90 4.57 

% SVP 100,00 100.00 100.00 

MD 0.953 0.951 0,954 

MIND 29.08 29,10 29.09 

M 28.56 28.56 28,56 

Ts (F) 396.71 399,75 401.25 

Ts (R) 856.40 859.44 860.94 

SUM SQRT DP 15.73 15.41 16,18 

N DP 24,00 24.00 24.00 

A VG SQRT DP 0.66 0.64 0.67 

CP 0.94 0.84 0.84 

Vs (ft/s) 47.97 47.06 49.43 

Ds (in) 75,00 75.00 75.00 

As (ft2) 30.68 30.68 30•68 

QS, FLOW, ACFM 88,309 86,627 90.989 

Q STD (ft3/min) 52,557 51,374 53,887 

Q STD DRY, FLOWSCFM 50,073 48,855 51,405 

WT (gin) 0.0144 0.0053 0,0030 

%1 96.25 97.10 96.43 

%C02 2.29 2.45 2.38 

%02 17.83 17,71 17,72 

%C0 0,00 0,00 0.00 

%N2 79,88 79.84 79.90 

PMRc (lb•/hr) 2.302 0.840 0,479 

Cs (GR/SCFD) 0.0054 0.0020 0,0011 

Theoratical amount of moisture Mat Ts can hold, 

If %M>%$VP, %SVP will be utilized in calculations. 

A VERA GE 

4.73 

399.24 

858.93 

48.15 

88,642 

52,899 

60,111 

2.37 

17.76 

1.207 

0.0028 

Page 14 of 30 
DATE 

SOURCE 

Run #I 

POINT# 

A1 

A2 

A3 

A4 

A5 

A6 

B1 

B2 

B3 

B4 

B5 

B8 

ISOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Inlet 

K= 3.2527 

Tm Ts dp dH SQRT DP % 02 

53 404 0.49 1.59 0.700 18.2 

55 405 0.57 1.85 0.755 18.0 

56 412 0.65 2.11 0.806 18.1 

58 405 0.54 1.76 0.735 18,2 

59 401 0.48 1.56 0.693 18.1 

59 404 0.38 1,24 0,616 

60 413 0.41 1.33 0.640 18.1 

59 425 0.54 1.76 0.735 18.0 

60 405 0.52 1.69 0.721 18,0 

62 410 0.54 1.76 0.735 17.9 

61 407 0.48 1.56 0.693 t7,9 

62 405 0.42 1.37 0.648 

58.67 

Vm(ft3) 

408.00 

Initial 

Final 

Total 

1.63 8,477 18.05 

corrected per 6C-1 18.14 

638.69 % N2 (BY DIFFERENCE) 

682,67 

43.98 %Excess Air 

Calibration 

Gas 

MId-Ranqe 

C02 

2,5 

3.0 

2.5 

3.0 

2.5 

3.0 

2,5 

3.0 

2.75 

79,11 

860.08 

Actual Instr•mer•t Reading % Error* 

Pre- .Post Pre- -Post 

0.0 0.0 0.1 0.00 0.48 

10.53 i0.6 10.4 0,33 0,62 

19.01 19.3 n/a 1.38 n/a 

Based upon 2% of span value (21%) 

Page 15 of 30 
DATE 

SOURCE 

Run #2 

POINT # 

A1 

A2 

A3 

A4 

A5 

A6 

B1 

B2 

B3 

B4 

B5 

B6 

lSOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Inlet 

K= 3.3206 

Tm Ts dp dH SQRTDP %02 

59 417 0.52 1.73 0.721 18.2 

60 407 0.57 1.89 0.755 18.2 

60 409 0.64 2.13 0.800 18.0 

63 410 0.59 1.96 0.768 18,3 

63 408 0.48 1.59 0.693 18.2 

63 398 0.40 1.33 0.632 

62 411 0,44 1.46 0.663 18.3 

63 413 0.50 1.66 0.707 18.2 

63 412 0.52 1.73 0,721 18,0 

64 415 0.54 1.79 0.735 18.0 

65 416 0.49 1.63 0.700 18.3 

65 404 0.41 1.36 0.640 

Vm(ft3) 

410.00 1.69 8.636 18.17 

corrected per 6C-1 18.35 

Initial 682,92 % N2 (BY DIFFERENCE) 

Final 727,38 

Total 44.46 %Excess Air 

Calibration Data 

Calibration Actual Instrument Reading 

Gas Pre. -Post Pre. 

Zero 0.0 0.1 0.0 0.48 

Mid-Ran=e 10.53 10.4 10.5 0,62 

• 19.01 n/a n/a n/a 

Based upon 2% of span value (21%) 

% EEoP 

% C02 

2.5 

2.5 

2.5 

2.5 

2.5 

3.0 

2.5 

2,5 

2.56 

79.09 

724.15 

.Post 

0.00 

0.14 

n/a 

Pago 16 of 30 
DATE 

SOURCE 

Run #3 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Inlet 

K= 3.3201 

Tm Ts dp dN SQRT DP % 02 % C02 

•- A1 61 415 0.47 1.56 0.686 18.4 2.5 

A2 62 416 0.54 1.79 0.735 18.1 2.5 

A3 64 419 0.60 1.99 0.775 18.3 2.5 

A4 63 418 0.56 1.86 0,748 18.3 2.5 

A5 64 420 0.51 1,69 0.714 18.4 2.5 

A6 64 418 0.37 1.23 0.608 18.4 2.5 

B1 62 409 0.49 1.63 0.700 18.3 

B2 65 410 0.55 1,83 0.742 18.3 2.5 

B3 64 4t 1 0.59 1.96 0.768 18.2 

B4 65 416 0.65 2.16 0,806 18.4 2.5 

• B6 65 408 0.51 1.69 0.714 18.4 

B8 67 405 0.45 1.49 0,671 

63.83 

Vm(ft3) 

413.75 

Initial 

Final 

Total 

1.74 8.687 18.32 

corrected per 8C.1 18,50 

727.91 % N2 (BY DIFFERENCE) 

773.45 

45.54 %F.xcess Air 

Calibration Actual 

Gaa 

Zero 0.0 

Mid-Ren(=e• 10.53 

• 19.01 

2.50 

79.00 

783.62 

Instrument Reading % Error* 

Pre- -Post Pre- -Post 

0.0 0.1 0.00 0.48 

10.5 10..4 0.14 0.62 

n/a n/a n/a n/a 

Based upon 2% of span value (21%) 

Page 17 of 30 
MOISTURE DATA 

DIFF Baghouse Inlet 

2/13/2007 

Run #1 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 5th Imp. 

BEGINNING 100 100 t00 100 300.0 

ENDING 112 120 100 100 309,7 

NET 12 20 0 0 9.7 

Run #2 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 5th Imp. 

BEGINNING 100 100 100 100 300.0 

ENDING 114 120 100 100 309.7 

NET 14 20 0 0 9.7 

Run #3 

1st Imp, 2nd Imp. 3rd Imp. 4th imp. 5th Imp, 

BEGINNING 100 100 100 100 300,0 

ENDING 112 124 100 100 315.3 

NET 12 24 0 0 15.3 

ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

K (846.72*Dn^4*dH@*Cp^2*(1,Bw)^2*Md*Tm*Ps)/(Ms*Ta*Pm) 

Run #1 Run #2 Run #3 

Module ID Apex #1 Apex #1 Apex #1 

Dn 0.280 0.280 0.280 

dH@ 1.638 1.638 1.638 

Y, gamma factor 0,gEH 0,984 0.984 

Cp 0.84 0.84 0.84 

Bw(FRACTION, NOT•,,•) 0.05 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 28.90 28.90 28.90 

PS (GAUGE) -0.48 -0.48 -0.48 

Ps 28.86 28.86 28.86 

Tin, F 60 65 65 

Tin, R 5t9.69 524.69 524.69 

Ms 28,45 28.45 28.45 

Ts, F 420 410 410 

Ts, R 879.69 869.69 869.69 

Pm 29.01 29.02 29.02 

K 3.2527 3.3206 3.3201 

Terminology 

Ms=APPARENT STACK GAS MOLECULAR WEIGHT 

=Md(1-Bw)+18Bw 

Md=DRY GAS MOLECULAR WEIGHT (29) OR 

=(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) 

Ps GAUGE=STACK STATIC PRESSURE (IN. H20) 

Ps=ABSOLUTE STACK PRESSURE (IN. Hg) 

Pro=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dW13.6) 

Page 18 of 30 
DATE 

SOURCE 

RUB #1 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Exhaust 

K= 3.9210 

Tm Ts dp dH SQRT DP % 02 % CO2 

•- A1 56 395 0.37 1.45 0.608 17.9 tI A2 56 394 0.38 1.49 0.616 18.2 2.0 

A3 59 395 0.39 1.53 0.624 18.1 

F•"" A4 61 395 0.40 1.57 0.632 18.1 2.5 

A5 63 396 0.40 1,57 0.632 18.2 

A6 65 398 0.41 1.61 0.640 18.0 2.0 

A7 66 397 0.36 1.41 0.600 18,2 • A8 67 397 0.40 1.57 0.632 18.1 

A9 67 397 0.44 1.73 0.663 18.0 2.5 

AIO 69 396 0.51 2,00 0.714 18.0 

All 70 396 0.54 2.12 0.735 17.9 2.5 

i. A12 70 396 0.54 2,12 0.735 17.9 

B1 66 397 0.51 2.00 0.714 17.8 2,5 

B2 68 396 0.53 2.08 0.728 18.0 2.0 

B3 69 398 0.53 2.08 0.728 18.1 2.0 

B4 70 399 0.49 1.92 0.700 17.9 2.5 

B5 71 398 0.49 1.92 0.700 18.0 2.0 

B6 72 397 0.42 1.65 0,648 18.1 2,0 

B7 73 398 0.39 1.53 0.624 17.8 2.5 

B8 73 398 0.38 1.49 0.616 17.6 

• B9 73 398 0.38 1,49 0.616 17.7 2,5 

BIO 74 397 0.39 1.53 0.624 17.8 

Bll 74 396 0.36 1.41 0.600 17.7 2.5 

B12 74 397 0.36 1.41 0.600 17.7 

87.75 

Vm(ft3) 

398.71 

Initial 

Final 

Total 

1.69 15.734 17.95 

corrected per 6C-1 17.83 

123.66 % N2 (BY DIFFERENCE) 

166.12 

42.46 %Excecs Air 

Calibration 

Gae 

Mid-Ranoe 

Actual Instrument Reading 

Pre- -Poet Pre. 

0.0 0.0 0.0 0.00 

10.53 10.6 10.6 0.33 

19.01 19.3 nla 1.38 

Based upon 2% of span value (21%) 

% Error* 

2.29 

79.88 

547.38 

-Post 

0.00 

0.33 

n/a 

P•ge 19 of 30 
DATE 

SOURCE 

ISOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Exhaust 

Run #2 K= 3.9190 

POINT# Tm Ts dp dH SQRT DP 

A1 

A2 

A3 

A4 

A5 

A8 

A7 

A8 

A9 

AIO 

All 

A12 

B1 

B2 

B3 

B4 

B5 

B8 

B7 

B8 

B9 

BIO 

Bll 

B12 

% 02 

66 402 0.36 1.41 0.600 

67 404 0.37 1.45 0.608 

68 403 0.37 1.45 0.608 

69 402 0.35 1.37 0.592 

71 402 0.37 1.45 0,608 

72 402 0.37 1,45 0.608 

73 402 0.37 1.45 0.608 

74 402 0.42 1.65 0.648 

74 398 0,47 1.84 0,686 

76 394 0.48 1.88 0.693 

76 393 0.46 1.80 0.678 

77 388 0.46 1.80 0.678 

73 403 0.52 2.04 0.721 

75 403 0.53 2.08 0.728 

76 403 0.52 2.04 0.721 

77 403 0.52 2.04 0.721 

78 402 0.46 1.80 0.678 

79 403 0.42 1.65 0.648 

79 403 0.37 1,45 0.608 

79 403 0.35 1.37 0.592 

78 403 0.38 1.49 0.616 

78 395 0,36 1.41 0,600 

79 391 0.33 1.29 0.574 

79 390 0.34 1.33 0.583 

17.9 

17.8 

17.7 

18.0 

17.7 

17.8 

17.9 

17.7 

17.8 

17.8 

17.9 

17.8 

17.9 

18.0 

18.0 

17.7 

17.8 

17.7 

17.6 

17.8 

17.9 

17.9 

74.71 

Vm(ft3) 

399,75 

Initial 

Final 

Total 

1.62 15.407 17.82 

corrected per 8C.1 17.71 

166.33 % N2 (BY DIFFERENCE) 

208.68 

42.35 %Excess Air 

Calibration 

Gas 

Mid-Ranae 

calibration Dat• 

Actual Instrument Reading 

Pre. -Post Pre0.0 0.0 0.0 0.00 

10.53 10,6 10,6 0.33 

19.01 n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

% C02 

2,5 

2.0 

2.5 

2.5 

2.5 

2.5 

2,5 

2.5 

2.5 

2•5 

2.5 

2.45 

79.84 

524.93 

-Post 

0.00 

0.33 

n/a 

Page 20 of 30 
DATE 

SOURCE 

Run #3 

POINT# 

A1 

A2 

A3 

A4 

A5 

A6 

A7 

A8 

A9 

AIO 

All 

A12 

B1 

B2 

B3 

B4 

B5 

B6 

B7 

B8 

B9 

BIO 

Bll 

ISOKINETIC DATA AND CALCULATIONS 

02/13/07 

DIFF Baghouse Exhaust 

K= 3.9197 

Tm Ts dp dH SORT DP % 02 

69 403 0,38 1.49 0.616 17.9 

70 404 0.37 1.45 0,608 17.8 

70 405 0.37 1.45 0.608 18,0 

72 404 0.39 1.53 0.624 18.1 

74 405 0.39 1.53 0.624 17,8 

75 404 0.40 1.57 0.632 17.9 

75 405 0.43 1.69 0.656 17.7 

75 406 0.43 1.69 0.656 17,8 

76 406 0.52 2.04 0.721 17.7 

76 406 0.62 2.43 0.787 17.9 

76 400 0.52 2,04 0.721 17.9 

76 392 0.42 1.65 0.648 

76 402 0.59 2.31 0.768 17.8 

78 401 0.58 2,27 0.762 t7.9 

79 401 0.58 2.27 0.762 17.8 

79 401 0.58 2.27 0.762 17.7 

80 400 0.55 2.16 0.742 17.7 

80 400 0.51 2.00 0.714 18.0 

80 401 0.42 1,65 0.648 17.9 

81 403 0.43 1.69 0.656 17.8 

80 402 0.44 1.72 0.663 17.8 

81 400 0.42 1.65 0.648 17.9 

80 391 0.33 1.29 0.574 17.7 

80 388 0,33 1.29 0.574 

76.58 

Vm(ft3) 

401.25 

Initial 

Final 

Total 

1.80 16.176 17.84 

corrected par 6C.1 17. 72 

208.82 % N2 (BY DIFFERENCE) 

253.21 

44.39 %Excess Air 

Calibration 

Gaa 

MId-Ranae 

Actual Instrument Reading 

Pre- -Poet Pro0.0 0,0 0.0 0.00 

10.53 10.6 10.6 0.33 

19,01 n/a n/a n/a 

Based upon 2% of span value (2t%) 

% Error* 

% C02 

2.5 

2.0 

2.5 

2.5 

2.5 

2.5 

2.0 

2,5 

2.5 

2.0 

2.5 

2.5 

2.38 

79.90 

525.75 

-Post 

0,00 

0.33 

n/a 

Page 21 of 30 
Run #1 

MOISTURE DATA 

DIFF Baghouse Exhaust 

2/13/2007 

1st Imp. 2nd imp. 3rd Imp. 4th Imp. 

BEGINNING 100 100 100 100.0 

ENDING 116 120 100 100.0 

NET 16 20 0 0.0 

5th Imp. 

300.0 

307.6 

7.6 

TOTALS 

43,8 

Run #2 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 

BEGINNING 100 100 100 100.0 

ENDING 116 118 102 100.0 

NET 16 18 2 0.0 

5•h Imp. 

300.0 

308.6 

8.6 

TOTALS 

44.8 

Run #3 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 

BEGINNING 100 100 100 100.0 

ENDING 114 116 100 100.0 

NET 14 16 0 0,0 

ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

K (846.72*Dn^4*dH@*Cp^2*(1-Bw)^2*Md*Tm*Ps)l(Ms*Ts*Pm) 

Run #1 Run #2 Run #3 

Module ID ATC #6 ATC #6 ATC #6 

Dn 0,284 0.284 0.284 

dH@ 1,771 1.771 1.771 

Y, gamma factor 1.081 1.081 1.081 

Cp 0.84 0.84 0.84 

Bw(FRACTION, NOT%) 0.05 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 28.90 28.90 28.90 

PS (GAUGE) -0.24 -0.24 -0.24 

Ps 28.88 28.88 28.88 

Tin, F 75 75 75 

Tm, R 534.69 534,69 534.69 

MS 28;45 28,45 28.45 

Ts, F 400 400 400 

Ts, R 859.69 859.69 859.69 

Pm 29,01 29.02 29.02 

K 3.9210 3.9190 3.9197 

Terminology 

Ms=APPARENT STACK GAS MOLECULAR WEIGHT 

=Md(I-Bw)+18Bw 

Md=DRY GAS MOLECULAR WEIGHT (29) OR 

=(0.44*%CO2)+(0,32*%O2)+(0.28*(%N2+%CO)) 

Ps GAUGE=STACK STATIC PRESSURE (IN. H20) 

Ps=ABSOLUTE STACK PRESSURE (IN, Hg) 

Pm=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dH/13.6) 

5th Imp. 

300.0 

313,3 

13.3 

TOTALS 

43,3 

Page 22 of 30 
SAMPLE CALCULATIONS 

Boral Bricks 

East Spencer, NC 

Run #1 

1) ABSOLUTE PRESSURE IN DRY GAS METER 

Pm P ATM + AVG DH/13.6 T STD= 

PSTD= 

P ATM Avg, OH Pm 

28.90 1.69 29.02 

2) ABSOLUTE 8TACK PRESSURE 

PS P ATM + Ps(GAUGE)/13.6 

P ATM PS(GAUGE) PS 

28.90 -0,24 28.88 

3) SAMPLE VOLUME ATSTANDARD CONDITIONS 

VM STD (VM)*(Y)*(T STD/TM)*(PM/P STD) 

Vm Tm Y Vm STD 

42.46 527.44 1.005 41.44 ft3 

4) VOLUME OF WATER COLLECTED, CORRECTED TO STANDARD CONDITIONS 

W STD W STDW + WSTDsg 

W STDw (.002673)*(VLQW)*(T 8TD/P STD) 

W STDsg (.002668)*VLQsg)*(T STD/P STD) 

WHERE 0.002673 0.00707 FT3/ML*IN, HG/17.64 DEG. R. 

WHERE 0,002668 0.00715 FT31G*IN.HGI17,64 DEG, R. 

VLQ (w) •P•.Q (sg) W 8TD 

36.00 0•00 t.70 •3 

5) TOTAL SAMPLE VOLUME AT STANDARD CONDITIONS 

V STD Vm STD + W STD 43,t4 ft3 

6) PERCENT MOISTURE IN STACK GAS 

%M (100)*(VV STD)/V STD 3.94% 

7) MOLE FRACTION OF DRY GAS 

MD (100-%M)I100 0.961 

528 DEG R. 

29.92 IN. HG 

Page 23 of 30 
SAMPLE CALCULATIONS 

Run #1 

8) MOLECULAR WEIGHT OF THE DRY GAS 

MWD (%CO2*0.44)+(O2*0.32)+((%CO+%N2)*0.28) 

%CO2 %02 %CO %N2 MWD 

2.3 17.8 0.0 79.9 29.08 

9) MOLECULAR WEIGHT OF THE WET GAS 

M (MWD)*(MD) + t8(1-MD) 

WHERE 18 MOLECULAR WEIGHT OF WATER, G/G-MOLE 

10) STACK VELOCITY 

VS (85.49)*(CP)*((TS/(PS)(M))^1/2*((SUM SQRT DP)tN DP)) 

where 85A9 Wseo* [Ib/lb-mole*ln,Hg)l(deg. R*ln H20)]^0.5 

CP Ts (R) SUM SQRT N DP 

0,84, 856.40 15.73 24 

11) 8TACK VOLUMETRIC FLOW RATE 

QS (60)*(VS)*(AS) 

t2) 

t4) 

AS (Inlet) QS 

30,68 88,t74 

VS 

47,90 

8TACK VOLUMETRIC FLOW RATE, STANDARD CONDITIONS INCLUDING MOISTURE 

Q STD Q STD DRY/MD 82,4/'7 

8TACK VOLUME FLOW RATE STANDARD CONDITIONS DRY 

Q STD DRY= 17,647*60*Md*Vs*A*(Ps/Ts(R)) 60,411 

POLLUTANT MASS RATE, CONCENTRATION BASIS 

PMRC (.1323)*(WT)*(Q STD)/V STD 

WHERE 0.1323 COMBINED CONVERSION FACTOR (60 MIN/HR*0.00220 LBS/QRAM) 

WT(GRAMS) PMRC 

0.0006 0.097 

16) PERCENT 18OKINETIC 

%1 (0.09450*Ts*Vm std)/(P$*Vs*An*TIme*Md) 

Run Time Area of Nozzle 

60 4.40E.04 

16) CONCENTRATION, GR/BCFD 

C$= 15.4`3 gr/gm WT/Vm STD 

Cs 0,0002 

%1 

95,60 

Page 24 of 30 
A• 

As 

C1• 

% EA 

F 

D• 

%1 

M 

%M 

N DP 

PAT• 

P• 

Ps 

Ps Gauge 

PsTv 

PMRC 

PMRU 

NO•NCLATURE 

(square inches), cross sectional area of nozzle 

(square feet), cross sectional area of stack 

Pitot tube calibration coefficient, dimensionless 

Percent excess a• 

(scfd/M•Btu), F factor 

(inches of water) average orifice meter reading 

(MMBt•.dhr), heat input rate 

Percent isokineticity 

(Ib/lb mole), molecular weight of wet gas 

Percent moisture 

Mole fraction of dry gas 

(lb/lb mole) molecular weight of dry gas 

Number of sampling data points 

(in Hg), local atmospheric pressure 

(in Hg), absolute pressure in dry gas meter 

(in Hg), absolute stack pressure 

(inches of water), measured static stack pressure gauge 

(29.92 in Hg), standard pressure 

0b/hr), polluter mass rate based on concentration 

(lb/mmBtu), specific emission rate 

Page 25 of 30 
Vp 

Qs 

NOMENCLAT• 

(continued) 

(inches of water), velocity pressure 

(•/min.)• actual stack volume flow,rote 

QSTD (flS/min.), stack volume flow rate at standard 

Conditions 

Time(min) duration of test 

TM 

Ts 

TSTD 

Vs 

VVsTD 

(°R), average dry gas meter temperature 

(°R), average smok temperature 

(528 OR), standard temperature 

(ml). liquid volume 

(its), sample volume measured by dr-y gas meter 

Sample volume at standard conditions 

(•se•), Mack velocity 

volume of water vapor c•lleeted, 

corrected to standard conditions 

(grams), total weight of particulate collected 

Page.26 of 30 
CALCinATION FO•AE 

1. Absolute pressure at the dry gas meter, Pm 

Pra-Pbar k1--•.6) 

2. Absolute stack pressure, Ps 

3. Sample volume at standard conditions, Vm(std) 

528°R 

29.92i•Hg 

4. Volume of water collected, corrected to standard conditions, Vv(std) 

V•(zd)• O. 04706 f13 × 

29.92" Hg 

× ml 

ml 528°R 

V•(,ta)e. 0.04715 fl3x 29.92"Hg × ml ml 528°R 

5. Total sample volume at standard conditions, Vstd 

6. Percent moisture in stack gas, %M 

%M Vv(aa) X 1 O0 

7. Mole Fraction of the dry gas, MD 

M•- O00-•M) 

100 

Page 27 of 30 
CALCULATION FO•AE 

(eontinued) 

-5: 

8. Molecular weight of the Dry Gas, MWD 

MWD 0.440(%CO 2)+ 0.320(%02)+ 0.280(%N 2 + %C0) 

9. Molecular weight of stack gas, wet basis, g/g-mole 0b/lb-mole), M 

10. Stack velocity, Vs 

x ] 

11. Average stack gas dry vohtmetrio flow rate, Qstd dry 

12. Pollutant mass rate, concentration basis, lbs/hr 

PMRC 0.1323Ib-min 

gram hr 

x grams x Q•ta + Vsta 

13. Percent Isokinetieity 

I= I00T• [K3V•° +(V'Y/T'XP•a' + Ah/13.6)] 

60xOxV•xgx• 

14. % Excess Air 

( (%02 0.5%CO) %EA =•(0.264 ×%N•)-%02 + 0.Sx %co)Xl00 

Page 28 of 30 
15. Dry Gas Meter Check 

Y• 10 10,0319 T•' In 

CALCULATION FORMULAE 

(continued) 

16. Heat Input Rate, mmBtu/hr 

H1 60 mird hr x dsef / min 

dscf / mmBtu 

x 

20.9- %02 

20.9 

17. Specific emission rate, lbs/mmBtu 

PMRC PMR U 

HI 

18. Modified Carrier Equation for Prediction of Stack Moisture with a Wet Bulb Thermometer 

%M 10 ( (0.000367XP , XTd T 

W 1"+ r, 32- 

1571 

19. Correction of Gas Concentrations for Calibration Error, Equation 6c-1 

20. VOC Emission Rate as {compound specified by molecular weight} 

g-mole 1 

x 

103 mg 

x Q,,aa• x3.75e -°6 

m3 293.15°K Xlxl06ppm 22.414 g liters xl03__x 

g-mole liter 273.15°K 

3.75e_06 0.0022/bs g 60rain m 3 

X X•X 

g lO00mg hour 35.315fl • 

Page 29 of 30