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, 2006TABLE 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 30INTRODUCTION
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 926a 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? NoNoYes Yes NoYes 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 30SOURCE 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 30SYSTEM 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 30SYSTEM

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 30RESULTS, 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 withpretest 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 30SAMPLING 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 30SAMPLING 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 0.1mgweighings 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 30F
Calo•tion

Form•aeHCI/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 30HCI/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 30PARTICULATE 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 30DATE SOURCE Run #I POINT# A1A2A3A4A5A6B1B2B3B4B5B8

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 C022,53.02.53.02.53.02,53.0
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 30DATE SOURCE Run #2 POINT # A1A2A3A4A5A6B1B2B3B4B5B6

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 % C022.52.52.52.52.53.02.52,5
2.56 79.09 724.15

.Post 0.00 0.14 n/a

Pago 16 of 30DATE 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 30MOISTURE 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 30DATE 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 30DATE SOURCE ISOKINETIC

DATA AND CALCULATIONS 02/13/07 DIFF Baghouse

Exhaust Run #2 K= 3.9190 POINT# Tm

Ts

dp

dH SQRT DP A1A2A3A4A5A8A7A8A9 AIO All A12B1B2B3B4B5B8B7B8B9BIO 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
2,52.02.5
2.52.52.52,52.52.52•52.5
2.45 79.84 524.93

-Post 0.00 0.33 n/a

Page 20 of 30DATE SOURCE Run #3 POINT# A1A2A3A4A5A6A7A8A9 AIO All A12 B1B2B3B4B5B6B7B8B9BIO 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* % C022.52.02.52.52.52.52.02,52.52.02.52.5
2.38 79.90 525.75

-Post 0,00 0.33 n/a

Page 21 of 30Run #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. 300.0 307.67.6 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. 300.0 308.68.6 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 30SAMPLE 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 30SAMPLE 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 30A•AsC1•% EA FD•

%1 M%M

N DP PAT• P•PsPs 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 30VpQs 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 30CALCinATION 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 30CALCULATION 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 3015.

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

g 22.414 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