EMISSIONS TESTING ON THE KILN EXHAUST BORAL BRICKS 3101 West 53 rcl Street South MUSKOGEE, OKLAHOMA 74401 (918) 687-6825

Client Telephone

Number (918) 682-0813

Client Facsimile

Number Source Testing Conducted: December 13, 2005 ATC Project Number P-06003

Providing Qua/it• Air Testing and Consuitin•g Services Since f981. ANALYTICAL TESTING

CONSULTANTS,

INC. 301 Brookdale

Street Kannapolis, N. C. 28083 (704) 932-3193

telephone (800) 733-3193

toll-free (704) 932-0570

facsimile corp@atc-net.net e-mail www.atc-net.net Web site Distribution: Mr. Frank Porter (Four copies) Issue Date: January 10, 2006TABLE OF CONTENTS Page

No. Introduction

......................................................................................................................... 3 Certification of Results

.................................................................................................... Source Description

.............................................................................................................. 4 Results Summaries

.............................................................................................................. 5 Results, Conclusions

and Comments

.................................................................................. 7 Sampling and Analytical

Procedures

.................................................................................. 8 References

......................................................................................................................... 11 Poilutant Emission

Calculations

............................................................................................ PM, HC1, and HF Emission

Rate Calculations 13 Stack Data for the Method

5/26a Sampling

Train 14 Moisture Data from M 5/26a Train

................................................................................. 17 Sulfur Dioxide/Sulfuric

Acid Mist Emission

Rate Calculation 18 Stack Data for the Method

8 Sampling

Train 19 Moisture Data from M 8 Train

........................................................................................ 22 Sample Calculations

(PM)

............................................................................................... 23 Nomenclature

.................................................................................................................... 25 Calculation Formulae

........................................................................................................ 27 Appendix

.......................................................................................................................... 30INTRODUCTION
This

report presents

the results of particulate

(PM), hydrogen

chloride

(HC1), hydrogen

fluoride (HF), sulfur dioxide

(SO2)and

sulfuric acid mist (SAM 1) emissions

testing performed

on the exhaust of the kiln at Boral Bricks, Inc. in Muskogee,

Oklahoma.

Emissions

testing were conducted while the kiln was fired on natural gas and operating

under normal conditions. The following

table outlines

the methodology

utilized.
US EPA Methodology Description Determination of TSP particulate Determination of sulfur dioxide and sulfuric acid concentration Isokinetic Sampling? Yes Yes 26a Hydrogen

Chloride/Hydrogen

Fluoride

Yes Emissions

Notes Combined with US EPA 26a 15 minute post-test purge Ion Chromatography Analysis Testing was conducted

by ANALYTICAL

TESTING

CONSULTANTS,

INC., Kannapolis, North Carolina.

Members

of the test team were Keith Poole-project

manager,

Don Burke, and Jason Treutel-technicians.

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 calculated

and reported correctly. No data or information

has knowingly

been omitted"

Technical Director/Report

Author W. Keith Poole Quality Manager/President C. Daniel MeCombs

SAM refers to mist from n2so 4 and also sulfur trioxide (SO3).SOURCE DESCRIPTION Testing was conducted

on the stack emitting

gases released

from a natural gas-fired

kiln at Boral Bricks, Inc in Muskogee,

Oklahoma.

The kiln exhaust is a round metal vertical

stack that is sixty (60) inches inside diameter.

Two 4" test ports were installed

90 degrees

across the stack for sampling train access. "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, final 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. During testing a production

rate o•ons

per hour of brick was processed

in the kiln according to the following

information. 3.5 lb/brick x 6,336 bricks/car

x 43 cars/day

x lbs/2,000

tons x days/24 hours

19.87 tons/hr

Page 4 of 30RESULTS SUMMARY SYSTEM Boral Brick Kiln Exhaust

TEST DATE

12/13/05 PARAMETER Run #1 Run #2 Run #3

AVERAGE GENERAL QS, FLOW, ACFM

82,335

80,398

81,434 81,389 Q STD DRY, FLOWSCFM

42,262

42,130

42,814 42,402 Vm STD (ft3)

47.70

45.58

46.04 %1 102.59

99.10

97.74 HI (e5 btu/hr)

54.353

54.976

60.536 56.622 Brick Production

Rate, Tons per Hour Mass Emission

Rates 19.87

Run #1 Run #2 Run #3

AVERAGE Particulate Matter, Ibs/hr

8.545

9.429

8.969 8.981 Particulate Matter, Ibs/ton

0.430

0.475

0.451 0.452 HCI, Ibs/hr

0.996

1.223

0.972 1.064 HCI, Ibs/ton

0.050

0.062

0.049 0.054 HF, Ibs/hr

20.747

18.222

20.301 19.757 HF, Ibs/ton

1.044

0.917

1.022 0.994

Page 5 of 30RESULTS SUMMARY SYSTEM Boral Brick Kiln Exhaust
TEST DA TE 12/13/05 PARAMETER Run #1 Run #2 Run #3 GENERAL QS, FLOW, ACFM

78,964

81,981

90,070 Q STD DRY, FLOWSCFM

41,495

42,292

45,258 Vm STD (ft3)

44.81

44.81

49.18 %1 98.15

97.83

98.77 HI (e5 btu/hr)

53.367

55.187

63.992 Brick Production

Rate, Tons per Hour Mass Emission

Rates

Run #1 Run #2 Sulfur dioxide,

Ibs/hr

74.980

71.546 Sulfur dioxide,

Ibs/ton

3.774

3.601 Sulfuric acid mist, Ibs/hr

5.391

5.369 Sulfuric acid mist, Ibs/ton

0.271

0.270

Run #3 83.277 4.191 13.392 0.674

AVERAGE
83,672 43,015

57.515 19.87

AVERAGE 76.601 3.855 8.051 0.405

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. Stack Velocities

and Volumetric

Flow Rates Stack velocities

were measured

at a mean 69.1 feet per second through the sixty inch diameter round stack yielding

a mean 81,389 actual cubic feet per minute with the method five sampling train. Comparative

flows from the method eight sampling

train were a stack velocity

of 71.02 feet per second and a mean volumetric

flow rate of 83,672 cubic feet per minute.

These values are within + 3%, which is well within the tolerance

limitations

of method two deviations

for variations for pitot tubes. Particulate Emissions Mass emissions

were calculated

utilizing

the M5 air flows corrected

to standard

conditions (42,402) and the brick production

rate of 19.87 tons per hour. Particulate

emissions

averaged 8.98 lbs/hr and 0.45 lbs/ton. Acid Gas Emission

Rates HC1 emissions

averaged

1.06 pounds per hour and 0.05 pounds per ton of processed

brick while HF emissions

averaged

19.76 lbs/hr and 1.0 lbs/ton. Mass emissions

of sulfur dioxide averaged

76.6 lbs/hr and 3.9 lbs/ton with SAM emissions averaging 8.1 lbs/hr and 0.41 lbs/ton.

Page 7 of 30SAMPLING AND ANALYTICAL

PROCEDURES

TSP particulate

testing and analysis

were performed

according

to procedures

developed

by the U. S. Environmental

Protection

Agency

(US EPA) 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). The method five sampling

train was combined

with US EPA method

26a by utilizing

all glass connections, replacing

the glass fiber filter with a quartz filter, and replacing

the DI water with 0.1 N H2SO4 in the first two impingers,

0.1 N NaOH in the third and fourth impingers;

a fifth impinger contained

300 grams of SiO2 desiccant.

The acid fraction

of the impingers

was analyzed for the HC1 and HF; the back halves were not analyzed

and were utilized only for protection of the sampling

pump. First Analytical,

a LELAP

certified

laboratory,

performed

the analyses. Test point locations

and sampling

port placement

for velocity

traverses

are shown in the data sheets. Test point locations

were calculated

based upon a 60" diameter

stack Twelve points were sampled

in each port on the round dryer stack for each sampling

train. All sample recovery

was conducted

in a clean field area. Sulfur dioxide and sulfuric acid mist sampling

were conducted

according

to US EPA method eight utilizing

method

5 type impingers

and an all-glass

sampling

train. The first impinger

was charged with 80% IPA followed

by an in-line filter (both were analyzed

for sulfuric acid mist). The second and third impinger

were loaded with 3 percent hydrogen

peroxide

and subsequently analyzed for sulfur dioxide.

At the end of each run, the trains were purged for fifteen minutes

at the average

flow rates of the sampling

runs. All titrations

were performed

by First Analytical

of Chapel Hill, NC. ATC Laboratory,

Equipment Laboratory equipment

that was utilized for gravimetric

sample analysis

included

the following: 1) Precisa 303A Analytical

Lab Balance-certification and annual maintenance by Applied

Weight Technologies,

Inc. (completed

3/4/2005). Prior to each use, the balance

is calibrated

with NIST Traceable

weights0.5000, 5.0000, 50.0000,

and 100.0000

grams, 2) A Precision

Scientific

Model 70 Thelco®

Oven-operated

at 105°C, and 3) a Nalgene®

5317-0180

Dessicator

cabinet with indicating

dessicant. Prior to the field test, filter media were prepared

by sequentially

numbering

3" 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 Page 8 of 30SAMPLING AND ANALYTICAL

PROCEDURES, continued

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 dessicator

cabinet until needed. After recovery,

each filter was stored individually

in petri dishes until transferred

to the dessicator 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 mg/1) was evaporated.

The maximum allowable

residue according

to USEPA

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. Vsarnple 0.0002x VB lank A filter blank was processed

in conjunction

with the samples

and is recorded

in the gravimetric lab report. This was for QA/QC purposes

only. Project Sampling

Issues Other than slightly

above average

vibrational

issues with the stack necessitating

several interruptions in sampling

to re-secure

the glass nozzles,

there were no sampling

issues that deviated from the scope of work or US EPA methodology. Quali ,ty Assurance

Procedures The following

steps were conducted

to ensure the accuracy

and precision

of this test project. 1) All laboratory

glassware

was cleaned

and prepped

according

to US EPA methodology and ATC SOPs prior to use. 2) All laboratory

glassware

used for gravimetric

determinations

were weighed

in duplicate with agreement

required

to less than 0.0005 grams. 3) All sampling

equipment

(nozzles,

pitot tubes, modules,

exit gas thermometers, thermocouple bridges,

etc) have primary

calibrations

performed

on an annual schedule. Page 9 of 30SAMPLING AND ANALYTICAL

PROCEDURES, continued 4)5)6)7)8)9) All sampling

equipment

is visually

inspected

prior to assembly

in the shop. Sampling trains are leak checked

at a vacuum

of no less than 15" Hg prior to the start of sampling. At the conclusion

of the sampling

project,

pitot tubes are inspected

according

to US EPA method

2 specifications,

thermocouples

are calibrated,

and the sampling module is calibrated

at test ranges. All data that has been entered into an Excel spreadsheet

in the field and onpreprinted ATC forms is double-checked

in the office and reviewed. The report is generated

and then submitted

for review prior to release. All third party lab data and calculations

are meticulously

checked

for accuracy and reporting

errors.

Page 10 of 30REFERENCES CODE OF FEDE•L

REGULATIONS•

Title 40, Part 60, Appendix

A, July 1, 2003.

Page 11 of 30CALCULATIONS PM, HC1, and HF Emission

Calculations Stack Data for Method

5/26a Train Moisture Data from Method

5/26a Train Sulfur Dioxide

and SAM Emission

Calculation Moisture Data from Method

8 Train Sample Calculations Nomenclature Calculation Formulae

Page 12 of 30Particulate, HCI and HF Emission

Rate Calculations
LOCATION: Boral Brick SOURCE: Kiln Exhaust
DATA DATE RUN TIME (min) Dn (in) An (ft2) AVG DH (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) P$ (IN HG) Tm (F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (ml) VV STD (ft3) V STD (ft3) %M % SVPMD MWDM Ts(F) Ts(R) SUM SQRT DP N DP A VG SQRT DPCP Vs (P/s) Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOWSCFM%1 % C02 %02 %C0 %N2 F FACTOR HI (e6 btu/hr) Parflcula•i ma=sgalh

(gm) PMRo([bl/hr)

HCl mass gain (gin) PMRc (Ibs/hr) HF mass gain (gin) PMRc (Ibs/hr)

Run #1 Run #2 Run #3 AVERAGE 12/13/05 12/13/05

12/13/05 60.00 60.00

60.00 0.257 0.256

0.257 3.60E-04 3.57E-04

3.60E-04 1.99 1.88

2.00 29.75 29.75

29.55 29.90 29.89

29.70 -0.78 -0.78

-0.78 29.69 29.69

29.49 38.54 51.54

55.38 498.23 511.23

515.07 47.37 46.45

47.58 47.70 45.58

46.04 75.20 66.10

45.70 3.21 2.69

1.84 50.91 48.27

47.88 6.30 5.57

3.84

5.24 100.00 100.00

100.00 0.937 0.944

0.962 29.18 29.04

29.10 28.48 28.43

28.68 496.83 484.54

492.21

491.19 956.52 944.23

951.90

960.88 21.96 21.56

21.78 24.00 24.00

24.00 0.92 0.90

0.91 0.84 0.84

0.84 69.89 68.24

69.12

69.09 60.00 60.00

60.00 19.63 19.63

19.63 82335 80398

81434

81389 45104 44616

44525

44748 42262 42130

42814

42402 102.59 99.10

97.74 3.15 2.29

2.75

2.73 17.00 16.94

16.61

16.85 0.00 0.00

0.00 79.85 80.77

80.64 87.1 87.1

87.1 54.353 54.976

60.536

56.622 0i0729 :0,0771'

0;0•29 01157 0i172.

0i1#81

0:i55 0 02• •'0•

0 02• 0 0 =• 0.0085 0.01 O0 0.0079 0.996 1.223

0.972

1.064 0.1770 0.1490

0.1650 20.747 18.222

20.301

19.757 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations. Page 13 of 30DATE SOURCE Run #1 POINT #

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Tm

Particulate,

HCI, and HF Emission

Rate Calculations K-- 2.3487 Ts dp

dH SQRT DP

% 02 A1 29

486

0.47

1.10

0.686 A2 30

490

0.60

1.41

0.775

16.9 A3 31

487

0.72

1.69

0,849 A4 32

495

0.82

1.93

0.906

17.0 A5 33

500

0.82

1.93

0,906 A6 34

499

0.89

2.09

0.943

16.9 A7 36

503

1.00

2.35

1.000 A8 37

494

0.64

1.50

0.800

17,0 A9 38

488

0.78

1.83

0.883 AIO 38

485

1.05

2.47

1.025

17.3 All 39

489

0.95

2,23

0,975 A12 39

480

0.85

2,00

0.922

16.9 B1 40

499

0.60

1.41

0.775

17.2 B2 40

506

1.10

2.58

1.049 B3 40

507

0.98

2.30

0.990

17.1 B4 41

508

0.78

1,83

0.883 B5 42

505

0.71

1.67

0.843

16,9 B6 43

492

0.94

2.21

0,970 B7 43

510

0.83

1.95

0.911 B8 43

505

0.72

1,69

0,849

16.7 B9 44

508

0.98

2.30

0.990 BIO 44

503

1.10

2.58

1.049 Bll 44

497

1.10

2.58

1.049 B12 45

488

0.88

2.07

0.938 38.54 Vm(ft3) Initial Final Total 1.99

21.962

16.99

3.15 corrected per 6C-1

17.00 365,695 % N2 (BY DIFFERENCE)

79.85 413.063 47.368 %Excess Air

416,31

Calibration Actual Gas Zero 0,0 • 11.02 • 19.01

1911 Based upon 2% of span value (21%)

Calibration

Data Instrument Reading

% Error* Pre. -Post

Pre-

-Post 0.1 0.1 0.48

0.48 11.0 11.1 0.10

0.38 n/a 0.43

n/a

% CO2 Fuel Factor Fo 3.5 1.14 3.5 1.11 3.0 1.33 3.0 1.30 3.5 °03 3.0 1.33 3.0 1.23 3.0 1.27 3.0 1.33
3.0 1.40

1,25

Page 14 of 30DATE SOURCE Run #2 POINT #

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Tm

Particulate,

HCI, and HF Emission

Rate Calculations K= 2.3036 Ts dp

dH SQRT DP

% 02 A 1

45

453

0.62

1.43

0.787

17.0 A2 46

450

0.72

1.66

0.849 A3 47

470

1.10

2.53

1.049

17.3 A4 47

476

0.89

2.05

0.943 A5 49

492

0.83

1.91

0.911

16.5 A6 49

503

0.80

1.84

0.894 A7 49

506

0.85

1.96

0.922

16.5 A8 49

513

0.81

1.87

0,900 A9 50

507

0.84

1.94

0.917

16.6 AIO 50

503

1.00

2.30

1.000 All 51

498

1,10

2.53

1.049

16.7 A12 52

485

0.53

1.22

0.728 B1 52

466

0.61

1.41

0,781

16.9 B2 53

477

0.60

1.38

0.775 B3 53

484

0.73

1.68

0.854

17.2 B4 53

483

0.75

1.73

0.866 B5 54

491

0.75

1.73

0.866

17.1 B8 54

497

0.58

1.34

0.762 B7 55

499

0.86

1.98

0.927

17.0 B8 55

491

0.72

1.66

0.849 B9 56

481

0.90

2.07

0,949

17.2 BIO 56

474

1.10

2.53

1.049 Bll 56

465

0.95

2.19

0.975

17.2 B12 56

465

0.93

2.14

0,964

% C02 Fuel Factor Fo 2.0 1.95 2.5 1.44 2.5 1.76 3.0 1.47 2.0 2.15 2.5 1.68 2.0 2.00 2.0 1.85 2.5 1,52 2.5 1.56 2.0 1.85 2.0 1.85
51.54 Vm(ft3) 484.54 Initial Final Total 1.88

21.565

16.93 corrected per 6 C- 1 16, 94 413.400 % N2 (BY DIFFERENCE, 459.853 46.453 %Excess Air

2.29 80.77 386,63

1.76

Calibration Actual Gas Zero 0.0 Mid-Range 11.02 • 19.01

19.1 Based upon 2% of span value (21%)

Calibration

Data Instrument Reading

% Error* Pre- .Post

Prs-

-Post 0.1 0.1 0.48

0.48 11.0 11.1 0.10

0.38 n/a 0.43

n/a

Page 15 of 30DATE SOURCE Run #3 POINT #

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Tm

Particulate,

HCI, and HF Emission

Rate Calculations K= 2.4079 Ts dp

dH SQRT DP

%02 A1 55

484

0.61

1.47

0.781 A2 54

503

0.64

1.54

0.800

16.9 A3 54

507

0.78

1.88

0.883 A4 54

495

0.76

1.83

0.872

16.7 A5 54

435

0.70

1.69

0.837 A6 54

509

0.85

2.05

0.922

16.8 A7 54

509

0.83

2.00

0.911 A8 54

516

0.72

1.73

0.849

16.6 A9 54

501

0.76

1.83

0.872 AIO 55

503

0.89

2.14

0.943

16.7 All 55

491

0.96

2.31

0.980 A12 55

468

0.87

2.09

0.933

16.7 B1 55

471

0.54

1.30

0.735 B2 55

475

1.10

2.65

1.049

16.7 B3 55

440

1.20

2.89

1.095 B4 55

504

0.84

2.02

0.917

16.5 B5 56

512

0.81

1.95

0.900 B6 57

521

0.80

1.93

0.894

16.5 B7 57

513

0.86

2.07

0.927 B8 57

516

0.89

2.14

0.943

16.7 B9 57

505

0.69

1.66

0.831 BIO 57

497

0.87

2.09

0.933 Bll 58

475

0.97

2.34

0.985 B12 58

463

0.97

2.34

0.985 55.38 Vm(ft3) 492.21 Initial

460.561 Final 508.140 Total 47.579

2.00

21.776

16.68 corrected per 6C.1

16.61 % N2 (BY DIFFERENCE, %Excess Air

Calibration Actual Gas Zero 0.0 Mid-Ran,qe 11.02 Hi-Ran_g• 19.01

19.1 Based upon 2% of span value (21%)

Calibration

Data % C02 Fuel Factor Fo 2.5 1.60 2.0 2.10 2.5 1.64 3.0 1.43 3.5 1.20 3,0 1.40 2.5 1.68 2.5 1.76 3.0 1.47 3.0 1.40

2.75 1.57 80.64 355.01

Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0.1 0.1 0.48

0.48 11.1 11.1 0.38

0.38 n/a 0.43

nla

Page 16 of 30Run #1

MOISTURE

DATA Kiln Exhaust 12/13/2005 1st Imp. 2nd Imp, 3rd Imp. 4th Imp. 5th Imp. TOTALS BEGINNING 100

100

100

100

300.0 ENDING 131

128

109

100

307.2 NET 31

28

9

0

7.2

75.2

Run #2 1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 5th Imp. TOTALS BEGINNING 100

100

100

100

300.0 ENDING 140

116

101

100

309.1 NET 40

16

0

9.1

66.1

Run #3 1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 5th Imp. TOTALS BEGINNING 100

100

100

100

300.0 ENDING 127

106

104

102

306.7 NET 27

6

4

2

6.7

45.7 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 Apex #1 Apex #1 Apex #1 Dn 0.257

0.256

0.257 dH@ 1.850

1.850

1.850 Y, gamma factor

0.951

0.951

0.951 Cp 0.84

0.84

0.84 Bw(FRACTION, NOT•/o)

0.05

0.05

0.05 Md 29.00

29.00

29.00 Pbar 29.75

29.75

29.55 PS (GAUGE)

-0.78

-0.78

-0.78 Ps 29.69

29.69

29.49 Tm, F 46.00

50.00

60.00 Tin, R 505.69

509.69

519.69 Ms 28.45

28.45

28.45 Ts, F 490.00

500.00

485.00 T$, R 949.69

959.69

944.69 Pm 29.86

29.90

29,89 K 2.3487

2.3036

2.4079 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 dH/13.6) Page 17 of 30Sulfuric Acid Mist Emission

Rate Calculation

LOCATION: Boral Brick SOURCE: Kiln Exhaust
DATA Run #1 Run #2 Run #3 DATE 12/13/05

12/13/05

12/13/05 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.257

0.255

0.257 An (ft2) 3.60E-04

3.55E-04

3.60E-04 AVG DH (in H20)

2.08

2.13

2.70 P ATM (in Hg)

29.75

29.75

29.55 Pm (in Hg)

29.90

29,91

29.75 Ps (GAUGE)

-0.78

-0.78

-0.78 Ps (IN HG)

29,69

29.69

29.49 Tm (F)

42.58

57.63

63.08 Tm (R)

502.27

517.32

522.77 Vm (ft3)

44.06

45.38

50.59 Vm STD (ft3)

44.81

44.81

49.18 VLQ (ml)

46.60

68.30

80.10 VV STD (ft3)

2.20

3.22

3.78 V STD (ft3)

47.01

48.03

52.96 %M 4.67

6.71

7.13 % SVP

100.00

100.00

100.00 MD 0.953

0.933

0.929 MWD 29.18

29.04

29.10 M 28.66

28.30

28.31 Ts (F) 490.83

487.92

502.21 Ts (R)

950.52

947.61

961.90 SUM SQRT DpI

21.20

21.90

23.81 N DP

24.00

24.00

24.00 AVG SQRT DP

0.88

0.91

0,99 C/• 0.84

0.84

0.84 Vs (rds)

67.03

69.59

76.45 Ds (in)

60.00

60.00

60.00 As (ft2)

19.63

19.63

19.63 QS, FLOW, ACFM

78964

81981

90070 Q STD (ft3/min)

43530

45332

48734 Q STD DRY, FLOWSCFM

41495

42292

45258 %1 98.15

97.83

98.77 %C02 3.15

2.29

2.75 %02 17.00

16.94

16.61 %C0 0.00

0.00

0.00 %N2 79.85

80.77

80.64 F FACTOR

87.1

87.1

87.1 HI (e6 btu/hr)

53.367

55.187

63.992 Sulfur dioxide mass (gm)

0.612

0.573

0.684 PMRc (Ibs/hr)

74.980

71.546

83,277 PMRU (Ible6btu)

1.405

1.296

1.301 Sulfuric acid mist mass (gm)

0.044

0.043

0.110 PMRc (Ibs/hr)

5.391

5.369

13,392 PMRU (Ib/e6btu)

0.101

0.097

0.209 TheoreticalamountofmoisturethatTscanhold, If %M>%SVP,

%SVP will be utilized in calculations. A VERA GE

6.17

493.65 953.34

71.02

83672 45865 43015 2.73 16.85

57.515

8.051 0.136 Page 18 of 30DATE SOURCE Run #1 POINT # A1A2A3A4A5A6A7A8A9AIO All A12B1B2B3B4B5B6B7B8B9BIO Bll B12

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Tm363637373838393939404142444445464646474748484950

Sulfuric acid mist Emission

Rate Calculation K= 2.6280 Ts dp

dH SQRT DP

% 02 450 0.850

2.23

0.922 465 0.990

2.60

0.995

16.9 472 1.050

2.76

1.025 487 0.910

2.39

0.954

17.0 510 0.720

1.89

0.849 512 0.840

2.21

0.917

16.9 513 0.970

2.55

0.985 516 0.740

1.94

0.860

17.0 513 0.720

1.89

0.849 509 0.970

2.55

0.985

17,3 509 1.100

2.89

1.049 513 1.100

2.89

1.049

16.9 474 0.600

1.58

0.775

17.2 471 0.750

1.97

0.866 477 0.590

1.55

0.768

17.1 493 0.590

1.55

0.768 493 0.430

1.13

0.656

16.9 497 0.710

1.87

0.843 513 1.200

3.15

1.095 512 0.640

1.68

0.800

16.7 491 0.620

1.63

0.787 478 0.720

1.89

0.849 470 0.680

1.79

0.825 442 0.530

1.39

0.728

% C02 Fuel Factor Fo 3.5 1.14 3.5 1.11 3.0 1.33 3.0 1.30 3.5 1.03 3.0 1.33 3.0 1.23 3.0 1.27 3.0 1.33
3.0 1.40

42.58 Vm(ft3) Initial Final Total 2.08

21.196

18.99

3.15 corrected per 6C-1

17.00 116.477 % N2 (BY DIFFERENCE)

79.85 160.536 44.059 %Excess Air

416.31

1.25

Calibration Actual Gas Zero 0.0 Mid-Range 11.02 Hi-Range 19.01

19.1 Based upon 2% of span value (21%)

Calibration

Data Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0,1 0,1 0,48

0.48 11,0 11.1 0.10

0,38 n/a 0.43

n/a

Page 19 of 30DATE SOURCE Run #2 POINT # A1A2A3A4A5A6A7A8A9AIO All A12B1B2B3B4B5B6B7B8B9BIO Bll B12

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Sulfuric acid mist Emission

Rate Calculation K= 2.5369 Tm Ts

dp

dH SQRT DP

% 02 53 483

0.61

1.55

0.781

17.0 54 475

0.63

1.60

0.794 55 425

0.78

1.98

0,883

17,3 55 484

0.72

1.83

0,849 55 502

0.98

2.49

0.990

16.5 55 505

0.94

2.38

0.970 55 511

0.80

2.03

0.894

16.5 56 498

0.67

1.70

0.819 56 489

0.78

1.98

0.883

16.6 57 479

0.89

2.26

0.943 57 474

0.88

2.23

0.938

16.7 57 459

0.61

1.55

0.781 58 466

0.58

1.47

0.762

16.9 59 466

0.92

2.33

0,959 59 474

0.93

2.36

0.964

17.2 59 489

0.74

1.88

0,860 59 504

0.76

1.93

0.872

17.1 60 513

0.97

2.46

0.985 60 521

0.97

2.46

0.985

17.0 60 516

0.91

2.31

0.954 61 515

0.91

2.31

0.954

17.2 61 511

0,97

2.46

0.985 61 504

1.10

2.79

1.049

17.2 61 447

1.10

2.79

1.049

% C02 Fuel Factor Fo 2.0 1.95 2.5 1.44 2.5 1.76 3.0 1.47 2,0 2.15 2.5 1.68 2.0 2.00 2.0 1.85 2.5 1.52 2.5 1.56 2.0 1.85 2.0 1.85
57.63 Vm(ft3) 487.92 Initial Final Total 2.13

21.902

16.93

2.29 corrected per 6C-1

16.94 174.739 % N2 (BY DIFFERENCE)

80.77 220.115 45.376 %Excess Air

386.63

1.76

Calibration Actual Gas Zer.__•o 0.0 Mid-Rang.• 11.02 • 19.01

19.1 Based upon 2% of span value (21%)

Calibration

Data Instrument Reading

% Error* Pra- -Post

Pre-

-Post 0.1 0.1 0.48

0.48 11.0 11.1 0.10

0.38 nla 0.43

nla

Page 20 of 30DATE SOURCE Run #3 POINT # A1A2A3A4A5A6A7A8A9AIO All A12B1B2B3B4B5B6B7B8B9BIO Bll B12

ISOKINETIC

DATA AND CALCULATIONS 12/13/05 Kiln Exhaust

Tm

Sulfuric acid mist Emission

Rate Calculation K= 2.7048 Ts dp

dH SQRT DP

% 02 499 0,73

1.97

0.854 490 0.99

2.68

0.995

16,9 492 1.05

2.84

1.025 494 0.91

2.46

0.954

16.7 500 0.75

2.03

0.866 454 0.99

2.68

0.995

16.8 512 0.93

2.52

0.964 525 0.87

2.35

0.933

16.6 528 0.80

2.16

0.894 527 0.91

2.46

0.954

16.7 520 1.10

2.98

1.049 519 1.20

3.25

1.095

16.7 464 0.81

2.19

0.900 459 1.10

2.98

1.049

16.7 478 0.83

2.24

0.911 489 0.70

1.89

0.837

16.5 500 0.65

1.76

0.806 516 0.71

1.92

0.843

16.5 516 1.20

3.25

1.095 523 1.30

3.52

1.140

16.7 521 1.30

3.52

1.140 521 1.40

3.79

1.183 504 1.40

3.79

1.183 502 1.30

3.52

1.140 616262626262626263636363626363646464646465656465 63.08 Vm(ft3) 502.21 Initial

232.407 Final 283.000 Total 50.593

2.70

23.807

16.68 corrected per 6C-1

16.61 % N2 (BY DIFFERENCE) %Excess Air

Calibration Actual Gas Zero 0.0 Mid-Ran.q• 11.02 • 19.01

19.1 Based upon 2% of span value (21%)

Calibration

Data % C02 FuelFactor Fo 2.5 1.60 2.0 2.10 2.5 1.64 3.0 1.43 3.5 1.20 3.0 1.40 2.5 1.68 2.5 1.76 3.0 1.47 3.0 1.40

2.75 1.57 80.64 355.01

Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0.1 0.1 0.48

0.48 11.1 11.1 0.38

0.38 n/a 0.43

n/a

Page 21 of 30Run #1 MOISTURE

DATA Kiln Exhaust 12113/2005 1st Imp. 2nd Imp. 3rd Imp. 4th Imp. TOTALS BEGINNING 100

100

100 300.00 ENDING 115

114

108 309.60 NET 15

14

8 9.60

46.6

Run #2 lstlmp.

2ndlmp.

3rdlmp.

4• Imp. TOTALS BEGINNING 100

100

100 300.00 ENDING 109

125

126 308.30 NET 9 25

26 8.30

68.3

dH KdP

Run #3 lstlmp.

2ndlmp.

3rdlmp.

4• Imp. TOTALS BEGINNING 100

100

100 300.00 ENDING 106

140

128 306.10 NET 6 40

28 6.10

80.1 ISOKINETIC SAMPLING

RATE CALCULATION

K (846.72*Dn^4*dH@*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm) Run #1 Run #2 Run #3 Module ID A TC #6 A TC #6 A TC #6 Dn 0.257

0.255

0.257 dH@ 2.070

2.070

2.070 Y, gamma factor

0.968

0.968

0.968 Cp 0.84

0.84

0.84 Bw(FRAGTION, NOT%)

0.05

0.05

0.05 Md 29.00

29.00

29.00 Pbar 29.75

29.75

29.55 PS (GAUGE)

-0.78

-0.78

-0.78 P$ 29.69

29.69

29.49 Tm, F 46.00

50:00

65.00 Tm, R 505.69

509.69

524.69 Ms 28.45

28.45

28.45 T$, F 490.00

500.00

490.00 T$, R 949.69

959.69

949.69 Pm 29.86

29.90

29.90 K 2.6280

2.5369

2.7048 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(INI

H20) Ps=ABSOLUTE STACK PRESSURE

(IN. Hg) Pm=METER ABSOLUTE

PRESSURE

(IN. Hg) Pbar + (avg dH/13.6) Page 22 of 30SAMPLE CALCULATIONS Boral Brick Muskogee, OK Run #1 1) ABSOLUTE

PRESSURE

IN DRY GAS METER Pm P ATM + AVG DH/13.6 T STD P STD P ATM

Avg. DH

Pm 29.75 1.99

29.90 2) ABSOLUTE

STACK PRESSURE Ps P ATM + Ps(GAUGE)/13.6
P ATM Ps(GAUGE)

Ps 29.75 -0.78

29.69 3) SAMPLE VOLUME AT STANDARD

CONDITIONS VM STD (VM)*(Y)*(T

STD/TM)*(PM/P

STD)
Vm Tm

Y

Vm STD 47.37 498.23

0.951

47.70 ft3 4) VOLUME OF WATER COLLECTED,

CORRECTED

TO STANDARD

CONDITIONS W STD W STDw + WSTDsg
W STDw (.002673)*(VLQw)*(T

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

STD/P STD)
WHERE 0.002673

0.04707 FT3/ML*IN.

HG/17.64 DEG. R. WHERE 0.002668

0.04715 FT3/G*IN.HG/17.64

DEG. R. VLQ (w) VLQ (sg) W STD 68.00 0.00

3.21 ft3 5) TOTAL SAMPLE VOLUME AT STANDARD

CONDITIONS
V STD Vm STD + W STD 6) PERCENT MOISTURE

IN STACK GAS %M (100)*(W STD)/V STD 6.30% 7) MOLE FRACTION

OF DRY GAS
MD (100-%M)/100 0.937 50.91 ft3

Page 23 of 30 528 DEG R. 29.92 IN. HGSAMPLE 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 3.2 17.0

0.0

79.9

29.18 9) MOLECULAR

WEIGHT OF THE WET GAS M (MWD)*(MD)

+ 18(1-MD) 28.48
WHERE 18 MOLECULAR

WEIGHT OF WATER, G/G-MOLE 10) STACK VELOCITY VS (85.49)*(CP)*((TSI(PS)(M))^112*((SUM SQRT DP)/N DP)) where 85.49 ft/sec* [Ib/Ib-mole*in.Hg)/(deg.

R'in H20)]^0.5
CP Ts (R) SUM SQRT

N DP VS 0.84 956.52

21.96

24 69.89 11) STACK VOLUMETRIC

FLOW RATE QS (60)*(VS)*(AS)
AS (inlet) QS 19.63 82335 12) STACK VOLUMETRIC

FLOW RATE, STANDARD

CONDITIONS

INCLUDING

MOISTURE Q STD Q STD DRWMD 45104 13) STACK VOLUME FLOW RATE STANDARD

CONDITIONS

DRY Q STD DRY= 17.647*60*Md*Vs*A*(Ps/Ts(R)) 42262 14) POLLUTANT

MASS RATE, CONCENTRATION

BASIS PMRC (.1323)*(WT)*(Q

STD)N STD WHERE 0.1323 COMBINED

CONVERSION

FACTOR (60 MIN/HR*0.00220

LBS/GRAM) WT(GRAMS) PMRC 0.0729 8.645 15) PERCENT ISOKINETIC %1 (0.09450*Ts*Vm

std)/(Ps*Vs*An*Time*Md) Run Time Area of Nozzle 60 3.60E-04 %1 t02.59 16) CONCENTRATION,

GR/SCFD Cs= 15.43 gr/gm WTNm STD Cs 0.0236

Page 24 of 30NOMENCLATURE

AsC•,% EA FDHHI%I M%M MD MWD N DP PATM PMPSPs Gauge PSTD PMRC PMRU

(square inches),

cross sectional

area of nozzle (square feet), cross sectional

area of stack Pitot tube calibration

coefficient,

dimensionless Percent excess air (scfd/MMBtu), F factor (inches of water) average

orifice meter reading (MMBtu/hr), heat input rate Percent isokineticity (lb/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 (lb/hr), pollutant

mass rate based on concentration (ib/mmBtu), specific

emission

rate
Page 25 of 30NOMENCLATURE, continued Dp (inches of water), velocity

pressure Qs (ft3/min.),

actual stack volume

flow rate QSTD (ft3/min.),

stack volume flow rate at standard Conditions Time(rain) duration

of test
TM (°R), average

dry gas meter temperature
Ts (°R), average

stack temperature
TSTD (528 °R), standard

temperature VLQ (ml), liquid volume

VM (ft3), sample volume measured

by dry gas meter VMSTD (ft3), Sample volume at standard

conditions
Vs (ft/sec), stack velocity
VVSTD (ft3), volume of water vapor collected, corrected to standard

conditions

WT (grams),

total weight of particulate

collected
Page 26 of 30CALCULATIONFORMULAE
1.

Absolute

pressure

at the dry gas meter, Pm

2. Absolute

stack pressure,

Ps

3. Sample volume at standard

conditions,

Vm(std) Pbar + Vm/•,,0 K1 × Vm ×Y×
r × (V,n × 528 × •'o)/(Tm × 29.9:Z) 528°R K1- 29.92inHg 4. Volume

of water collected,

corrected

to standard

conditions,

Vv(std)

0.04706 fi'x 29.92"Hg

x ml ml 528°R 29.92"Hg Vv(std)g 0.04715

J'x

x ml ml 528°R 5. Total sample volume at standard

conditions,

Vstd V•,,• Vm(•,•) + V+,•) 6. Percent moisture

in stack gas, %M %M V+ta) x 100
7. Mole Fraction

of the dry gas, MD

MD (100- %M) 100 Page 27 of 30CALCULATION FORMULAE,

continued
8. Molecular

weight of the Dry Gas, MWD MWD 0.440(%C02

)+ 0.320(%02)+

0.280(%

N2 + %C0)

9. Molecular

weight of stack gas, wet basis, g/g-mole

(lb/lb-mole),

M M MWD x MD + 18(1 MD)

10. Stack velocity,

Vs Vs=Kp XCp A•a•g X•p•x M
11. Average

stack gas dry volumetric

flow rate, Qstd dry Q•(a•y) 17.647 x 60x MDx V• x A t.r )
12. Pollutant

mass rate, concentration

basis, lbs/hr PMRC 0.1323lb

min x grams x Qsta + Vsta gram hr
13. Percent Isokineticity

I= 100T' [K3V•c +(Vr"Y/T"XPb"r

+ Ah/13.6)] 60x0xV, xP• xA,
14. % Excess Air -(. (%02 -0"5°/°C-0)

)×100

Page 28 of 30CALCULATION FORMULAE,

continued

15. Dry Gas Meter Check•1/2 Yc 10 0.0319 T,,

16. Heat Input Rate, mmBtu/hr HI 60 mird hr x dscf / minx dscf / mmBtu

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: 1100 lll 0 I6"6911-ITw+390'831-446])

] (0.000367XP•

XTa-Tw

•1 1571 19. Correction

of Gas Concentrations

for Calibration

Error, Equation

6c-1

20. VOC Emission

Rate as {compound

specified

by molecular

weight} ppmvdxM( g ) lbsC g •nole 1 X hr 22.414

liters xl03_xm3

293"15°K

lxlO6ppm g mole

liter 273.15 K

1 0 3 mg × __Q,tddry × 3.7 5e -°6 g

Where: 3.75e_06

O.O0221bs

x g x--x60min

m 3 g lO00mg

hour

35.315fl

3 Page 29 of 30APPENDIX
Isokinetic Sampling

Data Sheets Impinger Data Sheets Oxygen/Carbon Dioxide

Worksheets Gravimetric Lab Report-ATC Acid Gas Lab Report-First

Analytical Calibration Data

Page 30 of 30