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, 2006 
TABLE 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 .......................................................................................................................... 30 
INTRODUCTION 

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 30 
RESULTS 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 30 
RESULTS 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 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. 

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 30 
SAMPLING 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 30 
SAMPLING 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 0.1 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 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 30 
SAMPLING 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 on preprinted 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 30 
REFERENCES 

CODE OF FEDE•L REGULATIONS• Title 40, Part 60, Appendix A, July 1, 2003. 

Page 11 of 30 
CALCULATIONS 

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 30 
Particulate, 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 

% SVP 

MD 

MWD 

M 

Ts(F) 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQRT DP 

CP 

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 30 
DATE 

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 30 
DATE 

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 30 
DATE 

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 30 
Run #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 30 
Sulfuric 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 30 
DATE 

SOURCE 

Run #1 

POINT # 

A1 

A2 

A3 

A4 

A5 

A6 

A7 

A8 

A9 

AIO 

All 

A12 

B1 

B2 

B3 

B4 

B5 

B6 

B7 

B8 

B9 

BIO 

Bll 

B12 

ISOKINETIC DATA AND CALCULATIONS 

12/13/05 

Kiln Exhaust 

Tm 

36 

36 

37 

37 

38 

38 

39 

39 

39 

40 

41 

42 

44 

44 

45 

46 

46 

46 

47 

47 

48 

48 

49 

50 

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 30 
DATE 

SOURCE 

Run #2 

POINT # 

A1 

A2 

A3 

A4 

A5 

A6 

A7 

A8 

A9 

AIO 

All 

A12 

B1 

B2 

B3 

B4 

B5 

B6 

B7 

B8 

B9 

BIO 

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 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 

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 

61 

62 

62 

62 

62 

62 

62 

62 

63 

63 

63 

63 

62 

63 

63 

64 

64 

64 

64 

64 

65 

65 

64 

65 

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 30 
Run #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 30 
SAMPLE 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. HG 
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 

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 30 
NOMENCLATURE 

As 

C•, 

% EA 

F 

DH 

HI 

%I 

M 

%M 

MD 

MWD 

N DP 

PATM 

PM 

PS 

Ps 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 30 
NOMENCLATURE, 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 30 
CALCULATIONFORMULAE 

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 30 
CALCULATION 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 30 
CALCULATION 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 30 
APPENDIX 

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