EMISSIONS TESTING ON THE EXHAUST

OF #5 KILN AND THE DRYER

BYPASS

STACK BORAL BRICKS BORAL BRICKS,

INC. 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: September 8, 2005 ATC Project Number P-05129

Providing Qua/it), Air Testing and Consu#ing Sen, ices Since 1981.

Certificate #04044

Expiration Date 6/30105 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: October 17,2005TABLE OF CONTENTS Page No. Introduction 3 Certification of Results 3 Source Description 4 Results Summaries 5 Results, Conclusions

and Comments 8 Sampling and Analytical

Procedures 9 References 11 Emission Calculations 12
Kiln TSP Particulate

Emission

Rate Calculation 14 Hydrogen Chloride

Emission

Rate Calculation 15 Hydrogen Fluoride

Emission

Rate Calculation 16 Sulfur Dioxide

Emission

Rate Calculation 17 Sulfuric Acid Mist Emission

Rate Calculation 18 Dryer TSP Particulate

Emission

Rate Calculation 20 Hydrogen Chloride

Emission

Rate Calculation 21 Hydrogen Fluoride

Emission

Rate Calculation 22 Sulfur Dioxide

Emission

Rate Calculation 23 Sulfuric Acid Mist Emission

Rate Calculation 24
Kiln TSP/26a

Train Isokinetic

Data and Calculations 26 Moisture Data/Isokinefic

Sampling

Rate Equation

29 Method 8 Train Isokinefic

Data and Calculation 31 Isokinefic Sampling

Rate Equation 34 Dryer TSP/26a

Train Isokinetic

Data and Calculations 36 Moisture Data/Isokinetic

Sampling

Rate Equation

39 Method 8 Train Isokinetic

Data and Calculation 41 Isokinefic Sampling

Rate Equation 44 Sample Calculations 45 Nomenclature 47 Calculation Formulae 49 Appendix 52

Page 2 of 52INTRODUCTION

This report presents

the results of particulate,

hydrogen

chloride,

hydrogen

fluoride,

sulfur dioxide and sulfuric acid mist emissions

testing performed

on the exhausts

of Kiln #5 and the dryer bypass stack at Boral Bricks, Inc East Spencer,

North Carolina.

Emissions

testing were conducted while the kiln was fired on normal fuel and operation.
The following

table outlines

the methodology

utilized.

US EPA Methodology 5 Description Isokinetic Sampling?Yes

Notes Determination of TSP particulate Combined

with 26a 8 Determination

of sulfur dioxide and sulfuric acid

Yes

15 minute post-test purge concentration 26a Hydrogen

Chloride/Hydrogen

Fluoride Emissions

Yes

Ion Chromatography Analysis Testing was conducted

by ANALYTICAL

TESTING

CONSULTANTS,

INC., Kannapolis, North Carolina.

Members

of the test team were Dan McCombs-project

manager,

Don Burke, Chuck Emerson,

Brent Snider and Mike Stedwell-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 W. Keith Poole Test Report Author/Quality

Manager C. Daniel McCombs

Page 3 of 52SOURCE DESCRIPTION Testing was conducted

on two stacks emitting

gases released

from a wood-waste

fired kiln that provides process heat for a warming

room, dryer, and the #5 brick kiln at Boral Bricks, Inc in East Spencer,

North Carolina.

The primary

kiln exhaust is a square metal vertical stack that is approximately three feet in diameter.

Four 4" test ports were installed

equidistant

across the east face of the stack for sampling

train access. A damper immediately

following

the kiln exhaust takeoff is used for diverting

heated air into the dryer for pressure

and heat control.

This damper is used primarily

to keep a constant

temperature

in the dryer without regard to the ambient pressure. This damper diverts a portion of the hot gases to the dryer and allows the rest to be exhausted out of the stack. For the purposes

of the stack test, all gases and air were diverted

so that they would all leave the building

through

the 45" diameter

round exhaust stack. Two 4" test ports were installed

ninety degrees apart to facilitate

testing.

"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 twenty cars were put in the kiln and taken out during a twenty-four

hour period. There were 5,775 bricks on each car. Each brick weighed

3.40 pounds;

this yields a production rate of 8.2 tons per hour.

Page 4 of 52RESULTS SUMMARY SYSTEM Boral Bricks #5 Kiln Exhaust =• Combined flows and Emissions

from•l•,er,•al•d•l•lh•

TEST DATE

PARAMETER Combined Numbers GENERAL 09/08/05

Run 1 Run 2 Run 3

QS, FLOW, ACFM

28842

29156

29936 Q STD DRY, FLOWSCFM

17697

17287

18002
AVERAGE TONS OF BRICK F//RED PER HOUR DURING SAMPLING

AVERAGE

29311
17662
8.2

PARTICULATE EMISSIONSP.MRc

(Ibs/hr)
Pounds per Ton

3.305

3.288

2.801

HYDROGEN CHLORIDE

EMISSIONS

PMRc (Ibs/hr)
Pounds per Ton

1.487

1.535

1.626

HYDROGEN FLOURIDE

EMISSIONS

PMRc (Ibs/hr)
Pounds per Ton

11.437

11.505

12.008

SULFUR DIOXIDE

EMISSIONS

PMRc

(Ibs/hr)

7.698

9.300

10.753
Pounds per Ton Run two pounds per hour on dryer calculated

from average of Runs & 3 Run two grains per dscf on dryer calculated

from average of Runs &3 SULFURIC ACID MIST EMISSIONS

PMRc (Ibs/hr)

1.861

1.892

2.401
Pounds perTon 3.131
0.382

t .549
0.189

11.650
1.421

9.250
1.128

2.051
0.250 Page 5 of 52RESULTS SUMMARY

SYSTEM Boral Bricks

TEST DATE

09/08/05

PARAMETER R #1-K-26A

#2-K-26A

#3-K-26A
GENERAL QS, FLOW, ACFM

8376

8497 Q STD DRY, FLOWSCFM

4843

4890
Vm STD (ft3)

34.15

34.86
%1 105.48

106.64

9351
5542
38.51
103.94

A VERA GE

8741
5092

PARTICULATE EMISSIONS

PMRc (Ibs/hr)

1.058

1.160

1.009
Cs (GR/SCFD)

0.0255

0.0277

0.0212 1.076 0,0248

HYDROGEN CHLORIDE

EMISSIONS

PMRc (Ibs/hr)

0.5100

0.5510

0.5580 Cs(GR/SCFD) 0.0123

0.0131

0.0117

0.5397
0.0124

HYDROGEN FLOURIDE

EMISSIONS

PMRc (Ibs/hr)

3.6210

3.8410

3.8840
Cs (GR/SCFD)

0.0872

0.0916

0.0817

3.7820
0.0868

SULFUR DIOXIDE

EMISSIONS

PMRc (Ibs/hr)

2.8679

3.3829

3.7492
Cs (GR/SCFD)

0.0778

0.0813

0.0799

3.3333
0.0797

SULFURIC ACID MIST EMISSIONS

PMRc (Ibs/hr)

0.6633

0.0912

0.8775
Cs (GR/SCFD)

0.0180

0.0220

0.0187

0.5440
0.0196RESULTS SUMMARY

SYSTEM Boral Brick #5 Kiln (Dryer Exhaust)

DR YER TEST DATE

09/08/05

PARAMETER R #1-D R #2-D R #3,D
GENERAL QS, FLOW, ACFM

20466

20659

20585 Q STD DRY, FLOWSCFM

12854

12397

12460
Vm STD (ft3)

45.26

46.01

46.47
%1 101.01

106.48

106.98

A VERA GE

20570
12570

PARTICULATE EMISSIONS

PMRc (Ibs/hr)

2.247
Cs (GR/SCFD)

0.0204
HYDROGEN CHLORIDE

EMISSIONS

2.128

1.792
0.0200 0.0168

PMRc (Ibs/hr)

0.977

0.984

1.068
Cs (GR/SCFD)

0.0089

0.0093

0.0100 2.056
0.0191

1.010
0.0094

HYDROGEN FLOUR/DE

EMISSIONS

PMRc (Ibs/hr)

7.816

7.664

8.124
Cs (GR/SCFD)

0.0709

0.0721

0.0760 7.868
0.0730

SULFUR DIOXIDE

EMISSIONS

PMRc (Ibs/hr)

4.830

0.077

7.004
Cs (GR/SCFD)

0.0455

0.0007

0.0661 RUN TWO DRYER RESULTS

NOT USED IN AVERAGE
SULFURIC ACID MIST EMISSIONS

PMRc (Ibs/hr)

1.198

1.801

1.523
Cs (GR/SCFD)

0.0113

0.0167

0.0144 5.917
0.0374

1.507
0.0141RESULTS, CONCLUSIONS AND COMMENTS

Results are presented

in the preceding

Summary.

Additional

information

may be reviewed

in the Calculations and Appendices

sections

of this report.

Two manual sampling

trains were operated

simultaneously

on both stacks for three one-hour
runs. Method

5/26a was a combined

sampling

train sampling

for filterable

particulate,

HC1 and HF. The second train was method

8 sampling

for both SO2 and H2SO4..

Results are reported

on the summary

pages as separate

stacks and also combined

emissions

rates. An average

sulfur dioxide number was used for Run two of the Dryer for emission

rate calculations.

A short discussion is in the QA/QC

section of report in the Sampling

and Analytical

Procedures

and in the lab report..

The actual number

is listed in the results summary

and lab data. Moisture numbers

were taken from the method

5/26a runs as the IPA in the first impingers

of the Method 8 train can go through

the silica gel.
Please refer to the mass rates as presented

in the previous

RESULTS

SUMMARIES.

Page 8 of 52SAMPLING AND ANALYTICAL

PROCEDURES

TSP particulate

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). 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 second two impingers

and a fifth impinger with 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 45 1⁄4" diameter

dryer stack and a square 35 1⁄4" kiln stack.
Twelve points were sampled

in each port on the round dryer stack for the 5/26a sampling

train. Six points were sampled

in each of four ports on the kiln stack. All sample recovery

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

was conducted

according

to US EPA method eight utilizing

method

5 type impinger

all glass connection.

The first impinger

was loaded with 80% IPA followed

by an inline filter with both being used in the sulfuric acid mist analysis.

The second and third impinger

were loaded with 3 percent hydrogen

peroxide

and used for the sulfur dioxide analysis.

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

weights-0.5000, 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

Whatman®

934AH 3" glass fiber 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 Page 9 of 52SAMPLING AND ANALYTICAL

PROCEDURES, continued

numbered 150ml Griffin beakers were thoroughly

washed with warm, soapy water andovendried. 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.

0.0002 x WsampleWBlank

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.

QA/QC

An average

sulfur dioxide number was used for the Run two of the Dryer. The analysis

was extremely low, however

the acid mist results from the same run was in line with other runs. The low result was not because

of a leak but rather a mislabel

or handling.

Page 10 of 52•FE•NCES
CODE OF FEDERAL

•GULATIONS,

Title 40, Part 60, Appendix

A, July 1, 2003.

Page 11 of 52CALCULATIONS

Kiln Emission

Calculations TSP Particulate

Emissions Hydrogen Chloride

Emissions Hydrogen Fluoride

Emissions Sulfur Dioxide

Emissions Sulfuric Acid Mist Emissions Dryer Emission

Calculations TSP Particulate

Emissions Hydrogen Chloride

Emissions Hydrogen Fluoride

Emissions Sulfur Dioxide

Emissions Sulfuric Acid Mist Emissions
Kiln Data Sheets TSP/26a Train Isokinetic

Data and Calculations Moisture Data/Isokinetic

Sampling

Rate Equation Method 8 Train Isokinetic

Data and Calculations Isokinetic Sampling

Rate Equation Dryer Data Sheets TSP/26a Train Isokinetic

Data and Calculations Moisture Data/Isokinefic

Sampling

Rate Equation Method 8 Train Isokinetic

Data and Calculations Isokinetic Sampling

Rate Equation Sample Calculations
Nomenclature
Calculation Formulae

Page 12 of 52Kiln Calculation Sheets

Page

13 of 52PARTICULATE EMISSION

RATE

CALCULATION

LOCATION: Boral Bricks SOURCE: #5 Kiln Exhaust

Kiln Exhaust

DATADATE RUN TIME (min) Dn (in) An (ft2) A VG DH (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) Ps (IN HG)TIn(F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (ml) VV STD (ft3) V STD (ft3)%M % SVPMDMWDMTs(RTs(R) SUM SQRTDPN DP A VG SQRTDPCP Vs fit Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOW SCFM WT (gm)%1 %C02%02%C0%N2 PMRc (Ibs/hr) Cs (GR/SCFD)

R #1-K-26A R #2-K-26A R #3-K-26A AVERAGE 09/08/05 09/08/05

09/08/05 60.00 60.00

60.00 0.420 0.420

0,420 9.62E-04 9,62E-04

9.62E-04 1.21 1.23

1.42 29.54 29.54

29.54 29.63 29.63

29.64 -0.07 -0.07

-0.07 29.53 29.53

29.53 72.96 87.79

83.79 532.63 547.46

543.46 34.79 36.50

40.01 34.15 34.86

38.51 50.20 67.00

71.50 2.37 3.16

3.37 36.52 38.02

41.88 6,48 8.31

8.05

7.61 100.00 100.00

100.00 0.935 0.917

0.920 29.27 29.27

29.27 28,54 28.34

28.37 383.25 370.75

348.88

367.63 842,92 830.42

808.55

827.30 5.41 5.51

6.14 24.00 24.00

24.00 0.23 0.23

0.26 0.84 0.84

0.84 16.18 16.41

18,06

16.88 35.25 x35.25 8,63 8.63

8.63 8376 8497

9351

8741 5179 5333

6028

5513 4843 4890

5542

5092 0.0564 0.0625

0.0530 105.48 106.64

103.94 3.73 3.73

3.73

3.73 16.94 16.94

16.94

16.94 0,00 0.00

0.00 79.33 79.33

79.33 1.058 1.160

1.009

1.076 0.0255 0,0277

0.0212

0.0248 Theoretical amount of moisture that Tscan hold. If %M >%SVP, %SVP wfll be utilized in calculations Page 14 of 52HCI EMISSION

RATE

CALCULATION

LOCATION: Boral Bricks SOURCE: #5 Kiln Exhaust HCI RESULTSDATA

R #1-K.26A R #2.K.26A R #3-K.26A DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.420

0.420

0.420 An (ft2) 9.62E-04

9.62E-04

9.62E-04 A VG DH (in H20)

1.21

1.23

1.42 P A TM (in Hg)

29.54

29.54

29.54 Pm (in Hg)

29.63

29.63

29.64 Ps (GAUGE)

-0,07

-0.07

-0,07 Ps (IN HG)

29.53

29.53

29.53 Tm (F)

72.96

87.79

83.79 Tm (R)

532.63

547.46

543.46 Vm (ft3)

34.79

36.50

40,01 Vm STD (ft3)

34.15

34.86

38.51 VLQ (ml)

50.20

67.00

71.50 VV STD (ft3)

2.37

3.16

3.37 V STD (ft3)

36.52

38.02

41.88 %M 6.48

8.31

8.05 %SVP 100.00

100.00

100.00 MD 0.935

0.917

0.920 MWD 29.27

29.27

29.27 M 28.54

28.34

28.37 Ts (F)

383.25

370.75

348.88 Ts (R)

842.92

830.42

808.55 SUM SQRTDP

5.41

5.51

6.14 N DP

24.00

24.00

24.00 A VG SQRTDP

0.23

0.23

0.26 CP 0.84

0.84

0.84 Vs (ft/s)

16.18

16,41

18.06 Ds (in)

35.25 x 35.25 As (ft2)

8.63

8.63

8.63 QS, FLOW, ACFM

8376

8497

9351 Q STD (ft3/min)

5179

5333

6028 Q STD DRY, FLOWSCFM

4843

4890

5542 WT(gm) 0.0272

0.0297

0.0293 %1 105.48

106.64

103.94 %C02 3.73

3.73

3.73 %02 16.94

16.94

16.94 %C0 0.00

0.00

0.00 %N2 79.33

79.33

79.33 PMRc (Ibs/hr)

0.510

0.551

0.558 Cs(GR/SCFD) 0.0123

0,0131

0.0117 Theoretical amount of moisture that If %M >%SVP, %SVP will be utilized in VERA GE

7.61

367.63 827,30

16.88

874155135092

3.7316.94

0.540 0.0124
Ts can hold. calculation& Page 15 of 52HF EMISSION

RATE

CALCULATION

LOCATION: SOURCE: HF RESULTSDATADATE RUN TIME (min) Dn (in) An (ft2) A VG DR (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) Ps (IN HG)TIn(F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (ml) VV STD (ft3) V STD (ft3)%M % SVPMDMWDMTs(F)Ts(R) SUM SQRT DPN DP A VG SQRT DPCP Vs (ft/s) Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOWSCFM WT (gm)%1%C02%02%C0%N2 PMRc (Ibs/hr) Cs (GR/SCFD)

Boral Bricks #5 Kiln Exhaust

R #1-K-26A

R #2-K-26A

R #3-K-26A

AVERAGE 09/08/05 09/08/05

09/08/05 60.00 60.00

60,00 0.420 0.420

0.420 9.62E-04 9.62E-04

9.62E-04 1.21 1.23

1.42 29.54 29.54

29.54 29.63 29.63

29.64 -0.07 -0.07

-0.07 29.53 29.53

29.53 72.96 87.79

83.79 532.63 547.46

543.46 34.79 36.50

40.01 34.15 34.86

38.51 50.20 67.00

71.50 2.37 3.16

3.37 36.52 38.02

41.88 6.48 8.31

8.05

7.61 100.00 100.00

100.00 0.935 0.917

0.920 29.27 29,27

29.27 28.54 28.34

28.37 383.25 370.75

348.88

367.63 842.92 830.42

808.55

827.30 5.41 5.51

6.14 24.00 24.00

24.00 0,23 0.23

0.26 0.84 0.84

0.84 16.18 16.41

18.06

16.88 35.25 x 35.25 8.63 8.63

8.63 8376 8497

9351

874t 5179 5333

6028

65t3 4843 4890

5542

5092 0.1930 0.2070

0.2040 105.48 106.64

103.94 3.73 3.73

3.73

3.73 16.94 16.94

16.94

16.94 0.00 0.00

0.00 79.33 79.33

79.33 3.621 3.841

3.884

3.782 0.0872 0.0916

0.0817

0.0868 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations. Page 16 of 52SULFUR DIOXIDE

EMISSION

RATE CALCULATION

LOCATION: Boral Bricks SOURCE: #5 Kiln Exhaust SULFUR DIOXIDEDATA

R#1-M8

R#2-M8

R#3-M8

AVERAGE DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60,00

60.00

60.00 Dn (in)

0.416

0.416

0,416 An (ft2)

9.44E-04

9,44E-04

9.44E-04 A VG DH (in H20)

0.97

1,30

1.55 P A TM (in Hg)

29,54

29.54

29.54 Pm (in Hg)

29.61

29.64

29,65 Ps (GAUGE)

-0.07

-0,07

-0.07 Ps (IN HG)

29.53

29.53

29,53 Tm (F)

89.17

99.42

99.58 Tm (R)

548.84

559.09

559,25 Vm (ft3)

31.63

35.64

40.06 Vm STD (ft3)

29.15

32.27

36.29 VLQ (ml)

51.00

57.00

64.00 VV S TD (ft3)

2.43

2,72

3.05 VSTD (ft3)

31.58

34.99

39.33 %M 7.61

7.61

7.61

7.6t % SVP

100.00

100.00

100.00 MD 0.924

0.924

0.924 MWD 29.27

29.27

29.27 M 28.42

28.42

28.42 Ts (F)

378.21

364.00

342.25

361.49 Ts (R)

837.88

823.67

801,92

821.16 SUM SQRT DP

4.84

5,42

6.02 N DP

24.00

24.00

24.00 A VG SQRT DP

0.20

0.23

0.25 CP 0.84

0.84

0.84 Vs (ft/s)

14.46

16.06

17.62

16.05 Ds (in)

35.25 X 35.25 As (ft2)

8.63

8.63

8.63 QS, FLOW, ACFM

7487

8316

9122

8308 Q STD (ft3/min)

4657

5262

5929

5283 Q STD DRY, FLOWSCFM

4303

4862

5477

488t WT (gm)

O. 1470

O. 1700

O. 1880 %1 103.30

101.21

101.01 %C02 3.73

3.73

3.73

3.73 %02 16.94

16.94

16.94

16.94 %C0 0.00

0.00

0.00 %N2 79.33

79.33

79.33 PMRc (Ibs/hr)

2.8679

3.3829

3.7492

3.3333 Cs (GR/SCFD)

0.0778

0.0813

0.0799

0.0797 Theoretical amount of moisture that Ts can hold, If %M>%SVP,

%SVP will be utilized in calculations. Page 17 of 52SULFURIC ACID EMISSION

RATE

CALCULATION

LOCATION: Boral Bricks SOURCE: #5 Kiln Exhaust SULFURIC ACID MIST S03DATA

R #1-M8

R #2-M8

R #3.M8 AVERAGE DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.416

0.416

0.416 An (ft2)

9.44E-04

9.44E-04

9.44E-04 A VG DH (in H20)

0.97

1.30

1.55 P A TM (in Hg)

29.54

29.54

29.54 Pm (in Hg)

29,61

29.64

29.65 Ps (GAUGE)

-0.07

-0.07

-0.07 Ps (IN HG)

29.53

29.53

29.53 Tm (F)

89.17

99.42

99.58 Tm (R)

548.84

559.09

559.25 Vm (ft3)

31.63

35.64

40.06 Vm STD (ft3)

29.15

32.27

36.29 VLQ (ml)

51.00

57.00

64.00 VV STD (ft3)

2.43

2.72

3.05 VSTD (ft3)

31.58

34.99

39.33 %M 7.61

7.61

7.61

7.61 % SVP

100.00

100.00

100.00 MD 0.924

0.924

0.924 MWD 29.27

29.27

29.27 M 28.42

28.42

28.42 Ts (F)

378.21

364.00

342.25

361.49 Ts (R)

837.88

823.67

801.92

821.t6 SUM SQRT DP

4.84

5.42

6.02 N DP

24.00

24.00

24.00 A VG SQRT DP

0.20

0.23

0.25 CP 0.84

0.84

0.84 Vs (ft/s)

14.46

16.06

17.62

16.05 Ds (in)

35.25 X 35.25 As (ft2)

8.63

8.63

8.63 QS, FLOW, ACFM

7487

8316

9122

8308 Q STD (ft3/min)

4657

5262

5929

5283 Q STD DRY, FLOWSCFM

4303

4862

5477

4881 WT (gin)

0.0340

0.0460

0.0440 %1 103.30

101.21

101.01 %C02 3.73

3.73

3.73

3.73 %02 16.94

16.94

16.94

16.94 %C0 0.00

0.00

0.00 %N2 79.33

79.33

79.33 PMRc (Ibs/hr)

0.6633

0.9154

0.8775

0.8187 Cs (GR/SCFD)

0.0180

0,0220

0.0187

0.0196 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations. Page 18 of 52Dryer Calculation Sheets

Page 19 of 52PARTICULATE EMISSION

RATE

CALCULATION

LOCATION: Boral Brick SOURCE: #5 Kiln (Dryer Exhaust)

DATADATE RUN TIME (min) Dn (in) An (ft2) A VG DH (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) Ps (IN HG) Tm (F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (ml) VV S TD (ft3) V STD (ft3)%M % SVPMDMWDMTs(F)Ts(R) SUM SQRT DPN DP A VG SQR T DPCP Vs (ft/s) Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOWSCFM WT (gm)%1 %C02%02%C0%N2 PMRc (Ibs/hr) Cs (GR/SCFD)

R#1-D

R#2-D

R#3-D AVERAGE 09/08/05 09/08/05

09/08/05 60.00 60.00

60.00 0.345 0.345

0.345 6.49E-04 6.49E-04

6.49E-04 1,45 1.47

1.47 29.54 29.54

29.54 29.65 29.65

29.65 -0.20 -0.20

-0.20 29.53 29.53

29.53 80.00 83.13

86.08 539.67 542.80

545.75 48.18 49,26

50.02 45.26 46.01

46.47 28.00 73.00

67.00 1.32 3.44

3.16 46.58 49.45

49.63 2.83 6.96

6.37

5.39 100.00 100.00

100.00 0.972 0.930

0.936 29.27 29.27

29.27 28.96 28.49

28.56 346.38 348.21

346.29

346.96 806.05 807.88

805.96

806.63 10.51 10.51

10.50 24.00 24.00

24.00 0.44 0.44

0.44 0.84 0.84

0.84 30.54 30.83

30.72

30.70 45.25 45.25

45.25 11.17 11.17

11.17 20466 20659

20585

20570 13229 13324

13308

13287 12854 12397

12460

12570 0.0598 0.0597

0.0505 101.01 106.48

106.98 3.73 3.73

3.73

3.73 16.94 16.94

16.94

t6.94 0.00 0.00

0.00 79.33 79.33

79.33 2.247 2.128

1.792

2.056 0.0204 0.0200

0.0168

0.0191 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations. Page 20 of 52HCI EMISSION

RATE CALCULATION

LOCATION: Boral Brick SOURCE: #5 Kiln (Dryer Exhaust) HCL RESULTS

M 26-A DATA Run #1 Run #2 Run #3 AVERAGE DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60,00

60.00

60.00 Dn (in)

0.345

0,345

0.345 An (ft2)

6.496-04

6.496-04

6.496-04 A VG DH (in H20)

1.45

1,47

1.47 P ATM (in Hg)

29.54

29.54

29.54 Pm (in Hg)

29.65

29.65

29.65 Ps (GAUGE)

-0.20

-0.20

-0.20 Ps (IN HG)

29.53

29.53

29.53 Tm (F)

80.00

83.13

86.08 Tm (R)

539.67

542.80

545.75 Vm (ft3)

48.18

49.26

50.02 Vm STD (ft3)

45.26

46.01

46.47 VLQ (ml)

28.00

73.00

67.00 VV STD (ft3)

1.32

3.44

3.16 VSTD (ft3)

46.58

49.45

49.63 %M 2.83

6.96

6.37

5.39 % SVP

100.00

100.00

100.00 MD 0.972

0.930

0.936 MWD 29.27

29.27

29.27 M 28.96

28.49

28.56 Ts (F)

346.38

348.21

346.29

346.96 Ts (R)

806.05

807.88

805.96

806.63 SUM SQRT DP

10.51

10.51

10.50 N DP

24.00

24.00

24.00 A VG SQRT DP

0.44

0.44

0.44 CP 0.84

0.84

0.84 Vs (ft/s)

30.54

30.83

30.72

30.70 Ds (in)

45.25

45.25

45.25 As(ft2) 11.17

11.17

11.17 QS, FLOW, ACFM

20466

20659

20585

20570 Q STD (ft3/rnin)

13229

13324

13308

13287 Q STD DRY, FLOWSCFM

12854

12397

12460

12570 WT (gin)

0.0260

0.0276

0.0301 %1 101.01

106.48

106.98 %C02 3.73

3.73

3.73

3.73 %02 16.94

16.94

16.94

16.94 %C0 0.00

0.00

0.00 %N2 79.33

79.33

79.33 PMRc (Ibs/hr)

0.977

0.984

1.068

1.010 Cs (GR/SCFD)

0.0089

0.0093

0.0100

0.0094 Theoretical amount of moisture that Ts can hold, If %M>%SVP,

%SVP will be utilized in calculations. Page 21 of 52HF EMISSION

RATE

CALCULATION

LOCATION: Boral Brick SOURCE: #5 Kiln (Dryer Exhaust) HF RESULTS

M 26-A DATA Run #1 Run #2 Run #3 AVERAGE DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.345

0.345

0.345 An (ft2)

6.49E-04

6.49E-04

6.49E-04 AVG DH (in H20)

1.45

1.47

1.47 P ATM (in Hg)

29.54

29.54

29.54 Pm (in Hg)

29.65

29.65

29.65 Ps (GAUGE)

-0.20

-0.20

-0.20 Ps (IN HG)

29.53

29.53

29.53 Tm (F)

80.00

83.13

86.08 Tm (R)

539.67

542.80

545.75 Vm (ft3)

48.18

49.26

50.02 Vm STD (ft3)

45.26

46.01

46.47 VLQ (ml)

28.00

73.00

67.00 VV STD (ft3)

1.32

3.44

3.16 V STD (ft3)

46.58

49.45

49.63 %M 2.83

6.96

6.37

5.39 % SVP

100.00

100.00

100.00 MD 0.972

0.930

0.936 MWD 29.27

29.27

29.27 M 28.96

28.49

28.56 Ts (F)

346.38

348.21

346.29

346.96 Ts (R)

806.05

807.88

805,96

806.63 SUM SQRT DP

10.51

10.51

10.50 N DP

24.00

24.00

24.00 A VG SQRT DP

0.44

0.44

0.44 CP 0.84

0.84

0.84 Vs (ft/s)

30.54

30.83

30.72

30.70 Ds (in)

45.25

45.25

45.25 As(ft2) 11.17

11.17

11.17 QS, FLOW, ACFM

20466

20659

20585

20570 Q STD (ft3/min)

13229

13324

13308

13287 Q STD DRY, FLOWSCFM

12854

12397

12460

12570 WT (gm)

0.2080

0.2150

0.2290 %1 101.01

106.48

106.98 %CO2 3.73

3.73

3.73

3.73 %02 16.94

16.94

16.94

16.94 %C0 0.00

0.00

0.00 %N2 79.33

79.33

79.33 PMRc (Ibs/hr)

7.816

7.664

8.124

7.868 Cs (GR/SCFD)

0.0709

0.0721

0.0760

0.0730 Theoretical amount of moisture that Ts can hold, If %M>%SVP,

%SVP will be utilized in calculations. Page 22 of 52SULFUR DIOXIDE

EMISSION

RATE

CALCULATION ONLY AVERAGE

RUNS 1 & 3 LOCATION: Boral Brick SOURCE: #5 Kiln (Dryer Exhaust) SULFUR DIOXIDE

RESULTSDATA

Run#1

Run#2

Run#3 AVERAGE DATE 09/08/05

09/08/05

09/08/05 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.343

0.343

0.343 An (ft2)

6,42E-04

6.42E-04

6.42E-04 AVG DH (in H20)

1.73

1.84

1.77 P A TM (in Hg)

29.54

29.54

29.54 Pm (in Hg)

29.67

29.68

29,67 Ps (GAUGE)

-0.20

-0.17

-0.17 Ps (IN HG)

29.53

29.53

29.53 Tm (F)

75.46

83.71

86.71 Tm (R)

535.13

543.38

546.38 Vm (ft3)

45.60

47.39

47.10 Vm STD (ft3)

42.43

43.43

42.92 VLQ (ml)

65.00

65.00

65.00 VVSTD (ft3)

3.09

3.09

3.09 VSTD (ft3)

45.52

46.53

46.02 %M 6.79

6.65

6.72

6.72 % SVP

100.00

100.00

100.00 MD 0.932

0.934

0,933 MWD 28.84

28.84

28,84 M 28.10

28.12

28.11 Ts (F)

346.67

348.21

346.83

347.24 Ts (R)

806.34

807.88

806.50

806.9t SUM SQRTDP

10.41

10.56

10.37 N DP

24.00

24.00

24.00 A VG SQRT DP

0.43

0,44

0.43 CP 0.84

0.84

0.84 Vs (ft/s)

30.70

31.17

30.58

30.82 Ds (in)

45.25

45.25

45.25 As (ft2)

11.17

11.17

11.17 QS, FLOW, ACFM

20572

20889

20492

20661 Q STD (ft3/min)

13293

13473

13240

13335 Q STD DRY, FLOWSCFM

12390

12578

12350

12439 WT(gm) 0.1250

0.0020

0.1840 %1 99.38

100.23

100.88 %C02 0.00

0.00

0.00

0.00 %02 20.90

20.90

20.90

20.90 %C0 0.00

0.00

0.00 %N2 79.10

79.10

79.10 PMRc (Ibs/hr)

4.830

0.077

7.004

6.917 Cs (GR/SCFD)

0.0455

0.0007

0.0661

0.0558 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations. Page 23 of 52ACID MIST EMISSION

RATE

CALCULATION Method

8 LOCATION: Boral Brick SOURCE: #5 Kiln (Dryer Exhaust) SULFURIC ACID MIST RESULTS DATADATE RUN TIME (min) Dn (in) An (ft2) A VG DH (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) Ps (IN HG) Tm (F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (ml) VV STD (ft3) V STD (ft3)%M % SVPMDMWDMTs(F)Ts(R) SUM SQRT DPN DP A VG SQRT DPCP vs (ft/s) Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOWSCFM WT (gm)%1%C02%02%C0%N2 PMRc (Ibs/hr) Cs (GR/SCFD)

Run #1 Run #2 Run #3 AVERAGE 09/08105 09/08105

09/08/05 60.00 60.00

60.00 0.343 0.343

0.343 6.42E-04 6.42E-04

6.42E-04 1.73 1.84

1.77 29.54 29.54

29.54 29.67 29.68

29.67 -0.20 -0.17

-0.17 29.53 29.53

29.53 75.46 83.71

86.71 535.13 543.38

546.38 45.60 47.39

47.10 42.43 43.43

42.92 65.00 65,00

65.00 3.09 3.09

3.09 45.52 46,53

46.02 6.79 6.65

6.72

6.72 100.00 100.00

100.00 0.932 0.934

0.933 28.84 28.84

28.84 28.10 28.12

28.11 346.67 348.21

346.83

347.24 806.34 807.88

806.50

806.91 10.41 10.56

10.37 24.00 24.00

24.00 0.43 0.44

0.43 0.84 0.84

0.84 30.70 31.17

30.58

30.82 45.25 45.25

45.25 11.17 11.17

11.17 20572 20889

20492

20651 13293 13473

13240

13335 12390 12578

12350

12439 0.0310 0.0470

0.0400 99.38 100.23

100.88 0.00 0.00

0.00

0.00 20.90 20.90

20.90

20.90 0.00 0.00

0.00 79.10 79.10

79.10 1.198 1.801

1.523

1.507 0.0113 0.0167

0.0144

0,0141
Theoretical amount of moisture that Ts can hold. If %M>%SVP.

%SVP will be utilized in calculations. Page 24 of 52