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 17,2005 
TABLE 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 52 
INTRODUCTION 

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 52 
SOURCE 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 52 
RESULTS 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 EMISSIONS 

P.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 52 
RESULTS 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 

0.0196 
RESULTS 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 

0.0141 
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. 

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 52 
SAMPLING 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 52 
SAMPLING AND ANALYTICAL PROCEDURES, continued 

numbered 150ml Griffin beakers were thoroughly washed with warm, soapy water and ovendried. 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. 

0.0002 x Wsample 

WBlank 

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 52 
CALCULATIONS 

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 52 
Kiln Calculation 

Sheets 

Page 13 of 52 
PARTICULATE EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: #5 Kiln Exhaust Kiln Exhaust 

DATA 

DATE 

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 

% SVP 

MD 

MWD 

M 

Ts(R 

Ts(R) 

SUM SQRTDP 

N DP 

A VG SQRTDP 

CP 

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 52 
HCI EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: #5 Kiln Exhaust 

HCI RESULTS 

DATA 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 

8741 

5513 

5092 

3.73 

16.94 

0.540 

0.0124 

Ts can hold. 

calculation& 

Page 15 of 52 
HF EMISSION RATE CALCULATION 

LOCATION: 

SOURCE: 

HF RESULTS 

DATA 

DATE 

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 

% SVP 

MD 

MWD 

M 

Ts(F) 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQRT DP 

CP 

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 52 
SULFUR DIOXIDE EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: #5 Kiln Exhaust 

SULFUR DIOXIDE 

DATA 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 52 
SULFURIC ACID EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: #5 Kiln Exhaust 

SULFURIC ACID MIST S03 

DATA 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 52 
Dryer Calculation 

Sheets 

Page 19 of 52 
PARTICULATE EMISSION RATE CALCULATION 

LOCATION: Boral Brick 

SOURCE: #5 Kiln (Dryer Exhaust) 

DATA 

DATE 

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 

% SVP 

MD 

MWD 

M 

Ts(F) 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQR T DP 

CP 

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 52 
HCI 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 52 
HF 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 52 
SULFUR DIOXIDE EMISSION RATE CALCULATION 

ONLY AVERAGE RUNS 1 & 3 

LOCATION: Boral Brick 

SOURCE: #5 Kiln (Dryer Exhaust) 

SULFUR DIOXIDE RESULTS 

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) 0.343 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 52 
ACID MIST EMISSION RATE CALCULATION 

Method 8 

LOCATION: Boral Brick 

SOURCE: #5 Kiln (Dryer Exhaust) 

SULFURIC ACID MIST RESULTS 

DATA 

DATE 

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 

% SVP 

MD 

MWD 

M 

Ts(F) 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQRT DP 

CP 

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