PARTICULATE, HC1, HF 

and VISUAL EMISSIONS TESTING 

ON THE DRY INJECTION FABRIC FILTER BAGHOUSE (DIFF) 

 :'BORAL BRICKS 

700 South Long Street 

EAST SPENCER (ROWAN COUNTY), NC 28039 

(704) 636-1031 Plant Contact Telephone Number 

(704) 636-7865 Plant Facsimile Number 

Source Testing Conducted: 

July 20, 2007 

ATC Project Number 

P-07099 

Provic•ng Qua,#ty Air Tes•ng and Consu•'n.g Ser•ces Since 1981. 

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) 

Mr. Barry Schenk 

(One copy) 

Issue Date: 

August 8, 2007 
TABLE OF CONTENTS 

Page No, 

Introduction 3 

Certification of Results 3 

Source Description 4 

Results Summary 5 

Results, Conclusions and Comments 7 

Sampling and Analytical Procedures 8 

References 10 

Emission Calculations 11 

HC1/HF Mass Loading Calculation 12 

HC1/HF Outlet Emission Rate Calculation 13 

Particulate Emission Rate Calculation 14 

Isokinetic Data and Calculations (Inlet and Outlet) 15 

Moisture Data/Isokinetic Sampling Rate Equation (Inlet and Outlet) 21 

Sample Calculations 23 

Nomenclature 25 

Calculation Formulae 27 

Appendix 30 

Approved Test Plan A1 

NCDAQ Plan Approval Letter A25 

Isokinetic Sampling Data Sheets A27 

Impinger Data Records A36 

Portable Oxygen/Carbon Dioxide Measurements A37 

Source Surveys/Equal Areas A43 

Gravimetric Lab Report A51 

LELAP Certification A67 

I-IF/HC1 Laboratory Report A72 

Visible Emissions Observations A79 

VE Observers Certification A82 

Process Data A84 

Calibration Data A85 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 2 of 30 
INTRODUCTION 

This report presents the results of particulate, hydrogen chloride, hydrogen fluoride and visible 

emissions testing performed on the inlet/outlet of the new dry injection fabric filter baghouse 

recently installed on Brick Kiln #6 at Boral Bricks, Inc in East Spencer, North Carolina. 

Emissions testing were conducted while the kiln was fired at a rate of 25.2 tons fired product per 

hour. 

The following table outlines the methodology utilized. 

US EPA 

Methodology 

2 

Inlet/Outlet 

3a 

Inlet/Outlet 

4 

Inlet/Outlet 

Description 

Determination of Volumetric Flow 

rates 

Oxygen/Carbon dioxide concentration 

determinations 

Determination of Stack Moisture 

Content 

Isokinetic 

Sampling? 

No 

No 

Notes 

S-type pitottube 

Yes 

Determination of TSP particulate Yes 3 1-hr runs Outlet Only 

9 Determination of Opacity No 

26a Determination of Hydrogen Halide and Combined with M5 on 

Inlet/Outlet Halogen Emissions from Stationary Yes 

Sources Outlet/M4 on Inlet 

Semi-continuous 

analyzers 

Combined with USEPA 

M5 outlet/26A inlet 

Testing was conducted by ANALYTICAL TESTING CONSULTANTS, INC., Kannapolis, 

North Carolina. Members of the test team were Jason Treutel, Stewart Meadows, Brian Jones 

and Kent Childers. Mr. Frank Porter and Mr. Barry Schenk of Boral Bricks performed the visual 

emissions observations. 

CERTIFICATION OF RESULTS BY TEST FIRM 

"I certify under penalty of law that I believe the information provided in this document is true, 

accurate and complete. I am aware that there are significant civil and criminal penalties, including the 

possibility of fine or imprisonment or both, for submitting false, inaccurate or incomplete information." 

•. _____C'•• • •///,•/•,7 •//••Signature/Date Sign•tur•e/Date Y • 

Report Author Report Review 

W. Keith Poole• Technical Director 

Printed Name/Title 

Bill Kissel• President 

Printed Name/Title 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) Po7099 Page 3 of 30 
SOURCE DESCRIPTION 

Testing was conducted on the inlet/outlet of the new dry injection fabric filter (DIFF) baghouse 

that controls acid gas (HC1 and HF) and particulate emissions released from the wood-waste 

fired Brick Kiln #6 at Boral Bricks, located in East Spencer, North Carolina. The DIFF system 

injects hydrated lime into the brick kiln exhaust stream which reacts with HF and HC1 to form 

calcium fluoride and calcium chloride. The spent lime (CaF and CaC1) is removed from the 

exhaust air stream by bagfilters and is transported off site for disposal. The baghouse exhaust 

gas contains un-reacted pollutants and particulate matter. 

"Green" brick are stacked on drying racks and placed in a warming room, where initial drying 

occurs. The warming room is supplied with waste heat from the cooling section of the kiln. 

From the warming room, bricks enter the dryer where the temperature is raised and most of the 

process water is removed before entering the kiln. In the kiln, 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. 

The brick production rate during testing was 25.2 tons per hour. 

Boral'Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 4 of 30 
S YS TEM 

RESULTS SUMMARY 

Boral Bricks 

DIFF •aghouse 

TEST DATE 07/20/07 

PARAMETER Run #1 Run #2 Run #3 

GENERAL 

QS, FLOW, ACFM 100,309 106,524 113,368 

Q STD DRY, FLOWSCFM 52,519 54,325 57,437 

Vm S TD (ft3) 42.77 45.31 48.43 

%1 98.44 100.82 101.93 

Production Rate 

(tons per hour fired brick) 

HCI/HF MASS LOADING RATE 

PMRc (Ibs/hr)-HCI 2.226 2.189 2.118 

Cs (GR/SCFD)-HCI 0.0049 0.0047 0.0043 

PMRc (Ibs/hr)-HF 19.17 20.46 22.12 

Cs (GR/SCFD)-HF 0.0426 0.0439 0.0449 

HCI/HF EMISSION RA TE 

PMRc (Ibs/hr)-HCI < 

Cs (GR/SCFD)-HCI < 

HCI Emissions 

(/b/ton fired brick) 

PMRc (Ibs/hr)-HF < 

Cs (GR/SCFD)-HF < 

HF Emissions 

(/b/ton fired brick) 

0.153 0.133 0.130 

3.07E-04 2.58E-04 2.58E-04 

0.153 0.133 0.130 

3.07E-04 2.58E-04 2.58E-04 

A VERA GE 

t06,733 

54,760 

25.2 

2.178 

0.0046 

20.585 

0.0438 

0.138 

2.74E-04 

5.49E-03 

0.138 

2.74E-04 

5.49E-03 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 5 of 30 
S YS TEM 

RESULTS SUMMARY 

Boral Bricks 

DIFF Baghouse Exhaust 

TEST DATE 07/20/07 

PARAMETER Run #1 Run #2 Run #3 

GENERAL 

QS, FLOW, ACFM 108943 112626 113798 

Q STD DRY, FLOW SCFM 58285 59895 58595 

Vm STD (ft3) 40.27 41.85 41.90 

%1 98.12 99.24 101.56 

Production Rate 

(tons per hour fired brick) 

PARTICULA TE EMISSIONS 

PMRc (Ibs/hr) 3.964 2.707 0.481 

Cs (GR/SCFD) 0.0079 0.0053 0.0010 

PM Emissions (/b/ton) 

A VERA GE 

111789 

58925 

25.2 

2.384 

0.0047 

0,095 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 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. 

Emissions Results-Inlet 

Mean measured stack velocities on the seventy inch (70") horizontal inlet duct were 66.56 feet 

per second yielding an actual volumetric flow rate of 106,733 cubic feet per minute. The 

volumetric air flow rate was standardized to a mean 54,760 cubic feet per minute based upon 

stack conditions (moisture, temperature, static pressure and station pressure). 

Inlet loading mass rates of hydrogen fluoride were a mean 20.59 pounds per hour; HC1 averaged 

2.18 lbs/hr. Results were compared to the calculated emission levels of these constituents to 

determine removal efficiency. 

.Outlet 

The mean measured stack velocity of the seventy-five inch (75") outlet duct was 60.73 feet per 

second yielding an actual volumetric flow rate of 111,789 cubic feet per minute. Standardized 

flow rates (mean=58,925) were utilized in calculations of mass emissions of PM, HC1 and HF. 

Particulate emissions from the exhaust of the dry injection fabric filter baghouse (DIFF) 

averaged 2.38 lbs/hr and 0.095 lbs PM per ton of fired product, well in compliance with 40 CFR 

63 Subpart JJJJJ, table 1 emission limitations of 0.42 lbs/ton. 

Hydrogen fluoride was not detected in any of the outlet samples; emissions averaged <0.138 

lbs/hr and <5.49e -°3 lbs/ton fired product yielding a removal efficiency of >99.3% (calculated at 

the detection limit). The DIFF Baghouse was shown to be in compliance with the emission 

limitation of 0.057 lbs/ton. 

Hydrogen chloride was also not detected. Estimated emissions, based on the in-stack detection 

limit, are < 0.138 lbs per hour yielding a process-related emission rate of <5.49e "°3 lbs/ton of 

fired product, well in compliance with the Subpart JJJJJ standard of 0.26 lbs/ton. Removal 

efficiency of hydrogen chloride was calculated at >93.6%. 

No visible emissions were observed. 

Sampling and Analysis Notes 

Sampling and analyses were accomplished according to the site-specific test plan submitted to 

NCDENR on December 21, 2006. An approval letter was received on February 6, 2007. 

Approval for the re-test was included in a letter from Mr. David Hughes of NCDENR dated 

7/13/2007. A copy of this letter and the test plan are included in the appendix to this report. 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 7 of 30 
SAMPLING AND ANALYTICAL PROCEDURES 

TSP particulate emission testing and analysis were performed according to procedures developed 

by the U. S. Environmental Protection Agency (USEPA) and referred to as Method 5. Sampling 

port locations and number of test points to be used were determined according to Method 1. The 

above federal test methods appear in the Code of Federal Regulations (Reference 1). 

TSP measurements were combined with US EPA method 26a for determinations of hydrogen 

halides and halogens; only the halide and PM portion of the sampling train was of concern. A 

standard US EPA method 5/26a all-glass sampling train was utilized that employed pyrex or 

quartz glass nozzles and probe liners, pre-tared 3" round Pallflex quartz filters (lot #55356), and 

Teflon filter supports. The condenser train consisted of five glass impingers connected 

sequentially. The first two impingers were each charged with 100 ml of 0.1 N H2SO4; the third 

and fourth were filled with 100 ml of 0.1 N NaOH. The final impinger was initially charged 

with 300 grams of silica gel. All sample recovery was conducted in the on-site field trailer. 

Condenser train acid collections were measured and transferred to 500 ml Nalgene samples 

bottles. The sodium hydroxide fractions were measured and discarded since no further analysis 

was required. The front half of the sampling train (nozzle, probe and front half of the filter bell) 

was rinsed with reagent grade acetone and stored in 500 ml Nalgene® bottles until analysis. 

Liquid levels were marked on the sampling bottles with a grease pencil. 

Test point locations and sampling port placement for velocity traverses are shown in the data 

sheets. Test point locations were calculated based upon an outlet stack diameter of 75" and inlet 

stack diameter of 70". Upstreams/downstreams on the exhaust dictated maximum sampling 

points (24) while twelve total test points were measured on the inlet. 

Laboratory equipment that was utilized for the gravimetric sample analysis included the 

following: 

1) Precisa 303A Analytical Lab Balance-certification and annual maintenance by Applied 

Weight Technologies, Inc. (completed 3/2/2006). 

2) Prior to each use, the balance is calibrated with NIST Traceable weights-0.5000, 5.0000, 

50.0000, and 100.0000 grams, and 

3) a Nalgene® 5317-0180 Desiccator cabinet with indicating desiccant. 

Prior to the field test, filter media were prepared by sequentially numbering Pallflex quartz filters 

with a non-bleeding marker and oven drying. Duplicate weights were then performed on the 

filters to reach a constant weight. Additionally, sufficient quantities of numbered 150ml Griffin 

beakers were thoroughly washed with warm, soapy water and oven-dried. Once cooled, the 

beakers were also weighed to a constant weight and stored in the dessicator cabinet until needed. 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 8 of 30 
SAMPLING AND ANALYTICAL PROCEDURES 

(continued) 

After recovery, each filter was stored individually in petri dishes until transferred to the 

desiccator for a period of no less than twenty-four hours at room temperature and constant 

relative humidity; filters were then weighed to a constant weight (to the nearest 0.1 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 US EPA QA/QC documentation is 0.0001% grams. 

The net gain of the acetone blank was applied based upon this and a ratio of the volume of the 

sample to the volume of the blank according to the following example. 

0.0005 x Vsample 

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. 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 9 of 30 
REFERENCES 

CODE OF FEDERAL REGULATIONS, Title 40, Part 60, Appendix A, July 1, 2006. 

B0ral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 10 of 30 
CALCULATIONS 

HF/HC1 Inlet Loading Calculations 

HF/HCI Emissions Calculations 

Particulate Emissions Calculations 

Isokinetic Run Data 

Inlet 

Outlet 

Moisture Data/Isokinetic Sampling Rate Equation 

Sample Calculations 

Nomenclature 

Calculation Formulae 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 11 of 30 
HCI/HF Inlet Loading Rate Calculation 

LOCATION: Boral Bricks 

SOURCE: DIFF Baghouse Inlet 

DATA Run #1 Run #2 Run #3 

DATE 07/20/07 07/20/07 07/20/07 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.260 0,260 0.260 

An (ft2) 3,69E-04 3.69E-04 3.69E-04 

AVG DH (in H20) 1.68 1.87 2.09 

P ATM (in Hg) 29,25 29.25 29.25 

Pm (in Hg) 29.37 29.39 29.40 

Ps (GAUGE) -1.30 -1.30 -1.30 

Ps (INHG) 29.15 29.15 29.15 

Tm (F) 82.58 87.67 88.92 

Tm (R) 542.27 547.36 548.61 

Vm (ft3) 45.47 48.60 52.04 

Vm STD (ft3) 42.77 45.31 48.43 

VLQ (ml) 64.90 88.20 98.90 

VV STD (ft3) 3.06 4.16 4,66 

VSTD (ft3) 45.83 49.47 53.10 

%M 6,68 8.41 8.78 

% SVP 100.00 100,00 100.00 

MD 0,933 0.916 0,912 

MWD 29.17 29.20 29.26 

M 28.43 28.25 28.27 

Ts (F) 457.33 464.33 466.58 

Ts (R) 917.02 924.02 926.27 

SUM SQRT DP 9.94 10.48 11.15 

N DP 12.00 12.00 12.00 

AVG SQRT DP 0.83 0.87 0.93 

CP 0.84 0.84 0.84 

Vs (ft/s) 62.56 66.43 70.70 

Ds (in) 70.00 70.00 70.00 

As (ft2) 26.73 26.73 26.73 

QS, FLOW, ACFM "100,309 "106,524 '113,368 

Q STD (ft3/min) 56.277 59,312 62,969 

Q STD DRY, FLOWSCFM '52,519 54,325 57,437 

WT (gm)-HCI 0.0137 0.0138 0.0135 

WT (gm)-HF 0.1180 0.1290 0.1410 

%1 98.44 100.82 101.93 

%C02 3,17 3.33 3.75 

%02 ,16.66 16.56 16.60 

%C0 0.00 0.00 0.00 

%N2 80.17 80.11 79.65 

AVERAGE 

7.96 

462.75 

922.44 

66.56 

106,733 

59,519 

54,760 

3.42 

16.61 

PMRc(Ibs/hr)-HCl "2.226 2.189 2,118 2.178 

Cs (GR/SCFD)-HCI 0.0049 0.0047 0.0043 0.0046 

PMRc (Ibs/hr),HF ,19,170 "20.463 22.123 20.585 

Cs (GR/SCFD)-HF 0.0426 0.0439 0.0449 0.0438 

Theoretical amount of moisture that Ts can hold, 

If %M>%SVP, %SVP will be utilized in calculations. 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 12 of 30 
HCI/HF Emission Rate Calculation 

LOCATION: Boral Bricks 

SOURCE: DIFF Baghouse Outlet (Kiln #6) 

DATA Run #1 Run #2 Run #3 

DATE 07/20/07 07/20/07 07/20/07 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.257 0.257 0.257 

An (ft2) 3.60E-04 3.60E-04 3.60E-04 

AVG DH (in H20) 1.71 1.82 1.82 

P ATM (in Hg) 29.25 29.25 29.25 

Pm (in Hg) 29.38 29.38 29.38 

Ps (GAUGE) -0.42 -0.42 -0.42 

Ps (IN HG) 29.22 29.22 29.22 

Tm (F) 84.33 87.00 87.38 

Tm (R) 544.02 546.69 547.07 

Vm (ft3) 42.30 44.17 44.25 

Vm STD (ft3) 40.27 41.85 41.90 

VLQ (ml) 55.00 52.60 81.50 

VVSTD (ft3) 2.59 2.48 3.84 

VSTD (ft3) 42.86 44.33 45.74 

%M 6.05 5.59 8.40 

% SVP 100.00 100.00 100.00 

MD 0.939 0.944 0.916 

MWD 29.13 29.14 29.15 

M 28.46 28.51 28.21 

Ts (F) 445.79 455.67 457.58 

Ts (R) 905.48 915.36 917.27 

SUM SQRT DP 18.96 19.51 19.59 

N DP 24.00 24.00 24.00 

AVG SQRTDP 0.79 0.81 0.82 

CP 0.84 0.84 0.84 

Vs (ft/s) 59.18 61.18 61.82 

Ds (in) 75,00 75.00 75.00 

As (ft2) 30.68 30.68 30.68 

QS, FLOW, ACFM 108,943 -112,626 "113,798 

Q STD (ft3/min) 62,038 63,443 63,970 

Q STD DRY, FLOWSCFM 58,285 59,895 58,595 

WT(gm).HCI < 0.0008 0.0007 0.0007 

WT (gm)-HF < 0.0008 0.0007 0.0007 

%1 98.12 99.24 101.56 

%C02 3.00 3.00 3.00 

%02 ,16.37 16.45 16.80 

%C0 0.00 0.00 0.00 

%N2 80.63 80.55 80.20 

PMRc (Ibs/hr),HCI < 0.153 0.133 0.130 

PMRc (Ibs/hr)-HF < 0.153 0.133 0.130 

Cs (GR/SCFD),HCI < 0.0003 0.0003 0.0003 

Cs (GR/SCFD)-HF < 0,0003 0.0003 0.0003 

Theoretical amount of moisture that Ts can hold. 

If %M>%SVP, %SVP will be utilized in calculations, 

AVERAGE 

6.68 

453.01 

912.70 

60.73 

11t,789 

63,150 

58,925 

3.00 

16.54 

0.138 

0.138 

0.0003 

0.00031 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 13 of 30 
DATE 

SOURCE 

Run #1 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Inlet 

K= 2,4327 

Tm Ts dp dH SQRT DP % 02 % C02 Fuel Factor 

Fo 

A1 75 451 0.70 1.70 0.837 17.0 

A2 77 458 0.80 1.95 0.894 16.4 

A3 78 460 0.88 2.14 0.938 16.5 3.5 1.26 

A4 79 461 0.75 1.82 0.866 16.5 

A5 81 462 0.60 1.46 0.775 16.6 3.5 1.23 

A6 82 450 0.43 1.05 0.656 16.5 

B1 84 458 0.65 1.58 0.806 16.5 

B2 85 459 0,75 1.82 0.866 16.5 

B3 86 463 0.80 1.95 0.894 16.5 

B4 87 461 0.79 1,92 0.889 16.4 

B5 88 450 0.59 1.44 0,768 18.2 2.5 1.08 

B6 89 455 0.56 1.36 0.748 

457.33 

Initial 583.24 

Final 628.71 

Total 45.47 

1.68 9.937 16.69 

corrected per 6C.1 16.66 

% N2 (BY DIFFERENCE) 

%Excess Air 

Calibration Actual 

Gas 

Zero 0,0 

• 10.53 

• 19.01 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.0 0,0 0.00 

10.5 10.6 0.14 

19.0 n/a 0.05 

Based upon 2% of span value (21%) 

% Error* 

82.58 

Vm(ft3) 

3.17 1.19 

80.17 

369.66 

-Post 

0.00 

0.33 

n/a 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 15 of 30 
DATE 

SOURCE 

Run #2 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Inlet 

Tm 

K 2.4317 

dH SQRT DP %02 

A1 85 464 0.68 1.65 0.825 17.0 

A2 85 462 0.65 1.58 0.806 16.4 

A3 86 470 0.75 1.82 0.866 16.5 

A4 87 460 0.92 2.24 0.959 17.0 

A5 88 462 0.75 1.82 0.866 16.5 

A6 89 447 0.63 1.53 0.794 

B1 88 467 0.85 2.07 0.922 16.4 

B2 88 471 0.92 2.24 0.959 16.5 

B3 89 467 0.95 2.31 0.975 16.5 

B4 89 469 0.84 2.04 0.917 16.6 

B5 89 468 0.67 1.63 0.819 16.5 

B6 89 465 0.60 1.46 0.775 

87.67 

Vm(ft3) 

484.33 

Initial 629.08 

Final 677.68 

Total 48.598 

1.87 10.481 16.59 

corrected per 8C-1 16.56 

% N2 (BY DIFFERENCE) 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

• 10.53 

Hi-Ran_qg. 19.01 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.0 0.0 0,00 

10.6 10,5 0.33 

n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

% C02 Fuel Factor 

Fo 

3.0 1.30 

3.5 1.29 

3.5 1.26 

3.33 1.28 

80.11 

360.75 

.Post 

0.00 

0.14 

n/a 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 16 of 30 
DATE 

SOURCE 

Run #3 

POINT # 

A1 

A2 

A3 

A4 

A5 

A6 

B1 

B2 

B3 

B4 

B5 

B6 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Inlet 

K= 2.4174 

Tm Ts dp dH SQRT DP % 02 % C02 Fuel Factor 

Fo 

82 467 0.80 1.93 0.894 16.4 3.5 1.29 

83 473 0.87 2.10 0.933 16.5 

85 469 0.95 2.30 0.975 16.5 4.0 1.10 

87 471 0.94 2.27 0.970 16.3 

87 467 0.90 2.18 0.949 16.4 

89 467 0.80 1.93 0.894 16.4 

89 470 0.87 2.10 0.933 16.5 

91 458 1.03 2.49 1.015 16.3 

92 465 0.94 2.27 0.970 16.4 

93 468 0.84 2.03 0.917 16.3 4.0 1.15 

94 461 0.74 1.79 0.860 16.7 3.5 1.20 

95 463 0.70 1.69 0.837 

88.92 

Vm(ft3) 

466.58 

Initial 678.12 

Final 730.15 

Total 52.038 

2.09 11.145 16.43 

corrected per 6C-1 16. 60 

% N2 (BY DIFFERENCE) 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

• 10.53 

Hi-Ran¢j• 19.01 

Calibration Data 

3.75 1.18 

79.65 

375.36 

Instrument Reading % Error* 

Pre- -Post Pre- -Post 

0.0 -0.1 0.00 0.48 

10.5 10.3 0.14 1.10 

n/a n/a n/a n/a 

Based upon 2% of span value (21%) 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 17 of 30 
DATE 

SOURCE 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Outlet (Kiln #6) 

Run #1 K= 2.7168 

POINT # Tm Ts dp dH SQRT DP % 02 % C02 Fuel Factor 

Fo 

A1 77 441 0.80 2.17 0.894 16.6 3.0 1.43 

A2 78 442 0.72 1.96 0.849 

A3 79 443 0.70 1.90 0.837 16.4 3.0 1.50 

A4 79 443 0.71 1.93 0.843 

A5 80 444 0.67 1.82 0.819 16.4 3.0 1.50 

A6 81 444 0.65 1.77 0.806 

A7 81 445 0.53 1.44 0.728 

A8 82 446 0.56 1.52 0.748 

A9 82 447 0.56 1,52 0.748 

AIO 83 446 0.55 1.49 0.742 

All 83 446 0.54 1.47 0.735 

A12 83 436 0.52 1.41 0.721 

B1 84 438 0.48 1,30 0.693 

B2 85 448 0.51 1.39 0.714 

B3 86 449 0.51 1.39 0.714 16.5 3.0 1.47 

B4 87 448 0.51 1.39 0.714 

B5 88 448 0.53 1.44 0.728 16.6 3.0 1.43 

B6 88 449 0.54 1.47 0.735 

B7 88 450 0.76 2.06 0.872 

B8 89 450 0.67 1.82 0.819 16.4 3.0 1.50 

B9 89 450 0.75 2.04 0.866 

BIO 90 451 0.73 1.98 0.854 

Bll 91 448 0.77 2.09 0.877 

B12 91 447 0.81 2.20 0.900 

84.33 

Vm(ft3) Initial 

Final 

Total 

1.71 18.956 16.48 

corrected per 6C-1 16.37 

245.43 % N2 (BY DIFFERENCE) 

287.73 

42.30 %Excess Air 

Calibration 

Gas 

Zero 

Calibration Data 

Actual Instrument Reading 

Pre- -Post Pre0.0 0.0 0.0 0.00 

10.53 10.6 10.6 0.33 

19.01 19.2 n/a 0.90 

Based upon 2% of span value (21%) 

Error* 

3.00 1.47 

80.63 

333.45 

-Post 

0.00 

0.33 

n/a 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 18 of 30 
DATE 

SOURCE 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Outlet (Kiln #6) 

Run #2 K= 

POINT # Tm Ts dp 

2.7351 

dH SQRT DP %02 

A1 84 440 0.65 .78 0.806 16.6 

A2 84 455 0.75 2.05 0.866 

A3 84 455 0.67 1.83 0.819 

A4 84 455 0.71 1.94 0.843 

A5 85 456 0.68 1.86 0.825 

A6 85 457 0.75 2.05 0.866 16.6 

A7 86 457 0.71 1.94 0.843 

A8 86 457 0.70 1.91 0.837 16.5 

A9 87 457 0.60 1.64 0.775 

AIO 87 457 0.63 1.72 0.794 

All 87 456 0.57 1.56 0.755 

A12 88 452 0.59 1.61 0.768 

B1 87 452 0.53 1.45 0.728 

B2 88 457 0.53 1.45 0.728 16.8 

B3 88 457 0.55 1.50 0.742 

B4 88 458 0.54 1.48 0.735 

B5 88 458 0.55 1.50 0.742 16.6 

B6 88 457 0.82 2.24 0.906 

B7 89 458 0.71 1.94 0.843 

B8 89 458 0.52 1.42 0.721 16.7 

B9 89 459 0.78 2.13 0.883 

BIO 89 459 0.83 2.27 0.911 

Bll 89 457 0.85 2.32 0.922 

B12 89 452 0.73 2.00 0.854 

87.00 

Vm(ft3) 

455.67 

Initial 287.93 

Final 332.10 

Total 44.17 

1.82 19.509 16.63 

corrected per 6C-1 16.45 

% N2 (BY DIFFERENCE) 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Ranoe 10.53 

Hi-Rancle 19.01 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.0 0.0 0.00 

10,6 10.7 0.33 

n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

% C02 Fuel Factor 

Fo 

3.0 1.43 

3.0 1.43 

3.0 1.47 

3.0 1.37 

3.0 1.43 

3.0 1.40 

3.00 1.42 

80.55 

341.18 

-Post 

0.00 

0.8'1 

n/a 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 19 of 30 
DATE 

SOURCE 

ISOKINETIC DATA AND CALCULATIONS 

07/20/07 

DIFF Baghouse Outlet (Kiln #6) 

Run #3 K= 2.7195 

POINT # Tm Ts dp dH SQRT DP % 02 % C02 Fuel Factor 

Fo 

A1 83 457 0.68 1.85 0,825 16.8 3.0 1.37 

A2 84 457 0.64 1.74 0.800 

A3 84 457 0.75 2.04 0.866 

A4 84 458 0.73 1.99 0.854 16.9 3.0 1.33 

A5 84 457 0.70 1.90 0.837 

A6 85 458 0.78 2.12 0.883 

A7 85 458 0.63 1.71 0.794 

A8 86 459 0.63 1.71 0.794 16.7 3.0 1.40 

A9 87 459 0,67 1.82 0.819 

AIO 87 459 0.66 1.79 0.812 

All 88 456 0.60 1.63 0.775 

A12 88 452 0.60 1,63 0.775 

B1 88 451 0.53 1.44 0.728 

B2 88 459 0.56 1.52 0.748 16.6 3.0 1.43 

B3 88 460 0.60 1.63 0.775 

B4 89 459 0.55 1.50 0,742 

B5 89 459 0,52 1.41 0.721 

B6 89 458 0.61 1.66 0.781 16.7 3.0 1.40 

B7 89 458 0.71 1.93 0.843 

B8 90 459 0.70 1.90 0.837 

B9 90 459 0.80 2.18 0.894 16.8 3.0 1.37 

BIO 90 460 0.87 2.37 0.933 

Bll 91 460 0.83 2.26 0.911 

B12 91 453 0.71 1.93 0.843 

87.38 

Vm(ft3) 

457.58 

Initial 

Final 

Total 

1.82 19.587 16.75 

corrected per 6C.1 16.80 

332.32 % N2 (BY DIFFERENCE) 

376.57 

44.25 %Excess Air 

Calibration 

Gas 

Zero 

Calibration Data 

Actual Instrument Reading 

Pre- -Post Pre0.0 0.0 0.0 0.00 

10.53 10.7 10.3 0.81 

19.01 n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

3.00 1.38 

80.20 

383.91 

-Post 

0.00 

1.10 

n/a 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 20 of 30 
Run #1 

BEGINNING 

ENDING 

NET 

MOISTURE DATA 

DIFF Baghouse Inlet 

7/20/2007 

1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

0.1N H SO 0.1N H SO 0.1N NaOH 300 g SiO 

100 100 200 300.0 

136 120 200 308.9 

36 20 0 8.9 

TOTALS 

64,9 

Run #2 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

0.1NH2S04 O.1NH2SO 0.1NNaOH 300 g SiO2 TOTALS 

BEGINNING 100 100 200 300.0 

ENDING 150 118 204 316.2 

NET 50 18 4 16.2 88.2 

Run #3 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

O.1N H SO 0.1N H SO O.1N NaOH 300 g SiO2 

BEGINNING 100 100 200 300.0 

ENDING 162 120 207 309.9 

NET 62 20 7 9.9 

ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

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 Apex #1 Apex #1 Apex #1 

Dn 0.260 0.260 0.260 

dH@ 1.638 1.638 1.638 

Y, gamma factor 0.984 0.984 0.984 

Cp 0.84 0.84 0.84 

Bw(FRACTION, NOT%) 0.05 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 29.25 29.25 29.25 

PS (GAUGE) -1.30 -1.30 -1.30 

Ps 29.15 29.15 29.15 

Tm, F 85 88 88 

Tm, R 544.69 547.69 547.69 

Ms 28.45 28.45 28.45 

Ts, F 455 460 465 

Ts, R '914.69 919.69 924.69 

Pm 29.36 29.37 29.39 

K 2.4327 2.4317 2.4174 

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) 

Pm=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dH/13.6) 

TOTALS 

98.9 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 21 of 30 
Run #1 

BEGINNING 

ENDING 

NET 

MOISTURE DATA 

DIFF Baghouse Outlet (Kiln #6) 

7/20/2007 

1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

0..1NH2SO 0.1N H2SO, 0.1NNaOH 300 g SiO2 

100 100 200 300.0 

116 120 207 312.0 

16 20 7 12.0 

TOTALS 

55.0 

Run #2 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

o.1NH2SO 0.1NH2SO 0.1NNaOH 300 g SiO2 TOTALS 

BEGINNING 100 100 200 300.0 

ENDING 124 111 203 314.6 

NET 24 11 3 14.6 52.6 

Run #3 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 

0.1NH2SO 0.1NH2SO 0.1NNaOH 300 g SiO2 TOTALS 

BEGINNING 100 100 200 300.0 

ENDING 124 129 217 311.5 

NET 24 29 17 11.5 81,5 

ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

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 Apex 2 Apex 2 Apex 2 

Dn 0.257 0.257 0.257 

dH@ 1.898 1.898 1.898 

Y, gamma factor 0.999 0.999 0.999 

Cp 0.84 0.84 0.84 

Bw(FRA CTION, NOT%) 0.050 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 29.250 29.25 29.25 

PS (GAUGE) -0.42 -0.42 -0.42 

Ps 29.22 29.22 29.22 

Tm, F 80 93 90 

Tm, R 539.69 552.69 549.69 

Ms 28.45 28.45 28.45 

Ts, F 440 455 455 

Ts, R 899.69 914.69 914.69 

Pm 29.36 29.38 29.38 

K 2.7168 2.7351 2.7195 

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) 

Pm=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dH/13.6) 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 22 of 30 
SAMPLE CALCULATIONS 

Boral Bricks 

E. Spencer, NC 

Run #1 

1) ABSOLUTE PRESSURE IN DRY GAS METER 

Pm P ATM + AVG DH/13.6 T ST[3 

P STD 

P ATM Avg. DH Pm 

29.25 1.71 29,38 

2) ABSOLUTE STACK PRESSURE 

Ps P ATM + Ps(GAUGE)I13.6 

P ATM Ps(GAUGE) Ps 

29.25 -0.42 29.22 

3) SAMPLE VOLUME AT STANDARD CONDITIONS 

VM STD (VM)*(Y)*(T STD/TM)*(PM/P STD) 

Vm Tm Y Vm STD 

42.30 544.02 0.999 40.27 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 DEC. R. 

WHERE 0.002668 0.04715 FT3/G*IN,HG/17.64 DEC. R. 

VLQ (w) VLQ (sg) W STD 

43.00 12.00 2.59 ft3 

5) TOTAL SAMPLE VOLUME AT STANDARD CONDITIONS 

V STD Vm STD + W STD 42.86 if3 

6) PERCENT MOISTURE IN STACK GAS 

%M (100)*(W STD)N STD 6,05% 

7) MOLE FRACTION OF DRY GAS 

MD (100-%M)/100 0,939 

528 DEC R. 

29.92 IN. HG 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 23 of 30 
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 

3.0 16.4 0.0 80.6 29.13 

9) MOLECULAR WEIGHT OF THE WET GAS 

M (MWD)*(MD) + 18(1-MD) 28.46 

WHERE 18 MOLECULAR WEIGHT OF WATER, G/G-MOLE 

10) STACK VELOCITY 

VS (85.49)*(CP)*(•SI(PS)(M))^112*((SUM SQRT DP)/N DP)) 

where 85.49 ft/sec* [Ibllb-mole*in.Hg)l(deg. R'in H20)]^0.5 

CP Ts (R) SUM SQRT N DP VS 

0.84 905.48 18.96 24 69.18 

11) STACK VOLUMETRIC FLOW RATE 

QS (60)*(VS)*(AS) 

AS (inlet) QS 

30.68 108,943 

12) STACK VOLUMETRIC FLOW RATE, STANDARD CONDITIONS INCLUDING MOISTURE 

Q STD Q STD DRY/MD 62,038 

13) STACK VOLUME FLOW RATE STANDARD CONDITIONS DRY 

Q STD DRY= 17.647*60*Md*Vs*A*(Ps/Ts(R)) 58,285 

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 

0.0008 0.153 

15) PERCENT ISOKINETIC 

%1 (0.09460*Ts*Vm std)/(Ps*Vs*An*Time*Md) 

Run Time Area of Nozzle 

60 3.60E-04 

%1 

98.t2 

16) CONCENTRATION, GR/SCFD 

Cs= 15.43 gr/gm WTNm STD 

Cs 0.0003 

Boral Bricks East Spencer, NC (Kiln #6 DIFF BGHS Test) P-7099 Page 24 of 30