TESTING LOCATION General 121 Turners

Bend Coosa, Georg

Associates, Inc. SW, Suite S 35120121
ect No. 2005-0188 PREPARED

FOR Ms. Martha

West General Shale Brick 3211 N. Roan Street Johnson City, Tennessee

3760
April 2005

Chris LeMay Project Manager

PREPARED BYCoosa,

TABLE OF CONTENTS
Introduction Page 1.1 Facility & Source Description

........................................................................ 1-1 1.2 Control Device Description

................................................................................. 1-1 1.3 Test Team & Contact Information

.......................................................................... 1-1 1.4 Protoc01/Methodology

Deviations

........................................................................... 1-1 Summary of Results

..................................................................................................... 2-1 Testing Methodology 3.13.23.33.4 Volumetric

Flow Rate

........................................................................................ 3-1 Oxygen/Carbon Dioxide

...................................................................................... 3-1 Moisture

........................................................................................................ 3-2 Sulfur Dioxide

.................................................................................................. 3-2

APPENDICES Summary of Calculations Field Data Quality Control Data Process Operating

Data

LIST OF TABLES Summary of Emission Testing Results Source Testing Methodology VFR Calculations Moisture Calculations Emission CalculationsGeneral Shale Brick Compliance Emission Test Report Introduction

1.0 Introduction E. Roberts Alley & Associates,

Inc. (ERA&A)

was retained by General Shale Brick (General Shale) to conduct compliance emission testing on the Kiln K2 baghouse

exhaust at its Coosa, Georgia (Rome) facility. The purpose of the testing was to determine

the sulfur dioxide (SO2) emission rate to demonstrate

compliance

with emission limits detailed in the facility's air permit. 1.1 Facility and Source Description General Shale's Rome Facility manufactures

brick exterior building material.

Shale and clay are mined, crushed and sent through a screening

process prior to brick forming.

The brick is formed by extrusion.

Once the brick is extruded, it is dried in a green brick dryer and fired in a tunnel Kiln at temperatures

exceeding

1,900 degrees Fahrenheit. The Coosa Facility has two (2) kilns (K1 and K2) with a common exhaust. After being fired, the brick is cooled, packaged

and shipped to various locations. 1.2 Control System Description The Kiln emissions

are controlled

with a Dustex scrubber and baghouse.

The emission testing was performed

in the Kiln K2 baghouse

exhaust duct prior to the common stack for the kilns. 1.3 Test Team and Contact Information The emission testing was conducted

by Mr. Jeremy Hutchens,

Team Leader, and Mr. Andy Roth, Technician. Instrumental test data was recorded on site in ERA&A's

mobile laboratory.

Ms. Martha West of General Shale served as ERA&A's

on-site contact and coordinated

the testing with facility operations.

There were no representatives from the Georgia Department

of Natural Resources

present during the emission testing.
1.4 Protocol/Method

Deviations ERA&A conducted

a total of four (4) SO2 test runs due to a greater than ten (10) percent increase in volumetric

flow rate during SO2 test run 2. The SOz test run 2 data was not used to determine

the average SO2 emissions.

c:\\Projects\GeneralShale•Rome\2005 -0188\EmissionTestRepor Page I-1ResultsGeneral Shale Brick Compliance Emission Test Report Summary of Results

2.0 Smnmary

of Results ERA&A conducted

a total of four (4) SO2 test runs on the Kiln exhaust on March 17, 2005. A summmy

of the SO2 emission testing results is detailed in Table 2-1. A full velocity traverse was performed

before and after each SO2 test run. The volumetric

flow rate data listed in the table is the arithmetic

average of the pre and post velocity traverses. The average of SO2 runs 1, 3 and 4 was used to determine

source compliance.

Run 2 data was not used to determine compliance

due to a significant

change in flow during the test run. The Run 2 field data is included in Appendix B. Any difference

between the summary

results listed in the following

table and the detailed results contained in Appendix

A is due to rounding for presentation.
TABLE

2-1 SUMMARY OF EMISSION

TESTING

I•SULTS

Date 3/17/05

3/17/05

3/17/05 Start Time 9:47

12:31

13:48 End Time 10:47

13:31

14:48 Production/Control Device Data Production Rate, tons/hr Average BH Pressure Drop, inches of WC Lime Injection Rate, lbs/hr Lime Recycle Rate, lbs/hr Volumetric Flow Rate Data Temperature, °F Velocity, ft/sec Moisture, % CO2 Concentration,

% O2 Concentration,

% VFR, x 104 dscfm 7.2

7.2

7.2 2.9 2.9

2.9

2.9 45 45

45

45 0 0

0

0 224 196

194

205 24.0 39.2

39.6

34.3 4.6 4.6

4.6 3.2 3.2

3.2

3.2 17.5 17.5

17.5

17,5 1.I 1.8

1.9

1.6 Emission Data SO2 Concentration,

ppmvd SO2 Emission Rate, lbs/hr SO2 Emission Factor, lbs/ton 93.5

64.6

65.8

74i6 10.1 11.8

12.2

1114 1.4 1.6

1.7

li6

cA\Projects\GeneralShale\Rome\2005-0188\EmissionTestReport Page 2-1121 Tm'n•fs BeM Road; SW | General Shale Brick Compliance Emission Test Report Testing Methodology

3.0 Testing Methodology The emission testing program was conducted

in accordance

with the U.S. EPA Reference

Methods snmmarized

in Table 3-1. Method descriptions

and quality assurance

data are provided in the referenced

appendices. TABLE 3-1 SOURCE TESTING

METHODOLOGY

Volumetric Flow Rate 1-4 Oxygen/Carbon Dioxide 3A Moisture 4 Sulfur Dioxide 6C

3.13.23.33.4

CCCC

Instrumental

Analysis Instrumental Analysis

3.1 Volumetric

Flow Rate The sampling location and number of traverse points were selected in strict accordance

with EPA Reference

Method 1. A total of twenty (20) traverse points were used to determine

the average stack gas velocity pressure.

The velocity of the stack gas was measured

in strict accordance

with EPA Reference

Method 2. The stack gas velocity pressure was measured

using an S-type pitot and an inclined manometer

while the gas temperature

was measured with a Type-K thermocouple.

A complete traverse of the stack was conducted

before and after each test run.
3.2 Oxygen

Carbon Dioxide The concentrations

of oxygen and carbon dioxide in the stack gas were determined

in strict accordance

with EPA Reference Method 3A. The stack gas was withdrawn

through a stainless sample probe, heated Teflon sample lines, and gas conditioning

system to a CAI Model 200P O2/CO2 analyzer.

The gas conditioning

system was anoncontact condenser

used to remove the stack gas moisture.

Data was acquired online and reported in one-minute averages. An analyzer calibration

and system bias check were performed

before testing was initiated.

A system bias/drift check was also conducted

following

the completion

of each 60-minute

test run. Additional

analyzer calibrations were conducted

as needed.

EPA Protocol

calibration

gases were used to conduct analyzer calibrations,

drift checks, and system bias checks. ERA&A also utilized a laboratory

and field certified (EPA Method 205) gas
c:\\Projects\GeneralShale\Rome\2005-0 88kEn ssionTestReport Page 3-1Compliance Emission Test R@ort •.•,,,• ,4 •,,•;,,,•,,,,•,•, •,. ,•, •6.. Testing Me thodolo• dilution system to accurately

split high range calibration

gas to meet the requirements

of EPA Reference

Method 3A. Copies of all calibration

gas certificates

and Method 205 data can be found in Appendix

C.
3.3 Moisture The stack gas moisture content was determined

in strict accordance

with EPA Method 4 by conducting

a 30-minute moisture run during each emission test run. The moisture train consisted

of a stainless steel probe, clear sample line, gas conditioning

train, pump, and calibrated

dry gas meter. The conditioning

train consisted

of four (4) impingers. The first two (2) impingers

contained

100 mL of water, the third impinger was empty, and the fourth contained approximately 200 grams of silica gel. The gas conditioning

train contents were either measured

gravimetrically

or volumetrically before and after each test run.
3.4 Sulfur Dioxide The sulfur dioxide testing was conducted

in strict accordance

with EPA Method 6C. The sampling system consisted of a heated stainless steel probe, heated Teflon sample line, non-contact

gas conditioning

system, Western Research Model 72lM SO2 analyzer,

and data acquisition

system. ERA&A conducted

an initial analyzer calibration

and system bias check before compliance

testing commenced.

Additional

bias/drift

checks were conducted

following the completion

of each test run. A gas divider was used to dilute concentrated

EPA Protocol

calibration

gas to obtain the necessary

calibration

gas concentrations

described

in Method 6C. The gas divider was calibrated

in the field in accordance

with EPA Method 205 (see Appendix

C) prior to conducting

any testing. The sulfur dioxide data was logged and recorded in one-minute

averages.

c:\\Projects\GeneralShale\Rome\2005-0188\EmissionTestReport Page 3-2AssoCiates

121Tul•ers

Bend R0ad; SW COOS•i G•61igia General Shale Brick Compliance Emission Test Report Summary of Calculations

Meter Pressure (Pm), in. HgAH Pm Pb + 13.6

Pm 29.97 in. Hg + SAMPLE

CALCULATIONS

where,

Pb barometric

pressure, in. Hg AH Pressure differential

of orifice in. [-120 2.000 in. H20

30.12 in. Hg 13.6 in. H20/in. Hg

Absolute Stack Gas Pressure

(Ps), in. Hg
Ps Pb + Pg13.6 where,

Ps 29.97 in. Hg + -3.00 in.HeO 13.6 in. H:O/in. Hg

Pb barometric

pressure, in. Hg Pg Static Pressure, in. HzO 29. 75 in. Hg

Staudard Meter Volume (Vmstd), dscf Vmstd 17.647 x Yx Vmx Pm Tm

where,

Y meter correction

factor Vm meter volume, cf Pm meter pressure, in. Hg Tm meter temperature,

°R Vmstd 17. 647 °R/in. Hg x 1.008 x 21. 729 cf x 30.12 in. Hg 523.2 °R Vmstd 22.249 dscf
c:\\Projects\Ge neralShale'•Rmne\2005-0188\EmissionTestReport Page A-Cotnpliance Emission Tesl Report •:,,'• ',,,,,•. •,•,•,,',',,•,s' tt,.,,/,J, ,•..s:',•.o" Summary of Calculations
Standard Wet Volume (Vwstd), scf Vwstd O. 04707 x Vlc

where,

Vlc volume of HzO collected,

ml Vwstd =0.04707

fi•/mLx

23.7 mL 1.116 scf
Moisture Fraction (Bws)
Bws Vwstd 1.116 scf

O. 048 (Vwstd + Vmstd)

1.116 scf + 22.249 dscf where, Vwstd standard wet volume, scf Vmstd standard meter volume, dscf Moisture Content (MC), % Bws BwsxlO0

0.048×100

4.8%
Molecular Weight (DRY) (Md), Ib/lb-mole Md (0. 44 × % C0•) + (0.32 × % 0•) + (0.28 (100 % C0• % 0•)) Md (0.44×3.2)+(0.32×1Z5)+(0.28(100-3.2-17.5)) 29.21 lb/lb mole where, CO2 Runs 1, 3 & 4 average carbon dioxide concentration,

%d O• Runs 1, 3 & 4 average oxygen concentration,

%d
Molecular Weight (WET) (Ms), lb/ib-mole Ms Md (1 Bws) + 18 (Bws) where,

Md molecular

weight (DRY), lb/lb-mole Bws Runs 1, 3 & 4 average moisture fraction, dimensionless Ms 29.21 lb/lb mole •l 0.046) + 18 (0.046)

28. 70 lb/lb mole Average Velocity (Vs), ft/sec / Vs 85. 49 x Cp x •/ Delta P avg. x J Ps x Ms

c:\\Projects\GeneralShale\Rome\2005-0188\EmissionTestReport Page A-2General Shale Brick Compliance Emission Test Report Summary of Calculations where, Cp pitot tube coefficient Delta P velocity head of stack gas, in. H20 Ts absolute stack temperature,

°R Ps absolute stack gas pressure, in. Hg Ms molecular

weight of stack gas, lb/lb-mole

Vs 8549 fi [(lb/lb•o-mole)(in.

Hg) × I

684"0°R •ec• (R)(in.H20)

xO.84xO.384

in. H20 29.75 in. Hgx28.70

lb/lb-mole Vs 24. 7 ft/sec Average Stack Gas Flow at Stack Conditions

(Qa), acfm Qa 60 × Vs x As

where,

Vs stack gas velocity, ft/sec As cross-sectional

area of stack, if2 Qa 60 sec/min x 24. 7 fi/sec x 10.32 fi2 li5E÷ 04 acfm Average Stack Gas Flow at Standard

Conditions

(Qs), dscfm Qs 17. 64 7 x Qa x (1 Bws) x Ps
where, Qa average stack gas flow at stack conditions,

ft3/min Bws Runs 1, 3, & 4 average moisture content, dimensionless Ps absolute stack gas pressure, in. Hg Ts absolute stack temperature,

°R Qs 17. 647°R/in.

Hg x 1.5 E + 04 acfm x (1 O. 046) x 29. 75 in. Hg 684. 0 °R
SOz Emission

Rates (ERso2), lb/hr ERso Cso.,, x MWso,_ x Qs x 60 x 28. 32 24. 04 x 1. OE + 06 × 454

c:\\Projects\GeneralShalekRome\2005-0188\EmissionTestReport Page A-3Compliance Emission Test Report Summary of Calculations where, CSO 2 SO 2 concentration,

ppmvd MWso2 64.1 g/g-mole Qs pre/post run average volumetric

flow rate, dscfm ERso 93.5 uL/L x 64.1 g/g mole x 1.1 E + 04 dscJ• x 60 min/hr x 28. 32 L/cf 24. 04 L/g mole x 1.0 E + 06 uL/L × 454 g/lb lO.1lbs/hr

SO• Emission

Factor (EFso2), Ibs/ton of brick ERso2 EFso 2 PR

where, 10.1 lbs/hr EFso•

.4 lbs / ton 7. 2 tons/hr PR production

rate, tons of brick fired/hr

c:\\Projects\GeneralShale\Rome\2005-0188\EmissionTestRepor

Page A-4Compliance Emission Test Report Summary of Calculations

TABLE A-1 VFR CALCULATIONS
Run Number 2

3

4

5 Date 3/17/2005

3/17/2005

3/17/2005

3/17/2005

3/17/2005 Time 9:32

10:48

12:20

13:37

14:50 Point 0.15

0.18

0.43

0.41

0.39 Point 2 0.18

0.18

0.45

0.47

0.42 Point 3 0.20

0.20

0.46

0.48

0.46 Point 4 0.20

0.19

0.46

0.48

0.48 Point 5 0.21

0.18

0.46

0.49

0.52 Point 6 0.20

0.17

0.48

0.49

0.53 Point 7 0.17

0.15

0.43

0.43

0.48 Point 8 0.15

0.12

0.39

0.36

0.43 Point 9 0.14

0.10

0.31

0.32

0.31 Point 10 0.11

0.09

0.25

0.25

0.25 Point 11 0.15

0.14

0.49

0.48

0.50 Point 12 0.18

0.17

0.52

0.54

0.60 Point 13 0.21

0.18

0.58

0.56

0.60 Point 14 0.23

0.19

0.62

0.60

0.64 Point 15 0.23

0.20

0.63

0.66

0.64 Point 16 0.18

0.17

0.46

0.49

0.50 Point 17 0.16

0.14

0.39

0.40

0.42 Point 18 0.15

0.12

0.36

0.35

0.35 Point 19 0.13

0.11

0.32

0.31

0.31 Point 20 0.11

0.08

0.26

0.28

0.30 Square Root of Delta P, (in. H20)•'1⁄2

0.384

0.362 Pitot Tube Coefficient

(Cp) 0.84

0.84 Barometric Pressure (Pb), in. Hg

29.97

29.97 Static Pressure (Pg), in. H20

-3.00

-3.00 Stack Pressure (Ps), in. Hg

29.75

29.75 Stack Cross-sectional

Area (As), ft

10.32

10.32 Temperature (Ts), °F 224

224 Moisture Fraction (Bws) 0.046

0.046 CO2 Concentration

(CO2), %

3.2

3.2 02 Concentration

(O2), %

17.5

17.5 Molecular Weight (Ms), Ib/lb-mole

28.70

28.70 Velocity (Vs), ft/sec 24.7

23.3 Volumetric Flow Rate At Stack Conditions

(Qa), ACFM

15,275

14,408 At Standard Conditions

(Qs), DSCFM

11,190

10,547

0.617

0.621

0.630 0.84 0.84

0.84 29.97 29.97

29.97 -7.50 -7.50

-7.50 29.42 29.42

29.42 10.32 10.32

10.32 193 198

189 0.046 0.046

0.046 3.2 3.2

3.2 17.5 17.5

17.5 28.70 28.70

28.70 39.0 39.4

39.7 24,137 24,367

24,575 18,315 18,344

18,754

c:\\Projects\GeneralS hale•Rome\2005-0188\EmissionTestReport Page A-5General Shale Brick Compliance Emission Test Report Summary of Calculations

TABLE A-2 MOISTURE CALCULATIONS
Run Number 3 Date 3/17/2005

3/17/2005 Time 947-1017

1231-1301
Run Time, min Barometric Pressure, in. Hg Meter Correction

Factor Orifice Calibration

Value (e)(Pb)(Y) (Delta H@) (Vm)

3029.971.0081.968

3O29.971.0081.968

4

Mean 3/17/2005 1353-1423

Volume H20 Collected,

mL

(Vlc) 18.9 Standard Meter Volume, ft

(Vmstd)

22.249

22.328 Standard Water Volume, ft

(Vwstd)

1.116

0.890 Moisture Fraction (Measnred)

(BWS)

0.048

0.038

3O29.971.0081.968

3O29.971.0081.968 Meter Volume, ft 21.729

22.023

22.202

21.985 Meter Temperature,

°F

(Tm)

63.2

68.4

68.3

66.6 Meter Orifice Pressure, in. H20

(Delta H)

2.000

2.000

2.000

2.000 23.7 26.0

22.9 22.514 22.364 1.224 1.076 0.052 0.046

c:\\Proj ects\GeneralShale\Rome\2005-0188\EmissionTestReport Page A-6Compliance Emission Test Report Summary of Calculations

TABLE A-3 EMISSION CALCULATIONS
Run Number 3

4

Mean Date 3/17/2005

3/17/2005

3/17/2005 Time 947-1047

1231-1331

1348-1448
Run Time, rain (o)

60

60

60 Production Rate, tons of brick fired/hr Barometric Pressure, in Hg Volumetric Flow Rate, dscfm SO2 Concentration,

ppmvd (PR)(Pb)(Qs)(Cso2)

7.229.9710,86893.5

7.229.9718,330 64.6

7.229.9718,549 65.8

6O7.229.9715,916 74.6 SO2 Emission Rate, lb/hr (ERso2)

10.1

11.8

12.2

11.4 SO2 Emission Factor, lb/ton of brick

(EFso2)

1.4

1.6

1.7

1.6

c:\\Projects\GeneralShale•Rome\2005-0188\EmissionTestReport Page A-7Appendix BGENERAL SHALE KILN 2 RUN 1
DATE: 3/17/2005 ERA&A Analyzers Time 02 CO2 SO2 9:47:00 16.4

3.8 107.8 9:48:00 16.4

3.8 108.5 9:49:00 16.4

3.9 107.5 9:50:00 16.4

4.0 107,0 9:51:00 16.3

4.0 106.1 9:52:00 16.4

4.0 104,5 9:53:00 16.4

4.0 102.3 9:54:00 16.4

4.0 101.3 9:55:00 16.4

4.0 99.9 9:56:00 16.4

4.0 98.3 9:57:00 16.4

4,0 96.0 9:58:00 16.4

4.0 95.5 9:59:00 16.4

4.0 94,3 10:00:00 16.4

4.0 93.0 10:0t:00 16.3

4.1 93.6 10:02:00 16.3

4.1 94.9 10:03:00 16.3

4.1 92.0 10:04:00 17.0

3.6 85.0 10:05:00 18.6

2.6 47.2 10:06:00 17.6

3.2 63.5 10:07:00 16.1

4.2 91.5 10:08:00 15.9

4.4 99.8 10:09:00 16,0

4.3 101.1 10:10:00 16.0

4.3 101.8 10:11:00 16.1

4.3 101.8 10:12:00 16.1

4.3 102.3 10:13:00 16.2

4.3 100.4 10:14:00 16.3

4.2 97.6 10:15:00 16.3

4.3 97.1 t0:16:00 16.4

4.3 96.3 10:17:00 16.4

4.2 95,1 10:18:00 16.5

4.2 94.0 10:19:00 16.5

4.2 93.6 10:20:00 16,6

4.2 92.9 10:21:00 16.6

4.0 92.3 10:22:00 16.6

4.0 91.2 10:23:00 16.6

4.0 90.4 10:24:00 16.7

4.0 90.0 10:25:00 16.7

4.0 89.4 10:26:00 16.7

4.0 88.8 10:27:00 16.7

4.0 88.3 10:28:00 16.7

4,0 88.0 10:29:00 16.7

4.0 87.7 10:30:00 16.7

4.0 87.3 10:31:00 16,7

4.0 87.2 10:32:00 16.7

4.0 87.2 10:33:00 16.7

4.0 86.9 10:34:00 16.7

4,0 86.6 10:35:00 16.7

4.0 87.0 10:36:00 16.7

4,0 85.9 10:37:00 16.8

3.9 85.2 10;38:00 16.7

3.9 85.4 10:39:00 16.7

3.9 85.9 10:40:00 17.3

3.6 81.0 10:41:00 18.6

2.6 46,7 10:42:00 17.7

3.2 59.3 10:43:00 16.2

4.2 86.5 10:44:00 16.0

4.3 99,4 10:45:00 16.6

4.0 92.1 10:46:00 16.9

3.8 85.6

Uncorrected

Average 02 16.6

% CO2 4.0

% SO2 91,4

ppmvd
Corrected Average 02 16.6

% CO2 4.0

% SO2 93.5

ppmvdGENERAL SHALE K•LN 2 RUN 2
DATE: 3/17/2005 ERA&A Analyzers Time (32 CO2 SO2 11:13:00 16.1

4.0 116.3 11:14:00 16.0

4.0 115.7 11:15:00 16.1

4.0 108.8 11:16:00 16.8

3.5 99.4

02 11:17:00 18,4

2.3 55.2 CO2 11:16:00 17.4

3.0 75.3 SO2 11:19:00 t5,8

4,3 101.4 11:20:00 15,5

4.5 106.4 11:21:00 15.4

4.6 105.6 11:22:00 15.1

4.8 112.8 11:23:00 15.2

4.7 111.9

(32 11:24:00 15.2

4.8 110.8 CO2 11:25:00 15,3

4.7 110.4 SQ2 11:26:00 15.7

4.4 102.3 11:27:00 15.8

4.4 100.7 11:28:00 15.8

4.4 100.3 11:29:00 15.8

4.3 99.0 11:30:00 16.2

4.1 96.5 11:31:00 17.4

3.2 75.8 11:32:00 17.7

3.0 68.5 11:33:00 17.7

3.0 67.6 11:34:00 17.7

3.0 67.3 11:35:00 17.7

3.0 67.7 11:36:00 I7,9

2.9 65.1 11:37:00 18.0

2.8 62.8 11:38:00 17.9

2.8 62.7 11:39:00 17.9

2.9 63.3 11:40:00 17.9

2.9 63.6 11:41:00 17.9

2.8 63.4 11:42:00 17.8

2.9 66.0 11:43:00 18.0

2.7 65.9 11:44:00 18.1

2.7 63.4 11:45:00 18.2

2.6 61.3 11:46:00 18.1

2.7 59.8 11:47:00 18,0

2.8 62.4 11:48:00 18,0

2.7 62.6 11:49:00 18.0

2.7 61.9 11:50:00 18.0

2.7 62.4 11:51:00 18.1

2.7 62.1 11:52:00 18.8

2.2 54.1 11:53:00 19.4

1.7 32.9 11:54:00 18.6

2.3 53.1 11:55:00 17.7

3.0 67.4 11:56:00 17.7

3.0 71.6 11:57:00 17.7

3.0 70.3 11:58:00 17.8

2.9 67.6 11:59:00 17.7

2.9 66.7 12:00:00 17.7

2.9 67,3 12:01:00 17.8

2.9 66.9 12:02:00 17.8

2.9 66.1 12:03:00 17.8

2.9 66.1 12:04:00 17.8

2,9 66.6 12:05:00 17.9

2.8 66.3 12;06:00 17.9

2,8 65.5 12:07:00 17.9

2.8 66.3 12:08:00 17.9

2.8 66.7 12:09:00 17.9

2.8 65.9 12:10;00 17.9

2.8 66.5 12:11:00 17.9

2.8 66.2

Uncorrected

Average 17.4 % 3.2 % 75.5 ppmvd

Corrected Average 17,4 % 3.2 % 76.3 ppmvd

1-1GENERAL SHALE KILN 2 RUN 3
DATE: 3117/2005 ERA&A Analyzers Time 02 CO2 SO2 12:31:00 17.7

2.9 62.8 12:32:00 17.7

2.9 68.6 12:33:00 17.7

2.9 70,3 12:34:00 17.7

2.9 71,3 12:35:00 17.7

2.9 72.1 12:36:00 17.7

2.9 74.1 12:37:00 17.8

2.8 82.6 12:38:00 17.8

2.8 73,6 12:39:00 17.8

2.8 70.9 12:40:00 17.8

2.8 68.8 12:41:00 17.9

2.8 67.8 12:42:00 17.9

2.8 66.8 12:43:00 17.9

2.8 66.5 12:44:00 17.9

2.7 65.5 12:45:00 18.0

2.7 65.1 12:46:00 18.0

2.7 64.0 12:47:00 18.0

2.7 63.8 12:48:00 18.0

2.7 62,6 12:49:00 18.0

2,7 62.5 12:50:00 18.0

2.7 63.0 12:51:00 18.0

2.7 62.8 12:52:00 18.0

2.7 62.2 12:53:00 18.0

2.7 61.7 12:54:00 18.0

2.7 61.6 12:55:00 18.0

2.7 60,9 12:56:00 17.8

2.9 65.2 12:57:00 17.9

2.8 67.0 12:58:00 18.2

2.6 63.5 12:59:00 18.4

2.5 59.7 13:00:00 18.4

2.4 58.1 13:01:00 18.5

2.4 57,2 13:02:00 18.5

2.4 56,3 13:03:00 18.6

2.4 55.8 13:04:00 19,5

1,7 41.8 13:05:00 19.7

1.6 26.9 13:06:00 18.4

2.5 56.9 13:07:00 18.2

2.7 63,5 13:08:00 18.2

2.6 63,6 13:09:00 18.3

2.6 65.2 13:10:00 18.3

2.6 66.8 13:11:00 18.2

2.7 69.2 13:12:00 18.2

2.6 70.4 13:13:00 18.2

2.6 -/0.4 13:14:00 18.3

2.6 70.3 13:15:00 18.3

2,6 69.4 13:16:00 18.2

2.6 69.6 13:17:00 18.3

2.6 69.0 13:18:00 18.4

2.5 66.2 13:19:00 18.4

2.5 64.3 13:20:00 18.3

2.5 63.2 13:21:00 18.2

2.6 63.0 13:22:00 18.1

2.7 64.6 13:23:00 18,1

2,7 64.4 13:24:00 18.0

2.7 64.5 13:25:00 18.0

2,8 64.9 13:26:00 18,0

2.8 64.1 13:27:00 18.0

2.8 63.0 13:28:00 18.0

2.8 63.2 13:29:00 18.0

2.8 62.8 13:30:00 18.0

2,8 61.6

Uncorrected

Average 02CO2SO2 t8.12.664.3

%%ppmvd

Corrected Average O2 18.1

% CO2 2.6

% SO2 64.6 ppmvd

1-1GENERAL SHALE KILN 2 RUN 4

DATE: 3/17/2005 ERA&A Analyzers Time 02 CO2 SO2 13:48:00 17,5

3.1 71.4 13:49:00 17.5

3.2 73.7 13:50:00 17.5

3.1 74.5 13:51:00 17.6

3.1 75.0 13:52:00 17.6

3.1 74.6 13:53:00 17.5

3.1 78.5 13:54:00 17.7

3.0 74.7 13:55:00 17.7

3.0 75.6 13:56:00 17.8

2.9 69,6 13:57:00 17.8

2.9 66.5 13:58:00 17.8

2.9 65.7 13:59:00 17.9

2.9 64.2 14:00:00 17.9

2.9 63,5 14:01:00 17.9

2.9 63.7 14:02:00 17.9

2.9 63.7 14:03:00 17.9

2.9 63.6 14:04:00 17.9

2.9 63.4 14:05:00 17.9

2.9 62.7 14:06:00 17.8

2.9 63.6 14:07:00 17.9

2.9 63.9 14:08:00 17.9

2.9 63.3 14:09:00 17.9

2.9 62,4 14:10:00 17.9

2.9 62,1 14:11:00 17.9

2.9 62,1 14:12:00 17.9

2.9 62.1 14:13:00 17.9

2.9 62,0 14:14:00 18.0

2.9 61,7 14:15:00 18.0

2.8 61.3 14:16:00 18.8

2.3 51.7 14:17:00 19.4

1.8 30.9 14:18:00 18.4

2.6 52.6 14:19:00 17.6

3.2 66.3 14:20:00 17.6

3.1 67.8 14:21:00 17.7

3.1 67.2 14:22:00 17,6

3.1 67.6 14:23:00 17.6

3.1 67.7 14:24:00 I7.7

3.1 68.3 14:25:00 17,7

3.1 67.7 14:26:00 17.7

3.1 66,5 14:27:00 17.7

3.1 67.5 14:28:00 17.7

3.1 67.6 14:29:00 17.8

3.1 67.8 14:30:00 17,8

3.0 66.8 14:31:00 17.8

3.0 66.4 14:32:00 17.8

3.1 66.6 14:33:00 17.9

3,0 66.5 14:34:00 17.9

3,0 66,1 14:35:00 17.9

3.0 65.4 14:36:00 17.9

3,0 65.5 14:37:00 17.9

3.0 65,6 14:38:00 18.0

3,0 64.7 14:39:00 17.9

3.0 64.6 14:40:00 17.9

3,0 64.6 14:41:00 17.9

3.0 64.4 14:42:00 18.0

2.9 64.1 14:43:00 18.0

2.9 62.5 14:44:00 18,0

3.0 63.0 14:45:00 18.0

3,0 63.5 14:46:00 18.0

3.0 63.3 14:47:00 18.0

2,9 63.2

Uncorrected

Average 02CO2SO2 17.93.065.2

%%ppmvd
Corrected Average 02 17.9

% C02 3.0

% S02 65,8 ppmvd

1-1VELOCGY TF@ .VERSE

DATA

DUCT DATA Dist from far wall Equivalent diameter to outside of port 'T.• "• in

2 x ,depth x width Nipple length

• •" in

depth + width Depth of duct

• _'• ,.,•- in Width of duct(rec) in Area of duct

O .•, ;• in Dist from ports to nearest disturbance up- down- $[ream stream dia _E•_

•o
LOCATION OF TRAVERSE

POINTS Distance upstreana of distttrbance 1.0 1.5 2.0 1.0 1.5 2.0 20 24" L• <24- 8•t 8 t•4 567 Distance downstream from disturbance CIRCULAR DUCTS

23456789101;Ii:2Traverse point number on a diameter 23456789101112 14.6 6.7 4.4 3.2 85,4 25.0 14.6 10.5 75.0 29.6 19.4 93.3 70.4 32.3 87.4 67.7 95.6 80,689.596.8 (Percent of stack diameter from inside wall to traverse point) 2 4 6 8 r •0"•, 12 2.• 2.1 14622 6 |17.7 34 2 125.0 65 8 •65.6 77 4 4.4 85 4 ]75.0 91 8/ 82.3 97 / 88.2 _/ 93.397.9 RECTANGULAR DUCTS MEASUREMENTSDistai•ce Distance Traverse % of

from inside

from outside Point Diameter

wail

of port lO. 234567

9101I

2 3 • 5 6 7 8 9 10 11 12__ 25.0 16.7 12.5 10.0 8.3 7.1 6.3 5.6 5.0 4.5 4.2 75.0 50.0 37.5 30.0 25.0 21.4 18.8 16.7 15.0 •3.6 12.5 63.3 62.5 50.0 41.7 35.7 31.3 27.8 25.0 22.7 20.8 87.5 70.0 58.3 50.0 43.8 38.9 35.0 31,8 29,2 90.0 75.0 64.3 56.3 50.0 45,0 40.9 37.5 91.7 78.6 68.8 61.1 55.0 50.0 45.8 92.9 81.3 72.2 65.0 59.1 54.2 93.8 83.3 75.0 68.2 62.5 94.4 85.0 77,3 70.8 95.0 86.4 79.2 95.5 87.595.8

ALLEY & ASSOCIATESSOURCE

SKETCH

QA

60 Vs As Qs = QA (1-BWS

528 xTs 29.92

PsTPJS, VERSE

PT

0.•:• / AVERAGE

MOISTURE Vs0 s tVlettno.• 2 E. F•.ob•.::r•/•llr-:

Associates,

tnc...,•.--,•.'.£s-'•£-L•:.s•/z_•x•-.•,•L•/•- PROJECT

•('• •'" SOURCE R,'i• fs• • .• .• STACK DIrd•ENS•ON

'•&• "

CR.OSS

SECTIONAL

AREA PFFOT' TUBE iD# •-0!•

AVG COEFFICIENT

•• SKETCH

Vs 85.4.9 Cp •tAP ave -J Ts QA 60 Vs As

IVt•w Ps

Os Q,• (1-BWS)

52_ 8_ x ps Ts 29.92

TRAVERSE

PT

q

"7

"•/AP AVERAGE AP AVERAGE Ts AVERAGE MOISTURE Vs

Method 2 E. Roberts

Alley & Assoc ares, Inc.1ViETHOD 4 lV[OI[STURE

CALCULATIONS
SOURCE • (v,

YAVG DATE •//7•.5

START TIME -END TIME SAMPLE TIME METER VOLUME TOTAL METER

VOLUME,

Vm METER TEMP, F, IN/OUT

AVERAGE METER

TEMP, F, Tm BAROMETRIC PRESSURE,

Pb METER PRESSURE,

DH, in H20 CORRECTED VOLUME,

Vm(std) IMP 1, mL, PRE/POST •8o / •1• IMP 2, mL, PREIPOST coo / 10 o IMP 3, mL, PREIPOST 0 1 IMP 4, g, PRE/POST <SE;G.,• / •,'U:• ,0 V•:-•L-LD]IE-MO•ST-•RE,'--•-Vw(std'''`e,:':--::--) i-- .• \v.•

I! [. iqe.i

O. •--'5•0

I',IOTES• Vm(std) (17.64 X Vm X mofX (Pb + DH/13,6) Ta or Tm+ 460 Vw(std) Vie X C ilL, C=l 333 if of, C=0.04707 Bw$ Vw(std) Vm(std) + Vw(std) Moisture Percent Where: Vm(std)= VmmcfPbDHTa="fmVw(std) VIcBws

Bws X 100 Sample volume corrected to standard romp and pressure, sofor L Actual sample volume, calculated, sof or L Meter correction factor Barometric pressure, in. blg Meter pressure, in H20 Ambient temperature,

Deg F (Rotometer is used) Temperature of meter (DMG is used) Volume of water vapor at standard conditions, scf or L Volume of water condensed, mL Mole fraction of water vaporMETHOD 4 MOISTURE

CALCULATIONS

SOURCE ?•' A-,. O•Z PERSONNEL DATE .•')/7/•.5-

METERID

/-•-TG•

.YAvo
RUN# START TIME F5 • END TIME q • SAMPLE TIME =-Z ••• ¢30 "•ETER VOLUI•IE

PRE/POST TOTAL METER VOLUME,

Vm METER TEMP, F, IN/OUT

AVERAGE METER

TEMP, F, Tm BAROMETRIC PRESSURE,

Pb

i

METER PRESSURE,

DH, in H20 CORRECTED VOLUME,

Vm(std) IMP 1, mL, PRE/POST IMP 2, mL, PRE/POST IMP 3, mL, PRE/POST IMP 4, g, PRE/POST VOLUME WATER,

Vlc (mL) VOLUME MOISTURE,

Vw(std) gws

io':::' / 11"7

/

/ / /

MOISTURE PERCENT

NOTES: Vm(std) [17.64 X Vm X mcfX (Pb + OH/13 Ta or Tm+ 460 VIc X C Vw(std) if L, C=1.333 if of, C=0.04707
Bws Vw(std• Vm(std) Vw(std) Moisture Percent

Bws X 100 Where: Vm(std)= Vmmcf= pbDHTaTmVw(std) VIc

Sample volume corrected to standard temp and pressure, scf or L Actual sample volume, calculated, scfor L Meter correction factor Barometric pressure, in. Hg Meter pressure, in H20 Ambient temperature,

Deg F (Rotometer is used) Temperature of meter (DMG is used) Volume of water vapor at standard conditions, scf or L Volume of water condensed, mL Bws Mole fraction of water vapor

Moisture Calculations E. Roberts Alley & AssociatesModel #: C5000 Serial #: 1376 APEX INBTRUI,•NTS
EPA Method 522 Series

Calibration
Pro-Test Orifice Method English Units, English

Pactor

Filename: C:\Doettments

and S•ttings\stacyc\My

Documents\Company

Files\Stack

Test T•mplateskMethod

Templet
Revised• 7/25/95

Version: 2,2
*12/22/04 Barometric 29.97 (in. Theoretical Critical 14.14 (in.

valid test results, the Actual

should ba 1 in. Hg greater than the Theoretical

Critical

sho•n above.
The Critical Orifice Coefficient,

K', be entered in English units, (ft)•3*(deg

R)•0-5/((in-Hg

)w(min))'

GAS •ETER READINGS -CRITICAL ORIFICE READINGS-

(in H20)

1.90 3.56 5.50

Time Initisl

Final

Total

Inlet Outlet Inlet Outlet Serial# Coefficient

Initial Final Averase (min) (cuft) (cuft)

(cuft) (dog F) (dog F) (dog F) (dog F) (number) (see above) (in Rg) (dog F) (dog F) (dog F)

15.00 316.400 322.725

6.325

58.0 58.0 58.0 58.0 DO48

0.331 22.5 68,0 68.0 68.0

10.00 322.725 328.377

5.652

58.0 58.0 60.0 60.0 D055

0.438 21.0 68.0 68.0 68.0
10.00 328,377 335.436

7.059

60.0 60.0 61.0 57.0 D663

0.562 19.5 68.0 68.0 68.0
5.00 335.436 340.331

4.895

61.0 59.0 65.0 60.0 DG73

0.780 17.0 68.0 68.0 68.0
5.00 340.331 346,321

5.990

65,0 60.0 68.0 61.0 DOS1

0.959 15.0

68.0 68.0

ORIFICE DRY GAS METER ORIFICE

VOLUME VOLLq4E

VOLUME

VOLU}•

CALIBRATION

FACTOR
CORRECTED CORRECTED

CORE

CORE NOMINAL Vm(shd) Vm(std)

Vcz(std)

Vcr(std) 'Value Variation (c• ft)

(liters)

(cuft) (liters)

(cuft)

(number) (number)
6.465 183,1

6.476

183.4

6.468

1.002 -0.007
5.773 163.5

5.708

161,6

5•700

0,989 -0.020 7,217 204.4

7.330

207.6

7.321

1.016 0.007 5,008 141.8

5,084

144.0

5.078

3.015 0.007
6.131 173.6

6.257

177.2

6.249

1.021 0.012

C_•IERATION

FACTOR

V•lue Value a•iation (in H20) (ms E20) (in E20) 1.895 48.13 -0.073 1.936 49.16 -0.032 2,029 51.53 0,061 1,972 50.00 0,004 2,008 50.99 0,040

Average 1.008 1,968 49.98

Average

Calibration Y, the ratio of the reading of the calibration

the dry meter, acceptable tolerance

individual values

the average is Orifice Calibration

Factor dH@, the orifice differential

pressure in inches of that equates

0.75 cfm of air

at and 29,92 inches of Hg, acceptable toleran,/•' of imdlvidual values

the average is +-0.2.Certificate of A . a ysis

EPA Cylinder No:

SG9136100 Cylinder Pressure:

2,013 psig Certification Date:

01/16/2004 5480 Hamilton Bird, Theodore, AL 36582 (251) 653-2500 Fax: (251) 653-2530 www,•.irgas.com Protocol Gas

Mixture
Reference Number:

47-76361900-004 Expiration Date:

0111612007 Laboratory: ASG Mobile •}fi•a[ion•erformed in accordance

with "EPA Traceability

Protocol (Sept. 1997) using the assay procedures

hsted. Analytical Methodology

does not require correction

for analytical

interferences. •^• #47-040105/0065 Notes: AIRGAS PC 11u•,•3045

A,R,-,,-,,•

LOT

Do not use cylinder below t50 psig. Reference Standard

•r•formation
GMIS 0 Ar•a•ytical Results 1st Component 1st Analysis Date: R 1,026 S S 923.0 Z Z 0.0000 R 2rid Analysis Date: R 1,026 S S 923.0 Z Z 0.0000 R Approved

for Release

01/09/2004 923.0 Z 0.0000 Conc 923.0PPM 0.0000 R 1,020 Conc 923.0PPM 1,026 S 923.0 Conc 923.0PPM AVG: 923.0 PPM 01/16/20O4 923.0 Z 0.0000 Conc 923.0PPM 0.0000 R f,026 Conc 923.0PPM 1,026 S 923.0 Conc 923.0PPM AVG: 923.0 PPM Component_ CvL Number Concentratio• Sulfur Dioxide ND-15687 1,026 PPMAirgas Specialty Gases Certificate of Anaf sis: Cylinder Number:

CC162300 Cylinder Pressure:

1999.6 PSIG Certification Date:

0/26/2004 Certified Concentrations EPA Rroto¢o

Gas [Viix.tu . e
Reference Number: Expiration Date: Laboratory:

47-124024889-5 10/26/2007 ASG Mobile AL 5480 Hamilton Boulevard Theodore, AL 36582 251.653.2500 Fax: 251.653.2530 w¢c,,•.airgas.com

Procedure Component CARBON DIOXIDE OXYGEN NITROGEN Concentration

Accuracy

Analytical Principle 19.87 %

+/- 1%

NDIR 20.06 %

+/- 1%

PARAMAGN G1 Balance Certification performed

in accordance

with "EPA Traceability

Protocol (Sept. 1997)" using the assay procedures

listed. Analytical Methodology

does not require correction

for analytical

interferences. Notes:Airgas PO 110747905 •• Do not use cylinder below 150 psig.

App,oval

Signature

•-•-"

•£!' Reference Standard

•nforrnation
NTRIvl 82659 NTRM 82745 Anaiytical Results st Component st Analysis Date: 19.38 S 19.88 19.88 Z 0.000 0.000 R 19,38

Balance

s Comuone_nt

CVI Numbe.r

.Concentration_ NITROGEN OXYGEN

SG9163000

20.98 % NITROGEN CARBON DIOXIDE

SG9198981-

19.37 %

10/26/2004 Z 0.000

ConG 19.87 % R 19.38

Conc 19.87 % S 19.88

Conc 19,87 % AVG: 19,87 %

2rid Cow.portent 1st Analysis Date: R 20.98

S 20.06 S 20.06

Z 0.000 Z 0.000

R 20.98

.QXY'GE 10/26/2004 Z 0.000

Conc 20.06 % R 20.98

Conc 20.06 % S 20.06

Conc 20.06 % AVG: 20,06 %SULFUR D•OX•]DE

EFA METHOD

6C ]INSTRUMENTAL ANALYSIS

CAL][BRATIGN

DATA
PlantDate Location Operator Concentration Range Response

Time Calibration Accuracy

(Accuracy

• 2% of span value)

__ppm

Gas Cylinder

Actual

Analyzer Type No. Concentration

ZERO
HIGH Gas

MID

Cylinder

Actual

Analyzer No. •

ZERO & SPAN SYSTEM

BIAS

GAS •ITI•

F•AL TYPE •SPONSE

•SPONSE

(Accuracy

_+ 5% of span)

ppm (Drift + 3% of span)

ppm

GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE ZERO

GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE GAS

INITIAL

FINAL TYPE RESPONSE

RESPONSE ZERO

GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE ZERO GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE 9 "°[NSTRU•{%ENTAL ANALYSIS

CALIBRATION

•ATA

Concentration Range_ Calibration Accuracy

(Accuracy

Location. Operator

:•gdt Response Time

+ 2% of span)

cl

]22. •'}

GasType

ZERO
HIGH Cylinder No.

Actual Concentration

Analyzer

GasType 0. O

MID

Cylinder No.
,••I

Actual Concentration

Analyzer

ZERO & SPAN SYSTEM

BIAS

fviE O,

GAS INITIAL

FINAL TYPE •SPONSE

EESPONSE
zsao O, O•.o (Accuracy

+_ 5% of span) (Drift +_ 3% of span)

GAS INITIAL

FINAL TYpE •SeONSE

RESPONSE ZERO O, 0 O, 0 @" 0

GAS INITIAL

FINAL TYPE P,_ESPONSE

RESPONSE ZSaO O, O

4, • GAS

INITIAL

FINAL TYPE RESPONSE

RESPONSE ZEr,.O 0.0

O, 0

GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE ZERO

GAS INITIAL

FINAL TYPE RESPONSE

RESPONSE ZEROOXY©R',N -EYA •,•TfIO•D

ZA INSTRUL•ENTAL •NALYSiS

CALIBI•.T:EON

DATA

Response Time O. :)5 2% of span )

% Concentration Range

•d Cs_libration Acctu-acy:

(Accuracy

@':5 Gas Cylinder

Actual

/,ma[yzer Type No. Concentration

zmo •%

O, O O, 0
HIGH

Oas

Cylinder Type No.

Actual Concentration

_Analyzer

ZERO & SPAN SYSTEM

BIAS
¢

GAS INITIAL

FINAL TYPE •SPO•SE

•SPOHS•
z•ao 0• O

O, 0 •;• tO.O

•o,o

(Accuracy

_+ 5% of span) __% (Drift +_ 3% of span)

%

":,: .,'' "" ..} }"," ....... ::"N2"I..•I•:!•

-•'•'' •'•"•"e•ii '!
GAS INITIAL

FINAL TYPE PJESPONSE

PdgSPONSE ZERO C) ,0

O. O

':" 't,•;•:- •.:'.

.... ,,, :::.• ,.,' ,:-• i,:,: '< ',:: i.:•'. ••.•:

:;:. :•,::...•.:,, :.!•;'i•;•!.:.; ::::, !:-.-.. '::v#, •,::,! 'i•!•!•',••i,•.,:,..;,.:,..i•,,:.•.•,::,,:•-.: .:•. GAS INITIAL

F•'gAL TYPE P,_ESPONSE

RESPONSE ZERO GAS INITIAL TYPE P,_ESPONSE ZERO O.O/0.0

FINAL .RESPONSE /o, 0

GASTYPE. ZERO •NITiAL RESPONSE 0.©

FIN•,I, RESPONSE GAS

•!TIAL Tk-PE P,:ESPONSE

P,.ESPON SE ZEROPITOT TUBE

CAL•.BR&T•ON

v LEI}•%?

yes

no pZ[OOT •E •,•mmE•L_ //

"yes / no

2.0 >0 750 >2.0>3.0Sample .Probe Inspected By:

•-•-• inspection Date:

•_ Probe ID:

•

Pitot Tube Openiffgs

Damaged? Pitot Tube Aligmn.ent

OK? Calibration Required? External Tube Diameter

(Dt)* *Dt must be between 3/16 abd 3/8 Base-to-plane opening distances

(Pa and Pb)* *Pa Pb Vesl K 'est_

"/. Dt 0.375
Pa 0.4375 Pb 0.4375 Pa/Dt 1.17 (Must be between 1.05 and 1.5) Ifpitot does not meet the criteria specified above it must be repaired or calibrated in accordance with Sections 4,1.2 through 4.15 of Method 2. Baseline coefficient of 0.84 applied to pitots that meet inspection criteria. 2•Z :Z::, ::';:.Z:./2}:::::i':/2:!:!i:;::,i:•:"i{•••'.i••':. 4: 12 :/:i: 2Z:::'..I :. Target Temp. Ice-32F Ambient-70F Hot Oi]-150F Boiling H20-212F Hot Oil- 150F

Reference Temp.

.•ndicated Temp.

Temp. Difference

Difference

Specification % Difference

< 1.5

Comments:

Assoe a,$es0

00II