Pollution Control System Evaluation

and Source Emissions

Testing General Shale Rome, Georgia Brick

Co.

Compliance Emissions

Testing DES Baghouse

Stacks

K1 (Kiln A)

June 24, 2008 Entec Project

No.: 28161

16-D Commerce

Avenue

Hueytown,

Alabama

35023 Phone: (205) 491-6676

Fax (205) 491-6614 www.entecservices.cornEntec Services, inc. 16 D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614 Results of the June 24, 2008 Compliance Emissions

Testing DLS Baghouse

Stacks

K1 (Kiln A) at the General Shale

Brick Company

located

in Rome, Georgia
Submitted to: Genera| Shale

Brick

Company P.O. Box 3547 Johnson City, Tennessee

37602 Attention: Ms. Martha

West Entec Project

No. 28161 Completed By: Report Submitted

June 27, 2008 Reviewed By:

Project Leader Tom Lotz Technical Services

Manager hereby certify to the best of my knowledge

all field sampling

and laboratory

analysis

performed

for this report is authentic

and accurate.

It has been checked

for completeness

and accuracy.General Shale

Brick Table of Content

Section Executive

Summary Emissions

Summaries Detailed Test Results Sampling Procedures Location of Test Ports Diagram of Sampling

Train Diagram of Method 6C Sampling

Train Field Data Sheets

K1 Kiln A Baghouse

Stack Test Run No. 1 Test Run No. 2 Test Run No. 3 Control Room Production

Data Quality Assurance

/ Quality Control Procedures Field QA / QC Checklist Meter Orifice and Temperature

Check Sheet Fyrite Standardization Stratification Sheet Method 6C QA / QC Checklist Interference Check Test Protocol QSTI Certification

Documentation Gas Analyzer

Calibration

Data Analyzer Calibration

Error System Bias and Drift Calibration Gas Certificates Equipment Calibration Safety Documentation Test Nomenclature

and Calculations 237101112131421273436414244474849506267687074778587Executive Summar Entec Services,

Inc. was retained

by General

Shale Brick Co. to perform

compliance emissions testing for SO2 for the K1 (Kiln A) Dry Lime Scrubber

and DSL Baghouse

Stack at the facility located

in Rome, Georgia.

Mr. Tommy

Lotz, Jr., and Mr. David Bowman

of Entec Services,

Inc. conducted

the testing on June 24, 2008. Representing

General

Shale was Ms. Martha

West who coordinated

testing with the control

room production

activity. Representing the State of Georgia

was Mr. Daniel McCain. No difficulties

were encountered

in the field or in the laboratory

analysis

of the samples

by Entec Services,

Inc. The emissions

test summary

on the following

page gives a detailed summary of each test run compared

to the maximum

emission

limits set forth by the Georgia Department

of Natural

Resources

(GDNR).

Tests results

indicate

that the sulfur dioxide

emissions

results

were above the applicable

permit

limit as set forth by GDNR Permit

No. 325tolt5=0105-Vo02.0.•: 0 0

>0Detailed Test

ResultsSOURCE

OWNER: Entec

Services, inc. S==OURCE OVERVIEW

PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: SOURCE PERMIT

NUMBER: TEST PERFORMED: REFERENCE METHOD

TESTS:

PROJECT MANAGER ENVIRONMENTAL ANALYST

ASSISTANT OWNER'S REPRESENTATIVE: RULING AGENCY RULING AGENCY

REPRESENTATIVE: DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER: General Shale Brick Rome, Georgia
K1 Kiln A Annual Compliance

Testing Circular 3251-115-0105-V-02-0 Gas Testing Sample Location Volumetric Flow Molecular Weight Moisture Content Sulfur Dioxide Mr. Tommy Lotz, Jr. Mr. David Bowman

EPA Method EPA Method EPA Method EPA Method EPA Method

Ms. Martha West Georgia Department

of Natural Resources Mr. Daniel McCain 06/24/08 28161 2346CENTEC Services,

inc. Commerce Ave. Hue.,•__0•.n Alabama 35023 INPUT TEST DATA Client: Source: General Shale Brick K1 Kiln A Field Data Run Number Test Date Time Test Run Began Ended ling Time Stack Area Barometric Pressure Stack Static Pressure Pitot Tube Correction

factor Meter Correction

Factor Meter Delta H @ Meter Volume Meter Temperature Orifice Delta H Symbol

Y &H@

trn
Gain Silica Gel •

(Moisture len Concentration,

dry basis Carbon Dioxide Concentration,

dry basis Sulfur Dioxide Concentration,

dry basis Rt. of Delta P Stack Temperature CO= 802

Units

Military Time minutes Ft

in. H=0 dcf
F in. H=0 grams
grams %%ppm

Job No.:

1 06/24/O8 0800-0900 30 18.665 By:

2 06/24/08 28161 Tommy Lotz, Jr. Test Data 3 06/24/08 0925-1025 3O 18.665 1040-1140 3O

AVERAGE

3O 18.665 29.72 29.72 -0.20 -0.20 0.84 0.84 0.977 0.977 1.777 1.777 22.342 68.7

29.72

29.72 -0.58 -0.33 0.84 0.84 0.977 0.977 1.777 1.777 22.350 69.9 22.579 22.130 71.2 70.0 1.78 50.0 4.016.5 4.5 131.4 0.411 351.5 1.78 50.0

136.4 0.407 349.1

1.78

1.78 45.0 48.3 4.2 4.1 17.0 16.8 3.0 3.7 133.9 133.90 0.418 0.412 347.6 349.4ENTEC Services,
16-D Commerce Ave. H•eytown, Alabama 35023 CALCULATED TEST DATA Client: General Shale Brick Source: K1 Kiln A Description

.• Formulas Run Number

an-Ended f. Stack Pressure Pbar Pg/13__.___ -•. Meter Pressure Pber •H 13.E 3. Standard Meter Volume 17.64" y* (Vrr,/Trn)* (Pb,r AH 4a. Standard Volume of Water Vapor Condensed =0.04706*W=m •b. Standard Volume of Water Collected in Silica Gel

=0.04715*w=• 5. Moisture Fraction Molecular Weight Of Stack Gas, d__ry basis 0. Molecular Weight Of Stack Gas, wet basis =(Vwcl=td Vws•(,td))/(Vwc(std

Vw=•(=t•) 0.32*(02)+ 0.44"(CO2)+0.28"(100.(O2).(C • Md*(1-B,,),18.0*(B,, Velocity 12. Stack Gas Flow @ Stack Conditions

85.49*Cp*(sqrt &P),,g*SQRT((T.)

(p,*Mw)) 60*v.*A= 13. Stack Gas Flow @ Standard Conditions Q,*(T.•"l',)*(pjp,t 14. Stack Gas Flow @ D• Standard Conditions 16. Sulfur Dioxide (SO2) Gas Concentration Q,*(1-Bw,)*(T,•I'•)*(p=/p, =C=,= MW/385.1 10' 21. Sulfur Dioxide (SO•) Gas Concentration =Cso2 Qatd 60j

Post Meter Orifice Cal. (EMC ALT-009 Yqa) % Difference, (Calibration must be within 5% of original Y-factor) Sym Unit•

P= in. Hg Pm in. Hg 29.85 V•(=t= dscf 21.741 V•,o{=, s=f 2.353 v,,•(,,• scf 0.189 B,•= fraction 0.1047
M, f/g-mole 28.189
v, w• 29.03 Q• acfm 32,512 Q= scfm 20,995 1.• ]scfrn 18,797 cooz Ibs/dscf 2.19E-05 06/24/08 0800-0900 29.71 Job No.: Data input By: 28161 Tommy Lotz, Jr. Calculated Data 2 3 06/24/08 06/24/08 0925-1025 1040-1140 29.71 29.68 29.85 29.85 21.869 21.481 2.353 2.118 0.193 0.198 0.1043 0.0973 29.240 29.160 28.068 28.074 28.82 29.57 32,280 33,121 20,905 21,471 18,725 19,382 2.27E-05 2.23E-05 25.49 25.90

AVERAGE

29.70 29.85 21,697 2.275 0,193 0.1021 29.260 28.110 29.142 32,638 21,124 18,968 2.23E-05 25.35 •- 1"002•7 •-- 0'9969 i 1.0174 • 1.0057 -2.94%Sampling ProceduresProcedures The emission

rates were determined

using EPA Methods

1, 2, 3, 4, and 6C of the CFR Title 40, Part 60, Appendix

A and Part 63 Subpart

JJJJj (Brick MACT).

The calibration and quality

assurance

procedures

of EPA CFR 40 Part 60 Appendix

A for all methods, and the "Quality

Assurance

Handbook

for Air Pollution

Measurement

System"

Volume

III Stationary Source-Specific

Methods

were followed

throughout

the duration

of the field and laboratory testing.

The most current

version

for each method

(as described

in the Federal Register) was used. Stack Gas Volumetric

Flow Methods

1 and 2 The velocity

of the gas stream was determined

according

to EPA Reference

Method

1 and 2 by reading

the instantaneous

velocity

head with an inclined

manometer

at each sampling point with a calibrated

S-type pitot tube attached

adjacent

to the sample

nozzle. The stack pressure

was measured

with the static side of an S-type pitot tube. A calibrated pyrometer was used to measure

stack temperature

at each sampling

point.

The stack previously tested for cyclonic

flow according

to EPA Reference

Method

1. Stack Gas Molecular

Weight

Method

3 The carbon

dioxide

and oxygen

concentrations

were determined

using EPA Reference Method 3 (Fyrite Method).

A sample

of the flue gas was extracted

from the gas stream during each test. These samples

were analyzed

with a Fyrite gas analyzer.

The molecular weight of the gas was calculated

using the moisture,

oxygen

and carbon

dioxide

content and the measured

stack gas temperature. Moisture Content

Method

4 The moisture

content

used for calculating

the gas stream

flow rate was determined

by measuring the amount

of condensed

moisture

in the impingers

in the sampling

train as described in EPA Reference

Method

4 at the completion

of each test. Ice is placed around the impingers

and the outlet temperature

of the impinger

is monitored

and recorded throughout the duration

of the testing to verify the temperature

is less than 680 F.Sulfur Dioxide

Method

6C An Ametek

921 CE SO2 (Method

6C) analyzer

provided

continuous

analysis

of SO2 in the gas stream.

The basic analytical

principle

involves

quantitative

measurement

of the absorption of UV radiation

by SO2 molecules.

The analyzer

uses a single light source, which emits an appropriate

wavelength,

illuminating

the sample

cell through

which the sample is continuously

passed.

Narrow-band

optical filters are rotated

through

the beam, and the radiation

passed

through

the optical filters and sample

cell is detected

by a single photo-detector. The signal pulses from the photo-detector

are separated

by a multiplexor into a measuring

channel

and a reference

channel.

A log ratio amplifier

computes

the logarithm of the input signal ration, producing

a signal that is proportional

to the SO2 concentration. The dual-range

analyzer

has a digital readout,

as well as 0-10.0 V DC output terminals.

The full scale of the instrument

was set at 226.6 ppm. Samplin_• Syste•m The new test requirements

require

a stratification

test which was performed

and was determined that the gas stream

was unstratified.

The gas samples

were collected

from a single point that most closely

matches

the mean of the stratification

test data. Samples were extracted

from the gas stream

by a heated

stainless

steel probe maintained

at a set temperature of 250 degrees

Fahrenheit,

through

a hundred

(100) foot heated

sample

line that was heated

and maintained

at a temperature

between

225 and 250 degrees.

The gas is transported

to the test trailer then passed

through

a chilled

sample

conditioner

to remove the moisture

in the gas stream

and then to the analyzers.
Data Acquisition Concentration

values were collected

using a Baldwin

Environmental

RM Plus Parametrics data acquisition

system.

The data was recorded

every fifteen-seconds

and then averaged for each sixty-second

interval.

Each minute

average

was then averaged

for the duration

of each test run. During

all testing,

the unit was operating

within

normal

operating parameters, at a range appropriate

in accordance

with applicable

permits.Entec Services,

Inc 16 D Commerce

Ave. Hue.e.e.e.e.e.e.e.e..•town,

AL 35023 STACK DRAWING

& TRAVERSE

POINT LOCATION Client: General Shale Brick Source: K1 KilnA Job No. Input By: 28161 Tommy Lotz, Jr. Type of Traverse: Velocity (V) or Particulate (p):

_p Stack Diameter, inches:

58.5 Stack Height, feet:

100 Stack Properties:

Inches

Duct Diameters Upstream Disturbance:

226.0

3.86 Downstream Disturbance:

300.0

5.13

Port Type

Nipple Stack Area, Ft2: Number of Ports: Length of Port, inches: Total Number of Traverse Points: Number of Points per diameter:Port

Diameter

18.665 24.002010 58.5 INCHES

226.0

NCHES

300.£ INCHES

Point No.

Inside Stack

Outside Nipple Inches Inches 1.5 5.5 2 4.8 8.8 3 8.5 12.5 4 13.2 17.2 5 20.0 24.0 6 38.5 42.5 7 45.3 49.3 8 50.0 54.0 9 53.7 57.7 10 57.0 61.0
Adjusted points diameter > 24" no point closer than 1.0 inch Adjusted points diameter_< 24" no point closer than 0.5 inch Stack Diameters between 12-24 inches minimum points are 8 4 points per port if the 8 2 diameters downstream

and upstream criteria is met.

10EPA Method

Heated Probe (~248 F)

Temperature Sensors ,Wetted'i Sample Line Temperature / (<68° F)

Steel Condenser Empty
Exhaust

11Filter instrument Sampling EPA Method

6C

Three Way Valve

Heated Stainless Calibration

Gas Line

Heated Teflon Line

•unication Lines

Flow Control

Aoquisition System SO2

mpling Analyzers

Calibration Gases

12K1 (Kiln

A) Field Data

SheetsK1 (Kiln

A) Test Run

No.

1

14ENTEC Services,

inc. 16-D Commerce Ave. Hue_•town, Alabama 35023 Client: Source: General Shale Brick K1 Kiln A Test Date: Run Number:

VOLUMETRIC FLOW FIELD DATA, EPA METHODS

1-4

6/24/2008 Pre Run 1

Traverse Point 1-11-21-31-4

1-10 2-12-22-32-42-52-62-7 2-82-9 2-10

Delta P 0.19 0.20 0.18 0.19 0.21 0.17 0.14 0.12 0.08 0.06 0.26 0.25 0.26 0.27 0.26 0.18 0.16 0.16 0.13 0.10

0.18

Rt. Delta P

Delta H 0.4359 1.78 0.4472 1.78 0.4243 1.78 0.4359 1.78 0.4583 1.78 0.4123 1.78 0.3742 0.3464 0.2828 0.2449 0.5099 0.5000 0.5099 0.5196 0.5099 0.4243 0.4000 0.4000 0.3606 0.3162

0.4156 1.78

Stack 354 353354354353354 351351349 348 346350356 357 356358 354 351352353

352.7

Meter 68

68.7 6765717170

15Port/Point Ap, in.HzO Temp. °F Deg. from 90o to Null Port / Point &P, in.HzO

Temp. °F Port Point

&P, in.H20

Temp. °F ENTEC SERVICES,

INC, YELOC}TY Source: •'[t•• Project No.:

•/(

/ Stack I.D., Date:.. G •rometrJc Press •n Hg • •.•

Am(Ib•C•

s>' •• Pitot ID: •

P•tot Cp: •

T•vice" em Temperature:

"3

AVG Pitot Leak Check Pre Test R Post Test R % Moisture Wet Bulb Dry Bulb

Revision March 2005 LRK Static Pressure

Checked By

AVG Pitot Leak Check

rest % Moisture ulb Dry Bulb

17 Static Pressure

Checked By

AVGPitot Leak Check Pre Test R Post Test% Moisture Wet Bulb Dry Bulb

Pressure

Checked ByGeneral Shale Rome, GA Kiln A Brick

Run Number

Dat..._•e

Tim._._•e 6/24/2008 8:00:15 6/24/2008 8:01:15 6/24/2008 8:02:15 6/24/2008 8: 03:15 6/24/2008 8:04:15 6/24/2008 8: 05:15 6/24/2008 8: 06:15 6/24/2008 8:07:15 6/24/2008 8:08:15 6/24/2008 8:09:15 6/24/2008 8:10:15 6/24/2008 8:11:15 6/24/2008 8:12:15 6/24/2008 8:13:15 6/24/2008 8:14:15 6/24/2008 8:15:15 6/24/2008 8:16:15 6/24/2008 8:17:15 6/24/2008 8:18:15 6/24/2008 8:19:15 6/24/2008 8: 20:15 6/24/2008 8:21:15 6/24/2008 8:22:15 6/24/2008 8:23:15 6/24/2008 8: 24:15 6/24/2008 8:25:15 6/24/2008 8:26:15 6/24/2008 8:27:15 6/24/2008 8:28:15 6/24/2008 8:29:15

123.0 137.0 150.5 125.8 86.1 38.6 116.7 135.9 128.2 110,9 115.2 134.5 142.2 131.0 118.4 124.0 136.2 146.4 127,1 119.6 134.5 147.8 128.0 58.7 126.7 136.7 146.8 150.9 133.0 121.6

18General Shale

Brick Rome, GA Kiln A
_Run Number

Dat.__.•e

Tim._._•e 6/24/2008 8:30:15 6/24/2008 8:31:15 6/24/2008 8:32:15 6/24/2008 8:33:15 6/24/2008 8:34:15 6/24/2008 8:35:15 6/24/2008 8:36:15 6/24/2008 8:37:15 6/24/2008 8:38:15 6/24/2008 8: 39:15 6/24/2008 8: 40:15 6/24/2008 8:41:15 6/24/2008 8:42:15 6/24/2008 8:43:15 6/24/2008 8:44:15 6/24/2008 8:45:15 6/24/2008 8:46:15 6/24/2008 8:47:15 6/24/2008 8:48:15 6/24/2008 8:49:15 6/24/2008 8: 50:15 6/24/2008 8:51:15 6/24/2008 8:52:15 6/24/2008 8:53:15 6/24/2008 8:54:15 6/24/2008 8:55:15 6/24/2008 8:56:15 6/24/2008 8:57:15 6/24/2008 8:58:15 6/24/2008 8:59:15 Average

SO2 132.2 145.6 152.7 139.1 123.4 135.6 142.8 157.1 138.6 123.6 111.8 63.0 149.6 138.4 131.2 134.6 149.1 154.7 139.8 132.4 138.2 151.4 157.2 136.4 123.6 134.3 158.3 164.6 123.2 54.5 129.5

19Calculation

Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6/24/08Calibration

Gas Value 0.0 ppm SO 2 124.5 ppm SO2 Mean Reference

Values: 129.5 ppm SO 2

of Average

Emissions

Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run 1 Initial Calibration 2.4 ppm 122.6 ppm

Final Calibration

Average 1.5 ppm

1.95 122.9 ppm

122.76 Corrected Results: 131.4 ppm SO2

Basis: DRY

2OK1 (Kiln

A) Test Run

No.

2

21ENTEC Services,

inc. 16-D Commerce

Ave. Hueytown, Alabama 35023 Client: Source: General Shale Brick K1 Kiln A Test Date: Run Number:

6/2412008 Post 1/Pre 2

VOLUMETRIC FLOW FIELD DATA, EPA METHODS

1-4
Traverse Point 1-11-2

Delta P

Sq. Rt. Delta P 0.28 0.5292 0.26 0,5099 1-3 0.28 1-4 0.28 1-5 0.28 1-61-71-81-9 1-10 2-12-2

0.5292 0.5292 0.5292 0.20 0.4472 O. 18

0.4243 0.17 0.4123 0.15 0.3873 0.11 0.3317 O. 16

0.4000 O. 16

0.4000 2-3 O. 15

0.3873 2-4 0.15

0.3873 2-5 O. 16

0.4000 2-6 0.12

0.3464 2-7 0.10

0.3162 2-8 0.09 2-9 0.08

0.2828 2-10 0.07

0.2646

0.17 0.3000

0.4057

Delta H 1.78 1.78 1.78 1.78 1.78 1.78

1.78

Stack Temp. (°F) 357 358355356359355 353 354355 353353 352 345 345 345 345343342 340 339

350.2 Meter Temp. 707171737171

71.2

22General Shale Rome, GA Kiln A Brick

,Run Number

Dat..._•e

Tim.___•e 2 6/24/2008

9:25:45 2 6/24/2008

9:26:45 2 6/24/2008

9:27:45 2 6/24/2008

9:28:45 2 6/24/2008

9:29:45 2 6/24/2008

9:30:45 2 6/24/2008

9:31:45 2 6/24/2008

9:32:45 2 6/24/2008

9:33:45 2 6/24/2008

9:34:45 2 6/24/2008

9:35:45 2 6/24/2008

9:36:45 2 6/24/2008

9:37:45 2 6/24/2008

9:38:45 2 6/24/2008

9:39:45 2 6/24/2008

9:40:45 2 6/24/2008

9:41:45 2 6/24/2008

9:42:45 2 6/24/2008

9:43:45 2 6/24/2008

9:44:45 2 6/24/2008

9:45:45 2 6/24/2008

9:46:45 2 6/24/2008

9:47:45 2 6/24/2008

9:48:45 2 6/24/2008

9:49:45 2 6/24/2008

9:50:45 2 6/24/2008

9:51:45 2 6/24/2008

9:52:45 2 6/24/2008

9:53:45 2 6/24/2008

9:54:45

141.9 155.3 154.7 126.2 134.1 138.9 142.1 150.0 159.6 117.1 123,0 130.9 126.4 140.2 89.6 76.4 132,6 136.6 146.2 150.2 135.7 131.1 137.7 148.2 155.9 138.7 132.5 140.0 148.0 161.0

24General Shale

Brick Rome, GA Kiln A
_Run Number

_Date

Time 2 6/24/2008

9:55:45 2 6/24/2008

9:56:45 2 6/24/2008

9:57:45 2 6/24/2008

9:58:45 2 6/24/2008

9:59:45 2 6/24/2008

10:00:45 2 6/24/2008

10:01:45 2 6/24/2008

10:02:45 2 6/24/2008

10:03:45 2 6/24/2008

10:04:45 2 6/24/2008

10:05:45 2 6/24/2008

10:06:45 2 6/24/2008

10:07:45 2 6/24/2008

10:08:45 2 6/24/2008

10:09:45 2 6/24/2008

10:10:45 2 6/24/2008

10:11:45 2 6/24/2008

10:12:45 2 6/24/2008

10:13:45 2 6/24/2008

10:14:45 2 6/24/2008

10:15:45 2 6/24/2008

10:16:45 2 6/24/2008

10:17:45 2 6/24/2008

10:18:45 2 6/24/2008

10:19:45 2 6/24/2008

10:20:45 2 6/24/2008

10:21:45 2 6/24/2008

10:22:45 2 6/24/2008

10:23:45 2 6/24/2008

10:24:45 Average

143.2 134.0 81.4 88.9 156.2 134.6 134.4 138.9 147.3 154.4 134.7 128.4 136.9 147.6 156.4 132.7 114.9 137.5 152.8 159.3 69.8 53.0 116.3 125.8 133.8 143.3 143.6 154,0 157,6 137.2 134.2

25Caiculation

Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6/24/08Calibration

Gas Value 0.0 ppm SO2 124.5 ppm SO2 Mean Reference

Values: 134.2 ppm SO2

of Average

Emissions

Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run 2 Initial Calibration 1.5 ppm 122.9 ppm

Final Calibration

Average 1.7 ppm

1.62 122.3 ppm

122.59 Corrected Results: 136.4 ppm SO2

Basis: DRY

26KI (Kiln

A) Test Run

No.

3

27ENTEC Services,

inc. 16-D Commerce Ave. Hueytown, Alabama 35023 Client: Source: General Shale Brick K1 Kiln A Test Date: Run Number:

6/24/2008 Post 2/Pre 3

VOLUMETRIC FLOW FIELD DATA, EPA METHODS

1o4
Traverse Point 1-11-21-31-41-51-61-71-81-9 1-10 2-12-22-32-42-52-62-72-82-9 2-10

Delta P

Sq. Rt. DeltaP

Delta H O. 18

0.4243

1.78 0.18 0.4243

1.78 O. 18

0.4243

1.78 0.19 0.4359

1.78 0.19 0.4359

1.78 O. 16

0.4000

1.78 O. 14

0.3742 O. 12

0.3464 0.09 0.3000 0.08 0.2828 0.23 0.4796 0.24 0.4899 0.25 0.5000 0.25 0.5000 0.25 0.5000 O. 19

0.4359 0.17 0.4123 0.17 0.4123 Stack Temp. (°F) Meter Temp, (°F) 353 70 353 71 353 69 353 69 352 70 351 71 346 345 347345 345 345346348 348 351350 346343 341 0.13 0.3606 0.06 0.2449

0.17 0.4092

1.78

348.1

7n_n

2888o°• d

° 0ENTEC Services,

inc. 16-D Commerce

Ave. Hueytown, Alabama 35023 Client: Source: General Shale Brick K1 Kiln A Test Date: Run Number:

6/2412008 Post 3

VOLUMETRIC FLOW FIELD DATA, EPA METHODS

1-4
Traverse Point 1-11-21-31-41-51-61-71-81-9 1-10 2-12-22-32-42-52-62-72-82-9 2-10

Delta P 0.28 0.27 0.27 0.27 0.26 0.18 0.18 0.17 0.13

Sq. Rt. Delta 0.5292 0.5196 0.5196 0.5196 0.5099 0.4243 0.4243 0.4123 0.3606 0.11 0.3317 0.19 0.4359 0.19 0.19 0.20 0.20 0.16 0.15 0.13 0.11 0.10

0.19 0.4359 0.4359 0.4472 0.4472 0.4000 0.3873 0.3606 0.3317 0.3162

0.4274

Delta H

Stack Temp. (°F) 348346354 354353 350349 345343 341340 344346346 347349351347 345 343

347.1 Meter Temp. (°F)

3OGeneral Shale

Brick Rome, GA Kiln A

Run Number

Dat_._•e

Tim.___•e 3 6/24/2008

10:40:45 3 6/24/2008

10:41:45 3 6/24/2008

10:42:45 3 6/24/2008

10:43:45 3 6/24/2008

10:44:45 3 6/24/2008

10:45:45 3 6/24/2008

10:46:45 3 6/24/2008

10:47:45 3 6/24/2008

10:48:45 3 6/24/2008

10:49:45 3 6/24/2008

10:50:45 3 6/24/2008

10:51:45 3 6/24/2008

10:52:45 3 6/24/2008

10:53:45 3 6/24/2008

10:54:45 3 6/24/2008

10:55:45 3 6/24/2008

10:56:45 3 6/24/2008

10:57:45 3 6/24/2008

10:58:45 3 6/24/2008

10:59:45 3 6/24/2008

11:00:45 3 6/24/2008

11:01:45 3 6/24/2008

11:02:45 3 6/24/2008

11:03:45 3 6/24/2008

11:04:45 3 6/24/2008

11:05:45 3 6/24/2008

11:06:45 3 6/24/2008

11:07:45 3 6/24/2008

11:08:45 3 6/24/2008

11:09:45

so._22 142.7 162.9 148.7 131.0 138.1 146.2 157.5 152.7 127.9 130.9 142.4 123,0 71,1 106.9 101.3 132,1 134.4 133.2 129.9 147.1 156.9 149.6 132.2 141.7 144.1 135.0 156.5 168.8 133.5 87.9

31General Shale

Brick Rome, GA Kiln A

,Run Number

Date

Time 3 6/24/2008

11:10:45 3 6/24/2008

11:11:45 3 6/24/2008

11:12:45 3 6/24/2008

11:13:45 3 6/24/2008

11:14:45 3 6/24/2008

11:15:45 3 6/24/2008

11:16:45 3 6/24/2008

11:17:45 3 6/24/2008

11:18:45 3 6/24/2008

11:19:45 3 6/24/2008

11:20:45 3 6/24/2008

11:21:45 3 6/24/2008

11:22:45 3 6/24/2008

11:23:45 3 6/24/2008

11:24:45 3 6/24/2008

11:25:45 3 6/24/2008

11:26:45 3 6/24/2008

11:27:45 3 6/24/2008

11:28:45 3 6/24/2008

11:29:45 3 6/24/2008

11:30:45 3 6/24/2008

11:31:45 3 6/24/2008

11:32:45 3 6/24/2008

11:33:45 3 6/24/2008

11:34:45 3 6/24/2008

11:35:45 3 6/24/2008

11:36:45 3 6/24/2008

11:37:45 3 6/24/2008

11:38:45 3 6/24/2008

11:39:45 Average

so_•2 50.7 127.6 126.0 132.7 131.6 136.8 153.0 158.3 153.4 128.4 143.0 147.4 145.2 141.6 159.6 157.4 91.4 83.7 43.8 114.0 121.8 133.1 134.1 141.1 142.8 140.5 149.2 149,2 137.5 89.7 132.2

32Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6/24/08Calibration

Gas Value 0.0 ppm SO2 124.5 ppm SO2 Mean Reference

Values: 132.2 ppm SO2

of Average

Emissions

Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run 3 Initial Calibration 1.7 ppm 122.3 ppm

Final Calibration

Average 1.6 ppm

1.68 123.7 ppm

123.00 Corrected Results: 133.9 ppm SO 2

Basis: DRY

33Control .Room

Production Data

34Production Data The following

information

was received

from Ms. Martha

West of General

Shale Brick Company for the testing performed

at their facility in Rome, Georgia,

on June 24, 2008.

(Kiln A)
Brick Production

(tons/hr) Lime Feed Rate (Ibs/hr) Pressure Drop (inches) Coal Usage (Ibs/hr) Gas Usage (MCF/hr) June 24, 2008 Run 1

Run 2

Ru n 3 16.9 16.9

16.9 104.7 104.6

111.9 3.62 .r.17416 10.5 3.7317416 10.5

3.81 1 •426 10.5

35Quality Assurance / Quality Procedures

Control

36QA / QC Procedures Specific quality assurance

/ quality control procedures

were adhered

to during this test project to provide

valid and scientifically

defensible

data. For any environmental

field and laboratory

measurement,

a degree

of uncertainty

exists in the data due to inherent limitations of the measurement

systems

employed.

The objective

of a QA/QC

program is to produce

data of known

precision,

accuracy,

representation,

completeness

and comparability. The objective

in this test project

was to determine

compliance

with applicable air permit

requirements.

The final data user in this project

will be the Georgia Department

of Natural

Resources. The following

section

details all QC procedures

followed

during the manual

sampling activities.

@ Velocity/Volumetric Flow Rate Methods

1 and ;• Volumetric flow rates were determined

during each isokinetic

test run. QC steps were adhered

to during these tests: The following Reported duct dimensions

were checked

by physical

measurements

to determine cross-sectional duct area. Pitot tube coefficients

were determined

based on physical

measurement

techniques as delineated

in Method

2 The Type-S

pitot tube was visually

inspected

before and after sampling. The pitot tube was installed

on the sampling

probe with the proper orientation

and spacing from the sampling

nozzle. Before each series of tests, thermocouple

readings

for the silica gel impinger

exit temperature were checked

against

an N.I.S.T.

traceable

thermometer. The oil manometer

was leveled

and zeroed before each test run. Both legs of the pitot tube were leak-checked

before and after sampling. Proper orientation

of the pitot tube was maintained

while making

measurements. The roll and pitch axis of the pitot tube was maintained

at 90 o to the flow. An average

velocity

pressure

reading

was recorded

at each point instead

of recording extreme

high or low values. The pitot/manometer

umbilical

lines were inspected

before and after sampling

for moisture condensate.

Lines were cleared

if moisture

was found.
37@

Molecular

Wei ht Determination

Method

3 The carbon

dioxide

and oxygen

concentrations

were determined

using EPA Reference Method 3. A sample

of the flue gas was extracted

from the gas stream during each test. The samples

were analyzed

with a Fyrite gas analyzer.

The following

QC steps were adhered to during these tests: The sampling

train was leak checked

before and after each samples

was taken. The samples

were run in triplicate

for accuracy. Standardization was performed

to audit the reagents

and the operators

technique. A known

mixture

of CO2 and 02 was analyzed

and repeated

with 3 consecutive values +/- 0.5 percent

of the known value. Two NIST traceable

gas cylinders

were run against

the instrument

to audit the accuracy of the analyzer

and the analyzer

operator

technique.

One cylinder contained 2 to 4 percent

02 and 14 to 18 percent

CO2. The second

cylinder contained 2 to 4 percent

CO2 and about 15 percent

02. Moisture Determination

Method

4 Stack gas moisture

content

(B•vs) was determined

by dividing

the mass of moisture collected by the impingers

or stainless

steel condenser

and silica gel impinger

by the standardized volume

of gas sampled.

The following

QC steps were adhered

to during these tests:

= The indicating

silica gel was fresh for the first run and periodically

inspected

and replaced during runs, if needed.

o The analytical

balance

was placed in a clean, motionless

environment

for weighing.
• The balance

was leveled

and zeroed

if necessary

before each weighing.
" Preliminary

silica gel impinger

tare weights

and post-run

weights

were weighed

to the nearest

0.1 g. Before each series of tests, thermocouple

readings

for the silica gel impinger

exit temperature were checked

against

an N.I.S.T.

traceable

thermometer. The silica gel impinger

gas temperature

was maintained

below 68°F and recorded at every traverse

point. Each impinger

was wiped of surface

moisture

before post-run

weighing. The volume

of liquid captured

was measured

using a graduated

cylinder

with 1- milliliter increments.

38Sulfur Dioxide

Determination

Method

6C The sulfur dioxide

concentrations

were determined

using EPA Reference

Method

6C. A sample of the flue gas was extracted

from the gas stream

during each test. Moisture was removed

form the sample

and was analyzed

on a dry basis with an Instrumental gas analyzer.

The following

QC steps were adhered

to during these tests:
• Only analyzers

that have a resolution

or sensitivity

of at least < 2.0% of full-scale range are used.

" Upon the SO2 analyzers

initial use in the field, an interference

check was conducted. The reference

calibration

gases used in this test program

are certified

following EPA Protocol

Number

1 analysis.

Copies

of the calibration

gas certifications

are included in the instrument

calibration

section. The high level gas was equal to the calibration

span gas. The mid level gas was between

40 and 60 % of the calibration

span gas. The low level gas was < 20% of the calibration

span gas. In accordance

with EPA Method

6C a three-point

(i.e., zero, mid-, and high-range) analyzer calibration

error was conducted

on each reference

analyzer

prior to initiating the compliance

testing.

These

checks

were conducted

(after final calibration adjustments

were made) by injecting

the calibration

gases directly

into each gas analyzer

and recorded

the responses. The analyzer

calibration

error was less than + 2.0% or + 0.5 ppm of the calibration span gas for the zero, mid-range,

and high-range

calibration

gases. The probe material

was stainless

steel. The probe, filter and sample

line temperature

was maintained

above the dew point by heating,

prior to sample

conditioning. The sampling

system

bias was less than + 5.0 % or of the calibration

span gas for the zero and upscale

calibration

gases (+ 0.5 ppm absolute

difference). The system

response

time was calculated

during the initial sampling

system

bias. The drift for either the low-level

and mid-level

or high-level

gases was less than + 3.0% or of the calibration

span gas (+ 0.5 ppm absolute

difference). The sampling

system

was purged

> 2 times the system

response

time before each test run. Sample flow rate was maintained

within 10% during the entire test period. Data is recorded

at 1-minute

intervals. @

39All data collected

was within the calibration

span gas.

4oENTEC SERVICES, |NC FIELD QA/QC

CHECKLIST

souRcE TESTED: TYPE CONTROL

DEVICE:

•¢,i•f PERMIT NUMBER: PERMIT

LIMITS: TEST METHODS

USED: •_L•(_•___.___=.

MODIFICATIONS

TO METHOD:

•

1. Was Calibration

Data on site? (Methods

1-5 / CEMS CAL Gas) 2. Was Stack Diameter

/ Area & Trave•e

Points verified on fie•d data sheets? 3. Was a 10-minute

Meter Orifice Check pe•ormed? Results of check

•,• • • • Were Temperatures

Verified w/NIST Traceable

Thermometer? Was Prelimina•

Traveme

wl Cyclonic

Flow verification

Performed? Was previous

test data on soume used to determine

K factor? Was• maintained

at 248 +/- 25 o F? If not, explain 5.6.7.

10.
11.12.13.14. Was Filter Outlet Temperature

maintained

at 248 +/- 250 F? If not, explain Was Orsat or •)leak

checked

and standardization

perform•.•d Ambient 02 Reading

•%

Ambient

CO2 Reading_

b, as requ red? •O• Was Tedlar Gas Sampling

Bags used? If not, explain Were they leak-checked?

y or N Were Pitot Leak,4•hecks

performed

& recorded

on each field data sheet'• Pitot inspected?-.•.,x•

N Noted Visual Defects?

• Was Meter Leak Checks Performed

& recorded

on each field date sheet? Was Nozzle Diameter

measured

& recorded

on each field data sheet'• Nozzle inspected?

y or N Noted Visual Defects? Was Silica Gel Verified,

and recorded

for each test run?

As required:

Control room data supplied by:

'• Revision 2 December

2005 DLB 41 Percentage Used during test Run No.'s 1: • 2: •._.__.• 3: I • •i; natu reW•-•e;tC-•::r•eLLe;t

,N:m bet •d a,,,a•/•,• _reo°rded

°n F'eld Data Sheet-

•__•_.J'•/. aaer): /(,/• Date' •

via on-site, email, or fax.ENTEC SERVICES, iNC. METER ORIF|CE

AND

TEMPEP,

J•,TURE

CHECKS

Meter Box Number:. Original •H@-
Orifice Manometer Reading/tH equal to Dry Gas Meter Readings: Location:

===.=.L•/vv/• Barometric Pressure:

•,

Hg Original Y:

G c• • -=2 Bi=Annual Calibration

Date:

• •• Dry Gas Volume,

ft initial Final

Dry Gas Meter Inlet Temperature, °F initial Final

Total Volume: Average: Vm = Volume

of Dry Gas Meter Average: Tm= Average

Temperature

of Dry Gas Meter in degrees

Rankin

(+460) Pea• = Barometric

Pressure Dry Gas II•eter Outlet Temperature, °F Initial Final

Yc = 10NmX

•/{ 0.0319

X Trn/PBarrn} =10/( -?-•='•

)X•/•0.03.19X-"===•---•-'-•'•5-,.•. =( I.•

) x ( •.••

)= Is Y¢ < +/= 3% of Original

Y ? Thermocouple Check

(aiJ temperatures

are in o F) NIST Traceable Thermocouples I I.D. Stack (Post Require

/•)• Probe / Filter Box / •.• Filter Exit /

• Meter Outlet / Impinger Exit / Other Ambient

Temp.

Field Checks

Performed

By (Signature):, Rovision Soptornber

2005 DLB Reference

Temp.

42

Acceptance

Range +/-7.5 o +/- 5.4 o +/- 5.4 o +k2.0 ° +/- 5.4 o +/- 2.0 o +•5.4 °

OK?<: --s-: ..... • •,•.•'_-•,

ISOIIEC

"17025 AND A • ""•" "'*'" ,:,,•,,l•)-,>,:,)+ ..',>:.,., Oei'"'"•. No, 4371..1 51" 239

Instrument Identification: Model: 14-64.8-44 Start dards/l•:q

uipmer)t: Description empetatLire

Prob• Thermistor Module remperature Calibration Ba[l• '1'0'155 Tempera/ire Probe Thermistor Module "rein perature 6alibra Ion Ball• TCI 9'1 S/N: 72083396

Manufacturer

Control Company •e)_'ial Numbe_r

[:)Lie Date

NISr Traceable

Refurenc•-,, 149 8/14/07'

A6713030 A27129 7t10/07

1000207994 93139 157 1/14107

A6B06053 AI 7118

8/23/07

A6823089 A42238 Certificate Information: -Iecl•nicia)•: 68

Procedure:

CAL•03 Cal Date: I/'19/0! Test Conclilions:

23.0+C

39,0 %RH 1028 mBar CalDue; 1/18/09 Calibration Data: (New Instrument)

Nominal

As Left In Tol Min

Max

+uc IUR Unit(s)•_ Nomillal

As l:Oulld In-rol

••--•

L• ---• 2

]]•i--•

Y• •1• 3:•1i :'• •i•--• Yii

ii]i--

Qii-

i

ii1--7

:iii----iiJii•

;i:1 k ]L_ This IrisO'tmle)l[

was calJbra[od tlShlg IIlI[l'[ltllell•S

Traceable to National [llstittlle of StalIdards il)lcl Techliology,

Maintaioin• Accuracy:
Recali•ratlon:

CONTROL COMPANY

4455 Rex Road Friendswood,

TX77,546

USA Phone 28'1 482-1714

Fax 28'1 482-9448

service@controt3.com

www.control3.com C•)l'4rot Colnpal1,t ISO (1001 Out, lib/Cetlilied I)y (DNV• Del Nerske Veri•as, Cerlil;cale No. CEi•.T-(}

43ENTEC SERVICES, iNC. FYR•TE / ORSAT

STANDARD•ZATION Client: Source:Orsat/•Leak Check: Date of Test: Date of•rdization: Orsa•

#: •

•" Calibration Gases

Concentration % Container Type /] Cylinder

ID# Date of Expiration Tank 2

Tank1C0202
Tank2C0202 1 Actual Net

2 Actual Net Actual

Net Average Net Volume

Known Value

Difference

Difference Actual N

tual

Difference must be less than 0.5% ANALYST (Signature

/ Date):

Net

3

[ Average Net Actuall Net

Volume

Known Value

44Certificate of AnaJysis

Date of An.alysis: Ct•s!om.er Name: Grade of Product:

7/"/4/2005 PRIMARY

STANDARD

Reference

N[lrnber: Pad: Numbe•:

87•1 I0858887•5 X0. NI.,2P 15AC.zz6 __Cy_lj.nd e r Nurnbe_r •,C2 4 t 39

Notes:

• Re• Concentration CARBONDtOXIDE 3,000 %

:• •002 % P.XYG EN

t 5.00 o/,o

14.97 % NITROGEN Balance BaJance Actual Concentration

Relative Uncertainty__o.f

Ap•aly_Jj_C__a.I

Value: +I- t% of component

or +1- 0,02% of absolute, which ever is lower. Primary Standard

gas mixtures

are traceable

to N.I,S,T weights

and/or N.I,S,T gas mixture reference rnat#,ria Ap•:•r•'¢at Sigaature

45Certificate of Ana!ysis

Date of ,Anaiysis: Customer Name: Grade of Product:

7,'!4/2005 PRIMARY

S-rANDARD

Relerence

N umber; Part. Number: 87-110858887•4 X03Nf81P15AC225 C•]der Number CC214147

Notes:

Co___m.• • Actual Concentj'ation OXY •EN

3.000 %

2,993 % CARBON DIOXIDE

16,00 %

15,97 % N•TROGEN Ba•anc• Ba•anc, e Relative UncertaintE

of Analytical

Value: +l- I% of component

or +/. 0,02% of absolute, which ever is lower, Primary Standard

gas mfxtures

are traceable

to N.I.S.T weights

and/or N.I.S.T gas mixture reference materials,

,( ,7 (

46ENTEC SERVICES,

INC FIELD QA/QC

CHECKLIST Method 6C Sulfur

Dioxide

TYPE CONTROL

DEVICE: MODIFICATIONS TO METHOD:

Was valid Interference

Check (sum of responses

< 2.5 % of calibration

span) on site? 2 Was valid Certificate

of all Protocol 1 calibration

gases on site? 3 Was the High-level

gas equal to the calibration

span ? 4 Was the Mid-level

gas between 40 and 60 % to the calibration

span ? 5 Was the Low-level

gas < 20 % of the calibration

span ? 6 Was the sample kept above the dew point by heating prior to the sample cond tioner ? 7 Was the Analyzer Calibration

Error within +/-2 % or +/- 0.5 ppm of the calibration

span for all calibration gases ? 8 Was the System Bias within +/-5 % of the calibration

span for the low-scale and upscale gases ? 9 Was the System Response

Time Calculated

during the initial sampling system bias check? What was the System Response

Time ? o•.- J•

Seconds 10 Was the Drift within +/-3 % or +/- 0.5 ppm of the calibration

span for the low-scale and upscale gases ? 11 Was the sampling system purged > 2 times the system response time before each test run? 12 Was the minimum

time at each sampling point > 2 times the system response time ? 13 Was the sample flow rate within 10 % of the flow rate established

during the system response time check for each run ?

Flow rate:

C• k•

liters/minute 14 Was a stratification

test performed

before the first run ? What were the results of the stratificat on test? All points were: Within +/- 5 % or +/- 0.5 ppm of mean for 1-point sampling (unnstratified) Within +/- 10 % or +/- 1.0 ppm of mean for 3-point sampling (minimumally

stratified) Some points were > 10 % or 1.0 ppm of mean for 12-point sampling (stratified) 15 Was a Multi-point

or 3 point probe used ? 16 Was the flow rate from each point verified to be within 10 % of the mean flow rata for each run ? 17 Were all data points recorded in at least 1 minute averages? YE.__•S

NO _,2 J-.

18 Was the average concentration

for each run < the calibration

span ? Signature (Test Team Leader):,
48Date Analyzer

Model Component Analyzer Serial No. Span Cylinder ID
SG9120994 SG9120994 SG9120994 SG9120994

10/1/2007 Ametek 921 CE Sulfur Dioxide AD-921-5141

Interference

Response

Test

0-215 ppm Test Gas
SO2

coCO2

Concentration

213
495 9.76 20.79

Analyzer

Response

215

Total

Difference

2

3 *Specification (EPA Method 20) Sum of interference

responses

must not exceed 2% of span % of Span

Analyzer Response Instrument Span

X 100 % of Span
0.95

0.48

1.43

49Test ProtocolPollution Control System Evaluation

and Source Emissions

Testing May 27, 2008
Ms. DeAnna

Oser Air Branch

Georgia

Environmental

Protection

Division Re: Test Protocol

Reference

Letter for General

Shale

Rome GA K1 (Kiln A) DLS Baghouse

Stack

SO2 Entec Project

No.: 28161 Dear Ms. Oser, Please find attached

the test protocol

for General

Shale

Rome,

Georgia

facility

K1 (Kiln A) Dry Lime Scrubber

(DLS) Baghouse

Stack.

The protocol

outlines

the test procedures, the QA/QC

requirements,

and example

calculations.

Testing

has been scheduled for Tuesday

June 24, 2008.

Testing

will be conducted

in one day. It is understood that modification

to the permitted

test requirements

has been approved

on previous testing

to use EPA Method

6C for the determination

of Sulfur Dioxide.

The facility will supply all operation

parameters

that will be included

in the final report. If you should

have any additional

questions

about the protocol

please

call me at 205- 491-6676 or my cell at 205- 613-5473

and will make any changes

as required. Sincerely, Entec Services

|nc. Lynn Beane Operations Manager

16-D Commerce

Avenue

Hueytown,

Alabama

35023

Phone: (205) 491-6676

Fax (205) 491o 6614 www.entecservices•com 51En ec Services, inc. 16-D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614

Test Protocol

for the K1 (Kiln A) DLS Baghouse

Stack (Dry Lime Scrubber

w/Fabric

Filter Baghouse) Emissions Testing

at the General Shale

Company

facility

located

in Rome, Georgia
Submitted to: General Shale P.O. Box 3547 Johnson City, Tennessee

37602 Attention: Ms. Martha

West CC: State of Georgia

Department

of Natural

Resources

Air Protection

Branch

Entec Project

No. 28161 Reviewed By: Protocol

Emailed:

May 28, 2008 Completed By:

Tom Lotz QA/QC Manager Lynn Beane Operations Manager

52Scope of Work Entec services

will conduct

testing per the requirements

of General

Shale

Rome, GA Facility Title V Operating

Permit

No, 3251-115o0105oV-02-0. Testing

will be conducted for Sulfur Dioxide

emissions

on the K1 (Kiln A) Baghouse

Stack per GA permit requirements.

The proposed

test program

will take one (1) day to complete. Entec will perform

the testing during the week of June 23 rd, 2008 upon approval

of this test protocol

with an approximate

start time of 8:00 am. Procedures Testing will follow EPA Test Methods

1-4 & 6C of the CFR Title 40, Part 60, Appendix A. The calibration

and quality assurance

procedures

of EPA CFR 40 Part 60 Appendix A for test Methods

1-4 & 6C of the "Quality

Assurance

Handbook

for Air Pollution Measurement System"

Volume

III Stationary

Source-Specific

Methods

will be followed throughout the duration

of the field testing

and laboratory

analysis.

The most current CFR revision

of each method

(July 1, 2006) will be used. It is understood

that the State of Georgia

Department

of Natural

Resources

Air Protection Branch

may at their discretion

bring audit samples

to the test team for analysis in conjunction

with the other samples

as required.

The following

paragraphs summarize the methods

to be used, detailed

test procedures,

QA/QC

procedures,

and other documentation

to be used for this test program. Stack Gas Volumetric

Flow The velocity

of the gas stream

will be determined

according

to EPA Reference

Method 2 by reading

the instantaneous

velocity

head with an inclined

manometer

at each sampling point with a calibrated

S-type

pitot tube attached

adjacent

to the sample nozzle. The stack pressure

will be measured

with the static side of an S-type pitot tube. A calibrated

pyrometer

will be used to measure

stack temperature

at each sampling point. The stack will be tested for cyclonic

flow according

to EPA Reference

Method

2. Stack Gas Molecular

Wei9• The carbon

dioxide

and oxygen

concentrations

will be determined

using EPA Reference Method 3. A grab sample

of the flue gas will be extracted

from the gas stream

during each test run and analyzed

using a Fyrite analyzer.

The molecular

weight of the gas will be calculated

using the moisture,

oxygen

and carbon

dioxide

content

and the measured 53stack gas temperature.

The Fyrite sampling

system

will be verified

to be leak free prior to the analysis. Moisture Content

Method

4 The moisture

content

used for calculating

the gas stream flow rate will be determined

by measuring the amount

of condensed

moisture

in the stainless

steel condenser

and silica gel impinger

in the sampling

train as described

in EPA Reference

Method

4 at the completion of each test. A minimum

of 21 standard

cubic feet will be sampled

at a rate no greater

than 0.75 cfm.
Ice is placed

around

the condenser

and impinger.

The outlet temperature

of the impinger is monitored

and recorded

throughout

the duration

of the testing to verify the temperature is less than 68 ° F. Sulfur Dioxide

Method

613, A Western

Research

(or equivalent)

SO2 Method

6C analyzer

(or comparable)

will provided continuous

analysis

of SO2 in the gas stream.

The basic analytical

principle involves quantitative

measurement

of the absorption

of UV radiation

by SO2 molecules. The analyzer

uses a single light source,

which emits an appropriate

wavelength, illuminating the sample

cell through

which the sample

is continuously

passed.

Narrowband optical filters are rotated

through

the beam, and the radiation

passed

through

the optical filters and sample

cell is detected

by a single photo-detector.

The signal pulses from the photo-detector

are separated

by a multiplexor

into a measuring

channel

and a reference channel.

A log ratio amplifier

computes

the logarithm

of the input signal ration, producing

a signal that is proportional

to the SO2 concentration.

The dual-range analyzer has a digital readout,

as well as 0-10.0 V DC output terminals.

The full scale of the instrument

will be set at high level calibration

gas ppm value as required.

54QA / QC Procedures Specific quality assurance

/ quality control procedures

will be adhered

to during this test project to provide

valid and scientifically

defensible

data. For any environmental

field and laboratory

measurement,

a degree

of uncertainty

exists in the data due to inherent limitations of the measurement

systems

employed.

The objective

of a QA/QC

program is to produce

data of known

precision,

accuracy,

representation,

completeness

and comparability. The objective

in this test project

is to determine

compliance

with applicable air permit requirements.

The final data user in this project will be the State of Georgia Department

of Environmental

Quality. The following

section

details all QC procedures

to be followed

during the sampling. Velocitv=/Volumetric Flow RatP, Volumetric flow rates will be determined

during each isokinetic

test run. The following QC steps will be adhered

to during these tests:
® Reported

duct dimensions

will be checked

by physical

measurements

to determine cross-sectional duct area. Pitot tube coefficients

are determined

based on physical

measurement

techniques as delineated

in Method

2 before and after each test. The Type-S

pitot tube are visually

inspected

before and after sampling. The pitot tube is installed

on the sampling

probe with the proper

orientation

and spacing from the sampling

nozzle. Before each series of tests, thermocouple

readings

for the silica gel impinger

exit temperature are checked

against

an N.I.S.T.

traceable

thermometer. The oil manometer

is leveled

and zeroed before each test run. Both legs of the pitot tube are leak-checked

before and after sampling. Proper orientation

of the pitot tube is maintained

while making

measurements.

The roll and pitch axis of the pitot tube is maintained

at 90 o to the flow. An average

velocity

pressure

reading

is recorded

at each point instead

of recording extreme high or low values. The pitot/manometer

umbilical

lines are inspected

before and after sampling

for moisture condensate.

Lines are cleared

if moisture

is found. Molecular Weiqht

Determination

-__Fyrite

Anal sy• The carbon

dioxide

and oxygen

concentrations

are determined

using EPA Reference 55Method 3. A sample

of the flue gas is extracted

from the gas stream

during each test. The samples

are analyzed

with a Fyrite gas analyzer.

The following

QC steps are adhered to during these tests: The sampling

train is leak checked

before and after each sample

is taken. The samples

are run in triplicate

for accuracy. Standardization is performed

to audit the reagents

and the operators

technique.

A known mixture

of CO2 and 02 is analyzed

and repeated

with 3 consecutive

values +/- 0.5 percent

of the known value. Two NIST traceable

gas cylinders

are run against

the instrument

to audit the accuracy of the analyzer

and the analyzer

operator

technique.

One cylinder contains 2 to 4 percent

02 and 14 to 18 percent

CO2. The second

cylinder

contains 2 to 4 percent

CO2 and about 15 percent

02. I•/Ioisture Determination Stack gas moisture

content

(B•vs) is determined

by dividing

the mass of moisture collected by the impingers

or stainless

steel condenser

and silica gel impinger

by the standardized volume

of gas sampled.

The following

QC steps are adhered

to during these tests:

® The indicating

silica gel is fresh for the first run and periodically

inspected

and replaced during runs, if needed. The analytical

balance

is placed in a clean, motionless

environment

for weighing. The balance

is leveled

and zeroed if necessary

before each weighing. Preliminary silica gel impinger

tare weights

and post-run

weights

are weighed

to the nearest 0.1 g. Before each series of tests, thermocouple

readings

for the silica gel impinger

exit temperature are checked

against

an N.I.S.T.

traceable

thermometer. The silica gel impinger

gas temperature

is maintained

below 68°F and recorded

at every traverse

point. Each impinger

is wiped of surface

moisture

before post-run

weighing. The volume

of liquid captured

is measured

using a graduated

cylinder

with 1- milliliter increments. Sulfur Dioxide

Determination The sulfur dioxide

concentrations

will be determined

using EPA Reference

Method

6C. A sample

of the flue gas was extracted

from the gas stream

during each test. Moisture 56will be removed

form the sample

and analyzed

on a dry basis with an Instrumental

gas analyzer. The following

QC steps were adhered

to during these tests:
® Only analyzers

that have a resolution

or sensitivity

of at least < 2.0% of full-scale range are used.

® Upon the SO2 analyzers

initial use in the field, an interference

check was conducted. The reference

calibration

gases used in this test program

are certified

following

EPA Protocol Number

1 analysis.

Copies

of the calibration

gas certifications

are included in the instrument

calibration

section. The high level gas was equal to the calibration

span gas. The mid level gas was between

40 and 60 % of the calibration

span gas. The low level gas was < 20% of the calibration

span gas. In accordance

with EPA Method

6C a three-point

(i.e., Zero, mid-, and high-range) analyzer calibration

error was conducted

on each reference

analyzer

prior to initiating the compliance

testing.

These

checks

were conducted

(after final calibration adjustments

were made) by injecting

the calibration

gases directly

into each gas analyzer

and recorded

the responses. The analyzer

calibration

error was less than + 2.0% or + 0.5 ppm of the calibration span gas for the zero, mid-range,

and high-range

calibration

gases. The probe material

was stainless

steel. The probe, filter and sample

line temperature

was maintained

above the dew point by heating,

prior to sample

conditioning. The sampling

system

bias was less than + 5.0 % or of the calibration

span gas for the zero and upscale

calibration

gases (+ 0.5 ppm absolute

difference). The system

response

time was calculated

during the initial sampling

system

bias. The drift for either the low-level

and mid-level

or high-level

gases was less than + 3.0% or of the calibration

span gas (+ 0.5 ppm absolute

difference). The sampling

system

was purged

> 2 times the system

response

time before each test run. Sample flow rate was maintained

within 10% during the entire test period. Data is recorded

at 1-minute

intervals. All data collected

was within the calibration

span gas. @

@

57TEST CALCULATIONS EQUATIONS

2.3.4.5. Ps Pbar+(Pg/13.6)=( +

/13.6) Prn= Pbar +(&H/13.6)=( +

/13.6) Vmste=l 7.64 Vm Y (Pr•/-I-r,)=l

7.64*(

)*( Vwstd 0.04707

Vio=0.04707"( )= Bws-- Vwstd/(Vmstd

+ Vwstd)=(

)/(

+

)*(

/ )=

For saturated

sources

(No. 6 8 only): If No. 6 is Jess than No. 5 source is considered

saturated 6. TBws= (1 0 6"37" {2827/(ts+365)}/Ps=

1 0 6"37"{2827/(

+365)}/( 7. TVwstd= V,•std*( TB,,vs/1-

TBws)=(

)*( 8. TV•c= TVwstjO.04707

=(

/ 0.04707

)= 9. )/(1

12.13.14.15.16.

19.
20. )*(528/ Me= 0.44(%CO2)+0.32(%O2)+0.28((100-(%CO2+%O2)) =0.44(

)+0.32(

)+0.28(100-(

+ )= Ms= Me (1- Bws)+18

Bws=(

)*(1-

)+18( Vs= 85.49 Cp* •/AP 85.49*(0.84)*(

)%/(

/((

)( Qa Vs As 60=(

)(

)(60)= es Qa (1- Bws) (528/Ts)*(Ps/29.92)=( )(1- Cs=0.01543" (Mn/V•std)=0.01543*( /

)= PMR= Cs* es (60/7000)=( )*(

)*(60/7000)= Vn=T•/Ps*{(0.002669) V,c+ (V• Y P=)/Tn•)} =( /

)*{(0.002669)( )+(

)(

)(

)/(

)}= 17. I=Vol00/(60*e*Vs.Ao)=( )100 / (60)(

)(

)(

)= 18. %EA= 100%* {(%O2)-0.5*(%CO)}

/ {0.264(%N2)

(%02)+ 0.5*(%CO)} 100%*{( )-0.5(

)} / {0.264(

).(

)+0.5( Cs @ 50% EA= C•/1 -[{1.5(%02)-0.133(%N2)-0.75(%CO)}/20.9] =( / 1-[{1.5(

)-0.133(

)-0.75( Ib/mmBtu= (C•/7000)*{(Fd*20.9)/(20.9-%O2)} =(

/7000)*{(

)*20.9)/(20.9-( )}=

)))= )*( /29.92)=

)}/20.9]=

58ACECAvg CDirCGas CoCMCMA

Cv
CSDSBSB•MWSO2 Ibs/hr 385.1 x 10 eNOMENCLATURE FOR SULFUR

DiOXiDES

(Method

6C) Analyzer calibration

error, percent

of calibration

span. Average unadjusted

gas concentration

indicated

by recorder

for the test run, ppmv. Measured concentration

of a calibration

gas (low, med, high) when introduced in direct calibration

mode, ppmv Average effluent gas concentration

adjusted

for bias, ppmv. Average of initial and final system calibration

bias(or 2-point system calibration error) check responses

form the low level (zero) calibration

gas, ppmv. Average of initial and final system calibration

bias (or 2-point system calibration error) check responses

for the upscale

calibration

gas, ppmv. Actual concentration

of the upscale

calibration

gas, ppmv. Measured concentration

of a calibration

gas (low, mid, or high) when introduced in system calibration

mode, ppmv. Manufactured certified

concentration

of a calibration

gas (low, mid, or high), ppmv. Calibration span, ppmv. Drift assessment,

percent of calibration

span. System bias, percent of calibration

span. Post-run system calibration

error, percent

of calibration

span. Pre-run system bias, percent

calibration

span. Molecular weight of SO2, which is equal to 64.06 Sulfur Dioxide mass rate in pounds per hour Conversion factor

60ACE(7Eol)

SB(7E=2)

D(7Eo4) EQUATIONS FOR

SO2

(Method

6C) CDir Cv x 100 CS (

)/( Cs •,r X 100 CS

)/( SBfinal SBiJ )X
)X 100

100

CGas(7E-5) ( CAvg Co ) X CMA / (CM Co) )x(

)/(
16. SO2 Ibs/dscf

Cgas X MW / 385.1 x 10 6 ) x (64.06)/(385.1

x 106)
17. S02 Ibs/mmBTU=S02

Ibs/dscf

x F-factor

x ((20.9/(20.9-02))

x (

)x((20.9/20.9-( )) 17.

21. S02 Ibs/mmBTU=S02

Ibs/hr/Heat

Input mmBTU/hr ( )/( S02 Ibs/hr

S02 Ibs/dscf

x DSCFM

x 60

= x (

x (60)

61QSTI Certification Documentation

62636400

00

65 d66 dGas Analysis

Instrument Calibration Data

67Analyzer Calibration Error

68Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6/24/08

Analyzer

Calibration Error

Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run Sulfur Dioxide

Monitor Full Scale: Cylinder Number

276.7 ppm Method 6C Serial Number: AMETEK

900 $141 Reference Gas

Analyzer

Difference

Calibration Concentration Response Error (%) AAAA-aaaa/cg5 0.0 ppm

-0.2 ppm

-0.2 ppm

-0.07 % CC41911/cg8 124.5 ppm

124.0 ppm

-0.5 ppm

-0.18 % CC216106/cg2 276.7 ppm

276.7 ppm

0.0 ppm

0.00 %

69System Bias

and

Drift

70Sampling System

Bias

and

Drift

Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6 Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run
Monitor Type Analyzer

Cal Response
-0.2 ppm 124.0 ppm

Initial Cal Value 2.4 ppm 122.6 ppm

Pre Run Bias (%) 0.94 % -0.51%

FinalValue 1.5 ppm 122.9 ppm

Post Run Bias (%) 0.61% -0.40 %

Total Run Drift (%) 0.33 % 0.11%

71Sampling System

Bias

and

Drift

Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6 Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run 2 Monitor Type Analyzer

Cal Response
-0.2 ppm 124.0 ppm

Initial Cal Value 1.5 ppm 122.9 ppm

Pre Run Bias (%) 0.61% -O.4O %

Final Cal Value
o7 ppm 122.3 ppm

Post Run Bias (%) 0.69 % -0.61%

Total Run Drift (%) 0.07 % 0.22 %

72Sampling System

Bias

and

Drift

Test Performed

For: General Shale Brick Rome, GA Kiln A Compliance Date:6/24/08 Test Performed

By: Entec Services,

Inc. Birmingham Division Test Trailer 904 Tommy Lotz, Jr. Run 3
Monitor Type Analyzer

Cal Response
-0.2 ppm 124.0 ppm

Initial Cal Value 1.7 ppm 122.3 ppm

Pre Run Bias (%) 0.69 % -0.61%

Final Cal Value 1.6 ppm 123.7 ppm

Post Run Bias (%) 0.65 % -0.11%

Total Run Drift (%)
0.04 % 0.51%

73Calibration Gas

Certificates

74Part

Number: Cylinder Number: Laboratory: Analysis Date:

CERTIFICATE OF ANALYSIS Grade of Product:

EPA

Protocol E02NI99E15A3823 CC216106 ASG Port Allen-LA Mar06,2007 Expiration

Date: Mar 06, 2009 Reference

Number: Cylinder Volume: Cylinder Pressure: Valve Outlet: Airgas Specialty 6ases 1075 Cinclare Drive Port Allen, LA 70767 (225) 388-0900 FAX: (225) 368-0959 www.airgas.com 83-124088475-11 144 Cu.Ft. 2015 PSIG 66O

Certification performed in accordance with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed. Aea analytical Interferences.

This cylinder has total analytical uncertainty as stated below with a confidence level

y cal Methodology does not require correction for •nere are Ilo significant Impurities which affect the use of this calibration mixture. All concentration

are on a volume/volume

basis unless otherwise noted. Do Not Use This Cylinder below 150 psig.i.e. Mega Pascal

NTRM 00051215

SG91271 IOBAL

251 7PPM SULFUR DIOXIDE/NITROGEN JUl 01 2009 ANALYTICAL EQUIPMENT •c•al Prin•ip.le Las• Multipoint

Calibration

............ FTR Feb 22 •'

'' Triad Data Available

Upon Request Notes:
QA Approval

Page of 83-124088475-11

75CERTIFICATE OF ANALYSIS Grade of Product:

EPA

Protocol Part Number:

E02NI99E15A0005 Reference

Number:

83-124130319_3 Cylinder Number:

CC41911 Cylinder Volume:

144 Cu.Ft. Laboratory: ASG Port Allen LA

Cylinder Pressure:

2015 PSIG Analysis Date:

Apr 04, 2008 Valve Outlet:

660 Expiration Date: Apt 04, 2010 Airgas Specially Gases 1075 Cinclare Drive Port Allen, LA 70767 225.388,0900 FAX: 225,388.0959 w•V.airgas.c0m

Certification performed in accordance with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed, Analytical Methodology

does not require correction for Component
SULFUR DIOXIDE NITROGEN analytical interferences.

This cylinder has total analytical uncertainty as stated below with confidence revel of 95%. There are no significant impurities which affect the use of this calibration mixture. All concentrations

are on a volume/volume

basis unless otherwise noted, DoNot Use This Cyfir;der below 150 p•ig.t.e. Mega Pascal

Instrument/Make/Model FTIRMSO2 ANALYTICAL

RESULTS Requested Actual

Protocol Concentration Concentration

Method 125.0 PPM

124.5 PPM

G1 RalanceCALIBRATION STANDARDS Type Lot ID

Cylinder No

•oncentration Expiration

Date NTRM 06061116

CC206013

475.0PPM SULFUR DIOXIDE/NITROGEN ANALYTICAL EQUIPMENT Analytical Principle Total Relative Uncertainity +/- 1% NIST Traceable

Sep 01,2010
Last Multipoint

Calibration FTIR Mar 20, 2008 Triad Data Available

Upon _Request Notes::••.,••
QA Approval

Page of 83-124130319-3

76Equipment Calibrations

77SAMPLING AND ANALYTICAL

EQUIPMENT

CALIBRATIONS All of the emission

testing

equipment

used was calibrated

according

to the procedures outlined in the EPA CFR 40 Part 60 Appendix

"A" and the Quality Assurance

Ha___.•ndbook for Air Pollution

Measurement

System,o,,

Volume

III, EPA-600/4-77-O27b. T_vpe=S Pitot tube Calibrations The pitot tubes used for flow velocity

measurement

were checked

for dimensions

to verify a pitot coefficient

Cp of 0.84. Documentation

of the calibration

and calibration check for dimensional

measurements

is provided. Nozzle Calibration Sampling nozzles

were checked

visually

for nicks or damage

and for dimensional calibration prior to testing

by measuring

the nozzle

diameter

in at least three planes using a Vernier

micrometer.

Measurements

must agree to within +0.004-inches. Documentation is provided

on the individual

data sheets. Temperature Measuring

Device

Calibrations Each temperature

sensor

(stack gas, dry gas meter,

and impinger

exit) and readout was calibrated

at a minimum

of two points over the anticipated

range of use against

a NIST-traceable mercury-in-glass

thermometer.

All sensors/readouts

were calibrated prior to field sampling.

Stack gas thermocouples

must agree within 1.5% (expressed

in °R) of the reference

thermometer

through

out the entire calibration

range.

Dry gas meter thermocouples

must agree within +5.4°F

and impinger

exit thermocouples

must agree within ±2°F. Documentation

is provided. .Dry Gas Meter Calibrations Dry gas meters

were fully calibrated

against

a set of calibrated

orifices.

After assembly and leak checking,

the console's

pump is allowed

to run for 15-minutes

to warm up the dry gas meter and pump. For a pre-test

full calibration,

data are collected

at five (5) orifice manometer

(/•H) settings

of approximately:

0.32, 0.67, 1.2, 2.0, and 3.9 inches of H20. Gas volumes

of at least 5 ft 3 are used at all the orifice settings

and critical vacuums were obtained

at all of the calibration

points.

The individual

gas meter correction factors

(y•) are calculated

for each orifice setting and averaged.

The method requires that each of the individual

correction

factors

fall within ±2% of the average 78correction factor, or the meter be cleaned,

adjusted

or repaired

and recalibrated.

The orifice pressure

differential

(&H@) that equates

to 0.75 cfm of air at 68°F and 29.92 inches Hg is calculated

and along with the average

correction

factor (y) is marked

on the meter console. For the post-test

calibration

the alternative

Method

5 post-test

calibration

procedures were used (Emission

Measurement

Center Approved

Alternative

Method

ALT-009). Prior to the initial run a y-factor

check was performed

to ensure

that the meter was operating according

to the original

calibration

to within 3% of the original

y-factor.

79,<

•oooqo

2• ooooc

80

• •ggo•

0ENTEC Services,

inc. 16-D Commerce Ave.Hueytown,

Alabama 35023 Calibration Date:

12/31/2007 Calibrated by:

Tom Lotz

Entec Services

Temperature

Annual Thermocouple

Calibrations

Difference

Within **Reference Thermocouple ID Number

Source

Temperature

Temperature TC-1 ambient

66

65 TC-2 ambient

66

65 TC-3 ambient

66

66 TC-4 ambient

66

67 TC-6 ambient

66

66 TC-7 ambient

66

65 TC-8 ambient

66

65 TC-11 ambient

66

65 TC-12 ambient

66

66 TC-13 ambient

66

67 TC-14 ambient

66

67 TC-15 ambient

66

65 TC-16 ambient

66

65 TC-17 ambient

66

65 TC-19 ambient

66

66 TC-20 ambient

66

65 TC-21 ambient

66

67 TC-22 ambient

66

66 TC-23 ambient

66

65 TC-24 ambient

66

65

Degrees F

0

0

0

0

0

Tolerance Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesYes TCS ambient

66

65 Yes TCS 2

ambient

66

65 Yes TCS 3

ambient

66

65 Yes TCS 4

ambient

66

67 Yes TCS 5

ambient

66

66

0

Yes TCS 7

ambient

66

65 Yes TSC -8

ambient

66

65 Yes TSC -9

ambient

66

65 Yes TSC -10

ambient

66

66

0

Yes TSC -11

ambient

66

65 Yes TSC -12

ambient

66

•5 Yes TSC -13

ambient

66

66

0

Yes TSC -14

ambient

66

65 Yes TSC -15

ambient

66

65 Yes TSC 16

ambient

66

67 Yes F;uke Hand Held

ambient

66

66

0

Yes Fluke Hand Held 2

ambient

66

66

0

Yes Fluke Hand Held 3

ambient

66

66

0

Yes Temperature tolerance within +/- 2 F of acceptable ranges for all thermocouples. Note: NIST Traceable Digital Thermometer

Serial Number 72083241 was used as reference temperature 81ENTEC Services,

nc. 16-D Commerce Ave.Hueytown,

Alabama 35023 Calibration Date:

12/31/2007 Calibrated by:

Tom Lotz Annual Hot Box Thermocouple

Calibrations
Entec Services

Temperature

**Reference

Thermocouple ID Number

Source

Temperature

Temperature HOTBOX ambient

66

67 HOTBOX 2

ambient

66

67 HOTBOX 3

ambient

66

66 HOTBOX 4

ambient

66

65 HOTBOX 5

ambient

66

67 HOTBOX 6

ambient

66

67 HOTBOX 7

ambient

66

66 HOTBOX 8

ambient

66

66 HOTBOX 9

ambient

66

65 HOTBOX 10

ambient

66

65 HOTBOX 11

ambient

66

67 HOTBOX 12

ambient

66

67 HOTBOX 13

ambient

66

65 HOTBOX 14

ambient

66

67

Difference Degrees F 222

2

2

0

Within Tolerance Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Temperature tolerance within +1- 2 F of acceptable

ranges for all thermocouples. Note: NIST Traceable Digital Thermometer

Serial Number 72083241 was used as reference temperature

82ENTEC Services,

inc. 16-D Commerce Ave.Hueytown,

Alabama 35023 Calibration Date:

12/31/2007 Calibrated by:

Tom Lotz Annual Gooseneck

Thermocouple

Calibrations Entec Services

Temperature

**Reference

Thermocouple ID Number

Source

•erature

Te•erature GN-1 ambient

65

65 GN-2 ambient

65

66 GN-3 ambient

65

65 GN-4 ambient

65

64 GN-5 ambient

65

65 GN-6 ambient

65

64 GN-7 ambient

65

63 GN-8 ambient

65

65 GN-9 ambient

65

66 GN-10 ambient

65

65 GN-11 ambient

65

65 GN-12 ambient

65

66 GN-13 ambient

65

64 GN-14 ambient

65

64 GN-15 (Mini HB

ambient

65

66 GN-16 (Mini HB)

ambient

65

65 GN-17 ambient

65

64 GN-18 (Mini HB)

ambient

65

66 GN-19 (Mini HB)

ambient

65

66 GN-20 (Mini HB)

ambient

65

65 GN-21 ambient

65

64 ambient 65

65

Difference De_•gLees F

0

0

0

2

2

Within Tolerance Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Temperature tolerance within +/- 2 F of acceptable

ranges for all thermocouples. Note: NIST Traceable Digital Thermometer

Serial Number 72083241 was used as reference temperature

83Safety DocumentationPollution Control System Evaluation

and Source Emissions

Testing DA LY PROJECT

SAFETY

MEETING

FORN! (Toolbox Safety Meeting) Date: •

Job No.',,•(•{•

\

Plant:

•c•z'-•.•i,•/< Topic of Safe•

.eeting:

••

,.• ••

uired PPE: (Check

Required) Hard Hat __•__-Safety

Harness

or Fall Protection __•, Steel Toed Boots Special

Clothing

(Blues / Greens

/ Tyvex) .__• Safety Glasses CO Personnel

Monitor ._____• Ear Plugs Respirator

(w/PM or Gas Cartridges) •._•-•GIoves / Hot Gloves Long Sleeve

Shirt Other Requirements;

(List as needed) Attendees: Name (Print)
•)4)5)6)7)8)9) Facility required

additional

safety training

prior to entering

site: Yes or• Video Safety Class•

Literature Training

Class (MSHA) Rev 3: -3-06 86Test Nomenclature and

Calculations

87NOMENCLATURE AsAnACFM E•wsCsCaCpz•H APdscf EAE/Btu FKp

PbarPgPmPMR PstdQaQstdTBws

TmTstd
V,VmaVmstd VsVwcstd Vwsgstd WimpWsg Y Cross-sectional

area of stack, square feet Cross-sectional area of nozzle, square feet Actual cubic feet of gas per minute at stack conditions Proportion by volume of water vapor in gas stream Particulate concentration

in stack gas, gr/dscf Particulate concentration

in stack gas, gr/acf Pitot tube coefficient Pressure drop across orifice meter, inches water Velocity head of stack gas, inches water Cubic feet of dry gas corrected

to standard

conditions Excess Air Particulate Emission

Rate, pounds/mmBtu F-factor, 9640 dscf/MMBTU's

of heat input Constant (85.49) Total particulate

matter collected,

mg Molecular weight of stack gas; dry basis, Ib/Ib-mole Molecular weight of stack gas; wet basis, Ib/Ib-mole Percent of isokinetic

sampling Barometric pressure,

inches mercury Stack static pressure,

inches of water Barometric pressure

of dry gas meter, in. mercury Particulate mass rate, pounds/hour Absolute stack gas pressure,

inches mercury Barometric pressure,

standard

conditions,

29.92 inches Hg Volumetric flow rate, actual conditions,

ACF/min Volumetric flow rate, standard

conditions,

scf/min Volumetric flow rate, dry standard

conditions,

dscf/min Theoretical water vapor in the gas stream based on saturated

stack conditions,

proportion

by volume (dimensionless) Theoretical volume of water collected

based on saturated

stack conditions,

ml Theoretical volume

of water vapor in the gas sample

based on saturated

stack conditions, corrected to standard

temperature

and pressure,

scf Absolute average

dry gas meter temperature,

degree R (460) Absolute average

stack gas temperature,

degree R (460) Absolute temperature

at standard

conditions,

528 R Total sampling

time, minutes Total volume collected

in impingers

and silica gel, gr Volume of gas sampled

through

gas meter, cubic feet Volume collected

at stack conditions

through

nozzle, ACF Stack gas volume sampled,

ACF Volume of gas sampled

through

gas meter, cubic feet Average stack gas velocity,

feet/sec Volume of water vapor in gas sampled

from impingers,

standard

cubic feet Volume of water vapor in gas sampled

from silica gel, standard

cubic feet Total volume collected

in impingers,

gr Total volume collected

in silica gel, gr Dry gas meter calibration

factor

88TEST CALCULATIONS Kiln A- Run 1 EQUATIONS 1. Ps Pbar +(Pg/13.6)

,• 0"•,• 2. Pm= Pbar +(AH/13.6)

g • ,'7,•, 3. Vmstd=17.64*

Vm* Y* (Pro/Tin)

17.64"( 4a. Vwc(std)

0.04706

Wim p

0.04706*( 4b. Vwsg(std)

0.04715

Wsg

0.04715"( 5. Bws= Vwstd/(Vmstd+

Vwstd)

'•. 64 For saturated

sources

(No. 6 8 only): & TBws= (106.37. {2827/(ts+365)}/p• 7• TVwstd= Vmstd*( TBws/1- TBws) 8_.:, TVlc= TVwstd/0.04707

10.11.
12.

14.15. /13.6)= )-- 2o 5E5 06'37{2827/( +364,8)} / )*( )/( Ud= 0.44(%COJ+0.32(%O2)+0.28((100-(%CO2+%O2)) 0.44(

4o,• )+0.32(

•o,•

)+0.28(100-( Ms=Md(1-Bws)+laBws Z1•,3£

)*(1-

1041 Vs= 85.49 Cp* •/AP •/[Ts / (Ms* Ps)] )/(1)= 4, S + )+18( 85.49*(0.84)*( Qa Vs A• 60 Qs Qa* (528/Ts)*(Ps/29.92) )*(528/ Qstd Qa (1- Bws) (528/Ts)*(Ps/29.92)

=( •:•,•

)(1- Cs=0.01543" (Mn/V,•std)

0.01543"( E/Btu= (Cs/7000)*{(Fd*20.9)/(20.9-%02)} /7000)*{( )*20.9)/(20.9-( %EA= 100%* {(%OJ-0.5*(%CO)}

/ {0.264(%NJ

(%OJ+ 0.5*(%CO)} 100%*{( )-0.5(

)} / {0.264(

)-( PMR= Cs* Qstd (60/7000) )*( V•=Ts/P•*{(0.002669) V•o+ (V• Y P,•)/Ln)} / )*{(0.002669)( )+(

)( Ca=0.01543" (Mn/Vn)

0.01543*( / I=Vol00/(60*e*VZA,J )100/(60)(

)(

)*( )*(528/ ): 2t.

/29.92) )= )}=

)( )=)( )+0.5( )*(60/7000) )/(

)}=

89ACECAvgCDirCGas CoCMCMA

CvCSDSBSBfi,•al SB•MWSO2

Ibs/hr 385.1 x 10 6NOMENCLATURE FOR

SULFUR

DiOXiDES

(Method

6C) Analyzer calibration

error, percent

of calibration

span. Average unadjusted

gas concentration

indicated

by recorder

for the test run, ppmv. Measured concentration

of a calibration

gas (low, meal, high) when introduced

in direct calibration

mode, ppmv Average effluent gas concentration

adjusted

for bias, ppmv. Average of initial and final system calibration

bias(or 2-point system calibration error) check responses

form the low level (zero) calibration

gas, ppmv. Average of initial and final system calibration

bias (or 2-point system calibration error) check responses

for the upscale

calibration

gas, ppmv. Actual concentration

of the upscale

calibration

gas, ppmv. Measured concentration

of a calibration

gas (low, mid, or high) when introduced

in system calibration

mode, ppmv. Manufactured certified

concentration

of a calibration

gas (low, mid, or high), ppmv. Calibration span, ppmv. Drift assessment,

percent

of calibration

span. System bias, percent

of calibration

span. Post-run system calibration

error, percent

of calibration

span. Pre-run system bias, percent

calibration

span. Molecular weight of SO2, which is equal to 64.06 Sulfur Dioxide mass rate in pounds per hour Conversion factor

9OEQUATIONS FOR

SO2

(Method

6C) Kiln A- Run 1

ACE(7E-1)

SB(7E-2)

D(7E-4) CDi---.r "--C_v. X 100 CS C__s -___•Coir x 100 CS
SBfinal SBi[

)/

CGas(7E-5) CAvg C 0 X CMA / (C M Co) I.'B5 )=

16. S02 Ibs/dscf

Cgas x MW / 385.1 x 106 •o••(#r•4 )x(64.06)/(385.1x10

e)

17. SO2 Ibs/mmBTU=SO2

Ibs/dscf x F-factor x 20.9 / (20.9-02)) )x( )x(20.9/(20.9 ))=

17. SO2 Ibs/mmBTU=SO2

Ibs/hr/Heat

Input mrnBTU/hr )/(
21. SO 2 Ibs/hr

SO 2 Ibs/dscf x DSCFM x 60

91