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.corn 
Entec 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 

2 

3 

7 

10 

11 

12 

13 

14 

21 

27 

34 

36 

41 

42 

44 

47 

48 

49 

50 

62 

67 

68 

70 

74 

77 

85 

87 
Executive 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 

> 

0 
Detailed Test Results 
SOURCE 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 

2 

3 

4 

6C 
ENTEC 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 

4.0 

16.5 

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 

347.6 349.4 
ENTEC 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 Procedures 
Procedures 

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 

described 

measuring the amount of condensed moisture in the impingers in the sampling train as 

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 

2 

4.00 

20 

10 

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. 

10 
EPA Method 

Heated Probe 

(~248 F) 

Temperature 

Sensors 

,Wetted'i Sample Line 

Temperature 

/ (<68° F) 

Steel 

Condenser 

Empty 

Exhaust 

11 
Filter 

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 

12 
K1 (Kiln A) 

Field Data Sheets 
K1 (Kiln A) 

Test Run No. 1 

14 
ENTEC 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 

1-1 

1-2 

1-3 

1-4 

1-10 

2-1 

2-2 

2-3 

2-4 

2-5 

2-6 

2-7 

2-8 

2-9 

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 

353 

354 

354 

353 

354 

351 

351 

349 

348 

346 

350 

356 

357 

356 

358 

354 

351 

352 

353 

352.7 

Meter 

68 

68.7 

67 

65 

71 

71 

70 

15 

Port/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 

AVG 

Pitot Leak Check 

Pre Test R 

Post Test 

% Moisture 

Wet Bulb Dry Bulb 

Pressure 

Checked By 
General 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 

18 
General 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 

19 
Calculation 

Test Performed For: 

General Shale Brick 

Rome, GA 

Kiln A 

Compliance 

Date:6/24/08 

Calibration 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 

2O 
K1 (Kiln A) 

Test Run No. 2 

21 
ENTEC 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 

1-1 

1-2 

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 

1-6 

1-7 

1-8 

1-9 

1-10 

2-1 

2-2 

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 

358 

355 

356 

359 

355 

353 

354 

355 

353 

353 

352 

345 

345 

345 

345 

343 

342 

340 

339 

350.2 

Meter Temp. 

70 

71 

71 

73 

71 

71 

71.2 

22 

General 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 

24 
General 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 

25 
Caiculation 

Test Performed For: 

General Shale Brick 

Rome, GA 

Kiln A 

Compliance 

Date:6/24/08 

Calibration 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 

26 
KI (Kiln A) 

Test Run No. 3 

27 
ENTEC 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 

1-1 

1-2 

1-3 

1-4 

1-5 

1-6 

1-7 

1-8 

1-9 

1-10 

2-1 

2-2 

2-3 

2-4 

2-5 

2-6 

2-7 

2-8 

2-9 

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 

347 

345 

345 

345 

346 

348 

348 

351 

350 

346 

343 

341 

0.13 0.3606 

0.06 0.2449 

0.17 0.4092 1.78 348.1 7n_n 

28 
88o°• d ° 

0 
ENTEC 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 

1-1 

1-2 

1-3 

1-4 

1-5 

1-6 

1-7 

1-8 

1-9 

1-10 

2-1 

2-2 

2-3 

2-4 

2-5 

2-6 

2-7 

2-8 

2-9 

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) 

348 

346 

354 

354 

353 

350 

349 

345 

343 

341 

340 

344 

346 

346 

347 

349 

351 

347 

345 

343 

347.1 

Meter Temp. (°F) 

3O 
General 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 

31 
General 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 

32 
Test Performed For: 

General Shale Brick 

Rome, GA 

Kiln A 

Compliance 

Date:6/24/08 

Calibration 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 

33 
Control .Room Production Data 

34 
Production 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 

3.73 

17416 

10.5 

3.81 

1 •426 

10.5 

35 
Quality Assurance / Quality 

Procedures 

Control 

36 
QA / 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. 

adhered 

The samples were analyzed with a Fyrite gas analyzer. The following QC steps were 

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. 

38 
Sulfur 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 included are 

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. 

@ 

39 
All data collected was within the calibration span gas. 

4o 
ENTEC SERVICES, |NC FIELD QA/QC CHECKLIST 

souRcE TESTED: 

PERMIT NUMBER: 

TYPE CONTROL DEVICE: •¢,i•f 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• 

Was previous test data on soume used to determine K factor? 

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

5. 

6. 

7. 

10. 

11. 

12. 

13. 

14. 

If 

Was Filter Outlet Temperature maintained at 248 +/- 250 F? not, explain 

Was Orsat or •)leak 

Ambient 02 

checked and standardization perform•.•d 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 Pitot inspected?-.•.,x• N 

performed & recorded on each field data sheet'• 

Was 

Noted Visual Defects? • 

Meter Leak Checks Performed & recorded on each field date sheet? Was Nozzle Diameter Nozzle inspected? y 

measured & recorded on each field data sheet'• 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) 

Unit(s)•_ Nominal As Left In Tol Min Max +uc IUR 

Nomillal As l:Oulld In-rol 

••--• L• ---• 

2 ]]•i--• Y• •1• 3:•1i 

:'• •i•--• 

Yii ii]i-- Qii- i ii1--7 :iii----iiJii• k ;i:1 ]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-(} 

43 
ENTEC 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 

Tank 

1 

C02 

02 

Tank 

2 

C02 

02 

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 

Actuall Net 

Net Volume 

Known 

Value 

44 
Certificate 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 

which 

Relative 

ever 

Uncertainty__o.f 

is lower. 

Ap•aly_Jj_C__a.I Value: +I- t% of component or +1- 0,02% of absolute, 

Primary Standard gas mixtures are traceable to N.I,S,T weights and/or N.I,S,T reference rnat#,ria gas mixture 

Ap•:•r•'¢at Sigaature 

45 
Certificate 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 

which 

Relative UncertaintE of Analytical Value: +l- I% of component or +/. 0,02% of absolute, ever is lower, 

Primary Standard gas mfxtures are traceable to N.I.S.T weights and/or N.I.S.T reference gas mixture materials, 

,( ,7 ( 

46 

ENTEC 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 calibration span for all 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):, 

48 
Date 

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 

co 

CO2 

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 

49 
Test Protocol 
Pollution 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 

51 
En 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 

52 
Scope 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 

53 
stack 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. 

54 
QA / 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 

55 
Method 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 

56 
will 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. 

@ 

@ 

57 
TEST 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]= 

58 
ACE 

CAvg 

CDir 

CGas 

Co 

CM 

CMA 

Cv 

CS 

D 

SB 

SB• 

MW 

SO2 Ibs/hr 

385.1 x 10 e 

NOMENCLATURE 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 

60 
ACE 

(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) 

61 
QSTI Certification Documentation 

62 
63 
64 
0 

0 

0 

0 

65 

d 
66 

d 
Gas Analysis Instrument Calibration Data 

67 
Analyzer Calibration Error 

68 
Test 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 % 

69 
System Bias and Drift 

70 
Sampling 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% 

Final 

Value 

1.5 ppm 

122.9 ppm 

Post Run 

Bias (%) 

0.61% 

-0.40 % 

Total Run 

Drift (%) 

0.33 % 

0.11% 

71 
Sampling 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 % 

72 
Sampling 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% 

73 
Calibration Gas Certificates 

74 
Part 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 

analytical 

Certification 

Interferences. 

performed in 

This 

accordance 

cylinder 

with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed. Aea 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 

•c•al 

ANALYTICAL EQUIPMENT 

Prin•ip.le Las• Multipoint Calibration 

............ FTR Feb 22 •' '' 

Triad Data Available Upon Request 

Notes: 

QA Approval 

Page of 83-124088475-11 

75 
CERTIFICATE 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. 

DoNot 

All 

Use 

concentrations are on a volume/volume basis unless otherwise noted, 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 

Ralance 

CALIBRATION 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 

Notes::••.,•• Triad Data Available Upon _Request 

QA Approval 

Page of 83-124130319-3 

76 
Equipment Calibrations 

77 
SAMPLING 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 

78 
correction 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• 

0 
ENTEC 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 

Yes 

Yes 

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 

81 
ENTEC 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 

2 

2 

2 

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 

82 
ENTEC 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 

D e_•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 

83 

Safety Documentation 
Pollution 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 

•._•-•GIoves Respirator (w/PM or Gas Cartridges) / 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 

86 
Test Nomenclature and Calculations 

87 
NOMENCLATURE 

As 

An 

ACFM 

E•ws 

Cs 

Ca 

Cp 

z•H 

AP 

dscf 

EA 

E/Btu 

F 

Kp 

Pbar 

Pg 

Pm 

PMR 

Pstd 

Qa 

Qstd 

TBws 

Tm 

Tstd 

V, 

Vma 

Vmstd 

Vs 

Vwcstd 

Vwsgstd 

Wimp 

Wsg 

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 

88 
TEST 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) 

)/( )}= 

89 
ACE 

CAvg 

CDir 

CGas 

Co 

CM 

CMA 

Cv 

CS 

D 

SB 

SBfi,•al 

SB• 

MW 

SO2 Ibs/hr 

385.1 x 10 6 

NOMENCLATURE 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 

9O 
EQUATIONS 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