GENERAL SHALE BRICK'S 

BRICK KILN 

IN 

LOUISVILLE, KENTUCKY 

ON 

DECEMBER 18, 2001 
TABLE OF CONTENTS 

Section 

2 

3 

4 

Page 

Introduction and Executive Summary 1 

Test Results 

Summary of Test Results 

Table 

1 Summarized Test Results .................... 2 

2 Summarized Sulfur Dioxide Results 3 Graph 

1 Brick Kiln Emissions (Sulfur Dioxide) 4 Computer Input Parameters 

................... 5 

Complete Results 

Sampling and Analytical Procedures ................. 7 Figures 

1 Stack Breeching and Sample Point 

Location .................................. 12 

Field Data 

SO2 Field Data Sheets .............................. 13 Nomenclature & Equations SO2 ...................... 25 Nomenclature & Equations O•/CO2 ................... 26 

5 

6 

Plant Production Data 

............................. 27 

QA/QC Procedures and Results 

Calibrations and Gas Certificates ................... 28 

L 
REPORT CERTIFICATION 

The sampling and analysis performed for this report were carried out under my direction and hereby certify that the test report is authentic•/a,cyrate. Date: ,•'VL ,•1,•7 Signature: ,•.'/••, Torn• Lotz, Jr. / 

Program Manager 

have reviewed the testing details and results in this report, and hereby certify that the test report is authentic and accurate to the best of my knowledge. 

Date: ..)5:,.,.• c3 

Thomas E. Lotz 

Senior Program Manager 

SOURCE OWNER: 

OPERATOR'S NAME/LOCATION: 

SOURCE NAME: 

SOURCE IDENTIFICATIONS: 

TESTS PERFORMED: 

REFERENCE METHOD TESTS: 

TEST SUPERVISOR: 

DATES TESTS CONDUCTED: 

OWNER'S REPRESENTATIVE: 

General Shale Brick 

General Shale 

Louisville, Kentucky 

Brick Tunnel Kiln, plant 38 

Permit# 153-97 TV Emisssion Unit U7 

Compliance Test 

Sulfur Dioxide EPA Method 6C 

Mr. Tommy Lotz, Jr. 

December 18, 2001 

Mr. Phil Towles Environmental Specialist 

iii 
iNTRODUCTiON 

AND 

EXECUTIVE SUMMARY 
iNTRODUCTiON & EXECUTIVE SUMMARY 

Kilkelly Environmental Associates (KEA) was contracted by General Shale Brick to 

perform source emissions testing on the Brick Tunnel Kiln, plant 38 (permit# 153-97 TV 

Emisssion Unit U7 ) operated by General Shale and located in Louisville, Kentucky. 

Stack gas concentrations of sulfur dioxide (SO2) were measured. The SO2 emission 

limit for the Brick Tunnel Kiln is 28.63 grains/100 DSCF at 0% oxygen. 

The control devices associated with the kiln are a lime slurry scrubber in line with a 

baghouse before exhaust. SIC Code 3251 Face Brick/Structural Manufacture of brick 

from shale. The manufacturing process involves mining, grinding, screening, and 

blending of the raw materials followed by forming, cutting or shaping, drying, firing (or 

curing), cooling, storage, and shipping of the final products. 

Mr. Tommy Lotz, Jr. supervised the KEA test team in performing the emissions tests 

and collecting the test data on December 18, 2001. Mr. Phil Towles representing 

General Shale Brick, coordinated the test program with process operations. Ms. Jeani 

Bryant of the Air Pollution Control District of Jefferson County observed the tests. 

The testing started at 0742 and ended at 1056. The sulfur dioxide results of 15.14, 

18.40, and 21.50 grains per 100 dry standard cubic foot at 0% oxygen resulted in an 

average of 18.17 grains per dry standard cubic foot which is 64% of the allowable 

standard of 28.63 grains per dry standard cubic foot. 
SUMMARY OF TEST RESULTS 

The following is a summary of the sulfur dioxide emissions on the Brick Tunnel Kiln 

stack conducted on December 18, 2001. For complete information, see the following 

table (Table 1). 

Run Numbers Run 1 Run 2 Run 3 Average 

Date 12-18-01 12-18-01 12-18-01 

Time 0742 -0842 0849-0949 0956-1056 

Sulfur Dioxide, ppm 28.58 39.86 

Sulfur Dioxide, gr/100 dscf 

Sulfur Dioxide, gr/100 dscf 

@ 0% oxygen 

Oxygen, % 

Carbon Dioxide, % 

Allowable SO 2 Conc., 

gr/100dscf@ 0% O• 

% of Alowable 

3.33 

15.14 

3.48 

18.40 

16.31 16.95 

3.54 3.14 

28.63 28.63 

53 64 

34.46 

4.01 

21.50 

17.00 

3.09 

28.63 

75 

30.97 

3.61 

18.17 

16.75 

3.26 

28.63 

L 

2 I•CE•A 
TEST RESULTS 
KILKELLY ENVIRONMENTAL ASSOCIATES 

P,O. BOX 426 

TRUSSViLLE, AL 35173 

205=661-0743 

Brick Tunnel Kiln 

Run Number 

Test Date 

Test Location 

Test Time 

Oxygen Content, % v/v 

Carbon Dioxide Content, % v/v 

Sulfur Dioxide, ppm 

Sulfur Dioxide, gall00 dscf 

Sulfur Dioxide, 

gr/100 dscf @ 0% oxygen 

Allowable Sulfur Dioxide, 

gall00 dscf @ 0% oxygen 

1 2 

t2/18/01 12/18/01 

Outlet Outlet 

0742-0842 0849-0949 

16.31 16.95 

3.55 3.14 

28.58 29.86 

3.33 3.48 

3 

12/18/01 

Outlet 

0956-1056 

17.00 

3.09 

34.46 

4.01 

Average 

12/18/01 

Outlet 

0742-1056 

16.75 

3.26 

30.97 

3.61 

15.14 18.40 21.50 18.17 

28.63 28.63 28.63 28.63 

L Table 2 

• KE•A 
KILKELEY ENVIRONMENTAL ASSOCIATES 

Run Number 

Test Date 

Test Location 

Test Time 

P.O. BOX 426 

TRUSSVILLE, AL 35'i73 

205-661 =0743 

Brick Tunnel Kiln 

Summarized Air Test Results for General Shale Brick 

1 2 3 Average 

12/18/01 12/18/01 12/18/01 12/18/01 

Outlet Outlet Outlet Outlet 

0742-0842 0849-0949 0956-1056 0742-1056 

O 35 

o 

o 25 

"• 2O 

•0 

• 5 

0 0 

15.14 

Tunnel Kiln SO2 Emissions 

On December 18, 2001 

28.63 28.63 28.63 28.63 

18.40 

21.50 

18.17 

3 

Run Number 

I[]SO2 [] Allowed SO2 

Average 

Graph 1 
KILKELLY ENVIRONMENTAL ASSOCIATES 

P.O. BOX 426 

TRUSSVILLE, AL 35173 

205-661-0743 

Brick Tunnel Kiln 

Run Number 

Test Date 

Test Location 

Test Time 

Barometric Pressure, in Hg 

Run Time, minutes 

Sulfur Dioxide, ppm 

% Oxygen 

% Carbon Dioxide 

1 2 3 

12/18/01 12/18/01 12/18/01 

Outlet Outlet Outlet 

0742-0842 0849-0949 0956-1056 

29.63 29.63 29.63 

60 60 60 

28.58 29.86 34.46 

16.31 16.95 17.00 

3.55 3.14 3.09 

Average 

12/18/01 

Outlet 

0742-1056 

29.63 

60 

30.97 

16.75 

3.26 
KILKELLY ENVIRONMENTAL ASSOCIATES 

P.O. BOX 426 

TRUSSVILLE, AL 35173 

205=661-0743 

Brick Tunnel Kiln 

Run Number 

Test Date 

Test Location 

Test Time 

11. Sulfur Dioxide Concentration 

Pounds/DSCF 

Grains/DSCF 

Grains/100 dscf 

Grains/100 dscf @ 0% Oxygen 

1 2 3 

12/18/01 12/18/01 12/18/01 

Outlet Outlet Outlet 

0742-0842 0849-0949 0956-1056 

4.75E-006 4.97E-006 5.73E-006 

0.0333 0.0348 0.0401 

3.33 3.48 4.01 

15.14 18.40 21.50 

Average 

12/18/01 

Outlet 

0742-1056 

5.15E-006 

0.0361 

3.61 

18.17 

L 
SAMPLING 

AND ANALYTICAL 

PROCEDURES 
3. SAMPLING AND ANALYTICAL PROCEDURES 

General 

All sampling and analytical procedures for the determination ot: the particulate emissions 

from these sources were conducted in accordance with the Code of Federal Regulations, 

Title 40, Part 60, Appendix A, Methods 1-4, 3A & 6C, as amended. The sampling 

equipment used in these tests was properly calibrated (See Calibrations). The sulfur 

dioxide was determined on a dry basis using a nondispersive infrared instrument and then 

corrected to 0% oxygen using a Teledyne oxygen instrument. 

METHOD 6C 

"This method is applicable to the determination of sulfur dioxide (SO•) concentrations 

in controlled and uncontrolled emissions from stationary sources only when specified within 

the regulations. A gas sample is continuously extracted from a stack, and a portion of the 

sample is conveyed to an instrumental analyzerfor determination of SO 2 gas concentration 

using an ultraviolet (UV), nondispersive infrared (NDIR), or fluorescence analyzer. Performance specifications and test procedures are provided to ensure reliable data. 

The analytical range is determined by the instrumental design. For this method, a 

portion of the analytical range is selected by choosing the span of the monitoring system. 

The span of the monitoring system shall be selected such that the pollutant gas concentration equivalent to the emission standard is not less than 30 percent of the span. If at any 

time during a run the measured gas concentration exceeds the span, the run shall be 

considered invalid. 

The minimum detectable limit depends on the analytical range, span, and signal-to- noise ratio of the measurement system. For a well designed system, the minimum 

detectable limit should be less than 2 percent of the span. 

Span. The upperlimit of the gas concentration measurement range displayed on the 

data recorder. 

Calibration Gas. A known concentration of a gas in an appropriate diluent gas. 

Analyzer Calibration Error. The difference between the gas concentration exhibited 

by the gas analyzer and the known concentration of the calibration gas when the calibration 

gas is introduced directly to the analyzer. 

Sampling System Bias. The difference between the gas concentrations exhibited by the measurement system when a known concentration gas is introduced at the outlet of the 

sampling probe and when the same gas is introduced directly to the analyzer. 

Zero Drift. The difference in the measurement system output reading from the initial 

calibration response at the zero concentration level after a stated period of operation during which no unscheduled maintenance, repair, or adjustment took place. 

Calibration Drift. The difference in the measurement system output reading from the 

initial calibration response at a mid-range calibration value after a stated period of operation during which no unscheduled maintenance, repair, or adjustment took place. 
Response Time. The amount oftime required forthe measurement system to display 95 percent of a step change in gas concentration on the data recorder. 

Interference Check. A method for detecting analytical interferences and excessive biases through direct comparison of gas concentrations provided by the measurement 

system and by a modified Method 6 procedure. For this check, the modified Method 6 samples are acquired at the sample by-pass discharge vent. ,4 

Genera[ 

The sampling train consisted of a sample probe, heated sampling line, calibration 

valve assembly, a condenser to remove condensate from the sample gas while maintaining 

minimal contact between any condensate and the sample gas, particulate filter, sample 

pump, sample flow rate control, sample gas manifold, SO 2 analyzer (Western Research 721 

ATM serial # 93-721M-7998-3 KEA #1) and a Strata Data Acquisition System. 

The following measurement system performance specifications were complied with 

during these tests: 

1. Analyzer Calibration Error Less than + 2% of the span for the zero, mid-range, 

and high-range calibration gases. 

2. Sampling System Bias Less than + 5% of the span for the zero, and mid- or 

high-range calibration gases. 

L 

1Method 6C Determination of Sulfur Dioxide Emissions from Stationary Sources ( Instrumental Analyzer Procedure), Code of Federal Regulations, Title 40, Section 60, Appendix A, July 1, 2000. 
3. Zero Drift Less than + 3% of the span over the period of each run. 

4. Calibration Drift Less than + 3% of the span over the period of each run. 

Measurement System Preparation 

The system was assembled by following the manufacturer's written instruction for 

preparing and preconditioning the gas analyzer and the other system components. Various 

calibration gases were then introduced and all necessary adjustments were made to 

calibrate the analyzer and the data recorder. 

Then an analyzer calibration error check was conducted by introducing calibration 

gases to the measurement system at the back of the analyzer and all measurements were 

less than + 2% of the span for any of the calibration gases. Next the sampling system bias 

check was conducted by introducing calibration gases at the calibration valve installed at 

the outlet of the sampling probe. A zero, mid-range, and high-range gas were introduced. 

During this check, the system was operated at the normal sampling rate, and no 

adjustments to the measurement system other than those necessary to achieve proper 

calibration gas flow rates to the analyzer was done. The response time was determined 

during this check. All measurements were less than + 5% of the span for either the zero 

or upscale calibration gas. 

Emission Test Procedure 

The probe was positioned at the sampling location and sampling began at the same 

rate as used during the system calibration drift test. A constant sampling rate was 

maintained during the entire run. The sampling time per run was 60 minutes, and data was 

not collected until twice the system response time had elapsed. Immediately following each 

run, the sampling system bias check was redone without making any adjustments to the 

measurement system. All values were within acceptable limits. The average of the initial 

and final bias check values were used to calculate the gas concentration for the run. 

METHOD 3A 

This method is appficable to the determination of oxygen (Oz) and carbon dioxide (CO•) concentrations in emissions from stationary sources only when specified within the regulations. A sample is continuously extracted from the effluent stream: a portion of the 
sample stream is conveyed to an instrumental analyzer(s) for determination of 02 and C02 

• 

concentration(s). Performance specifications and test procedures are provided to ensure 

reliable data. The measurement system consists of the same majorsubsystems as defined in Method 6C, Sections 3.1.1, 3.1.2, and3.1.3. Span, Calibration Gas, AnalyzerCalibration Error, Sampling System Bias, Zero Drift, Calibration Drift, Response Time, and Calibration Curve. Same as in Method 6C, Sections 3.2 through 3.8, and 3.10/'2 

General 

The sampling train consisted of a sample probe, heated sampling line, calibration 

valve assembly, a condenser to remove condensate from the sample gas while maintaining 

minimal contact between any condensate and the sample gas, particulate filter, sample 

pump, sample flow rate control, sample gas manifold, CO2 analyzer (Fuji CO2 KEA #2 

serial #N3A2454T) and 02 analyzer (Teledyne KEA #2 serial # 138493) and a Strata Data 

Acquisition System. 

The following measurement system performance specifications were complied with during these tests: 

1. Analyzer Calibration Error Less than + 2% of the span for the zero, mid-range, 

and high-range calibration gases. 

L 

2Method 3A Determination of Oxygen and Carbon Dioxide Concentrations in Emissions from Stationary Sources (Instrumental Analyzer Procedure), Code of Federal Regulations, Title 40, Section 60, Appendix A, July 1, 2000. 
2. Sampling System Bias Less than __+ 5% of the span for the zero, and mid- or 

high-range calibration gases. 

3. Zero Drift Less than _+ 3% of the span over the period of each run. 

4. Calibration Drift Less than + 3% of the span over the period of each run. 

Measurement System Preparation 

The system was assembled by following the manufacturer's written instruction for 

preparing and preconditioning the gas analyzer and the other system components. Various 

calibration gases were then introduced and all necessary adjustments were made to 

calibrate the analyzer and the data recorder. 

]'hen an analyzer calibration error check was conducted by introducing calibration 

gases to the measurement system at the back of the analyzer and all measurements were 

less than + 2% of the span for any of the calibration gases. Next the sampling system bias 

check was conducted by introducing calibration gases at the calibration valve installed at 

the outlet of the sampling probe. A zero, mid-range, and high-range gas was introduced. 

During this check, the system will be operated at the normal sampling rate, and no 

adjustments to the measurement system other than those necessary to achieve proper 

calibration gas flow rates to the analyzer was done. The response time was determined 

during this check. All measurements were less than _+ 5% of the span for either the zero 

or upscale calibration gas. 

Emission Test Procedure 

The probe was positioned at the sampling location and sampling began at the same 

rate as used during the system calibration drift test. A constant sampling rate was 

maintained during the entire run. The sampling data was not be collected until twice the 

system response time had elapsed. Immediately following each hour of testing, the 

sampling system bias check was redone without making any adjustments to the measurement system. All values were within acceptable limits. The average of the initial and final 

bias check values were used to calculate the gas concentration for the run. The Oxygen 

data was used to correct the sulfur dioxide data. 

L 
STACK BREECHING AND SAMPLE POINT LOCATION 

Brick Tunnel Kiln Stack 

119" 

540" 

Traverse Point # Distance from Stack Wall, 

inches 

1,9 

2 6,5 

3 13,0 

4 31.6 

5 37,5 

6 42.t 

L 

Figure 

12 KE•A 
FIELD DATA 
•'•-aiis#ation Error •st at •5-5•-• S=i-RA•A V•rsion 210 /' 02 CO2 

% % 

12-18-2001 07:05:07 7.845 1.779 

12-18-2001 07:06:07 1.466 0.092 

12-18-2001 07:07:07 1.057 0.085 

12-18-2001 07:08:07 0.872 0.08 

12-18-2001 07:09:07 0.765 0.078 

12-18-2001 07:10:07 0.689 0.081 

12-18-2001 07:11:07 0.631 0.081 

12-18-2001 07:12:07 0.587 0.077 

12-18-2001 07:13:08 0.548 0.076 

12-18-2001 07:14:07 0.514 0.073 

12-18-2001 07:15:07 0.54 0.079 

12-18-2001 07:16:07 16.663 12.957 

12-18-2001 07:17:07 22.182 18.007 

12-18-2001 07:18:07 22.144 18.007 

12-18-2001 07:19:07 13.494 10.83 

12-18-2001 07:20:07 12.464 9.9 

12-18-2001 07:21:07 12.472 9.88 

12-18-2001 07:22:07 1.923 1,358 

Calibration Error Test at Run 

Operator: Tommy Lotz, 

Plant Name: 

Location: 

02 

CO2 

SO2 

1 

General Shale 

Louisville, KY 

Reference Cylinder Numbers 

Zero Low-range Mid-range 

CC129687 CC52194 

CC129687 CC52194 

CC52194 SG9'163425 

Date/Time 12-18-2001 07:22:51 PASSED 

Analyte 02 CO2 SO2 

Units % % ppm 

Zero Ref Cyl 0 0 0 

Zero Avg 0.497 0.075 0.54 

Zero Error% 2 0.4 0.4 

Low Ref Cyl 

Low Avg 

Low Error% 

Mid Ref Cyl 12.1 10.1 46 

Mid Avg 12.474 9.897 44.85 

Mid Error% 1.5 1 0.9 

High Ref Cyl 22 17.8 124 

High Avg 22.172 18.015 125.17 

High Error% 0.7 1.1 0.9 

SO2 

ppm 

231.49 

109 

114.57 

125.09 

125.25 

125.26 

125.29 

125.35 

125.18 

125.2 

125.1 

57.64 

4.48 

4.86 

5.51 

2.48 

0.08 

32.82 

High-range 

CC 13243 

CC 13243 

SG9140313 

02 

Volts 

0.3138 

0.0586 

0.0423 

0.0349 

0.0306 

0.0275 

0.0253 

0.0235 

0.0219 

0.0206 

0.0216 

0.6665 

0.8873 

0.8857 

0.5397 

0.4985 

0.4989 

0.0769 

CO2 

Volts 

0.0889 

0.0046 

0.0043 

0.004 

0.0039 

0.004 

0.0041 

0.0039 

0.0038 

0.0037 

0.0039 

0.6479 

0.9004 

0.9004 

0.5415 

0.495 

0,494 

0.0679 

SO2 

Volts 

4.6299 

2.18 

2.2915 

2.5017 

2,5049 

2.5051 

2.5058 

2.5071 

2.5036 

2.504 

2.5019 

1.1527 

0.0896 

0.0972 

0.1101 

0.0496 

0.0016 

0.6564 

L 
'11T•l•ystem t•i• Check tOf Run 1-• S-i RA A v•rsion21U 

02 CO2 SO2 02 CO2 SO2 % % ppm Volts Volts Volts 12-18-2001 07:23:56 5.155 1.348 44.54 0.2062 0.0674 0.8907 12-18-2001 07:24:55 12.649 8.715 63.83 0.506 0.4357 1.2767 12-18-2001 07:25:56 10.524 7.733 39.04 0.4209 0.3866 0.7809 12-18-2001 07:26:56 0.446 0.167 114.05 0.0178 0.0084 2.281 12-18-2001 07:27:56 0.518 0.134 130.78 0.0207 0.0067 2.6156 12-18-2001 07:28:56 1.114 0.362 97.03 0.0446 0.0181 1.9405 12-18-2001 07:29:56 0.335 0.111 69.65 0.0134 0.0056 1.393 12-18-2001 07:30:56 0.314 0.112 67.48 0.0125 0.0056 1.3496 12-18-2001 07:31:56 0.295 0.11 66.22 0.0118 0.0055 1.3244 12-18-2001 07:32:56 0.326 0.112 64.68 0.013 0.0056 1.2937 12-18-2001 07:33:55 0.541 0.153 61.06 0.0216 0.0077 1.2212 12-18-2001 07:34:56 5.304 1.459 46.74 0.2122 0.073 0.9348 12-18-2001 07:35:55 0.242 0.087 46.33 0.0097 0.0044 0.9266 12-18-2001 07:36:56 7.225 5.57 28.98 0.289 0.2785 0.5795 12-18-2001 07:37:56 12.381 9.899 1.6 0.4952 0.4949 0.0321 

Initial System Bias Check for Run 1 

Operator: 

Plant Name: 

Location: 

02 

CO2 

SO2 

Tommy Lotz, Jr. 

General Shale 

Louisville, KY 

Reference Cylinder Numbers 

Zero Span 

CC129687 CC52194 

CC129687 CC52194 

CC52194 SG9163425 

Date/Time 12-18-2001 07:38:13 PASSED 

Analyte 02 CO2 SO2 

Units % % ppm 

Zero Ref Cyl 0 0 0 

Zero Cal 0.497 0.075 0.54 

Zero Avg 0.264 0.089 1.6 

Zero Bias% 0.9 0.1 0.9 

Zero Drift% 

Span RefC 12.1 10.1 46 

Span Cal 12.474 9.897 44.85 

Span Avg 12.381 9.899 46.39 

Span Bias% 0.4 0 1.2 

Span Drift% 
u• ;i Begin. s KAVA version z.O 

or: Tommy Lotz, Jr. 

ame: General Shale 

Location: Louisville, KY 

02 CO2 

% % 

12-18-2001 07:39:14 13.995 7.102 

12-18-2001 07:40:13 16.148 3.721 

Begin calculating run averages 

12-18-2001 07:42:01 16.238 3.658 

12-18-2001 07:43:01 16.123 3.706 

12-18-2001 07:44:01 16.046 3.753 

12-18-2001 07:45:01 16.086 3.724 

12-18-2001 07:46:01 16.067 3.733 

12-18-2001 07:47:01 16.117 3.7 

12-18-2001 07:48:00 16.105 3.702 

12-18-2001 07:49:01 16.132 3.686 

12-18-2001 07:50:00 16.19 3.655 

12-18-2001 07:51:01 16.193 3.652 

12-18-2001 07:52:01 16.264 3.608 

12-18-2001 07:53:01 16.223 3.638 

12-18-2001 07:54:01 16.343 3.56 

12-18-2001 07:55:01 16.321 3.569 

12-18-2001 07:56:01 16.372 3.544 

12-18-2001 07:57:00 16.436 3.53 

12-18-2001 07:58:01 16.562 3.485 

12-18-2001 07:59:00 16.695 3.403 

12-18-2001 08:00:01 16.689 3.401 

12-18-2001 08:01:01 16.758 3.361 

12-18-2001 08:02:01 16.928 3.24 

12-18-2001 08:03:01 17.148 3.058 

12-18-2001 08:04:01 16.962 3.222 

12-18-2001 08:05:01 16.779 3.336 

12-18-2001 08:06:00 16.307 3.636 

12-18-2001 08:07:01 16.55 3.42 

12-18-2001 08:08:00 16.503 3.443 

12-18-2001 08:09:01 16.533 3.428 

12-18-2001 08:10:01 16.462 3.468 

12-18-2001 08:11:01 16.545 3.41 

12-18-2001 08:12:01 16.472 3.452 

12-18-2001 08:13:01 16.611 3.399 

12-18-2001 08:14:01 16.535 3.433 

12-18-2001 08:15:00 16.509 3.441 

12-18-2001 08:16:01 16.571 3.418 

12-18-2001 08:17:00 16.584 3.415 

12-18-2001 08:18:01 16.775 3.31 

12-18-2001 08:19:01 16.702 3.36 

12-18-2001 08:20:01 16.746 3.359 

12-18-2001 08:21:01 16.659 3.415 

12-18-2001 08:22:01 16.678 3.41 

12-18-2001 08:23:01 16.673 3.413 

08:24:00 16.738 3.368 

2-18-2001 08:25:01 16.69 3.357 

18-2001 08:26:00 16.544 3.439 

SO2 

ppm 

18.62 

72.36 

54.07 

38.59 

39.17 

40.24 

37.25 

32.66 

31.26 

29.28 

27.48 

28.43 

28.83 

29.18 

28.69 

26.69 

26.75 

29.31 

31.1 

33.59 

32.91 

31.31 

24.89 

15.41 

11.97 

11.39 

10.34 

14.67 

14.35 

t4.84 

17.16 

19.46 

20.74 

22.78 

20.89 

25.83 

30.51 

34.27 

33.07 

35.55 

48.85 

51.31 

55.76 

45.56 

44.98 

36.64 

26.19 

02 

Volts 

0.5598 

0.6459 

0.6495 

0.6449 

0.6419 

0.6434 

0.6427 

0.6447 

0.6442 

0.6453 

0.6476 

0.6477 

0.6506 

0.6489 

0.6537 

0.6528 

0.6549 

0.6575 

0.6625 

0.6678 

0.6676 

0.6703 

0.6771 

0.6859 

0.6785 

0.6711 

0.6523 

0.662 

0.6601 

0.6613 

0.6585 

0.6618 

0.6589 

0.6644 

0.6614 

0.6604 

0.6628 

0.6634 

0.671 

0.6681 

0.6698 

0.6664 

0.6671 

0.6669 

0.6695 

0.6676 

0.6618 

CO2 

Volts 

0.3551 

0.1861 

0.1829 

0.1853 

0.1876 

0.1862 

0.1867 

0.185 

0.1851 

0.1843 

0.1827 

0.1826 

0.1804 

0.1819 

0.178 

0.1785 

0.1772 

0.1765 

0.1743 

0.1702 

0.17 

0.168 

0.162 

0.1529 

0.1611 

0.1668 

0.1818 

0.171 

0.1721 

0.1714 

0.1734 

0.1705 

0.1726 

0.1699 

0.1716 

0.172 

0.1709 

0.1707 

0.1655 

0.168 

0.1679 

0.1707 

0.1705 

0.1706 

0.1684 

0.1679 

0.1719 

S02 

Volts 

0.3724 

1.4472 

1.0814 

0.7718 

0.7835 

0.8049 

0.745 

0.6531 

0.6251 

0.5856 

0.5496 

0.5686 

0.5766 

0.5837 

0.5737 

0.5339 

0.5349 

0.5862 

0.622 

0.6717 

0.6581 

0.6262 

0.4979 

0.3082 

0.2393 

0.2277 

0.2068 

0.2933 

0.287 

0.2968 

0.3431 

0.3892 

0.4147 

0.4555 

0.4179 

0.5167 

0.6103 

0.6854 

0.6615 

0.711 

0.9769 

1.0263 

1.1152 

0.9112 

0.8997 

0.7328 

0.5238 
/,'d'2• •-zUO• u•:2/:O'l 

12-18-2001 08:28:01 

12-18-2001 08:29:01 

12-18-2001 08:30:01 

12-18-2001 08:31:01 

12-18-2001 08:32:01 

12-18-2001 08:33:01 

12-18-2001 08:34:01 

12-18-2001 08:35:00 

12-18-2001 08:36:01 

12-18-2001 08:37:00 

12-18-2001 08:38:01 

12-18-2001 08:39:01 

12-18-2001 08:40:01 

12-18-2001 08:41:01 

Average of Test Run 

12-18-2001 08:41:01 

Test Run 1 End 

16.62 3.391 25.32 0.6648 0.1696 0.5063 

16.564 3,43 24.24 0.6626 0.1715 0,4848 

16,659 3.371 25.08 0.6664 0.1686 0.5016 

16.618 3.392 25.2 0.6647 0.1696 0.5039 

16.625 3.394 24.35 0.665 0.1697 0.4871 

16.676 3.365 22,73 0.667 0,1682 0.4545 

16.669 3.361 25.08 0.6668 0.1681 0,5015 

16.777 3.308 25.64 0.6711 0.1654 0.5128 

16.682 3.372 24.99 0.6673 0.1686 0.4998 

16.786 3.316 26,78 0.6714 0.1658 0.5356 

16,749 3.335 28.95 0.67 0.1667 0.579 

16,794 3.31 32,01 0.6718 0.1655 0.6403 

16.787 3.316 29.6 0.6715 0,1658 0.5919 

16.957 3.236 35.53 0.6783 0.1618 0.7105 

17.029 3.189 36,23 0.6812 0.1595 0.7246 

02 CO2 SO2 02 CO2 SO2 

% % ppm % % ppm 

16.553 3,447 29.27 0.6621 0.1723 0.5853 
•e• •as L;ne(;t• Tor t•un 1 S HA I2• ve•ibn 2i0 

02 CO2 SO2 02 

% % ppm Volts 

12-18-2001 08:42:02 5.274 1.11 38.23 0.211 

12-18-2001 08:43:01 0.125 0.107 46.15 0.005 

12-18-2001 08:44:02 6.542 4.919 31.05 0.2617 

12-18-2001 08:45:02 12.284 9.867 1.32 0.4913 

Final System Bias Check for Run 

Operator: Tommy Lotz, Jr. 

Plant Name: General Shale 

Location: Louisville, KY 

02 

CO2 

SO2 

Reference Cylinder Numbers 

Zero Span 

CC129687 CC52194 

CC129687 CC52194 

CC52194 SG9163425 

Date/Time 12-18-2001 08:45:37 PASSED 

Analyte 02 CO2 SO2 

Units % % ppm 

Zero Ref Cyl 0 0 0 

Zero Cal 0.497 0.075 0.54 

Zero Avg 0.133 0.109 1.2 

Zero Bias% 1.5 0.2 0.5 

Zero Drift% -0.5 0.1 -0.3 

Span Ref C 12. t 10.1 46 

Span Cal 12.474 9.897 44.85 

Span Avg 12.289 9.874 46.1 

Span Bias% 0.7 0.1 1 

Span Drift% -0.4 -0.1 -0.2 

Ini Zero Avg 0.264 0.089 1.6 

Ini Span Av 12.381 9.899 46.39 

Run Avg 16.553 3.447 29.27 

Co 0.198 0.099 1.4 

Cm 12.335 9.887 46.25 

Correct Avg 16.305 3.454 28.58 

CO2 

Volts 

0.0555 

0.0054 

0.2459 

0.4934 

SO2 

Volts 

0.7645 

0.9229 

0.6209 

0.0265 
b K/4 •AVerston z.0 

ommy Lotz, Jr. 

eneral Shale 

Location: Louisville, KY 

02 

% 

12-18-2001 08:46:37 14.658 

12-18-2001 08:47:37 16.914 

Begin calculating run averages 

12-18-2001 08:49:01 16.802 

12-18-2001 08:50:02 16.874 

12-18-2001 08:51:01 16.803 

12-18-2001 08:52:02 16.927 

12-18-2001 08:53:01 16.891 

12-18-2001 08:54:02 16,94 

12-18-2001 08:55:01 16.913 

12-18-2001 08:56:02 16.921 

12-18-2001 08:57:01 16.957 

12-18-2001 08:58:01 16.886 

12-18-2001 08:59:02 16.974 

12-18-2001 09:00:01 16.915 

12-18-2001 09:01:02 17.013 

12-18-2001 09:02:01 17.002 

12-18-2001 09:03:02 17.174 

12-18-2001 09:04:01 t7.215 

12-18-2001 09:05:02 17.138 

12-18-2001 09:06:01 17.181 

12-18-2001 09:07:01 17.107 

12-18-2001 09:08:02 17.2 

12-18-2001 09:09:01 17.189 

12-18-2001 09:10:02 17.173 

12-18-2001 09:11:01 17.033 

12-18-2001 09:12:02 17.032 

12-18-2001 09:13:01 17.049 

12-18-2001 09:14:02 17.004 

12-18-2001 09:15:01 17.071 

12-18-2001 09:16:01 17.004 

12-18-2001 09:17:02 17.105 

12-18-2001 09:18:01 17.008 

12-18-2001 09:19:02 17.072 

12-18-2001 09:20:01 17.072 

12-18-2001 09:21:02 17.074 

12-18-2001 09:22:01 17.109 

12-18-2001 09:23:02 17.023 

12-18-2001 09:24:01 17.105 

12-18-2001 09:25:01 17.164 

12-18-2001 09:26:02 17.266 

12-18-2001 09:27:01 17.176 

12-18-2001 09:28:02 17.219 

12-18-2001 09:29:01 17.236 

12-18-2001 09:30:02 17.2 

112-18-2001 09:31:01 17.282 

2-18-2001 09:32:02 17.416 

•4•-18-2001 09:33:01 17.607 

CO2 

% 

6.656 

3.282 

3.346 

3.309 

3.366 

3.295 

3.307 

3.287 

3.3 

3.294 

3.275 

3.324 

3.271 

3.297 

3.233 

3.258 

3.17 

3.13 

3.189 

3.172 

3.224 

3.167 

3.167 

3.142 

3.227 

3.226 

3.215 

3.24 

3.203 

3.234 

3.168 

3.237 

3.196 

3.189 

3.189 

3.163 

3.219 

3.162 

3.149 

3.089 

3.159 

3.136 

3.12 

3.143 

3.092 

2.988 

2.823 

SO2 

ppm 

12.44 

21.57 

15.88 

17.35 

18.19 

18.36 

18.6 

19.69 

21.66 

24.19 

25.91 

31.15 

31.29 

32.37 

29.79 

29.21 

42.54 

46.62 

52.22 

59.22 

67.59 

72.52 

75.47 

61.8 

53.93 

57.73 

54.99 

42.34 

33.57 

30.13 

28.6 

25.78 

25.49 

21.71 

21.55 

20 

20.31 

20.28 

19.45 

20.35 

20.67 

23.97 

27.06 

31.7 

32.18 

28.67 

16.09 

02 

Volts 

0.5863 

0.6766 

0.6721 

0.675 

0.6721 

0.6771 

0.6756 

0.6776 

0.6765 

0.6769 

0.6783 

0.6755 

0.6789 

0.6766 

0.6805 

0.6801 

0.687 

0.6886 

0.6855 

0.6873 

0.6843 

0.688 

0.6875 

0.6869 

0.6813 

0.6813 

0.682 

0.6802 

0.6828 

0.6802 

0.6842 

0.6803 

0.6829 

0.6829 

0,683 

0.6844 

0.6809 

0.6842 

0.6865 

0.6906 

0.6871 

0,6887 

0.6894 

0.688 

0.6913 

0.6966 

0.7043 

C02 

Volts 

0.3328 

0.1641 

0.1673 

0.1655 

0.1683 

0.1648 

0.1653 

0.1643 

0.165 

0.1647 

0.1637 

0.1662 

0.1636 

0.1648 

0.1617 

0.1629 

0.1585 

0.1565 

0.1595 

0.1586 

0,1612 

0.1584 

0.1583 

0.1571 

0.1613 

0.1613 

0.1608 

0.162 

0.1602 

0.1617 

0.1584 

0.1618 

0.1598 

0.1595 

0.1595 

0.1581 

0.161 

0.1581 

0.1574 

0.1545 

0.158 

0.1568 

0.156 

0.1572 

0.1546 

0.1494 

0.1412 

SO2 

Volts 

0.2488 

0.4315 

0.3177 

0.3471 

0.3637 

0.3673 

0.372 

0.3937 

0.4333 

0.4838 

0.5182 

0.6231 

0.6258 

0.6474 

0.5958 

0.5842 

0.8508 

0.9325 

1.0445 

1.1844 

1.3519 

1.4504 

1.5094 

1.2361 

1.0785 

1.1545 

1.0998 

0.8468 

0.6715 

0.6026 

0.572 

0.5156 

0.5099 

0.4342 

0.4311 

0.3999 

0.4061 

0.4056 

0.3891 

0.4069 

0.4133 

0.4793 

0.5411 

0.6339 

0.6437 

0.5733 

0.3218 

1.8 
12-18-2001 09:35:02 17.294 

12-18-2001 09:36:01 17.076 

12-18-2001 09:37:02 17.222 

12-18-2001 09:38:01 17.23 

12-18-2001 09:39:02 17.273 

12-18-2001 09:40:01 17.233 

12-18-2001 09:41:02 17.323 

12-18-2001 09:42:01 17.236 

12-18-2001 09:43:01 17.343 

12-18-2001 09:44:01 17.262 

12-18-2001 09:45:01 17.3 

12-18-2001 09:46:02 17.333 

12-18-2001 09:47:02 17.399 

12-18-2001 09:48:01 17.458 

Average of Test Run 02 

% 

12-18-2001 09:48:01 17.132 

Test Run 2 End 

z.UUl ;i0:56 U.I•UI515 U. 1495••. 2•-••- 

3.057 10.06 0.6918 0.1529 0.2012 

3.184 13.66 0.683 0.1592 0.2733 

3.053 18.82 0.6889 0.1527 0.3764 

3.048 21.49 0.6892 O. 1524 0.4298 

3.02 23.8 0.6909 0.151 0.4761 

3.045 27.57 0.6893 0.1522 0.5513 

2.988 33.41 0.6929 0.1494 0.6681 

3.044 35.3 0.6894 0.1522 0.7061 

2.976 27.02 0.6937 0.1488 0.5404 

3.023 27.65 0.6905 0.1512 0.5529 

3 15.12 0.692 0.15 0.3024 

2.978 15.73 0.6933 0.1489 0.3145 

2.968 20.56 0.696 0.1484 0.4112 

2.946 28 0.6983 0.1473 0,5601 

C02 SO2 02 C02 S02 

% ppm % % ppm 

3.157 30.28 0.6853 0.1578 0.6056 

L 
,,,,'F'inai SyStem •as L;neck tot Run 2. 

% 

,12-18-2001 09:49:02 6.615 

12-18-2001 09:50:01 0.105 

12-18-2001 09:51:02 7.288 

12-18-2001 09:52:02 12.245 

STl•AiAVersi6n 210 

CO2 SO2 02 CO2 SO2 

% ppm Volts Volts Volts 

1.273 36.87 0.2646 0.0637 0.7374 

0.124 46.01 0.0042 0.0062 0.9202 

5.561 27.61 0.2915 0.2781 0.5521 

9.893 1.1 0.4898 0.4946 0.0221 

Final System Bias Check for Run 2 

Operator: 

Plant Name: 

Location: 

02 

CO2 

SO2 

Tommy Lotz, Jr. 

General Shale 

Louisville, KY 

Reference Cylinder Numbers 

Zero Span 

CC129687 CC52194 

CC129687 CC52194 

CC52194 SG9163425 

Date/Time 12-18-2001 09:52:24 PASSED 

Analyte 02 CO2 SO2 

Units % % ppm 

Zero Ref Cyl 0 0 0 

Zero Cal 0.497 0.075 0.54 

Zero Avg 0.134 0.13 1.06 

Zero Bias% 1.5 0.3 0.4 

Zero Drift% 0 0.1 -0.1 

Span Ref Cyl 12.1 10.1 46 

Span Cal 12.474 9.897 44.85 

Span Avg 12.247 9.894 45.96 

Span Bias% 0.9 0 0.9 

Span Drift% -0.2 0.1 -0.1 

Ini Zero Avg 0.133 0.109 1.2 

Ini Span Avg 12.289 9.874 46.1 

Run Avg 17.132 3.157 30.28 

Co 0.133 0.119 1.13 

Cm 12.268 9.884 46.03 

Correct Avg 16.95 3.142 29.86 

L 

20 ::EA 
b{un 3 •egm. • HA • version 2:0 

Operator: Tommy Lotz, Jr. 

Plant Name: General Shale 

Location: Louisville, KY 

12-18-2001 09:53:25 

12-18-2001 09:54:24 

Begin calculating run averages 

02 

% 

15.152 

17.289 

12-18-2001 09:56:01 17.236 

12-18-2001 09:57:02 17.317 

12-18-2001 09:58:01 17.23 

12-18-2001 09:59:02 17.293 

12-18-2001 10:00:01 17.25 

12-18-2001 10:01:01 17.273 

12-18-2001 10:02:01 17.288 

12-18-2001 10:03:01 17.238 

12-18-2001 10:04:01 17.285 

12-18-2001 10:05:01 17.217 

12-18-2001 10:06:02 17.273 

12-18-2001 10:07:01 17.255 

12-18-2001 10:08:02 17.229 

12-18-2001 10:09:01 17.212 

12-18-2001 10:10:01 17.214 

12-18-2001 10:11:01 17.26 

12-18-2001 10:12:01 17.217 

12-18-2001 10:13:01 17.124 

12-18-2001 10:14:01 17.005 

12-18-2001 10:15:01 17.058 

12-18-2001 10:16:01 17.004 

12-18-2001 10:17:02 17.04 

12-18-2001 10:18:01 17.043 

12-18-2001 10:19:01 17.005 

12-18-2001 10:20:01 17 

12-18-2001 10:21:01 16.906 

12-18-2001 10:22:01 16.998 

12-18-2001 10:23:01 16.955 

12-18-2001 10:24:01 17.013 

12-18-2001 10:25:01 16.972 

12-18-2001 10:26:02 17.041 

12-18-2001 10:27:01 17.172 

12-18-2001 10:28:02 17.072 

12-18-2001 10:29:01 17.152 

12-18-2001 10:30:01 17.11 

12-18-2001 10:31:01 17.178 

12-18-2001 10:32:01 17.211 

12-18-2001 10:33:01 17.081 

12-18-2001 10:34:01 17.053 

12-18-2001 10:35:02 17.028 

12-18-200:1 10:36:01 17.069 

12-18-2001 10:37:02 17.005 

10:38:01 17.083 

2-18-2001 10:39:01 17.049 

18-2001 10:40:01 17.093 

C02 

% 

5.982 

3.034 

3.055 

3 

3.056 

3.022 

3.042 

3.027 

3.016 

3.047 

3.012 

3.048 

3.023 

3.066 

3.097 

3.105 

3.103 

3.07 

3.082 

3.117 

3.187 

3.161 

3.197 

3.173 

3.168 

3.196 

3.192 

3.244 

3.21 

3.246 

3.212 

3.241 

3.204 

3.141 

3.215 

3.181 

3.204 

3.168 

3.123 

3.178 

3.196 

3.208 

3.175 

3.213 

3.166 

3.176 

3.15 

SO2 

ppm 

16.52 

39.4 

49.67 

52.39 

56.86 

63.49 

65.92 

69 

70.35 

77.43 

80.39 

81.7 

83 

94.15 

101.26 

104.53 

103.46 

97.68 

95.4 

77.4 

69.49 

63.17 

56.86 

52.66 

47.38 

38.33 

28.23 

24.29 

21.73 

17.27 

15.18 

13.02 

10.91 

9.74 

9.17 

8.78 

8.43 

8.58 

9.31 

10.2 

10.55 

10.79 

11.28 

11.05 

10.73 

10.23 

9.2 

02 

Volts 

0.6061 

0.6916 

0.6894 

0.6927 

0.6892 

0.6917 

0.69 

0.6909 

0.6915 

0.6895 

0.6914 

0.6887 

0.6909 

0.6902 

0.6891 

0.6885 

0.6886 

0.6904 

0.6887 

0.685 

0.6802 

0.6823 

0.6802 

0.6816 

0.6817 

0.6802 

0.68 

0.6762 

0.6799 

0.6782 

0.6805 

0.6789 

0.6816 

0.6869 

0.6829 

0.6861 

0.6844 

0.6871 

0.6885 

0.6833 

0.6821 

0.6811 

0.6828 

0.6802 

0.6833 

0.682 

0.6837 

CO2 

Volts 

0.2991 

0.1517 

0.1527 

0.15 

0.1528 

0.1511 

0.1521 

0.1514 

0.1508 

0.1523 

0.1506 

0.1524 

0.1512 

0.1533 

0.1549 

0.1552 

0.1551 

0.1535 

0.1541 

0.1559 

0.1594 

0.1581 

0.1598 

0.1587 

0.1584 

0.1598 

0.1596 

0.1622 

0.1605 

0.1623 

0.t606 

0.162 

0.1602 

0.1571 

0.1608 

0.159 

0.1602 

0.1584 

0.1561 

0.1589 

0.1598 

0.1604 

0.1588 

0.1607 

0.1583 

0.1588 

0.1575 

S02 

Volts 

0.3304 

0.788 

0.9933 

1.0478 

1.1372 

1.2699 

1.3184 

1.38 

1.407 

1.5485 

1.6077 

1.634 

1.66 

1.883 

2.0251 

2.0906 

2.0692 

1.9535 

1.908 

1.548 

1.3898 

1.2634 

1.1373 

1.0531 

0.9476 

0.7667 

0.5646 

0.4857 

0.4346 

0.3454 

0.3O36 

0.2604 

0.2183 

0.1947 

0.1834 

0.1755 

0.1686 

0.1715 

0.1863 

0.2041 

0.211 

0.2158 

0.2257 

0.2211 

0.2146 

0.2046 

0.1839 
12-18-2001 10:42:01 

12-18-2001 10:43:01 

12-18-2001 10:44:02 

12-18-2001 10:45:01 

12-18-2001 10:46:02 

12-18-2001 10:47:01 

12-18-2001 10:48:01 

12-18-2001 10:49:01 

12-18-2001 10:50:01 

12-18-2001 10:51:01 

12-18-2001 10:52:01 

12-18-2001 10:53:02 

12-18-2001 10:54:01 

12-18-200t 10:55:02 

Average of Test Run 

12-18-2001 10:55:02 

Test Run 3 End 

1/.u•b 3.15• 8••18 0.6826 

17.085 3.156 7.17 0.6834 0.1578 0.1433 

17.117 3.127 6.62 0.6847 0.1563 0.1325 

17.078 3.154 6.2 0.6831 0.1577 0.1239 

17.14 3.116 5.58 0.6856 0.1558 0.1115 

17.078 3.157 5.01 0.6831 0.1578 0.1002 

17.22 3.095 4.49 0.6888 0.1547 0.0898 

17.178 3.113 4.21 0.6871 0.1556 0.0842 

17.21 3.089 3.99 0.6884 0.1545 0.0798 

17.168 3.086 3.72 0.6867 0.1543 0.0743 

17.15 3.095 3.63 0.686 0.1548 0.0726 

17.431 2.905 3.61 0.6972 0.1452 0.0722 

17.449 2.848 3.66 0.698 0.1424 0.0731 

17.309 2,981 3.46 0.6924 0.149 0.0692 

17.149 3.083 3.31 0.686 0.1541 0.0661 

02 CO2 SO2 02 CO2 SO2 

% % ppm % % ppm 

17.144 3.121 34.89 0.6858 0.1561 0.6977 

L 

22 
.•y•tem bias une•K tor Run 3. 

02 C02 S02 

ppm % % 

•12-18-2001 10:56:02 9.681 2.019 14.17 

12-18-2001 10:57:02 0.113 0.133 46.06 

12-18-2001 10:58:02 0.083 0.129 46.39 

12-18-2001 10:59:02 1.815 1.239 44.94 

12-18-2001 11:00:02 12.167 9.896 4.76 

02 

Volts 

0.3872 

0.0045 

0.0033 

0.0726 

0.4867 

Final System Bias Check for Run 3 

Operator: Tommy Lotz, Jr. 

Plant Name: General Shale 

Location: Louisville, KY 

Reference Cylinder Numbers 

Zero Span 

02 CC129887 CC52194 

CO2 CC129687 CC52194 

SO2 CC52194 SG9'163425 

Date/Time 12-18-2001 11:00:52 

Analyte 02 CO2 

Units % % 

Zero Ref Cyl 0 0 

Zero Cal 0.497 0.075 

Zero Avg 0.083 0.128 

Zero Bias% 1.7 0.3 

Zero Drift% -0.2 0 

Span Ref Cyl 12.1 10.1 

Span Cal 12.474 9.897 

Span Avg 12.222 9.922 

Span Bias% 1 0.1 

Span Drift% -0.1 0.1 

PASSED 

SO2 

ppm 

0 

0.54 

1.32 

0.6 

0.2 

46 

44.85 

46.38 

1.2 

0.3 

Ini Zero Avg 0.134 0.13 1.06 

Ini Span Avg 12.247 9.894 45.96 

Run Avg 17.144 3.121 34.89 

Co 0.108 0.129 1.19 

Cm 12.234 9.908 46.17 

Correct Avg 16.999 3.091 34.46 

C02 

Volts 

0.1009 

0.0066 

0.0064 

0.062 

0.4948 

SO2 

Volts 

O.2834 

0.9212 

0.9277 

0.8988 

0.0952 
,'•un averages Corrected foi 

perator: Tommy Lotz, Jr. 

Plant Name: General Shale 

Location 

Run 

Louisville, KY 

02 CO2 SO2 

% % ppm 

1 16.305 3.454 28.58 

2 16.95 3.142 29.86 

3 16.999 3.091 34.46 

L 
NOMENCLATURE FOR SULFUR DIOX•DE 

Cgas 

C 

Co 

ma 

MW 

SO2 PPH 

385.1 x 106 = Conversion factor 

= Effluent gas concentration, dry basis, ppm 

= Average gas concentration indicated by gas analyzer, dry basis, ppm 

= Average of initial and final system calibration bias check responses for 

the zero gas, ppm 

= Average of initial and final system calibration bias check responses for 

the upscale calibration gas, ppm 

Actual concentration of the upscale calibration gas, ppm 

Molecular weight of SO2, which is equal to 64.07 

Sulfur dioxide mass rate in pounds per hour 

EQUATIONS FOR SO2 

C gas 

= (C-Co•,,) x (Cn•a), / (Cm Co) 

L 

SO 2 #/DSCF Cgas X MW / 385.1 x 10 6 

= ( ,;,!•,bb ) x (64.07)/(385.1 x 106) = 

SO 2 Gr/DSCF = SO2 #/DSCF x 7000 

SO2 Gr/100DSCF = SO 2 GR/DSCF x 100 

= ( • .--'-> •> •!.> ) x ( •• 
NOMENCLATURE FOR OXYGEN/CARBON DIOXIDE 

Cgas 

C 

Co 

Cm 

Cma 

= Effluent gas concentration, dry basis, ppm 

= Average gas concentration indicated by gas analyzer, dry basis, ppm 

= Average of initial and final system calibration bias check responses for 

the zero gas, ppm 

= Average of initial and final system calibration bias check responses for 

the upscale calibration gas, ppm 

= Actual concentration of the upscale calibration gas, ppm 

EQUATIONS FOR 

C gas (C-C 0)x (Cma) /(C m C0) 

:/<'.." 

o, ,,t Ix( •, )/( :::-;;,•:•, )= 

L 
PLANT PRODUC 

DATA 

TiON 
QNQC PROCEDURES 

AN D RES U LTS 
6. QA/QC PROCEDURES AND RESULTS 

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, representativeness, 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 PA Dept. 

of Environmental Protection, Bureau of Air Quality. 

PROCEDURES FOR SAMPLING 

The following sections detail all QC procedures followed during the manual sampling 

activities. 

CONTINUOUS EMISSION MONITORING QC PROCEDURES 

In accordance with EPA Methods 3A and 6C a three-point (i.e., zero, mid-, and high-range) 

analyzer calibration error check was conducted on each reference analyzer prior to initiating 

the compliance testing. These checks were conducted (after final calibration adjustments 

are made) by injecting the calibration gases directly into each gas analyzer and recording 

the responses. 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 this section 

Zero and upscale calibration checks were performed both before and after each test run in 

order to quantify reference measurement system calibration drift and sampling system bias. 

Upscale is either the mid- or high-range gas, whichever most closely approximates the flue 

gas level. During these checks, the calibration gases are introduced into the sampling 

system at the probe outlet so that they are analyzed in the same manner as the flue gas 

samples. Drift is defined as the difference between the pre- and post-test run calibration 

check responses. Sampling system bias is the difference between the test run calibration 

check responses (system calibration) and the initial calibration error responses (direct 

analyzer calibration) to the zero and upscale calibration gases. If an acceptable post-test 

bias check result is obtained, but the zero or upscale drift result exceeds the drift limit, then 

the test run result is valid; however, the analyzer calibration error and bias check 
procedures must be repeated before conducting the next test run. A run is considered 

invalid and must be repeated if the post-test zero or upscale calibration check result 

exceeds the bias specification. The calibration error and bias checks must be repeated and 

acceptable results obtained before testing can resume. 


Re•earch TrianS•e Paf!i N,C, 2,7709 

phone 919/.•44-372'2 

CERT•FICATE OF ANALY$18: EPA PROTOCOL GAS •XTURE, ,: :, 

ANALy•!•• 

Carbon Dioxide 10.1% 

Nitrogen 

NC TA 

Type•'SRM Sample # C__.•l.tnder # •. 

GMt8 CC13313 24,824 % O2,'N2 

GMI8 C061376 19,36 % CO2JN2 

•j.N.STR UM ENTA T I.O_N_N 

Beckman 7,•5 O2 001419 

Rosemount 880 CO2 00418 

Last Date Gallb..LaJ, e• 

04/08/01 

04/02/01 

Analytic:el M,,mh c•d 

Paramagnetio 

Non-Elispersive n Fra 

laboratory. Every error has been made to determine o•je•tfvely the ormation requested. However, in 

connection wi• •i• report, Natlonat 8psoialty Gases shall have no liability in excess of estabtisl•ed •,atge for 

this service. Assayecl at National 8penalty Gases, 630 United Drive, Dumam, NC 27713 (919• 544-3772 

'*AnzlylJoet a•ow=•*/ir•.4ude• • Kr•,'n •tt•¢ •our¢.• which, at {•, h•lu• px'eei•o• of •he analyti• n•lr•me•. I•$G g2C 

.32 
Oxygen •t. 1% 

Carbon Dioxide •7.8% 

E•eckman 755 02 001419 

Rosamount 880 CQ2 00418 

131/04J01 

01/0•Ol 

P aramagnetic 

Non.d;spers•ve infrared 

laborato•. Eve• efto• ha• #sen made tO d•ermine o•i•ly the info•ation r•ueSte•, However, 

this sewi¢¢, A•aye0 • Natlona• 8peciaRy G•s•, 630 Unit• O• c, Dumam, NC 27713 (919• 544-3772