EMISSIONS TESTING 

FOR HF, F2, PARTICULATE HF, AND PARTICULATE 

ON KILN #1 EXHAUST (S-8) 

BORAL BRICKS 

Old Highway 22 

WEAKLEY COUNTY (Gleason), TN 38229 

(901) 648-5527 

November 4, 1998 

REPORT # 6057 

ANALYTICAL TESTING CONSULT ANTS, INC. 

30 1 Brookdale Street 

Kannapolis, N.C. 28083 

(704) 932-3193 

Distribution: 

Mr. David Johnson 

(Five copies) 

Issue Date: 

December 8, 1998 

/ 
TABLE OF CONTENTS 

Page 

Number 

Introduction .......................................... 1 

Certification of Results ........................... 1 

Process Description .................................... 2 

Process Sketch .................................. 3 

Results Summary ...................................... 4 

Results, Conclusions and Comments ....................... 5 

Sampling and Analytical Procedures ....................... 6 

References ........................................... 8 

Data and Calculations .................................. 9 

Particulate Emission Rate Calculation ............... 10 

Particulate Flouride Emissions .................... 11 

Hydrogen Flo uri de Emissions in 0.1N H2 S04 •...••.•. 12 

Flourine Emissions in 0.1N NaOH ................. 13 

(blank corrected) 

Flourine Emissions in 0.1N NaOH ................. 14 

(uncorrected) 

Nomenclature ........................................ 15 

Calculation Formulae .................................. 17 

Data Sheets .......................................... 19 

ii 

, 
INTRODUCTION 

This report presents the results of particulate and fluoride emissions testing on the #I kiln 

exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted on Wednesday 

November 4, 1998. 

Testing was conducted by Mr. John Welch of ANALYTICAL TESTING CONSULT ANTS, 

INC., Kannapolis, NC. 

CERTIFICATION OF RESULTS 

"By our signature we certify that the testing and the reporting of the test results contained herein are 

prepared to the best of our abilities and that, to our knowledge, the data have been calculated and reported 

correctly. No data or information has knowingly been omitted." 

[Jtd_~ W. Keith Poole 

l 

John Welch 

Test Report Preparation Test Team Leader 
PROCESS DESCRIPTION 

Bora! Bricks. Gleason Plant 

Bora! Bricks, Gleason Plant manufactures facing brick using clay, sawdust, recycled brick, and 

other body additives. Clay and green sawdust are delivered to the plant by truck. Moist ball clay 

is unloaded into the facility's primary crusher and carried via conveyor belt to a convered Raw 

Material Storage (a.k.a. Clay Storage) Building where it is stockpiled. Filler clay and sawdust 

are delivered directly to the Raw Material Storage Building and stockpiled. Off-spec bricks are 

carried by truck form the shipment preparation area to an outside stockpile area. As needed, the 

bricks are loaded inot an apron feeder and carried via conveyor into the Clay Storage Building 

whre they are processed through a hammermill (grinder) and vibrating screen to achieve a size 

suitable for reintroducing the off-spec brick back into the new brick body mixes. Using conveyor 

belts, the crushed brick (referred to as "grog") is then stockpiled in the Clay Storage Building. 

As needed, clay, sawdust, and grog are loaded into feeders. These feeders deposit raw materials 

inot one common belt conveyor. Before bieng shaped into a final form, the blend is carried by 

belt conveyors through a series of preparation machines which include: a disintegrator, followed 

by a smooth roller, followed by another disintegrator, followed by a controlled rate additive 

feeder (used as needed), follwed by two pug mills in series. As the clay enters the pug mills, 

water may be added depending on the moisture content of the clay. "Pugged" clay is then 

extruded as a column. 

Facial colorants are added to some products. These colorants typically consist of sand coatings 

mixed with other additives. All of the clay preparation and manufacturing equipment is 

contained in a covered building. The sand coatings are prepared in the covered Coatings Storage 

Area which is connected to the Clay Prep Building. If necessary, stored sand is dried in a rotary 

dryer prior to use. Coatings, including the dried sand, are,placed in hoppers for use in the coating 

operation. 

After being coated and textured, the extruded clay column is cut into green brick. Green brick 

are then stacked on kiln cars by a setting machine and placed in holding rooms where the green 

bricks' moisture content is lowered slightly. Kiln cars exit the holding rooms directly into one of 

four dryers (two sets). The purpose of these dryers is to further reduce the moisture content of 

the bricks. Each set of dryers has an exhaust stack, which have been determined to emit 

insignificant levels of pollutants. Both the holding rooms and dryers are heated with waste heat 

from the cooling sections of the kilns. 

Finally, dried brick are moved from the dryers into one of two identical tunnel kilns. Final 

evaporation of free water, dehydration, oxidation, vitrification, flashing, and cooling of bricks 

occurs in the kilns. The fuel used in the kilns is natural gas. Exhaust from the kilns exit 

respective stacks (ID#'s S-8 and S-9). Brick exiting the kiln are packaged and moved to outside 

storage prior to distribution. 

2 
~ "0 

8 

Raw Material Storage ffidg. 

Clay :-* Primary 

----

Covered ~ Raw Material ---.. Disintegrating ___, Smooth Rolling f-+ Disi

Unl011ding Crushing Stookplles Feedllrs 

O:ff-Spoo 

. Brick I-to 

Storage 

Off-Spec Brick 

Packaging 

and Storage 

t 

Screening Sand 

Stomge 

, Sawdll!it Unloading Apron Grinding Yw 

Feeder ~ SandDzyer 

(SD-1) 

I 

+E) 

waste he&t Mauufaduring Bldg. !""_, __ , ___ ,_,_, __ , __ • _,, .... -.-----. 

Firing 

(TK-1, TK-2) 

js-s .. S-91 ~ D.cying (D-1 toD-4) ~ ' It' I Holding . Room (H-l) .__ __ --- IS-2 ~ S-51 + .._ 

Process Flow Diagram 

Boral Brieks, Gleason Plant 

Cutting& 

Setting ~ 

-t 

Additive & C011ting 

__. 

Storage 

• 

Hoppers wate

(O>noo

wat

(once

II' 

Cooting& 

~ 

E

Texturlug 

~ 

waste return b

........

....

~ 
RESULTS SUMMARY 

SYSTEM Boral Brick 

Kiln #1 

TEST DATE 11-4-98 

PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE 

GENERAL 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

Vm STD (ft3) 36.63 37.40 37.48 

%1 97.39 102.37 104.55 

PROCESS RATE, TPH 5.9 

PARTICULATE EMISSIONS 

PMRc (lbs/hr) 0.109 0.140 0.098 0.116 

Cs (gr/scfd) 0.0014 0.0019 0.0013 0.0015 

FLOUR/DE EMISSIONS 

PARTICULATE FLOUR/DES (lbslhr) 8.33e-03 2.80e-03 1.04e-02 7.17e-03 - j ·- / 

(contained on M5 /liter) 

HYDROGEN FLOUR/DE (LBSIHR) 3.43e+00 4.05e+00 3.84e+00 3.77e+00 

(front half of impinger train) 

COMBINED HYDROGEN FLOUR/DE 

EMISSIONS (LBSIHR) 3.44e+00 4.05e+00 3.85e+00 3.78e+00 

FLOUR/NE (LBSIHR) 5.44e-02 4.67e-02 5.79e-02 5.30e-02 f) I' 0: :. 

(back half of impinger train, corrected for blank) 

FLOUR/NE (LBSIHR) 1.57e-01 1.46e-01 1.56e-01 1.53e-01 (.). I_) 

(back half of impinger train, not corrected for blank) 

HF EMISSIONS LBS/TON 0.64 

4 
RESULTS, CONCLUSIONS AND COMMENTS 

A summary of some pertinent results appear in the preceding RESULTS SUMMARY. For 

additional information please consult the CALCULATIONS and DATA SHEETS sections of 

this report. 

The mean velocity of the #I Kiln exhaust stack was determined to be 37.05 feet per second (ft/s) 

through the 37.5" round exhaust stack. This yielded a mean actual volumetric flowrate of 17,050 

cubic feet per minute (ACFM). The standard flowrate was calculated by applying corrections 

for: 1) barometric pressure- 30.05" Hg, 2) static pressure of the stack (-0.2 I" H20), 3) moisture 

content of each individual run- A VG.=8.48%, and 4) the corresponding stack temperatureA VG.=479.5° Fahrenheit. The corresponding mean standard volumetric flowrate was 8,835 

SCFM. 

Total hydroflouric acid emissions (HF contained on the filter and in the acidic impingers) 

averaged 3. 780 pounds per hour or I I 7,593 ~J-g/m . The average process rate was 5.9 tons brick 

per hour. This yields an emission rate of 0.64 lbs hydroflouric acid per ton of product kiln dried. 

5 
SAMPLING AND ANALYTICAL PROCEDURES 

Sampling and analysis were performed according to procedures developed by the U.S. 

Environmental Protection Agency (USEPA) and referred to as Methods I. 2. 3, 4, 5, and 26a. 

Three repetitions of USEP A method 5/26a were 

performed on the exhaust of the #1 Kiln stack. 

(The sampling train is shown to the right). The 

optional moisture knockout and short-stemmed 

sulfuric acid first impinger were deemed 

unnecessary for this location due to low moisture 

content and low to moderate concentrations of the 

analyte of concern. A numbered, pre-tared heated 

Teflon® filter was utilized in the heated filter 

box. Method 5 particulate was performed on the 

filter prior to analysis for particulate flourides. 

First Analytical Laboratories of Chapel Hill, NC 

performed the analysis according to US EPA 

method 26a., ion chromatography with 

f'JI >=)-I_ ,..., "••"' ,,..b. fit. Ill ~y l iil. 

ti ~ .. • ,,._ 

l • Plio! Tube ~ptleu: \ ~ Slftco lkl 

Mu•mU•• O.tll"•oM 

O.tN HZSCM 

Colib .. l•d 

Orlllu ···-\ Y•~nm 

flo• \ o •••• 

i . ?,~ 'i' 

Figure 26A-1. Sampling Train 

conductivity detection. Please refer to their report in the DATA SHEETS section of this report 

for additional details. 

All laboratory results were blank corrected. Blanks were comparatively low except for the 

reagent blank of the basic impingers (NaOH). This blank was more than half of the level of the 

samples. These results have, therefore, been reported as both blank corrected and uncorrected. 

The mass detected in the back half of the sampling train (NaOH), as F, was less than five percent 

of the mass detected in the front half of the sampling train (H2S04). 

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

following: 

1) FisherScentific XA Analytical Lab Balance-certified and annual maintenance 

by Lab Tech, Inc. Prior to each use, the balance is calibrated with NIST 

Traceable weights-0.5, 5.0, and 50.0 grams, 

2) a Precision Scientific Model 70 The leo® Oven-operated at I 05'C, 

3) a FisherScientific IsoTemp water bath operated at a temperature high enough 

to evaporate acetone without creating a rolling boil, and 

6 
SAMPLING AND ANALYTICAL PROCEDURES, CON'T. 

4) a Nalgene® 5317-0180 Dessicator cabinet with indicating dessicant. 

Prior to the field test, filter media were prepared by sequentially numbering Teflon® 3" filters 

with a non-bleeding marker and oven drying. Duplicate weighings were then completed on the 

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

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

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

Field particulate samples (front half rinse) were collected in 500ml Nalgene® sample containers 

and sealed with Teflon® Tape to ensure no sample loss. An additional quality assurance step is 

to mark the liquid level on the sides of each sample bottle with a grease pencil. 

Each filter was recovered and stored individually in petri dishes until transfer to the oven for 

drying. Each filter is oven dried for a period of no less than twenty-four hours at 105°C and 

weighed to a constant weight to the nearest 0.01 mg. A blank of the acetone reagent will be 

collected in the field, along with the field samples and analyzed side by side. 

7 
REFERENCES 

I. CODE OF FEDERAL REGULATIONS, Title 40, Part 60, Appendix A, July 1, 1997. 

8 
DATA AND CALCULATIONS 

Method Five Particulate Emission Rate Calculation 

Hydrogen Flouride Emissions-Filter Only 

Hydrogen Flouride Emissions-Front Half of Irnpinger Train Only 

Flourine Gas Emissions-Back Half of Irnpinger Train Only 

Total Flouride Emission Rate Calculation 

Run Data 

Moisture Data 

Isokinetic Sampling Data 

Nomenclature 

Calculation Formulae 

9 
PARTICULATE EMISSION RATE CALCULATION 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11-4-98 11-4-98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An (ft2) 5.33e-04 5.33e-04 5.33e-04 

AVG DH(in H20) 1.21 1.22 1.17 

PATM (in Hg) 30.05 30.05 30.05 

Pm (in Hg) 30.14 30.14 30.14 

Ps (GAUGE) -0.21 -0.21 -0.21 

Ps (IN HG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD (ft3) 36.63 37.40 37.48 

VLQ(ml} 77.20 81.60 79.70 

VVSTD (ft3) 3.64 3.84 3.76 

VSTD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts(F) 479.71 479.12 479.58 479.47 

Ts (R) 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As {ft2) 7.67 7.67 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD (ft3/min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 0.0034 0.0045 0.0032 

%/ 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc {lbs!hr) 0.109 . 0.140 0.098 0.116 

Cs (gr/scfd) 0.0014 0.0019 0.0013 0.0015 

10 
PARTICULATE FLOURIDE EMISSIONS 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11-4-98 11-4-98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An (ft2) 5.33e-04 5.33e-04 5.33e-04 

A VG DH (in H20) 1.21 1.22 1.17 

PATM(in Hg) 30.05 30.05 30.05 

Pm (in Hg) 30.14 30.14 30.14 

Ps(GAUGE) -0.21 -0.21 -0.21 

Ps(INHG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD(ft3) 36.63 37.40 37.48 

VLa(ml} 77.20 81.60 79.70 

VV STD(ft3) 3.64 3.84 3.76 

V STD{ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts(F) 479.71 479.12 479.58 479.47 

Ts(R) 939.71 939.12 939.58 939.47 

SUMSaRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSaRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

as, FLOW, ACFM 17219 17141 16792 17050 

a STD (ft3/mln) 9746 9708 9504 9652 

a STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 2.60e-04 9.ooe-05 3.40e-04 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc (lbslhr) 8.33e-03 2.80e-03 1.04e-02 7.17e-03 

Cs far/scfd) 1.1 Oe-04 3.71 e-05 1.40e-04 9.55e-05 

11 
HYDROGEN FLOURIDE EMISSIONS 

FLOURIDES DETECTED IN 0.1N H2S04 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11-4-98 11-4-98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An (ft2) 5.33e-04 5.33e-04 5.33e-04 

AVG DH (in H20) 1.21 1.22 1.17 

PATM(in Hg) 30.05 30.05 30.05 

Pm (in Hg) 30.14 30.14 30.14 

Ps (GAUGE) -0.21 -0.21 -0.21 

Ps (IN HG) 30.03 30.03 30.03 

Tm (F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD (ft3) 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VV STD (ft3) 3.64 3.84 3.76 

VSTD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts (F) 479.71 479.12 479.58 479.47 

Ts (R) 939.71 939.12 939.58 939.47 

SUMSORTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVG SORTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

OS, FLOW, ACFM . 17219 "17141 16792 17050 

Q STD (ft3/min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM "9063 . 8803 8639 8835 

WT(gm) 9.74e+01 1.02e+02 1.05e+02 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 3.43 4.05 3.84 

PMRc (lbs!hr) 3.43e+00 4.05e+00 3.84e+00 3.77e+00 

Cs (gr/scfd) 4.51 e-02 5.36e-02 5.1 9e-02 5.02e-02 

12 
FLOURINE (as F) EMISSIONS 

IN 0.1N NaOH 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

Blank Corrected 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 114-98 11·4-98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

On (in) 0.312 0.312 0.312 

An (ft2) 5.33e-04 5.33e-04 5.33e-04 

AVG DH (in H20) 1.21 1.22 1.17 

PATM (in Hg) 30.05 30.05 30.05 

Pm (lnHg) 30.14 30.14 30.14 

Ps(GAUGE) ·0.21 -0.21 -0.21 

Ps (IN HG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD (ft3) 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VV STD (ft3) 3.64 3.84 3.76 

V STD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts (F) 479.71 479.12 479.58 479.47 

Ts (R} 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVG SGRT DP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD (ft3/min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 1.70e-03 1.50e-03 1.90e-03 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc (lbslhr) 5.44e-02 4.67e-02 5.79e-02 5.30e-02 

Cs (ar!scfd) 7.16e-04 6.19e-04 7.82e-04 7.06e-04 

13 
FLOURINE (as F) EMISSIONs 

IN 0.1N NaOH 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

not corrected for blank 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11·4·98 11·4·98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An {ft2} 5.33e-04 5.33e-04 5.33e-04 

AVG DH (in H20) 1.21 1.22 1.17 

PATM(in Hg) 30.05 30.05 30.05 

Pm (in Hg) 30.14 30.14 30.14 

Ps (GAUGE) -0.21 -021 -0.21 

Ps (IN HG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm{R) 517.96 516.00 518.29 

Vm {ft3) 35.67 36.28 36.53 

Vm STD{ft3} 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VV STD{ft3} 3.64 3.84 3.76 

V STD(ft3} 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts (F) 479.71 479.12 479.58 479.47 

Ts(R} 939.71 939.12 939.58 939.47 

SUMSORTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As {ft2} 7.67 7.67 7.67 

OS, FLOW, ACFM 17219 17141 16792 17050 

Q STD {ft3/min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 4.90e-03 4.70e-03 5.10e-03 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc {/bs!hr) 1.57e-01 1.46e-01 1.56e-01 1.53e-01 

Cs _19r/scfd) 2.06e-03 1.94e-03 2.1 Oe-03 2.03e-03 

14 
BlfJ- 112 

EMISSIONS TESTING 

FOR HF, F2, PARTICULATE HF, AND PARTICULATE 

ON KILN #1 EXHAUST (S-8) 

BORAL BRICKS 

Old Highway 22 

WEAKLEY COUNTY (Gleason), TN 38229 

(901) 648-5527 

November 4, 1998 

REPORT# 6057 

ANALYTICAL TESTING CONSULT ANTS, INC. 

301 Brookdale Street 

Kannapolis, N.C. 28083 

(704) 932-3193 

Distribution: 

Mr. David Johnson 

(Five copies) 

Issue Date: 

December 8, 1998 
TABLE OF CONTENTS 

Page 

Number 

Introduction .......................................... 1 

Certification of Results ........................... 1 

Process Description .................................... 2 

Process Sketch ................................... 3 

Results Summary ...................................... 4 

Results, Conclusions and Comments ....................... 5 

Sampling and Analytical Procedures ....................... 6 

References ........................................... 8 

Data and Calculations .................................. 9 

Particulate Emission Rate Calculation ............... 10 

Particulate Flouride Emissions .................... 11 

Hydrogen Flouride Emissions in O.lN H2S04 •....•.•• 12 

Flourine Emissions in 0.1N NaOH ................. 13 

(blank corrected) 

Flourine Emissions in O.lN NaOH ................. 14 

(uncorrected) 

Nomenclature ........................................ 15 

Calculation Formulae .................................. 17 

Data Sheets .......................................... 19 

11 
INTRODUCTION 

This report presents the results of particulate and fluoride emissions testing on the #1 kiln 

exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted on Wednesday 

November 4, 1998. 

Testing was conducted by Mr. John Welch of ANALYTICAL TESTING CONSULTANTS, 

INC., Kannapolis, NC. 

CERTIFICATION OF RESULTS 

"By our signature we certify that the testing and the reporting of the test results contained herein are 

prepared to the best of our abilities and that, to our knowledge, the data have been calculated and reported 

correctly. No data or infomwtion has knowingly been omitted." 

W. 

Wbd~ Keith Poole l John Welch 

Test Report Preparation Test Team Leader 

1 
PROCESS DESCRIPTION 

Bora! Bricks. Gleason Plant 

Boral Bricks, Gleason Plant manufactures facing brick using clay, sawdust, recycled brick, and 

other body additives. Clay and green sawdust are delivered to the plant by truck. Moist ball clay 

is unloaded into the facility's primary crusher and carried via conveyor belt to a convered Raw 

Material Storage (a.k.a. Clay Storage) Building where it is stockpiled. Filler clay and sawdust 

are delivered directly to the Raw Material Storage Building and stockpiled. Off-spec bricks are 

carried by truck form the shipment preparation area to an outside stockpile area. As needed, the 

bricks are loaded inot an apron feeder and carried via conveyor into the Clay Storage Building 

whre they are processed through a hammermill (grinder) and vibrating screen to achieve a size 

suitable for reintroducing the off-spec brick back into the new brick body mixes. Using conveyor 

belts, the crushed brick (referred to as "grog") is then stockpiled in the Clay Storage Building. 

As needed, clay, sawdust, and grog are loaded into feeders. These feeders deposit raw materials 

inot one common belt conveyor. Before bieng shaped into a final form, the blend is carried by 

belt conveyors through a series of preparation machines which include: a disintegrator, followed 

by a smooth roller, followed by another disintegrator, followed by a controlled rate additive 

feeder (used as needed), follwed by two pug mills in series. As the clay enters the pug mills, 

water may be added depending on the moisture content of the clay. "Pugged" clay is then 

extruded as a column. 

Facial colorants are added to some products. These colorants typically consist of sand coatings 

mixed with other additives. All of the clay preparation and manufacturing equipment is 

contained in a covered building. The sand coatings are prepared in the covered Coatings Storage 

Area which is connected to the Clay Prep Building. If necessary, stored sand is dried in a rotary 

dryer prior to use. Coatings, including the dried sand, are,placed in hoppers for use in the coating 

operation. 

After being coated and textured, the extruded clay column is cut into green brick. Green brick 

are then stacked on kiln cars by a setting machine and placed in holding rooms where the green 

bricks' moisture content is lowered slightly. Kiln cars exit the holding rooms directly into one of 

four dryers (two sets). The purpose of these dryers is to further reduce the moisture content of 

the bricks. Each set of dryers has an exhaust stack, which have been determined to emit 

insignificant levels of pollutants. Both the holding rooms and dryers are heated with waste heat 

from the cooling sections of the kilns. 

Finally, dried brick are moved from the dryers into one of two identical tunnel kilns. Final 

evaporation of free water, dehydration, oxidation, vitrification, flashing, and cooling of bricks 

occurs in the kilns. The fuel used in the kilns is natural gas. Exhaust from the kilns exit 

respective stacks (ID#'s S-8 and S-9). Brick exiting the kiln are packaged and moved to outside 

storage prior to distribution. 

2 
~ ll 

!;! 

Raw Material Storage Bldg. 

Clay ~ Prillllll}' • Covered • Raw Material ~ Disintegrating f-. Smooth Rolling ....... Disin

Unloading Crushing r Stockpile& Feeders 

Off-Speo 

. Brick .... 

Storago 

Off-Spec Brick 

Pw:kaging 

and Storage~ Sa'etming ' Sand Sawdust Stomge ' Unloading Apron r+ Grinding .~ Feeder SandDzyer (SD-1) I S-1 J waste beat Manufaduring Bldg. r ......... ---··-·---.-··--·-- Firing • (TK-1, TK-2) 

I I S-8. S-91 ~ Drying ~ Holding . (D-1 toD-4) Room(H-1) I+- I S-6, S-71 I S-2 Ia 8·5 

Process Flow Diagram 

Boral Bricks, Gleason Plant 

Cutting& ..._ 

Setting ~ 

Additive & Coating 

Storage ~ 

Hoppers wate

(,.nooc

wate

("'"""

CC8ling& ..._ E

TexturiDg • 

ll1l b

-

.

---

~ 
RESULTS SUMMARY 

SYSTEM Bora! Brick 

Kiln #1 

TEST DATE 11-4-98 

PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE 

GENERAL 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

Vm STD(ft3) 36.63 37.40 37.48 

%1 97.39 102.37 104.55 

PROCESS RATE, TPH 5.9 

PARTtCULA TE EMISSIONS 

PMRc (Jbs/hr) 0.109 0.140 0.098 0.116 

Cs (grlscfd) 0.0014 0.0019 0.0013 0.0015 

FLOUR/DE EMISSIONS 

PARnCULA TE FLOUR/DES {lbs/hr) 8.33e-03 2.80e-03 1.04e-02 7.17e-03 C),c:>U71/ 

(contained on MS filter) 

HYDROGEN FLOUR/DE (LBS/HR) 3.43e+OO 4.05e+00 3.84e+00 J.ne+OO 

(front half of implnger train) 

COMBINED HYDROGEN FLOUR/DE 

EMISSIONS (LBS/HR) 3.44e+OO 4.05e+00 3.85e+00 3.78e+00 ? 77' ...... ' ' " 

FLOURINE (LBS/HR) 5.44e-02 4.67e-02 5.79e-02 5.30e-02 0, t);; 3 

(back half of lmpinger train, corrected for blank) ~-

FLOURINE (LBS/HR) 1.57e-01 1.46e-01 1.56e-01 1.53e·01 0- ?S"" 

(back half of impinger train, not corrected for blank) 

HF EMISSIONS LBS/TON 0.64 

4 
RESULTS, CONCLUSIONS AND COMMENTS 

A summary of some pertinent results appear in the preceding RESULTS SUMMARY. For 

additional information please consult the CALCULATIONS and DATA SHEETS sections of 

this report. 

The mean velocity of the #1 Kiln exhaust stack was determined to be 37.05 feet per second (ftls) 

through the 37.5" round exhaust stack. This yielded a mean actual volumetric tlowrate of 17,050 

cubic feet per minute (ACFM). The standard flowrate was calculated by applying corrections 

for: 1) barometric pressure- 30.05" Hg, 2) static pressure of the stack (-0.21" H,O), 3) moisture 

content of each individual run- AVG.=8.48%, and 4) the corresponding stack temperatureAVG.=479.SO Fahrenheit. The corresponding mean standard volumetric flowrate was 8,835 

SCFM. 

Total hydroflouric acid emissions (HF contained on the filter and in the acidic impingers) 

averaged 3.780 pounds per hour or 117,593 f1-g/m3

• The average process rate was 5.9 tons brick 

per hour. This yields an emission rate of 0.64lbs hydrotlouric acid per ton of product kiln dried. 

5 
EMISSIONS TESTING 

FOR HF, F2, PARTICULATE HF, AND PARTICULATE 

ON KILN #1 EXHAUST (S-8) 

BORAL BRICKS 

Old Highway 22 

WEAKLEY COUNTY (Gleason), TN 38229 

(901) 648-5527 

November 4, 1998 

REPORT# 6057 

ANALYTICAL TESTING CONSULT ANTS, INC. 

301 Brookdale Street 

Kannapolis, N. C. 28083 

(704) 932-3193 

Distribution: 

Mr. David Johnson 

(Five copies) 

Issue Date: 

December 8, 1998 
TABLE OF CONTENTS 

Page 

Number 

Introduction .......................................... 1 

Certification of Results ........................... 1 

Process Description .................................... 2 

Process Sketch .................................. 3 

Results Summary ...................................... 4 

Results, Conclusions and Comments ....................... 5 

Sampling and Analytical Procedures ....................... 6 

References ........................................... 8 

Data and Calculations .................................. 9 

Particulate Emission Rate Calculation ............... 10 

Particulate Flouride Emissions .................... 11 

Hydrogen Flouride Emissions in O.lN H2S04 ••••••.•• 12 

Flourine Emissions in 0.1N NaOH ................. 13 

(blank corrected) 

Flourine Emissions in 0.1N NaOH ................. 14 

(uncorrected) 

Nomenclature ........................................ 15 

Calculation Formulae .................................. 17 

Data Sheets .......................................... 19 

II 
INTRODUCTION 

This report presents the results of particulate and fluoride emissions testing on the #I kiln 

exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted on Wednesday 

November 4, 1998. 

Testing was conducted by Mr. John Welch of ANALYTICAL TESTING CONSULTANTS, 

INC., Kannapolis, NC. 

CERTIFICATION OF RESULTS 

"By our signature we cenify that the testing and the reporting of the test results contained herein are 

prepared to the best of our abilities and that, to our knowledge. the data have been calculated and reported 

correctly. No data or infomzation has knowingly been omitted." 

W. 

w~~ Keith Poole l John Welch 

Test Report Preparation Test Team Leader 
PROCESS DESCRIPTION 

Boral Bricks. Gleason Plant 

Bora! Bricks, Gleason Plant manufactures facing brick using clay, sawdust, recycled brick, and 

other body additives. Clay and green sawdust are delivered to the plant by truck. Moist ball clay 

is unloaded into the facility's primary crusher and carried via conveyor belt to a convered Raw 

Material Storage (a.k.a. Clay Storage) Building where it is stockpiled. Filler clay and sawdust 

are delivered directly to the Raw Material Storage Building and stockpiled. Off-spec bricks are 

carried by truck form the shipment preparation area to ail outside stockpile area. As needed, the 

bricks are loaded inot an apron feeder and carried via conveyor into the Clay Storage Building 

whre they are processed through a harnmermill (grinder) and vibrating screen to achieve a size 

suitable for reintroducing the off-spec brick back into the new brick body mixes. Using conveyor 

belts, the crushed brick (referred to as "grog") is then stockpiled in the Clay Storage Building. 

As needed, clay, sawdust, and grog are loaded into feeders. These feeders deposit raw materials 

inot one common belt conveyor. Before bieng shaped into a final form, the blend is carried by 

belt conveyors through a series of preparation machines which include: a disintegrator, followed 

by a smooth roller, followed by another disintegrator, followed by a controlled rate additive 

feeder (used as needed), follwed by two pug mills in series. As the clay enters the pug mills, 

water may be added depending on the moisture content of the clay. "Pugged" clay is then 

extruded as a column. 

Facial colorants are added to some products. These colorants typically consist of sand coatings 

mixed with other additives. All of the clay preparation and manufacturing equipment is 

contained in a covered building. The sand coatings are prepared in the covered Coatings Storage 

Area which is connected to the Clay Prep Building. If necessary, stored sand is dried in a rotary 

dryer prior to use. Coatings, including the dried sand, are.placed in hoppers for use in the coating 

operation. 

After being coated and textured, the extruded clay column is cut into green brick. Green brick 

are then stacked on kiln cars by a setting machine and placed in holding rooms where the green 

bricks' moisture content is lowered slightly. Kiln cars exit the holding rooms directly into one of 

four dryers (two sets). The purpose of these dryers is to further reduce the moisture content of 

the bricks. Each set of dryers has an exhaust stack, which have been determined to emit 

insignificant levels of pollutants. Both the holding rooms and dryers are heated with waste heat 

from the cooling sections of the kilns. 

Finally, dried brick are moved from the dryers into one of two identical tunnel kilns. Final 

evaporation of free water, dehydration, oxidation, vitrification, flashing, and cooling of bricks 

occurs in the kilns. The fuel used in the kilns is natural gas. Exhaust from the kilns exit 

respective stacks (ID#'s S-8 and S-9). Brick exiting the kiln are packaged and moved to outside 

storage prior to distribution. 

2 
1l 

eJ 

Rllw Material Storage mag. 

Clay W Primacy 

Unloadingl1 Crushing r-+1 Covered Stccltp!les SmaolhRolling 

__!_ 

Suetmiog 

_!_ 

Oft:.Speo Apron H 

Brick Feeder I '--- Storage Grinding 

Off-Succ Brlck 

Sawdust 

Unloading 

Sand 

Storage 

+or 

SandDzyer 

(SD-1) 

-r 

+E) 

Additive & Cotlting I 

Storage 

+ Hoppers w

(u

wa

(no

--·-·-

Packaging H Firing 

Manufaduring Bldg. 

and Storago (TK.-1, TK.-2) 

_j I S-8,, S-9 

·-

Holding 

Rcom (H-1) 

j_ ls-y-71 I 

,. 

Process Flow Diagram 

Boral Bricks. Gleason Plant 

Cutting& 

Setting 

waste return 
RESULTS SUMMARY 

SYSTEM Boral Brick 

Kiln #1 

TEST DATE 11-4-98 

PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE 

GENERAL 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

Vm STD(ft3) 36.63 37.40 37.48 

%1 97.39 102.37 104.55 

PROCESS RATE, TPH 5.9 

PART/CULA TE EMISSIONS 

PMRc (lbs/hr) 0.109 0.140 0.098 0.116 

Cs (gr/scfd) 0.0014 0.0019 0.0013 0.0015 

FLOUR/DE EMISSIONS 

PARTICULATE FLOUR/DES (lb$/hr) 8.33e-03 2.80e-03 1.04e-02 7.17e-03 (), vcJ7 17 

(contained on MS filter) 

HYDROGEN FLOUR/DE (LBS/HR) 3.43e+00 4.05e+00 3.84e+00 3.77e+00 

(front hsff of implnger train) 

COMBINED HYDROGEN FLOUR/DE _, EMISSIONS 

•-74 (LBSIHR) 3.44e+00 4.058+00 3.85e+OO 3.78e+OO ..,.__ ; ,' r_ 

FLOUR/NE (LBS/HR) 5.44e-02 4.67e-02 5.79e-02 5.30e-02 D,<J:;5 

(back haff of impinger train. corrected for blank) 

FLOURINE (LBS/HR) 1.57e-01 1.46e-01 1.56e-01 1.53e-01 o. ,_, 

(back haff of lmp/nger train, not corrected for blank) 

HF EMISSIONS LBS/TON 0.64 

4 
RESULTS, CONCLUSIONS AND COMMENTS 

A summary of some pertinent results appear in the preceding RESULTS SUMMARY. For 

additional information please consult the CALCULATIONS and DATA SHEETS sections of 

this report. 

The mean velocity of the #I Kiln exhaust stack was detennined to be 37.05 feet per second (fils) 

through the 37.5" round exhaust stack. This yielded a mean actual volumetric flowrate of 17,050 

cubic feet per minute (ACFM). The standard flowrate was calculated by applying corrections 

for: I) barometric pressure- 30.05" Hg, 2) static pressure of the stack (-0.21" H20), 3) moisture 

content of each individual run- AVG.=8.48%, and 4) the corresponding stack temperatureAVG.=479.SO Fahrenheit. The corresponding mean standard volumetric flowrate was 8,835 

SCFM. 

Total hydroflouric acid emissions (HF contained on the filter and in the acidic impingers) 

averaged 3.780 pounds per hour or I 17,593 f.l-g/m3

• The average process rate was 5.9 tons brick 

per hour. This yields an emission rate of 0.64 Ibs hydroflouric acid per ton of product kiln dried. 

5 
SAMPLING AND ANALYTICAL PROCEDURES 

Sampling and analysis were performed according to procedures developed by the U.S. 

Environmental Protection Agency (US EPA) and referred to as Methods l, 2, 3, 4, 5, and 26a. 

Three repetitions of US EPA method 5/26a were 

performed on the exhaust of the #I Kiln stack. 

(The sampling train is shown to the right). The 

optional moisture knockout and short-stemmed 

sulfuric acid first impinger were deemed 

unnecessary for this location due to low moisture 

content and low to moderate concentrations of the 

analyte of concern. A numbered, pre-tared heated 

Teflon® filter was utilized in the heated filter 

box. Method 5 particulate was performed on the 

filter prior to analysis for particulate flourides. 

First Analytical Laboratories of Chapel Hill, NC 

e.1NH:rsot 

.. ...,..... 

_... Dfl' a.. v.c ... .., ..... , __ 

performed the analysis according to USEPA Figure 26A-l. Sampling Train 

method 26a., ion chromatography with 

conductivity detection. Please refer to their report in the DATA SHEETS section of this report 

for additional details. 

All laboratory results were blank corrected. Blanks were comparatively low except for the 

reagent blank of the basic impingers (NaOH). This blank was more than half of the level of the 

samples. These results have, therefore, been reported as both blank s;orrected and uncorrected. 

The mass detected in the back half of the sampling train (NaOH), a,5 F, was less than five percent 

of the mass detected in the front half of the sampling train (H2S04). 

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

following: 

1) FisherScentific XA Analytical Lab Balance-certified and annual maintenance 

by Lab Tech, Inc. Prior to each use, the balance is calibrated with NIST 

Traceable weights-0.5, 5.0, and 50.0 grams, 

2) a Precision Scientific Model 70 Thelco® Oven-operated at lOSOC, 

3) a FisherScientific IsoTemp water bath operated at a temperature high enough 

to evaporate acetone without creating a rolling boil, and 

6 
SAMPLING AND ANALYTICAL PROCEDURES, CON'T. 

4) a Nalgene® 5317-0180 Dessicator cabinet with indicating dessicant. 

Prior to the field test, filter media were prepared by sequentially numbering Teflon ® 3" filters 

with a non-bleeding marker and oven drying. Duplicate weighings were then completed on the 

filters to a constant weight. Additionally, a sufficient quantity of numbered 150m! Griffin 

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

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

Field particulate samples (front half rinse) were collected in 500rnl Nalgene® sample containers 

and sealed with Teflon® Tape to ensure no sample loss. An additional quality assurance step is 

to mark the liquid level on the sides of each sample bottle with a grease pencil. 

Each filter was recovered and stored individually in petri dishes until transfer to the oven for 

drying. Each filter is oven dried for a period of no less than twenty-four hours at l05°C and 

weighed to a constant weight to the nearest 0.01 mg. A blank of the acetone reagent will be 

collected in the field, along with the field samples and analyzed side by side. 

7 
REFERENCES 

1. CODE OF FEDERAL REGULATIONS, Title 40, Part 60, Appendix A, July l, 1997. 

8 
DATA AND CALCULATIONS 

Method Five Particulate Emission Rate Calculation 

Hydrogen Flouride Emissions-Filter Only 

Hydrogen Flouride Emissions-Front Half of Irnpinger Train Only 

Flourine Gas Emissions-Back Half of Irnpinger Train Only 

Total Flouride Emission Rate Calculation 

Run Data 

Moisture Data 

Isokinetic Sampling Data 

Nomenclature 

Calculation Formulae 

9 
PARTICULATE EMISSION RATE CALCULATION 

LOCAnON: Bora/ Brick 

SOURCE: Kiln#1 

DATA RUN#1 RUN#2 RUN#3 AVERAGf 

DATE 11-4-98 11-4-98 11-4-98 

RUN nME (min) 60.00 60.00 60.00 

Dn {In) 0.312 0.312 0.312 

An {ft2} 5.33e-04 5.33e-04 5.33e-04 

A VG DH (in H20} 1.21 1.22 1.17 

PATM(InHg) 30.05 30.05 30.05 

Pm{lnHg) 30.14 30.14 30.14 

Ps(GAUGE) -0.21 -0.21 -0.21 

Ps(INHG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm(R} 517.96 516.00 518.29 

Vm {ft3} 35.67 36.28 36.53 

Vm STD {ft3} 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VV STD {ft3} 3.64 3.84 3.76 

V STD(ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts(F) 479.71 479.12 479.58 479.47 

Ts(R) 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ft/s) 37.42 37.25 36.49 37.05 

Ds(ln) 37.50 37.50 37.50 

As (ft2) 7.67 7.67. 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD {ft3/mln) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 0.0034 0.0045 0.0032 

%/ 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 . 0.00 

%N2 80.58 80.54 80.54 

PMRc (lbs/hr) 0.109 0.140 0.098 0.116 

Cs (Qr/scfd) 0.0014 0.0019 0.0013 0.0015 

10 
PARTICULATE FLOURIDE EMISSIONS 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

DATA RUN#1 RUN#2 RUN#3 AVERAG.E 

DATE 11-4-98 11-4-98 11-4-98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (In) 0.312 0.312 0.312 

An (ft2) 5.33e-04 5.33e-04 5.33e-04 

AVG DH (In H20) 1.21 1.22 1.17 

PATM(inHg) 30.05 30.05 30.05 

Pm{ln Hg) 30.14 30.14 30.14 

Ps(GAUGE) -0.21 -0.21 -0.21 

Ps(INHG) 30.03 30.03 30.03 

Tm{F) 57.96 56.00 58.29 

Tm{R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD {ft3) 36.63 37.40 37.48 

VLQ (ml} 77.20 81.60 79.70 

VV STD{ft3) 3.64 3.84 3.76 

V STD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts (F) 479.71 479.12 479.58 479.47 

Ts (R) 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ft/s) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD {ft31min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 2.60e-04 9.00e-05 3.40e-04 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc (lbslhr) 8.33e-03 2.80e-03 1.04e-02 7.17e-Q3 

cs (or/scfd) 1.10e-04 3.71e-05 1.40e-04 9.55e-05 

11 
HYDROGEN FLOURIDE EMISSIONS 

FLOURIDES DETECTED IN 0.1N H2S04 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11-4-98 11·4·98 11-4-98 

RUN nME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An (ft2) 5.33e·04 5.33e-04 5.33e-04 

AVG DH(In H20) 1.21 1.22 1.17 

PATM(InHg) 30.05 30.05 30.05 

Pm (In Hg) 30.14 30.14 30.14 

Ps(GAUGE) -0.21 -0.21 -0.21 

Ps (INHG) 30.03 30.03 30.03 

Tm (F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD (ft3) 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VVSTD (ft3) 3.64 3.84 3.76 

V STD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts(F) 479.71 479.12 479.58 479.47 

Ts (R) 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ft/s) 37.42 37.25 36.49 37.05 

Ds (In) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD (ft31min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 9.74e+01 1.02e+02 1.05e+02 

%1 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 3.43 4.05 3.84 

PMRc (lbslhr) 3.43e+00 4.05e+00 3.84e+00 3.77e+00 

cs (gr/scfd) 4.51 e-02 5.36e-02 5.19e-02 5.02e-02 

12 
FLOURINE (as f") EMISSIONS 

IN 0.1N NaOH 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

Blank Corrected 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11·4·98 11·4·98 11·4·98 

RUN TIME (min) 60.00 60.00 60.00 

On (in) 0.312 0.312 0.312 

An (ft2} 5.33e·04 5.33e·04 · 5.33e·04 

AVG DH (in H20) 1.21 1.22 1.17 

PATM(InHg) 30.05 30.05 30.05 

Pm (inHg) 30.14 30.14 30.14 

Ps(GAUGE) ·0.21 ·0.21 ·0.21 

Ps(JNHG) 30.03 30.03 30.03 

Tm(F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm {ft3) 35.67 36.28 36.53 

Vm STD {ft3) 36.63 37.40 37.48 

VLQ{m/) 77.20 81.60 79.70 

WSTD{ft3) 3.64 3.84 3.76 

V STD(ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts(F) 479.71 479.12 479.58 479.47 

Ts (R) 939.71 939.12 939.58 939.47 

SUMSORTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSORTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds(ln) 37.50 37.50 37.50 

As {ft2) 7.67 7.67 7.67 

OS, FLOW, ACFM 17219 17141 16792 17050 

Q STD (ft3/mln) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 1.70e·03 1.50e-03 1.90e·03 

%/ 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc (Jbslhr) 5.44e·02 4.67e·02 5.79e·02 5.30e-02 

cs far!scfd) 7.16e·04 6.19e-04 7.82e·04 7.06e..Q4 

13 
FLOURINE (as r> EMISSioNs 

IN 0.1N NaOH 

LOCATION: Bora/ Brick 

SOURCE: Kiln #1 

not corrected for blank 

DATA RUN#1 RUN#2 RUN#3 AVERAGE 

DATE 11·4·98 11·4·98 11·4·98 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0.312 0.312 0.312 

An (ft2} 5.33e·04 5.33e·04 5.33e-04 

AVG DH (In H20) 1.21 1.22 1.17 

PATM (in Hg) 30.05 30.05 30.05 

Pm (inHg) 30.14 30.14 30.14 

Ps (GAUGE) ·0.21 ·0.21 ·0.21 

Ps (IN HG) 30.03 30.03 30.03 

Tm (F) 57.96 56.00 58.29 

Tm(R) 517.96 516.00 518.29 

Vm (ft3) 35.67 36.28 36.53 

Vm STD(ft3) 36.63 37.40 37.48 

VLQ (ml) 77.20 81.60 79.70 

VVSTD (ft3) 3.64 3.84 3.76 

V STD (ft3) 40.27 41.24 41.24 

%M 7.00 9.32 9.11 8.48 

MD 0.93 0.91 0.91 

MWD 29.26 29.26 29.26 

M 28.47 28.21 28.23 

Ts (F) 479.71 479.12 479.58 479.47 

Ts (R} 939.71 939.12 939.58 939.47 

SUMSQRTDP 11.93 11.82 11.58 

NDP 24.00 24.00 24.00 

AVGSQRTDP 0.50 0.49 0.48 

CP 0.84 0.84 0.84 

Vs (ftls) 37.42 37.25 36.49 37.05 

Ds (in) 37.50 37.50 37.50 

As (ft2) 7.67 7.67 7.67 

QS, FLOW, ACFM 17219 17141 16792 17050 

Q STD (ft3/min) 9746 9708 9504 9652 

Q STD DRY, FLOW SCFM 9063 8803 8639 8835 

WT(gm) 4.90e·03 4.70e-03 5.1 Oe-03 

%/ 97.39 102.37 104.55 

%C02 4.00 4.00 4.00 4.00 

%02 15.42 15.46 15.46 15.44 

%CO 0.00 0.00 0.00 

%N2 80.58 80.54 80.54 

PMRc (lbs/hr) 1.57e-01 1.46e-01 1.56e-01 1.53e·01 

Cs (gr/scfd) 2.06e·03 1.94e-03 2.10e-03 2.03e-03 

14 
NOMENCLATURE 

AN (square inches), Cross sectional area of nozzle 

AS (square feet), Cross sectional area of stack 

CP Pitot tube calibration coefficient 

% EA Percent Excess Air 

F (scfd/10 6 BTU), F factor 

DH (inches of water) Average orifice meter reading 

HI (million BTU/hr), Heat Input Rate 

% I Percent Isokineticity 

M (lb/lb mole), Molecular Weight of wet gas 

% M Percent Moisture 

MD Mole fraction of dry gas 

MWD (lbllb mole) molecular weight of dry gas 

N DP Number of sample points 

P ATM (in Hg), Local atmospheric pressure 

PM (in Hg), Absolute pressure in dry gas meter 

PS (in Hg), Absolute stack pressure 

PS GAUGE (inches of water), Measured static stack pressure gauge 

P STD (29.92 in Hg), Standard pressure 

PMRC (lblhr), Pollutant mass rate based on concentration 

PMRU (lb/mil!ion BTU), Specific emission rate 

15 
NOMENCLATURE (CONTINUED) 

DP (inches of water), Velocity pressure 

QS (cubic feet/min.), Actual stack volume flow rate 

Q STD (cubic feet/min.), Stack volume flow rate at standard 

conditions 

TM (degrees R), Average dry gas meter temperature 

TS (degrees R), Average stack temperature 

T STD (528 degrees R), Standard temperature 

VLQ (ml), Liquid volume 

VM (cubic feet), Sample volume measured by dry gas meter 

VM STD (cubic feet), Sample volume at standard conditions 

VS (ft/sec), stack velocity 

VV STD (cubic feet), Volume of water vapor collected, 

corrected to standard conditions 

WT (gm), Total weight of particulate collected 

TIME (MlN.) Duration of test 

16 
CALCULATION FORMULAE 

1. Absolute pressure in dry gas meter 

PM= P ATM + DH/13.6 

2. Absolute Stack Pressure 

PS = P ATM + PS gauge/13.6 

3. Sample volume at standard conditions 

VM STD =(GAMMA FACTOR, 0.983)(VM) (T STDrrM) (PMJP STD) 

4. Volume of water collected, corrected to standard conditions 

VV STD = (.00267) (VLQ) (T STD/P STD) 

5. Total sample volume at standard conditions 

V STD = VM STD + VV STD 

6. Percent moisture in stack gas 

%M = (100) (VV STD)N STD 

7. Mole Fraction of dry gas 

MD= (l00-%M)/l00 

8. Molecular weight of the wet gas 

M = (MWD) (MD)+ 18(1-MD) 

9. Stack velocity 

VS = (85.48)(CP)((TS/(PS)(M))"'((Sum DPt' N DP)) 

10. Stack volume flow rate 

QS = (60)(VS)(AS) 

17 
CALCULATION FORMULAE (CONTINUED) 

II. Stack volume flow rate, standard conditions including 

moisture 

Q STD = (T STDIP STD)(PSffS )(QS) 

12. Stack volume flow rate standard conditions dry 

Q STD DRY= (Q STD)(l-%M) 

13. Pollutant mass rate, concentration basis 

PMRC = (.1323)(WT)(Q STD)N STD 

14. Pollutant mass rate ratio of areas basis 

PMRA = (.1323)(WT)(AS)(I44)/(Tirne)(AN) 

15. Percent lsokineticity 

%I= (100) (PMRA)/PMRC 

16. Average pollutant mass rate 

PMR A VG = (PMRA + PMRC)/2 

17. %Excess Air 

%EA = (100) (%oxygen- (.5)(%carbon monoxide) 

(.264)(%nitrogen)- %oxygen+ (.5) (%carbon monoxide) 

18. Heat input rate 

HI= ((.6) (Q STD DRY)/F)((20.9- %oxygen)/20.9) 

19. Specific emission rate 

PMRU = PMR AVO/HI 

18 
DATA SHEETS 

Method 5/26a Sampling Data Sheets 

Preliminary Traverse Data Sheets 

Impinger Data Sheets 

Gas Analysis Data Sheets 

Source Test Survey 

Equal Area Calculations 

Chain of Custody Record 

Laboratory Reports 

Gravimetric Analysis 

Hydroflouric Acid Lab Results 

Calibration Information 

19 
~AL.1Y'I·.1.\,;AL 

·.~:ES·~·.1.NC" .:ONsuLT.AN·rs, !NC. 

KANNAPOLo~.S, N.C. 

MODULE SAMPLING DATA SHEET 

LOCATION 

CLIENT Boral 

Gleason. 

Brick DATE 

11-4-9~ Pbar JO. D 5 

TN SOURCE /Ciw I Ps - o. ~I 

LEAK 

TEST 

RA'rEs-____ 

TEAM _:3-V..J 

SETUP 

RuN # Method 5 

Comments: 

Start .ooY e./5 "Hg AH@ f. 7 5 NOZZLE. • 'J/j lc# G/... l J3., f' f: __ /5o D Y 

end .01 ~@ 5 "Hg Tm &5 % H20 ts.% I 

PITOT: Ts 5oS Gamma Factor_ /.~0 Agency Personnel On 

BS:~,Q Md _.29.~()~- Pm_ ~3_o.tl,. 

0 

Zo 

/0 

II 

FORM 

T. = meter temperature T. ,. stack temperature TP :a probe temperature Tr :a filter temperature T1 • exhaust temP.erature o

... P. = Velocity head differential pressure AH ,. pressure differential acrose the orifice meter v. u:t) • gaa sa
CLIENT Boral Brick 

LOCATION Gleason, TN 

TEST TEAM Jw 

AN.IU.IY'r .1.~ 'J:ES'J.'.LNC" .:ONsuLTAN'l'S, !Nc. 

KANNAPOL.1.S, N.C. 

MODULE SAMPLING DATA SHEET 

DATE 11-4-98 

SOURCE j(; I,.; 4 I 

RUN # 

__ l.....CON'l' 

Pbar 30. oS 

Ps 

-~.fl./ 

Method 5 LEAK RATES. SETUP-- - ·-------- Comments: 

.A.H@ ____ --,,.r 

% l12U ___ 7'-----

M

F

P

PI TOT Agency Personnel On S

S'o I ., 

,~ 

S' S I '' 

c. a 

FORM 16 

T_.. 

~P. 

= 

= 

meter 

Velocity temperature. head d~fferential T. = stack temperature TP = probe temperature Tl' • filter temperatura T, • exhaust t~erature of 

pressure AH = pressure differential acroaa the orifice mater V_.. (ft ) • gas sam
CLIENT Boral Brick 

LOCATION Gleason, TN 

TEST TEAM J""' 

AN.tu..YT.L\..AL -~·ES·~·.LNr •.;0NsuLT.A1'4·l'S, !Nt:. 

KANNAPOL.:S, N.C. ·' 

MODULE SAMPLING DATA SHEET 

DATE 11-4-98 Pbar 30.D5 

SOURCE 

1<:1-v~/ Ps -(J.,/2/ 

~~g-- -------- SETUI'-

RUN # 2 Method _ ___5~ __ _ 

Comments: 

Start__._Q_~ 

~'Ha: AH@ /. 7"i NOZZLE o3125c#tt ) 

end ,co '3 @ Z "Ha: Tm (o{) % H20 ~_%_ 

-

PITOT: Ts 1'1~ Gamma Factor /. OCJ Agency Personnel On 

start 

A _t_./J --"- B.f 'I-"H2.Q Md 2'7 Pm. 

o5 

0 

5 

Zt> 

Z.5 

FORM 16 

T. = meter ~· 

AP. = Velocity temperature head differential T. = stack pressure temperature &a TP = oz pressure probe temper:.;i.'• T, = filter temperature T~. ,. exhaust t~erature o

dif:f ~· ·:ial across the orifice meter v. (ft) ~ ;as sa
CLIENT Boral Brick 

LOCATION Gleason. TN 

TEST TEAM. J vJ 

.A.NA.L~YT .1.\..AL ·x.ES·~·~tlC" .;ON:suLTAL'I'rS, !Nt:. 

KANNAPOL.LS, N.C. 

MODULE SAMPLING DATA SHEET 

DATE 11-4-98 

SOURCE /( : I ..! '"" I 

RUN# 2-CONT 

Pbar 30.D5 

Ps - o. 21 

LEU RATES Method 5 - -. - -sETUP- ---- Comments: 

AH@------7"'--

% n 2vo ______ :?~-

M

F

P

Agency Personnel On S

) 

S"tJ 

S5 

0 

FORM 

T.._ = meter temperature T. • atack temperature TD • proba temperatura T2 AP. = Velocity head differential pressure AH = prassura • filter temperatura Tl = exhaust t~erature o~ 

differential across the orifica mater v. (:f!t } = gas sam
AN.N..YT .L\,;AL '.L'.ES'.L' .LHC" .;ONsuLTJw'l'S, !NC. 

KANNAPOLJ.S, N.C. 

MODULE SAMPLING DATA SHEET 

CLIENT Boral Brick DATE 11-4-98 Pbar SO. 0 S LOCATION Gleason. TN SOURCE .K;Iw £I Ps -o. Z I TEST TEAM .J....., RUN # 

__ 3 ____ Method 5. Z. (.A LEAK1U.TES ·sETUP ------ Comments: 

start.ol'f @I) "Hq AH@ 1.7'5 NOZZLE. '?.12.''5 ( # <!. L l 

end ,0/0@ /_I)_"Ha Tm ~0 % H20 (, 1D 

P:ITOT: T. LJ'i{ D Gamma Factor / ()0 Agency Personnel On 

start 

A 'i.<f n B'6(/'ng2Q Md z~.I9D Plll, 30.11.{ 

5 

lf 

5' 

(') 

zs 

~0 

30 

POIIM 

'1". = meter temperature T. • stack temperature TP • probe temperature 'l'r • filter temperature '1'1 AP. = Velocity head dit'ferential pressure AH • exhaust t~erature o

= pressure different-ial aero•• the orifice meter v. (ft } • gas sam

--- ----
ANA.UY'T .l.l.:AL 'l'ES'l'.l..L'\IC ;ON:su.L.T~·l'S, .:CNC. 

KANNAPOL~~. N.C. 

· MODULE SAMPLING DATA SHEET 

Pbar_ 3o.oS 

% v•------~---------

Agency Personnel On Si

'I~ 

Jf'> 

5(; 

() 

T. 

AP. 

= 

= 

meter 

Velocity temperature head differential '1'. • stack pressure temperature AH Tp = a probe temperature T~ • filter temperature Tt = exhaust tamP.erature of 

pressure differential across the orifice meter v. (ft ) = gas sam
ANALYTICAL TESTING CONSULTANTS, INC. 

KANNAPOLIS, N.C. 

TRAVERSE DATA AND FLOW COMPUTATION 

CLIENT Boral Brick 

LOCATION Gleason, TN 

DATE 11-4-98 

SOURCE K:.t..,.; ~I 

TEST TEAML-~·JL~=-------------------- RUN # PRE 

-------------------------------------------------------------------

Pbar __ ~~~---­

Time __ ~~~:~i~~~~~o~-

Pitot # ' 

Dry Bul~) SP ("Hg "WG -o.z I 

Fs for P tot 0.84 

1.t8 (Avg.)= +460= T8 (Rankin) 

2 • Duct Area=Ac Ft2 

3. P 8=Pb•r ±SP in. Hg. 

4. Rho.*(530/T8 )*(P8 /29.92)= lbs/ft 3 

5 .K=constant= 1096.5/ ( (G.D.) 112

) =---=---

6. Velocity=K*F. * (VPavg) 112 ft/min. 

7.VOLUME(avg)= A*V= ACFM 

8.SCFM=Volume*(530/T8 )*(P.I29.92)= 

-----~'SCFM(wet) 

Rho= specific weight of Air= 0.075 lbs/ft3 

!= angle in degrees to yield dP of 0 

FORM 15 

Wet Bulb (°F)_-;---::----

Pitot Type special 

Stack I.D. 37.~" 

SKETCH 
ROH# 

I 

P'ORM 11 

ANALYTICAL TESTING CONSULTANTS, INC. 

KANNAPOLIS, N.C. 

XMPXNGER DATA SHEET 

/1>/J,... I II>",., I 

./N~Si:'i" .INIIN<.III 

3<>0d- S":"~ 

~II. j'J 

ML 

DATA BY------/J.r~I.£/ _____ APPROVBD BY------------
A.l~A.L r llLA.L Tb~TlNli CUN~ULTANT.S, lNC. 

KANNAPOLIS, N.C. ATLANTA, GEORGIA 

GAS ANALYSIS DATA SHEET 

CLIENT Boral Brick 

LOCATION Gleason. TN 

DATE 11-4-98 

CAL. GAS 

ZERO 

MID-RANGE 

HI-RANGE 

ACTUAL 

CONCENTRATION 

nitrogen 

ILl% 

SOURCE. __ ~J<~-~·~N-~ __ 1 ______ __ 

INSTRUMENT(S) Teledyne/Fyrite 

ANALYST __ ~j~~---------------

INSTRUMENT 

READING 

20.9% 

%ERROR 

*Carbon Dioxide by Fyrite (fyrites calibrated according to manufacturer's specifications. 

POINT OTHER REMARKS 

I 

2 

3 

4 

5 

6 

7 

8 ,{) 

9 D 

10 

1

APPlies to f-factor tests. 
ANALYTICAL TESTING CONSULTANTS, INC. 

KANNAPOLIS, N.C. A1LANTA, GEORGIA 

GAS ANALYSIS DATA SHEET 

CLIENT Boral Brick SOURCE. __ ~}~~~~~N~~--~-------

LOCATION Gleason, TN INSTRUMENT(S) Teledyne/Fyrite 

DATE 11-4-98 ANALYST __ ~j~~---------------

CAl,, GAS ACTUAL INSTRUMENT %ERROR 

CONCENTRATION READING 

ZERO nitrogen 

MID-RANGE I 1.1% 

HI-RANGE 20.9% 

*Carbon Dioxide by Pyrite (fyrites calibrated according to manufacturer's specifications. 

POINT REMARKS 

1 'l.o 

2 '/.0 

3 .5 lf.D 

4 5. t. l./.t:> 

5 tf ¥. 0 

6 'I '/.0 

7 5.5 0 

8 I 'i. 0 

9 '1.0 

10 ) </. 0 

11 1 r lf $<t> 

1

Applies to f-factor tests. 
ANALYTICAL TESTING CONSULTANTS, INC. 

KANNAPOLIS, N.C. A1LANTA, GEORGIA 

GAS ANALYSIS DATA SHEET 

CLIENT Bora! Brick 

LOCATION Gleason. TN 

DATE I 1-4-98 

CAL. GAS 

ZERO 

MID-RANGE 

HI-RANGE 

ACTUAL 

CONCENTRATION 

nitrogen 

I 1.1% 

SOURCE __ ~·~I<~·~·~~N~~~~---------

INSTRUMENT(S) Teledyne/Fyrite 

ANAL YST ___ ""jc...:,_.;~-----------

INSTRUMENT 

READING 

20.9% 

%ERROR 

*Carbon Dioxide by Fyrite (fyrites calibrated according to manufacturer's specifications. 

POINT OTHER REMARKS 

I /~. '- '{. 0 

2 5.'1 L/.0 

3 5'. s '1.~ 

4 '/.D 

5 J 5'. (,. I{, I) 

6 15'. 3 t/.P 

7 ~3 '/.{) 

8 /).t/ l/.0 

9 I 5. '( 1/,p 

10 ;5.S tf.p 

I I /5.'1 
ANALYTICAL TESTING CONSULTANTS 

SOURCE SURVEY AND DESCRIPTION 

SYSTEM TYPE: BOll..ER / PROCESS OTHER 

NARRATIVEDESCRIPTION: /);l..t:'i:> i!ol!.:<.t:. Aile t"hvcb FRo,.. THe l::>i!yER.~ XAJT<> 

T~E: /(_,"JtJ, (.-,., ... 1 E:IIA?oiZilT;o.V 0 ~ l='i2.l:lf .,..; .... ,ell, .dE-I+yi::>AI>.T:ow I oJ<: ~ ......... ,., 

ViTi2·.r,, .. T;.,.., ~1"'">1-\;.c>b """'l:> £.ool;.,(. of' i1.;z;.:..Ks oc::t:.ui2.S rtu Tl-\t ' 

I I • 

)(; JI\J. TI-l--l F.Jcii.)Sc!:'b i~~> TilE- 1CIJ•"S NAT"~"'' GAS, EKI-\"""""T til~.-. 

-r ~ {: )£.: '-"' t "'\\A.:>""T' T "iZo.:>(.A A- "'3 7. '5 '' C:.T ... .:.1( , 

PURPOSE OF TESTING: / COMPLIANCE._-==::::-=:::;:::c=--EV ALUA TION 

PROCESS RATE OR CAP::-A:-:c==rr=Y::-:-=_-=_-: ___ =---- DETERMINED BY: 

CONTROL EQUIPMENT: SCRUBBER ESP BAGHOUSE 

OTHER Ill': A 

CONTROL EQUIPMENT OPERATING PARAMETERS: PRESSURE DROP ______ _ 

OTHER ¥ 

SAMPLING LOCATION DATA: 

I 

DISTANCE DOWNSTREAM FROM FLOW DISTURBANCE: 

NATURE OF DISTURBANCE: BEND~EXPANSION, B:-:;YP-=;A~s-=-s.-=D:-=U:-::C=T:-. ----

OTHER 

DISTANCE UPSTREAM FROM FLOW D-I-STU_RB_AN __ CE_:---=7""1,_--------

NA TURE OF DISTURBANCE: IS""TACK EXHAUSU FAN, EXPANSION, DUCT, 

OTHER. 

INDNIDUAL STACK / -:CO::-=M-::M-:0::-N:-:-:Sc-:T,-:-A-::C-:::K:-----------

STACK DIAMETER OR DIMENSIONS: ---=::::-::3<::7.:::·:-"5':::'=' :-==:----:-;;-----

NUMBER OF PORTS: POINTS P _ _,/c.-<,9.~---­

SKETCH: 

..,..,.,/(. ~ " ,.- ,)~;~ "";z, G';r'~'"_{l.::ll.:..:;,u __________ __.( 

J - - - l-----,;.../(,;,_;_t_N __ -:7 __ --..J 

~ J ;:!8 ~TIMA TED TEMPERATURE: <\ o S" • r ESTIMATED MOISTURE: & X 

GAS COMPOSmON BY: ffl ift,.1>0XYGEN METER, INSTRUMENTAL, 7 

OTHER T £ lE 't:> l.J t; 

LABORATORY INFORMATION: 

SAMPLE RECOVERY:ATC LABORATORY _ __;_/ ___ CL.EAN FIELD AREA-----

ATC VAN OTHER SAMPLESH~MENT: ATCVAN ;?c OTHER ----------

SAMPLE ANALYSIS: ATC OTHER 

FILTER MATERIAL: GELMAN NE WHATM7 AN.,..:.,..-;::93:-:4,-;-A-:::H:-------

OTHER TEFI • ., 
ANALYTICAL TESTING CON.SliL'I'J...NTS, .INC. 

LOCATION (,/_,E,~i ).,..., 

} 

D . .UE /l/3/98' , I 

J03 Bo@/ B;z.,K 

tnaT Ka N #I !·!ADE EY ___ 

1

.;fl:.f:.w::!::'_· ___ c:>BCJ3D EY r 

Descripticr: EQUAL AREA. CALCUlJ.T·IONS 

ROU!\!J DD C!' - Trl.!:.L\~ POI!~T T~.!;. VERSE P.r.?. Dll.K~T.t.R 

. 

STACK I.}). =37 :)" 11 

"P.::>!'-.1 T 1,% Cl'f' lli! S'T" 1>1 C: 

l.:C'~· - :6:~L'\CTS"",. <i.tJCft'ES 

1 I 2 . ./ 11-"<l 

2 I 6.7 I ,1. s-1 

.3 I 1/.8 I 7'13' 

4t/7-7 6. t, $1 

.s I 25.0 19}? 

I I 

6 3.5: 5" 1 13. 5 I 

7 I 64-S ..-<'1.11 

8 1 75.0 .:1Y- /~ 

. r I 82.3 j 30. ?'< 

10 1 88.2 i33.a2 

. II 1 . 93.31_5K.9~ 

12 1 97.3 lsc. s-
NOTE: 

FORM3 

ANALYTICAL TESTING CONSULTANTS, INC. 

CHAIN OF CUSTODY RECORD 

0 

Jl I I 

11 It 

PLEASE MARK LIQUID LEVEL ON ALL SAMPLE BOTTLES WITH GREASE PENCIL. 

SEAL TIGHTLY AND RE-CHECK UPON DELIVERY TO LAB PERSONNEL. 
'

';W!'.n• 

W""'· 

.

.... ;··' 

. . GRAVIMETRIC ANAL YS/S RESULTS 

t- CLIENT: 

LOCATION: 

SOURCE: 

OATE: 

_ 1 I FRAcnON 1: Bto\!4tiS 

RUN I FILTER I OR FINAL WEIGHT INmAL TARE WEIGHT NET 

BEAKERID #1 #2 11 #2 GAIN l BLANK /.,7 7~. 7'1 8 '?_ 7 8'· 7'! 'fS 7 7Y.7lf yy ?Y. 7'f5?7 ~- ()()D I 

I !33 7'1. S' ,Pt.. z. 7 f. 5.1(,./ 7~5;1..~ 7'!.S:L3' tJ. oo Z_L 

z IY'l 1?..?~~(,0 7!3.o!'t'3 f.i'.oU3 Y3.o8'.t~ lo.oc37 

l 3 li!J '!j ?/.7~/3 3'/. ?o;S 'II. C. 'I YC. 'i/. t. 'H7 o.ooz.7 

l 

l 

I FRACTION 2: t• l TE.'iS 

l RUNt FILTER I OR FINAL WEIGHT INmAL TARE WEIGHT NET 

BEAKER 10 #1 12 11 12 GAIN 

, 

BLANK rz.o3 o. ZZ7S tJ . .:2.:1. 73 /'J. Z.27S o. '2.'2.73 0. ()[)0 () 

I T~DO 0.:1../l.f" IJ .• u~~ " . .J II "' CJ, 2 I 2 I o. ooo'\ z 'L/}C I tJ.JPI(} ll. ~ :Z cln n._2Z. '3 I l'l. '2. z. '3D ll. l'lOO q 

..3 T202. _(). ~l.'lt'J /) . .:2 2.<1 C) 6.2'2.'3.'{ CJ. z.:z ... '3 ~ o.oooJ.. 

1 

l 

l COMBINED FRACTIONS 

RUN# NETGAIN,GM NETGAIN,GM BLANKI1 BLANKt2 TOTALS l FRACTION#1 FRACTION#2 CORRECTION CORRECTION {GRAMS) 

J l'l.OO Z.(. o~ooo..S 0. OO() I {), 000_0 Q. C03'1 2. t>. no 37 6. f"JDD 9 ll.oool D.oooo tJ.oo'-1 S 

] -3 a_. 007 ... 7 /J . rmD (. 1'>. DOC; I (')_ /) () {) 0 "'·"CJ 3..t 

LAB TECHNICIAN _____ ~(lLFT;=-~t.Jp'J-::;.~ L _______ _ DATE_--->'-(UI.L!--'/ ...L.......9 ~-f..L.CL....ry __ _ 

209 

J 
First Analytical Laboratories 

ANALYSIS REPORT 

Hydrofluoric Acid 

Fluorine 

Particulate Fluoride 

Project: Boral Brick 

Prepared for: 

Analytical Testing Consultants, Inc. 

301 Brookdale Street 

Kannapolis, NC 28083 

Reviewed and Approved by: 

William H. Wadlin, Ph. D. 

Laboratory Manager 

December 2, 1998 
First Analytical Laboratories 

CASE NARRATIVE 

Project #: 81112 

Client: Analytical Testing Consultants 

Client Project ID: Boral Brick 

Samples: 

Report Date: 02-Dec-98 

Three sets of samples and a blank set were submitted for determination of fluorine 

compounds. All were received intact with no apparent leakage. 

Preparation: 

No sample preparation is required for the aqueous samples. These were diluted 

however, to avoid matrix effects. Specifically, the high sulfate from the acidic impingers 

would saturate the analytical column if not diluted. The high alkalinity of the basic 

impingers distorts the chromatogram, so these were typically diluted by a factor of five. 

The filters were soaked overnight in deionized water to extract the particulate 

fluorides. These solutions were then filtered and diluted to 50 ml. 

Analysis: 

The fluoride level in each sample was determined by Ion Chromatography with 

conductivity detection. ' 

Results: 

The results are presented as total milligrams of the compound of interest as shown 

in the column headings on the results table on the next page. On the calculation page all 

of the results are calculated as mg of HF. To obtain the final results for fluorine and 

particulate fluoride, these values have been multiplied by the appropriate gravimetric 

factors. 

Fluoride was found in all of the samples, including the blanks. For the acidic 

impinger solutions and the filters, the blank levels are insignificant compared to the 

corresponding sample levels. For the basic impingers, the blank level is more than half 

of the sample levels, so these should be blank corrected by the user. 

Quality Control: 

All of the samples and standards were run in duplicate. The spike recovery (87%) 

is well within the normal range of 75% to 125%. The blanks are described above in the 

results section. 
First Analytical Laboratories 

1126 Burning Tree Dr. Chapel Hill, NC 27514 Tel. (919) 942-8607 

FAX (919) 929-8688 

ANALYSIS REPORT 

Project#: 81112 

Client: Analytical Testing Consultants 

Client Project ID: # Borel Brick 

Report Date: 02-Dec-98 

Date Received: 24-Nov-98 

Total Milligrams in Sample 

Sample 

Run 1 

Run 2 

Run 3 

Blank 

Spike 

%Recovery 

HF 

mg 

O.lN H2S04 

109 

132 

128 

2 

87% 

Fluorine Fluoride 

mg mg 

O.lN NaOH Filter 

4.9 0.29 

4.7 0.12 

5.1 0.37 

3.2 0.03 
FLUORIDE 

RUN 1 

IC ANALYSIS RUN SUMMARY AND CALCULATION WORKSHEET 

Client: Analytical Testing Consultants IDL = 

Proj. #: 81112 Spike Cone. = 

Dote: 02-Dec-98 

Sample ID Test Dil'n Volume 

Client FAL Sol'n Fodor ml 

mg/L 

0.1 N H2S04 IMPINGERS 

Run 1 81112.A1 13.23 20 412 

Run 2 81112.A2 6.32 50 417 

Run 3 81112.A3 6.18 50 415 

Blank 81112.AB 0.24 20 350 

0.1N NaOH IMPINGERS 

Run 1 81112.B1 1.69 5 304 

Run 2 81112.B2 1.62 5 305 

Blank 81112.BB l. 11 5 300 

SPIKE 81112.A2 10.69 %REC= 87.4% 

QUALITY CONTROL DATA 

Calibration True Peak 

Conc,ppm Height Regression 

Blank 0.00 0 0 

Standard 1 1.00 322 287 

Standard 2 5.00 1536 1436 

Standard 3 10.00 2952 2872 

Standard 4 15.00 4219 4308 

Regression Output: 

Constant 

Sid Err of Y Est 

R Squared 

No. of Observations 

Degrees of Freedom 

X Coefficient(s) 

Sid Err of Coef. 

287.1766 

4.268962 

0.00 

79.979 

0.998 

5.000 

4.000 

Peak 

Height 

3799 

1816 

1774 

69 

487 

466 

319 

3070 

0.10 mg/L 

5.00 mg/L 

Total 

mg 

108.99 

131.81 

128.14 

1.67 

2.58 

2.47 

1.66 
FLUORIDE 

RUN 2 

IC ANALYSIS RUN SUMMARY AND CALCULATION WORKSHEET 

Client: Analytical Testing Consultants 

Proj. #: 81112 

Date: 02-Dec-98 

Sample ID 

Client 

Run 3 

FILTERS 

Run 1 

Run 2 

Run 3 

Blank 

Calibration 

FAL 

81112.83 

81112.F1 

81112.F2 

81112.F3 

81112.F8 

True 

Test 

Sol'n 

mg/L 

1.75 

5.95 

2.61 

7.86 

0.68 

Peak 

Dil'n Volume 

Factor ml 

5 306 

50 

50 

50 

50 

Canc,ppm Height Regression 

Blank 0.00 0 

Standard 1 1.00 312 

Standard 2 5.00 1489 

Standard 3 10.00 2896 

Standard 4 15.00 4177 

Regression Output: 

Constant 

Sid Err of Y Est 

R Squared 

No. of Observations 

Degrees of Freedom 

X Coefficient(s) 

Std Err of Coef. 

283.067 

3.289826 

0 

287 

1436 

2872 

4308 

0.00 

61.635 

0.999 

5.000 

4.000 

IDL = 

Peak 

Height 

496 

1686 

740 

2224 

192 

0.10 mg/L 

Total 

mg 

2.68 

0.30 

0.13 

0.39 

0.03 
5 

4 

1 

0 -~/ 

IC Calibration; Fluoride 

FAL # 81112; Run 1; 12/01/98 

~ 

/ v 

v ?~ # 

~ 

' ' ' 

~ 

~ 

' 

0 2 4 6 8 10 12 14 

Concentration, ppm 

--a- Peak.Afea -+--- llcigl:t 

Ne'16C:..-t ~re-s. s,.,;....._ 

I 

' 

I 

I 

I ' 

' 

i 

I 

' 

' 

' 

I 

' 

' 

' 

' ' 

' 

i 

' 

' 

16 
5 

4 

1 

0 

IC Calibration; Fluoride 

FAL # 81112; Run 2; 12/02/98 

~ 

~ v 

~ 

J ~ 

/ ;:/' 

d-

/ v 

' ' ' 

0 2 4 6 8 10 12 14 

Concentration, ppm 

---- Peak.AN& ----+---- ll1igt;~t 

~~~·~tt 

I 

I 

' ' I 

I 

I 

I 

' 

16 
November 5. 1998 

First Analytical Laboratories 

3 Mount Bolus Road 

Chapel Hill, N.C. 27514 

Attn: Bill Wadlin 

Dear Bill. 

ANALYTICAL TESTING CONSULTANTS. INC. 

SPECIAUSTS IN FlEW DATA COLLECTION 

Enclosed are the samples from Bora! Brick on sampling performed by ATC. The method used 

was EPA method 26a. The analysis is for particulate fluoride, hydrogen fluoride and fluorine. If 

you have any questions please call before analysis and talk to Keith Poole or me. There were 

three runs conducted and each run should have three separate items for analysis. 

Run I 

filter 

I & 2 impingers 

3 &4 impingers 

There should be the same for runs #2 and #3. 

Also included is a blank for each of these solutions or filters. 

Kindest Regards, 

Dan McCombs 

301 Brookdale Street o Kannapolis, NC 28083 o (704) 932-3193 o FAX (704) 932-0570 

P.O. Box 886 o Roswell, GA 30077 o (770) 587-5696 o FAX (770) 993-7915 
NOTE: 

FORM3 

ANALYTICAL TESTING CONSULTANTS, INC. 

CHAIN OF CUSTODY RECORD 

II I I 

Jl It 

PLEASE MARK LIQUID LEVEL ON ALL SAMPLE BOTTLES WITH GREASE PENCIL 

SEAL TIGHTLY AND RE-CHECK UPON DELIVERY TO LAB PERSONNEL 
BAROMETER #1 CALIBRATION 

1 ..r"''''" ' .. :! ; ... : .

•··· . i'1oAfe''"'o:' . "' "''!' ''1 " 'sfA'tloN y ·· +•''·•· fi8Essufl'E'·~:::><'E!A •··•,, .~"- ,. ..• F!Q · M ... lttEJ:i.o , · ·· "'EAo .... bG ••· • :., ·· AI5JUsl'MeNfl',~:: 1N t1Alis I ...... " ............... J.,, .. .!. .. . 10/24/97 29.51 29.46 0.05 SM 

11/13197 30.07 30.02 0.05 JW 

12/18/97 29.87 29.88 0.01 SM 

01/08/98 29.41 29.56 0.15 SM 

02/06/98 29.78 29.81 0.03 JW 

03/11/98 29.86 29.80 0.06 SM 

04/03/98 29.94 29.87 0.07 JW 

05/05/98 30.03 29.98 0.05 SM 

06/09/98 29.99 29.98 0.01 SM 

07/13198 29.79 29.86 0.07 KP 

08/12/98 29.94 29.87 0.07 SM 

09/07/98 30.00 29.91 0.09 JW 

10/02/98 30.12 30.09 0.03 JW 

BAROMETER #2 CALIBRATION 

l.·"~\·t<~·,'"''riMr""~'~!"''f;stA'fra»;ga···gs§@eF\ii;;'~:a·•· .. JJ~:t II~M ·k , - · ,-~1 ~~r"t!-.. j , · ,. '·'· .... ' -" "- .. , - ~ .- rlii:'.M,.{l;..,_" t\t1 .. f:iMrttJ:Il··a"'loll'~'7{'' - ', ___ ~~-? "',t;.t;:t__, t'!l • %•11 '(ii.Aoagsrh~N"'i'·~~:·:>"··rNI"':r~us ·', '; .,, .- ... ,...,iJYt --~~ .I;'T~Mtp! < IJ.: ... -. .. 1 

10/24/97 29.51 29.57 0.06 SM 

11/13/97 30.07 29.94 0.13 JW 

12/18/97 29.87 29.78 0.09 SM 

01/08/98 29.41 29.40 0.01 SM 

02/06/98 29.78 29.74 0.04 JW 

03/11/98 29.86 29.91 0.05 SM 

04/03/98 29.94 29.99 0.05 JW 

05/05/98 30.03 30.10 0.07 SM 

06/09/98 29.99 30.02 0.03 SM 

07/13/98 29.79 29.77 0.02 KP 

08/12/98 29.94 29.96 0.02 SM 

09/07/98 30.00 30.02 0.02 JW 

10/02/98 30.12 30.12 0.00 JW 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

P BAR 29.74 

MODULE ID ATC #1 

BY WELCH 

0.5 3.96 4.08 70 85 10 1.75 0.997 

1 5.60 5.79 70 87 10 1.75 0.996 

1.5 6.85 7.09 70 88 10 1.75 0.995 

2 7.89 8.18 70 90 10 1.75 0.996 

3 9.66 10.04 70 93 10 1.74 0.997 

1.75 0.996 
POST TEST MODULE CALIBRATION CALCULATION 

DATE 11/27/98 

P BAR 30.01 

MODULEID ATC1 

BY WELCH 

C>FilFICE . Vw .. Vd Tw Td. flME. DH@ vi 

1.00 5.71 5.73 84 88 10 1.75 1.001 

1.00 5.72 5.76 84 89 10 1.74 1.000 

1.00 5.69 5.75 84 89 10 1.76 0.996 

1.75 0.999 
PYREX NOZZLE CALIBRATION DATA FORM 

Glass Nozzles 

DATE 10/05/98 

CALIBRATED BY Welch 

where: 

NOZZLE 

. I.D. 

NO'··· 

40g 

41g 

42g 

NOZZLE DIAMETE:R' 

Di D2 D3 

(lt-JCf:iES) (ft-JCHI;S) ... (INCHES) 

0.3125 0.3125 0.3125 

0.3125 0.3125 0.3125 

0.3125 0.3125 0.3125 

DIAMETER 

DIFF.*' 

(INCHES) 

0.000 

0.000 

0.000 

=THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

=MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

=AVERAGE OF THREE DIAMETERS 

AVERAGE 

DiA.'" 

(lt-JCHES) 

0.313 

0.313 

0.313 

.I 
Dt= 

TYPE "S" P/TOT TUBE INSPECTION DATA FORM 

PIToT TUBE I. D. !Ewnsz:l DATE Em'Y,0.6[98J 

PITOT TUBE ASSEMBLY LEVEL? XX YES NO 

PITOT TUBE OPENINGS DAMAGED? ----YES(EXPLAIN BELOW) _..;.;X.;.;.X _ NO 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313' 

#1 0 3 0 0 

#2 5 1 0 0 

0.375 Pa= 0.495 Pb= 0.496 

COMMENTS 

nn•>nirln<: across 

Beta = alignment of the face openings acroSs the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR _S;;;;h~a;:;.;n:;;,e...:..R:..:o.;;;.be;;;.:rt~s;..._ _____ _ 
Dt= 

TYPE "5" PITOT TUBE INSPECTION DATA FORM 

PITOTTUBE I.D. DATE I 'LOJ!Opt98! 

PITOTTUBE ASSEMBLY LEVEL? _..;.X,;;.;X-.__YES ____ No 

PITOTTUBE OPENINGS DAMAGED? ----YES(EXPLAIN BELOW) _.:..;x;.;.x_ NO 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313" 

#1 1 2 0 0 

#2 2 2 0 0 

0.375 Pa= 0.487 Pb= 0.487 

COMMENTS 

nn•onio,n" across 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of n A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR _S:;;:h~a::..:n:.;;.e..:.R:;:o.::;:be::,:.rl.:;;s;..... _____ _ 
Dt= 

TYPE "S" PITOT TUBE INSPECTION DATA FORM 

PITOT TUBE J.D. U::t::r~-1 

PITOT TUBE ASSEMBLY LEVEL? XX YES NO 

PITOT TUBE OPENINGS DAMAGED? ----YES(EXPLAIN BELOW) _..;.;X~X_NO 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 3 1 0 0 

#2 1 1 0 0 

0.375 Pa= 0.492 Pb= 0.493 

COMMENTS 

nnr~nir,no:: across rse 

Beta = alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALl BRA TOR _S;;;.h;.;,;a;;;.n;.;;e~R.;.;o;.;;b;,;;e.;.;rt;;.s -------
THERMOCOUPLE CALIBRATION DATA FORM 

DATE 01/06/98 THERMOCOUPLE NO. 32 

AMBIENT TEMP., F 67 BAROMETRIC PRESS., IN. Hg 29.91 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273) ·(TEST TEMP., C+273)/REF TEMP, C+273]"100<1.5% 

' ' 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ .;.01;;,;/0;.;;6/;.;;9.;;.8 __ THERMOCOUPLE NO. 33 

AMBIENT TEMP., F 67 BAROMETRIC PRESS., IN. Hg 29.91 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

REFRIGERATOR 

BOILING WATER 207 207 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]*100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ .;.01;;.;/0;.;;6;.;;/9.;.8 __ THERMOCOUPLE NO. 36 

AMBIENT TEMP., F 67 BAROMETRIC PRESS., IN. Hg 29.91 

CALIBRATOR ~=~~Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

2 REFRIGERATOR 34 33 0.203 

3 BOILING WATER 207 206 0.150 

*=TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REFTEMP, C+273]'100<1.5% 

.. 
1 0 0 •:::s ;; 1D'r 

CG.!. \'l.1of :.)..:::i!i ___ _;,_; ___ _ 

0:·::.-gen 11. 1.~ 

FEDERAl lAW FORBIDS 

TRANSPORTATION IF REFillED. 

PENAlTY UP TO $25,000 FINE AHD 

5 YEARS IMPRISONMENT . 

(49 u.s. c. 1809). 

GASES :v.o.S. 
A TEST PLAN FOR 

HYDROGEN FLUORIDE & TOTAL FLUORIDE 

EMISSIONS TESTING 

ON THE KILN EXHAUST STACK 

BORAL BRICKS 

Old Highway 22 

Weakley County (Gleason), TN 38229 

(901) 648-5527 

Applicable Permit and Emission Source Reference Nos: 

044890P/92-0052-02 

044891P/92-0052-03 

prepared by: 

W. Keith Poole 

Issue Date: 

October 13, 1998 

ANALYTICAL TESTING CONSULTANTS, INC. 

301 Brookdale Street 

Kannapolis, N. C. 28083 

(704) 932-3193 
TABLE OF CONTENTS 

Page number 

Notification Letter ..................................... 3 

Source Survey and Description 

.............................................. 4 

Process Flow Diagram-bora! Bricks, Inc. Gleason, Tn Plant 

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

Process Description ............................... 6 

Test Methods and Procedures ............................. 7 

Module Sampling Data Sheet ...................... 22 

Traverse Data and Flow Computation ............... 23 

Quality Assurance ..................................... 24 

Test Report Outline ................................... 25 

Results Summary ..................................... 26 

Plant Entry and Safety .................................. 27 

Calibration Data ...................................... 28 
ANALYTICAL TESTING CONSULTANTS. INC. 

SPECIAUSTS IN FlEW DATA COLLECTION 

October 12, 1998 

Mr. Jeryl Stewart, Chief of Compliance Validation 

Tennessee Department of Environment and Conservation 

401 Church Street 

9th Floor, L & C Annex 

Nashville, TN 37243-1531 

Dear Mr. Stewart, 

This is to inform your office that ANALYTICAL TESTING CONSULTANTS, INC. is scheduled to 

conduct emissions testing on the source listed below. You and/or members of your staff are invited to 

witness part or all testing. 

TEST SITE: 

SYSTEM TO BE TESTED: 

TEST METHOD(S): 

TEST DATE: 

TEST TIME: 

COMPANY CONTACT IND!VlDUAL: 

TEST TEAM LEADER: 

Sincerely, 

w.~(?~ 

W. Keith Poole 

cc: Mr. David Johnson, Bora! Bricks, Inc. 

Mr. John Welch, A TC 

Bora! Bricks, Inc. 

Gleason, TN 

One of the two following sources 

Tunnel Kiln # 1 Exhaust 

T unnd Kiln #2 Exhaust 

EPA Methods 1, 2, 3, 4, 5, 26a 

(HF and Total Flourides) 

Wednesday, November 4, 1998 

8:00AM 

Mr. David Johnson 

Environmental Manager 

Bora! Bricks, Inc. 

Columbus, Georgia 

(334) 480-2487 

Mr. John Welch 

301 Brookdale Street o Kannapolis, NC 28083 o (704) 932-3193 o FAX (704) 932-0570 

P.O. Box 886 o Roswell, GA 30077 o fj70) 587-5696 o FAX (770) 993-7915 
SOURCE SURVEY AND DESCRIPTION 

SYSTEM TYPE: ______ BOILER~_..x~ ___ PROCESS ____ OTHER 

NARRATIVE DESCRIPTION: 

Please see the following page for a complete process description. 

PURPOSE OF TESTING: 

PROCESS RATE OR CAPACITY: 

DETERMINED BY: 

____ COMPLIANCE _ _..X~- EVALUATION 

8.5 TPH of green brick maximum. average usage 7.8 TPH 

Fired with Natural gas (maximum heat input 18.5 mmbtulhr 

To be tracked and documented by Bora! Brick personnel 

CONTROL EQUIPMENT: NONE- An ID Fan pulls exhaust gases from the Kiln at a rate 

of approximately 18.000 cubic feet per minute at an estimated exhaust temperature of 550 degrees F. 

SAMPLING LOCATION DATA: 

DISTANCE DOWNSTREAM FROM FLOW DISTURBANCE: Will be according to 

USEPA method 1. 

DISTANCE UPSTREAM FROM FLOW DISTURBANCE: according to USEPA method 1 

INDIVIDUAL STACK __ __,YE"""'-S _____ COMMON STACK ____ _ 

STACK DIAMETER OR DIMENSIONS: Kiln #1-3.25'. Kiln #2- 2.3' x 3' 

NUMBER OF PORTS: Per EPA I POINTS PER PORT: Per EPA method 1 

SKETCH: See following page for a process schematic. 

ESTIMATED TEMPERATURE: 500°F. ESTIMATED MOISTURE: 6-8% 

GAS COMPOSITION BY: PYRITE. OXYGEN METER, INSTRUMENTAL, OTHER ______________ ___ 

LABORATORY: 

SAMPLE RECOVERY: ATC LABORATORY XXX CLEAN FIELD AREA ___ _ ATCVAN ________ OTHER _______ _ 

SAMPLE SHIPMENT: ATC VAN XXX OTHER~-------

SAMPLE ANALYSIS: First Analytical Laboratories 

3 Mount Bolus Road 

Chapel Hill, NC 27514 

Attn.: Mr. Bill Wadlin 

FILTER MATERIAL: GELMAN AJE_WHATMAN 934AH_ OTHER Pallflex 3" Teflon 

4 
~ 1J 

EJ 

Raw Material Storage Bldg. 

Clay f-* Primary Covered _ _. Raw Material r+ Disintegrating r-. Smooth Rolling __. Disi

Unloading Crushing Stockpiles Feed!n~ t 

Screening Sand 

Storage Sawdust t Off-Spec Unloading Apron Grinding ....... Brick ~ r-. Storage Fr:OOcr S&ndDryer ' 

(SD-1) 

I 

I 

Off-Spec Brick +E] 

Paclrnging 1+- and Storage 

waste heat Manuf'adnring Bldg. r· ---······---------=t-·- . ··---------... • 

Firing 

(TK-1, TK.-2) 14--

' 

I S-8,, S-91 ~ Drying (D-1 toD-4) ' I S-(i~ S-71 t rt- Holding Rcom(H-1) ~ ' I S-2 ~ S-51 ,.. 

Process Flow Diagram 

Boral Bricks. Gleason Plant 

Cutting& 

Setting ~ + 

Additive & Coating 

• • 

Storage 

+ 

Hoppers wate

(,..n...,

_wa

(!>!lOO

ir 

Cooting& ~ E

Texturing 

+ 

waste return b

.....

--

~ 
PROCESS DESCRIPTION 

Bora! Bricks, Gleason Plant manufactures facing brick using clay, sawdust, recycled brick, and other 

body additives. Clay and green sawdust are delivered to the plant by truck. Moist ball clay is 

unloaded into the facility's primary crusher and carried via conveyor belt to a convered Raw Material 

Storage (a.k.a. Clay Storage) Building where it is stockpiled. Filler clay and sawdust are delivered 

directly to the Raw Material Storage Building and stockpiled. Off-spec bricks are carried by truck 

form the shipment preparation area to an outside stockpile area. As needed, the bricks are loaded 

inot an apron feeder and carried via conveyor into the Clay Storage Building whre they are processed 

through a harnmermill (grinder) and vibrating screen to achieve a size suitable for reintroducing the 

off-spec brick back into the new brick body mixes. Using conveyor belts, the crushed brick (referred 

to as "grog") is then stockpiled in the Clay Storage Building. As needed, clay, sawdust, and grog 

are loaded into feeders. These feeders deposit raw materials inot one common belt conveyor. Before 

bieng shaped into a final form, the blend is carried by belt conveyors through a series of preparation 

machines which include: a disintegrator, followed by a smooth roller, followed by another 

disintegrator, followed by a controlled rate additive feeder (used as needed), follwed by two png 

mills in series. As the clay enters the pug mills, water may be added depending on the moisture 

content of the clay. "Pugged" clay is then extruded as a column. 

Facial colorants are added to some products. These colorants typically consist of sand coatings 

mixed with other additives. All of the clay preparation and manufacturing equipment is contained 

in a covered building. The sand coatings are prepared in the covered Coatings Storage Area which 

is connected to the Clay Prep Building. If necessary, stored sand is dried in a rotary dryer prior to 

use. Coatings, including the dried sand, are placed in hoppers for use in the coating operation. 

After being coated and textured, the extruded clay column is cut into green brick. Green brick are 

then stacked on kiln cars by a setting machine and placed in holding rooms where the green bricks' 

moisture content is lowered slightly. Kiln cars exit the holding rooms directly into one of four dryers 

(two sets). The purpose of these dryers is to further reduce the moisture content of the bricks. Each 

set of dryers has an exhaust stack, which have been determined to emit insignificant levels of 

pollutants. Both the holding rooms and dryers are heated with waste heat from the cooling sections 

of the kilns. 

Finally, dried brick are moved from the dryers into one of two identical tunnel kilns. Final 

evaporation of free water, dehydration, oxidation, vitrification, flashing, and cooling of bricks occurs 

in the kilns. The fuel used in the kilns is natural gas. Exhaust from the kilns exit respective stacks 

(ID#'s S-9 and S-9). Brick exiting the kiln are packaged and moved to outside storage prior to 

distributiOn. 

6 
TEST METHODS AND PROCEDURES 

This package will outline a testing protocol for the sampling scheduled for Wednesday, November 

4, 1998 at the Gleason, TN plant of Bora! Bricks, Inc. Please call if you have any questions 

regarding the information contained herein. There are no anticipated changes to existing EPA 

methods to accomplish this testing. 

US EPA methods 1-5 and 26a will be utilized in determining the exhaust gas flow rate, temperature 

profile, total front half particulate (as defined at 250' F and method 5), particulate flouride, hydrogen 

flouride, and flourine emission rates. The following pages will present brief descriptions of these 

methods. 

A. Method 1 - Sample and Velocity Traverses for Stationary Sources 

PRINCIPLE AND APPLICABILITY 

a. Principle. To aid in the representative measurement of pollutant emissions and/or total 

volumetric flow rate from a stationary source, a measurement site where the effluent stream is 

flowing in a known direction is selected, and the cross-section of the stack is divided into a number 

of equal areas. A traverse point is then located within each of these equal areas. 

b. Applicability. This method is applicable to flowing gas streams in ducts, stacks, and flues. 

The method cannot be used when: (1) flow is cyclonic or swirling (see Section 2.4), (2) a stack is 

smaller than about 0.30 meter (12 in.) in diameter, or 0.071 m2 (113 in.2) in cross-sectional area, 

or (3) the measurement site is less than two stack or duct diameters downstream or less than a half 

diameter upstream from a flow disturbance. Items two and three do not apply to this source and it 

is not expected that cyclonic flow will be present. However, utilizing an angle indicator and special 

pi tot, the presence or absence of cyclonic flows will be documented on traverse data sheets. 

B. Method 2- Determination of Stack Gas Velocity and Volumetric Flow Rate 

CType S Pitot Tube) 

PRINCIPLE AND APPLICABILITY 

a. Principle. The average gas velocity in a stack is determined from the gas density and from 

measurement of the average velocity head with a TypeS (Stausscheibe or reverse type) pi tot tube. 

b. Applicability. This method is applicable for measurement of the average velocity of a gas 

stream and for quantifying gas flow. 

7 
TEST METHODS AND PROCEDURES, CON'T. 

C. Method 3 ·Gas Analysis for the Determination of Drv Molecular Weight 

PRINCIPLE AND APPLICABILITY 

a. Principle. A gas sample is extracted from a stack by one of the following methods: (I) 

Single-point, grab sampling; (2) single-point, integrated sampling, or (3) multi-point, integrated 

sampling. The gas sample is analyzed for percent C02, percent 0 2, and, if necessary, percent CO. 

For dry molecular weight determination, either an Orsat or a Pyrite may be used for the analysis. 

b. I. Applicability. This method is applicable for determining carbon dioxide and oxygen 

concentrations and dry molecular weight of a sample from a gas stream of a fossil-fuel combustion 

process. The method may also be applicable to other processes where it has been determined that 

compounds other than C02, 0 2• CO, and N2 are not present in concentrations sufficient ot affect the 

results. 

2. Other methods, as well as modifications to the procedure described herein, are also 

applicable for some or all of the above determinations. Examples of specific methods and 

modifications include: (I) A multi-point sampling method using an Orsat analyzer to analyze 

individual grab samples obtained at each point; (2) a method using C02 or 0 2 and stoichiometric 

calculations to determine dry molecular weight; and (3) assigning a value of 30 for dry molecular 

weight, in lieu of actual measurements, for processes burning natural gas, coal, or oil. These 

methods and modifications may be used, but are subject to the approval of the administrator, U.S. 

Environmental Protection Agency (EPA). 

D. Method 3a • Determination of Oxygen and Carbon Dioxide Concentrations in Emissions 

from Stationary Sources Unstrumental Analyzer Method) 

PRINCIPLE AND APPLICABILITY 

a. Principle. A sample is continuously extracted from the effluent stream: a portion of the 

sample stream is conveyed to an instrumental analyzer for determination of Oxygen concentration. 

b. Applicability. This method is applicable to the determination of oxygen and carbon 

dioxide concentrations in emissions from stationary sources only when specified in the regulations. 

E. Method 4 ·Determination of Moisture Content in Stack Gases 

PRINCIPLE AND APPLICABILITY 

a. Principle. A gas sample is extracted at a constant rate from the source; moisture is 

removed from the sample stream and determined either volumetrically or gravimetrically. 

8 
TEST METHODS AND PROCEDURES, CON'T. 

b. Applicability. This method is applicable for determining the 

moisture content of stack gas. 

b.l Two procedures are given. The first is a reference method, for accurate 

determinations of moisture content (such as are needed to calculate emission data). The second is 

an approximation n;~ethod, which provides estimates of percent moisture to aid in setting isok:inetic 

sampling rates prior to a pollutant emission measurement run. 

b.2 The reference method is often conducted simultaneously with a pollutant 

emission measurement run; when it is, calculation of percent isokinetic, pollutant emission rate, etc., 

for the run shall be based upon the results of the reference method or its equivalent. The reference 

method shall be employed for this source. 

F. Method 5 -Determination of Particulate Emissions from Stationary Sources 

I. PRINCIPLE AND APPLICABILITY 

1.1 Principle. Particulate matter (PM) is withdrawn isok:inetically from the source and collected on 

a glass fiber filter maintained at a temperature in the range of 120 ± 14 oc (248 ± 25°F) or such other 

temperature as specified by an applicable subpart of the standards or approved by the Administrator, 

U.S. Environmental Protection Agency, for a particular application. The PM mass, which includes 

any material that condenses at or above the filtration temperature, is determined gravimetrically after 

removal of uncombined water. 

1.2 Applicability. This method is applicable for the determination of PM emissions from stationary 

sources. 

G. Method 26A -Determination of Hydrogen Halide and Halogen Emissions from Stationary 

Sources - Isokinetic Method 

I. APPLICABILITY, PRINCIPLE, INTERFERENCES, PRECISION, BIAS, AND STABILITY 

1. I Applicability. This method is applicable for determining emissions of hydrogen 

halides (HX) [hydrogen chloride (HCl), hydrogen bromide (HBr), and hydrogen fluoride (HF)] 

and halogens (X2) [chlorine (CI2) and bromine (Br2)] from stationary sources. This method 

collects the emission sample isok:inetically and is therefore particularly suited for sampling at 

sources, such as those controlled by wet scrubbers, emitting acid particulate matter (e.g., 

hydrogen halides dissolved in water droplets). [Note: Mention of trade names or specific 

products does not constitute endorsement by the Environmental Protection Agency.] 

9 
TEST METHODS AND PROCEDURES, CON'T. 

1.2 Principle. Gaseous and particulate pollutants are withdrawn isokinetically from the 

source and collected in an optional cyclone, on a filter, and in absorbing solutions. The cyclone 

collects any liquid droplets and is not necessary if the source emissions do not contain them; 

however, it is preferable to include the cyclone in the sampling train to protect the filter from any 

moisture present. The filter collects other particulate matter including halide salts. Acidic and 

alkaline absorbing solutions collect the gaseous hydrogen halides and halogens, respectively. 

Following sampling of emissions containing liquid droplets, any halides/halogens dissolved in 

the liquid in the cyclone and on the filter are vaporized to gas and collected in the impingers by 

pulling conditioned ambient air through the sampling train. The hydrogen halides are solubilized 

in the acidic solution and form chloride (Cl"), bromide (Br·), and fluoride (r) ions. The halogens 

have a very low solubility in the acidic solution and pass through to the alkaline solution where 

they are hydrolyzed to form a proton (H+), the halide ion, and the hypohalous acid (HClO or 

HBrO). Sodium thiosulfate is added to the alkaline solution to assure reaction with the 

hypohalous acid to form a second halide ion such that 2 halide ions are formed for each molecule 

of halogen gas. The halide ions in the separate solutions are measured by ion chromatography 

(IC). If desired, the particulate matter recovered from the filter and the probe is analyzed 

following the procedures in Method 5. [Note: If the tester intends to use this sampling 

arrangement to sample concurrently for particulate matter, the alternative TeflonR probe liner, 

cyclone, and filter holder should not be used. The TeflonR filter support must be used. The tester 

must also meet the probe and filter temperature requirements of both sampling trains.] 

1.3 Interferences. Volatile materials, such as chlorine dioxide (Cl02) and ammonium 

chloride (NH4Cl), which produce halide ions upon dissolution during sampling are potential 

interferents. Interferents for the halide measurements are the halogen gases which 

disproportionate to a hydrogen halide and an hypohalous acid upon dissolution in water. The use 

of acidic rather than neutral or basic solutions for collection of the hydrogen halides greatly 

reduces the dissolution of any halogens passing through this solution. The simultaneous 

presence of both HBr and Cl2 may cause a positive bias in the HCl result with a corresponding 

negative bias in the Cl2 result as well as affecting the HBr/Br2 split. High concentrations of 

nitrogen oxides (NO,) may produce sufficient nitrate (NO;) to interfere with measurements of 

very low Br· levels. 

1.4 Precision and Bias. The method has a possible measurable negative bias below 20 

ppm HCl perhaps due to reaction with small amounts of moisture in the probe and filter. Similar 

bias for the other hydrogen halides is possible. 

1.5 Sample Stability. The collected Cl" samples can be stored for up to 4 weeks for 

analysis for HCl and Cl2. 

1.6 Detection Limit. The in-stack detection limit for HCl is approximately 0.02 flg per 

liter of stack gas; the analytical detection limit for HCl is 0.1 flg/ml. Detection limits for the 

other analyses should be similar. 

10 
TEST METHODS AND PROCEDURES, CON'T. 

2. APPARATUS 

2.1 Sampling. The sampling train is shown in Figure 26A-1; the apparatus is similar to 

the Method 5 train where noted as follows: 

[;' 

• 

I Pitot Tube 

Teflon or Quartz 

Filter 

Heated Probe 

Manometer 

~ 

Heated 

B" 

Calibrated 

Otifice 

r 

Inclined 

Manometer 

Figure 26A-1. 

O_INH2S04 

Co= Vacuum 

Frne 

\ Gau!'e 

0 

I 

Dry Gas Vacuum 

Meter Pump 

Sampling Train 

11 
TEST METHODS AND PROCEDURES, CON'T. 

2.1.1 Probe Nozzle. Borosilicate or quartz glass; constructed and calibrated according to 

Method 5, Sections 2.1.1 and 5.1, and coupled to the probe liner using a Teflon• union; a 

stainless steel nut is recommended for this union. When the stack temperature exceeds 210°C 

( 41 ooF), a one-piece glass nozzle/liner assembly must be used. 

2.1.2 Probe Liner. Same as Method 5, Section 2.1.2, except metal liners shall not be 

used. Water-cooling of the stainless steel sheath is recommended at temperatures exceeding 

500°C. Teflon" may be used in limited applications where the minimum stack temperature 

exceeds 120 oc (250 oF) but never exceeds the temperature where Teflon" is estimated to 

become unstable (approximately 210 °C). 

2.1.3 Pi tot Tube, Differential Pressure Gauge, Filter Heating System, Metering System, 

Barometer, Gas Density Determination Equipment. Same as Method 5, Sections 2.1.3, 2.1.4, 

2.1.6, 2.1.8, 2.1.9, and 2.1.10. 

2.1.4 Cyclone (Optional). Glass or Teflon". Use of the cyclone is required only when 

the sample gas stream is saturated with moisture; however, the cyclone is recommended to 

protect the filter from any moisture droplets present. 

2.1.5 Filter Holder. Borosilicate or quartz glass, or Teflon" filter holder, with a Teflon" 

filter support and a sealing gasket. The sealing gasket shall be constructed of Teflon" or 

equivalent materials. The holder design shall provide a positive seal against leakage at any point 

along the filter circumference. The holder shall be attached immediately to the outlet of the 

cyclone. 

2.1.6 Impinger Train. The following system shall be used to determine the stack gas 

moisture content and to collect the hydrogen halides and halogens: five or six impingers 

connected in series with leak-free ground glass fittings or any similar leak-free noncontaminating 

fittings. The first impinger shown in Figure 26A-1 (knockout or condensate impinger) is 

optional and is recommended as a water knockout trap for use under high moisture conditions. 

If used, this impinger should be constructed as described below for the alkaline impingers, but 

with a shortened stem, and should contain 50 ml ofO.l N H2S04 • The following two impingers 

(acid impingers which each contain 100 ml of 0.1 N H2S04) shall be of the Green burg-Smith 

design with the standard tip (Method 5, Section 2.1.7). The next two impingers (alkaline 

impingers which each contain 100 ml of 0.1 N NaOH) and the last impinger (containing silica 

gel) shall be of the modified Green burg-Smith design (Method 5, Section 2.1.7). The 

condensate, acid, and alkaline impingers shall contain known quantities of the appropriate 

absorbing reagents. The last impinger shall contain a known weight of silica gel or equivalent 

desiccant. Teflon" impingers are an acceptable alternative. 

12 
TEST METHODS AND PROCEDURES, CON'T. 

2.1.7 Ambient Air Conditioning Tube (Optional). Tube tightly packed with 

approximately !50 g of fresh 8 to 20 mesh sodium hydroxide-coated silica, or equivalent, 

(Ascarite IIR has been found suitable) to dry and remove acid gases from the ambient air used to 

remove moisture from the filter and cyclone, when the cyclone is used. The inlet and outlet ends 

of the tube should be packed with at least !-em thickness of glass wool or filter material suitable 

to prevent escape of fines. Fit one end with flexible tubing, etc. to allow connection to probe 

nozzle following the test run. 

2.2 Sample Recovery. The following items are needed: 

2.2.1 Probe-Liner and Probe-Nozzle Brushes, Wash Bottles, 

Glass Sample Storage Containers, Petri Dishes, Graduated Cylinder or Balance, and Rubber 

Policeman. Same as Method 5, Sections 2.2.1, 2.2.2, 2.2.3, 2.2.4, 2.2.5, and 2.2.7. 

2.2.2 Plastic Storage Containers. Screw-cap polypropylene or polyethylene containers to 

store silica gel. High-density polyethylene bottles with Teflon screw cap liners to store impinger 

reagents, !-liter. 

2.2.3 Funnels. Glass or high-density polyethylene, to aid in sample recovery. 

2.3 Analysis. For analysis, the following equipment is needed: 

2.3.1 Volumetric Flasks. Class A, various sizes. 

2.3.2 Volumetric Pipettes. Class A, assortment, to dilute samples to calibration range of 

the ion chromatograph (IC). 

2.3.3 Ion Chromatograph. Suppressed or nonsuppressed, with a conductivity detector 

and electronic integrator operating in the peak area mode. Other detectors, a strip chart recorder, 

and peak heights may be used. 

3. REAGENTS 

Unless otherwise indicated, all reagents must conform to the specifications of the 

Committee on Analytical Reagents of the American Chemical Society (ACS reagent grade). 

When such specifications are not available, the best available grade shall be used. 

3.1 Sampling. 

3.1.1 Water. Deionized, distilled water that conforms to American Society of Testing 

and Materials (ASTM) Specification D 1193-77, Type 3. 

13 
TEST METHODS AND PROCEDURES, CON'T. 

3.1.2 Acidic Absorbing Solution, 0.1 N Sulfuric Acid (H2S04). To prepare I L, slowly 

add 2.80 ml of concentrated H2S04 to about 900 ml of water while stirring, and adjust the final 

volume to I L using additional water. Shake well to mix the solution. 

3.1.3 Alkaline Absorbing Solution, 0.1 N Sodium Hydroxide (NaOH). To prepare I L, 

dissolve 4.00 g of solid NaOH in about 900 ml of water and adjust the final volume to 1 L using 

additional water. Shake well to mix the solution. 

3.1.4 Filter. TeflonR mat (e.g., PallflexR TX40HI45) filter. When the stack gas 

temperature exceeds 210 oc ( 410 °F) a quartz fiber filter may be used. 

3.1.5 Silica Gel, Crushed Ice, and Stopcock Grease. Same as Method 5, Sections 3.1.2, 

3.1.4, and 3.1.5, respectively. 

3.1.6 Sodium Thiosulfate, (Na2S,Q33 5 H,O). 

3.2 Sample Recovery. 

3.2.1 Water. Same as Section 3.1.1. 

3.2.2 Acetone. Same as Method 5, Section 3.2. 

3.3 Sample Analysis. 

3.3.1 Water. Same as Section 3.1.1. 

3.3.2 Reagent Blanks. A separate blank solution of each absorbing reagent should be 

prepared for analysis with the field samples. Dilute 200 ml of each absorbing solution (250 ml of 

the acidic absorbing solution, if a condensate impinger is used) to the same final volume as the 

field samples using the blank sample of rinse water. If a particulate determination is conducted, 

collect a blank sample of acetone. 

3.3.3 Halide Salt Stock Standard Solutions. Prepare concentrated stock solutions from 

reagent grade sodium chloride (NaCI), sodium bromide (NaBr), and sodium fluoride (NaF). 

Each must be dried at 11 0°C for 2 or more hours and then cooled to room temperature in a 

desiccator immediately before weighing. Accurately weigh 1.6 to 1.7 g of the dried NaCl to 

within 0.1 mg, dissolve in water, and dilute to I liter. Calculate the exact Cl' concentration using 

Equation 26A-l. 

Jlg CUm!= g ofNaCl x 103 x 35.453/58.44 Eq. 26A-1 

In a similar manner, accurately weigh and solubilize 1.2 to 1.3 g of dried NaBr and 2.2 to 2.3 g of 

NaF to make !-liter solutions. Use Equations 26A-2 and 26A-3 to calculate the Br· and pconcentrations. 

Jlg Br'lml = g of NaBr x 103 x 79.904/102.90 Eq. 26A-2 

Jlg F/ml = g ofNaF x 103 x 18.998/41.99 Eq. 26A-3 

Alternately, solutions containing a nominal certified concentration of 1000 mg!L NaCl are 

commercially available as convenient stock solutions from which standards can be made by 

appropriate volumetric dilution. Refrigerate the stock standard solutions and store no longer than 

I month. 

3.3.4 Chromatographic Eluent. Same as Method 26, Section 3.2.4. 

14 
TEST METHODS AND PROCEDURES, CON'T. 

4. PROCEDURE 

Because of the complexity of this method, testers and analysts should be trained and 

experienced with the procedures to ensure reliable results. 

4.1 Sampling. 

4.1.1 Pretest Preparation. Follow the general procedure given in Method 5, Section 

4.1.1, except the filter need only be desiccated and weighed if a particulate determination will be 

conducted. 

4.1.2 Preliminary Determinations. Same as Method 5, Section 4.1.2. 

4.1.3 Preparation of Sampling Train. Follow the general procedure given in Method 5, 

Section 4.1.3, except for the following variations: 

Add 50 rnl of 0.1 N H2S04 to the condensate impinger, if used. Place 100 rnl of 0.1 N 

H2S04 in each of the next two impingers. Place 100 rnl of 0.1 N NaOH in each of the following 

two impingers. Finally, transfer approximately 200-300 g of pre weighed silica gel from its 

container to the last impinger. Set up the train as in Figure 26A-1. When used, the optional 

cyclone is inserted between the probe liner and filter holder and located in the heated filter box. 

4.1.4 Leak-Check Procedures. Follow the leak-check procedures given in Method 5, 

Sections 4.4.1 (Pretest Leak-Check), 4.1.4.2 (Leak-Checks During the Sample Run), and 4.1.4.3 

(Post-Test Leak-Check). 

4.1.5 Train Operation. Follow the general procedure given in Method 5, Section 4.1.5. 

Maintain a temperature around the filter and (cyclone, if used) of greater than !20 °C (248 °F). 

For each run, record the data required on a data sheet such as the one shown in Method 5, Figure 

5-2. If the condensate impinger becomes too full, it may be emptied, recharged with 50 rnl ofO.l 

N H2S04, and replaced during the sample run. The condensate emptied must be saved and 

included in the measurement of the volume of moisture collected and included in the sample for 

analysis. The additional 50 rnl of absorbing reagent must also be considered in calculating the 

moisture. After the impinger is reinstalled in the train, conduct a leak-check as described in 

Method 5, Section 4.1.4.2. 

4.1.6 Post-Test Moisture Removal (Optional). When the optional cyclone is included in 

the sampling train or when moisture is visible on the filter at the end of a sample run even in the 

absence of a cyclone, perform the following procedure. Upon completion of the test run, connect 

the ambient air conditioning tube at the probe inlet and operate the train with the filter heating 

system at least 120°C (248 °F) at a low flow rate (e.g., t.H =I in. HzO) to vaporize any liquid 

and hydrogen halides in the cyclone or on the filter and pull them through the train into the 

impingers. After 30 minutes, turn off the flow, remove the conditioning tube, and examine the 

cyclone and filter for any visible moisture. If moisture is visible, repeat this step for 15 minutes 

and observe again. Keep repeating until the cyclone is dry. [Note: It is critical that this is 

repeated until the cyclone is completely dry.] 

15 
TEST METHODS AND PROCEDURES, CON'T. 

4.2 Sample Recovery. Allow the probe to cool. When the probe can be handled safely, 

wipe off all the external surfaces of the tip of the probe nozzle and place a cap loosely over the 

tip. Do not cap the probe tip tightly while the sampling train is cooling down because this will 

create a vacuum in the filter holder, drawing water from the irnpingers into the holder. Before 

moving the sampling train to the cleanup site, remove the probe, wipe off any silicone grease, 

and cap the open outlet of the irnpinger train, being careful not to lose any condensate that might 

be present. Wipe off any silicone grease and cap the filter or cyclone inlet. Remove the 

umbilical cord from the last impinger and cap the irnpinger. If a flexible line is used between the 

first irnpinger and the filter holder, disconnect it at the filter holder and let any condensed water 

drain into the first irnpinger. Wipe off any silicone grease and cap the filter holder outlet and the 

irnpinger inlet. Ground glass stoppers, plastic caps, serum caps, TeflonR tape, ParafilrnR, or 

aluminum foil may be used to close these openings. Transfer the probe and filter/irnpinger 

assembly to the cleanup area. This area should be clean and protected from the weather to 

minimize sample contamination or loss. Inspect the train prior to and during disassembly and 

note any abnormal conditions. Treat samples as follows: 

4.2.1 Container No. I (Optional; Filter Catch for Particulate Determination). Same as 

Method 5, Section 4.2, Container No. 1. 

4.2.2 Container No. 2 (Optional; Front-Half Rinse for Particulate Determination). Same 

as Method 5, Section 4.2, Container No. 2. 

4.2.3 Container No. 3 (Knockout and Acid Irnpinger Catch for Moisture and Hydrogen 

Halide Determination). Disconnect the irnpingers. Measure the liquid in the acid and knockout 

irnpingers to ±I rnl by using a graduated cylinder or by weighing it to ±0.5 g by using a balance. 

Record the volume or weight of liquid present. This information is required to calculate the 

moisture content of the effluent gas. Quantitatively transfer this liquid to a leak-free sample 

storage container. Rinse these irnpingers and connecting glassware including the back portion of 

the filter holder (and flexible tubing, if used) with water and add these rinses to the storage 

container. Seal the container, shake to mix, and label. The fluid level should be marked so that 

if any sample is lost during transport, a correction proportional to the lost volume can be applied. 

Retain rinse water and acidic absorbing solution blanks and analyze with the samples. 

4.2.4 Container No. 4 (Alkaline Irnpinger Catch for Halogen and Moisture 

Determination). Measure and record the liquid in the alkaline irnpingers as described in Section 

4.2.3. Quantitatively transfer this liquid to a leak-free sample storage container. Rinse these two 

irnpingers and connecting glassware with water and add these rinses to the container. Add 25 rng 

of sodium thiosulfate per ppm halogen-dscrn of stack gas sampled. [Note: This amount of 

sodium thiosulfate includes a safety factor of approximately 5 to assure complete reaction with 

the hypo halo us acid to form a second CJ· ion in the alkaline solution.] Seal the container, shake 

to mix, and label; mark the fluid level. Retain alkaline absorbing solution blank and analyze with 

the samples. 

16 
TEST METHODS AND PROCEDURES, CON'T. 

4.2.5 Container No.5 (Silica Gel for Moisture Determination). Same as Method 5, 

Section 4.2, Container No. 3. 

4.2.6 Container Nos. 6 through 9 (Reagent Blanks). Save portions of the absorbing 

reagents (0.1 N H2S04 and 0.1 N NaOH) equivalent to the amount used in the sampling train; 

dilute to the approximate volume of the corresponding sa!llples using rinse water directly from 

the wash bottle being used. Add the same ratio of sodium thiosulfate solution used in container 

No. 4 to the 0.1 N NaOH absorbing reagent blank. Also, save a portion of the rinse water alone 

and a portion of the acetone equivalent to the amount used to rinse the front half of the sampling 

train. Place each in a separate, prelabeled sample container. 

4.2.7 Prior to shipment, recheck all sample containers to ensure that the caps are wellsecured. Seal the lids of all containers around the circumference with TeflonR tape. Ship all 

liquid samples upright and all particulate filters with the particulate catch facing upward. 

4.3 Sample Preparation and Analysis. Note the liquid levels in the sample containers and 

confurn on the analysis sheet whether or not leakage occurred during transport. If a noticeable 

leakage has occurred, either void the sample or use methods, subject to the approval of the 

Administrator, to correct the final results. 

4.3.1 Container Nos. I and 2 and Acetone Blank (Optional; Particulate Determination). 

Same as Method 5, Section 4.3. 

4.3.2 Container No.5. Same as Method 5, Section 4.3 for silica gel. 

4.3.3 Container Nos. 3 and 4 and Absorbing Solution and Water Blanks. Quantitatively 

transfer each sample to a volumetric flask or graduated cylinder and dilute with water to a final 

volume within 50 rnl of the largest sample. 

4.3.3.1 The IC conditions will depend upon analytical column type and whether 

suppressed or nonsuppressed IC is used. Prior to calibration and sample analysis, establish a 

stable baseline. Next, inject a sample of water, and determine if any Ct, Br·, or p- appears in the 

chromatogram. If any of these ions are present, repeat the load/injection procedure until they are 

no longer present. Analysis of the acid and alkaline absorbing solution samples requires separate 

standard calibration curves; prepare each according to Section 5.2. Ensure adequate baseline 

separation ofthe analyses. 

4.3.3.2 Between injections of the appropriate series of calibration standards, inject in 

duplicate the reagent blanks and the field samples. Measure the areas or heights of the ct·, Br·, 

and p- peaks. Use the average response to determine the concentrations of the field samples and 

reagent blanks using the linear calibration curve. If the values from duplicate injections are not 

within 5 percent of their mean, the duplicate injection shall be repeated and all four values used 

to determine the average response. Dilute any sample and the blank with equal volumes of water 

if the concentration exceeds that of the highest standard. 

4.4 Audit Sample Analysis. Audit samples must be analyzed subject to availability. 

17 
TEST METHODS AND PROCEDURES, CON'T. 

5. CALIBRATION 

Maintain a laboratory log of all calibrations. 

5.1 Probe Nozzle, Pilot Tube, Dry Gas Metering System, Probe Heater, Temperature 

Gauges, Leak-Check of Metering System, and Barometer. Same as Method 5, Sections 5.1, 5.2, 

5.3, 5.4, 5.5, 5.6, and 5.7, respectively. 

5.2 Ion Chromatograph. To prepare the calibration standards, dilute given amounts (1.0 

ml or greater) of the stock standard solutions to convenient volumes, using 0.1 N H2S04 or 

0.1 N N aOH, as appropriate. Prepare at least four calibration standards for each absorbing 

reagent containing the three stock solutions such that they are within the linear range of the field 

samples. Using one of the standards in each series, ensure adequate baseline separation for the 

peaks of interest. Inject the appropriate series of calibration standards, starting with the lowest 

concentration standard first both before and after injection of the quality control check sample, 

reagent blanks, and field samples. This allows compensation for any instrument drift occurring 

during sample analysis. Determine the peak areas, or height, of the standards and plot individual 

values versus halide ion concentrations in J.Ig/ml. Draw a smooth curve through the points. Use 

linear regression to calculate a formula describing the resulting linear curve. 

6. QUALITY CONTROL 

Same as Method 5, Section 4.4. 

7. QUALITY ASSURANCE 

7.1 Applicability. When the method is used to demonstrate compliance with a 

regulation, a set of two audit samples shall be analyzed. 

7.2 Audit Procedure. The currently available audit samples are chloride solutions. 

Concurrently analyze the two audit samples and a set of compliance samples in the same manner 

to evaluate the technique of the analyst and the standards preparation. The same analyst, 

analytical reagents, and analytical system shall be used both for compliance samples and the 

Environmental Protection Agency (EPA) audit samples. 

7.3 Audit Sample Availability. Audit samples will be supplied only to enforcement 

agencies for compliance tests. Audit samples may be obtained by writing the Source Test Audit 

Coordinator (MD-77B), Quality Assurance Division, Atmospheric Research and Exposure 

Assessment Laboratory, U.S. Environmental Protection Laboratory, Research Triangle Park, NC 

27711 or by calling the Source Test Audit Coordinator (STAC) at (919) 541-7834. The request 

for the audit samples should be made at least 30 days prior to the scheduled compliance sample 

analysis. 

18 
TEST METHODS AND PROCEDURES, CON!T. 

7.4 Audit Results. Calculate the concentrations in mg/dscm using the specified sample 

volume in the audit instructions. Include the results of both audit samples, their identification 

numbers, and the analyst's name with the results of the compliance determination samples in 

appropriate reports to the EPA regional office or the appropriate enforcement agency. (NOTE: 

Acceptability of results may be obtained immediately by reporting the audit results in mg/dscm 

and compliance results in total flg HCI/sample to the responsible enforcement agency.) The 

concentrations of the audit samples obtained l:)y the analyst shall agree within 10 percent of the 

actual concentrations. If the 10 percent specification is not met, reanalyze the compliance 

samples and audit samples, and include initial and reanalysis values in the test report. Failure to 

meet the 10 percent specification may require retests until the audit problems are resolved. 

8. CALCULATIONS 

Retain at least one extra decimal figure beyond those contained in the available data in 

intermediate calculations, and round off only the final answer appropriately. 

8.1 Nomenclature. Same as Method 5, Section 6.1. In addition: 

I Bx· = Mass concentration of applicable absorbing solution blank, flg halide ion 

(Cl', Br·, F)/ml, not to exceed 1 flg/ml which is 10 times the published 

analytical detection limit of 0.1 fl g/ml. (It is also approximately 5 percent 

of the mass concentration anticipated to result from a one hour sample at 

10 ppmv HCI.) 

C = Concentration of hydrogen halide (HX) or halogen (X2 ), dry basis, 

mg/dscm. 

mHX = Mass of HCl, HBr, or HF in sample, ug. 

mx2 = Mass of Cl2 or Br2 in sample, ug. 

Sx· = Analysis of sample, ug halide ion (Cl·, Br·, F)lml. 

V, Volume of filtered and diluted sample, ml. 

8.2 Average Dry Gas Meter Temperature and Average Orifice Pressure Drop. See data 

sheet (Figure 5-2 of Method 5). 

8.3 Dry Gas Volume. Calculate VmC><d> and adjust for leakage, if necessary, using the 

equation in Section 6.3 of Method 5. 

8.4 Volume of Water Vapor and Moisture Content. Calculate the volume of water vapor 

V w(><d> and moisture content Bw, from the data obtained in this method (Figure 5-2 of Method 5); 

use Equations 5-2 and 5-3 of Method 5. 

8.5 Isokinetic Variation and Acceptable Results. Use Method 5, Sections 6.11 and 6.12. 

8.6 Acetone Blank Concentration, Acetone Wash Blank Residue Weight, Particulate 

Weight, and Particulate Concentration. For particulate determination. 

8.7 Total flg HCl, HBr, or HF Per Sample. 

mHX = K V, (Sx·- B,.-) Eq. 26A-4 

where: KHcc = 1.028 (flg HCI/flg-mole)/(flg Cl'/flg-mole). 

KHB, = 1.013 {flg HBrlflg-mole)/(flg Br'/flg-mole). 

KHF = 1.053 {flg HF/flg-mole)/{flg F/flg-mole). 

19 
TEST METHODS AND PROCEDURES, CON'T. 

8.8 Total !Jg Cl2 or Br2 Per Sample. 

mx2 = V, (Sx·- Bx-) Eq. 26A-5 

8.9 Concentration of Hydrogen Halide or Halogen in Flue Gas. 

C = K mHX.xzN m(~dl Eq. 26A-6 

where: K = 10·3 mg/!Jg 

8.10 Stack Gas Velocity and Volumetric Flow Rate. Calculate the average stack gas 

velocity and volumetric flow rate, if needed, using data obtained in this method and the equations 

in Sections 5.2 and 5.3 of Method 2. 

9. BIBLIOGRAPHY 

1. Steinsberger, S.C. and J. H. Margeson. Laboratory and Field Evaluation of a 

Methodology for Determination of Hydrogen Chloride Emissions from Municipal and Hazardous 

Waste Incinerators. U.S. Environmental Protection Agency, Office of Research and 

Development. Publication No. 600/3-89/064. 

Aprill989. Available from National Technical Information Service, Springfield, VA 22161 as 

PB89220586/ AS. 

2. State of California Air Resources Board. Method 421 -Determination of 

Hydrochloric Acid Emissions from Stationary Sources. March 18, 1987. 

3. Cheney, J.L. and C.R. Fortune. Improvements in the Methodology for Measuring 

Hydrochloric Acid in Combustion Source Emissions. J. Environ. Sci. Health. Al.2(3): 337-350. 

1984. 

4. Stem, D.A., B.M. Myatt, J.F. Lachowski, and K.T. McGregor. Speciation of Halogen 

and Hydrogen Halide Compounds in Gaseous Emissions. In: Incineration and Treatment of 

Hazardous Waste: Proceedings of the 9th Annual Research Symposium, Cincinnati, Ohio, May 

2-4, 1983. Publication No. 600/9-84-015. 

July 1984. Available from National Technical Information Service, Springfield, VA 22161 as 

PB84-234525. 

5. Holm, R.D. and S.A. Barksdale. Analysis of Anions in Combustion Products. In: Ion 

Chromatographic Analysis of Environmental Pollutants, E. Sawicki, J.D. Mulik, and 

E. Wittgenstein (eds.). Ann Arbor, Michigan, Ann Arbor Science Publishers. 1978. pp. 99-110. 

H. GENERAL TESTING PROCEDURES 

Prior to testing and following mobilization on site, the test team leader will direct activities that 

will include: 

,,. confirmation of stack diameter, upstreams and downstreams, 

and port placements, 

,,. preliminary flow and temperature profile (including cyclonic 

flow checks) and static pressure measurement, 

20 
TEST METHODS AND PROCEDURES, CON'T. 

,,.. selection of a suitable nozzle and setup of sampling computer 

spreadsheet, 

,,.. assembly of first particulate/HF sampling train, 

,,. leak check of sampling train at operating temperature, and 

,,. coordinating with the plant that the system is stable. 

Once these detenninations have been made, isokinetic sampling will begin. Three one hour runs 

will be made on the exhaust for particulate, hydrogen flouride and total flourides. Preliminary 

flow measurements will be performed prior to the inital test run and will include a detailed check 

for the presence/absence of cyclonic flows. An angle indicator will be utilized according to 

US EPA protocol to verify this condition. 

Emission rates will be presented in terms of lbs/hr and grains per dry standard cubic foot. Please 

see the sample RESULTS SUMMARY for additional information. 

21 
Start @ "Hq 

end @ "Hq 

PI TOT: 

start 

A 11 B 

end 

A II B_ 

T~ME· 

FORM 16 

"H,Q 

"H.O 

. lPT· 

ANAL~YT ... \..AL .LES.L ... NG .ON,.;;,vLT.r:u. .. rS, INI.... 

KANNAPOL ... -.;, N.C. 

MODULE SAMPLING DATA SHEET 

DATE, ____________ __ Pbar __________ __ 

SOURCE, __________ _ Ps ____________ __ 

RUN 

AH@ __________ _ NOZZLE (# ) 

Tm. ____________ __ % H20. ______ _ 

Ts•----------- Gamma Factor ___ __ Agency Personnel On 

Md. ________ __ 

Pitot I.D. 

' 

L~NE I T'\, I "U''I!L,. '___E._ T•o 

~ 

Pm ____________ __ 

K Factor 

T Po I T •· . ~ ,.. ~ T 'p'o 

Start Time 

.. u. I"· ·All. (in.)H;o. (in.)l't,O V!

PT 

£P. 

Tn = 

= 

meter 

Velocity 

temperature T. ~ stack temperature TP = probe temperature Tt = filter temperature T1 = exhaust temperature o

head differential pressure £H = pressure differential across the orifice meter v. (ftl) = gas sa

?? 
ANALYTICAL TESTING CONSULTANTS, INC. 

KANNAPOLIS, N.C. 

TRAVERSE DATA AND FLOW COMPUTATION 

CLIENT __________________________ __ DATE, __________________ __ 

LOCATION, ________________________ __ SOURCE, ________________ ___ 

TEST TEAM, ________________________ _ RUN #·------------------ ------------------------------------------------------------------- Pbar __________ __ 

Time 

Pito~t~#~-------

Dry Bulb ( °F) ______ __ 

SP ( "Hg /"WG) ---------

Fs for Pitot 

Wet Bulb {°F) ________ _ 

Pitot Type __________ _ 

Stack I.D. 

------------------------------------------------------------------- TRAVERSE· v SQ. ROOT STACK '"•-''•- . 

POINT· . •· in9i;.es v TEMP., 

I 

' 

I 

I 

1\ 

I 

II 

' 

1/ 

I 

I 

' STJM 

l.t.(Avg, )= +460= T.(Rank~n) 

1. Duct Area=A= Ft' 

I. P 5 =Pbar ±SP in. Hg. 

L Rho.*(530/T5 )*(P./29.92)= lbs/ft 3 

; .K=constant= 1096.51 ((G. D.) 112

) =--,.---::-----

;. Velocity=K*F. * (VPavg) 112 ft/min. 

I.VOLUME(avg)= A*V= ACFM 

. 1CFM=Volume*(530/T5 )*(P5 /29.92)= 

----~ ,SCFM(wet) 

tho= specific weight of Air= 0.075 lbs/ft 3 

:= angle in degrees to yield dP of 0 

'0RM 15 

23 

dP ANGLE1 

OF . 0° "REF.· {0 dP) 

SKETCH 
QUALITY ASSURANCE 

ANALYTICAL TESTING CONSULTANTS, INC. performs quality assurance utilizing guidelines 

presented by the USEPA in QUALITY ASSURANCE HANDBOOK FOR AIR POLLUTION 

MEASUREMENT SYSTEMS. VOLUME ill. STATIONARY SOURCE SPECIFIC METHODS 

EPA-600/4-94-038b. Additionally, refer to company document, ONQC GUIDELINES FOR 

ANALYTICAL TESTING CONSULTANTS. INC. 

Other specific quality assurance procedures normally fall within the domain of the analytical 

laboratory where general guidelines are outlined by Skoog and West, ANALYTICAL 

CHEMISTRY, Holt, Rinehart, and Winston, May, 1975. 

Calibration records of pertinent testing equipment are part of this test plan package. 

24 
TEST REPORT OUTLINE 

Cover 

Introduction 

Source Description 

Results Summary 

Results, Conclusions, and Comments 

Sampling and Analytical Procedures 

Calculations 

Particulate Emission Rate 

Hydrogen Flouride Emission Rate Calculation 

Run Data and Averages 

Nomenclature 

Calculation Formulae 

Data Sheets 

Method 5/26a Sampling Data Sheets 

Impinger Data Sheets 

Stack Gas Analysis Data Sheets 

Chain of Custody Sheets 

Source Test Survey 

Equal Area Determinations 

Laboratory Reports 

Calibration Information 

25 
RESULTS SUMMARY 

SYSTEM 

TEST DATE 

PARAMETER 

GENERAL 

Qs, FLOW, ACFM 

Qs dry, FLOW SCFM 

Vm std, CUBIC FT, 

%I 

BORALBRICK 

KILN EXHAUST 

NOVEMBER4, 1998 

RUN#l 

PARTICULATE EMISSIONS 

PMRC, LBS/HR 

Cs, GRISCFD 

HYDROGEN FLOURIDE 

PMRC, LBS/HR 

Cs, GR/SCFD 

TOTAL FLOURIDE 

PMRC LBS/HR 

Cs, GR/SCFD 

RUN#2 RUN#3 

26 

AVERAGE 
PLANT ENTRY AND SAFETY 

This is at the discretion of our client. Specific procedures are available from that source. For 

additional questions relating to Analytical Testing Consultants, Inc. safety procedures and policy, 

please request a copy of our SAFETY MANUAL. 

27 
BAROMETER #1 CALIBRATION 

10/24/97 29.51 29.46 0.05 SM 

11/13/97 30.07 30.02 0.05 JW 

12/18/97 29.87 29.88 0.01 SM 

01/08/98 29.41 29.56 0.15 SM 

02/06/98 29.78 29.81 0.03 JW 

03/11/98 29.86 29.80 0.06 SM 

04/03/98 29.94 29.87 0.07 JW 

05/05/98 30.03 29.98 0.05 SM 

06/09/98 29.99 29.98 0.01 SM 

07/13/98 29.79 29.86 0.07 KP 

08/12/98 29.94 29.87 0.07 SM 

09/07/98 30.00 29.91 0.09 JW 

10/02/98 30.12 30.09 0.03 JW 

. QJ,\JE 

10/24/97 

11/13/97 

12/18/97 

01/08/98 

02/06/98 

03/11/98 

04/03/98 

05/05/98 

06/09/98 

07/13/98 

08/12/98 

09/07/98 

10/02/98 

BAROMETER #2 CALIBRATION 

29.51 

30.07 

29.87 

29.41 

29.78 

29.86 

29.94 

30.03 

29.99 

29.79 

29.94 

30.00 

30.12 

BAROMETES.BEADING 

29.57 

29.94 

29.78 

29.40 

29.74 

29.91 

29.99 

30.10 

30.02 

29.77 

29.96 

30.02 

30.12 

ADJ.USTMENT 

0.06 

0.13 

0.09 

O.D1 

0.04 

0.05 

0.05 

0.07 

0.03 

0.02 

0.02 

0.02 

0.00 

INITIALs! 

SM 

JW 

SM 

SM 

JW 

SM 

JW 

SM 

SM 

KP 

SM 

JW 

JW 
INTERFERENCE RESPONSE TEST 

1.·. •.. :INTERFERENCE . CYLINDER INSTRUMENT 

.. GAS . ·CONTENTS REAOIN.G 

OXIDES OF NITROGEN 8550 PPM/N2 0 

CARBON MONOXIDE 48700 PPM/N2 0 

SULFUR DIOXIDE 4810 PPM/N2 0 

CARBON DIOXIDE 19.6%/N2 0.1 

NITROGEN 100% N2 0.1 

\ 

···"ffi ··-..:.;_,.. 

. ' ) _, 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

P BAR 29.74 

MODULE ID ATC #1 

BY WELCH 

!ORIFICE · VW ··•··. Vd.·.·.··.··. Tw·· .· ... TIME . . DH@ 

0.5 3.96 4.08 70 85 10 1.75 0.997 

1 5.60 5.79 70 87 10 1.75 0.996 

1.5 6.85 7.09 70 88 10 1.75 0.995 

2 7.89 8.18 70 90 10 1.75 0.996 

3 9.66 10.04 70 93 10 1.74 0.997 

1.75 0.996 
_.·\ PRIMARY MODULE CALIBRATION CALCULATION ... ; 

DATE 01/09/98 

P BAR 29.74 

MODULE ID ATC#2 

BY WELCH 

I.Qf!IFICE ··vw .. Vd Tw' .Td . , .. tiME . .. ·. DH@ y 

0.5 4.07 4.16 72 85 10 1.67 1.001 

1 5.75 5.9 72 86 10 1.67 0.998 

1.5 7.05 7.25 72 89 10 1.66 1.000 

2 8.11 8.37 72 91 10 1.66 0.999 

3 9.83 10.21 72 95 10 1.69 0.997 

1.67 0.999 
I 

./ 

PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

PBAR 29.74 

MODULE ID ATC#3 

BY WELCH 

!ORIFICE.·. .VW .... ···· Vd. ... Tw To •·. . . TIME DH@. y 

0.5 4.08 4.21 72 87 10 1.66 0.995 

1 5.69 5.87 72 87 10 1.70 0.994 

1.5 6.98 7.23 72 89 10 1.69 0.993 

2 8.12 8.38 73 91 10 1.67 0.997 

3 10.01 10.31 73 91 10 1.65 0.996 

1.67 0.995 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

PBAR 29.74 

MODULE ID ATC#4 

BY WELCH 

!ORIFICE· Vw . ··.Vd • Tw: Td TIME ·oH@ ' Y' . 

0.5 3.87 4.06 69 93 10 1.80 0.995 

1 5.47 5.78 69 98 10 1.79 0.996 

1.5 6.67 7.09 69 103 10 1.79 0.998 

2 7.71 8.17 69 101 10 1.79 0.996 

3 9.39 9.94 69 103 10 1.80 0.998 

1.79 0.996 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 1-5-98 

PBAR 29.56 

MODULE ID ATC#5 

BY SROBERTS 

!ORIFICE· Vw· · Vd 

0.5 4.02 4.16 

1 5.68 5.89 

1.5 7 7.25 

2 7.99 8.31 

3 9.87 10.16 

Tw Td 

70 

70 

70 

70 

71 

92 

92 

92 

93 

93 

TIME> .··•·· .. ··oH© v····· · 1 

10 

10 

10 

10 

10 

1.69 

1.69 

1.67 

1.71 

1.68 

1.69 

1.005 

1.002 

1.002 

0.998 

1.004 

1.002 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

PBAR 29.74 

MODULE ID ATC#6 

BY WELCH 

IOBIPlCE vw·· ·vd .. •···.··. .... .Tw ... :· Td ···.· .. "(IKAE . ·.· .. · DH@' ' -·- ,,._,, y 

0.5 4.42 4.59 67 87 10 1.39 0.998 

1 6.22 6.54 67 91 10 1.39 0.992 

1.5 7.57 7.96 67 93 10 1.40 0.994 

2 8.75 9.27 67 98 10 1.39 0.995 

3 10.66 11.32 68 102 10 1.40 0.995 

1.39 0.995 
PRIMARY MODULE CALIBRATION CALCULATION 

DATE 01/09/98 

P BAR 29.74 

MODULE ID ATC #7 

BY WELCH 

TlM.E .. DH@, :.y I 

0.5 4.64 4.78 70 84 10 1.28 0.995 

1 6.58 6.81 70 85 10 1.27 0.991 

1.5 8.04 8.35 70 89 10 1.27 0.994 

2 9.17 9.55 71 93 10 1.29 0.995 

3 11.27 11.82 70 97 10 1.27 0.995 

1.27 0.994 
o1 NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY Welch 

20 0.124 0.125 0.127 0.003 0.125 

21 0.130 0.130 0.132 0.002 0.131 

22 0.125 0.125 0.125 0.000 0.125 

23 0.135 0.135 0.135 0.000 0.135 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS: EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** =MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY WELC 

30 0.176 0.174 0.177 0.002 0.176 

31 0.168 0.168 0.170 0.002 0.169 

32 0.184 0.185 0.185 0.001 0.185 

33 0.182 0.184 0.185 0.003 0.1_84 

34 0.180 0.181 0.183 0.003 0.181 

35 0.180 0.179 0.182 0.002 0.180 

36 0.193 0.195 0.195 0.002 0.194 

37 0.180 0.183 0.183 0.003 0.182 

38 0.190 0.190 0.193 0.003 0.191 

39 0.180 0.180 0.180 0.000 0.180 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** =MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
I __/ 

NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY WELCH 

40A 0.255 0.255 0.255 0.000 0.255 

t-------'-4..:..:1 A-'-~ 0.250 0.250 0.250 0.000 0.250 

!-----4C.:2::.j TO BE RECONDITIONED ERR ERR 

43 TO BE RECONDITIONED ERR ERR 

44 0.260 0.259 0.260 0.001 0.260 

45 0.252 0.254 0.255 0.003 0.254 

46 0.255 0.254 0.255 0.001 0.255 

47 o.26o o.259 o:26 o.oo1 o.26o 

48 0.265 0.264 0.266 0.001 0.265 

49 o.250 o.250 o:25o o.ooo o.25o 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** = MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.0041NCHES 

*** =AVERAGE OF THREE DIAMETERS 
. :I 

. . 

~ 

... 

NOZZLE CALIBRATION OAT A FORM 

DATE 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** = MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
. ·; ___;;,.; 

NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY WELCH 

61 0.380 0.382 0.382 0.002 0.381 

62 0.377 0.378 0.380 0.003 0.378 

64 0.385 0.384 0.386 0.001 0.385 

66 0.385 0.385 0.385 0.000 0.385 

67 0.377 0.378 0.375 0.002 0.377 

68 0.375 0.375 0.375 0.000 0.375 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** =MAxiMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN . 

. DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
. ::J 

___ .) 

NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** . =MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY WELCH 

81 0.500 0.500 0.500 0.000 0.500 

83 0.495 0.495 0.495 0.000 0.495 

84 0.505 0.506 0.507 0.002 0.506 

88 0.500 0.500 0.500 0.000 0.500 

89 0.501 0.501 0.501 0.000 0.501 

.. ·.·.· .. · ..···•·•··••···••····. ·.·· · .. ···.·. .·.·· ... ~.·· ..••.... ····• ~.· . ) .. ·. < 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** = MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL T00.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
.. i 

.· ~· 

NOZZLE CALIBRATION OAT A FORM 

DATE 03/13/97 

CALIBRATED BY WELCH 

90 0.700 0.703 0.702 0.003 0.702 

91 0.725 0.725 0.727 0.002 0.726 

92 0.724 0.726 0.725 0.002 0.725 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** =MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
NOZZLE CALIBRATION DATA FORM 

DATE 03/13/97 

CALIBRATED BY WELCH 

100 1.377 1.378 1.378 0.001 1.378 

1 0 1 1 . 120 1 . 120 1 .120 0. 000 1 . 120 

where: 

* =THREE DIFFERENT NOZZLE DIAMETERS; EACH DIAMETER MUST BE 

WITHIN 0.001 INCHES 

** =MAXIMUM DIFFERENCE BETWEEN ANY TWO DIAMETERS, IN. 

DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

*** =AVERAGE OF THREE DIAMETERS 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE 01/07/98 THERMOCOUPLE NO. 

-------- 40 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR 

.· . REFERENCE' 

·. . POtNi·. 

;, 

1 

2 

Roberts REFERENCE THERMOMETER MERCURY·IN·GlASS 

. souRcE· REFERENcE tHERMocouPLE: TEMPERATuRE 

.·. (SPECIFY) TEMP;. ~ClTENTIOMdEA .•... · DIFFERENCE 

. ·•·· . • F TEMP~tlAT0RE, F ·.. . . %•• 

AMBIENT 71 71 0.000 

REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

*=TYPE OF CALIBRATION SYSTEM USED 

**=[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]*100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ ...;0;.;1;.;/0;;.7/;,;;9.;;.8 __ THERMOCOUPLE NO. 41 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY·IN·GLASS 

·. • SOURCE* REFERENCE THERMOCOUPLE TEMPERATURE 

·.• .. ·.··•· • Ncf 

· '<s~~dFYJ TEMP;·.· f'()iENTioMEm~ · · Du=F'ERENcE 

· ·· . :· : :i> . Ft~;MPERAT~~E. t:: . · · · r~·~ 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

*=TYPE OF CALIBRATION SYSTEM USED 

**=[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE 01/07/98 THERMOCOUPLE NO. 42 

AMBIENT TEMP., F ___ ..;7..;1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GlASS 

·_.••_-···.······· . ' -' . , Fl.~FERENGE ~; ~- ; '· '. . ·- ., ' -' ' . '. 

POINT 

.•.•... , NO. 

·.· ... ,,:. . 

SOURCE-' REFERENCE /T~ERMOCO(JPLE •• TEMPERAtURE 

(SPEGIFY) ·TEMP: POTENTiOMETER . IDIFFJ.:REN¢E 

FYE:MPERATyRE; F 

AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 35 0.203 

3 BOILING WATER 210 211 0.149 

• =TYPE OF CALIBRATION SYSTEM USED 

•• = [(REF TEMP, C+273) -(TEST TEMP., C+273)/REF TEMP, C+273]"1 00<1.5% 
•• ·1 

-·.::-.~ 

THERMOCOUPLE CALIBRATION DATA FORM 

DATE _ __,.;....;..;......;..;.. 01/07/98 __ THERMOCOUPLE NO. 43 

AMBIENT TEMP., F ____ 7_1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLAss 

' REFERENCE· I·. . . • I .. POINT •.. _.·· 

. .·. • NO. 

soul'!cE· REFi:HENcE: THERM6cbi.JPLE TEMPER.A.fURE: 

. (SPECIFY} . TEMP: P~~~NTIOMETER '• DIFFE~~Nc~ 

. ·. ,> _i F TEMPERATURE, F %•• 

AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• = [(REF TEMP, C+273) • (TEST TEMP., C+273)/REF TEMP, C+273]*1 00<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE ___ 01/07/98 THERMOCOUPLE NO. ..;......; __ 44 

AMBIENT TEMP., F ____ 7_1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

·· i· .•. ·. •_ •. _RE~$~E:Nc~· · ... ' SOURCE* REFERENC:E THERMOCOUPLE TEMPEit4,TURi: . '-; -· 

.·. POINT. ' • .• (SPECii=Y) .. 

• •••• • ••• ·••••• •••• d. ; •• 

.. · .. ··•··No. · 

1 AMBIENT 

2 REFRIGERATOR 

3 BOILING WATER 

• =TYPE OF CALIBRATION SYSTEM USED 

TEMP. PoTENTIOMETER . · biFFEF{ENGE F TEMP~RATURE, F . 

71 71 0.000 

34 35 0.203 

210 211 0.149 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]*100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ .,.:0:..;1.:.;/0;,;.7.:.;/9;;;8 __ THERMOCOUPLE NO. 45 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY . . IN GU>.SS 

. · .. ·REFERENCE . SOURCE* REFEREf:JGE -THERMocoUPLE 

. ~ . - ,• 

TtMPERAfURE 

. 

I . POINT (SPECIFY} TEMP, .POTENTIOMETE;R DIFFERENCE 

... · NO. . F TEMpERATURE, F=· .. : ~/o~• 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• = [(REF TEMP, C+273) - (TEST TEMP., G+273)/REF TEMP, G+273]*1 00<1.5% 
..J 

THERMOCOUPLE CALIBRATION DATA FORM 

DATE 

__ 

01/07/98 ;...;...;.~--

THERMOCOUPLE NO. 46 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

.•.... /: REFERENCE ..... 

POiNT. 

·. .. SOlJRCE' REFEREIIIGE THERMOCOUPLE·.· TEMPER,A.T(JRE 

(~PEtiFY) .... TEMP: ~OTENTIOMETER · ... DIFFEREI\ICE 

•NO, 

AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

*=TYPE OF CALIBRATION SYSTEM USED 

**=[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE LOl/07/9.8 I 

PITOT TUBE ASSEMBLY LEVEL? XX YES _....;.;;..;....._ 

____ No 

PITOT TUBE OPENINGS DAMAGED?;..· ____ YES(EXPLAIN BELOW) _.;..;X-.X_NO 

r . ·. GRITICALALIGNMENTMEASUREMENT;S. 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = ____ .;;.;0.~3.;.;75;;.. 

COMMENTS 

CALIBRATION REQUIRED? 

2 

1 

Pa= 0.486 

3 0 0 

1 

Pb = 0.486 

YES XX NO 

Alpha - alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
! TYPE "S" PITOT TUBE INSPECTION DATA FORM 

PITOT TUBE I. D. DATE !:01/07798! 

PITOT TUBE ASSEMBLY LEVEL? _...;;x;;.;X __ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?;..· ----YES(EXPLAIN BELOW) -~XX~_ NO 

r .:':· .. · .... MEASUREMENT 

#1 

#2 

Dt = ____ ..;;..0-;.;3.;..75;;;.. 

COMMENTS 

>CRITlCALAUGNMENTMEAS(JREMENTS ·. 

ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

5 2 0 0 

2 2 0 0 

Pa= 0.501 Pb= 0.502 

~ . .. . . .. rl c;;;.,A;,:;L;,:;I_~;;,;.~;;.;- _T.;.:_ ~~~.:..;N~R,:.:;E;;:O:.;;:U,::,I R;,; __ ~:=,~,:, .• ~·-'""':-:""'. ,..,....,...,...,.,.:.,.:. :.,.· ,""_ •:""',:"'":· -. Y.:.,_. E:S;;.··'""'· ·"'"····,;.<_.-: -__ ,....._: .-.• "'". """. ·"" .. .:..;~~~~--~...:XX.:;:.,.,..,.._.., ... - .... . ··----- ~ 

. J 

Alpha- alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w =difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "5" PITOT TUBE INSPECTION DATA FORM 

PITOTTUBE I.D. li'::~\43J~;:C f?o:l DATE 1.01/07/981 

PITOT TUBE ASSEMBLY LEVEL? _ _.;.;X~X __ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?;_· ____ YES(EXPLAIN BELOW) _..;.x.;;.x.;....._ NO 

·. ··" ,. -- ·.·CRITICAL ALIGNMENT MEASUREMENT;.S ; ·,. 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = ____ 0;:.:·.;;::3.:..;75::.. 

COMMENTS 

Pa= 

5 3 0 

3 2 0 

0.485 Pb = 0.484 

CALIBRATION REOU!REO? YES XX NO 

1

,.,• r < '', •' ,•·,: •,,' • ~,, "'' ' • / • 

_: -.·.- .. :;::_; :·:·· -: ·-··. :.·.:,.-...... <~._.-_;. L·::,:-:· . ·-~· , -..... ;.:.: :_, :-.' .· 

0 

0 

Alpha= alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w =difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
. 

~-·· 

TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE I Qt/07/98' I 

PITOT TUBE ASSEMBLY LEVEL? _....;.;X;;.;X __ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?;..· ____ YES(EXPLAIN BELOW) -~X.:.:.X_ NO 

1.:·- ··.·· .. · •GRITICALALIGNMENT"MEASUREMENTS. 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = ___ __;;;0.:.::.3:.:.75:::.. 

COMMENTS 

CALIBRATION REQUIRED? 

0 

1 

Pa= 0.452 

0 0 0 

2 0 0 

Pb = 0.453 

YES XX NO 

- ·-~- -1 :> ... :~:--;_;,_::~~:-;::·:_~,_,:;:;t··-::\~~~--:~~--- ·:\;-.r::_.:;;s-·:-:-~::;:·.-;:: ;··- ,:·'·\::·.·~: -,; .. __ i.:: .· -· ··-._:·_-: ... ~ .. <:-_ : __ -, __ , , ,;'-.· -, ·-_,_::· ,~~-- -- · · 

Alpha- alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w =difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALl BRA TOR Shane Roberts 

. ·'.:. -,_:_., 
~--

·. j 

.-" 

TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE I 01/07l98'l 

PITOT TUBE ASSEMBLY LEVEL? _...;.;XX;.;...._ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?;.._ ___ YES(EXPLAIN BELOW) _,.:.:X~X_NO 

• .GRITICALALIGNMENT MEASI.JHE:MENTS .. 

MEASUREMENT 

#1 

#2 

Dt = ____ .;;;.0·:.;;3.:..75::.. 

COMMENTS 

Pa= 

ALPHA 

<10 deg. 

3 

2 

0.515 

BETA z w 

<5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

2 0 0 

2 0 0 

Pb= 0.515 

CALIBRATION REQUIRED? YES XX NO 

. I 

·L·.··~:-··-':.· A ~~:-+-:-:~~=~~~----::~~~~~:"..:';··~··"'= ·. --"• . . . .,· .. -. ·y···· ....... ~.··I • . ·-· ... ···- Alpha- alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "S" PITOTTUBE INSPECTION DATA FORM 

DATE JOJ/Q7/98J 

PI TOT TUBE ASSEMBLY LEVEL? _.....;.;X;..;X __ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?;...· ----YES(EXPlAIN BELOW) _.:.;X;.:.X_ NO 

I . ,· -· GRITICALAt:IGNMENJ MEASUREMENrS " 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313" 

#1 

#2 

Dt = ____ 0::.;·,;;:.37:..:5::... 

COMMENTS 

3 

6 

Pa= 0.515 

1 0 

2 0 

Pb= 0.515 

CALIBRATION REQUIRED? YES XX NO 

0 

0 

·1. ·.·. . . .. .. .. . " •.. .. •. . .. ... . '.J ~ >~··:. ':,,.._):.:'·,\,-_:.:.,.'· ,·,_,:,·",•.·:·- ~<;·_';;·---~---:·>:-> .. ,,,·· :.:·'.-._;.:_:, .. : ·~:\ ... .. ·-_ 

Alpha = alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1 .50 *Dt) 

CALIBRATOR Shane Roberts 
' ·! 

THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ ..;0;.;.1/:.;:0;;;7/~9.;.8 __ THERMOCOUPLE NO. 50 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY·IN·GLASS 

.• · ..• · .• ·REFERENCE 

. POINt . 

· souRcE· REFERENCE THEFirviocourLE: ·· 'ri::MF>EFIA'f;URE 

. ;(SpE(;;IFY). TEMP •. POTENTIOMETER DIFFERENCE 

· .. 1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

.. ; [(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE _ ___;;.;.;.;;..;.;;;..;;. 01/07/98 __ THERMOCOUPLE NO. 50 A 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

';,;;.~:;---~-, ·><' ..... ~E-·"" ,;;t;"".,~ ~-rr.~.-~rr::'"F'( . .,;.-·_..,., '_-'· __ -,. ·-~ -:~.-;~'$i0_ ~- ;;,-::_-., .. , -,~ ,.,, __ -t.".'~--~~ii""'%'%> ;· ,,. _, · .,_._ -:.,;,.;'-*!._,,:<'fJ-: \i:C:!':~ ._. .,,.~ ,!;:..:·:~- .. ;-_, .. ,.~.,~·-~·,_, -. ~ ·_-:--f"" 

;, ·;§,.A_ FE;Rcr~GEJ';•]';o;;,_:·,:-.:~::-;;,;so. RCE·.i REFERIOI•CEtTHERJV•OCOUPLE;'iici_l)::MPERAIURE 

~;t·'~ !.f't;::.;·~_:·,.!?~ir~~~i~~~~~{it&~~~~~t~i··:r~:-',\~~;~~i~~f~~ir~R,~~fG;~r~~~?~Fl~ 1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED • 

•• = [(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]*1 00<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ 01/07/98 THERMOCOUPLE NO. ;...;.;..;.;.;..;..;; __ 51 

AMBIENT TEMP., F ___ ..;..7..;..1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

· souFi¢E* REFERENcE tHERMocouPLE. 'rEMPERA'r.lif;lE 

. (SPECIFY). ·.··•··•· TE~P. POTENTI()I';1;#ER ( DIFFERENCE 

F TEfvlpERATURE; F . . . . o/o·~ 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]"100<1.5% 

- .·.' __, 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ ..;:D;.:;1/..;:D.:.:7/.;;9;;;.8 __ THERMOCOUPLE NO. 52 

AMBIENT TEMP., F ___ .;,.7.;,.1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GU.ss 

< REFERE!'.fCE ·. . .. SOURGE •. REFERENCE THERMOCOUPLE 'rEMPERATUR~ 

. , . . POINT . . (~PEtiFY) T~~P. POtENTIGJM~ER DIFFERENt~ 

NO,·... · .. , : ·. · ., .. ·. :_ ·. F TEMPERATURE, F " '0 ' ' 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273) ·(TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE 01/07/98 THERMOCOUPLE NO. 53 

AMBIENT TEMP., F ___ ..;7..;1~-- BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

·· .. •· .· REFERENC:E ··.·. · .. · • -S()URCE* REFERENCE THERMOCOUPLE . TEiviPERAtUFlE 

.. ·.· (SPEGIF'Y) TEMP: POTENTIOMETER .... ·. IJIFFERE~CE . . '_ : ; .; _·:&o-~-~ 

.. P()INT·. :·· 

t;.~b. '· 

AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 33 0.203 

3 BOILING WATER 210 210 0.000 

*=TYPE OF CALIBRATION SYSTEM USED 

*• =[(REF TEMP, G+273}- (TEST TEMP., C+273)/REF TEMP, C+273]*100<1.5% 
·.; 

THERMOCOUPLE CAL/ BRA TION DATA FORM 

DATE __ ..;0;.;:1/:.;;0.;.;7/.;;.9;.8 __ THERMOCOUPLE NO. 54 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

•.. ·. R~f-'~~E~~E, .. _ ... 

•,.· •. •· ··_; •• :;-POQ~}''.• 

• SOURCE* REFERENCE THERMOCOUPLE · TEMpERAT\IRE 

(8,PEOIFY) .. , TEMP. POTE~TJOM~E~; .[)IFFERENCE 

;· ·. FTEMPERATJR~.--~< . o/o** 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 209 0.149 

*=TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]*100<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ 01/07/98 .;,.;;..;..;.;..;....;...__ THERMOCOUPLE NO. 55 

AMBIENT TEMP., F ____ 7_1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

, R~~ERENCE •··•.··••···•· •.· ..•. ·souRCE' REFERENCE THERMOCOUPLE . TEMPERATURE 

POINT ·(~PEbiFY) TEMP. P~TENTiOMETEFI DIFFERENCE 

. . . ..•. • • NO: . . F TEM~I;'RATURE, F ... · ... •. . %*• 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

*=TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
THERMOCOUPLE CALIBRA T/ON DATA FORM 

DATE __ ...;0;.;1.:.:/0;,;.7:.;/9.;;.8 __ THERMOCOUPLE NO. 56 

AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GlASS 

·:.,<REFERENGE ·· .•.. · ••... '>,SOUR(JE'H~FERENCE THERMOCOUPLE . -TEMf'EJ;lATtiF!E 

.. '' '.·.···· ..• · ·i="·.POINT . . •. (SI'E<:;IFY} TEMP. Pbl;ENJIOMETER ·', DIFFERENCE 

< ·. ·.. . •.•..•. _. ~6. < : ' . < .·. FTEMPEFlAl;U 81;, F ·. %;,~ 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)" (TEST TEMP., C+273)/REF TEMP, C+273]'1 00<1.5% 
·-.: 

THERMOCOUPLE CALIBRATION DATA FORM 

DATE __ ..;;0..;.;1/..;;0.;.;7/.;;.98;;_ __ THERMOCOUPLE NO. 57 

AMBIENT TEMP., F ___ ..;,7..;,1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN GLASS 

.•. · REFE.FlENCE . SOLJRbE· FiEFERENCE . THERMOCOUPLE _: :tE:MPERArl.JRE 

.. POINT (sPEciFY) tEMP.· PoTENTioMEtER . oiF~EREf\lc§ 

.•. No. . .· .·. I= 'mi1F'E:F!AJURE,F .. o;d"• 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'1 00<1.5% 
THERMOCOUPLE CALIBRATION DATA FORM 

DATE 01/07/98 THERMOCOUPLE NO. 58 

AMBIENT TEMP., F ___ _;7_;1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS 

I 'iJ .· F\EFERENGE:· S0lJRcE• REFERENGE. THERMOCOUPLE TEMPERATURE .. 

.. PoiNJ . (SP,EGIFY) TEMP' POTENTIOMETER DI.FFEREj\jCE 

. '· .. JIIO . F TEMPERATL!RE, F ·· . o;o•* 

1 AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

• =TYPE OF CALIBRATION SYSTEM USED 

•• =[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]•1 00<1.5% 
;;,l 

p 

THERMOCOUPLE CALIBRATION DATA FORM 

DATE _......;;.;.;..;;..;..;..;..;; 01/07/98 

__ 

THERMOCOUPLE NO. 59 

AMBIENT TEMP., F ___ ..;7..;1 ___ BAROMETRIC PRESS., IN. Hg 29.93 

CALIBRATOR 'Roberts REFERENCE THERMOMETER MERCURY~IN-GlASS 

REFERENCE' 

' - , -~- . ' ' ' . 

o"POINT·· 

··. SOURCE'REFERENGE THERMOCQUPLE TEMPERATURE 

. . • (~PECifv) TEMP. POtENTIOMETER· . DIFFERENCE 

·· ... · ··· No> ·.···. · . i= T~MP$RATl.J!'\E, i= 

AMBIENT 71 71 0.000 

2 REFRIGERATOR 34 34 0.000 

3 BOILING WATER 210 210 0.000 

'=TYPE OF CALIBRATION SYSTEM USED 

"=[(REF TEMP, C+273)- (TEST TEMP., C+273)/REF TEMP, C+273]'100<1.5% 
TYPE "S" PITOT TUBE INSPECTION DATA FORM 

PtTOTTUBEt.D. I '<.·~o•· • DATE 1.:()1/07/98. 

PITOT TUBE ASSEMBLY LEVEL? _...;.;XX;.;..._ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?;.._ ___ YES(EXPLAIN BELOW) _...:..:X::...:X_NO 

.. · · ·. ·········' CRITICAL ALI.GNMENT MEASUREMENTS. • 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = 0.375 ----~.;..;.. 

COMMENTS 

CALIBRATION REQUIRED? 

< -.-,., ---·· 

1 

2 

Pa= 0.507 

1 0 0 

0 0 0 

Pb= 0.507 

YES XX NO 

Alpha = alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "S" PITOTTUBE INSPECTION DATA FORM 

PITOT TUBE I.D. DATE I.0.1l07/98sf 

PITOT TUBE ASSEMBLY LEVEL? _ _;.;X:_:X __ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?;......o ___ YES(EXPLAIN BELOW) _...:.XX.;;.:..._ NO 

J:)~.Z:,:'~'/';;;\':,~~t~r:\_!£r::L:;,:eRIII.G:a.ru:AUlGNME;NTIMEASUBEME;NTS. :··.•····-····;:.,:.·_·· ,_ ... -•• ·,···•••-· I 

MEASUREMENT ALPHA BETA Z W 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313' 

#1 2 2 0 0 

#2 1 0 

Dt= 0.375 Pa= 0.475 Pb= 0.475 

COMMENTS 

~j _,-.,~~;~~~~~~~~-~:~~~~.:~;,:~-·"··-~ .• t., •. ., .•.. ~~-~ --~-·-0·. x: ... '"~S .. "."'"''""'•cc··'"· ·"" 

Alpha= alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb =base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "5" PITOT TUBE INSPECTION DATA FORM 

PITOT TUBE I.D. DATE IO.V07/98:'l 

PITOT TUBE ASSEMBLY LEVEL? _ _;.;XX;.;...._ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?;.._ ___ vES(EXPLAIN BELOW) _.:.:XX~_ NO 

I · .. < •.:., \)co< GRIT1GAL ALIGNMENT MEASUREMENTS • 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313" 

#1 

#2 

Dt = ____ o;;.;·.;;;.37.:....;5;;.. 

COMMENTS 

CALIBRATION REQUIRED?_ 

2 

1 

Pa= 0.475 

2 0 0 

0 

Pb= 0.475 

YES XX NO 

Alpha= alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w =difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE I 01/07/98! 

PITOT TUBE ASSEMBLY LEVEL? _...;.;X;.;.X __ YES NO 

---- PITOT TUBE OPENINGS DAMAGED?;_· ____ YES(EXPLAIN BELOW) _..;...;X;;..;.X_NO 

. CRITICAL ALIGNMENT MEASUREMENTS · ... ·· 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = ____ .::;0·;.:::3..:..;75::... 

COMMENTS 

1 

1 

Pa= 0.465 

0 0 

2 0 

Pb= 0.466 

CALIBRATIONREQUIRED? YES XX NO 

0 

0 

k.:>:·:\o, .. :•\:il·C:i .. :.·· ····.:·•· ·· · ·.·.:: ... · .... ,;,: ..•. · . : .. :0: .::, ......•••....... · ., r--

Aipha =alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "8" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "5" PITOT TUBE INSPECTION DATA FORM 

DATE I 01/0.7/98! 

PITOTTUBE ASSEMBLY LEVEL? _..:X.:.:.X.:....._ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?'----- YES(EXPLAIN BELOW) _..,:X.:.:.X.:....._ NO 

, CRITICAL ALIGNrviENTMEASUREMENTS . · · 

MEASUREMENT 

#1 

#2 

Dt = ___ ......;;:0.:.::.3;.:..7:::..5 

COMMENTS 

Pa= 

ALPHA 

<10 deg. 

1 

3 

0.459 

BETA z w 

<5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

1 0 0 

3 0 0 

Pb = 0.459 

. CALIBRATION REQUIRED? YES XX NO 

I 

1.·:.;"::_, ,·· .. ,.:.,;.: ··''.. . . .. .::.,. .. , .... : ,, ..... . .... ·_,... · ... '>I 

Alpha - alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "5" PITOTTUBE INSPECTION DATA FORM 

DATE !.01/07/98: I 

PITOT TUBE ASSEMBLY LEVEL? _...;.;;XX;.;...._ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?:.,._ ___ YES(EXPLAIN BELOW) -~x~x.;..__ NO 

'

· .. ·- -- . . ... , ' '. CRITICAL ALIGNMENT MEASUREMENTS .. 

MEASUREMENT ALPHA BETA z w 

<10deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313' 

#1 

#2 

Dt = ____ 0.375 ...;..;.;;~ 

COMMENTS 

Pa= 

0 3 0.0625 

2 0 0.0625 

0.534 Pb= 0.534 

CALIBRATION REQUIRED? YES XX NO 

0 

0 

I . .. . •' ., . ". ·' . ....... " .... ' ' ·' .. ' ,• ... . ., . ' ' ' '. '· '' . . ....... --·., .. ·,.:.·- ··-····· · .... -·.:--.. -:-. 

Alpha - alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "8" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "S" PITOT Tl/BE INSPECTION DATA FORM 

DATE I Ot/07./981 

PITOT TUBE ASSEMBLY LEVEL? -~XX;.:..._ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?:,.· ____ vES(EXPLAIN BELOW) _.:.;X~X- NO 

I ~' . ' : ·. . ·· CHI TICAL ALIGNMENT MEASllREMENTS · ..···· . , ·.··· · 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313' 

#1 

#2 

Dt = ____ .:;:,0·;:;:3:.:.;75~ 

COMMENTS 

4 

3 

Pa= 0.472 

1 0.005 0 

2 0.005 0 

Pb= 0.472 

.... ,. CALIBRATION REQUIRED?.· YES XX NO 

l~o:·?~~-_::,~~~_:_ ... i"'i .. + ... ~~-~ ... f~·~--:-:::.'"'i/ :',...:-:·:'._)·_""; _--~-,-·_:·-<·:'""··_:(-- -~.,..~;~: ... ::_: """ .. ~;~--"'"! -. -,...· • .... · ---· .._:·. ,"'"·,...·.-........ "":; .i""·'""··,:·'"""" ... , ·~· · _,;.......,.-..... ··--· ""··:·--·----,.-:~ :-.... ·; --:--.\-""·'""·. "". '""""-... "".-~ ,.;;·· .......,.;....;'""""..;...Jr · · --- Alpha= alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE I OJ/07/981 

PITOT TUBE ASSEMBLY LEVEL? XX YES _....;.;;..;._._ ____ No 

PITOT TUBE OPENINGS DAMAGED?;_· ____ YES(EXPLAIN BELOW) _...;.x.;;.x.;._._ NO 

.·. CHITI.CAL ALIGNMENT MEASUREMENTS 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313" 

#1 

#2 

Dt = 0.375 ----=~ 

COMMENTS 

Pa= 

0 0 0 

1 2 0 

0.503 Pb = 0.503 

, . CALIBRATION REQUIRED? YES XX NO 

1::• ... :.. . :.;-".•.:·.: .... ·:·· >''', . . . . ... . . • . .. . '"" . 

0 

0 

Alpha= alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb =base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
TYPE "5" PITOTTUBE INSPECTION DATA FORM 

DATE I OJ/07/98.1 

PITOT TUBE ASSEMBLY LEVEL? _...:.:XX;;__ YES ____ NO 

PITOT TUBE OPENINGS DAMAGED?;..· ----YES(EXPLAIN BELOW) _.:.:X.:.:.X_ NO 

I . L::i .. > . CRFHCALALIGNMENT; MEASUREMENTS 

MEASUREMENT ALPHA BETA z w 

<10 deg. <Sdeg. MUST BE MUST BE 

<0.125' <0.0313' 

#1 

#2 

Dt = ___ __;0;,;;;.3:.:,7~5 

COMMENTS 

0 

0 

Pa= 0.5 

0 0 

0 0 

Pb= 0.5 

CALIBRATION REQUIRED? YES XX NO 

0 

0 

Alpha - alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z =difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 

. I 
TYPE "S" PITOT TUBE INSPECTION DATA FORM 

DATE I 01/07/981 

PITOT TUBE ASSEMBLY LEVEL? -'""'""'X;.;X __ YES ____ No 

PITOT TUBE OPENINGS DAMAGED?;..· ----YES(EXPLAIN BELOW) _...;X..;;X~- NO 

I ·--.. ·· CRITICALALIGNMENTMEASUREMENTS 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125' <0.0313" 

#1 

#2 

Dt = ____ ..:::0;.;:. 3;.:..7:::.,5 

COMMENTS 

CALIBRATION REQUIRED? 

•".'' . '• 

,::, ·_ ' ' . :· .. ,-;,,_.,_ ... 

2 

1 

Pa= 0.503 

1 0.03125 0 

0 0.03125 0 

Pb= 0.503 

YES XX NO . · .. 

Alpha= alignment of the face openings across the transverse tube axis 

Beta = alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt = the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1.05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 

I 
TYPE "S" P/TOT TUBE INSPECTION DATA FORM 

DATE Joj/Q7/98J 

PITOT TUBE ASSEMBLY LEVEL?. _....;.;XX;.;...._YES NO 

---- PITOT TUBE OPENINGS DAMAGED?;...· ----YES(EXPLAIN BELOW) _..:.;x;..;.x_ No 

....• •····•··· .: ··.• CRITICALAllGNMENTMEASUHEMENTS 

MEASUREMENT ALPHA BETA z w 

<10 deg. <5 deg. MUST BE MUST BE 

<0.125" <0.0313" 

#1 

#2 

Dt = ___ ......;;:0.;.:;:.3:.:.;75:::.. 

COMMENTS 

0 

0 

Pa= 0.487 

0 0 

0 0 

Pb= 0.487 

CALIBRATION REQUIRED? YES XX NO 

0 

0 

1-·-:-_,_:-:~----~,~~-:.\:.;;:::·L:'~-- -~~-<~;;::\~;;:.::~:-·;::,;\:_ -::- _ .. :--·-.,.~, ;:;:_,::· -· ",. -.· -----: ·., ; --__ :_.,;: - , .- : .. -.. _ --·· ... ;- -. · · -I 

Alpha = alignment of the face openings across the transverse tube axis 

Beta= alignment of the face openings across the longitudinal tube axis 

z = difference in length of "A" side and "B" side 

w = difference in alignment from the zero line along the transverse tube axis. 

Dt =the external tubing diameter 

Pa & Pb = base to opening plane distances (should be equal and 

between 1 .05 and 1.50 *Dt) 

CALIBRATOR Shane Roberts 
~) · ... -

SS-28018 

:.;. .. 

_.~. 

·- .; / . :::;:::_..: 

FEDERAL LAW FORSIDS 

TRA!IS?ORTATION IF R:FILLED. 

PENALTY UP TO S25.000 FINE AHl> 

5 YEARS l!o\PRISONMENT . 

(49 U.S.C. 1 S09). 

G.~s:::s ;-i.o.s. 

---:---
mission clag products 

Division of MCP Industries, Inc. 10/1/90 

P.O. Box 6 • Pinsburg, KS 66762 • (316) 2]1-1400 • Fax (316) 231-1475 

JanuarY 6, 1998 

Barry Storer 

Boral Bricks 

P.O. Box 72 

Gleason, Tennessee 38229 

l.'"··t, '''fiJt•• '11~: .. /' 

'.i 

Dear Barry: 

Enclosed are your total Flu;or~Jie analysis 

certificates. The loss on ignition··(LOI) of these 

buff brick samples averaged 7.6\. 

We are working on the Sulfur ~eterminator and 

will not have those test result8 in"the near future. 

AJF/df 

Enclosure 

Si'tlcerely, 

(j_ . '1~ · • Joel Fra zf=.r . L 

· gr. Ceramic Technology 

. Chlef Geologist 

\!. 
Mission Clay Products 

Division ofMCP Industries, Inc. 

P.O. Box 6 . Pittsburg, KS 66762. (S.6) ••1400 

== z;;;;;ug---=-------=~---:=lll-•czD!I:=~========= 

tertifioote of,_tcrfvsi5 

Date: 11-14-96 ·. 

Sample ID: BORAL Bricks - · G1easorr <i!N' ~·Fired 

Analysis Requested: Total Fluoride 

Results ~ 12 6 

Error(+/-) ~ 7 

ppm 

"'

., 

,, . . 

.' :~' 

-Buff Brick 

Comments: _____________ ;_ ___________ _ 

Lab Technician: A.J . 

..•. 

•;. 
Mission Clay Products 

Division of MCP Industries, Inc; · 

P 0. Box 6 . Pittsburg, KS 66762. ()16) •·1400 

, . 

. 

Date: ll-14-98 

Sample ID: BORAL Brick.s - Gleason TNC~·unfired Buff Brick 

Analysis Requested: Total Fluoride 

Results= 551 ppm 

Error(+/-)= 2 B 

:. 

Comments:------------~..:....-·~''--------------

· .. ' .. 

..---~- -

" 

- c, ' . ....-0 c, r1- ·-r-

,. Lab Technician: A.J. 

_rt.!.fD"' ,._ ~ t-fl~AI-tiL-f,...r 

...J!-E---- r. ( 1) sB>o 

I 3 5 
I CLEMSON 

UN 1 VB li.·S 1 T Y .· 

To: Barry Storer: Bora! Bridca, Gl~uon Plant. 

Prom: f1111 Frederic; 

Subject: Pyrohydrolysis Data 

December 12, ·1997 

Attached m the reiUlts·oftbe m~ balanoe ttlll doae on your aamplts. The potential 

.emission• 1ro reported 11 if all the tluorideeareln tt., fbrm ofHF. While thle it not ~actly 

correct, this I• the fo~ acc111pted by motl atata. 

PIIIUC note that theee final figures, 0.66 fbr the buff and 1.25 f~r therell, are in pounds of 

HF per I ton ofBr•d clay. For compariaon, I have lien results from other ceramic plants 

that range from 0.3Q poUIIds to 1.40 pounda per toll. · 

We wiU mail you tht original copy ofthllllnf.ormatiDc. In the meantime, pltue call if you 

have any queatiol!ll: Keep in mind that WI can ioat ,our Individual raw mlterials for you in 

. order to determine the major aources of the tluoridel. 

Thank you for the opportu!ilty to work with. you ind pleaiiC ex:cuM the delay. We h1vc. 

been swamped with emlallions t11111t1 for.the l11t ICIWrllmomhs. 

Wlth beat regarda, 

<Yhrr-'4-~ 

~imP~ed~c 

Ciil"T&I\ FOR iiNOINEERINQ C811AMIC MIINUrACTUIIINO 

· CoU•a• uf En,inccrinf 6. Scicnct: ;oo Clc~n R.aft.h 81"Yd. 'AnP.trson, SC l96l.' 

864.6S6:109 •. PAX 864 •• 1091 
anple Fluoride 

caiption LOI Concenb ation 

0.0798 348 

34 

0.0833 637 

42 

' 

Equivalent 

HF 

(llg/g Df fRd clay 

3fiiS 

36 

871 

44 

>" 

.\ 

Mass Balance 

(Potential HF Emissiofts) 

IF/g fired c:lay) {Jb IF/toll filed cay) 

331 o.ee 

62tS 1..2S 

--

() •I 
Sanple 

Destoiption 

Jr) 

d) 

LOI 

0.0796 

O.O!m 

Fluoride 

Equi~ Mass Balance 

Concenb alion HF (Potential HF Emissiofts) . (j.IJ/g lind *Y) (llglg of lAd ~If fifad clay) {lb HF/Ia fired cay)' 348 368 

34 38 331 o.ea 

637 871 

42 44 82$ ~~ 

Sa111pte Ftuodde LOIIConc: Equivalent HF Mass Balanc:e (Potentl .. HF EIRinions) 

tFIJ fired cfiJ) l(lb HF~ 

913 

94 

O.Ofllllll . 471 

98 

~~:,c(Ci7 

862 

-

/ 

No +e__ : GJ" u 

~ 

.t, 'u .... , .: le __,.. 

, 'r A' e. I e s ..t- 

c /. 7 2 I b /1 t=(-1 <>"- --4"' d c./? r e~ " I 1-- -fo .- j. "',_ 6,.. ( c k_ --:::====::= 

-'"/ ~+~ ba..se.., v.Je..'v"' YH.\Jo<r :seen "'- #=--/-hod-- h;Jf-.___ b<?i='ore.. {pe~ {(.. (11«"~...-). 

re5._./,t. ,'s/ .,t-~~re..J2.-~/ A:JA/7 ;'<~_s/!o,.,.,£/f!.., ~ c-~1/~ a! 
Fluoride 

escription (Potential IF EiRinions) fin!d c:lly) I lib IFIIvn llred 

O.ODIIII 

94 

471 

98 

a9 

-

f03 

~{:,c(a.l 

. 1162 1.12 

- 0.71 

N 0 +e_ : CJ,_, rJ'I ,' <>-o , £, /e -;.-

/. 

II r. 'I ;!<'e. I e -1--- 

c • 72 lb rrr-(;o,___--1-t,d c./? re.!>o.~./1-- -r;;_. -!-an. /,.-/c.k _ ~ 

Wf ,.-{';::. base., We.'v <a n"ve....- .:;een "'- :#=- -f-'-<><-1- h!Jf-.- b<?+:ore. c;;., (<.,IV"«"'-..-)· 

res.__./f ,'.s/ ,Lfi~re-!2~e/ AJf../; /"'~_;1/o,-.,£/~. -~ c-c.!/e cl 

7 s4..-e~ OJ't_ f.t>/3D/",( and. -1-o\d_ hifh --J-o ·.re.;,;vc/.::.nn: ~ "'-"c-lhe,.-

t/e ol- .7--/J"'-... .h<-rl'l{!a:J bric~ -!2r re-/.t'.s,L,J- jf;,7 ,/l,;,·c~if'J 

wo<.-< ;rl_. c:!= So cfu"''j Mxl f,.../c/.... a/ :P~f'/ br:cLs.-

1-f'.Ju(-1 /s nEJ,L -6ac/~'l due. do,)e_ __£.,-- j;;,IK--£ rero,Lt'(/ 1 -lf,e_. 

" v ( 

9 lfot""tF(~r. -Hrtd.. c\o'j IJi:::.<./u«.. w,'l\ bt_ IAS•c:L q/su "'-

1.~.--- 4-h.c."' el<.'pu.t-o d. ~- sh.ov. td be. ver-/ c.onserv~iive.). 

p;] 

/