EMISSIONS TESTING FOR HF, F2, PARTICULATE HF, AND PARTICULATE ON KILN #1 EXHAUST (S-8) 

### BORAL BRICKS Old Highway 22 WEAKLEY COUNTY (Gleason), TN38229 (901) 648-5527 November4, 1998 REPORT # 6057

ANALYTICAL TESTING CONSULTANTS, INC. 301Brookdale Street Kannapolis, N.C. 28083 (704) 932-3193 Distribution: Mr. DavidJohnson (Five copies)

Issue Date: December 8, 1998 /

### TABLE OF CONTENTS Page Number Introduction .......................................... 1 Certification ofResults ........................... 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 HydrogenFlouride Emissions in 0.1N 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 ofparticulate and fluoride emissions testing on the #I kiln exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted onWednesday November 4, 1998. Testing was conducted by Mr. JohnWelch ofANALYTICAL TESTING CONSULTANTS, INC., Kannapolis, NC.

CERTIFICATION OF RESULTS "By oursignature we certify that the testing andthe reporting of the test results containedhereinare preparedto the bestof ourabilities and that, to ourknowledge, the data have been calculatedand reported correctly. No data orinformation has knowingly been omitted."



# [Jtd_~ W. Keith Poole 

# l John Welch Test Report Preparation Test TeamLeader

### 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 conveyorinto 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 brickbody 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 ofpreparation 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 ofthe clay. "Pugged" clay is then extruded as a column. Facial colorants are added to some products. These colorants typically consist ofsand coatings mixed with other additives. All ofthe claypreparation and manufacturing equipment is contained in a coveredbuilding. The sand coatings are prepared in the covered Coatings Storage Area which is connected to the Clay Prep Building. Ifnecessary, 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 andplaced 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 ofthese dryers is to further reduce the moisture content of the bricks. Each set ofdryers has an exhaust stack, which have been determined to emit insignificant levels ofpollutants. Boththe holding rooms and dryers are heated with waste heat from the cooling sections ofthe kilns. Finally, dried brick are moved from the dryers into one oftwo identical tunnel kilns. Final evaporation offree water, dehydration, oxidation, vitrification, flashing, and cooling ofbricks occurs in the kilns. The fuel usedin the kilns is natural gas. Exhaust from the kilns exit respective stacks (ID#'s S-8 and S-9). Brickexiting the kiln are packaged and moved to outside storage prior to distribution. 2**~** "0 8 Raw Material Storage ffidg. Clay Prep Bldg.

Clay :-* Primary ---- Covered **~** Raw Material

---.. Disintegrating

___, Smooth Rolling

f-+ Disintegrating

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 or **~r--** Additive & C011ting Additive
.... Feeders

__.

Storage r-

• Mixing

Hoppers water __.. (pug

mill}

(O>noociod) J water--+ Mixing (oncedad) (pug mill) I

II' Cooting& **~** Extruding Texturlug **I~**

**~ ~**  waste return belt ......... ._. Emissions flow ....__. Material Flow **~** Unoontrollcd stack

### RESULTS SUMMARY SYSTEM Boral Brick Kiln #1 TESTDATE 11-4-98 PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE GENERALQS, FLOW, ACFM 17219 17141 16792 17050 Q STD DRY, FLOWSCFM 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/DEEMISSIONS
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 halfofimpinger 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 halfofimpinger train, corrected for blank) FLOUR/NE (LBSIHR) 1.57e-01 1.46e-01 1.56e-01 1.53e-01 (.). I_) (back halfofimpinger train, not corrected for blank)

HFEMISSIONS LBS/TON 0.64 4

### RESULTS, CONCLUSIONS AND COMMENTS A summary ofsome pertinentresults appear in the preceding RESULTS SUMMARY. For additional information please consult the CALCULATIONS and DATA SHEETS sections of this report. The mean velocity ofthe #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 perminute (ACFM). The standard flowrate was calculatedby applying corrections for: 1) barometric pressure- 30.05" Hg, 2) static pressure ofthe stack (-0.2 I" H20), 3) moisture content ofeach individual run- AVG.=8.48%, and 4) the corresponding stack temperatureAVG.=479.5° Fahrenheit. The correspondingmean 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 II7,593

**~J-g/m**

**.** The average process rate was 5.9 tons brick perhour. This yields an emission rate of0.64 lbs hydroflouric acid per ton ofproduct 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 ofUSEPA method 5/26a were performed onthe exhaust ofthe #1 Kiln stack. (The samplingtrain 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 ofthe analyte ofconcern. 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 ofChapel Hill, NC performed the analysis according to USEPA method 26a., ion chromatography with 

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Figure 26A-1. Sampling Train conductivity detection. Please refer to their report in the DATASHEETS section ofthis report for additional details. All laboratory results were blank corrected. Blanks were comparatively low except for the reagent blank ofthe basic impingers (NaOH). This blank was more than halfofthe level ofthe samples. These results have, therefore, been reported as both blank corrected and uncorrected. The mass detected in the backhalfofthe sampling train (NaOH), as F, was less than five percent ofthe mass detected in the front halfofthe 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 byLabTech, 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 Theleo® Oven-operated at I05'C, 3) a FisherScientific IsoTemp water bath operated at a temperature high enough to evaporate acetone without creating a rolling boil, and

6

### SAMPLINGAND ANALYTICALPROCEDURES, CON'T. 4) aNalgene® 5317-0180 Dessicatorcabinet with indicating dessicant. Priorto 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 ofnumbered 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. Fieldparticulate samples (front halfrinse) were collected in 500mlNalgene® 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 ofeach 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 ofno less than twenty-four hours at 105°C and weighed to a constant weight to the nearest 0.01 mg. A blank ofthe 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 HydrogenFlouride Emissions-Filter Only Hydrogen Flouride Emissions-Front HalfofIrnpingerTrain Only Flourine Gas Emissions-Back HalfofIrnpinger 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, FLOWSCFM 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 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 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, FLOWSCFM 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) 1.1Oe-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 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, FLOWSCFM "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 (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

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 AVG SGRTDP 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, FLOWSCFM 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 notcorrected 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 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 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, FLOWSCFM 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 FORHF, F2, PARTICULATE HF, AND PARTICULATE ON KILN #1 EXHAUST (S-8) 

### BORAL BRICKS Old Highway 22 WEAKLEY COUNTY (Gleason), TN 38229 (901) 648-5527 November4, 1998 REPORT# 6057

ANALYTICAL TESTING CONSULT ANTS, INC. 301 Brookdale Street Kannapolis, N.C. 28083 (704) 932-3193 Distribution: Mr. DavidJohnson (Five copies)

Issue Date: December 8, 1998

### TABLE OF CONTENTS Page Number Introduction .......................................... 1 Certification ofResults ........................... 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 HydrogenFlouride Emissions in O.lN H2S04 •....•.•• 12 Flourine Emissions in 0.1NNaOH ................. 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 ofparticulate and fluoride emissions testing on the #1 kiln exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted onWednesday November4, 1998. Testing was conductedby Mr. John Welch ofANALYTICALTESTING CONSULTANTS, INC., Kannapolis, NC.



### CERTIFICATION OF RESULTS "By oursignature we certify that the testing and the reporting of the test results containedhereinare prepared to the bestof ourabilities and that, to ourknowledge, the data have been calculatedand reported correctly. No data orinfomwtion has knowingly been omitted."



# Wbd~ W. Keith Poole 

# l John Welch Test Report Preparation Test TeamLeader



### 1

### PROCESS DESCRIPTION Bora! Bricks. Gleason Plant Boral Bricks, Gleason Plant manufactures facing brickusing clay, sawdust, recycledbrick, and otherbody additives. Clay and green sawdust are delivered to the plant bytruck. Moist ball clay is unloaded into the facility's primarycrusher and carried via conveyorbelt to a converedRaw 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 carriedby truck form the shipment preparation area to an outside stockpile area. As needed, the bricks are loaded inot an apron feeder and carried viaconveyorinto 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 brickbackinto the new brickbody 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 carriedby belt conveyors through a series ofpreparation 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 clayenters the pugmills, water maybe added depending on the moisture content ofthe clay. "Pugged" clay is then extrudedas a column. Facial colorants are added to some products. These colorants typicallyconsist ofsandcoatings mixedwith other additives. All ofthe claypreparation and manufacturingequipment is containedin a coveredbuilding. The sand coatings are prepared in the covered Coatings Storage Area which is connected to the ClayPrep Building. Ifnecessary, 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. Afterbeing coated and textured, the extrudedclaycolumn is cut into green brick. Green brick are then stacked on kiln cars by a setting machine andplacedin holdingrooms where the green bricks' moisture content is lowered slightly. Kiln cars exitthe holding rooms directly into one of four dryers (two sets). The purpose ofthese dryers is to further reduce the moisture content of the bricks. Each set ofdryers has an exhaust stack, which have been determined to emit insignificant levels ofpollutants. Both the holding rooms and dryers are heated with waste heat from the cooling sections ofthe kilns. Finally, dried brick are movedfrom the dryers into one oftwo identical tunnel kilns. Final evaporation offree water, dehydration, oxidation, vitrification, flashing, and cooling ofbricks occurs inthe kilns. The fuel usedin the kilns is natural gas. Exhaustfrom the kilns exit respective stacks (ID#'s S-8 and S-9). Brickexitingthe kiln are packaged and moved to outside storage prior to distribution. 2**~** ll !;! Raw Material Storage Bldg. <lay Prep BldK•

Clay **~** Prillllll}'

• Covered

• Raw Material **~** Disintegrating

f-. Smooth Rolling ....... Disintegrating

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

. I+-

(D-1 toD-4) Room(H-1)

I S-6, S-71 I S-2 Ia 8·5 Process Flow Diagram Boral Bricks, Gleason Plant Cutting&

..._ Setting **~** or :-- Additive Additive & Coating

Fccdcrs

Storage **~** r- Mixing Hoppers water

(pug mill)

(,.nooclod) J water __... Mking ("'"""'odl (pug mill) CC8ling& ..._ Extruding

... TexturiDg • J ll1l belt - .. + Emissions flow ---11> Material Flow **~** Uncontrolled stack

### RESULTS SUMMARY SYSTEM Bora! Brick Kiln #1 TESTDATE 11-4-98 PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE GENERALQS, FLOW, ACFM 17219 17141 16792 17050 Q STD DRY, FLOWSCFM 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 PARnCULATEFLOUR/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 halfofimplnger train) COMBINED HYDROGEN FLOUR/DE ? 

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

...... ' ' " FLOURINE(LBS/HR) 5.44e-02 4.67e-02 5.79e-02 5.30e-02 

### 0, t);; 

### 3 (backhalfoflmpinger train, corrected forblank)

**~-** FLOURINE (LBS/HR) 1.57e-01 1.46e-01 1.56e-01 1.53e·01 0- ?S"" (backhalfofimpinger train, notcorrectedforblank)

HFEMISSIONS LBS/TON 0.64 4

### RESULTS, CONCLUSIONS AND COMMENTS
A summary ofsome 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 ofthe #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 perminute (ACFM). The standard flowrate was calculatedby applying corrections for: 1) barometric pressure- 30.05" Hg, 2) static pressure ofthe stack (-0.21" H,O), 3) moisture content ofeach 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 of0.64lbs hydrotlouric acid per ton ofproduct kiln dried.



### 5EMISSIONS TESTING FORHF, F2, PARTICULATE HF, AND PARTICULATE ON KILN #1 EXHAUST (S-8) 

### BORAL BRICKS OldHighway 22 

### WEAKLEY COUNTY (Gleason), TN38229 (901) 648-5527 November4, 1998 REPORT# 6057

ANALYTICALTESTING CONSULT ANTS, INC. 301 Brookdale Street Kannapolis, N. C. 28083 (704) 932-3193 Distribution: Mr. DavidJohnson (Five copies)

Issue Date: December 8, 1998

### TABLE OF CONTENTS Page Number Introduction .......................................... 1 Certification ofResults ........................... 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 H2 S04 ••••••.•• 12 Flourine Emissions in 0.1N NaOH ................. 13 (blank corrected) Flourine Emissions in0.1N NaOH ................. 14 (uncorrected) Nomenclature ........................................ 15 Calculation Formulae .................................. 17 Data Sheets .......................................... 19

II

### INTRODUCTION This report presents the results ofparticulate and fluoride emissions testing on the #I kiln exhaust at the Bora! Brick facility in Gleason, Tennessee. Testing was conducted on Wednesday November4, 1998. Testing was conducted byMr. John Welch ofANALYTICALTESTINGCONSULTANTS, INC., Kannapolis, NC.

CERTIFICATION OF RESULTS "By oursignature wecenify that the testing andthe reporting of the test results containedhereinare prepared to the bestof ourabilities and that, to ourknowledge. the data have been calculatedand reported correctly. No data or infomzation has knowingly been omitted."



# w~~ W. Keith Poole 

# l John Welch Test Report Preparation Test TeamLeader

### PROCESSDESCRIPTION Boral Bricks. Gleason Plant Bora! Bricks, Gleason Plant manufactures facing brickusing clay, sawdust, recycled brick, and otherbody additives. Clay and green sawdust are delivered to the plantbytruck. Moistball clay is unloaded into the facility's primarycrusher and carried via conveyor belt to a converedRaw Material Storage (a.k.a. Clay Storage) Building where it is stockpiled. Filler clay and sawdust are delivered directly to the RawMaterial Storage Building and stockpiled. Off-spec bricks are carriedby truck form the shipmentpreparation 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 brickbody 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 commonbelt conveyor. Beforebieng shaped into a final form, the blendis carried by belt conveyors through a series ofpreparationmachines which include: a disintegrator, followed by a smoothroller, followed by another disintegrator, followed by a controlledrate additive feeder (used as needed), follwed bytwo pug mills in series. As the clayenters the pug mills, water may be added depending on the moisture content ofthe clay. "Pugged" clay is then extruded as a column. Facial colorants are added to some products. These colorants typicallyconsist ofsand coatings mixed with other additives. All ofthe clay preparation and manufacturing equipment is contained in a coveredbuilding. The sand coatings are prepared in the covered Coatings Storage Area which is connected to the ClayPrep Building. Ifnecessary, 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 greenbrick. Green brick are then stacked onkiln cars by a setting machine and placedinholdingrooms 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 ofthese dryers is to further reduce the moisture content of the bricks. Each set ofdryers has an exhaust stack, which have been determined to emit insignificant levels ofpollutants. Both the holding rooms and dryers are heated with waste heat from the cooling sections ofthe kilns. Finally, dried brick are moved from the dryers into one oftwo identical tunnel kilns. Final evaporation offree water, dehydration, oxidation, vitrification, flashing, and cooling ofbricks occurs in the kilns. The fuel used inthe kilns is natural gas. Exhaust from the kilns exit respective stacks (ID#'s S-8 and S-9). Brickexiting the kiln are packaged and moved to outside storage prior to distribution. 21leJRllwMaterialStoragemag.<layPrepBids.ClayWPrimacyUnloadingl1Crushingr-+1CoveredStccltp!lesSmaolhRollingor__!_Suetmiog_!_Oft:.SpeoApronHBrickFeederI'---StorageGrindingOff-SuccBrlckSawdustUnloadingSandStorage+orSandDzyer(SD-1)-r+E)AdditiveAdditive&CotltingIIStorage+Hopperswater--tl(u..,a,d)water(notedod).....t=Mlxing(pugmlll)j_Mixing(pugmill)--·-·-PackagingHFiringManufaduringBldg.andStorago(TK.-1,TK.-2)_jIS-8,,S-9·-HoldingRcom(H-1)j_ls-y-71I,.ProcessFlowDiagramBoralBricks.GleasonPlantCutting&Setting,,wastereturnbelt·----.Emissionsflow---+MaterialFlowUncontrolledslllck.

### RESULTS SUMMARY SYSTEM Boral Brick Kiln #1 TESTDATE 11-4-98 PARAMETER RUN#1 RUN#2 RUN#3 AVERAGE GENERALQS, FLOW, ACFM 17219 17141 16792 17050 Q STD DRY, FLOWSCFM 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/DEEMISSIONS PARTICULATEFLOUR/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 (fronthsffofimplnger train) COMBINED HYDROGENFLOUR/DE _, •-74 EMISSIONS (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 (backhaffofimpinger train. correctedforblank) FLOURINE (LBS/HR) 1.57e-01 1.46e-01 1.56e-01 1.53e-01 o. ,_, (backhaffoflmp/nger train, not corrected forblank)

HFEMISSIONS LBS/TON 0.64 

### 4

### RESULTS, CONCLUSIONS AND COMMENTS
A summary ofsomepertinentresults appearin the preceding RESULTS SUMMARY. For additional information please consult the CALCULATIONS and DATA SHEETS sections of this report. The mean velocity ofthe #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 perminute (ACFM). The standard flowrate was calculatedby applying corrections for: I)barometric pressure- 30.05" Hg, 2) static pressure ofthe stack (-0.21" H20), 3) moisture content ofeach individual run- AVG.=8.48%, and 4) the corresponding stack temperatureAVG.=479.SO Fahrenheit. The correspondingmean standard volumetric flowrate was 8,835 SCFM. Total hydroflouric acid emissions (HFcontained on the filter and in the acidic impingers) averaged 3.780pounds perhouror I 17,593 f.l-g/m3• The average process rate was 5.9 tons brick per hour. This yields an emissionrate of0.64 Ibs hydroflouric acid per ton ofproduct 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 l, 2, 3, 4, 5, and 26a. Three repetitions ofUSEPAmethod 5/26a were performed on the exhaust ofthe 

### #I Kiln stack. (The samplingtrain 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 ofthe analyte ofconcern. A numbered, pre-tared heated Teflon® filter was utilized inthe heated filter box. Method 5 particulate was performed onthe filter prior to analysis for particulate flourides. First Analytical Laboratories ofChapel 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 theirreport in the DATA SHEETS section ofthis report for additional details. All laboratory results were blank corrected. Blanks were comparativelylow except for the reagent blank ofthe basic impingers (NaOH). This blank was more than halfofthe level ofthe samples. These results have, therefore, been reported as both blank s;orrected and uncorrected. The mass detected in the back halfofthe sampling train (NaOH), 

### a,5 F, was less than five percent ofthe mass detected in the front halfofthe sampling train (H2S04). Laboratoryequipment that was utilized for the particulate sample analysis included the following: 1) FisherScentificXA Analytical Lab Balance-certified and annual maintenance byLabTech, Inc. Priorto each use, the balance is calibrated with NIST Traceable weights-0.5, 5.0, and 50.0 grams, 2) a Precision ScientificModel 70 Thelco® Oven-operated at 

### lOSOC, 3) a FisherScientific IsoTemp waterbath 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-bleedingmarker and oven drying. Duplicate weighings were then completed on the filters to a constant weight. Additionally, a sufficient quantity ofnumbered 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 halfrinse) 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 ofeach 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 ofno less than twenty-four hours at l05°C and weighed to a constant weight to the nearest 0.01 mg. A blank ofthe 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 ParticulateEmission Rate Calculation Hydrogen Flouride Emissions-Filter Only Hydrogen Flouride Emissions-Front HalfofIrnpingerTrain Only Flourine Gas Emissions-Back HalfofIrnpinger 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 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 (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, FLOWSCFM 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 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 (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, FLOWSCFM 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

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 (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, FLOWSCFM 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) 4.51e-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

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 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, FLOWSCFM 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 notcorrected forblank 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

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, FLOWSCFM 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 ofnozzle AS (square feet), Cross sectional area ofstack CP Pitot tube calibration coefficient % 

### EA Percent Excess Air F (scfd/10 6 BTU), F factor DH (inches ofwater) Average orifice meter reading

HI (million BTU/hr), Heat Input Rate % 

### I Percent Isokineticity

M (lb/lb mole), MolecularWeight ofwet gas % 

### M Percent Moisture MD Mole fraction ofdry gas MWD (lbllb mole) molecular weight ofdry 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 ofwater), 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 ofwater), 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 ofwater vapor collected, corrected to standard conditions WT (gm), Total weight ofparticulate collected TIME (MlN.) Duration oftest

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 =(GAMMAFACTOR, 0.983)(VM) (T STDrrM) (PMJP STD) 4. Volume ofwater collected, corrected to standardconditions 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 stackgas %M = (100) (VV 

### STD)N STD 7. Mole Fraction ofdry gas MD= (l00-%M)/l00 8. Molecular weight ofthe wet gas M = (MWD) (MD)+ 18(1-MD) 9. Stack velocity VS = (85.48)(CP)((TS/(PS)(M))"'((SumDPt' N 

### DP)) 10. Stack volume flow rate QS = (60)(VS)(AS)

17

### CALCULATIONFORMULAE (CONTINUED) II. Stack volume flow rate, standard conditions including moisture Q STD = (T STDIP 

### STD)(PSffS )(QS) 12. Stack volume flow rate standardconditions 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 ofareas basis PMRA = (.1323)(WT)(AS)(I44)/(Tirne)(AN) 15. Percent lsokineticity %I= (100) (PMRA)/PMRC 16. Average pollutant mass rate PMR AVG = (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 ImpingerData Sheets Gas Analysis Data Sheets Source Test Survey Equal Area Calculations Chain ofCustodyRecord LaboratoryReports 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

CLIENT Boral Brick DATE **11-4-9~** Pbar JO. D 5 Module I .D. /.J.TC.*'/

LOCATION Gleason. TN SOURCE /Ciw I Ps

- o.

**~I** Filter # r.2oo

TEST TEAM _:3-V..J RuN #

Method 5 Pitot I.D. 3(..

LEAK RA'rEs-____ SETUP 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

% H

2 0 ts.% I

PITOT: Ts 5oS

Gamma Factor_

**/.~0** Agency Personnel On Site

__________________ _

**BS:~,Q**

Md **_.29.~()~-** Pm_

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0 Zo /0 II FORM T. = meter temperature T.

,. stack temperature TP :a probe temperature Tr :a filter temperature T

1 • exhaust temP.erature of last impinger

... P. = Velocity head differential pressure AH

,. pressure differential acrose the orifice meter v. u:t) • gaa sample volumeCLIENT 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:

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# **T/~O** Pitot I.D.

**3~**

PI TOT Agency Personnel On Site,

__________ _

S'o I

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= meter temperature. T. = stack temperature TP = probe temperature Tl' • filter temperatura T, • exhaust

**t~erature** of last impinger

**~P.** = Velocity head

**d~fferential** pressure AH = pressure differential acroaa the orifice mater V_.. (ft ) • gas sample volumeCLIENT 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 Module I.D.//.T.tt:_,/

SOURCE**1<:1-v~/** Ps -(J.,/2/ Filter# **T"~-'1**

RUN # 2 Method

_ **___5~** __ _ Pi tot I. D. 3 :J.

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start A

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T. = meter temperature T. = stack temperature TP oz probe temper:.;i.'• T, = filter temperature

**T~.** ,. exhaust**t~erature** of last !mping"er

AP. = Velocity head differential pressure &a = pressure dif:f **~·** ·:ial across the orifice meter v. (ft)

**~** ;as sample volumeCLIENT 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 Method 5

LEU RATES

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---- Comments: AH@------7"'-- % n 2 vo

______ **:?~-** Module I.D. ;t.rc'/ Filter # T .;2o 1 Pitot I.D. **3~** Agency Personnel On Site

_________________ _

) S"tJ S5 0 FORM T.._ = meter temperature T. • atack temperature TD • proba temperatura T

2 • filter temperatura Tl = exhaust**t~erature o~**  last impinger

AP. = Velocity head differential pressure AH = prassura differential across the orifica mater v. (:f!t } = gas sample volumaAN.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.....,

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____ Method 5. Z. (.A

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

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% **v•------~---------** Agency Personnel On Si,;e,

____________ =/

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**T~** • filter temperature Tt = exhaust tamP.erature of last impinger

AP. = Velocity head differential pressure AH = pressure differential across the orifice meter v. (ft ) = gas sample volume

## 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 

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**37.~"**

SKETCHROH# 

## I

P'ORM 11 

### ANALYTICAL TESTING CONSULTANTS, INC. KANNAPOLIS, N.C. XMPXNGER DATA SHEET

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### 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~~---------------
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POINT OTHER REMARKS I 2 3 4 5 

### 6 7 8 ,{) 9 

## D 10

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### APPlies to f-factor tests.

## ANALYTICALTESTING 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 

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## 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 ANALYST ___ 

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# ANALYTICAL TESTING CONSULTANTS, INC. CHAIN OF CUSTODY RECORD

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### t- CLIENT: LOCATION: SOURCE:

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## 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 ofsamples and a blank set were submitted for determination offluorine 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 offive. 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 arepresented as total milligrams ofthe compound ofinterest as shown in the column headings on the results table on the next page. On the calculationpage 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 thanhalf ofthe sample levels, so these should be blank corrected by the user. Quality Control: All ofthe samples and standards were run in duplicate. The spike recovery (87%) is well within the normal range of75% 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 0.03FLUORIDE 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 ofY Est RSquared No. of Observations Degrees of Freedom XCoefficient(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 1.66FLUORIDE 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 ofY Est RSquared 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

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# -~/ IC Calibration; Fluoride FAL

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



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### 16November 5. 1998 First Analytical Laboratories 3 Mount Bolus Road Chapel Hill, N.C. 27514 Attn: Bill Wadlin Dear Bill. 

## ANALYTICALTESTING 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 ofthese 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) 993-7915NOTE: 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 .. '..

### :! ; ...:

..



### i'1oAfe''"'o:' "

### 'sfA'tloN

**fi8Essufl'E'·~:::><'E!A** 

### · M,··· "'EAo ••·• :., ··
**AI5JUsl'MeNfl',~::**

### 1Nt1Alis I r"''''" •··· . "' "''!' ''1 y ·· +•''·•· •··•,,

**.~"-** ,. ..• F!Q
...

### lttEJ:i.o ....bG......"...............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·•·**

## ..**f:iMrttJ:Il··a"'loll'~'7{'' '(ii.Aoagsrh~N"'i'·~~:·:>"··rNI"':r~us** 

## 1

..
**JJ~:t II~M**  ·k , - ·

**,-~1 ~~r"t!-**  ..j , · ,. '·'· .... ' -" "-
.. , -

**~** .- rlii:'.M,.{l;..,_" t\t1 - ',
___**~~-?** "',t;.t;:t__, t'!l • %•11 ·', '; .,, .- ...,...,iJYt

**--~~ .I;'T~Mtp!**  < IJ.:
... -... 

### 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 TESTMODULE 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

## PYREXNOZZLE CALIBRATIONDATA 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 ANYTWO DIAMETERS, IN. DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO0.004 INCHES =AVERAGE OF THREE DIAMETERS AVERAGE DiA.'" (lt-JCHES)



## 0.313 0.313 0.313 

# .IDt= 

### TYPE "S" P/TOTTUBEINSPECTIONDATA FORM PIToTTUBE 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" PITOTTUBEINSPECTION 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 TUBEINSPECTION 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) 

### CALlBRATOR

### _S;;;.h;.;,;a;;;.n;.;;e~R.;.;o;.;;b;,;;e.;.;rt;;.s-------

### THERMOCOUPLE CALIBRATIONDATA 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 •• =[(REFTEMP, C+273) ·(TESTTEMP., C+273)/REF TEMP, C+273]"100<1.5%

' '

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

### THERMOCOUPLE CALIBRATIONDATA FORM DATE __ .;.01;;.;/0;.;;6;.;;/9.;.8__THERMOCOUPLE NO. 36 AMBIENTTEMP., 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 •• =[(REFTEMP, C+273)- (TEST TEMP., C+273)/REFTEMP, C+273]'100<1.5%



# ..100 •:::s ;; 1D'r CG.!. \'l.

1of :.)..:::i!i ___ _;,_; ___ _ 0:·::.-gen 11.

**1.~**

FEDERAl lAWFORBIDS 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 QualityAssurance ..................................... 24 Test Report Outline ................................... 25 Results Summary ..................................... 26 Plant Entry and Safety .................................. 27 Calibration Data ...................................... 28

## ANALYTICALTESTING CONSULTANTS.INC. SPECIAUSTS IN FlEW DATA COLLECTION October 12, 1998 Mr. Jeryl Stewart, ChiefofCompliance Validation Tennessee Department ofEnvironment 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 ofyour staffare invited to witness part or all testing. TEST SITE: SYSTEM TO BE TESTED:

TEST METHOD(S): TEST DATE: TEST TIME: COMPANYCONTACT IND!VlDUAL:

TEST TEAM LEADER: Sincerely,



# w.~(?~

W. Keith Poole
cc: Mr. DavidJohnson, Bora! Bricks, Inc. Mr.John Welch, ATC Bora! Bricks, Inc. Gleason, TN One ofthe two following sources Tunnel Kiln # 1Exhaust Tunnd 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

### SOURCESURVEYAND 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 ofgreen 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 ofapproximately 18.000 cubic feet per minute at an estimated exhaust temperature of550 degrees F. SAMPLING LOCATION DATA: DISTANCE DOWNSTREAM FROM FLOW DISTURBANCE: Will be according to USEPA method 1. DISTANCE UPSTREAM FROM FLOWDISTURBANCE: according to USEPA method 1 INDIVIDUAL STACK__ __,YE"""'-S_____ COMMON STACK____ _ STACK DIAMETER ORDIMENSIONS: 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: FirstAnalytical Laboratories 3 Mount Bolus Road Chapel Hill, NC 27514 Attn.: Mr. Bill Wadlin FILTERMATERIAL: GELMAN AJE_WHATMAN 934AH_OTHER Pallflex 3" Teflon 4**~** 1J EJ Raw Material Storage Bldg. Clay Prep Bldg.

Clay f-* Primary Covered

_ _. Raw Material

r+ Disintegrating r-. Smooth Rolling

__. Disintegrating

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 14--

(TK-1, TK.-2)

' 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 + or **~** Mditive Additive & Coating

..... Feeders

• • Storage L

+ • Mixing

Hoppers water

(pug mlll)

(,..n...,.Jod) J _water_. Mixing (!>!lOO!od) (pug mill) ,

ir Cooting& **~** Extruding Texturing + l waste return belt ...... _.. Emissions flow ---+ Material Flow **~** Uncontrolled stack:

### PROCESS DESCRIPTION Bora! Bricks, Gleason Plantmanufactures facing brick usingclay, sawdust, recycledbrick, and other body additives. Clay and green sawdust are delivered to the plant by truck. Moist ball clay is unloadedinto the facility's primary crusherandcarried viaconveyorbelt to a converedRawMaterial 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 conveyorinto the Clay StorageBuilding whre they are processed through a harnmermill (grinder) and vibrating screen to achieve 

## asize suitable for reintroducingthe off-spec brick backinto the new brickbodymixes. Using conveyorbelts, the crushedbrick (referred to as "grog") is then stockpiled in the Clay Storage Building. As needed, clay, sawdust, and grog are loaded into feeders. These feeders depositraw materials inot onecommonbeltconveyor. Before bieng shaped into a final form, the blend is carried by belt conveyors through a series ofpreparation 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 ofthe 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 ofthe claypreparation and manufacturing equipment is contained in a covered building. The sandcoatings are prepared in the covered Coatings Storage Area which is connected to the Clay Prep Building. Ifnecessary, 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. Afterbeing 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' moisturecontent is lowered slightly. Kiln cars exit the holdingrooms directly into oneoffour dryers (two sets). The purpose ofthese dryers is to further reduce the moisture content ofthe bricks. Each set of dryers has an exhaust stack, which have been determined to emit insignificant levels of pollutants. Both the holdingrooms and dryers are heated with waste heat from the cooling sections ofthe kilns. Finally, dried brick are moved from the dryers into one of two identical tunnel kilns. Final evaporation offree water, dehydration, oxidation, vitrification, flashing, and coolingofbricks occurs in thekilns. 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 ANDPROCEDURES This package will outline atesting 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. USEPA methods 1-5 and 26a will be utilized in determining the exhaust gas flow rate, temperature profile, total front halfparticulate (as defined at 250'F and method 5), particulate flouride, hydrogen flouride, and flourine emission rates. The following pages will present briefdescriptions ofthese methods. 

### A. Method 1 - Sample and Velocity Traverses for Stationary Sources PRINCIPLE AND APPLICABILITY
a. Principle. To aid in the representative measurement ofpollutant 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 ofthe stackis divided into a number ofequal areas. A traverse point is then located within each ofthese equal areas. b. Applicability. This methodis 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 stackis 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 orless 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 pitot, the presence or absence ofcyclonic flows will be documented on traverse data sheets. 

### B. Method 2- Determination ofStack Gas Velocity and Volumetric Flow Rate CType S Pitot Tube) PRINCIPLE AND APPLICABILITY
a. Principle. The average gas velocity in a stack is determinedfrom the gas density and from measurement ofthe average velocity head with a TypeS (Stausscheibe or reverse type) pitot tube. b. Applicability. This methodis applicable for measurement ofthe average velocity ofa gas stream and for quantifying gas flow.

7

### TESTMETHODS AND PROCEDURES, CON'T. C. Method 3 ·GasAnalysis for theDetermination ofDrvMolecularWeight PRINCIPLE AND APPLICABILITY
a. Principle. A gas sample is extracted from a stack by one ofthe 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, ifnecessary, percent CO. Fordry molecular weight determination, either an Orsat or a Pyrite maybe used for the analysis. b. I. Applicability. This method is applicable for determining carbon dioxide and oxygen concentrations and dry molecularweight ofa sample from a gas stream ofa fossil-fuel combustion process. The method may also be applicable to otherprocesses where it has been determined that compounds otherthan C02, 0 2•CO, andN2 are notpresentin 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 methodusing C02 or 0 2 and stoichiometric calculations to determine dry molecularweight; and (3) assigning a value of30 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 ofthe administrator, U.S. Environmental Protection Agency (EPA). 

### D. Method 3a •Determination ofOxygen and Carbon Dioxide ConcentrationsinEmissions from StationarySources Unstrumental Analyzer Method) PRINCIPLEANDAPPLICABILITY
a. Principle. A sample is continuously extracted from the effluent stream: a portion ofthe sample stream is conveyed to aninstrumental analyzer for determination ofOxygenconcentration. 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 ofMoisture Contentin 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 ofstack gas. b.l Two procedures are given. The first is a reference method, for accurate determinations ofmoisture content (such as are needed to calculate emission data). The second is an approximation

**n;~ethod,** 

### which provides estimates ofpercent moisture to aid in setting isok:inetic samplingrates prior to a pollutant emission measurement run. b.2 The reference method is often conducted simultaneously with a pollutant emission measurementrun; when itis, calculation ofpercent isokinetic, pollutantemission rate, etc., for the run shall be basedupon the results ofthe reference method or its equivalent. The reference method shall be employed for this source. 

### F. Method 5 -Determination ofParticulate 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 of120 ± 

### 14

## oc (248 ± 

### 25°F) or such other temperature as specified by an applicable subpart ofthe 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 ofuncombined water. 1.2 Applicability. This method is applicable for the determination ofPM emissions from stationary sources. 

### G. Method 26A -Determination ofHydrogen 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 ofhydrogen halides (HX) [hydrogen chloride (HCl), hydrogen bromide (HBr), and hydrogen fluoride (HF)] and halogens (X2) 

### [chlorine (CI2) 

### and bromine (Br 2)] 

### from stationary sources. This method collects theemission 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 oftrade 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 isokineticallyfrom 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 ifthe 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 otherparticulate matterincluding halide salts. Acidic and alkaline absorbing solutions collect the gaseous hydrogen halides and halogens, respectively. Following sampling ofemissions containing liquid droplets, anyhalides/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 ofhalogen gas. The halide ions in the separate solutions are measured byionchromatography (IC). If

### desired, the particulate matterrecovered 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 ofboth samplingtrains.] 1.3 Interferences. Volatilematerials, such as chlorine dioxide (Cl02) 

### and ammonium chloride (NH4

### Cl), whichproduce halide ions upon dissolution during sampling arepotential interferents. Interferents for the halide measurements are the halogen gases which disproportionate to a hydrogen halide and an hypohalous acid upon dissolution in water. Theuse ofacidic rather than neutral or basic solutions for collection ofthe hydrogen halides greatly reduces the dissolution ofany halogens passing through this solution. The simultaneous presence ofboth 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/Br 2 

### 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 possiblemeasurable negative bias below 20 

### ppm HCl perhaps due to reaction with small amounts ofmoisture in the probe and filter. Similar bias for the other hydrogen halides is possible. 1.5 Sample Stability. The collected Cl" samples canbe stored for up to 4 weeks for analysis for HCl and Cl2. 

### 1.6 DetectionLimit. The in-stack detection limit for HCl is approximately0.02 

### flg per liter ofstack gas; the analytical detection limit for HCl is 

### 0.1 flg/ml. Detection limits for the other analyses should be similar.


### 10

### TESTMETHODS AND PROCEDURES, CON'T. 2. APPARATUS 2.1 Sampling. The sampling train is shown inFigure 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

### TESTMETHODS AND PROCEDURES, CON'T. 2.1.1 Probe Nozzle. Borosilicate orquartz glass; constructed and calibrated according to Method 5, Sections 2.1.1 and 5.1, and coupled to the probe liner using aTeflon• union; a stainless steel nut is recommended for this union. When the stack temperature exceeds 210°C ( 41ooF), 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 ofthe 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 estimatedto become unstable (approximately 210 °C). 2.1.3 Pitot Tube, Differential Pressure Gauge, Filter Heating System, Metering System, Barometer, Gas Density DeterminationEquipment. 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 ofthe 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 aTeflon" filter support and a sealing gasket. The sealing gasket shall be constructed ofTeflon" or equivalent materials. The holder design shall provide a positive seal against leakage at anypoint alongthe filter circumference. The holder shall be attached immediately to the outlet ofthe 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 connectedin series with leak-free ground glass fittings or any similarleak-free noncontaminating fittings. The first impinger shown in Figure 26A-1 (knockout orcondensate impinger) is optional and is recommended as a water knockout trap for use under high moisture conditions. Ifused, 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 (acidimpingers which each contain 100 ml of0.1 N H2S04) shall be ofthe Greenburg-Smith design with the standard tip (Method 5, Section 2.1.7). The next two impingers (alkaline impingers which each contain 100 ml of0.1 N NaOH) and the last impinger (containing silica gel) shall be ofthe modified Greenburg-Smith design (Method 5, Section 2.1.7). The condensate, acid, and alkaline impingers shall contain known quantities ofthe appropriate absorbing reagents. The last impinger shall contain a known weight ofsilicagel 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 tightlypacked with approximately !50g offresh 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 ofthe tube should be packed with at least !-emthickness ofglass wool or filter material suitable to prevent escape offines. Fit one end with flexible tubing, etc. to allow connection to probe nozzle following the test run. 2.2 SampleRecovery. 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-cappolypropylene 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 orhigh-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. Otherdetectors, a strip chart recorder, and peak heights may be used. 3. REAGENTS Unless otherwise indicated, all reagents must conform to the specifications ofthe 

### Committee on Analytical Reagents ofthe 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 ofTesting 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 (H2

### S04). 

### To prepare I L, 

### slowly add 2.80 ml ofconcentrated H2

### S04 

### to about 900 ml ofwater 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 ofsolid NaOH in about 900 ml ofwater 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, CrushedIce, and Stopcock Grease. Same as Method 5, Sections 3.1.2, 3.1.4, and 3.1.5, respectively. 3.1.6 Sodium Thiosulfate, (Na2

### S,Q3

### 35 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 ofeach absorbing reagent shouldbe prepared for analysis with the field samples. Dilute 200 ml ofeach absorbing solution (250 ml of the acidic absorbing solution, ifa condensate impinger is used) to the same final volume as the field samples using the blank sample ofrinse water. If

### a particulate determination is conducted, collect a blanksample ofacetone. 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 110°C for 2 or more hours and then cooled to room temperature in a desiccator immediatelybefore weighing. Accurately weigh 1.6 to 1.7 g ofthe dried NaCl to within 0.1 mg, dissolve in water, and dilute to I liter. Calculate the exact Cl' concentrationusing 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 ofdried 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 ofNaBr 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

### TESTMETHODS AND PROCEDURES, CON'T. 4. PROCEDURE Because ofthe complexity ofthis 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 ifa particulate determination will be conducted. 4.1.2 Preliminary Determinations. Same as Method 5, Section 4.1.2. 4.1.3 Preparation ofSampling Train. Follow the general procedure given in Method 5, Section4.1.3, except for the following variations: Add 50 rnl of0.1 N H2S04 to the condensate impinger, ifused. Place 100 rnl of0.1 N H2S04 in each ofthe next two impingers. Place 100 rnl of0.1 N NaOH in each ofthe following two impingers. Finally, transfer approximately 200-300 g ofpreweighed silica gel from its container to the last impinger. Set up the train as in Figure 26A-1. When used, the optional cyclone is insertedbetween the probe liner and filter holder and locatedin 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, ifused) ofgreater than !20 °C (248 °F). Foreachrun, record the datarequired on a data sheet such as the one shown in Method 5, Figure 5-2. Ifthe 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 inthe measurement ofthe volume ofmoisture collected and includedin the sample for analysis. The additional 50 rnl ofabsorbing 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 ofa sample run even in the absence ofa cyclone, perform the following procedure. Uponcompletion ofthe 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 oron the filter and pull them through the train into the impingers. After 30 minutes, turn offthe flow, remove the conditioning tube, and examine the cyclone and filter for any visible moisture. Ifmoisture 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 canbe handled safely, wipe offall the external surfaces ofthe tip ofthe probe nozzle and place a cap loosely overthe 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 ofthe irnpinger train, being careful not to lose any condensate that might bepresent. Wipe offany siliconegrease and capthe filter or cyclone inlet. Remove the umbilical cord from the last impinger andcap the irnpinger. Ifa flexible line is used betweenthe first irnpinger and the filter holder, disconnect it at the filter holder and let any condensed water drain into the first irnpinger. Wipe offany siliconegrease and cap the filter holder outlet and the irnpinger inlet. Ground glass stoppers, plastic caps, serum caps, TeflonR tape, ParafilrnR, or aluminum foil maybe 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 samplecontamination or loss. Inspect thetrain prior to and during disassembly and note any abnormal conditions. Treat samples as follows: 4.2.1 ContainerNo. I (Optional; Filter Catch for Particulate Determination). Same as Method 5, Section4.2, ContainerNo. 1. 4.2.2 ContainerNo. 2 (Optional; Front-HalfRinse for Particulate Determination). Same as Method 5, Section4.2, Container No. 2. 4.2.3 Container No. 3 (Knockout and Acid Irnpinger Catch for Moisture and Hydrogen HalideDetermination). Disconnect theirnpingers. Measure theliquid in the acid and knockout irnpingers to ±I rnl by using a graduated cylinder orby weighing it to ±0.5 g by using a balance. Record the volume or weight ofliquid present. This information is required to calculate the moisture content ofthe effluent gas. Quantitatively transfer this liquid to a leak-free sample storage container. Rinse these irnpingers and connecting glassware including the backportion of the filter holder (and flexible tubing, ifused) with water and add these rinses to the storage container. Seal thecontainer, shake to mix, and label. Thefluid level shouldbemarked so that ifany sample is lost during transport, a correction proportional to the lost volume can be applied. Retain rinse water and acidic absorbing solution blanks and analyzewith 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 ofsodiumthiosulfate perppmhalogen-dscrn ofstack gas sampled. [Note: This amount of sodiumthiosulfate includes a safety factor ofapproximately 5 to assure completereaction with the hypohalous acid to form a second

### CJ· ion in the alkaline solution.] Seal the container, shake to mix, and label; mark thefluid level. Retain alkaline absorbing solution blank and analyze with the samples. 16

### TEST METHODS AND PROCEDURES, CON'T. 4.2.5 ContainerNo.5 (Silica Gel for Moisture Determination). Same as Method 5, Section 4.2, ContainerNo. 3. 4.2.6 ContainerNos. 6 through 9 (Reagent Blanks). Saveportions ofthe 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 ofthe corresponding sa!llples using rinse water directly from the wash bottle being used. Add the same ratio ofsodiumthiosulfate solution used in container No. 4 to the 0.1 N NaOH absorbing reagent blank. Also, save a portion ofthe rinse water alone and aportion ofthe acetone equivalent to the amount used to rinse the front halfofthe 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 ofall 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 ornot leakage occurred during transport. Ifa noticeable leakage has occurred, either void the sample oruse methods, subject to the approval ofthe 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 ContainerNo.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 ofthe 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 ofwater, and determine ifany Ct, Br·, or

### p- appears in the chromatogram. Ifany ofthese ions are present, repeat the load/injection procedure until they are no longer present. Analysis ofthe 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 ofthe appropriate series ofcalibration standards, inject in duplicate the reagent blanks and the field samples. Measure the areas or heights ofthe 

### ct·, Br·, and

### p- peaks. Use the average response to determine the concentrations ofthe field samples and reagent blanks using the linearcalibration curve. Ifthe values from duplicate injections are not within 5 percent oftheir 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 ofwater ifthe concentration exceeds that ofthe 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 ofall calibrations. 5.1 Probe Nozzle, Pilot Tube, Dry Gas Metering System, Probe Heater, Temperature Gauges, Leak-Check ofMetering System, andBarometer. 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 

### orgreater) ofthe stock standard solutions to convenient volumes, using 0.1 N H2

### S04 

### or 0.1 N NaOH, as appropriate. Prepare at least four calibration standards for each absorbing reagent containing the three stock solutions such that they are within the linearrange ofthe field samples. Using one ofthe standards in each series, ensure adequate baseline separation for the peaks ofinterest. Inject the appropriate series ofcalibration standards, starting with the lowest concentration standard first both before and afterinjection ofthe 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, ofthe standards and plot individual values versus halide ion concentrations in J.Ig/ml. 

### Draw a smooth curvethrough 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 oftwo 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 ofcompliance samples in the same manner to evaluate the technique ofthe 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

### TESTMETHODSAND 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 ofboth audit samples, theiridentification numbers, and the analyst's name withthe results ofthe compliance determination samples in appropriate reports to the EPAregional office or the appropriate enforcement agency. 

### (NOTE: Acceptability ofresults maybe obtained immediately byreporting the audit results in mg/dscm and complianceresults in total flg HCI/sample to the responsible enforcement agency.) The concentrations ofthe audit samples obtained l:)y the analyst shall agree within 10 percent ofthe actual concentrations. Ifthe 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 offonly the final answer appropriately. 8.1 Nomenclature. Same as Method 5, Section 6.1. In addition: I Bx· = Mass concentration ofapplicable absorbing solution blank, flg halide ion (Cl', Br·, F)/ml, not to exceed 1flg/ml which is 10 times the published analytical detection limit of0.1 flg/ml. (Itis also approximately 

### 5 percent ofthe mass concentration anticipated to result from a one hoursample at 10 ppmv HCI.) C 

## = Concentration ofhydrogen halide (HX) or halogen (X 2), dry basis, mg/dscm. mHX = Mass ofHCl, HBr, orHF in sample, ug. mx2 

## = Mass ofCl2 orBr 2 in sample, ug. Sx· 

## = Analysis ofsample, ug halide ion (Cl·, Br·, F)lml. V, Volume offiltered and diluted sample, ml. 8.2 Average Dry Gas Meter Temperature and Average Orifice Pressure Drop. See data sheet (Figure 5-2 ofMethod 5). 8.3 Dry Gas Volume. Calculate VmC><d> and adjust for leakage, ifnecessary, using the equation in Section 6.3 ofMethod 5. 8.4 Volume ofWater Vapor and Moisture Content. Calculate the volume ofwater vapor Vw(><d> and moisture content Bw, from the data obtained in this method (Figure 5-2 ofMethod 5); use Equations 5-2 and 5-3 ofMethod 5. 8.5 Isokinetic Variation and Acceptable Results. Use Method 5, Sections 6.11 and 6.12. 8.6 Acetone BlankConcentration, Acetone Wash BlankResidue 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 Br 2 

### Per Sample. mx2 = 

### V, (Sx·- Bx-) Eq. 26A-5 8.9 Concentration ofHydrogen Halide or Halogen in Flue Gas. C 

## = KmHX.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, ifneeded, using data obtained in this method and the equations in Sections 5.2 and 5.3 ofMethod 2. 9. BIBLIOGRAPHY 1. 

### Steinsberger, S.C. andJ. H. Margeson. Laboratory andFieldEvaluation ofa Methodology for Determination ofHydrogen Chloride Emissions from Municipal and Hazardous Waste Incinerators. U.S. Environmental Protection Agency, Office ofResearch and Development. Publication No. 600/3-89/064. Aprill989. Available from National Technical Information Service, Springfield, VA 22161 as PB89220586/AS. 2. State ofCalifornia Air Resources Board. Method421 -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 ofHalogen and Hydrogen Halide Compounds in Gaseous Emissions. In: Incineration and Treatment of Hazardous Waste: Proceedings ofthe 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 ofAnions in Combustion Products. In: Ion Chromatographic Analysis ofEnvironmental 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 ofstack diameter, upstreams and downstreams, and port placements,

,,.preliminary flow and temperature profile (including cyclonic flow checks) and static pressure measurement,


### 20

### TESTMETHODS AND PROCEDURES, CON'T.

,,.. selection ofa suitable nozzle and setup ofsampling computer spreadsheet,

,,.. assembly offirst particulate/HF sampling train,

,,. leak check ofsampling 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 hourruns 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 ofcyclonic flows. An 

### angle indicator will be utilized according to USEPA protocol to verify this condition. Emission rates will be presented in terms oflbs/hr and grains per dry standard cubic foot. Please see the sample RESULTS SUMMARY for additional information.

21Start @ "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

__________ __ Module I.D.

________ __

SOURCE,

__________ _ Ps

____________ __ Filter #____________ _

RUN

I.D.

AH@ __________ _ NOZZLE (# )

Tm. ____________ __ % H 2 0.

______ _ Ts•----------- Gamma Factor

___ __ Agency Personnel On Site,

____________ __

Md. ________ __ Pitot I.D.

' **L~NE** I

T'\,

I

"U''I!L,. '___E._ T•o **~** Pm

____________ __

K Factor

T I T •·

Po . **~**

,..

**~** T 'p'o Start Time

.. u. I"· ·All.

(in.)H;o. (in.)l't,O V!'j PT Finish Time **i~~j~::~;.~b~~~\i;;~,** •

Tn = meter temperature T.

**~** stack temperature TP = probe temperature Tt = filter temperature T 1 = exhaust temperature of last impinger

£P. = Velocity head differential pressure £H = pressure differential across the orifice meter v. (ftl) = gas sample volume

??

## 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. P5 =Pbar ±SP in. Hg. L Rho.*(530/T5 )*(P./29.92)= lbs/ft3 ; .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/ft3 := angle in degrees to yield dP of 0 '0RM 15 23 dP ANGLE 1 OF

. 0° "REF.· {0 dP)

SKETCH

### QUALITY ASSURANCE
ANALYTICALTESTING 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, andWinston, May, 1975. Calibration records ofpertinent testing equipment are part ofthis 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 

### HYDROGENFLOURIDE PMRC, LBS/HR Cs, GR/SCFD TOTAL FLOURIDE PMRC LBS/HR Cs, GR/SCFD RUN#2 RUN#3

26 

### AVERAGE

### PLANTENTRY 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 ofour SAFETYMANUAL.



### 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

# INTERFERENCERESPONSE 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 0.999I ./ 

# 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 0.994o1 

### 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 OFTHREE 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 ANYTWO DIAMETERS, IN. DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUALTO 0.004 INCHES 

### *** =AVERAGE OF THREE DIAMETERSI __/ 

### 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 ANYTWO 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 BETWEENANY TWO DIAMETERS, IN. DIAMETER DIFFERENCE MUST BE LESS THAN OR EQUAL TO 0.004 INCHES 

### *** =AVERAGE OFTHREE 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 OFTHREE DIAMETERS..i

.·

**~·** 

### NOZZLE CALIBRATION OATA 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 ANYTWO 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 1.378 101 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 EQUALTO 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 CALIBRATIONDATA 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 **=[(REFTEMP, 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) -(TESTTEMP., 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)/REFTEMP, C+273]*1 00<1.5%

### THERMOCOUPLE CALIBRATIONDATA 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
•• =[(REFTEMP, 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.

. 

### FTEMpERATURE, 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 •• = [(REFTEMP, C+273) - (TESTTEMP., G+273)/REF TEMP, G+273]*1 00<1.5%

# ..J THERMOCOUPLE CALIBRATION DATA FORM DATE 01/07/98 THERMOCOUPLE NO. 

# __**;...;...;.~--** 46 71 BAROMETRIC PRESS., IN. Hg 29.93 AMBIENT TEMP., F 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" PITOTTUBEINSPECTION 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 TUBEINSPECTION DATA FORM PITOT TUBE I.D. DATE 

### !:01/07798! PITOTTUBE 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 TUBEINSPECTION 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

·. ··" ,. 

### -- ·.·CRITICALALIGNMENT 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" PITOTTUBEINSPECTION DATA FORM DATE 

# IQt/07/98'

# I PITOTTUBE ASSEMBLY LEVEL? _....;.;X;;.;X__YES ____NO PITOTTUBE 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 ofthe 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) CALlBRATOR Shane Roberts . ·'.:. -,_:_.,**~--**

·. j .-" 

### TYPE 

### "S" PITOTTUBEINSPECTION DATA FORM DATE 

# I01/07l98'l PITOTTUBE ASSEMBLY LEVEL? _...;.;XX;.;...._YES ____NO PITOTTUBE OPENINGS DAMAGED?;.._ ___YES(EXPLAIN BELOW)

**_,.:.:X~X_NO** •.GRITICALALIGNMENTMEASI.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·.··~:-··-':.· ~~:-+-:-:~~=~~~----::~~~~~:"..:';··~··"'=** 

## .......

**~.··I** 

## .·-· ... ···- A ·. --"•
. . . .,·..-. ·y···· • 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" PITOTTUBEINSPECTION DATA FORM DATE 

### JOJ/Q7/98J PITOTTUBE ASSEMBLY LEVEL? _.....;.;X;..;X
__YES ____NO PITOTTUBE OPENINGS DAMAGED?;...·---- YES(EXPlAIN BELOW) 

### _.:.;X;.:.X_ NO 

# I

. ,· -· 

### GRITICALAt:IGNMENJMEASUREMENrS " 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 ofthe 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

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

### THERMOCOUPLE CALIBRATION DATA FORM DATE 01/07/98 THERMOCOUPLE NO. 

# _ ___;;.;.;.;;..;.;;;..;;.

# __ 50A AMBIENT TEMP., F 71 BAROMETRIC PRESS., IN. Hg 29.93 CALIBRATOR Roberts REFERENCE THERMOMETER MERCURY-IN-GLASS

**';,;;.~:;---~-,**·><'.....

**~E-·"" ,;;t;"".,~**  **~-rr.~.-~rr::'"F'(**. .,;.-·_..,.,'_-'·
__ -,.

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**~-**

## ;;,-::_-.,..,

**-,~**

## ,.,,__**-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 •• =[(REFTEMP, C+273)- (TEST TEMP., C+273)/REFTEMP, 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 *• =[(REFTEMP, G+273}- (TESTTEMP., 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 CALIBRATIONDATA 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;U81;, 

### 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 •• =[(REFTEMP, C+273)" (TESTTEMP., C+273)/REFTEMP, 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 •• =[(REFTEMP, 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" PITOTTUBEINSPECTION DATA FORM PtTOTTUBEt.D. 

# I

**'<.·~o•·** 

## • DATE 

### 1.:()1/07/98. PITOTTUBEASSEMBLY LEVEL? _...;.;XX;.;..._YES ____No PITOT TUBE OPENINGS DAMAGED?;.._ ___YES(EXPLAIN BELOW) 

### _...:..:X::...:X_NO

.. · · ·. ·········' CRITICALALI.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" 

### PITOTTUBEINSPECTIONDATA FORM PITOT TUBE I.D. DATE 

## I.0.1l07/98sf PITOT TUBEASSEMBLY 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 TUBEINSPECTION DATA FORM PITOTTUBE I.D. DATE 

### IO.V07/98:'l PITOTTUBE 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" PITOTTUBEINSPECTION DATA FORM DATE 

# I01/07/98! PITOTTUBE ASSEMBLY LEVEL? _...;.;X;.;.X__YES NO 

# ---- PITOTTUBE OPENINGS DAMAGED?;_·____YES(EXPLAIN BELOW) 

### _..;...;X;;..;.X_NO

. CRITICALALIGNMENT 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 

# I01/0.7/98! 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 ofthe 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" PITOTTUBEINSPECTION DATA FORM DATE 

### !.01/07/98:

# I PITOTTUBE ASSEMBLY LEVEL? _...;.;;XX;.;...._YES ____NO PITOTTUBE OPENINGS DAMAGED?:.,._ ___YES(EXPLAIN BELOW)

**-~x~x.;..__** 

### NO 

# ' · ..·- -- 

### . ...., ' '. 

### CRITICAL ALIGNMENTMEASUREMENTS
.. 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/BEINSPECTION DATA FORM DATE 

# IOt/07./981 PITOTTUBEASSEMBLY LEVEL?**-~XX;.:..._** YES ____ No PITOTTUBE OPENINGS DAMAGED?:,.·
____vES(EXPLAIN BELOW)**_.:.;X~X-** 

### NO 

## I**~'** 

### . ' : ·. 

### .·· CHITICAL 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" 

### PITOTTUBEINSPECTION DATA FORM DATE 

# IOJ/07/981 PITOT TUBE ASSEMBLY LEVEL? XX YES _....;.;;..;._._ ____No PITOT TUBE OPENINGS DAMAGED?;_·____YES(EXPLAIN BELOW) 

# _...;.x.;;.x.;._._ NO

.·. CHITI.CAL ALIGNMENTMEASUREMENTS 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 =baseto opening plane distances (should be equal and between 1.05 and 1.50 *Dt) CALIBRATOR Shane Roberts

### TYPE 

### "5" PITOTTUBEINSPECTION DATA FORM DATE 

# IOJ/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" PITOTTUBEINSPECTION DATA FORM DATE 

# I01/07/981 PITOTTUBE 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/TOTTUBEINSPECTION 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 ofthe 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 

# '''fiJt•• l.'"··t,**'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

**~** 126 Error(+/-)

**~** 7 ppm 

# "' ., 

### ,, 

# .

.

.'

**:~'** -Buff Brick

Comments:_____________ ;_ ___________ _

Lab Technician: 

### A.J. ..•. •;.

# Mission 

# Clay Products Division ofMCP Industries, Inc; · P0.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 I35

# 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 

## onyour aamplts. 

### The potential 

### .emission• 1ro 

### reported 11 if

### all the

### tluorideeareln

### tt.,fbrm ofHF. 

### While

### thle 

### itnot**~actly** 

### correct, this I• the**fo~** 

### acc111pted

### by motl 

### atata. 

### PIIIUC note

### that 

### theee final 

### figures, 0.66 fbr

### the buffand 1.25

### f~rtherell, are in 

### pounds of HF per I 

### ton ofBr•dclay. 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, 

### pltuecall 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 ofthe tluoridel. Thankyou 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 beatregarda,

# <Yhrr-'4-~**~imP~ed~c**

Ciil"T&I\ FOR iiNOINEERINQ C811AMIC MIINUrACTUIIINO
· CoU•a• ufEn,inccrinf6. Scicnct: ;oo**Clc~n**R.aft.h81"Yd. 'AnP.trson, SC l96l.' 864.6S6:109•.PAX 864•• 1091PyrohydrotJSisDataBORAL-GLEASONSanpleFluorideDateDescaiptionLOIConcenbation1219N78G1-Dried(bull'}0.079834812110197BG1·Fil8d3412110N7BG2-Dried(red)0.0833637BG2-Firad42'EquivalentHF(llg/gDffRdclay3fiiS3687144>".\MassBalance(PotentialHFEmissiofts)IF/gfiredc:lay){JbIF/tollfiledcay)331o.ee62tS1..2S--()•I' (') (l Pyrohydrof:pis Data BORAl.- GLEASON Sanple Date Destoiption 1'1!91rl7 BG 1- Dried (boJr) 1211tw7 BG 1- Fillld 1.21'11W7 BG 2- Dried (red) 121tcW7 BG 2- Fired Pyrohydrolysls Data

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$
**~~** \ OORAL- GLEAS<M I Date
I

Sa111pte Ftuodde LOIIConc: Equivalent

HF Mass Balanc:e (Potentl .. HF EIRinions) tFIJ fired cfiJ) l(lb **HF~** 6113197 6113197 lt1fW7 6'16/W

913 94 O.Ofllllll

. 471 98 **~~:,c(Ci7**
862 -

/ **~** h'l e.- No +e__

:

GJ" u .t, 'u ....
, .: le __,.. ,

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A' e. I e s ..t- TA c /. 7 2

I b /1 t=(-1 <>"- --4"' d c./?

r **e~** " I 1-- -fo .- j. "',_ 6,.. ( c k_ --:::====::= ,'.5 ""-'"/ **~+~** ba..se.., v.Je..'v"' YH.\Jo<r :seen "'- #=--/-hod-- h;Jf-.___ b<?i='ore.. **{pe~** {(.. **(11«"~...-).** (),e.. re5._./,t. ,'s/ **.,t-~~re..J2.-~/** A:JA/7 **;'<~_s/!o,.,.,£/f!.., ~**  **c-~1/~** a!Pyrohydrol)'sis Data BORAL- GLEASON Date
Fluoride Description

(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 h' / E- N 0 +e_
:

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