General Sha e 

Rome, Georgia 

Compliance Emissions Testing 

DES Baghouse Stacks K1 (Kiln A) 

February 26, 2008 

Entec Project No.: 28127 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491=6614 

www.entecservices.com 
Entec Services, 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the February 26, 2008 

Compliance Emissions Testing 

DLS Baghouse Stacks K1 (Kiln A) at the 

General Shale Brick Company located in 

Rome, Georgia 

Submitted to: 

General Shale Brick Company 

P.O. Box 3547 

Johnson City, Tennessee 37602 

Attention: Ms. Martha West 

Entec Project No. 28127 

Completed By: 

Report Submitted March 24, 2008 

Reviewed By: 

Project Leader 

Tom Lotz 

Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed for 

this report is authentic and accurate. It has been checked for completeness and accuracy. 
Executive Sumrnarv 

Entec Services, Inc. was retained by General Shale Brick Co. to perform compliance 

emissions testing at the facility located in Rome, Georgia. Mr. Tommy Lotz, Jr., Mr. 

Johnathan Cochran, and Mr. Trent McMahan of Entec Services, Inc. conducted the 

testing on February 27, 2008. Representing General Shale was Ms. IVlartha West who 

coordinated testing with the control room production activity. 

Entec Services, Inc. encountered no difficulties or problems during the sampling of this 

emissions source. The emissions test summaries on the following pages compared each 

test run to the Georgia Department of Natural Resources (GDNR) Permit No. 3251o115- 

0105=V=02-0. The total combination of HAPs per ton of brick processed was 0.047 which 

is below the limit of 0.150. The sulfur dioxide emissions were above the allowable limit. 
o o 
Detailed Test Results 
SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

RULING AGENCY: 

Entec Services, inc. 

SOURCE OVERVIEW 

General Shale Brick 

Rome, Georgia 

Kiln A 

Annual Compliance Testing 

Circular 

3251-115-0105-V-02-0 

Gas with HCI and HF 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Sulfur Dioxide 

HCI HF 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Mr. Tommy Lotz, Jr. 

Mr. Art Otero 

Mr. Trent McMahan 

Mrs. Martha West 

Georgia Department of Natural Resources 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

02/26/08 

28127 

2 

3 

4 

6C 

26A 
ENTEC Services, inc. 

16-D Commerce Ave. Hue o•[g_•..• Alabama 35023 

INPUT TEST DATA 

Client: 

Source: 

General Shale Brick 

Kiln A 

Field Data 

Run Number 

Test Date 

Symbol Units 

Job No.: 28127 

Data Input By: Art Otero 

Test Data 

Time Test Run Began Ended Military Time 

Sampling Time e minutes 

Stack Area A, Ft 

Barometric Pressure P•a, in. Hg 

in. H20 Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

P•I 

Cp 

Y 

Meter Delta H @ /tH(• in. H20 

iNozzle Diameter o. inches 

Meter Volume v,, dcf 

Meter Temperature tm °F 

Avg. Orifice Delta H ,•H in. Hz0 

Impingers Weight Gain (Moisture) w•mp grams 

Silica Gel Impinger Weight Gain (Moisture) w,• grams 

3xygen Concentration, dry basis o2 % 

•arbon Dioxide Concentration, dry basis co2 % 

;ulfur Dioxide Concentration, dry basis so2 ppm 

•vg. Sq. Rt. of Delta P (sqrt AP)av. (in. H=0) 

;tack Temperature t, °F 

otal Hydrogen Chloride collected, mg 

otal Hydrogen Fluoride collected, mg 

HCL 

HF 

mg 

mg 

02/26/08 

0835-0939 

6O 

18.665 

0.84 

0.978 

1.856 

0.305 

02/26/08 

1034-1137 

60 

18.665 

0.84 

0.978 

1.856 

0.305 

3 

02/26/08 

1201-1305 

6O 

18.665 

0.84 

0.978 

1.856 

0.305 

AVERAGE 

60 

29.13 

-0.27 

0.84 

0.978 

1.856 

0.305 

41.333 40,327 41.709 41.123 

73.5 74.0 80.2 75.9 

1.53 1.51 1.67 1.57 

52.7 54.2 49.1 52.0 

8.9 7.9 9.1 8.6 

16.5 16.5 16.5 16.5 

4.5 5.0 4.0 415 

110.8 119.8 t16.1 115.57 

0.516 0.514 0.538 0.523 

314.0 312.3 315.0 313.8 

9.5 8.0 10.4 9.3 

1.0 0.8 1.3 tn 
ENTEC Services, inc. 

16-D Commerce Ave•lebama 35023 

CALCULATED TEST DATA 

Client: General Shale Brick 

Source: Kiln A 

Description Formulas S•,mbol 

Run Number 

Test Date 

Time Began-Ended 

I. Stack Pressure P•, P,/13.6 

2. Meter Pressure Pb• •'H 113.6 

3, Standard Meter Volume 17.64" y* (VM"]'m)* tP•r &H 113.6 

4a. Standard Volume of Water Vapor Condensed 

4b. Standard Volume of Water Collected in Silica Gel 

=0,04706*W•mp 

=0.04715'W• 

5. Moisture Fraction 

9. Molecular Weight Of Stack Gas, dry basis 

10, Molecular Weight Of Stack Gas, wet basis 

11. Average Stack Gas Velocity 

12. Stack Gas Flow @ Stack Conditions 

=(v•stdl Vw•l)l(V•(=•dl Vw•=,•I V,•=,•)) 

0.32"(O=)+ 0.44"(c0=)+0.2e'(100-(o•).(c0=) 

M•*(1-B•)+lS.0*(B•) 

85.49*Cp*(sqrt &p)=•I*SQRT((T,) 

60*v=*A 

13. Stack Gas Flow @ Standard Conditions 

14. Stack Gas Flow @ Dry Standard Conditions 

14b. Hydrogen Chlodde concentration @ Std.Cond.,GrainslCu.Ft. 

14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. 

=(0.01543*HCL•)/Q•= 

=(0.01543*HFn•)/Q• 

15b. Hydrogen Chlodde emissions Ibs per hour 

15b. Hydrogen Fluodde emissions, Ibs per hour 

16. Sulfur Dioxide (SO2) Gas Concentration 

=(60t7000)"HCLQ=d*Q=•d 

=(60/7000)*HFQ•d*Q 

=C•=* MW 1385.1 10' 

-•1. Sulfur Dioxide (SO2) Gas Concentration =Cso• 

!4. Isokinetic Sampling Rate, Percent 100"Vnl 

'ost Meter Orifice Cal, (EMC ALT-009 Yqa) 

Difference. (Calibration must be within •1% of original Y-factor) 

Q= 

Q= 

HCLcs 

NFcs 

HF -Ibs/hr 

SO•lblhr 

Job No.: 28127 

Data Input By: Art Otero 

Units Calculated Data 

2 3 AVERAGE 

02/26/08 

Mllaary Tin'• 

in. Hg 

in. Hg 

dscf 

fraction 

g/g-mole 

g/g-mole 

f'ds 

scfm 

dscfm 

grldscf 

grldscf 

Ibs/hr 

Ibs/hr 

% 

0835-0939 

29.11 

29.24 

39.086 

2.480 

0.420 

0,0691 

29.380 

28.594 

36.73 

40,020 

26,554 

24,720 

0,004 

9.000 

0.79 

0,08 

02/26/0• 

1034-1137 

29.11 

29.24 

38.097 

2.551 

0.372 

0.0713 

29.460 

28,643 

35.50 

39,761 

26.436 

24.552 

0.003 

0,000 

0.68 

0.07 

02/26/08 

1201-1305 

29.11 

29.25 

38.965 

2.311 

0,429 

0.0657 

29.300 

28.558 

37.30 

41,769 

27,677 

25,859 

0.004 

29.11 

29.25 

38,716 

2.447 

0.407 

0,0687 

29,380 

28.598 

36.178 

40,517 

26,889 

25,043 

0.004 

0.001 0.000 

0.91 0,80 

0.11 

1.84E-05 1.99E-05 1.93E-05 

27.34 29,36 29.96 

96.95 95.14 92.39 

0,09 

1.92E-05 

28.89 

94.83 

1.0003 1.0178 1.0417 1.0199 
Procedures 

The emission rates were determined using EPA Methods 1, 2, 3, 4, 6C and 26A of the 

CFR Title 40, Part 60, Appendix A and Part 63 Subpart JJJJJ (Brick MACT). The 

calibration and quality assurance procedures of EPA CFR 40 Part 60 Appendix A for all 

methods, and the "Quality Assurance Handbook for Air Pollution Measurement System" 

Volume III Stationary Source-Specific Methods were followed throughout the duration of 

the field and laboratory testing. The most current version for each method (as described 

in the Federal Register) was used. 

Stack Gas Volumetric Flow Methods 1 and ? 

The velocity of the gas stream was determined according to EPA Reference Method 1 and 

2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample nozzle. 

The stack pressure was measured with the static side of an S-type pitot tube. A calibrated 

pyrometer was used to measure stack temperature at each sampling point. The stack 

previously tested for cyclonic flow according to EPA Reference Method 1. 

Stack Gas Molecular Weight- Method -• 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3 (Fyrite Method). A sample of the flue gas was extracted from the gas stream 

during each test. These samples were analyzed with a Fyrite gas analyzer. The molecular 

weight of the gas was calculated using the moisture, oxygen and carbon dioxide content 

and the measured stack gas temperature. 

Moisture Content Method 4 

The moisture content used for calculating the gas stream flow rate was determined by 

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

described in EPA Reference Method 4 at the completion of each test. Ice is placed around 

the impingers and the outlet temperature of the impinger is monitored and recorded 

throughout the duration of the testing to verify the temperature is less than 680 F. 


Sulfur Dioxide Method 

An Ametek 921 CE SO2 (Method 6C) analyzer provided continuous analysis of SO2 in 

the gas stream. The basic analytical principle involves quantitative measurement of the 

absorption of UV radiation by SO2 molecules. The analyzer uses a single light source, 

which emits an appropriate wavelength, illuminating the sample cell through which the 

sample is continuously passed. Narrow-band optical filters are rotated through the 

beam, and the radiation passed through the optical filters and sample cell is detected by 

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

multiplexor into a measuring channel and a reference channel. A log ratio amplifier 

computes the logarithm of the input signal ration, producing a signal that is proportional 

to the SO2 concentration. The dual-range analyzer has a digital readout, as well as 0- 

10.0 V DC output terminals. The full scale of the instrument was set at 226.6 ppm. 

Hydrogen Chloride / Hydrogen Fluoride Method 26,•. 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 

degrees and of button hook design) was calibrated before and after the test using a 

micrometer and was recorded on the field data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of sixty (60) minutes. The gases were drawn through a glass nozzle attached to a 

heated glass lined probe. The probe was maintained at the proper settings to obtain an 

exit temperature of greater than 248 o F during sampling. The gases then proceeded 

through borosilicate glass filter holder, with a Teflon frit filter support through a Teflon 

filter to remove particulate matter. The filter was maintained at a temperature of greater 

than 248 0 F. These temperatures were recorded at each point on the field data sheets. 

The gases were then scrubbed through a series of four pre-weighed impingers to capture 

hydrogen halides and halogens and moisture. (The optional first impinger for a knockout 

for moisture was not used.) The first and second impingers contained approximately 100 

ml of a 0.1N H2SO,• (acid) solution and the third and fourth impingers contained 

8 
approximately 100 ml of a 0.1 N NaOH (alkaline) solution. The fifth impinger contained 

pre weighed silica gel to remove any remaining moisture. The gases pass through the 

impinger series in an ice bath to maintain a maximum exit temperature of 68 0 F. This 

temperature was also recorded on the data sheets. The clean and cool gases then 

entered the meter box where the gas flow and temperature were measured. 

After the completion of the test the sampling train and the probe nozzle assembly was 

transferred to the cleanup area making sure no particulate was lost. The cleanup data 

was recorded. 

Each impinger was first verified for moisture, then the first and second impinger contents 

were transferred to its container, weighed and the rinsing from the glassware were added 

to this container. The third and fourth impinger was transferred to its respective 

container, and the rinsing from the glassware was added to this container. The silica gel 

from the fifth impinger was transferred to its respective tared container and weighed. A 

blank of the sulfuric acid solution and sodium hydroxide were taken. These containers 

were clearly marked and transported to our office. The samples were shipped to Test 

America an approved and certified lab in Georgia. 

•g System 

The new test requirements require a stratification test which was performed and was 

determined that the gas stream was unstratified. The gas samples were collected from a 

single point that most closely matches the mean of the stratification test data. Samples 

were extracted from the gas stream by a heated stainless steel probe maintained at a set 

temperature of 250 degrees Fahrenheit, through a hundred (100) foot heated sample line 

that was heated and maintained at a temperature between 225 and 250 degrees. The 

gas is transported to the test trailer then passed through a chilled sample conditioner to 

remove the moisture in the gas stream and then to the analyzers. 

Data Acquisition 

Concentration values were collected using a Baldwin Environmental RM Plus 

Parametrics data acquisition system. The data was recorded every fifteen-seconds and 

then averaged for each sixty-second interval. Each minute average was then averaged 
for the duration of each test run. During all testing, the unit was operating within normal 

operating parameters, at a range appropriate in accordance with applicable permits. 

10 
Entec Services, Inc 

16 D Commerce Ave. Hueytown, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: General Shale Brick Job No. 28127 

Source: Kiln A Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (P): _p Port Type Nipple Port Diameter 4.0" 

Stack Diameter, inches: 58.5 Stack Area, Ft2: 18.665 

Stack Height, feet: 100 Number of Ports: 2 

Stack Properties: Inches Duct Diameters Length of Port, inches: 4.00 

226.0 3.86 Total Number of Traverse Points: 20 

300.0 5.13 Number of Points per diameter: 10 

Upstream Disturbance: 

Downstream Disturbance: 

58.5 •NCHES 

NCHES 

Inside Stack Outside Nipple 

Point No. Inches Inches 

1.5 5.5 

2 4.8 8.8 

3 8.5 12.5 

4 13.2 17.2 

5 20,0 24.0 

6 38.5 42.5 

7 45.3 49.3 

8 50.0 54.0 

9 53.7 57.7 

10 57.0 61.0 

Adjusted points diameter > 24" no point closer than 1.0 inch 

Adjusted points diameter < 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 8 2 diameters downstream and 

upstream criteria is met. 

,.( INCHES 

11 
Train 

EPA Methods 6C 

Three Way Valve 

Calibration Gas Line 

Heated Teflon Line 

Flow Control 

Panel 

iication Lines 

Acquisition System 

OO0 

Air Sampling 

Analyzers 

Calibration 

Gases 

12 
Method 26A Sampling Train 

Filter Z• %mperature 

and •[• 

Temperature 

S•nSo•s 

np!ngi npmg• npmg• 

•3 #4 

(}.IN D.1N 

bso •aO•- •aO• 

Impinger Exit Temperature 

(<680 F) 

npmg, 

#5 

•250 

lica G 

Temperature__] 

13 
K1 (Kiln A) 

Field Data Sheets 
KI (Kiln A) 

Run No. 1 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: General Shale Brick Test Date: 2/26/2008 

Source: Kiln A Run Number: 1 

PARTICULATE W/HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5/26A 

Traverse Point 

1-1 

1-2 

1-3 

1-4 

1-5 

1-6 

Delta P 

0.23 

0.31 

0.28 

Sq. Rt. Delta P Delta H 

0.4796 1.29 

0.5568 1.75 

0.5292 1.58 

0,30 0.5477 1.69 

0,24 0.4899 1.35 

0.18 0.4243 1.01 

1-7 0.21 0.4583 1.18 

1-8 0.21 0.4583 1.18 

1-9 O, 19 0.4359 1.07 

1-10 0.14 0.3742 0.79 

2-1 0,44 

2-2 

2-3 

2-4 

2-5 

2-6 

2-7 

2-8 

2-9 

2-10 

0.45 

0.41 

0,36 

0.30 

0,28 

0,26 

0.24 

0.22 

0.20 

0.27 

Stack Temp. (°F) Meter Temp. (°F 

314 67 

312 68 

311 71 

312 72 

310 73 

309 73 

308 73 

K-Factor 

5.63 

310 72 

310 72 

300 72 

0.6633 2.48 320 

0.6708 2,53 320 

0.6403 2.31 

0.6000 2.03 

0.5477 1.69 

0.5292 1.58 

0.5099 1.46 

0.4899 1.35 

0.4690 1.24 

0.4472 1.13 

0.5161 1.53 

73 

75 

322 78 

318 78 

321 75 

317 75 

317 75 

319 76 

315 76 

315 76 

314.0 73.5 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Run Number Dat___•e Tim____•e SO•2 

Run Number Date Time 

2/26/2008 8:34:45 

2/26/2008 8:35:45 

212612008 8:36:45 

2/26/2008 8:37:45 

2/26/2008 8:38:45 

2/26/2008 8:39:45 

2/26/2008 8:40:45 

2/26/2008 8:41:45 

2/26/2008 8:42:45 

2/26/2008 8:43:45 

212612008 8:44:45 

2/26/2008 8:45:45 

2/26/2008 8:46:45 

2/26/2008 8:47:45 

2/26/2008 8:48:45 

2/26/2008 8:49:45 

2/26/2008 8:50:45 

2/26/2008 8:51:45 

2/26/2008 8:52:45 

2/26/2008 8:53:45 

2/26/2008 8:54:45 

1 2/26/2008 8:55:45 

2/26/2008 8:56:45 

2/26/2008 8:57:45 

SO2 

56.0 

104.3 

105.3 

102.8 

109.0 

115.1 

117.9 

100.4 

110.8 

110.8 

112.5 

117.9 

122.7 

107.9 

116.9 

105.9 

70.4 

129.9 

114.0 

104.7 

114.9 

113.3 

120.1 

123.2 

18 
2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/2612008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

8:58:45 

8:59:45 

9:00:45 

9:01:45 

9:02:45 

9:03:45 

9:04:45 

9:05:45 

9:06:45 

9:07:45 

9:08:45 

9:09:45 

9:10:45 

9:11:45 

9:12:45 

9:13:45 

9:14:45 

9:15:45 

9:16:45 

9:17:45 

9:18:45 

9:19:45 

9:20:45 

9:21:45 

9:22:45 

9:23:45 

9:24:45 

9:25:45 

9:26:45 

9:27:45 

9:28:45 

9:29:45 

9:30:45 

9:31:45 

9:32:45 

9:33:45 

Average 

120.0 

111.0 

116.9 

124.2 

138.6 

136.6 

123.8 

112.2 

72.6 

126.2 

111.0 

101.4 

110.7 

112.8 

117.4 

111.5 

99.2 

110.9 

113.4 

120.2 

126.8 

112.6 

121.4 

109.9 

70.3 

119.2 

92.6 

101.9 

111.0 

115.2 

115.4 

106.2 

109.3 

120.8 

121.5 

126.2 

111.3 

19 
Average Emissions 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2/26/08 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 1 

Calibration Gas Value 

0.0 ppm SO2 

125.1 ppm SO 2 

Initial Calibration 

4.0 ppm 

125.3 ppm 

Final Calibration Average 

3.8 ppm 3.90 

125.2 ppm 125.25 

Mean Reference Values: 

111.3 ppm SO2 

Corrected Results: 

110.8 ppm SO• 

Basis: 

DRY 

2O 
ENTEC SERVICES, •NC. 

SAMPLE RECOVERY DATA SHEET 

Client / Location: _General Shale Brick Sampling Date(s):_2-26=2008 

Run No,: 

impingers 

Final Wt. 

Initial Wt. 

Net Weight 

1 Recovery Date: 

1 2 3 

715.7 725.3 732,3 

694.8 702.0 723.8 

20.9 23.3 8.5 

Moisture imp.: 52.7 Grams 

Description of Impinger Contents: clear 

Description of Particulate on Filter: NIA 

Silica Gel Color: mixed 

Filter I.D. Number: N/A 

Probe Rinse Container No.: N/A 

Impinger Contents Container No.: R-I 

Run No.: 2 Recovery Date: 

Impingers 1 2 3 

Final Wt. 731.9 695.5 739.2 

Initial Wt. 702.1 678.0 732.3 

Net Weight 29.8 17.5 6.9 

Moisture Imp.: 54.2 Grams 

Description of Impinger Contents: clear 

Description of Particulate on Filter: NIA 

Silica Gel Color: mixed 

Filter I.D. Number: NIA 

Probe Rinse Container No.: N/A 

Impinger Contents Container No.: R-2 

Run No.: 3 Recovery Date: 

Impingers 1 2 3 

Final Wt. 722.4 707.6 710.5 

Initial Wt. 693.t 692.6 705.7 

Net Weight 29.3 15 4.8 

Moisture Imp.: 49.1 Grams 

Description of Impinger Contents: clear 

Description of Particulate on Filter: N/A 

Silica Gel Color: mixed 

Filter I.D. Number: NIA 

Probe Rinse Container No.: N/A 

Impinger Contents Container No.: R-3 

BLANKS: Probe Rinse: 

2/26/2008 Recovered By: AO 

4 5 6 Si|ical Gel 

714.5 •• 870.0 

7tl.8 • • 861.1 

Moisture Gel,: 8.9 Grams 

Sealed: Y N 

Percent Spent: 15 % 

Filter Container No,: N/A 

Liquid Level Marked/Sealed: Y N 

Liquid Level Marked ISealed: Y N 

2/26/2008 

4 

719.1 

714.5 

4.6 

Recovered By: 

5 6 

AO 

Silical Gel 

877.9 

870.0 

Moisture Gel.: 7.9 Grams 

Sealed: Y N 

Percent Spent: 20 % 

Filter Container No.: NIA 

Liquid Level Marked/Sealed: Y N 

Liquid Level Marked/Sealed: Y N 

Recovered By: AO 

4 5 6 Silical Gel 

• 811.4 

Moisture Gel.: 9.1 Grams 

212612008 

710.3 

710.1 

Sealed: Y N 

Percent Spent: 10 % 

Filter Container No.: N/A 

Liquid Level Marked ISealed: Y N 

Liquid Level Marked ISealed: Y N 

Impinger: X Filter: 

Project No.: 28127 

21 
K1 (Kiln A) 

Run No. 2 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: General Shale Brick Test Date: 2/26/2008 

Source: Kiln A Run Number: 2 

PARTICULATE W/HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5/26A 

Traverse Point 

1-1 

1-2 

1-3 

1-4 

1-5 

1-6 

1-7 

1-8 

1-9 

1-10 

2-1 

2-2 

Delta H Delta P 

0.28 

0.26 

0.20 

0.29 

0.32 

0,25 

0.21 

0,15 

0.13 

0,19 

0.37 

0.32 

2-3 0.34 

2-4 0.40 

2-5 

2-6 

2-7 

2-8 

2-9 

2-10 

K-Factor 

5.63 

0.37 

0.30 

0.24 

0.21 

0.30 

0.25 

0.27 

Sq. Rt. Delta P 

0.5292 1.58 

0.5099 1.46 

0.4472 1.13 

0.5385 1.63 

0.5657 1.80 

0,5000 1.41 

0.4583 1.18 

0.3873 0.84 

0.3606 0.73 

0.4359 1.07 

0.6083 2.08 

0.5657 1.80 

0.5831 1.91 

0.6325 2.25 

0.6083 2.08 

0.5477 1.69 

0.4899 1.35 

0.4583 1.18 

0.5477 1.69 

0.5000 1,41 

Stack Temp. (°F) Meter Temp. (°F 

316 70 

319 70 

316 7O 

317 71 

317 71 

318 72 

313 72 

310 72 

307 73 

301 73 

314 74 

315 74 

315 75 

313 76 

311 77 

307 77 

310 78 

309 78 

313 78 

305 79 

312.3 74.0 

23 
..( 
2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/2612008 

2/2612008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

10:33:45 

10:34:45 

10:35:45 

10:36:45 

10:37:45 

10:38:45 

10:39:45 

10:40:45 

10:41:45 

10:42:45 

10:43:45 

10:44:45 

10:45:45 

10:46:45 

10:47:45 

10:48:45 

10:49:45 

10:50:45 

i0:51:45 

10:52:45 

10:53:45 

10:54:45 

10:55:45 

10:56:45 

10:57:45 

10:58:45 

10:59:45 

11:00:45 

11:01:45 

11:02:45 

11:03:45 

11:04:45 

11:05:45 

11:06:45 

11:07:45 

11:08:45 

111.3 

119.1 

113.0 

105.6 

115.6 

137.2 

143.8 

134.9 

108.8 

66.8 

130.0 

t22.5 

117.8 

117.3 

125.9 

130.5 

132.6 

125.7 

113.7 

122.9 

136.2 

149.2 

146.1 

131.3 

119.5 

77.7 

137.1 

115.6 

113.1 

124.2 

135.8 

141.8 

135.2 

124.8 

135.1 

140.1 

25 
2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

212612008 

2/26/2008 

2/26/2008 

212612008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

11:09:45 

11:10:45 

11:11:45 

11:12:45 

11:13:45 

11:14:45 

11:15:45 

11:16:45 

11:17:45 

11:18:45 

11:19:45 

11:20:45 

11:21:45 

11:22:45 

11:23:45 

11:24:45 

11:25:45 

11:26:45 

11:27:45 

11:28:45 

11:29:45 

11:30:45 

11:31:45 

11:32:45 

Average 

145.6 

142.3 

140.5 

142.6 

129.8 

78.7 

107.1 

8O.7 

82.5 

85.7 

85.1 

76.7 

81.2 

109.1 

123.0 

124.5 

124.5 

126.0 

135.9 

146.6 

125.2 

68.8 

126.1 

121.9 

119.5 

26 
Average Emissions 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2/26/08 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 2 

Calibration Gas Value 

0.0 ppm SO2 

125.1 ppm SO2 

Initial Calibration 

3.8 ppm 

125.2 ppm 

Final Calibration 

3.7 ppm 

124.0 ppm 

Average 

3.75 

124.59 

i•lean Reference Values: 

119.5 ppm SO2 

Corrected Results: 

t19.8 ppm SO 2 

Basis: 

DRY 

27 
KI (Kiln A) 

Run No.3 

28 
LT__•Z 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: General Shale Brick Test Date: 2/26/2008 

Source: Kiln A Run Number: 3 

PARTICULATE W/HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5/26A 

Traverse Point Delta P 

1-1 0.21 

1-2 0.29 

1-3 

1-4 

1-5 

1-6 

1-7 

1-8 

1-9 

Sq. Rt. Delta P 

0.4583 

0.5385 

0.31 0.5568 

0.31 0.5568 

0.33 

0,22 

0.25 

0.18 

0.13 

1-10 0.16 

2-1 0,47 

2-2 

2-3 

2-4 

0.5745 

0.4690 

0.5000 

0.4243 

0.3606 

0.4000 

0.6856 

0.43 0.6557 

0.43 0.6557 

0.40 

2-5 0,34 

2-6 0.33 

2-7 

2-8 

2-9 

0.6325 

0.5831 

2-10 

0.5745 

0.28 0.5292 

0.31 0.5568 

0.31 0.5568 

0.24 

K-Factor 

5.63 0.30 

0.4899 

Delta H 

1.18 

1.63 

1.75 

1.75 

1.86 

1.24 

1.41 

1,01 

0.73 

0.90 

2.65 

Stack Temp. (°F) 

321 

318 77 

318 77 

315 

319 

313 

316 

Meter Temp. (°F) 

77 

77 

78 

79 

79 

312 79 

314 8O 

314 80 

316 8O 

2.42 312 81 

2.42 310 81 

2.25 

1,91 

320 82 

317 82 

317 

312 

313 

314 

83 

83 

83 

83 

1.86 

1.58 

1.75 

1.75 

1.35 

0.5379 1.67 

308 83 

315.0 80.2 

3O 
3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

11:33:45 

12:01:30 

12:02:30 

12:03:30 

12:04:30 

12:05:30 

12:06:30 

12:07:30 

12:08:30 

12:09:30 

12:10:30 

12:11:30 

12:12:30 

12:13:30 

12:14:30 

12:15:30 

12:16:30 

12:17:30 

12:18:30 

12:19:30 

12:20:30 

12:21:30 

12:22:30 

12:23:30 

12:24:30 

12:25:30 

12:26:30 

12:27:30 

12:28:30 

12:29:30 

12:30:30 

12:31:30 

12:32:30 

12:33:30 

12:34:30 

12:35:30 

141.4 

125.6 

69.1 

121.9 

127.7 

125.3 

115.4 

121.8 

126.4 

130.0 

129.7 

118.9 

123.3 

131.7 

147.7 

148.2 

134.3 

132.5 

72.3 

127.2 

121.7 

108.4 

119.1 

126.6 

128.5 

127.3 

115.3 

122.8 

127.0 

130.9 

138.4 

128.1 

136.7 

134.3 

72.5 

100.8 

31 
3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

2/26/2008 

12:36:30 

12:37:30 

12:38:30 

12:39:30 

12:40:30 

12:41:30 

12:42:30 

12:43:30 

12:44:30 

12:45:30 

12:46:30 

12:47:30 

12:48:30 

12:49:30 

12:50:30 

12:51:30 

12:52:30 

12:53:30 

12:54:30 

12:55:30 

12:56:30 

12:57:30 

12:58:30 

12:59:30 

Average 

77.3 

75.3 

77.5 

78.7 

93.7 

92.3 

105.0 

115.1 

119.5 

123.0 

115.8 

124.7 

137.4 

133.7 

71.5 

95.1 

72.7 

77.1 

106.9 

116.4 

118.3 

112.1 

125.0 

129.7 

115.0 

32 
Calculation of Average Emissions 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2126

Calibration Gas Value 

0.0 ppm SO 2 

125.1 ppm SO2 

Mean Reference Values: 

115.0 ppm SO2 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 3 

Initial Calibration 

3.7 ppm 

124.0 ppm 

Final Calibration Average 

3.5 ppm 3.60 

123.4 ppm 123.69 

Corrected Results: 

116.1 ppm SO 2 

Basis: 

DRY 

33 
Control Room Production Data 

34 
Production Data 

The following information was received by email from rvls. Martha West of General Shale 

Brick Company for the testing performed at their facility in Rome, Georgia, on February 

26, 2008. 

K1 (Kiln A) 02-26=2008 

Brick Production 18.9 tonslhr 

Lime Feed Rate 74.3 Ibs/hr 

Pressure Drop 

Coal Usage 

Gas Usage 

4.4 in ches 

262.25 Ibs/hr 

4,583 scf/hr 

35 
Quality Assurance / Quality Control 

Procedures 

36 
QA / QC Procedures 

Specific quality assurance / quality control procedures were adhered to during this test 

project to provide valid and scientifically defensible data. For any environmental field 

and laboratory measurement, a degree of uncertainty exists in the data due to inherent 

limitations of the measurement systems employed. The objective of a QA/QC program 

is to produce data of known precision, accuracy, representation, completeness and 

comparability. The objective in this test project was to determine compliance with 

applicable air permit requirements. The final data user in this project will be the 

Georgia Department of Natural Resources. 

The following section details all QC procedures followed during the manual sampling 

activities. 

Velocity / Volumetric Flow Rate Methods I and 2 

Volumetric flow rates were determined during each isokinetic test run. The following 

QC steps were adhered to during these tests: 

Reported duct dimensions were checked by physical measurements to determine 

cross-sectional duct area. 

Pitot tube coefficients were determined based on physical measurement techniques 

as delineated in Method 2 

The Type-S pitot tube was visually inspected before and after sampling. 

The pitot tube was installed on the sampling probe with the proper orientation and 

spacing from the sampling nozzle. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature were checked against an N.I.S.T. traceable thermometer. 

The oil manometer was leveled and zeroed before each test run. 

Both legs of the pitot tube were leak-checked before and after sampling. 

Proper orientation of the pitot tube was maintained while making measurements. 

The roll and pitch axis of the pitot tube was maintained at 900 to the flow. 

An average velocity pressure reading was recorded at each point instead of 

recording extreme high or low values. 

The pitot/manometer umbilical lines were inspected before and after sampling for 

moisture condensate. Lines were cleared if moisture was found. 

3? 
Molecular Weight Determination Method 3 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3. A sample of the flue gas was extracted from the gas stream during each test. 

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

adhered to during these tests: 

The sampling train was leak checked before and after each samples was taken. 

The samples were run in triplicate for accuracy. 

Standardization was performed to audit the reagents and the operators technique. 

A known mixture of CO2 and 02 was analyzed and repeated with 3 consecutive 

values ÷/- 0.5 percent of the known value. 

Two NIST traceable gas cylinders were run against the instrument to audit the 

accuracy of the analyzer and the analyzer operator technique. One cylinder 

contained 2 to 4 percent 02 and 14 to 18 percent CO2. The second cylinder 

contained 2 to 4 percent CO2 and about 15 percent 02. 

Moisture Determination Method 4 

Stack gas moisture content (Bws) was determined by dividing the mass of moisture 

collected by the impingers or stainless steel condenser and silica gel impinger by the 

standardized volume of gas sampled. The following QC steps were adhered to during 

these tests: 

The indicating silica gel was fresh for the first run and periodically inspected and 

replaced during runs, if needed. 

The analytical balance was placed in a clean, motionless environment for weighing. 

The balance was leveled and zeroed if necessary before each weighing. 

Preliminary silica gel impinger tare weights and post-run weights were weighed to 

the nearest 0.1 g. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature were checked against an N.I.S.T. traceable thermometer. 

The silica gel impinger gas temperature was maintained below 68°F and recorded 

at every traverse point. 

Each impinger was wiped of surface moisture before post-run weighing. 

The volume of liquid captured was measured using a graduated cylinder with 1- 

milliliter increments. 

38 
Sulfur Dioxide Determination Method 6C 

The sulfur dioxide concentrations were determined using EPA Reference Method 6C. A 

sample of the flue gas was extracted from the gas stream during each test. Moisture 

was removed form the sample and was analyzed on a dry basis with an Instrumental 

gas analyzer. The following QC steps were adhered to during these tests: 

Only analyzers that have a resolution or sensitivity of at least < 2.0% of full-scale 

range are used. 

Upon the SO2 analyzers initial use in the field, an interference check was 

conducted. 

The reference calibration gases used in this test program are certified following 

EPA Protocol Number 1 analysis. Copies of the calibration gas certifications are 

included in the instrument calibration section. 

The high level gas was equal to the calibration span gas. 

The mid level gas was between 40 and 60 % of the calibration span gas. 

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

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

analyzer calibration error was conducted on each reference analyzer prior to 

initiating the compliance testing. These checks were conducted (after final 

calibration adjustments were made) by injecting the calibration gases directly into 

each gas analyzer and recorded the responses. 

The analyzer calibration error was less than _+ 2.0% or _+ 0.5 ppm of the calibration 

span gas for the zero, mid-range, and high-range calibration gases. 

The probe material was stainless steel. 

The probe, filter and sample line temperature was maintained above the dew point 

by heating, prior to sample conditioning. 

The sampling system bias was less than +_ 5.0 % or of the calibration span gas for 

the zero and upscale calibration gases (_+ 0.5 ppm absolute difference). 

The system response time was calculated during the initial sampling system bias. 

The drift for either the low-level and mid-level or high-level gases was less than _+ 

3.0% or of the calibration span gas (_+ 0.5 ppm absolute difference). 

The sampling system was purged > 2 times the system response time before each 

test run. 

Sample flow rate was maintained within 10% during the entire test period. 

Data is recorded at 1-minute intervals. 

39 
All data collected was within the calibration span gas. 

procedures that were followed 

sampling system were: 

HCI/HF Sampling I•lethod 26A 

Accurate particulate concentrations are dependent on the HCI/HF concentrations from 

the stack gas by the use of a series of specialized reagents in the impingers and 

recovered after sampling, and the standardized gas sample volume measured. QC 

so that representative data was collected by the 

Only clean, well-maintained sampling equipment was used. 

Sampling ports were inspected and cleaned prior to sampling. 

All equipment was calibrated according to EPA standards. The dry gas meter was 

fully calibrated within the past 12 months using a set of calibrated orifices. 

The sampling train components exposed to sample gas were constructed of glass 

or Teflon. 

Accurate barometric pressure was recorded at least once per day. 

The dry gas meter thermocouples were compared to ambient temperature prior to 

the test run as a check on operation. 

Pretest and post-test leak-checks were completed (must be less than 0.02 cfm or 

4% of the average sampling rate). 

Before each series of tests, thermocouple readings for meter temperature, filter 

hotbox, probe, and filter exit temperatures were checked against an N.I.S.T. 

traceable thermometer. 

Readings of the dry gas meter, meter orifice pressure (AH), meter temperatures, 

filter hotbox temperatures, probe temperatures, and filter exit temperatures were 

taken at every traverse point. 

Probe and filter temperatures were monitored and maintained at greater than 248 0 F. 

The filter exit temperature was maintained at greater than 248 0 F. 

The gas meter was read to the thousandth of a cubic foot for the initial and final 

readings. 

The sampling velocity through the nozzle was maintained within 10% of the stack 

gas velocity (isokinetic sampling rate at 100+10%). 

All nozzle/probe recovery items were pre-cleaned and kept in containers when not 

being used. 

The 0.1 N H2SO4 capture liquid in the first two impingers was recovered and placed 

40 
into a container for analysis of HCI/HF. 

The 0.1 N NaOH capture liquid in the last two impingers was recovered and placed 

into a container for analysis of CI/F (if needed). 

Each impinger and connecting glassware was rinsed with distilled water three times 

and added to the respective container. 

The H2SO4 solution was collected for laboratory analysis. 

Liquid levels were marked on sample containers and sealed for shipment to the 

laboratory. 

Prior to the initial run a y-factor check was performed to ensure that the meter was 

operating according to the original calibration to within 3% of the original y-factor. 

For the post-test calibration the alternative Method 5 post-test calibration 

procedures were used (Emission Measurement Center Approved Alternative 

Method ALT-009). 
ENTEC SERVICES, 

FIELD QA / QC CHECKLIST 

PERMIT NUMBER: O• 

TEST METHODS USED: 

CONTROL AGENCY: • • ON SITE REPRESENTATIVE: 

PERMIT LIMITS: • 

MODIFICATIONS TO METHOD: 

YE_.=..=•S 

1. Was Calibration Data on site? (Methods 1-5 / CEMS CAL Gas) 

2. Was Stack Diameter I Area & Traverse Points verified on field data sheets? 

3. Was a 10-minute Meter Orifice Check performed? 

Results of check 

4. Were Temperatures Verified wl NIST Traceable Thermometer? 

5. Was Preliminary Traverse wl Cyclonic Flow verification performed? 

6. Was previous test data on source used to determine K factor? 

Was Probe & Hot Box Temperatures maintained at 248 ÷/•3 ° F? 

If not, explain 

8. Was Filter Outlet Temperature maintained at 248 +/- 25 ° F? _• 

If not, explain 

9. Was Orsat or Fyrite leak checked and standardization performed as required? Ambient 02 Reading •.,O,• % Ambient CO2 Readingj % 

10. Was Tedlar Gas Sampling Bags used? If not, explain _• r'•z 

Were they leak-checked? Y or N 

11. Were Pitot Leak Checks performed & recorded on each field data sheet? Pitot inspected? •or N Noted Visual Defects? /•1•.¢.. 

12. Was Meter Leak Checks performed & recorded on each field date sheet? 

13. Was Nozzle Diameter measured & recorded on each field data sheet? Nozzle inspected? (£•or N Noted Visual Defects?. /IJt>•.e_ 

14. Was Silica Gel Verified, and recorded for each test run? 

Percentage Used during test- Run No.'s//l• =•= 2: •3•> 3: • 

15. Was Acetone Lot Number v•rded on Field Data Sheet 

mature (Test Team Leader):__.•//•'//•_//L// Date: 

by: c,/•--•. As required: Control room data supplied • 

wa on-site, email, or fax. 

Revision 2 December 2005 DLB 4 2 
ENTEC SERVICES, iNC. 

METER ORiFiCE AND TEMPERATURE CHECKS 

Meter Box Numbe•. 

Origina| AH@ -, /. •'•'• 

Lee=ion: 

Barometric Pressure: • "Hg 

Original Y: 

Bi-Annual Calibration Date: 

Total Volume: 

Temperature, 

Vm = Volume of Dry Gas Meter 

Average: 

Final 

•7 

Dry Gas •ete•' Ouffet 

Initial 

Average: 

"•'m = Average Temperature of Dry Gas Meter in degrees Rankin (+460) 

PBarm Barometric Pressure 

Yc = 10NmX •/{ 0.0319 X Tm/Paarm} 

= 101( 7.&o• )xV•0.0319x( /'a& )/(•.37 )} 

•s Y¢ < +/- 3% of Original Y ? •6• ¢ 

The•ocouple Check (all tem••s am in o F) NIST Traceable 

Thermocouple• I I.D. 

Probe I 

Freer Exit 

Ambient Temp. 

Meter Outlet / •"- 

Impinger Ex• / 

Field Checks 

Reference Temp. Acceptance Range 

+1- 7.5 o 

+/- 5.4 o 

+1-5.4 ° 

+1-2..0 o 

+/- 5.4 o 

+1-2.0 o 

+1o 5.4 o 

Revision September 2005 DLB • 3 
,,•.:..--• Calibration 

,•,.,•,,,b• • ISO/tEC t7025 ANO 

•,•.- Ce•. No.: 4371.'1511•40 

Instrument Identification: 

Model: 14-648-44 S/N: 72083397 Manufacturer 

Standards/Equipment: 

Des• 

Temperature Probe 

Thermialor Module 

Temperature Calibration Bath TC155 

Temperature Probe 

'rl•ermislor Module 

Temperalure Calibration Ball] TC191 

Control Company 

Serial Number Due Date •.$T Traceable Reference 

149 8/14/07 A6713030 

A27129 7110/07 100020769,i 

93139 

157 11/14/07 A6B06053 

A17118 8123/07 A6823089 

A42238 

Certificate Information: 

Technician: 68 

Test Conditions: 23.0"C 39.0 %RH 

Calibration Data: (N• i•-strument) 

Unit(s) Nominal As l':ound In Tol • Nominal 

•C N.A. • 0.001 

"C N.A, 99.999 

Procedure: CAL-03 

1028 mBar 

Cal Date: 1/19/07 

As Left In "rol 

Cal Due: 1/18/09 

Max ±uc [UR 

99.6 Y 99.0 101 0 0 059 >4 

This Instrument was calibrated using Instruments Traceable to National Institute of Standards and Technology. 

Maintaining Accuracy: 

Recalibration: 

CONTROL COIVlPANY 4455 Rex Road Friendswood, T× 77546 USA 

Phone 281 482-1714 Fax 281 482-9448 service@control3.com www,control3,com 

Comrol Compa=ty •s •O 9001 Quality Cetlil•ed by (DNV) Oel Nors•e Veritas. Ceddi,:ale No. CERT.01805.AQ.HOLI 
• 

ENTEC SERVICES, iNC. 

ORSAT STANDARDiZATiON 

source: •','•,/1 

Orsat / F•eak Check: 

Date of Test: 

Date of Standardization:, 

Orsat / Fyrite ID #: 

Ca|ibrat•on Gases 

Vendor 

Gas 

Tank 

Concentration, (%) 

Carrier Gas 

Container Type 

Cylinder ID # 

Date of Expiration 

Tank 2 

02 •02 

/q. q7 3.002, 

•5 

Tank 1 

Actual Net 

2 

Actual Net 

/ •.o 

•'.o 

3 

Actual Net 

/•,.O 

Average 

Net 

Volume 

Value 

Difference 

0.0.• 

Tank 1 

2 

Actual 

CO2 

O2 

Net 

3.0 

2 

Actual Net 

/•.o 

3 

Actual Net 

•.o 

/•'.o 

Average 

Net 

Volume 

Value 

/z/ 97' 

Difference 

45 
Certificate of Analysis 

Date of Analysis: 

Customer Name: 

Grade of Product; 

7/14/2005 

PRIMARY STANDARD 

Reference Number: 

Part NLlmber: 

87•110858887-5 

X03N!82P15AC226 

C_C_ylinder Number 

CC214139 

Component _•l.Ueste d 

CARBON DIOXIDE 3.000 % 

OXYGEN 15.00 % 

NITROGEN Balance 

3.002 

14.97 

Balance 

Notes: 

Relative Uncertainty of Analytical Value: +/- 1% of component or +f- 0.02% of absolute, 

which ever is lower. 

Primary Standard gas mixtures are traceable to N.I.S.T weights and/or N.I.S.T gas mixture 

reference mat,.rials ..... ...... 

Approvnl Signalure u-.' 
Certificate of Analysis 

Date of Analysis: 

Customer Name, 

Grade of Prodclct: 

7," 14/2005 

PR}MARY STANDARD 

Reference N umber: 

Part Number: 

87-110858887-4 

X03 N 181P 15AC225 

_Cylinder Number 

CC214147 

Component _•e_q u ested 

Concentration 

Actual Concentration 

OXYGEN 3.000 % 2,993 % 

CARBON DIOXIDE t6.00 % 15.97 % 

NITROGEN Balance. Balance 

Notes: 

Relative Uncertainty_o_f,,,An.•!y•.i£#! ,•alM#,; +1- 1% of component or +/- 0,02% of absolute, 

which ever is lower. 

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

reference materials, 

Ap.:.•ruval Sigr•ak•r•-' .,/ k......• ':' •.,--./"'/ 

Page 47 
ENTEC Se ices, Inc. 

16 D Commerce Ave, Hueytown, AL 35023 

Preliminary Traverse & Cyclonic Flow Verification 

Client: General Shale Brick 

Source: Kiln A 

Test Date: 02/26/08 

Run No.: Preliminary Test 

Traverse Point Delta P 

1-1 0.23 

1-2 0,31 

1-3 0.28 

1-4 0.30 

1-5 0,24 

1-6 0.18 

1-7 0,21 

1-8 0.21 

1-9 0.19 

1-10 0.14 

2-1 0.44 

2-2 0.45 

2-3 0,41 

2-4 0.36 

2-5 0,30 

2-6 0,28 

2-7 0.26 

2-8 0.24 

2-9 0.22 

2-10 0.20 

Average 0.27 

Sq. Rt. Delta P 

0,4796 

0.5568 

0.5292 

0.5477 

0.4899 

0.4243 

0.4583 

0.4583 

0.4359 

0.3742 

0.6633 5 

0.6708 5 

0.6403 

0.6000 

0.5477 

O.5292 

0.5099 

0.4899 

0.4690 

0.4472 

0.5161 

Note: Based on the preliminary traverse the flow is not considered cyclonic 

Null Reading (Angle) 

o 

Stack Temp. (°F) 

314 

0 312 

311 

312 

0 310 

0 309 

308 

310 

0.75 

0 310 

0 300 

320 

320 

322 

0 318 

0 321 

0 317 

317 

319 

315 

0 315 

314.0 

48 
49 
ENTEC SERVICES, INC 

FIELD QA / QC CHECKLIST 

Method 6C Sulfur Dioxide 

TEST METHODS USED: 

TYPE CONTROL DEVICE: 

MODIFICATIONS TO METHOD: 

Was valid Interference Check (sum of responses < 2.5 % of calibration span) on site? 

2 Was valid Certificate of all Protocol t calibration gases on site? 

3 Was the High-level gas equal to the calibration span ? 

4 Was the IVlid-level gas between 40 and 60 % to the calibration span ? 

5 Was the Low-level gas < 20 % of the calibration span ? 

6 Was the sample kept above the dew point by heating prior to the sample conditioner ? 

7 Was the Analyzer Calibration Error within +/-2 % or +/- 0.5 ppm of the calibration span for all 

calibration gases ? 

YE.=.•S NO 

8 Was the System Bias within +/-5 % of the calibration span for the low-scale and upscale gases ? 

9 Was the System Response Time Calculated during the initial sampling system bias check? 

What was the System Response Time ? | o• Seconds 

10 Was the Drift within +/-3 % or +/- 0.5 ppm of the calibration span for the low-scale and upscale 

gases ? 

11 Was the sampling system purged > 2 times the system response time before each test run? 

12 Was the minimum time at each sampling point > 2 times the system response time ? 

13 Was the sample flow rate within 10 % of the flow rate established during the system response time 

check for each run ? Flow rate: • ¢• liters/minute 

14 Was a stratification test performed before the first run ? 

What were the results of the stratification test? 

All points were: Within +/- 5 % or +/- 0.5 ppm of mean for 1-point sampling (unnstratified) 

Within +/- 10 % or +/- 1.0 ppm of mean for 3-point sampling (minimumally stratified) 

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

15 Was a Multi-point or 3 point probe used ? 

16 Was the flow rate from each point verified to be within 10 % of the mean flow rate for each run ? 

17 Were all data points recorded in at least 1 minute averages? 

18 Was the average concentration fo•/•c•libration span? 

Signature (Test Team Leader): • 

50 
Interference Response Test 

Date 10/1/2007 

Analyzer Model Ametek 921 CE 

Component Sulfur Dioxide 

Analyzer Serial No. AD-921-5141 

Span 0-215 ppm 

Cylinder iD Test Gas Concentration 

SG9120994 

SG9120994 

SG9120994 

SG9120994 

S02 

CO 

213 

Analyzer Response 

215 

495 

CO2 9.76 

O2 20.79 

Total 

*Specification (EPA Method 20) Sum of interference responses must not exceed 2% of span 

Difference % of Span 

0.95 

0.48 

% of Span Analyzer Response X 100 Instrument Span 

1.43 

51 
Test Protocol 

.52 
Pollution Control System Evaluation and Source Emissions Testing 

January 25,2008 

Ms. DeAnna Oser 

Air Branch Georgia Environmental Protection Division 

Test Protocol Reference Letter for General Shale Rome GA 

K1 (Kiln A) DLS Baghouse Stack HC• / HF, & SO2 

Entec Project No.: 28127 

Dear Ms. Oser, 

Please find attached the test protocol for General Shale Rome, Georgia facility K1 

(Kiln A) Dry Lime Scrubber (DLS) Baghouse Stack. The protocol outlines the test 

procedures, the QA/QC requirements, and example calculations. Testing has been 

scheduled for Tuesday February 26, 2008. Testing will be conducted during one day. 

It is understood that modification to the permitted test requirements has been approved 

on previous testing to use EPA Method 6C for the determination of Sulfur Dioxide. The 

facility will supply all operation parameters to meet permitting requirements under the 

MACT and will be included in the final report. 

If you should have any additional questions about the protocol please call me at 205- 

491-6676 or my cell at 205- 613-5473 and will make any changes as required. 

Sincerely, 

Entec Services inc. 

Lynn Beane 

Operations Manager 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 

6614 www.enl•cse rvices, com 

Fax (205) 491- 
En ec Services, inc. 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Test Protocol for the 

KI (Kiln A) DLS Baghouse Stack 

(Dry Lime Scrubber w/Fabric Filter Baghouse) 

Emissions Testing at the 

Genera• Shale Company facility located in 

Rome, Georgia 

Submitted to: 

General Shale 

P.O. Box 3547 

Johnson City, Tennessee 37602 

Attention: Ms. Martha West 

CC: State of Georgia Department of Natural Resources Air Protection Branch 

Entec Project No. 28127 

Reviewed By: 

Protocol Emailed: January 25, 2008 

Completed By: 

Tom Lotz 

QA/QC Manager 

Lynn Beane 

Operations Manager 

54 
Scope of Work 

Entec services will conduct testing per the requirements of General Shale Rome, GA 

Facility Title V Operating Permit No. 3251=115-0105=V=02-0. Testing will be 

conducted for hydrogen chloride, hydrogen fluoride, and Sulfur Dioxide emissions on 

the K1 (Kiln A) Baghouse Stack per requirements of Part 63 Subpart JJJJJ Brick 

MACT. The proposed test program will take one (1) day to complete. Entec will 

perform the testing during the week of February 18, 2008 upon approval of this test 

protocol a final date will be set and updated via email to GA-DNR with an approximate 

start time of 9:00 am. 

Procedures 

Testing will follow EPA Test Methods 1-4 w/26A & 6C of the CFR Title 40, Part 60, 

Appendix A and Part 63 Subpart JJJJJ. The calibration and quality assurance 

procedures of EPA CFR 40 Part 60 Appendix A and Part 63 for test Methods 1-4 w/26A 

& 6C of the "Quality Assurance Handbook for Air Pollution Measurement System" 

Volume III Stationary Source-Specific Methods will be followed throughout the duration 

of the field testing and laboratory analysis. The most current CFR revision of each 

method (July 1, 2006) will be used. 

It is understood that the State of Georgia Department of Natural Resources Air 

Protection Branch may at their discretion bring audit samples to the test team for 

analysis in conjunction with the other samples as required. The following paragraphs 

summarize the methods to be used, detailed test procedures, QA/QC procedures, and 

other documentation to be used for this test program. 

Stack Gas Volumetric Flow 

The velocity of the gas stream will be determined according to EPA Reference Method 

2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure will be measured with the static side of an S-type pitot tube. 

A calibrated pyrometer will be used to measure stack temperature at each sampling 

point. The stack will be tested for cyclonic flow according to EPA Reference Method 2. 

55 
Stack Gas Molecular Weight. 

The carbon dioxide and oxygen concentrations will be determined using EPA Reference 

Method 3. A grab sample of the flue gas will be extracted from the gas stream during 

each particulate test run and analyzed using and Fyrite analyzer. The molecular weight 

of the gas will be calculated using the moisture, oxygen and carbon dioxide content and 

the measured stack gas temperature. The Fyrite sampling system will be verified to be 

leak free prior to the analysis. 

Moisture Content (Combined w/Method 26A} 

The moisture content used for calculating the gas stream flow rate is determined by 

measuring the amount of condensed moisture in the series of impingers in the sampling 

train as described in EPA Reference Method 4 at the completion of each test. The 

moisture content will be conducted in conjunction with EPA Method 26A. 

The moisture collection system consists of a series of impingers. Ice is placed around 

the impingers to maintain a temperature <680 F. The outlet temperature of the impingers 

is monitored and recorded throughout the duration of the testing to verify the 

temperature is below <680 F. 

Hydrogen Chloride I Hydrogen Fluoride 

Preliminary data will be used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box will be leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines will be performed as outlined in Method 

26A and will be recorded on the data sheets. The nozzle (glass or Teflon lined with an 

angle of taper of 30 degrees and of button hook design) will be calibrated before and 

after the test using a micrometer and will be also recorded on the data sheets. 

The sampling probe will be placed at each sampling point to provide a total sampling 

time of at least 60 minutes and a volume of at least 31.8 cubic feet. The gases will be 

drawn through a glass nozzle attached to a heated glass lined probe. The probe and 

filter will be maintained at the proper setting to obtain a temperature of greater than 248 

0 F. The gases then proceeded through borosilicate glass filter holder, with a Teflon frit 

filter support through a tarred Teflon or quartz fiber filter to remove particulate matter. 

The exit of the filter will be maintained at a temperature of greater than 248 0 F. These 

temperatures will be recorded at each poir•eon the data sheets. 
The gases will be then scrubbed through a series of five impingers (optional impinger 

not included) to capture hydrogen halides and halogens and moisture. The optional first 

irnpinger for a knockout for moisture will not be used since the source it is a dry 

baghouse system. The second and third impingers will contain approximately 100 ml of 

a 0.1N H2SO4 solution and the fourth and fifth impingers will contain approximately 100 

ml of a 0.1 N NaOH solution. The sixth impinger will contain pre weighed silica gel to 

remove any remaining moisture. The gases pass through the impinger series in an ice 

bath to maintain a maximum exit temperature of 68 0 F. This temperature will be also 

recorded on the data sheets. The clean and cool gases then entered the meter box 

where the gas flow and temperature will be measured. 

After the completion of the test leak rate determinations will be made. Then the sampling train and the probe nozzle assembly will be transferred to the cleanup area making 

sure no sample will be lost. The cleanup data will be recorded. 

The first, second and third impinger contents will be transferred to its tarred container, 

weighed and the rinsing from the glassware will be added to this container. The fourth 

and fifth impinger contents will be transferred to its respective tarred container, weighed 

and the rinsing from the glassware will be added to this container. The silica gel from 

the fifth impinger will be transferred to its respective tarred container and weighed. A 

blank of the sulfuric acid solution, sodium hydroxide, distilled water and acetone will be 

taken. These containers will be clearly marked and transported to the laboratory for 

analysis. 

A State of Georgia approved and accredited laboratory will perform all of the laboratory 

analysis. 

Sulfur Dioxide Method 6C 

A Western Research (or equivalent) SO2 Method 6C analyzer (or comparable) will 

provided continuous analysis of SO2 in the gas stream. The basic analytical principle 

involves quantitative measurement of the absorption of UV radiation by SO2 molecules. 

The analyzer uses a single light source, which emits an appropriate wavelength, 

illuminating the sample cell through which the sample is continuously passed. Narrowband optical filters are rotated through the beam, and the radiation passed through the 

optical filters and sample cell is detected I• a single photo-detector. The signal pulses 
from the photo-detector are separated by a multiplexor into a measuring channel and a 

reference channel. A log ratio amplifier computes the logarithm of the input signal 

ration, producing a signal that is proportional to the SO2 concentration. The dual-range 

analyzer has a digital readout, as well as 0-10.0 V DC output terminals. The full scale of 

the instrument will be set at high level calibration gas ppm value as required. 

58 
QA / QC Procedures 

Specific quality assurance / quality control procedures will be adhered to during this test 

project to provide valid and scientifically defensible data. For any environmental field 

and laboratory measurement, a degree of uncertainty exists in the data due to inherent 

limitations of the measurement systems employed. The objective of a QA/QC program 

is to produce data of known precision, accuracy, representation, completeness and 

comparability. The objective in this test project is to determine compliance with 

applicable air permit requirements. The final data user in this project will be the State of 

Georgia Department of Environmental Quality. 

The following section details all QC procedures to be followed during the sampling. 

Velocity / Volumetric Flow Rate 

Volumetric flow rates will be determined during each isokinetic test run. The following 

QC steps will be adhered to during these tests: 

Reported duct dimensions will be checked by physical measurements to determine 

cross-sectional duct area. 

Pitot tube coefficients are determined based on physical measurement techniques 

as delineated in Method 2 before and after each test. 

The Type-S pitot tube are visually inspected before and after sampling. 

The pitot tube is installed on the sampling probe with the proper orientation and 

spacing from the sampling nozzle. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature are checked against an N.I.S.T. traceable thermometer. 

The oil manometer is leveled and zeroed before each test run. 

Both legs of the pitot tube are leak-checked before and after sampling. 

Proper orientation of the pitot tube is maintained while making measurements. The 

roll and pitch axis of the pitot tube is maintained at 90 o to the flow. 

An average velocity pressure reading is recorded at each point instead of recording 

extreme high or low values. 

The pitot/manometer umbilical lines are inspected before and after sampling for 

moisture condensate. Lines are cleared if moisture is found. 

Molecular Weight Determination Fyrite Analysis 

The carbon dioxide and oxygen concentrations are determined using EPA Reference 

Method 3. A sample of the flue gas is extracted from the gas stream during each test. 
The samples are analyzed with a Fyrite gas analyzer. The following QC steps are 

adhered to during these tests: 

The sampling train is leak checked before and after each sample is taken. 

The samples are run in triplicate for accuracy. 

Standardization is performed to audit the reagents and the operators technique. A 

known mixture of CO2 and 02 is analyzed and repeated with 3 consecutive values 

+/- 0.5 percent of the known value. 

Two NIST traceable gas cylinders are run against the instrument to audit the 

accuracy of the analyzer and the analyzer operator technique. One cylinder 

contains 2 to 4 percent 02 and 14 to 18 percent CO2. The second cylinder contains 

2 to 4 percent CO2 and about 15 percent 02. 

Moisture Determination 

Stack gas moisture content (Bws) is determined by dividing the mass of moisture 

collected by the impingers or stainless steel condenser and silica gel impinger by the 

standardized volume of gas sampled. The following QC steps are adhered to during 

these tests: 

The indicating silica gel is fresh for the first run and periodically inspected and 

replaced during runs, if needed. 

The analytical balance is placed in a clean, motionless environment for weighing. 

The balance is leveled and zeroed if necessary before each weighing. 

Preliminary silica gel impinger tare weights and post-run weights are weighed to the 

nearest 0.1 g. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature are checked against an N.I.S.T. traceable thermometer. 

The silica gel impinger gas temperature is maintained below 68°F and recorded at 

every traverse point. 

Each impinger is wiped of surface moisture before post-run weighing. 

The volume of liquid captured is measured using a graduated cylinder with 1- 

milliliter increments. 

Sulfur Dioxide Determination 

The sulfur dioxide concentrations will be determined using EPA Reference Method 6C. 

A sample of the flue gas was extracted from the gas stream during each test. Moisture 

will be removed form the sample and analyzed on a dry basis with an Instrumental gas 

analyzer. The following QC steps were adl•ed to during these tests: 
Only analyzers that have a resolution or sensitivity of at least < 2.0% of full-scale 

range are used. 

Upon the SO2 analyzers initial use in the field, an interference check was 

conducted. 

The reference calibration gases used in this test program are certified following EPA 

Protocol Number 1 analysis. Copies of the calibration gas certifications are 

included in the instrument calibration section. 

The high level gas was equal to the calibration span gas. 

The mid level gas was between 40 and 60 % of the calibration span gas. 

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

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

analyzer calibration error was conducted on each reference analyzer prior to 

initiating the compliance testing. These checks were conducted (after final 

calibration adjustments were made) by injecting the calibration gases directly into 

each gas analyzer and recorded the responses. 

The analyzer calibration error was less than _+ 2.0% or + 0.5 ppm of the.calibration 

span gas for the zero, mid-range, and high-range calibration gases. 

The probe material was stainless steel. 

The probe, filter and sample line temperature was maintained above the dew point 

by heating, prior to sample conditioning. 

The sampling system bias was less than _+ 5.0 % or of the calibration span gas for 

the zero and upscale calibration gases (_+ 0.5 ppm absolute difference). 

The system response time was calculated during the initial sampling system bias. 

The drift for either the low-level and mid-level or high-level gases was less than + 

3.0% or of the calibration span gas (+ 0.5 ppm absolute difference). 

The sampling system was purged > 2 times the system response time before each 

test run. 

Sample flow rate was maintained within 10% during the entire test period. 

Data is recorded at 1-minute intervals. 

All data collected was within the calibration span gas. 
TEST CALCULATIONS 

EQUATIONS 

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

2. Pn• Pbar +(&H/13.6)=( + ( /13.6) 

3. Vrnst,•=l 7.64 Vm Y (P,•/Tn•)=I 7.64*( )*( )*( 

4. Vwst• 0.04707 V•0=0.04707"( )= 

5. Bws Vwstd/(Vmstd + Vwstd)=( )/( + )= 

/ )= 

For saturated sources (No. 6 8 only): If No. 6 is less than No. 5 source is considered saturated 

6. TBws (106.37. {2827/(ts.365)}/ps 10 6"37"{2827/( +365)}/( 

7. TVwstd Vr.std*( TBws/1- TBws)=( )*( 

8. TV•c= TVwst•/0.04707 =( ) / ( 0.04707 )= 

9. 

12. 

13. 

14. 

15. 

16. 

19. 

20. 

)/( 1 

M•= 0.44(%CO2)+0.32(%O2)+0.28((100-(%CO2+%O2)) 

=0.44( )+0.32( )+0.28(100-( + )= 

Ms M,• (1- Bws)+18 Bws=( )*(1- )+18( 

Vs 85.49 Cp* •/AP •/(Ts/(Ms* Ps)) 

85.49*(0.84)*( )*•/( /(( )( 

Qa Vs As 60=( )( )(60)= 

Qs Qa (1- Bws) (528/Ts)*(P,J29.92)=( )(1- 

C&=0.01543* (Mn/Vmstd)=0.01543*( / )= 

PMR= Cs* Qs (6017000)=( )*( )*(60/7000)= 

Vn=Ts/Ps*{(0.002669) V=c+ (Vn• Y Pn•)/Trn)} 

=( / )*{(0.002669)( )+( )( 

•=Vnl00/(60*e*Vs*An)=( )100 / (60)( )( 

)*(528/ 

)))= 

)*( /29.92)= 

)( )/( )}= 

)( )= 

%EA= 100%* {(%O•)-0.5*(%CO)} / {0.264(%N•) (%02)+ 0.5*(%CO)} 100%*{( )-0.5( )} / {0.264( )-( )+0.5( 

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

=( / 1-[{1.5( )-0.133( )-0.75( 

Ib/mmBtu= (Cs17000)*{(F,•*20.9)l(20.9-%0•)} 

=( /7000)*{( )'20.9)/(20.9-( )}= 

)}/20.9]= 

62 
NOMENCLATURE 

AS 

An 

ACFM 

Bws 

C• 

Ca 

Cp 

AH 

AP 

dscf 

EA 

E/Btu 

F 

Kp 

Md 

Ms 

I 

Pbar 

Pg 

Pin 

PMR 

Ps 

Pstd 

Q. 

Qs 

TBw• 

TVlc 

TVwstd 

Tin 

Tstd 

0 

Vm 

V• 

Vins•d 

V• 

Vwstd 

Y 

Cross-sectional area of stack, square feet 

Cross-sectional area of nozzle, square feet 

Actual cubic feet of gas per minute at stack conditions 

Proportion by volume of water vapor in gas stream 

Particulate concentration in stack gas, gr/dscf 

Deionized water blank residue concentration, mg/g 

Pitot tube coefficient 

Pressure drop across orifice meter, inches water 

Velocity head of stack gas, inches water 

Cubic feet of dry gas corrected to standard conditions 

Excess Air 

Particulate Emission Rate, pounds/mmBtu 

F-factor, 9640 dscf/MMBTU's of heat input 

Constant (85.49) 

Total particulate matter collected, mg 

Molecular weight of stack gas; dry basis, Ib/lb-mole 

Molecular weight of stack gas; wet basis, Ib/Ib-mole 

Percent of isokinetic sampling 

Barometric pressure, inches mercury 

Stack static pressure, inches of water 

Barometric pressure of dry gas meter, in. mercury 

Particulate mass rate, pounds/hour 

Absolute stack gas pressure, inches mercury 

Barometric pressure, standard conditions, 29.92 "Hg 

Volumetric flow rate, actual conditions, ACF/min 

Volumetric flow rate, dry standard conditions, dscf/min 

Theoretical water vapor in the gas stream based on saturated stack conditions, proportion 

by volume (dimensionless) 

Theoretical volume of water collected based on saturated stack conditions, ml 

Theoretical volume of water vapor in the gas sample based on saturated stack conditions, 

corrected to standard temperature and pressure, scf 

Absolute average dry gas meter temperature, degree R (460) 

Absolute average stack gas temperature, degree R (460) 

Absolute temperature at standard conditions, 528 R 

Total sampling time, minutes 

Total volume collected in impingers and silica gel, ml 

Volume of gas sampled through gas meter, cubic feet 

Volume collected at stack conditions through nozzle, ACF 

Stack gas volume sampled, ACF 

Volume of gas sampled through gas meter, cubic feet 

Average stack gas velocity, feet/sec 

Volume of water vapor in gas sampled, standard cubic feet 

Dry gas meter calibration factor 

63 
NOMENCLATURE FOR SULFUR DiOXiDES (Method 6C) 

ACE 

CAv• 

CDir 

CGas 

Co 

CM 

CMA 

Cv 

CS 

D 

SB 

SBfinal 

SB• 

MW 

SO2 Ibs/hr 

385.1 x 106 

Analyzer calibration error, percent of calibration span. 

= Average unadjusted gas concentration indicated by recorder for the test run, 

ppmv. 

Measured concentration of a calibration gas (low, reed, high) when introduced 

in direct calibration mode, ppmv 

= Average effluent gas concentration adjusted for bias, ppmv. 

= Average of initial and final system calibration bias(or 2-point system calibration 

error) check responses form the low level (zero) calibration gas, ppmv. 

Average of initial and final system calibration bias (or 2-point system calibration 

error) check responses for the upscale calibration gas, ppmv. 

Actual concentration of the upscale calibration gas, ppmv. 

Measured concentration of a calibration gas (low, mid, or high) when 

introduced in system calibration mode, ppmv. 

Manufactured certified concentration of a calibration gas (low, mid, or high), 

ppmv. 

= Calibration span, ppmv. 

Drift assessment, percent of calibration span. 

System bias, percent of calibration span. 

Post-run system calibration error, percent of calibration span. 

Pre-run system bias, percent calibration span. 

Molecular weight of SO2, which is equal to 64.06 

Sulfur Dioxide mass rate in pounds per hour 

Conversion factor 
ACE 

(7E=1) 

SB 

D 

(7E=4) 

CDi__r Cv_ x 100 

CS 

( )/( 

Cs _.r X 100 

CS 

( 

SBfinal SBil = 

)/( 

)X 100= 

)X 100= 

CGas 

(7E=5) 

(CAvg Co) X CMA/(CM Co) 

( )X( )/( 

16. SO2 Ibs/dscf = 

Cgas X Me / 385.1 x 106 

( x (64.06)/(385.1 x 106) 

17. SO2 Ibs/mmBTU= 

SO2 Ibs/dscf x F-factor x ((20.9/(20.9-O2)) 

( ) x ( )x((20.9/20.9-( ))= 

17. SO2 Ibs/mmBTU= 

SO2 Ibs/hr/Heat Input mmBTU/hr 

( )/( ) 

21. SO2 Ibs/hr = SO2 Ibs/dscf x DSCFM x 60 

= ( )x( ) x (6o) = 

65 
QSTI Certification Documentation 

66 
0 o• 
68 
• O 

Z© 
N 

© 
Laboratory Analysis 
ENTEC SERVICES, INC 

LABORATORY SAMPLES QA/QC CHECKLIST 

METHOD(S): 

RECOVERY DATE: 

Description of Impinger Contents: 

Test Run No.'s 1: ..• 

Impinger Contents Container Number: 

Test Run No.'s 1"_ ,/-•--/ 2: /Z-- • 3: 

Samples Sealed and Stored in Secure Container?•r N 

Liquid Level Marked? •r N 

Filter ID Number: 

Test Run No.'s 1: •• 2: 

Description of Paniculate on Filter: 

Test Run No.'s 1" 

Filter Container Number: 

Test Run No.'s 1: 

Samples Sealed and S{ored in Secure Con{ainer? Y or N 

Probe Rinse Con{ainer Number: 

Tes{ Run No.'s 1" 

Samples Sealed and S{ored in Secure Con{ainer? 

Liquid Level Marked? Y or N 

Probe Rinse Rea•en{: 

Labora{o• Blanks: 

Probe Rinse: Impinger: • FiRer: O{her: 

Were samples anal•ed by En{ec 8e•ices, Inc.? Y or• 

If not, Laborato• Peffo•ing Analysi• 

YorN 

Lot Number: 

*** if using outside I•)l•oratory services please fib out the following chain of custody. 

;•It•':: .:!i:.t!::;i•!• •,,. 'i!:i::,:i•iE•'•!::•.'i: 

S,gnature. • Date. •>•.. •10• S,gnature: E,;• • • 

rintName:_•. 0 Time(24hr): /a :00 PrintName: /•/4• 

Signature (Project Manager or T@r): Date: • 

Revision 2 September 2005 TLj 7 2 
FAX MESSAGE 

Subject.' 

This material is intended only for the use of tl•e individual(s) or entity to whom it is addressed and may contain information that 

is l•vileged and confidential It iS our policy that fecsimile$ are Intended for and should be used for business purposes only, If 

you are not the intended recipient, or the employee or agent responsible for delivering this material to the intended recipient, 

you are I•ereby notified that any die.ruination, distribution or copying of this fao•imile is strictly prohibited, ff you have 

received this communication in error, please no•fy the sender, Thank you for your professional consideration and 

cooperation, 

900 Lakeside Drive Mobile, AL 36693 tel 251,666.6633 fax 251,666,6696 www,testamet|cainc.com 

73 
Sent: Thursday, March 13, 2008 5:14 

To: 'tomlotzsr@entercservices.com' 

Norris, Jim 

Hi 

Here's a brief summary of the data. Please let me know if you have any questions, 

Units= mg/L 

Lab ID Sample ID 

R-1 Kiln A Sta•k R-2 Kiln A •l•,k 

1 R-3 Kiln A Stack 

| 0.1N H2SO4 Blank 

700-27653-1 

700•27653• 

700-27653-3 

700-27653-4 

HCL as chlodde 

21 

ii 27 

Not detected 

HF as fluoride 

2,2 

2.0 

3.3 

Not detected 

Thanks, 

CHARLES L. NEWTON 

Project Manager 

TestAmerica 

THE LEADERS IN ENVIRONMENTAL TESTING 

900 Lakeside Drive 

Mobile, AL 36693 

Tel 251.666.6633 Fax 251.666.6696 cell 251.89&3973 

www. testa m e r_Lc.o•n c, co m 

3/13/2008 

?4 

ENTEC SERVICES, iNC. 

Chain of Custody 

Client General Shale Brick Project No, _2•.127 

Rome• GA Lab Name: 

•o• NO• 20•9•=6676 Ent• Job No• 

2/26/2008 

2/26/2OO8 

2F•/2008 

2/27/2008 

.=•mgl• COllected by: A. Otero 

• •u• •: T. LO•, •r. 

Email R•u• To: 

• ;.0:• •=• •.•, ,, •,,,: 

R-1 Kiln A • 

R-3 Kilq A Stack 

0.1 N H•804 Blank 

28127 

76 
Gas Analysis •nstrument Calibration Data 
Analyzer Calibration Error 

?8 
Analyzer Calibration Error 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2/26/08 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 

Sulfur Dioxide Monitor 

Full Scale: 226.6 ppm 

Cylinder Reference Gas 

Number Concentration 

Method 6C 

Serial Number: WR900 SN AD-92-1-5 

Analyzer Difference Calibration 

Response Error (%) 

SG917038BAL/cg12 0.0 ppm 1.1 ppm 1.1 ppm 0.49 % 

CC178851/cgl 125.1 ppm 125.8 ppm 0.7 ppm 0.29 % 

XC025683B/cg2 226.6 ppm 226.5 ppm -0.1 ppm -0.04 % 

?9 
System Bias and Drift 

80 
Sampling Systen Bias and 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2/26/08 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 1 

Monitor 

Type 

Analyzer Cal 

Response 

1.1 ppm 

125.8 ppm 

Initial Cal 

Value 

4.0 ppm 

125.3 ppm 

Pre Run 

Bias (%) 

1.28 % 

-0.22 % 

Final Cal 

Value 

3.8 ppm 

125.2 ppm 

Post Run 

Bias (%) 

1.19% 

-0.26 % 

Total Run 

Drift (%) 

0.09 % 

0.04 % 

81 
Sampling System E ias and Drift 

Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2126

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 2 

Monitor 

Type 

SO2 

SO2 

Analyzer Cal 

Response 

1.1 ppm 

125.8 ppm 

Initial Cal 

Value 

3.8 ppm 

125.2 ppm 

Pre Run 

Bias (%) 

1.19% 

-0.26 % 

Final Cal 

Value 

3.7 ppm 

124.0 ppm 

Post Run 

Bias (%) 

1.15% 

-0.79 % 

Total Run 

Drift (%) 

0.04 % 

0.53 % 

82 
Test Performed For: 

General Shale Brick 

Rome, GA Facility 

Kiln A 

Compliance Testing 

Date:2/26/08 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 904 

Tommy Lotz, Jr. 

Run 3 

Monitor 

Type 

SO2 

SO 2 

Analyzer Cal 

Response 

1.1 ppm 

125.8 ppm 

Initial Cal 

Value 

3.7 ppm 

124.0 ppm 

Pre Run 

Bias (%) 

1.15% 

-0.79 % 

Final Cal 

Value 

3.5 ppm 

123.4 ppm 

Post Run 

Bias (%) 

1.06 % 

-1.06 % 

Total Run 

Drift (%) 

0.09 % 

0.26 % 

83 
Calibration Gas Certificates 

I]4 
Equipment Calibrations 
SAMPLING AND ANALYTICAL EQUIPMENT CALIBRATIONS 

All of the emission testing equipment used was calibrated according to the procedures 

outlined in the EPA CFR 40 Part 60 Appendix "A" and the Quality Assurance Handbook 

for Air Pollution Measurement System,•, Volume III, EPA-600/4-77-027b. 

Type-S Pitot tube Calibration• 

The pitot tubes used for flow velocity measurement were checked for dimensions to 

verify a pitot coefficient Cp of 0.84. Documentation of the calibration and calibration 

check for dimensional measurements is provided. 

Samplin.• Nozzle Calibration 

Sampling nozzles were checked visually for nicks or damage and for dimensional 

calibration prior to testing by measuring the nozzle diameter in at least three planes 

using a Vernier micrometer. Measurements must agree to within -+0.004-inches. 

Documentation is provided on the individual data sheets. 

Temperature Measuring Device Calibration-• 

Each temperature sensor (stack gas, dry gas meter, and impinger exit) and readout 

was calibrated at a minimum of two points over the anticipated range of use against a' 

NIST-traceable mercury-in-glass thermometer. All sensors/readouts were calibrated 

prior to field sampling. Stack gas thermocouples must agree within 1.5% (expressed in 

[]R) of the reference thermometer through out the entire calibration range. Dry gas 

meter thermocouples must agree within _+5.4•:F and impinger exit thermocouples must 

agree within _+2F. Documentation is provided. 

Dry Gas Meter Calibration• 

Dry gas meters were fully calibrated against a set of calibrated orifices. After assembly 

and leak checking, the console's pump is allowed to run for 15-minutes to warm up the 

dry gas meter and pump. For a pre-test full calibration, data are collected at five (5) 

orifice manometer (L•H) settings of approximately: 0.32, 0.67, 1.2, 2.0, and 3.9 inches of 

H20. Gas volumes of at least 5 ft3 are used at all the orifice settings and critical 

vacuums were obtained at all of the calibration points. The individual gas meter 

correction factors (Yi) are calculated for each orifice setting and averaged. The method 

requires that each of the individual correction factors fall within +2% of the average 

86 
correction factor, or the meter be cleaned, adjusted or repaired and recalibrated. The 

orifice pressure differential (AH@) that equates to 0.75 cfm of air at 68°F and 29.92 

inches Hg is calculated and along with the average correction factor (y) is marked on 

the meter console. 

For the post-test calibration the alternative Method 5 post-test calibration procedures 

were used (Emission Measurement Center Approved Alternative Method ALT-009). 

Prior to the initial run a y-factor check was performed to ensure that the meter was 

operating according to the original calibration to within 3% of the original y-factor. 
0 
TYPE S PITOT TUBE iNSPECTiON DATA SHEET 

LEVEL 

"•: z 

Distance Between 

Tube OD 

Parameter 

Assembl•/Level? 

Holes Damaged? 

Obstructed? 

•2 

A 

Z A sin 7 

W A sin e 

PA 

PA- PB 

DT 

Thermocouple Cal. 

Thermocouple Cal. 

Value 

Yes 

Allowable Range 

Yes 

No No 

No No 

0 -10 < cd < +10 

0 -10 < 0•2 < +10 

0 -5 < 131 < +5 

9O 

90 

.988 

0 

0 

.494 

.494 

_5 < < +5 

for 1/4" OD, 0.526 to 0.750 

for 3/8" OD, 0.788 to 1.125 

W < 0.031" 

for 1/4" OD, 0.263 to 0.375 

for 3/8" OD, 0.394 to 0.563 

for 1/4" OD, 0.263 to 0.375 

for 3/8" OD, 0.394 to 0.563 

0 -0.063 to 0.063" 

.375 0.188 to 0.375" 

67 Reference temp. 

67 Probe Thermocouple 

Certification 

certify that the Type S pitot tube/probe ID # ESP= 62B meets or exceeds all specifications, 

criteria and/or applicable design features and is hereby assigned a pitot tube calibration 

factor Cp of 0.84 

Certified and Calibrated By: 

Date Certified: 

Lalan R. Kirby 

12/21/2007 

Annual Calibration 

89 
ENTEC Services, nc. 

16-D Commerce Ave.Hue•own, Alabama 35023 

Calibration Date: 12/31/2007 Calibrated by: Tom Lotz 

Annual Thermocouple Calibrations 

Entec Serv=ces Temperature **Reference Thermocouple Difference Within 

ID Number Source Temperature Temperature Degrees F Tolerance 

66 65 TC-1 

TC-2 

TC-3 

TC-4 

TC-6 

TC-7 

TC-8 

TC-11 

TC-12 

TC-13 

TC-14 

TC-15 

TC-16 

ambient 

ambient 66 

ambient 66 

Yes 

65 Yes 

66 0 

ambient 66 67 

ambient 66 66 

ambient 66 

ambient 66 

65 

65 

ambient 66 65 

ambient 66 

ambient 66 

ambient 66 

66 

67 

67 

ambient 66 65 

66 65 

66 65 

66 66 

ambient 

TC-17 ambient 

TC-19 ambient 

ambient 66 65 

ambient 66 

ambient 66 

ambient 66 

ambient 66 

ambient 66 

67 

66 

65 

65 

65 

ambient 66 65 

66 

66 

66 

TC-20 

TC-21 

TC-22 

TC-23 

TC-24 

TCS 

TCS 2 

TCS 3 

TCS 4 

TCS 5 

TCS 7 

TCS 8 

ambient 

ambient 

ambient 

ambient 

ambient 

66 

66 

TCS 9 ambient 66 

TCS- 10 ambient 66 

TCS 11 ambient 66 

ambient 66 

66 

TCS 12 

TCS- 13 

TCS 14 

TCS- 15 

66 

66 

ambient 

ambient 

ambient 

TCS 16 

Fluke Hand Held 

Fluke Hand Held 2 

Fluke Hand Field 3 

ambient 66 

ambient 66 

ambient 66 

ambient 66 

65 

67 

66 

65 

65 

65 

66 

65 

65 

66 

65 

65 

67 

66 

66 

66 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

o Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

emperature tolerance within +/- 2 F of acceptable ranges for all thermocouples. 

Note: NIST Traceable Digital Thermometer Serial Number 72083241 was used as reference temperature 

90 
Calibration Date: 

ENTEC Services, lnc, 

16-D Commerce Ave.Hueytown, Alabama 35023 

1/2/2007 Calibrated by: Tom Lotz 

Annual Hot Box Thermocouple Calibrations 

Entec Services Temperature **Reference Thermocouple Difference W•thin 

ID Number Source Temperature Temperature Degrees F Tolerance 

HOTBOX ambient 

HOTBOX 2 ambient 

HOTBOX 3 ambient 

66 67 

66 67 

66 66 

HOTBOX 4 ambient 66 

HOTBOX 5 ambient 66 

HOTBOX 6 ambient 

65 

67 

Yes 

Yes 

Yes 

Yes 

Yes 

66 67 Yes 

HOTBOX 7 ambient 66 66 0 Yes 

HOTBOX 8 ambient 66 66 0 Yes 

66 65 Yes 

66 65 Yes 

66 67 Yes 

66 

ambient 

ambient 

ambient 

67 

66 65 

Yes 

Yes 

HOTBOX 9 

HOTBOX 10 

HOTBOX 11 

HOTBOX 12 ambient 

HOTBOX 13 ambient 

HOTBOX 14 ambient 66 67 Yes 

Temperature tolerance within +/- 2 F of acceptable ranges for all thermocouples. 

Note: NIST Traceable Digital Thermometer Serial Number 221243179 was used as reference temperature 

91 
ENTEC Services, inc. 

t6-D Commerce Ave,Huey•own, Alabama 35023 

Calibration Date: 1/2/2007 Calibrated by: 

Annual Gooseneck Thermocouple Calibrations 

...... 

Tom Lotz 

Entec Services Temperature **Reference Thermocouple Difference Within 

ID Number Source Temperature Temperature Degrees F Tolerance 

GN-1 ambient 

GN-2 ambient 

GN-3 

GN-4 

GN-5 

64 

64 

ambient 64 

ambient 64 

ambient 

ambient 

ambient 

ambient 

04 

64 

64 

64 

ambient 64 

ambient 64 

ambient 

ambient 

ambient 

64 

64 

64 

ambient 64 

ambient 64 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

64 

64 

64 

64 

64 

64 

65 Yes 

65 Yes 

65 

65 

64 

63 

63 

63 

65 

64 

65 

65 

63 

63 

64 

65 

63 

64 0 

65 

65 

65 

65 

GN-6 

GN-7 

GN-8 

GN-9 

GN-10 

GN-11 

GN-12 

GN-13 

GN-14 

Yes 

GN-15 (Mini 

GN-16 (Mini 

GN-17 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

GN-18 (Mini 

GN-19 (Mini HB) 

GN-20 (Mini HB) 

GN-21 

GN-22 (Mini HB) 

'emperature tolerance within +1- 2 F of acceptable ranges for all thermocouples. 

Note: NIST Traceable Digital Thermometer Serial Number 221243179 was used as reference temperature 

92 

Safety Documentation 

94 
Pollution Control System Evaluation and Source Emissions Testing 

Required PPE: (Check Required) 

Hard Hat 

Steel Toed Boots 

Safety Glasses 

Ear Plugs 

Gloves / Hot Gloves 

Safety Harness or Fall Protection 

Special Clothing (Blues / Greens / Tyvex) 

CO Personnel Monitor 

Respirator (w/PM or Gas Cartridges) 

Long Sleeve Shirt 

Other Requirements; (List as needed) 

Attendees: Name (Print) 

4) 

5) 

6) 

7) 

8) 

9) 

Facility required additional safety training prior to entering site: 

Video Safety Class• Literature 

Yes or No 

Training Class (MSHA) 

Rev 3:-3-06 

95 
Test Nomenclature and Calculations 
NOMENCLATURE 

A8 

An 

ACFM 

Bws 

Ca 

Cp 

AH 

AP 

dscf 

EA 

E/Btu 

F 

Kp 

Mn 

Pbar 

P• 

Prn 

PMR 

Pstd 

Qa 

) Qs 

Qstd 

TB•s 

mVlc 

TVwstd 

Tm 

Tstd 

V•c 

Vm 

Vn 

Vma 

Vmstd 

vs 

Vwcstd 

Vwsgstd 

Wimp 

W,• 

Y 

Cross-sectional area of stack, square feet 

Cross-sectional area of nozzle, square feet 

Actual cubic feet of gas per minute at stack conditions 

Proportion by volume of water vapor in gas stream 

Particulate concentration in stack gas, gr/dscf 

Particulate concentration in stack gas, gdacf 

Pitot tube coefficient 

Pressure drop across odfice meter, inches water 

Velocity head of stack gas, inches water 

Cubic feet of dry gas corrected to standard conditions 

Excess Air 

Particulate Emission Rate, pounds/mmBtu 

F-factor, 9640 dscf/MMBTU's of heat input 

Constant (85.49) 

Total particulate matter collected, mg 

Molecular weight of stack gas; dry basis, Ib/Ib-mole 

Molecular weight of stack gas; wet basis, Ib/Ib-mole 

Percent of isokinetic sampling 

Barometric pressure, inches mercury 

Stack static pressure, inches of water 

Barometric pressure of dry gas meter, in. mercury 

Particulate mass rate, pounds/hour 

Absolute stack gas pressure, inches mercury 

Barometric pressure, standard conditions, 29.92 inches Hg 

Volumetric flow rate, actual conditions, ACF/min 

Volumetric flow rate, standard conditions, scf/min 

Volumetric flow rate, dry standard conditions, dscf/min 

Theoretical water vapor in the gas stream based on saturated stack conditions, proportion by volume (dimensionless) 

Theoretical volume of water collected based on saturated stack conditions, ml 

Theoretical volume of water vapor in the gas sample based on saturated stack conditions, corrected to standard temperature and pressure, scf 

Absolute average dry gas meter temperature, degree R (460) 

Absolute average stack gas temperature, degree R (460) 

Absolute temperature at standard conditions, 528 R 

Total sampling time, minutes 

Total volume collected in impingers and silica gel, gr 

Volume of gas sampled through gas meter, cubic feet 

Volume collected at stack conditions through nozzle, ACF 

Stack gas volume sampled, ACF 

Volume of gas sampled through gas meter, cubic feet 

Average stack gas velocity, feet/sec 

Volume of water vapor in gas sampled from impingers, standard cubic feet 

Volume of water vapor in gas sampled from silica gel, standard cubic feet 

Total volume collected in impingers, gr 

Total volume collected in silica gel, gr 

Dry gas meter calibration factor 

97 
EQUATIONS 

1. P.= Pbar +(Po/13.6) 

2. Pm= Pbar +(&H/13.6) 

3. Vr•st,: 17.64 Vm Y (PnJTrn) 

4a. Vwc(std) 004706 Wimp 

4b. Vwsg(st,•) 0.04715 Wso 

5. Bws Vw,l•/(Vrn,td + Vw,td) 

For saturated sources (No. 6 8 only): 

TEST CALCULATIONS 

Kiln A- Run 1 

0.04706*( 

0.04715*( 

Z.gqq •, )/( 

6i TBw• (10 637- {2827/(ts+365)}/Ps 10637-{2827/( 

TVwsta Vm•ta*( TBws/1- TBws) 

• TV•c= TVwstd/0.04707 

+a•..l•/( 

)*( )/( 1 )= 

Md 0.44(%CO2)+0.32(%O2)+0.28((100-(%CO2+%O2)) 

0.44( ,,•.,,• )+0.32( |•,,,• )+0.28(100-( 

12. 

14. 

15. 

23. 

)+18/ .(b(o'tl )= "Z,£. •cl 5(0 

Qa= V, As "60 3 l•,#'l •?a )( I•. I8• S )(60)= 

)) 

Q,= Qa* (528/Ts)*(Ps/29.92) )*(528/ )*( /29.92) 

Qst• Qa (1- Bws) (528/Ts)*(Ps/29.92) =('•"b•)•"•,,)(1- o• )*(528/ ""•'•4 

./-" Cs=0.01543*(Mn/Vm,t•) 0.01543*( (•.,• •flo{•(• )= 

E/Btu= (Cs/7000)*{(F•*20.9)/(20.9-%O2)} 

/7000)*{( )'20.9)/(20.9-( )}= 

%EA= 100%* {(%O2)-0.5*(%CO)} / {0.264(%N2) (%02)+ 0.5*(%CO)} 

•"•P/JV•= 100%*{( )-0.5( )} / {0.264( )-( 

C: Qs,, (60/7000) °•O-C0"•)*( •,4'• • 

)+0.5( 

)*(60/7000) 

Vn=TJPs*{(0.002669) V,c+ (Vm Y Pm)/mm)} "=1'•f4 •,•,11•1)*{(0.002669)( •,"• 

Ca=0.01543 (Mn/V,•) 0.01543*( 

:11• )( z•l. z•ze, )/( 555.5)} 

)= 

I=Vol00/(60*e*V,*A,) (i,•.25&%•t.)100/(60)( 60 )( •5.q$'lZ )( .tbO• 5t::r#•)= C•.I• / 

98 
NOMENCLATURE FOR SULFUR D OXIDES (Method 6C) 

ACE 

CAvg 

CDir 

CGas 

Co 

CM 

CMA 

Cv 

CS 

D 

SB 

SBfinal 

SB• 

MW 

SO2 Ibs/hr 

385.1 x 106 

Analyzer calibration error, percent of calibration span. 

Average unadjusted gas concentration indicated by recorder for the test run, ppmv. 

= Measured concentration of a calibration gas (low, reed, high) when introduced in 

direct calibration mode, ppmv 

Average effluent gas concentration adjusted for bias, ppmv. 

Average of initial and final system calibration bias(or 2-point system calibration 

error) check responses form the low level (zero) calibration gas, ppmv. 

Average of initial and final system calibration bias (or 2-point system calibration 

error) check responses for the upscale calibration gas, ppmv. 

Actual concentration of the upscale calibration gas, ppmv. 

= Measured concentration of a calibration gas (low, mid, or high) when introduced in 

system calibration mode, ppmv. 

Manufactured certified concentration of a calibration gas (low, mid, or high), ppmv. 

Calibration span, ppmv. 

Drift assessment, percent of calibration span. 

System bias, percent of calibration span. 

Post-run system calibration error, percent of calibration span. 

Pre-run system bias, percent calibration span. 

Molecular weight of SO2, which is equal to 64.06 

Sulfur Dioxide mass rate in pounds per hour 

Conversion factor 

99 
Kiln A- Run 1 

ACE 

(7E-1) 

SB 

(7E-2) 

D 

(7E-4) 

CDir C_•_ X 100 

CS 

CS_ CDir X 100 

CS 

SBfinal SBil 

)/( 2,%•o • )x lOO 

CGas 

(7E-5) 

(CAvg Co)X CMA/(CM Co) 

16. SO2 Ibs/dscf 

Cg•s x MW 385.1 x 10 e 

(64.06)/(385.1 x 106) 

17. SO2 Ibs/mmBTU= 

SO2 Ibs/dscf x F-factor x 20.9 / (20.9-02)) 

x x (20.9 / 20.9 ))= 

17. SO2 Ibs/mmBTU= 

SO 2 Ibs/hr/Heat Input mmBTU/hr 

)/( 

21. SO2 Ibs/hr SO2 Ibs/dscf x DSCFM x 60 

x (60) 

100