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Plant ID and Location: 

USG Interiors, Inc. 

27384 Highway 61 

Red Wing, Minnesota 

Permit: 04900007-003 

Emission Sources: 

Cupola No. 1 (EU001) 

Cupola No. 2 (EU002) 

Test Locations: 

Afterburner (EU001) Stack 

(SV009) 

Comprehensive 

Emissions Test Report

Afterburner Stack 

USG Interiors, Inc 

Sulfur Dioxide and Carbonyl Sulfide 

 Compliance Testing 

Test Date: October 3, 2007 

Report Date: October 8, 2007

Prepared for: 

Angela Aalbers 

USG Interiors, Inc. 

27384 Highway 61 

Red Wing, Minnesota 

(651) 388-3513

Prepared by: 

Pace Analytical Services, Inc. 

Field Services Division 

1700 Elm Street, Suite 200 

Minneapolis, MN 55414 

(612) 607-1700 

Pace Project No. 0708-107 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 1 of 18
Table of Contents

Report Cover 1 

Table of Contents 2 

Executive Summary 3 

Introduction 4 

Results Summary 5 

Summary Table 6 

 Table 1 Results Summary 7 

Detail Tables 8 

 Table 2 Moisture Detail 9 

 Table 3 Airflow Detail 10 

Process Description 11 

Test Procedures 12 

 Figure 1 Test Location Schematic 16 

Signatures 17 

Appendix A Field Data Sheets and Documentation A-1 

Appendix B Quantitation and Laboratory Reports B-1 

Appendix C Calculation Equations C-1 

Appendix D Quality Assurance Information D-1 

Appendix E Source/Process/Plant Information E-1 

Appendix F Test Protocol and Pretest Correspondence F-1 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Executive Summary

USG Interiors contracted Pace Analytical Services, Inc. to perform sulfur dioxide (SO2) 

and carbonyl sulfide (COS) emissions compliance testing on the afterburner stack at the 

USG Interiors facility located in Redwing, Minnesota. Testing was performed on 

October 3, 2007. Summary results are highlighted in the following table: 

Test Results Summary

Parameter Run 1 Run 2 Run 3 Average

Volumetric Airflow 

 

 ACFM 67,550 70,930 68,640 69,040 

 SCFM 17,020 17,7490 17,250 17,340 

 DSCFM 15,480 16,370 15,890 15,910 

Emission Rate (LB/HR) 

 

 SO2 260 306 288 285 

 COS <0.11 <0.11 <0.11 <0.11 

Emission Concentration (PPM Dry) 

 

 SO2 1,683 1,870 1,819 1,791 

 COS <0.72 <0.72 <0.72 <0.72 

COS Emission Limit 2.05 LB/HR 

SO2 Emission Limit 371 LB/HR 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Introduction

Pace Analytical Services, Inc. personnel conducted SO2 and COS emission compliance 

testing on the afterburner stack at the USG Interiors facility located in Red Wing, 

Minnesota. James Trowbridge, Terry Harrington and Adam Birr performed on-site 

testing activities. Terry Borgerding provided administrative project management. Larry 

Dettmer with USG Interiors coordinated plant activities during testing. On-site activities 

consisted of the following measurements: 

- SO2, three independent one-hour monitoring periods. 

- COS, three independent one-hour monitoring periods. 

- Moisture, three independent one-hour sampling periods. 

- Orsat gas composition, integrated gas samples collected concurrent with above. 

- Volumetric airflow, measurements during each constituent test run. 

The project objectives were to quantify SO2 and COS emission constituents and 

compare them to applicable air emissions regulations stipulated by MPCA and the 

facility permit. These measurements were performed at normal operating condition. 

Quality protocols comply with all regulatory compliance testing requirements. 

Subsequent sections summarize the test results and provide descriptions of the process 

and test methods. Supporting information and raw data are in the appendices. 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Results Summary

Results of SO2 and COS determinations are summarized in Table 1. The SO2 emission 

rate averaged 285 LB/HR at an average concentration of 1791 PPM Dry. The COS 

emission rate averaged <0.11 LB/HR at an average concentration of <0.72 PPM Dry. 

Subsequent tables provide expanded detail of the testing results. 

The data in this report are indicative of emission characteristics of the measured 

sources for process conditions at the time of the test. Representations to other sources 

and test conditions are beyond the scope of this report. 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Summary Table

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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USG Interiors, Inc.

Red Wing, Minnesota Sulfur Determinations

Pace Project No. 0708-107 Afterburner Stack (SV 009)

Report Date: 10/8/07 TEST 1

Parameter Run 1 Run 2 Run 3 Average

Date of Run 10/3/2007 10/3/2007 10/3/2007 10/3/2007

Time of Run 838-938 1018-1118 1200-1300

Sample Duration (Minutes) 60 60 60

Stack Temperature (°F) 1,578 1,592 1,583 1,584

Duct Moisture Content (%v/v) 9.0 7.7 7.9 8

Volumetric Flow Rate

 ACFM 67,550 70,930 68,640 69,040

 SCFM 17,020 17,740 17,250 17,340

 DSCFM 15,480 16,370 15,890 15,910

Compound Concentration

 mg/dscm

 SO2 4,485 4,984 4,846 4,772

 COS <1.8 <1.8 <1.8 <1.8

 PPM, Dry

 SO2 1,683 1,870 1,819 1,791

 COS <0.73 <0.72 <0.72 <0.72

Compound Mass Rate (LB/HR)

 SO2 260 306 288 285

 COS <0.11 <0.11 <0.11 <0.11

Table 1

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Detail Tables

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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USG Interiors, Inc.

Red Wing, Minnesota Orsat and Moisture Details

Pace Project No. 0708-107 Afterburner Stack (SV 009)

Report Date: 10/8/07 Test 1

Parameter Run 1 Run 2 Run 3

Date of Run 10/3/07 10/3/07 10/3/07

Time of Run 838-938 1018-1118 1200-1300

Run Duration (Minutes) 60.0 60.0 60.0

Orsat (%v/v)

 Dry Basis

 Carbon Dioxide 18.39 19.42 19.95

 Oxygen 2.89 2.49 2.07

 Carbon Monoxide * * *

 Nitrogen 78.72 78.09 77.99

 WetBasis

 Carbon Dioxide 16.73 17.92 18.38

 Oxygen 2.62 2.30 1.90

 Carbon Monoxide * * *

 Nitrogen 71.61 72.07 71.85

Portable O2 Monitor Average (%v/v) 2.9 2.5 2.1

Average Flue Gas Temerature (°F) 1578 1592 1583

Metered Sample Volume (CF) 52.20 46.00 44.70

Dry Standard Sample Volume (DSCF) 49.75 43.42 41.88

Moisture Collected (ml) 105.0 77.0 76.0

Moisture Content (%v/v) 9.04 7.70 7.87

Molecular Weight of Flue Gas (lb/lb-mole)

 Dry 31.06 31.21 31.27

 Wet 29.88 30.19 30.23

Fo 0.980 0.948 0.944

 *Carbon monoxide was not measured, concentrations assumed less than 0.01%.

Table 2

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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USG Interiors, Inc.

Red Wing, Minnesota Airflow Measurements

Pace Project No. 0708-107 Afterburner Stack (SV 009)

Report Date: 10/8/07 TEST 1

Parameter Run 1 Run 2 Run 3 Average

Date of Run 10/3/2007 10/3/2007 10/3/2007

Time of Measurement 0838 1018 1200 0838-1200

Number of Sampling Ports 2 2 2

Number of Points Sampled 16 16 16

Barometric Pressure (In. Hg) 29.19 29.19 29.19 29.19

Static Pressure (In. WC) -1.26 -1.36 -1.31 -1.31

Absolute Flue Gas Pressure (In. Hg) 29.10 29.09 29.09 29.09

Average Flue Gas Temperature (F) 1578 1592 1583 1584

Average Moisture Content (%v/v) 9.0 7.7 7.9 8.2

Dry Molecular Wt. of Gas (lb/lb-mole) 31.1 31.2 31.3 31.2

Flue Gas Average Velocity (FPS) 47.39 49.76 48.15 48.43

Duct Dimension (Inches) 66.0 66.0 66.0

Duct Cross-sectional Area (Sq. Ft.) 23.76 23.76 23.76

Volumetric Flow Rate

 ACFM 67,550 70,930 68,640 69,040

 SCFM 17,020 17,740 17,250 17,340

 DSCFM 15,480 16,370 15,890 15,910

Table 3

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Process Description

USG produces mineral wool at its plant in Red Wing. Melting and fiberizing raw 

materials produce mineral wool. The major component is slag, which is a by-product 

from the steel industry. Stone is used as an additive to change the melt chemistry to 

produce the best quality wool for production. The mineral wool is then sent to other 

facilities to be made into products such as ceiling tiles. USG has two cupolas for melting 

raw materials. A cupola is a vertical cylindrical shaft furnace used to melt incoming 

minerals and then direct the molten slag out of a discharge notch. Once out of the 

notch, the molten slag (approximately 2600 oF) flows down troughs and is then placed 

on rotating wheels. As the wheel rotates, the molten slag is forced off the wheel into a 

“wall” of air, which converts (fiberizes) the molten slag into fibers. Once the mineral wool 

is formed, it is collected in a large “Blow Chamber” (one for each cupola) and is baled 

for shipment. 

Main emission sources involved in this process are the two cupolas, where the stone 

and slag are heated and melted with coke and the blow chambers where the wool fibers 

are collected. Cupola melt rate is limited to 22.2 LB/HR. Pollution control equipment for 

the cupolas include a baghouse and thermal oxidizer. Pollution control equipment for 

the blow chamber includes a dry filter system. After the air passes through the dry filter 

system, then it is exhausted to the atmosphere. The operating rates for the test were 

within the range of normal operating parameters. 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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Test Procedures

EPA Method 1 specifies test location acceptability criteria and defines the minimum 

number of traverse points for representative sampling. Linear measurements from 

upstream and downstream flow disturbances and the duct equivalent diameter are 

compared and the distances related to number of diameters. A flow disturbance can be 

defined as anything that changes or upsets the direction of flow within the duct including 

bends, dampers, fans, shape or size transitions and open flames. Method 1 stipulates 

that test ports should be located at least eight diameters downstream and two diameters 

upstream of any flow disturbance. The minimum acceptable criteria are two diameters 

downstream and 0.5 diameters upstream of flow disturbances. The test location must 

also be free of cyclonic or multidirectional flow. Once the distances have been 

determined, the values are used to select the minimum number of traverse points for 

representative sampling. Shorter distances require a greater number of traverse points. 

The test site configuration is shown in Figure 1 and has the following characteristics: 

 Test Location: Afterburner Stack 

 Duct Cross-sectional Dimension: 66” 

 Distance From Upstream Disturbance: 1398“ 

 Number of Duct Diameters: 21.1 

 Distance To Downstream Disturbance: 294 “ 

 Number of Duct Diameters: 4.5 

 Cyclonic or Multidirectional Flow: No, verified 

 Number of Traverse Points: 16

EPA Method 2 defines procedures used to measure linear velocity and volumetric flow 

rate of a confined gas stream. Using traverse points determined by EPA Method 1, 

multiple differential pressure measurements (pitot impact opening versus static 

pressure) are made using a pitot tube and differential pressure gauge. The individual 

measurements are averaged and combined with the gas density to calculate the 

average gas velocity. The velocity and duct cross-sectional area are used to calculate 

the volumetric flow rate. The volumetric flow rate is expressed as actual cubic feet per 

minute (ACFM), standard cubic feet per minute (SCFM), and dry standard cubic feet per 

minute (DSCFM). The technician maintains comprehensive test records on handwritten 

field data sheets. Details of the equipment used to measure gas velocity include: 

 Pitot Tube: S-Type 

 Differential Pressure Gauge: Oil Manometer 

 Temperature Device: Type K Thermocouple 

 Barometer Type: Electronic Digital Barometer 

 Gas Density Determination: EPA Method 3 

 Gas Moisture Determination: EPA Method 4 

EPA Method 3A defines procedures to measure carbon dioxide (CO2) and oxygen (O2) 

concentrations from stationary sources. A stainless steel sampling probe and a heatPace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 12 of 18
traced TeflonTM sampling line draw a sample of the gas stream from the duct to a 

thermo-electric gas conditioner to remove moisture. The sample gas stream is 

delivered to a Horiba infrared gas analyzer to quantify CO2 concentrations. A Teledyne 

chemical cell gas analyzer quantified O2 concentrations. Zero grade cylinder nitrogen 

provides zero gas and span gases include varying concentrations of EPA Protocol 1 

CO2/O2 standards. A computerized data acquisition system and stripchart recorder (in 

parallel) log CO2/O2 concentrations for one-minute averages. The logged results are 

integrated to test periods and tabulated with spreadsheet software. The operator also 

maintains comprehensive test records on handwritten field data sheets. Equipment 

used for CO2/O2 testing include: 

 Probe Material: Stainless Steel 

 Moisture Removal: Thermo-electric 

 Transfer Line: TeflonTM 

Instrument: Servomex M1400 

Analytical Technique: Paramagnetic 

Calibration Gas: EPA Protocol 1 

EPA Method 4 defines procedures to measure the moisture content of emissions gas 

streams from stationary sources. A stainless steel sampling probe draws a sample of 

the gas stream from the duct to a series of impingers to condense the water vapor. The 

first two impingers initially contain deionized water and a third impinger is empty. A 

desiccant packed drying column follows the impingers to quantitatively collect the 

remaining moisture. An ice bath maintains the impinger train temperature (outlet) at 

68°F or less. Collected water condensate is measured and discarded. Method 4 

equations convert the condensed liquid volume to a gas volume. The water vapor 

volume compared with the dry standard gas volume collected through the isokinetic 

train determines the moisture content of the emissions gas stream and is reported in 

percent by volume. 

 Probe Material: Stainless Steel 

 Impinger Train Material: Borosilicate glass 

 Desiccant: Drierite 

 Condensate Measure: Graduated Cylinder 

 Desiccant Measure: Electronic balance 

EPA Method 6C defines procedures to measure sulfur dioxide (SO2) from stationary 

sources. A stainless steel sampling probe and a heat-traced TeflonTM sampling line 

draw a sample of the gas stream from the duct to a thermo-electric gas conditioner to 

remove moisture. The sample gas stream is delivered to an API M100AH ultraviolet 

gas analyzer to quantify SO2 emissions. Zero grade cylinder air provides zero gas and 

span gases include varying concentrations of EPA Protocol 1 SO2 standards. A 

computerized data acquisition system and stripchart recorder (in parallel) log SO2

concentrations for one-minute averages. The logged results are integrated to test 

periods and tabulated with spreadsheet software. The operator also maintains 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 13 of 18
comprehensive test records on handwritten field data sheets. Equipment used for SO2

testing include: 

 Probe Material: Stainless Steel 

 Moisture Removal: Thermo-electric 

 Transfer Line: TeflonTM 

Instrument: API M100AH 

Analytical Technique: Ultraviolet detector 

Calibration Gas: EPA Protocol 1 

EPA Method 320 defines procedures to speciate and quantify gas-phase compounds 

using extractive Fourier Transform Infrared Spectrometry (FTIR). A probe and sample 

line of inert materials draw a sample gas stream from the source and continuously 

deliver it to a sample cell at a constant rate. Sample interface materials and application 

of heat depend on the constituents of interest. Infrared energy directed through the cell 

and returned to an interferometer classifies spectral separations based on the sample 

gas composition. Collected mid-range infrared interferograms are converted to 

absorbance spectra and compared to existing library reference standards to identify and 

quantify gas constituents. A diaphragm or rotary vane pump downstream of the cell 

moves the gas sample through the interface components and safely to vent. Elevated 

interface temperatures inhibit condensation of moisture and volatile constituents when 

appropriate. Sample cell pressure is monitored and maintained within ±10” WC of 

atmospheric. The FTIR operator completes Field Data Sheets as a comprehensive 

record of testing parameters. 

Commercial and empirically generated (internal) library spectra provide the bases for 

qualitative identification. Multiple compounds can be identified from sample spectra 

because each constituent has unique spectral features. Sample cell path length and 

absorbance magnitude establish the concentrations of gas components. An ethylene 

calibration transfer standard (CTS) certifies the cell path length when compared to 

reference standard spectra (known path length). The library standards used in this 

project are located in the Method Map in Appendix D.include: 

Test data are electronically recorded and stored as single beam, absorbance, residual, 

and interferogram spectra. Final test reports display tabulated instrument concentration 

logs and handwritten field data. Test data are archived by project. 

Primary calibration gases are EPA Protocol 1 ethylene in nitrogen. Target constituent 

gas calibrations occur as appropriate, subject to availability. Appendix D presents 

calibration trials, matrix spiking, detection limit derivations and other quality procedures. 

Spectral interpretation empirically derives theoretical compound detection limits by 

applying a known standard until the visual presence of the compound reaches at least 

two times the baseline signal-to-noise ratio (SNR). 

Quantitative uncertainties are listed for all sample spectra and are approximately ±30%. 

Classical least squares fit (CLSF) calculations through Autoquant Pro derive the 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 14 of 18
reported uncertainties. Analytical precision is also approximately ±30%. Recovery of 

certified ethylene calibration transfer standards verified precision on-site. 

Based on project data quality objectives, EPA Method 320 was modified to exclude: 

• Fractional Calibration Uncertainties (FCU) calculations 

• Fractional Method Uncertainties (FMU) calculations 

• Root Mean Square Deviation (RMSD) calculations 

• Bias of Spiking Calculations 

Details of FTIR instrumentation are shown below. 

 Sample Flow Rate: ~1-3 L/min. 

 Probe Material: Stainless steel 

 Transfer Lines: Teflon (heated) 

Sample Cells: 10 Meter Optical Path Length 

Cell Windows: Zinc Selenide 

Sample Interface Temp.: ~250°F 

Instrument: Midac I2000 Gas Phase FTIR 

Detector: Mercury Cadmium Telluride (MCT) 

Wave Number Range: 4500 – 650 cm-1

 Scans/Result: 16/64 Co-added Scans 

Resolution: 0.5 cm-1 

Gain: 1 

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 15 of 18
	









 

  


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Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 16 of 18
Report Signatures

Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

Page 17 of 18
Pace Analytical

FSD 0708-107 Report Date 10/8/2007

USG Interiors, Inc.

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