Compliance Te Brick Kiln D O, Lim•
Testing Location: •,• •.General Shale Brick, Inc. Plant 36 770 Webster

Road !__u._e..oRid ge, Virginia

Prepared for: Ms. Martha

West General Shale Brick, Inc. 3211 North Roan Street Johnso_n City, Tennessee

37601

Date Submitted: June 2008

Chris LeMay Project Manager

E. Roberts Alley & Associates,

Inc. 1931 Central Parkway SW, Suite S Decatur. AL 35601 Phone: (256) 351-0121 Fax: (256) 351-0151 ERA&A Project No. 2008-0206 Prepared By:l.O

1.11.21.31.4 2.03.0 3.13.23.33.4 TABLE OF CONTENTS Introduction

................................................................................................................................................ 1-1 Facil ity and Source Descriptions I-1 Project Team

............................................................................................................................................... 1- Laboratory

.................................................................................................................................................. 1-1 Protocol/Method Deviations

........................................................................................................................ 1-1 Snmmary of Results

.................................................................................................................................... 2-I Testing Methodology

.................................................................................................................................. 3-1 U.S. EPA Reference

Test Methods

& 2 Volumetric

Flow Rate 3- U.S. EPA Reference

Test Method 3 Oxygen/Carbon

Dioxide 3-1 U.S. EPA Reference

Test Method 4 Moisture Content 3-1 U.S. EPA Reference

Test Method 26A Hydrogeu

Chloride/Hydrogen

Fluoride 3-1

Appendix A Appendix B Appendix C Appendix D Appendix E Sample Calculations Field Data Laboratory Data Quality Assurance/Quality

Control Data Process Operatin•Control

System Data APPENDICES

Table 2- Table 3- LIST OF TABLES Summary of Compliance

Testing Results Source Testing Methodology

c:\\Projccts\Gcncra[ Shale Brick. lnc.\2008-0206\Compliance

Report Page1.0 Introduction E. Roberts Alley & Associates,

Inc. (ERA&A)

was retained by General Shale Brick, Inc. (General Shale) to conduct emission testing at Plant 36 located in Blue Ridge, Virginia.

Testing was conducted

on the inlet and outlet of the dry lime absorber (DLA) to demonstrate

compliance

with the hydrogen

chloride (HC1) and hydrogen

fluoride (HF) reduction efficiency

(RE) requirements

listed in the Virginia Department

of Environmental

Quality (DEQ) Permit Registration No. 20447, conditions

17 and 18. ERA&A personnel

conducted

the emission testing while General Shale provided all process operating and control system data to support the testing results.

1.1 Facility and Source Descriptions General Shale manufactures

brick exterior building material.

Shale and clay are mined, crushed and sent through a screening process prior to brick forming by extrusion.

Once the brick is extruded,

it is dried and fired in a tunnel kiln at approximately

2,000 °F. The facility operates two kilns (A & B) with a common exhaust. After being fired, the brick is cooled, packaged and shipped to various locations.

The interkiln dryer/kiln

emissions

are controlled

with an ohlmann type DLA (Unit #6). The exhaust stack is located outside the kiln building on the east side.

i.2 Project Team The emission testing was conducted

by Mr. Stacey Ctmningham

(Team Leader), Mr. Chris Landtroop

and Mr. Larry Moore. Mr. Chris LeMay served as ERA&A's

Project Manager while Ms. Brandy Hughes served as the Report Coordinator. Ms. Martha West of General Shale served as ERA&A's

technical contact and coordinated

the testing with facility operations.

1.3 Laboratory HCI and HF analyses were performed

by Maxxam Analytical

Inc. of Burlington,

Ontario, Canada.

1.4 Protocol/Method

Deviations The were no deviations

from the Stack Test Protocol form submitted

to DEQ on March 24, 2008 or U.S. EPA Reference Test Methods.

c:\\Projects\General Shale Brick, lnc.\2008-0206\Compliance

Report Page I-ISummary of ResultsCompliance Test Report S•tmmary ofl•esttlts

2.0 Summary

of Results ERA&A conducted

compliance

testing on the DLA at the Blue Ridge, Virginia facility. Testing was conducted

on May 20, 2008 and consisted of three (3) 60-minute

test runs on the inlet and outlet of the unit.
Table 2-1 provides a summary of the emission testing restllts. Any difference

between the summary restllts listed in the following

table and the detailed results contained

in Appendix

B is due to rounding for presentation.
Table 2-1 Summary of Compliance

Testing Results

Date Run Time, rain Process/Control System Data Brick Production,

tons/hr Coal Usage, lbs/hr Gas Usage, mcf/hr DLA Differential

Pressure, in. WC Limestone Feed, Ibs/hr Hydrogen Chloride

Data Inlet Emission Rate, lbs/hr Outlet Emission Rate, lbs/hr Reduction Efficiency,

% Hydrogen Fluoride Data Inlet Emission Rate, Ibs/hr Outlet Emission Rate, Ibs/hr Reduction Efficiency,

% 5/20/08 60

17.04 1,450 I0.1 0.25 200

3.23.1

17.10.4

5/2O/08 60

17.04 1,450 10.1 0.25 200

3.43.3

16.0.4

5/20/08 60

17.04 1,450 10.1 0.25 200

3.43.5

16.6 0.5

17.04 1,450 10.1 0.25 200

3.33.3

16.6 0.597

c:\\Projects\(3eneral Shale Brick, Inc.•008-0206\Compliance

Rcport Page 2-1Testing Methodology/k\

g_.v.. (.•.•.• • •, •,.• General 577ale Brick. Inc. Compliance Test Report Testing Methodolog),

3.0 Testing Methodology The emission testing program was conducted

in accordance

with the U.S. EPA Reference

Test Methods listed in Table 3-1. Method descriptions

are provided below, while quality assurance/quality

control data is provided

in Appendix D.

Table 3-1 Sonrce Testing Methodology

Volumetric Flow Rate (VFR) 1-2 Oxygen/Carbon Dioxide (O2/CO2) 3 Fyrite Analysis Mois!ure Content (BWS) 4

Gravimetric

Analysis Hydrogen Chloride/Hydrogen

Fluoride (HCI/HF)

26A lsokinetic

Sampling

3.1 U.S. EPA Reference

Test Methods

& 2 Volumetric

Flow Rate The sampling

location and number of traverse (sampling)

points were selected in accordance

with U.S. EPA Reference Test Method I. A full velocity traverse (U.S. EPA Reference

Test Method 2) was conducted

during each test run to determine

the average stack gas velocity pressure, static pressure and temperature.

The velocity and static pressure measurement

system consisted

of an S-type pitot tube and inclined manometer

while the stack gas temperature was measured

with a K-type thermocouple

and pyrometer.

3.2 U.S. EPA Reference

Test Method 3 Oxygen/Carbon

Dioxide The oxygen and carbon dioxide concentrations

in the inlet and outlet gas streams were determined

in accordance with U.S. EPA Reference

Test Method 3. One (l) integrated

bag sample was procured during each test nm at each location and analyzed on site with a Fyrite O:/CO• analyzer.

The Fyrite solutions were verified before and after testing by conducting

a calibration

check with EPA Protocol

Oz/COz gas. The remaining

stack gas constituent

was assumed to be nitrogen for the stack gas molecular

weight determination.

3.3 U.S. EPA Reference

Test Method 4 Moisture

Conteot The gas moisture

contents were determined

in accordance

with U.S. EPA Reference

Test Method 4. The gas conditioning trains consisted of a series of chilled impingers.

Each impinger was pre and post-weighed

on the same analytical balance to determine

the amount of moisture condensed

during each test run.
3.4 U.S. EPA Reference

Test Method 26A Hydrogen

Chloride/Hydrogen

Fluoride The hydrogen

chloride and hydrogen fluoride concentrations

were determined

in accordance

with U.S. EPA Reference Test Method 26A. The complete sampling system consisted of a glass nozzle, heated glass-lined

probe, heated Teflon filter, gas conditioning

train, pump and calibrated

d•3• gas meter. The gas conditioning

train consisted

of five (5) impingers contained

in an ice/water bath. The first and second impingers

contained

100 mL of 0.1 N H2SO•, the third and fourth contained

100 mL of 0.1 N NaOH and the fifth contained approximately

200 grams of silica gel.

c:\\Prqjects\General Shale Brick, lnc.\2008-0206\Compliance

Report Page 3-1Colnpliance Fes'l Report
L•,,,,,,,,,,,-,,•;,z •,...,•:,.,.,,,,•; H,,,/u, .*,z,.o Test#lg Methodology Following the completion

of each test run, the sampling train was leak checked at a vacuum pressure greater than or equal to the highest vacuum pressure observed

during the rnn. The impingers

were weighed on an electronic balance to determine

the amount of moisture gained. The contents of the first two (2) impingers

were recovered

in Sample Container

1. All connecting

glassware,

including

the back half of the filter holder, were rinsed with DI water and these rinses added to Sample Container

1. The contents of impingers

three (3) and four (4) were recovered in Sample Container

2. All connecting

glassware,

from the inlet of the third impinger to the outlet of the fourth impinger,

were rinsed with DI water and these rinses added to Sample Container

2. Container

2 will be held unless further analysis is requested.

All containers

were sealed, labeled, and liquid levels marked for transport to Maxxam Analytics

Inc. in Burlington, Ontario, Canada. The samples were analyzed by high performance

liqnid chromatography

(HPLC).

c:\\Projects\General Shale Brick, Inc.•2008-0206\Compliance

Report Page 3-2•=•)•(•-)•]•_• General Shale Brick. Inc. Compliance 7•sl Report dppenclix A Sample Calculations Example calculations

are provided/or

Rzm l-lnlet, unless othet•vise

noted.
Meter Pressure (Pro), in. Hg

AH Pm: Pb + 13.6

where, Pb barometric

pressure, in. Hg AH pressure differential

of orifice in. H20

Pm: 28.52 &. Hg 1.100 in. H•O 13.6 in. [•O/in. Hg 28.60 m. Hg

Absolute Stack Gas Pressure (Ps), in. Hg

Ps Pb + Pg13.6

where, Pb barometric

pressure, in. Hg Pg static pressure, in. H20

Ps 28.52 in. Hg 0.10 in.H•O 13.6 in. HeO/in. big 28.53 in. ttg

Standard Meter Volume (Vmstd), dscf

V•std= 17.647 x Y x Vm x Pm Y•n where, Y meter correction

factor Vm meter volume, cf Pm meter pressure, in. Hg Tm meter temperature,

°R 17.647°R/in. Hg x 0.999 x 36.332cfx

28.60in. Hg 535.8 °R 34.193c&cf

Standard Wet Volume (Vwstd), scf Vwstd= O. 04707x Vlc where, Vlc volume of H20 collected,

ml
Vwstd 0.04707 ftS/mL x 53.5 mL 2.518 scf

cA\Projects\General Shale Brick, Inc.\2008-0206\Compliance

Report Page A-1General Shale Brick. h•c. Compliance Test Report Appendix/l Sample Calculations
Moisture Fraction (BWS)

BWS Vwstd (Vwstd + Vmstd) where, Vwstd standard wet volume, scF Vmstd standard meter volume, dscf

BWS 2.518 scf

0.069 2.518 scf + 34.193
Molecular Weight (DRY) (Md), Ib/Ib-mole Md (0.44 x CO_, ) + (0.32 x 0:) + (0.28 (100 CO 02) ) where, CO•_ carbon dioxide concentration,

% O-, oxygen concentration,

% Mcl =(0.44x3.0)+(O.32x

17.0) •(0.28(100-3.0-

1ZO)) 29. 16 Ib/lb-rnole
Molecular Weight (WET) (Ms), Ib/lb-mole Ms" Md U- B WS) + 18 (BWS) where, Md molecular

weight (DRY), lb/lb-mole BWS moisture fraction, dimensionless
Ms 29.16 lb/lb- mole(l- O. 069)+ 18(0. 069) 28. 39lb/lb- mol• Average Velocity (Vs), ft/sec•p TS •• 85.49 x @ x •-A--fi avg. x s x Ms where, Cp pitot tube coefficient AP velocity head of stack gas, in. H20 Ts absolute stack temperature,

°R Ps absolute stack gas pressure, in. Hg Ms molecular

weight of stack gas, Ib/Ib-mole

Vs 85 49 fi /(lb/lb- mole) (in. Hg) f

821.9 °R •ec]] (°R)(in.H•O)

x 0.84 x 0.306 in.H,O x •] 28.53 in. Hg x 28.391b/Ib

mole 22.1 fi sec

c:\\Projects\General Shale Brick, lnc.\2008-0206\Compliance

Report Page A-2Compliance Test Report AppendLv ,,1 &tmple Calculations Average Staek Gas Flow at Stack Conditions

(Qa), aefm Qa 6O x Vs x As where, Vs stack gas velocity, ft/sec As cross-sectional

area of stack, ft Qa 60 sec/min x 22.1ft/sec

x 23.36fi 2 3.1E +O4 acJm Average Stack Gas Flow at Staadard

Conditions

(Qs), dscfin Qs 17.647 x Qa x (1-BWS)

x Ps
where, Qa average stack gas flow at stack conditions,

ft3/min BWS moisture fraction, dimensionless Ps absolute stack gas pressure, in. Hg Ts absolute stack temperature,

°R Qs=17.647 °R x3.1E+04

acf
x (1-0.069)x in. Hg

rain

28. 53 in. Hg 821.9°R 1. BE+ 04 dscfm Hydrogen Chloride Concentration

(Cnc0 mg/dscm

C H('I l'•t HCI x35.313 I)nstd x I.OE + 03 where, MHC• hydrogen

chloride mass, ng Vmstd standard meter volume, dscf

CH(, 46,000 ugx 35.313 ft3/m 34.193 dscf x 1.0E+ 03uglmg

47.5 mg dscm Hydrogen Chloride

Emission

Rate (ER•Ic0, Ibs/hr •Rtt( MH(,Ix Qsx 60 Umstdx 4.54E 08 where, MHc• hydrogen

chloride mass, ug Vmstd standard meter volume, dscf Qs stack gas flow rate at standard conditions,

dscfin ERm, 46,000 ug x 1.8E + 04dscfmx 60min/hr 34. 193 dscfx 4.54 E + 08 ug/lb =3.2 lbs hr

c:\\Prqjects\General Shale Brick, Inc.•2008-0206\Compliance

Report Page A-3Hydrogen Chloride Reduction

Efficiency

(RE), %

RE ( ER lnlet- -- --ER outlet
× O0 ERhdet where, ERh•kt inlet HCI emission rate, lbs/hr ERou,let outlet HCI emission rate, lbs/hr =13.2lbs/hr-( 3"llbs/hrl•

x 100 3.0 % RE 3.2 lbs hr

HF emissions

were calculated

by the approach presented

for HCI.

c:\\Projects\General Shale Brick, [nc.\2008-0206\Compliance

Report Page A-4Appendix B ILocation:

GS (Plant 36)- Roanoke, VA Source: DLA Inlet Date: 05/20/08 Project No.: 2008-0206

Engineering. Environmental. Health & Safety Surveying

Method 1 Velocity Traverse Data

Distance from far *vail to outside of port: 62.00 Nipple length:

4.0•0__ Depth of Dnet (Ds): 58.00 Width of Duct (Ws): 58.00 Cross Sectional Area of Duct (As): 23.36 No. of ports:

in.in.

Up-stream (A): 2.8 ft. 0.6 Duct Diameters in. Down-stream

(B): 15.0 ft. 3.1 Duct Diameters in. Equivalent Diameter:

58.0 ft Number of traverse points total: 24

Traverse point Number Diameter

23456789l0II12 LOCATION

OF TRAVERSE

POINTS RECTANGULAR STACKS

Number oftraverse ports diameter 2 3 4 5 6 7 8 9 10 I1 12 25.0 16,7 12.5 10.0 8,3 7.1 6.3 5.6 5.0 4.5 4.2 75.0 50.0 37.5 30.0 25.0 21.4 18.8 16.7 15.0 13.6 12.5 63.3 62.5 50.0 41.7 35.7 31,3 27,8 25.0 31.8 20.8 87.5 70.0 58,3 50.0 43.8 38.9 35.0 22.7 29.2 90,0 75.0 64.3 56.3 50.0 45.0 40.9 37.5 91.7 78.6 68.8 61,1 55.0 50.0 45.8 92.9 81,3 72.2 65.0 59.1 54.2 93.8 83.3 75.0 68.2 62.5 94.4 85.0 77.3 70.8 95.0 86.4 79.2 95.5 87.5 95.8 *Percent of stack diameter from inside wall to traverse point. EXAMPLE RECTANGULAR STACK CROSS SECTION DIVIDED INTO 12 EQUAL AREAS, WITH TRAVERSE AT CENTROID 0,0, 0,0 0 0 0,0 o'©,, © 0

Minimum number of traverse points for particulate traverses Duct Diameters Upstream from Flow Disturbance*

(Distance A) 0.5 1.0

1.5

2.0 "Higher Number is for

T i ":*'•i:•*"' Rectangular Stacks or Ducts

-'• 12.._....9_0 16

in.) Fiow Point of Any Type ofDishlrbance --q

12 (Bend, Expansion, Contraction, etc.)

8 9 2.5

2 4 5 6 7

9 10 Duct Diameters Downstram from Flow Disturbance*

(Distance B)

Traverse

% of Point Diamete•
6.3 2 18.8 3 31.3 4 43.8 5 56.3 6 68.8 7 81.3 8 93.8 910
12 Distance from Distance fron outside of inside wall port 3.65 7.65 10.90 14.90 18.15 22.15 25.40 29.40 32.65 36.65 39.90 43.90 47.t5 51.15 54.40 58.40

Notes:

Test Personnel

(signature/date) Test eam Leader (stgnature/date)Location: Date: GS (Plant 36) Roanoke,

VA 05/20/08
sse¢ aSes Source: DLA Inlet Project No.: 2008-0206

Method 1 Verification

of Absense

of Cyclonic

Flow (Section 11.4) Engineering Environmental.

Health & Safety. Surveying

Sample Point 123456

AP @ Reference 0.31 0.28 0.24 0.21 0.17 0.16 7 0.15 8 0.13 9 0.24 101112131415161718 0.20 0.16 0.14

Angle (AP=0)

1110

109116
1012 0.14 11 0.14 8 0.15 7 0.10 0.19 0.16 19 0.14 20 0.13 21 0.14 22 0.14 23 0.15 24 0.11

0.17 9.0 25262728293031323334353637383940 Average 79910119

QA/QC ReviewerLocation:

GS (Plant 36) Roanoke,

VA

Engineering Environmental.

Health & Safety. Surveying

Run 1 Source: DLA Inlet Project No.: 2008-0206

Method 3 Gas Analysis

Data

Analysis Number 123 Average Repeatability (P/F):

Date: % COz 3.03.03.03.0P

5/20/08 %05 17.0 17.0 17.0 17.0P

% Nz 80.0 80.0 80.0 80.0P

Run 2 Analysis Number

2
Average Repeatability (P/F):

Date: % COz 3.03.03.03.0

5/2O/08 % O2 16.0 16.5 16.5 16.3

% Nz 81.0 80.5 80.5 80.7

Run 3

Date:

5/20/08 Analysis Number

% CO

% 02

% N2 1 3.0

16.5

80.5 2 3.0

16.5

80.5 3.0 16.5

80.5 Average 3.0

16.5

80.5 Repeatability (P/F):

P

p

p Acceptability for Orsat Repeat Analysis CO2 > 4% + 0.3% C02 -< 4% _+ 0.2% 02 > 15% + 0.3% 02 -< 15% _+ 0.2% Ambient

Check

Analysis Typ.e 02 20.5 % C02 0.0 %

Orsat report to 0.1% Fyrite report to 0.5%

QA/QC ReviewerLocation: ,GS (Plant 36) Roanoke, VA Date(s): 05/20/08 Source: DLA Inlet Project No. 2008-0206

En£1ineerin•7 Env ronmental Health & Safety Survey n•

Method 4 Moisture Data

Sample 1D: Run

Filter ID: Date: 5/20/08

IMPINGER VOLUME,

ml 2 3

4

5

6

7

8

Total H2SO4 H2SO4

NaOH

NaOH

Silica 100.0 100.0

100.0

100.0

231.1 631,1 118.0 116.0

108.0

104.0

238,6 684,6 16.0 8.0

4.0

7.5 18.0 53.5 hnpinger Color:

Clear" Labeled?

Yes Silica Gel Condition:

OK Sealed?

Yes Sample ID: Run 2

Filter ID: Date: 5/20/08

IMPINGER VOLUMEr

ml 2 3

4

5

6

7

8

Total H2SO4 H2SO4

NaOH

NaOH

Silica 100.0 100.0

100.0

100.0

220.0 122.0 114.0

106.0

102.0

228.4 22.0 14.0

6.0

2.0

8.4 620.0 672.4 52.4 hnpinger Color:

Clear Labeled?

Yes Silica Gel Coodition:

OK Sealed?

Yes Sample 1D: Run 3

Filter 1D: Date: 5/20/08

IMPINGER VOLUME•

ml 3 4

5

6

7

8

Total NaOH NaOH

Silica 226.7 626.7 2 H2SO4 H2SO4 100.0 100.0

100,0

100.0 116.0 112,0

106.0

102.0 12.0 6.0

2,0 Clear 16.0 lmpinger Color: Silica Gel Condition:

OK 241.0 14.3Labeled? Sealed?

Yes Ycs 677.0 50.3

Comments:

Test Perso/nnel

(signature/date)Locatlou: GS (Plant 36) Roauoke, VA Date: 05/20/08 STACK DATA (EST) % Moisture:

7.3 % est. Barometric: 30.00 in Hg Static Press: 0.12 inWC Stack Press: 30.01 in Hg %CO2: 3.5 % %02: 16.5 %

EQUIPMENT METER BOX: 1665 ¥: 0.999 DH@: 1.707 PITOT 1D: PR-19

Start Time: End Time: 10:44 AM

Source: DLA Inlet 11:52 AM Project No.: 2008-0206 FILTER NO-• N/A STACK DATA (EST)
Est. Tin: 80 °F Est. Ts: 334 °F Est. dP: 0.14 in WC Est. Dn 0.374 inches Cp: 0.84 NOZZLE ID: G-901 Run

LEAK CHECKS Pre Mid Posl

MOISTURE

DATA Total Liquid Vol. (ml) 53.5 K-FACTOR 12.074

Vohune Corrections

A-I2345678B-I2345678C-I2345678 %N2/CO:

80.0 Md: Ms: Sample Time (minutes) Dry Gas Meter Reading (ft 3) Begiii End 0.00 2.50

908.514 2.50 5.00

909.982 5.00 7.50

911.450 7.50 10.00

912.744 10.00 12.50

914.020 12.50 15.00

915.275 15.00 17.50

916.585 17.50 20.00

917.882 20.00 22.50

919.176 22.50 25.00

920.540 25.00 27.50

921,893 27.50 30.00

923.376 30.00 32.50

924.920 32.50 35.00

926.630 35.00 37.50

928.480 37.50 40.00

930.250 40.00 42.50

932.052 42.50 45.00

933.528 45.00 47.50

935.018 47.50 50.00

936.580 50.00 52.50

938.142 52.50 55.00

939.720 55.00 57.50

941,367 57.50 60.00

943.140 60.00 944.846

Final DGM

944.846 % 29.22 lb/lb-mole 28.40 lb/lb-mole

Du: 0.375 Depth/Width (in): 58.0 58.0 Stack Area: 23.36 ft

Leak Rate: 0.003 'ump Vacuum:

15 Pitot Tube: Pass Gas Temperatiires

(° E Pitot DGM

Orifice Press. Pump Tube Average

Stack DH (in. H20) Vac(in. Arab. Arab.

Hg.) 65 65 Ideal Actual 0.09 65

356 1.03 1.03 2 0,09 65

369 1.01 1.02 2 0.07 66

372 0.79 0.79 2 0.07 67

374 0,79 0,79 2 0.07 67

368 0.79 0.79 2 0.07 68

353 0.81 0.81 2 0.07 70

355 0.81 0.81 2 0.07 71

35L 0.81 0.81 2 0.09 74

366 1.04 1.04 2 0.07 75

365 0.81 0.81 2 0.09 76

370 1.03 1.04 3 0.10 77

370 1.15 1.15 3 0.12 78

370 1.38 1.37 3 0.13 79

356 1.53 1.53 4 0.12 80

350 1.42 1.42 4 0.13 81

358 1.53 1.52 4 0.09 78

362 1.05 1.05 3 0.09 81

373 1.04 1.04 3 0.10 82

363 1.17 1.17 3 0. I0 82

355 1,18 1.19 3 0.10 83

356 1.18 1.19 3 0.11 84

358 1.30 1.30 3 0.12 84

360 1.41 1.42 4 0.11 85

352 1.31 1.30 4

/'" Orsat

•"° Analyzer

I:V • Fyfite

0.000 cfin #1 4 in Hg #2 Pass Total Gat Temps' Imp. Probe Filter Exit

66 65 64 XAD

cfcfcf

Vs % ISO (fps)

255 258 65 N/A 101,6 21.08 260 265 63 N/A 102.4 21.25 264 266 61 N/A 102.3 18.77 266 264 60 N/A 100.8 18.79 265 265 60 N/A 98.8 18.73 266 267 61 N/A 102.0 18.56 265 265 62 N/A 100.7 18.58 266 266 63 N/A 100.3 18.57 267 265 66 N/A 93.4 21.21 265 265 65 N/A 104.7 18.69 265 267 65 N/A 101.4 21.26 266 265 65 N/A 100.0 22.41 264 263 64 N/A 101.0 24.55 263 266 63 N/A 103.9 25.33 265 265 62 N/A 102.9 24.25 265 265 62 N/A 101.0 25.37 265 265 64 N/A 100.1 21.16 267 265 63 N/A 101.1 21.30 265 266 62 N/A 99.8 22.32 267 266 61 N/A 99.4 22.21 265 268 62 N/A 100.2 22.22 267 268 62 N/A 99.7 23.33 266 267 64 N/A 102.9 24.40 265 266 64 N/A 102.7 23.25

Super Sat'd VIII DP (WC)

Tm Run Time

1.029 m

2.38 mm 60.0 rain 36.332 ft

0.09 in Vr%a Vws•a

% Hz O 0.968 dscm

0.071 scm (meas.)[ 34.194 dscf

2.518 scf 6.9

24.3 °C 75.8 °F Qsd

Ts Max DH (WC)

%1S0

Vs 183.3 °C Vac. 27.929 mm 6.74 m/s 361.9 °F 4 1.100 in

98.1

22.13 ftJs Qsw Qa Yqa 501 dscmm

538 scmm

878 acmm 17,686 dscfm

18,997 scfin

31,013

acfin

-1.7

Test Personnel

(signature/date) TestTeam

Lead•: (signature/date)Location: GS (Plaut 36) Roanok% VA Date: 05/20/08 '•'• ac• oAtA % Moisture:

6.9 % est. Barometric: 30.00 in Hg Static Press: 0.12 in WC Stack Press: 30.01 .in Hg %CO2: 3.5 % %02: 16.5 %

EQUIPMENT METER BOX: 1665 Y: 0.999 DH@: 1.707 inH20 PITOT ID: PR-19 Cp: 0.84 NOZZLE ID: G-904 %N2/CO: 80.0 Md: 29.22 lb/lb-mole Ms: 28.45 lb/lb-mole Start Time: 12:30 PM End Ti•ne: 1:42 PM STACK DATA (EST) FILTER l•'•.
Est. Tm: 76 Est. Ts: 362 °F Est. dP: 0.09 in WC Est. Dn: 0.420 inches

LEAK CHECKS Source: DLA Inlet

Ruu 2 Project No.: 2008-0206 MOISTURE

DATA Total Liquid V•I. (ml)

Pre Mid Post

52.4 K FACTOR 13.640

Volume Corrections DR: 0.390 in Depth/Width (in): 58,0 58.0 Stack Area: 23.36 ft

• Pitot • Sample Time -• (minutes)

Dry Gas Meter DP • Reading (ft 3) Begin/ End

(in. H20) A-I 0.00 2.50

944,•78

0.10 2 2.50 5.00

946.630

0,10 3 5,00 %50

948.315

0.09 4 7.50 10.00

949.953

0,09 5 10.00 12.50

951.572

0.09 6 12.5( 15.00

953,170

0.11 7 15.00 17.50

955,000

0.12 8 17.50 20.00

956,867

0.09 B-I 20.00 22.50

958.499

0.09 2 22.50 25.00

960.107

0.09 3 25.00 27.50

961.770

0.10 4 27.50 30.00

963.395

0.10 5 30.00 32.50

965.147

0.09 6 32.5( 35.00

966.777

0.10 7 35.00 37.50

968.520

0.10 8 37.50 40.00

970,230

0.10 C-I 40.00 42.50

971.926

0.09 2 42.50 45.00

973.530

0,I0 3 45.00 47.50

975.270

0.10 4 47.50 50.00

976.960

0.10 5 50.00 52.50

978.688

0.14 6 52.50 55.00

980.830

0,14 7 55,00 57.50

982.980

0.12 8 57.50 60.00

984,740

0.12 60.00 986.610

Final DGM:

986.610 Leak Rate: 0.000 ?ump Vacuum:

10 Pitot Tube: Pass

0.000 cfin #1 4 iu Hg #2 Pass Total Gas Temperatures

(°F) Gas Wem•'• (°F) DGM Orifice Press. Pump Vac

hn •, Average Stack Dtl (in. 1120) (in. Probe Filter Exit_ XAD % ISO Arab. Arab.

tlg.) Ideal Actual 77 368 1.36 1.35 3 263 258 66 N/A 98.5 22.37" 84 360 1.39 1,38 3 265 261 65 N/A 98.7 22.2• 86 363 1.25 1.25 3 265 264 65 N/A 100.9 21.15 87 365 1.25 1,25

264 266 64 N/A 99.7 21.18 87 366 1.25 1,25 3 266 265 64 N/A 98.5 21.19 88 367 1.53 1.52

265 264 62 N/A 102.0 23.44 88 369 1.6• 1.66 3 265 263 61 N/A 99.7 24.51 88 355 1.27 1.26 3 268 265 63 N/? 99.7 21.05 86 373 1.24 1.24 3 266 265 64 N/A 99.7 21.28 87 374 1.24 1.24 3 265 264 63 N/A 103,0 21.29 86 365 1.39 1.38 3 264 267 64 N/A 95.2 22.32 85 365 1.38 1.38 3 265 266 62 N/A 102.8 22.32 85 360 1.25 1.26 3 265 267 63 N/A 100.5 21.11 85 357 1.40 1.39 "3 265 268 63 N/A 101.1 22.22 85 360 1.39 1,40 3 267 266 64 N/A 100.0 22.26 85 354 1.40 1.40 3 266 266 64 N/A 98.8 22.18 84 363 1.25 1.25 3 264 265 67 N/A 99.2 21.15 84 370 1.37 1.38 3 265 266 64 N/A 102.6 22.39 84 360 1.39 1.38 3 265 267 63 N/A 99.0 22.26 84 355 1.40 1.40 3 266 266 63 N/A 100.9 22.19 85 253 2.24 2.23 4 265 265 64 N/A 98.9 24.56 85 345 1.98 1.98 4 267 265 64 N/A 105.4 26.09 85 357 1.68 1.67 4 265 267 65 N/A 93.9 24.34 85 356 1.68 1.67 4 265 267 65 N/A 99.7 24.32 cfcfef

•'• Orsat f-- Analyzer

i'•" Fyrite Ws(lOs)

C" Super Sal'd Vm DP (WC) Ran Time

1.179 m 2.60 mm 60.0 rain 41.632 ft 0.10 Vm•t Vw•t•

%H20 1,091 dscm

0.070 scm I(meas.)] 38.536 dscf

2.466 scf 6.0

Test Personnel

(signature/date) 29.6 °C 85.2 °F Tm

Ts Max DH (WC)

%1SO

Vs 180.8 °C Vac. 36.587 mm

7.03 m/s 357.5 °F 4 1.440 in

96.7 Qsd Qsw

Qa

Yqa 530 dscmm

564 scmm

915 acmm

-2.7 18,712 dscfm

19,906 scfm

32,325

acfm

23.06 fi/s

Testffeam Le,'fi•-• (signature/date)Location: GS (Plant 36) Roanoke, VA

Start Time: 2:18 PM Date: 05/20/08 End Time: 3:25 PM ,..STACK DATA (EST) % Moista•re:

6.0 %est. Barometric: 30.00 in Hg Static Press: 0.12 in WC Stack Press: 30.01 in Hg %CO2: 3.5 % %02: 16.5 % %N2/CO: 80.0 % Md: 29.22 lb/lb-mole Ms: 28.55 lb/lb-mole

EQUIPMENT
METER BOX: 1665 Y: 0.999 DH@: 1.707 PITOT ID: PR-19 Cp: 0.84 NOZZLE ID: G-904 Du: 0.390 ill H20

Depth/Width (in): 58.0 58.0 Stack Area: 23.36 ft Sample Time (mim•tes) Dry Gas Meter Reading (ft 3) Begiu End A- 0.00 2.50

986.765 2 2.50 5.00

988.350 3 5.00 7.50

990.150 4 7.50 10.00

991.906 5 10.00 12.50

993.635 6 12.50 15.00

995.300 7 15.00 17.50

997.067 8 17.50 20.00

998.847 B-I 20.00 22.50

1000.600 2 22.50 25.00

1002.273 3 25.00 27.50

1004.000 4 27.50 30.00

1005.712 5 30.00 32.50

1007.408 6 32.50 35.00

1009.037 7 35.00 37.50

1010.650 8 37.50 40.00

1012.270 C-I 40.00 42.50

1013.830 2 42.50 45.00

1015.765 3 45.00 47.50

1017.647 4 47.50 50.00

1019.400 5 50.00 52.50

1021.020 6 52.50 55.00

1022.610 7 55.00 57.50

1024.300 8 57.50 60.00

1026.230 60.00 1027.922

Final DGM:

1027.922 STAC• DATA (EST)
Est. Tin: 85 °F Est. Ts: 358 °F Est. dP: 0.10 in WC Est. Dn: 0.405 inches

Pre in Leak Rate: 0.001 'ump Vacuum:

8 Pitot Tube: Pass Gas Temperatures

(°F Pitot DGM

Orifice Press DP Average

Stack Amb. Amb. DH (in H20) (in. llzO) Ideal Actual 0.09 76

359 1.25 1.26 0.12 77

352 1.69 1.68 0.10 78

354 1.41 1.40 0.10 78

358 1.40 1.40 0.10 78

363 1.39 1.40 0.11 80

365 1.53 1.53 0.11 80

363 1.53 1.53 0.10 80

351 1.42 1.42 0.09 77

356 1.26 1.26 0.10 80

359 1.40 1.40 0.10 81

364 1.40 1.40 0.10 81

367 1.39 1.39 0.09 81

369 1.25 1.25 0.09 81

369 1.25 1.25 0.09 81

366 1.25 1.26 0.08 81

359 1.12 1.13 0.13 81

356 1.83 1.83 0.12 80

355 1.69 1.69 0.10 80

360 1.40 1.40 0.09 80

367 1.25 1.25 0.09 80

369 1.25 1.24 0.10 80

370 1.38 1.38 0,13 81

371 1.80 1.80 0.10 81

358 1.41 1.40

Sonrce: DLA hdet

RIll1 3 Project No.: 2008-0206 FILTER NO.

MOISTURE

DATA N/A Total Liquid Vol. (ml) 50.3 K FACTOR 14.176 LEAKCHECKS Mid Post 0.000 cfin #1 4 in Hg #2 Pass Total Gas Temps (°F) Pump hnp. Vac Probe Filter Exit (in, Hg)

3 256 250 66 4 260 254 63 3 263 259 64 3 267 262 62 3 265 265 61 4 264 265 63 4 266 264 64 3 264 267 63 3 265 264 67 3 263 266 65 3 266 265 62 3 265 263 59 3 265 264 61 3 266 266 64 3 267 267 63 3 265 265 63 4 264 265 66 4 265 265 64 4 265 265 62 3 264 267 60 3 265 263 63 4 263 265 64 4 264 264 63 4 265 265 63 Volume Correctionscfcfcf

XAD

N/A N// N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Ws % ISO (fps)

98.5 21.0"• 96.4 24.}}
102.8 22.14 101.5 22.19 98.1 22.26 99.0 23.37 99.6 23.34 102. 22.10 103.6 21.03 101.1 22.20 100.3 22.27 99.6 22.31 100.9 21.19 99.9 21.19 100.2 21.15 101.8 19.86 99.1 25.27 100.4 24.26 102.7 22.22 10o.4 21.1• 98.7 21.19 99.6 22.35 99.7 25.50 98.8 22.19

Super Sat'd W$ i" O•at

i"' Analyzer

[•" Fyrite Vm DP (WC)

Tm

Ts

Max DH (we)

% ISO RunTime 1.165 m 2.56 mm 26.5 °C 183.1 °C Vac. 35.930 mm 60.0 rain 41.157 t"I 0.10 iu 79.7 °F 361,7 °F

4 1.415 in Vmsta Vws•a

%H•O

Qsd

Qsw

Qa 1.090 dscm

0.067 sere (meas.)

525 dscmu,

558 scmm 38.482 dscf

2,368 scf 5.8

18,550 dscfm

19,692 scfin

32,142

97.4
910 acmm acfm

6.99 m/s 22.93 ffs

-2.6

est ersonnel

(signatnre/date) Test•"

Lea• (signature/date)Location: VFR CALCULATIONS
SOlllrce: Project No.:

Point Point 2 Point 3 Point 4 Point 5 Point 6 Point 7 Point 8 Point 9 Point 10 Point 11 Point 12 Point 13 Point 14 Point 15 Point 16 Point 17 Point 18 Point 19 Point 20 Point 21 Point 22 Point 23 Point 24 0113 0.I2 0.13 0.09

O: 10 0,10
0',.12 0,12 0.10 0,09 O. 10 0,09 0.10 0.11 0,11 Oi,i2 0.11 0.09 O. 10 0.09 0.09 6169 0.10 0.10 0.10 0.09 0.09 0.10 0.09 0.10 0.09 0.10 0.08 0.09 0.13 0.10 0•12 0.10 0.10 0.10 0.09 0.14 0.09 0.14 0.10 0.12 0.13

0,09 O.IO 0.09 0.09 0.09 0.10 0.10 0.09 0.09 0.09 O.lO 0.10 0.10 0.11 0.10 0.10 0.10 0.10 0.10 0.10 0.11 0.12 0.12
•quare Root of Delta P Pitot Tube Coefficient Barometric Pressure, in. Hg Static Pressure, in. H20 Stack Pressure, in. Hg Stack Depth, in. $tack Width, in. •tack Cross-sectional

Area, ft Temperature, °F Moisture Content, % CO2 Concentration,

% 02 Concentration,

% (Cp)(e•)(P•)(Ps)(Ds) (Ws)(As)(Ts)(MC) (co2) (02)

0:84

0.84

28.53 28.53 58.0 58.0 58.0 58.0 23.36 23.36 361.9 357.5 6.9 6.0 3.0 3i0 I.•,0 16.3

0.84 28•52o.08 28.53 58.0 58.0 23,36 361.7 5.83.016.5

0.84 28.52 0.09 28.53 58.0 58.0 23.36 360.3 6.23.016.6 Molecular Weight, lb/lb-mole

(dry)

(Md)

29.16

29.13

29.14

29.14 MOlecular Weight, lb/lb-mole

(wet)

(Ms)

28.39

28.46

28.49

28.45 Velocity, ft/sec (Vs)

22.1

23.1

2•.9

22.7 J[
Stack Conditions,

acfm (Qa)

3i,•0i3

•2,32•

•21i42

3i182"} Standard Conditions,

dscfm

(Qs)

17,686

18,712

18,550

18,31611

Rev. 04111/06Location: EMISSION

CALCULATIONS

Project
Number

Start Time T/ane 1t Time, min (0)

60 60

, 60 essure, in. Hg (Pb)

28.52 28.52

28:•2 •ction Factor (Y)

0.•99 0.999

-01999- Calibration Value (Delta H@) 1:.707 1.707

i.707 de, ft (Vm)

36.3•2

41.632

41.157

39.707 •erature, °F (Tm)

75:8

85.2

79•7

80.2 Pressure, in. WC (Delta H) 1.100

1.440

1.415

1.318 H20 Collected,

mL (Vlc)

53.5

52.4

50.3

52.1 Diameter, in (Dn)

0.375

0.390

0.390

0 385 ozzle, ft (An)

0:00077

0.00083

0 00083

0.00081
en Chloride Mass, gg (M.c,)

4•, 000 Hydrogen Fluoride Mass, gg (MHv) 25•;333
Standard Meter Volume, ft (Vmstd)

34A93

38:535

3•.•81 Standard Water Volume, ff (Vwstd)

2.518

2.466

2.368 Moisture Fraction (BWS)

0.069

0.060

0.058

0.062 Meter Pressure, in Hg (Pm)

28.60

28.63

28.62

28.62 Volume at Nozzle, ft (Vn)

59.937

66.585

66.678

64.400 [sokinetic Sampling

Rate, (%) (I)

98.1

96.7

97.4

97A OGM Calibration

Check Value, (+/- 5%)

(Yqa)

-1.7

......

2.6

-2.3 Hydrogen Chloride Concentration,

mg/dscm

(C•c 0 47.5

48.6

49.6

48.5 Hydrogen Chloride Concentration,

ppmvd

(CHCl)pp

31.29

31.99

32 64

31.97 Hydrogen Chloride Emission Rate, lbs/hr

(ERHc0

3.15

3.40

3.44

3.33 Hydrogen Fluoride Concentration,

mg/dscm

(C•v)

258.2

229.1

238.6

242.0 Hydrogen Fluoride Concentration,

ppmvd

(CHF)ppm

310.'32

275.35

286,77

290,81 Hydrogen Fluoride Emission Rate, lbs/hr

(ERnv)

17.10

16.06

16.58

16.58Location:

GS Brick (Plant 36)-Roauok%

VA Date: 05/20/08 Source: DLA Ontlet Project No.: 2008-0206

Engineering Environmental.

Health & Safety. Surveying

Method 1 Velocity Traverse Data

Distance from far wall to outside of port: 76.50 in. Nipple length:

5.00 in. Depth ofDnct (Ds):.. 71.50 in. Cross Sectional Area of Duct (As): 27.88 ft No. of ports:

2 Distance A: 14.0 ft. 2.3 Duct Diameters Distance B: 70.0 ft. 11.7 Duct Diameters
Nnmber of traverse poiuts total:

Tl'averse point Numbe•

on a DiameteJ

LOCATION

OF TRAVERSE

POINTS CIRCULAR STACKS Number of traverse ports on a diameter 2 4 6 8 10 12 14.6 6.7 4.4 3.2 2.6 2.1 2 85.4 25.0 14.6 10.5 8.2 6.7 75.0 29.6 19.4 14.6 11.8 93.3 70.4 32.3 22.6 17.7 85.4 67.7 34.2 25.0 95.6 80.6 65.8 35.6 89.5 77.4 64.4 96.8 85.4 75.0 91.8 82.3 97.4 88.2 93.3 97.9 *Percent of stack diameter tiom inside wall to t•averse point.

EXAMPLE

CIRCULAR

STACK CROSS SECTION DIVIDED INTO 12 EQUAL AREAS, WITH LOCATION

OF TRAVERSE

POINTS

50
• 40i

301 Minimum number of traverse points for particulate traverses Duct Diameters Upstream from Flow Disturbance*

(Distance A)

0.5 1.0

1.5 Higher Number is Rectangtdar Stacks or Ducts

24 or 25

Flow Point of An•, Type of Disturbance Bend,Expansion, Conl•aclion, elc.) 2.0

2.5

•l 16--1

12

2 4 5 6

[ 8 or 9

7 8 9 10 Duct Diameters Downstram from Flow Disturbance*

(Distance B) Notes:

Traverse

% of Distance fi'om Point Diameter

inside wall

4.4 3.15 2 14.6

10.44 3 29.6

21.16 4 70,4

50.34 5 85.4

61.06 6 95.6

68.35

10

12 Distance fi'or¢ outside of port
8.15 15.44 26.16 55.34 66.06 73.35

QA/QC ReviewerLocation: Date: GS Brick (Plant 36)-Roanoke,

VA 05/20/08
Asse% e es Source: DLA Outlet Project No.: 2008-0206

Method 1 -Verification

of Absense

of Cyclonic

Flow (Section 11.4) Engineering. Environmental.

Health & Safety. Surveying

Sample Point

AP @ Reference 0.13 0.14

101112131415

Angle (AP=0) 5
3 0.15 7 4 0.16 6 5 0.15 6 6 0.12 5 0.10 0.13 0.16 5 0.16 6 0.15 0.13 45

161718192021
232425262728293031323334353637383940 0.14 Average

QA/QC Reviewer 5.7Location:

GS Brick (Plant 36)-Roanoke,

VA Source: DLA Outlet Project No.: 2008-0206

Method 3 Gas Analysis

Data Engineering. Environmental.

Health & Safety. Surveying

Run 1 Analysis Number

Average

Date:

5/20/08 % COz 3.03.03.03.0

% 02 17.5 17.5 17.5 17.5

% N2 79.5 79.5 79.5 79.5 Repeatability (P/F):

P

p

p

RuII 2

Date:

5/20/08 Analysis Nmnber

% CO2

% 02

% N2 1 3.0

17.0

80.0 2 3.0

17.0

80.0 3 3.0

17.0

80.0 Average 3.0

17.0

80.0 Repeatability (P/F):

P

p

p

Date: 5/20/08 % COz

% O2

% N2 3.0 17,0

80.0 3.0 17.0

80.0 3.0 17.0

80.0 3.0 17.0

80.0 P P

P Run 3 Analysis Number" 123 Average Repeatability (P/F): Acceptability for" Orsat Repeat Analysis CO2 > 4% _+ 0.3% C02 -< 4% + 0.2% O2 > 15% + 0.3% 02 -< 15% + 0.2% Ambient

Check

Analysis TyI• 02 20.5 % C02 0.0 %

Orsat report to 0.1% Fyrite report to 0.5%

QA/QC ReviewerLocation:

GS Brick (Plant 36)-Roanoke,

VA

E, ROBERTS

FI 0 0 R AT E Engineering Environmental.

Health & Safety, Surveying Source: DLA Outlet )roject No. 2008-0206

Method 4 Moisture

Data

Contents Initial Final Gain Run 1 Date:

5/20/08 Filter ID: N/A IMPINGER VOLUME,

ml 1 2 H2SO4 H2SO4 100.0 100.0 116.0 122.0 16.0 22.0 Impinger Color:

NaOH 100.0 104.0 4.0 Clear

4

5 NaOH Silica 100.0 229.0 100.0 238.4 0.0 9.4 Silica Gel Condition:

OK

7 Total

629.0 680.4 51.4

Run 2 Date:

5/20/08 Filter ID: N/A IMPINGER VOLUME,

ml 1 2

3

4

5

6

7

8

Total Contents H2SO4

H2SO4

NaOH

NaOH

Silica Initial 100.0

100.0

100.0

100.0

231.6 631.6 Final 132.0

112.0

102.0

100.0

241.6 687.6 Gain 32.0

12.0

2.0

0.0

10.0 Impinger Color: Clear

Silica Gel Condition:

OK 56.0

Contents Initial Final Gain Run 3 Date:

5/20/08 Filter ID: N/A IMPINGER VOLUME,

ml

H2SO4 100.0 H2SO4 100.0

NaOH I00.0

NaOH 100.0

Silica 228.8 134.0 112.0

100.0

100.0

237.8 34.0 12.0

0.0

0.0

9.0 Impinger Color: Clear

Silica Gel Condition:

OK Total

628.8 683.8 55.0

QA/QC ReviewerLocation: GS Brick (Plant 36 Date: 5/20/2008

.Roanoke, VA

Start Time: 10:44 AM Run [VALID

End Time: 11:49 AM

Sonrce: DLA Outlet Project No.: 2008-0206 FILTER NO.

MOISTURE

DATA N/A Total Liquid Volume (mi• 51.4 K-FACTOR 16.131

Mid

Pmnp ]--' Vac(in. LEAKCHECKS Post

Volnme Corrections 0.002 cfin #!

cf 5 in Hg #2

cf Pass Total

cf Gas Temps (•F)Imp. Probe Filter Exit XAD % ISO Vs(fps Hg.) 63 3 264 3 266 3 265 3 266 3 265 2 266 4 266 5 265 4 265 4 267 3 266 hi'l'ACK DATA !EST__)

I•,•UIPMEN•"

STACK DATA (EST__) % M•._%

est. METER BOX: 1600

Est. Tin: 80 •F Barometric: 30.00_inHg g:•.

Est. Ts: 329 F Static Press: 0.18 _in WC

AH @: 2.255

Est. dP: 0.14 in WC Stack Press: 30.01 in Hg

PITOT ID: PR-02

Est. Dn 0.375 inches
%O2: 16.5 %

NOZZLE ID: G-801 Pre %N2/CO:• "%

Dn: •"

Leak Rate: 0.005 Md: 29.22 lb/lb-mole

Diameter:

71.5 in •umpVacuum:

15 Ms: 28.43 lb/Ib-mole

StackArea:

27.88 •

PitotTnbe:

Pass

• Gas Temperaa•res

(°F)

• SampleTime Pitot DGM

Orifice Press Dry •as ivleter • 0nmutes)

Reading (ft •) Tube Average

Stack AH (in. tl20)
Arab. Amb. Begin End 65

67 ideal Actnal A-I 0.00 5•

35•.064

0.12

65

329 1'1"88 1,88 .00 0.00

35 .4 8

0. 3

66

a.03 2.03 10.00 15.00

358.957

0 12 69

336 1.88 1.88 •5.00 20.00

362.340

0.13

71

335 2.05 2.05 20.00 25.00

365.922

0.1l

74

336 1.74 1.75 25.00 30.00

369.208

0.07

77

334 1.12 1.12 B-I 30.00 35.00

371.867

0.12

77

335 1.91 1.91 35.00 40,00

375.323

0.18

81

335 2.88 2.88 40.00 45.00

379.355

0.14

82

335 2.25 2.25 45.00 50.00

383.008

0.13

83

336 2.09 2 09 50,00 55.00

386.743

0.11

84

335 1.78 1.77 6 55.00 60.00

390.068

0.09

84

334 1.46 1.45 3 266 60.00 393.142

Final DGM:

393.142

i''" Orsat

•"• Analyzer

• F/|•te

64 63 265 66 N/A 101.3 23.9 266 47 N/A 102.3 24,9 265 47 N/A 101.5 24.0 267 51 N/A 102.9 24.9' 264 54 N/? 102.0 23.0• 265 55 N/A 102.6 18.3' 267 67 N/A 102.1 24.0 266 55 N/A 96.8 29.4 268 53 N/A 99.1 25.92 264 54 N/A 105.0 25.01 265 55 N/A 101.3 22.9• 265 55 N/A 103.4 20.7[

Saturated Vm AP (in WC)

Tm

Ts Max RunTime 1.163 m

3.03 mm 24.5 °C 168.1 °C Vac. 60.0 min 41.078 ft

0.12 in 76.1 °F 334.6 °F

5 Vm• Vwstd

% H•O

Qsd

Qsw 1.121 dscm

0.069 scm I(n,eas.)l

693 dscmm

736 scmm 39.570 dscf

2.419 scf

5.8

24,484 dscfm

25,992 scfm
QA/QC Reviewer All (in WC)

%1SO

Vs 48.810 mm

7.47 m/s 1.922 in

97.9 Qa

24.52f•s X•(qa 1,162 acmm 41,023 acfinLocatiou: GS Brick (Plaut 36 Date: 05/20/08 STACK DATA (EST) % Moisture:

6.0 % est. Barometric: 30.00 in Hg Static Press: 0.18 in WC Stack Press: 30.01 in Hg %CO2: 3.5 % %02: 16.5 %N2/CO: 80.0 %

•-Roanok% VA

Start Titne: 12:30 PM Run 2 ]VALID

End Ti•ne: 1:39 PM EQUIPMENT METER BOX: 1600 Y: 1.021 AH@: 2.255 inH20 STACK DATA (EST), FILTER
Est. Tin: 76 °F

N/A Est. Ts: 335 °F Est. dP: 0.12 in WC Est. Dn: 0.390 inche• PITOT ID PR-02 Cp: 0.84 NOZZLE ID: G-801 Dn: 0.375 in

Pre Leak Rate: 0.002 Mid Source: DLA Outlet Project No.: 2008-0206 MOISTURE

DATA Total Liquid Volume (ml) 56.0 K FACTOR 16.175 LEAK CHECKS Post 0.000 cfin

Volume Corrections #1 cf

A-I23456B-I23456 Md: 29.22 Ib/Ib-mol¢ Ms: 28.55 lb/lb-mole Sample Time (minutes) Dry Gas Meter Reading (f13) Diameter:

71.5 in 'ump Vacuum:

10 Stack Area: 27.88 flz

Pitot Tube: Pass Pitot Gas Temperatures

Begin Eud 0.00 5.00

393.315 5.00 10.00

396.727 10.00 15.00

400.400 15.00 20.00

404,040 20.00 25.00

407.575 25.00 30.00

411.300 30.00 35.00

414,320 35,00 40.00

417.810 40.00 45.00

421.205 45.00 50.00

424.708 50.00 55.00

428,358 55.00 60.00

431.965 60.00 435.036

Final DGM:

435,036

DP DGM

Orifice Press. __•,Average Stack AH (in. H20)
Arab. {in. H20 Ideal Actual 0.12 84

335 1.97 1.97 0.13 86

336 2,14 2.14 4 0.13 87

337 2.14 2.t4 4 0.12 87

337 1.98 1.98 4 0.12 87

337 1.98 1.98 4 0.11 86

337 1.81 1.82 4 0A2 84

335 1.97 1•98 4 0.11 85

334 1.81 1.81 4 0.12 84

336 1.97 1.98 4 0.13 84

336 2.13 2.13 5 0.12 84

336 1.97 1.98 4 0.10 84

363 1.59 1.59 3

•"• Orsat

Analyzer

}•" Fyrite

5 in Hg #2 Pass Total Pump ---•s Temps (•E)

Vac Imp. (iu. ,Probe Filter Exit Hg

3 255 251 65 265 259 61 262 263 62 266 265 63 267 266 64 265 266 65 265 267 66 265 265 53 264 266 53 266 268 52 265 265 54 267 265 55

cf

XAD %ISG Vs(fps)

N/? 98.7 "• N/A 101.8 24.96 N/A 100.8 24.97 N/A 101.8 23.99 N/A 107.3 23,99 N/A 91.0 22.97 N/A 100.9 23.96 N/A 102.3 22.93 N/¢ 101.4 23.98 N/A 101.5 24.96 N/A 104,4 23.98 N/A 98.9 22.26

Saturated Vm Ruo Time

1.181 m • 60.0 rain 41.721 ft •¢• Vtns•a

Vwst 0.075 sem 1.119 dscm 39.524 dscf

2.636 scf AP (in WC)

Tm 3.02 mm 29.5 °C 0.12 tn 85.2 °F %H20 Qsd (meas,) 6.3 688 dscmm 24,286 dscfm

Ts

Max AH (in WC) 170.1 °C Vac. 49.742 mm 338.3 °F 5 1.958 in Qsw Qa 734 scmm

1,164 25,918 scfm

41,098

%!SO

98.6

acfm

Ws 7.49 m/s 24.57 fl/s gqa
-1.9
QA/QC ReviewerLocation: Start Time: 2:18 PM Date: End Time: 3:22 PM

A-I23456B-I23456 GS Brick (Plant 36)-Roanoke•

VA 05/20/08 Rnn 3 [VALID STACK DATA (EST) 6.3 % est. 30.00 in Hg 0.18 in WC 30.01 in Hg

EQUIPMENT MEYER BOX: 1600 Y: 1.021 AH@: 2.255 PITOT ID: PR-02 in H20 STACK 'bATA (EST)
Est. Tin: 85 °F Est. Ts: 338 °F •Est. dP: 0.12 in WC Est. Dn: 0.388 inches % Moisture: Barometric: Static Press: Stack Press: %CO2: %02: %N2/CO: 3.5 % 16.5 % 80.0 %

Cp: 0.84 NOZZLE ID: G-801 Dn: 0.375 in Source: DLA Outlet Project No.: 2008-0206 FILTER NO.

MOISTURE

DATA N/A Total Liquid Volume 0hi) 55.0 K FACTOR 16.288 LEAK CHECKS Pre Mid Post Leak Rate: 0.000

0.000 cfin

Volume Corrections #1 cf Md: 29.22 lb/lb-mole Ms: 28.51 lb/lb-mole Sample Time (minntes) Dry Gas Meter Reading (ft 3) Begin End 0.00 5.00

435.468 5.00 10.00

438.460 10.00 15.00

442.200 15.00 20.00

445.755 20.00 25.00

449.400 25.00 30.00

452.870 30.00 35.00

456.076 35.00 40.0(

459.483 40.00 45.00

462.930 45.00 50,00

466.560 50.0( 55.00

470.710 55.00 60.00

474.276 60.00 477.500

Final DGM:

477.500

Diameter:

71.5 in Stack Area: 2"•'•--.88 flz 'ump Vacuum:

10 Pitot Tube: Pass Gas Temperatures

(°F Pitot DGM

Orifice Press. DP Average

Stack AH (in. H20)
Anlb. (in. H20 Ideal Actual 0.1( •6

334 1.61 1.62 3 0.15 76

335 2.41 2.42 4 0.13 77

335 2.10 2.11 4 0,13 77

336 2.09 2.09 4 0.12 78

335 1.94 1.94 4 0.10 78

334 1.62 1.62 4 0.12 76

334 1.93 1.94 4 0.12 78

334 1.94 1.94 4 0.13 78

335 2.10 2.10 5 0.18 78

336 2.90 2.90 6 0.12 78

335 1.94 1.94 5 0.11 79

334 1.78 1.78 5 6 in Fig Pass Total Te•,•r)...•.o, Gas Pump hnp. Vac Probe Filter Exit (in. Hg) XAD

259 262 65 N/A 262 263 55 N/? 265 267 45 N/A 265 265 47 N/A 267 266 49 N/A 265 265 49 N/A 264 264 53 N/A 265 265 51 N/A 264 266 49 N/A 264 263 51 N/? 264 264 52 N/? 266 265 55 N/A

cfcf

% ISO: !•i

96.3 98.6 26.81 100.4 24.96 103.0 24.97 101.7 23.98 102.8 21.87 100.2 23.96 101.0 23.96 102.3 24.96 99.6 29.38 104.5 23.98 98.4 22.94

•'"" O•sat

Analyzer

• Fyri|e Saturated Vm Run Time

1.190 m 60.0 min 42.032 ft Vnls m

Vws• dscm 0.073 scm 1.144 40.400 dscf

2.589 scf AP (in WC)

Tm

Ts Max 3.18 mm

25.2 °C 168.2 °C Vac. 0.13 in 77.4 °F 334.8 °F 6 %HzO Qsd

Qsw (meas.)] 708 dscmm

753 scram 6.0 25,012 dscfin

26,609 scfm QA/QC Reviewer AH (in WC)

%1SO

Vs 51.647 mm 2.033 in

7.65 m/s 97.9 25.11 ft/s Qa1,190 acmm 42,005 acfm

-2.1I, ocation: GS Brick (Plant 36)-Roanol

Sourcei DLA Outlet Project No.: 2008-0206
Run Run 2

Run 3 5/20/08 5/20/08

5/20/08 3tart Time 10:44 AM 12:30 PM 2:18 PM Time 11:49 AM 1:39 PM 3:22 PM Time, rain 60

60

60

Average

60 VELOCITY HEAD, in. WC 0.12 0.12

0.10 2 0.13

0.13

0.15 0.12 0.13

0.13 0.13 0.12

0.13 5 0.11

0.12

0.12 6 0.07

0.11

0.10 Point 7 0.12

0.12

0.12 8 0.18

0.11

0.12 9 0.14

0.12

0.13 10 0.13

0.13

0.18 Point 11 0.11

0.12

0.12 12 0.09

0.10

0.11 CALCUI,ATED DATA Square Root of dP (in. WC) l/z 0.346

0.345

0.354 Coefficient (Cp)

0.84

0.84

0.84 Pressure, in. Hg

(Pb)

28.52

28.52

28.52 3tatic Pressure, in. H20 (Pg)

0.11

0.10

0.12 Pressure, in. Hg (Ps)

28.53

28.53

28.53 Depth, in. (Ds)

71.50

71.50

71.50 Stack Cross-sectional

Area, ft

(As)

27.88

27.88

27.88 °F (Ts)

334.6

338.3

334.8 °R (Ts)

794.6

798.3

794.8 2ontent, % (MC)

5.8

6.3

6.0 Concentration, % (CO2)

3.0

3.0

3.0 Concentration, % (02)

17.5

17.0

17.0 Weight, Ib/lb-mole

(dry)

(Md)

29.18

29.16

29.16 Molecular Weight, Ib/lb-mole

(wet)

(Ms)

28.53

28.46

28.49 locity, ft/sec (Vs)

24.5

24.6

25.1

0.11 0.14 0.13 0.13 0.12 0.09 0.12 0.14 0.13 0.15 0.12 0.10
0.348 0.84 28.52 0.11 28.53 71.50 27.88 335i9 795.9 6,03.0 i7.2 29.17 28.49 24.7 VOLUMETRIC FLOW RATE At Stack Conditions,

acfm (Qa)

41,023

41,098

42,005

41;375 )nditions, dscfm

(Qs)

24,484

24,286

25,012Location: GS Brick (Plant 36)-Roanoke,

VA Source: DLA Outlet Project No.: 2008-0206
Run Number Date Start Time 3top Time Run

Run 2 Run 3 05/20/08 05/20/08

05/20/08 t0:44 AM 12:30 PM 2:18 PM 11:49 AM 1:39 PM 3:22 PM Average

INPUT DATA ?•un Time, min Barometric Pressure, in. Hg Meter Correction Factor Orifice Calibration

Value Meter Volume, f• Meter Temperature,

°F Meter Temperature,

°R Meter Orifice Pressure, in. WC Volume H20 Collected, mL qozzle Diameter, in Area of Nozzle, ft Hydrogen Chloride Mass, ug Hydrogen Fluoride Mass, ug

(0)

60

60

60

60 (Pb) 28.52

28.52

28.52

28.52 (Y) 1.021

1.021

1.021

1.021 (AH @) 2.255

2.255

2.255

2.255 (Vm) 41.078

41.721

42.032

41.610 (Tm) 76.1

85.2

77.4

79.6 (Tin) 536.1

545.2

537.4

539.6 (AH) 1.922

1.958

2.033

1.971 (VIe) 51.4

56.0

55.0

54.1 (Dn) 0.375

0.375

0.375

0.375 (An) 0.00077

0.00077

0.00077

0.00077 (Mncl) 38,000

40,000

43,000

40,333 (MHF) 5,400

5,500

5,700

5,533 Standard Meter Volume,

ISOKINETIC

DATA (Vmstd) 39.570

39.524

40.400

39.832 Standard Water Volume, fi• Moisture Fraction Meter Pressure, in Hg Volume at Nozzle, f• •lsokinetic Sampling Rate, (%) DGM Calibration

Check Value, (+/- 5%)

(Vwstd)

2.419

2.636

2.589

2.548 (BWS) 0.058

0.063

0.060

0.060 (Pr•0 28.66

28.66

28.67

28.66 (Vn) 66.276

66.853

67.866

66.998 (I) 97.9

98.6

97.9

98.1 (Yqa) 1.1

-1.9

-2.1

1.7 EMISSION CALCULATIONS Hydrogen Chloride Concentration,

mg/dscm

(C•c•) Hydrogen Chloride Concentration,

ppmvd

(Cnc•pv, Hydrogen Chloride Emission Rate, lbs/hr

(ERact) Hydrogen Fluoride Concentration,

mg/dscm

(CnF) Hydrogen Fluoride Concentration,

ppmvd

(CHF)ppm 3ydrogen Fluoride Emission Rate, lbs/hr

(ERnv)

33.9

35.7

37.6 22.3 23.5

24.8 3.11 3.25

3.52 4.8 4.9

5.O 5.8 5.9

6.0 0.44 0.45

0.47

35.7 23 5

4.9 59Appendix CYour Project #: 2008-0206 Site: GENERAL

SHALE BRICK Attention: Chris Lemay E Roberts Alley & Associates 1931 Central Pky SW Suite B Decatur, AL USA 35601 Report Date: 2008/06/09 CERTIFICATE OF ANALYSIS MAYO(AM JOB #: A851380 Received: 2008/05/21,

12:00 Sample Matrix: lmpinger Solution # Samples Received:

6
,•nalyses Hydrogen Halides in H2SO4 Imp. (M26A) Final Volume of Impinger Date Quantity Extracted 6 2008/05/29 6 2008/05/29

Date Analyzed

Laboratory Method 2008/05/29 BRL SOPo00104 2008/06/04

Method Reference EPA Method 26A

Encryption Key •

Hadley
09 Jun 2008 13:29:50 -04:00 Please direct all quesuons regaramg [n•s Certificate of Analysis to your Project Manager.
JAMES HARTLEY, Burlington Project Manager Email: James.Hartley@MaxxamAnalytics.com Phone# (905) 332-8788 Ext:288

Maxxam has procedures

in place to guard against improper use of the electronic signature and have the required "signatories",

as per section 5.10.2 of ISO/IEC 17025:2005(E),

signing the reports. SCC and CAEAL have approved this reporting process and electronic report format.

Maxxam Analytics Inc. is a NELAC accredited laboratory. Certificate # CANA001. Use of the NELAC logo however does not insure that Maxxam is accredited for all of the methods indicated. This certificate shall not be reproduced

except in full, without the written approval of Maxxam Analytics Inc. Maxxam has procedures in place to guard against improper use of the electronic signature and have the required "signatories", as per section.

Total cover pages:
Page of 6 This document is in electronic format, hard copy is available on request. 5555 North Service Road, Burlington, Ontario, Canada L7L 5H7

Tel: (905) 332-8788 Toll Free: (800) 668-0639 Fax: (905) 332-9169Maxxam

Job #: A851380 Report Date: 2008/06/09 E Roberts Alley & Associates Client Project #: 2008-0206 Project name: GENERAL

SHALE BRICK
RESULTS OF ANALYSES

OF IMPINGER

SOLUTION

Maxxam ID Sampling Date

Volume Miscellaneous Parameters Hydrochloric Acid Hydrochloric Acid

Y74398 2008•5•0 Units RUN 01-DLA OUTLET

Y74400

Y74401

Y74402 2008/05/20 2008/05•0

2008/05/20 RUN02-DLA OUTLET RUN 03-DLA RUN 01-DLA OUTLET INLET

DL QC Batch

!Hydrochloric Acid Hydrochloric Acid Hydrofluoric Acid Hydrofluoric Acid Hydrofluoric Acid Hydrofluoric Acid

ml

ugugugugugugugug
RDL Reportable Detection Limit QC Batch Quality Control Batch

270

260

38000

54OO

260

3O0

40000 43000

46000

55OO 5700

250000

1524832

400 1524839 4O0 1524839 400 1524839 1000 1524839 200 1524839 200 1524839 200 •1524839 4000 1524839

!Maxxam ID Sampling Date Y74403

Y74404 2008/05/20 2008/05/20 Units RUN02-DLA

RUN 03-DLA DL INLET INLET

•/olume ml Vliscellaneous Parameters Hydrochloric Acid

ug Hydrochloric Acid

ug Hydrofluoric Acid

ug Hydrofluoric Acid

ug
RDL Reportable Detection Limit QC Batch Quality Control Batch

280

270

53000 54000 250000 260000

•C Batch

1524832

1000 1524839 1000 1524839 4000 1524839 4000 1524839

5555 North Service Road, Burlington, Ontario, Canada L7L 5H7 Page 2 of 6

Tel: (905) 332-8788 Toll Free: (800) 668-0639 Fax: (905) 332-9169Maxxam

Job #: A851380 Report Date: 2008/06/09 E Roberts Alley & Associates Client Project #: 2008-0206 Project name: GENERAL

SHALE BRICK

Test Summary

Maxxam ID Sample ID Matrix
Test Description •ydrogen Halides in H2SO4 Imp. (M26A) Final Qolume of Impinger

Y74398 RUN 01-DLA OUTLET Impinger Solution Instrumentation

Batch tC/SPEC 1524839 1524832 Collected

2008/05/20 Shipped Received 2008/05/21

2008/06/04 Prepared Analyzed

Analyst 2008/05/29 2008/05/29

A S 2008/06/04 FMO

Maxxam ID Y74400 Sample ID RUN 02-DLA OUTLET Matrix Impinger Solution Test Description Instrumentation

Batch Hydrogen Halides in H2SO4 Imp. (M26A)

IC/SPEC

1524839 IFinal •olume of Impinger 1524832 Collected

2008/05/20 Shipped Received 2008/05/21 Prepared Analyzed

Analyst 2008/05/29 2008/05/29

A S 2008/06/04 2008/06/04

FMO

Maxxam ID Y74401 Sample ID RUN 03-DLA OUTLET Matrix Impinger Solution Test Description Instrumentation

Batch Hydrogen Halides in H2SO4 Imp. (M26A)

IC/SPEC

1524839 Final •}olume of Impinger 1524832 Collected

2008/05/20 Shipped Received 2008/05/21 Prepared Analyzed

Analyst 2008/05/29 2008/05/29

A S 2008/06/04 2008/06/04

FMO

Maxxam ID Y74401 Dup Sample ID RUN 03-DLA OUTLET Matrix Impinger Solution
Test Description IHydrogen Halides in H2SO4 Imp. (M26A)

Maxxam ID Sample ID Matrix
Test Description [Hydrogen Halides in H2SO4 Imp. (M26A) [Final •olume of Impinger Instrumentation

Batch IC/SPEC 1524839 Collected

2008/05/20 Shipped Received 2008/05/21 Prepared Analyzed

Analyst 2008/05/29 2008/05/29

A S

Y74402 Collected

2008/05/20 RUN 01-DLA INLET Shipped Impinger Solution Received

2008/05/21 Instrumentation Batch

Prepared

Analyzed

Analyst IC/SPEC 1524839

2008/05/29

2008/05/29

A S 1524832 2008/06/04

2008/06/04

FMO

Maxxam ID Y74403 Sample ID RUN 02-DLA INLET Matrix Impinger Solution Test Description Instrumentation IHydro,clen Halides in H2SO4 Imp. (M26A)

IC/SPEC IFinal Volume of Impinger Collected

2008/05/20 Shipped Received 2008/05/21 Batch Prepared

Analyzed

Analyst 1524839 2008/05/29

2008/05/29

A S 1524832 2008/06/04

2008/06/04

FMO

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Tel: (905) 332-8788 Toll Free: (800) 668-0639

Fax: (905) 332-9169I vll

a

a m

Maxxam Job #: A851380 Report Date: 2008/06/09 E Roberts Alley & Associates Client Project #: 2008-0206 Project name: GENERAL

SHALE BRICK

Test Summary

Test Description I_•ydro,qen Halides in H2SO4 Imp. (M26A) •-•inal •olume of Impinger

Maxxam ID Y74404 Collected

2008/05/20 Sample ID RUN 03-DLA INLET Shipped Matrix ImpingerSolution Received 2008/05/21 Instrumentation Batch

Prepared

Analyzed

Analyst iC/SPEC 1524839

2008/05/29

2008/05/29

A S 1524832 2008/06/04

2008/06/04

FMO

5555 North Service Road, Burlington. Ontario, Canada L7L 5H7 Page 4 of 6

Tel: (905) 332-8788 Toll Free: (O00) 668-0639 Fax: (905) 332-9169Maxxam

Job #: A851380 Report Date: 2008/06/09 E Roberts Alley & Associates Client Project #: 2008-0206 Project name: GENERAL

SHALE BRICK

Results relate only to the items tested.

GENERAL COMMENTS

5555 Norf• Service Road, Burlington, Ontario, Canada L7L 5H7 Page 5 of 6

Tel: (905) 332-8788 Toil Free; (800) 668-0639 Fax: (905) 332-9169QA/QC E Roberts Alley & Associates Attention: Chris Lemay Client Project #: 2008-0206 P.O. #: Project name: GENERAL

SHALE BRICK Quality Assurance

Report Maxxam Job Number: GA851380
Date Batch Num Init 1524839 A S Analyzed QC Type

Parameter yyyy/mm/dd

Value %Recovery

Units

QC Limits MATRIX SPIKE (Y74401) Hydrochloric

Acid 2008/05/29

0, RDL=400

97 ug

80- 120 Hydrofluoric Acid 2008/05/29

0, RDL=200

103 ug

80 120 Spiked Blank

Hydrochloric

Acid 2008/05/29

0, RDL=200

96 ug

90 110 Hydrofluoric Acid 2008/05/29

0, RDL=200

98 ug

90 110 Method Blank

Hydrochloric

Acid 2008/05/29

ND, RDL=200

ug Hydrofluoric Acid 2008/05/29

ND, RDL=200

ug RPD Hydrochloric

Acid 2008/05/29

0.06

%

20 Hydrofluoric Acid 2008/05/29

0.7

%

20 kiD Not detected :•PD Relative Percent Difference SPIKE Fortified sample

Page 6 of 6 This document is in electronic format, hard copy is available on request. 5555 Nonth Service Road, Burlington, Ontario, Canada L7L 5H7

Tel: (905) 332-8788 Toll Free; (800) 668-0639 Fax: (905) 332-9169SAIVIPLE RECEIPT

LOG

Maxxam Analyties

Inc. BILL FCD-00051/1 Page of

Lab Name.- Pickup/received by (Name)." Pickup/received by (Signature): Client Project 1D: Maxxam Analytics

Inc,• Burlingion

Laboratory • Date:•/•/A/

rime:

Cooler ID

Temp.Appendix DModel

%: 8-275 Serial 4:1665

IMPORTANT
IMPORTANT APEX INSTRUMENTS

EPA Method 5 522 SoEies Meter BOX Cmlibration
Pro-Test Orifice M•thod English M•ter Units, English K' Factor

Filenam8: C:\Documents

and Settlngs\paulg\Desktop\[D•4

Cal Template.xls]522ORPR5 Revised: 7/25/95

Version: 2.2

Date: 4/11/2008 Barometrl• Pressure:

29.26 Gin. Theoretical Critical Vacuous:--->

13.80 (in.

For valid test results, the Actual Vecutu• should be 2 in. Hg greater than the Theoretical

critical Vacutun shown above, The Critical Orifice Coefficient,

R', must be entered in English units, (ft)^3•(deg R)^0.5/((in.Hg)•(min)).

DRY GAS •ETERREADINGS -CRITICAL ORIFICEREADINGSd8 (in s20)
0.47 0.97
1.40 2.45
3.85

Volume Volume Volume Initial Temps. Final Temps. Orifice K' Orifice Actual Ambient Temperature Time Initial Final Total Inlet Outlet •nlet Outlet Serial| Coefficlen%

Vacuum Initial Final Average (min) (cuft) (cuft) (c• ft) (dog F) (dog F} (dog F) (dog F) (nt•nber) (sea above} (in Hg) (dog F} (dog F) {d•g F) 15.00 622.600 620.673 6.073 79.0 79.0 79.0 79.0 DGll 0,307 20.0 80,0 01.0 80,5 10.00 635.500 641.285 5.785 80.0 80.0 81.0 81.0 DG16 0.448 19.5 81.0 80.0 80.5 I0.00 641,600 648.640 7.040 80.0 80.0 81.0 81.0 DG19 0.535 18.5 81.• 63.0 82.0 5.00 649.300 653.735 4.435 80.0 80.0 81.0 81.0 DG24 0,672 16.5 81.0 81.g 81.0 5.00 660,600 666.370 5.770 82.0 82.0 83.0 83.0 •G32 0.877 14.5 80.0 82.0 01.0

ORIFICE ORIFICE

VOII/ME VOLUME

VOIMME VOLL•E VOLUME CORRECTEO CORRECTED CORE Nf•4INAL Vm(std} Vm(std)

Vcr(std) Vcr(std) (C• ft) (liters}

(cuft} {liters} (cu 5.822 164.9

5.796 164.• 6.069 5,536 156.8

5.638 159.7 5.904 6=746 191.1

6.724 190.4 7.061 4,261 120.7

4.227 119.7 4.430 5.543 157.0

5.5•6 •56.2 5.782

CALIBRATION

FACTOR

CALIBRATION

FACTOR
Y Value Variation

Value Value fariation {n•mbsr) (nurixbo_e)

(in H20) (rrm't H20) (in H20) 0.995 -0.004

1.696 43.09 -O.Oll 1.018 0.019

1.640 41.85 -0.068 0.997 -0.003

1.664 42.26 -0.043 0.992 -0,008

1.842 46.79 0.135 0.995 -0,004

1,693 43.01 -0.014
Average y

0.999 1,707 43,36 < Average

For Calibration

•actor Y, the ratio of the reading of the calibratio•

to the dry gas meter, acceptable tolerance of individual values from the average is +-0.02. For Orifice Calibration

Factor dH@, the orlflc• differential

pressure in inches of H20 that equates to 0.75 ofm of air at 68 F and 29.92 inches of Hg, acceptable tolerance of individual values from the average is +-0.2.Date: Meter Box ID:
Reference Calibrator: Serial No.: Cal. Expiration: Thermocouple

Calibration 2/8/2008 #1665
Extech Model 42312 55000154 9/23/2007

(1) Stack

(2) Probe (3) Filter (4) Impingers
(5) Auxiliary

•6) DGM Inlet/Outlet

(Ambient Check)

F

R

F

R

% 0 460

5

465

-1.1 50 510

53

513

-0.6 100150300500150300150 30003268 560

103

563

-0.5 610 154

614

-0.7 760 306

766

-0.8 960 505

965

-0.5 610 155

615

-0.8 760 307

767

-0.9 610 155

615 760 307

767 460 6

466 492 36

496

-0.8 528 71

531

-0.6 -0.8 -0.9 -1.3

0 460

6

466

-1.3 50 510

53

513

-0.6 100 560

103

563

-0.5 150 610 614

-0.7 300500 760960 533

154 30650574

766965534 73

-0.8 -0.5
Note: Accuracy must be within +/- 2%
°R °F + 460

Accuracy Reference

Temp (°R) Display Temp (°R) Reference Temp (°R)

X 100

Completed by: Paul E. GreenE. R 0 B E R T $

• C 0 R 0 R A T E D Engineering. Environmental.

Health & Safety. Surveying

Date: Calibrated By:

Nozzle Calibration

E. Roberts Alley & Associates,

Inc. 1931 Central Parkway SW, Suite S Decatur, AL 35601 Phone: (256) 351-0121 Fax: (256) 351-0151 ERA&A Project No. •008•0206

Notes: 0.003

0.375 0 002 0.390

a: Three different nozzle diameter measurements-record

to 0.001" b: Max Diff maximum difference between any two diameters is 0.004

c: Average D average ofDl, D2, and D3

Rex. 03 03 06E, R 0 B R T S

I• e 0 R P 0 R A T E D Engineering. Environmental.

Health & Safety. Surveying
Inspected Inspection Date: Probe ID:

Sample Probe Calibration

E. Roberts Alley & Associates,

Inc. 1931 Cent,al Parkway SW, Suite S Decatur, AL 35601 Phone: (256) 351-0121 Fax: (256) 3511-0151 ERA&A Project No. 2008=0206

Geometric Pitot Calibration Pitot Tube Openings

Damaged?

i" Yes i• No Pitot Tube Alignment

OK?

iT Yes f•'• No Calibration Required?

f'• Yes • No
External Tube Diameter

(Dt)*

Dt =0.375 *Dr must be between 3/16 abd 3/8 Base-to-plane opening distances

(Pa and Pb)*

Pa 0.4375 *Pa Pb Pb 0.4375 PaJDt 1.17 (Must be between 1.05 and 1.5) lfpitot does not xneet the criteria above, it must be repaired•calibrated

in accordance with Sections 4.1.2 through 4.15 of Method 2. Baseline coefficient of 0.84 applied to pitots that meet inspection criteria. Thermocouple Calibration

Ice

'); Ambient Boiling H20 Hot Oil Specification % Difference

1.5

525.0

67:0

527.0

2.0

0.4%

Comments:

Rex.' 03.03,,06Model

#: C5000 Serial @: 1600

IMPORTANT
IMPORTANT APEX INSTRUMENTS
EPA Method 5 522 Series Meter Calibration
Pre-Test Orifice Method English Meter Box Units, English K' Factor

Filename: C:\Documents

and 8ettings\paulg\Desktop\|DGM

Cal Template.xls]522ORPR5 Revised: 7/25/95

Version: 2.2

Date: 12/3/2007 8arometri• Pressure:

29.79 (in. Hg) Theoretical Critical Vacuum:--->

14.05 (in.

valid test results, the Actual Vacut• should be to in. Hg greater than the Theoretical

Critical Vacul•m shown above. The Critical Orifice Coefficient,

K', must be entered in English •nits, (ft)^3•(deg R)^0.5/((in.Hg),(min)).

METER READINGS -CRITICAL ORIFICEREADINGSdH (in H20)
0.70
1.25
2.20
4.20 6.50

Volume Volume Volume Initial TeI•ps, Final Temps. Orifice

Orifice Actual Ambient Temperature Time Initial Final Total Inlet Outlet Inlet Outlet Serial# Coefficien%

VacuLt• Initial Final Average (min) (cuft) (cuft) (cuft) (deg F) (deg F) (deg F) (deg F) (numbeD) (see above) (in Sg) (deg F) (deg F) (deg F) 15.00 780,200 786.463 6•263 67.0 67.0 68.0 68.0 DG48 O.331 22.0 70.0 69.0 69.5 10.00 707.100 792.677 5.577 68.8 68.0 69.0 69.0 DG55 0.438 21.5 69.0 69.0 69.0 18.00 801.200 808.388 7.188 70.0 70.0 71.0 7•.0 DG63 0.562 19.5 70.0 70.0 70.0 5.00 809.200 814.153 4,953 71.0 71.0 72.0 72.0 DG73 0.780 16.5 70.0 70.0 70.0 5.00 814.800 820.858 6.058 72.0 72.0 73.0 73.0 DGSl 0.959 14.0 70.0 71.0 70.5

METER ORIFICE GAS METER

ORIFICE

VOLt• VOLU•E

VOLUME

VOLUME CORRECTED CORRECTED N•INAL Vm(std) Vm(std)

Vcr(std) Vcr(std) (cuft) (liters)

(c• ft) (liters) (cuft) 6.250 177.0

6.•28 182.0 6.477 5.562 157.5

5.668 160.5 5,706 7.159 202.7

7,272 206.0 7.335 4.948 140.1

5.044 142.8 5.087 6.074 172.0

6.204 175.7 6.263

CA•LIBEATION

FACTOR

CALIBP4%TIOM

FACTOR dH@ Valu• Variation

Value Value fariation (number) (nt•nb•r)

(in H20) (•m H20) (in H20) 1.028 0.008

2,137 54.28 -0.i18 1,019 -0.002

2,177 55.30 -0.078 1.016 -0.005

2,319 58.90 0.064 1.019 -0.001

2,296 58.32 0.041 1.021 0.001

2.344 59.54 0.090

Note: Average 1.021 2.255 57.27

Average

For Calibration

Factor Y, the ratio of the reading of the calibration

met8r to the dry meter, acceptable tolerance of individual val•es from the average +-0.02. Orifice Calibration

Factor dH@, the orifice differential

pressure in inches Of H20 that equates to 0.75 cfm of air at 68 and 29.92 inches of Hg, acceptable tolerance of individual values from the average is +-0.2.Date: Meter Box ID:
Reference Calibrator: Serial No.: Cal. Expiration: Then'nocouple

Calibration 1/2/2008 #1600
ExtechMode142312 55000154 9/23/2007

Stack

(2) Probe •3) Filter (4) Impingers
(5) Auxiliary

(6) DGM Inlet/Outlet

(Ambient Check) 460

460

0.0 50 510

47

507

0.6 100 560

97

557

0.5 150 610

149

609

0.2 300 760

304

764

-0.5 500 960

508

968

-0.8 150 610

151

611

-0.2 300 760

306

-0.8 151306 150 610 766611766 760 300

-0.2 -0.8 0 46O

0

460

0.0 32 492

29

489

0.6 68 528

66

526

0.4 460 510 5O100150 4798150 30650968 30050071 560

460507558610766969528 610 760960531

0.00.60.40.0-0.8 -0.90.6 Note: Accuracy must be within +/- 2%
°R °F + 460

Accuracy Reference

Temp (°R) Display Temp (°R) Reference Temp (°R)

X 100

Completed by: Paul E. GreenLocation: GS Brick (Plant 36)-Roanoke,

VA

ROBERTS

INCORPORATED Source: DLA Outlet Project No.: 2008-0206

Calibrations
Engineering. Environmental.

Health & Safety. Surveying

Nozzle Calibrations

Calibrated

By:

Nozzle ID Date Run No(s) (iuitials) Number
5/20/08 SC

1-3

G-801

•Three different nozzle dial•'•ter measurements-record

to 0.001 inches. Maximum difference between any two diamete• is 0.004 inches.

Nozzle Diameter
D1 D2

D3 inches inches

inches 0.376 0.375

0.375

Max Difference inches 0.001

Average D
inches 0.375

Pitot Calibrations

Calibrated

By:

Probe Date Run No(s) (initials)

ID No. Pitot Tube Pitot Tube Calibration Opening Damage Aligmnent

Required
5/20/08 SC

External Tub{ Diameter (Dt)* *Dt must be between 3/16 aud 3/8 1-3

PR-02

No

Ok

No

Dt =0.375

Base-to-plane

opening distances (Pa and Pb)* Pa 0.4375 Pb 0.4375 *Pa Pb Pa/Dt I. 17

Must be between 1.05 and 1.5
If pitot does not meet the criteria above, it must be repaired/calibrated

in accordance with Sections 4.1.2 through 4.15 of Method 2. Baseline coefficient of 0.84 applied to pitots that meet inspection criteria.
Probe Tbermocouple

Calibration

Probe ID No.

PR-02

Reference Temperature (°F) (°R) 65.0 525.0

Indicated Temperature (°F) (°R) 64.0 524.0

Difference Temperature (oF)1.0

Difference %0.2%Appendix E 1From:

Brandy Hughes Sent: Thursday,

May 22, 2008 12:22 PM To: Chris LeMay Subject: FW: General

Shale Brick, Roanoke

Plant 36 Production

Data Brandy Hughes Project Engineer E. Roberts Alley & Associates,

Inc. 300 10th Avenue South Nashville, TN 37203 615-850-3508 (Direct) 615-373-1567 (Main) 615-373-3697 (Fax) 615-476-0559 (Cell) •,.•[al!•y•.• _.b. r• [•dyh@•ra_l!•Y,CQm

From: West Hartha [mailto:Martha.West@generalshale.com] Sent: Thursday,

May 22, 2008 12:15 PM To: Stacey Cunningham Co: Brandy Hughes Subject: General Shale Brick, Roanoke

Plant 36 Production

Data Hi Stacey, Following,

you will find the production

data and kiln parameters

for the stack test you performed

on May 20 th at our Roanoke,

VA plant. Please

let me know if you have questions. Thank you for all your help. May 20, 2008

Test Plant 36 Production 17.04 tons/hr Coal Usage

1450 Ibs/hr Gas Usage

10.1 MCF/hr Limestone Feed Rate 200 Ibs/hr Differential Pressure

0.25 inches Thanks Again! Martha

En viromnemal.Engineer
General ShaIe BricAi, Inc. P.O. Box 354 7 Joh•tson Ci05 •I)'V 3/602 P/zone: (423)952-4240 F•: (423)9• 2-4160

file:/A\eralley\data\Users\ChrisLe\My Documents\Company\Projects\General Shale Brick\...

6/12/2008