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 

1.1 

1.2 

1.3 

1.4 

2.0 

3.0 

3.1 

3.2 

3.3 

3.4 

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 Page 

1.0 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-I 
Summary of Results 
Compliance 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 

3.2 

3.1 

17.1 

0.4 

5/2O/08 

60 

17.04 

1,450 

10.1 

0.25 

200 

3.4 

3.3 

16. 

0.4 

5/20/08 

60 

17.04 

1,450 

10.1 

0.25 

200 

3.4 

3.5 

16.6 

0.5 

17.04 

1,450 

10.1 

0.25 

200 

3.3 

3.3 

16.6 

0.5 

97 

c:\\Projects\(3eneral Shale Brick, Inc.•008-0206\Compliance Rcport Page 2-1 
Testing 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 3-1 
Colnpliance 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 + Pg 

13.6 

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-1 
General 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-2 
Compliance 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-3 
Hydrogen 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• RE x 100 3.0 % 

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-4 
Appendix B I 
Location: 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 

2 

3 

4 

5 

6 

7 

8 

9 

l0 

II 

12 

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 

9 

10 

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 

1 

2 

3 

4 

5 

6 

AP @ Reference 

0.31 

0.28 

0.24 

0.21 

0.17 

0.16 

7 0.15 

8 0.13 

9 0.24 

10 

11 

12 

13 

14 

15 

16 

17 

18 

0.20 

0.16 

0.14 

Angle (AP=0) 

11 

10 

10 

9 

11 

6 

10 

12 

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 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

Average 

7 

9 

9 

10 

11 

9 

QA/QC Reviewer 
Location: 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 

1 

2 

3 

Average 

Repeatability (P/F): 

Date: 

% COz 

3.0 

3.0 

3.0 

3.0 

P 

5/20/08 

%05 

17.0 

17.0 

17.0 

17.0 

P 

% Nz 

80.0 

80.0 

80.0 

80.0 

P 

Run 2 

Analysis Number 

2 

Average 

Repeatability (P/F): 

Date: 

% COz 

3.0 

3.0 

3.0 

3.0 

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 Reviewer 
Location: ,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 

14.3 

Labeled? 

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-I 

2 

3 

4 

5 

6 

7 

8 

B-I 

2 

3 

4 

5 

6 

7 

8 

C-I 

2 

3 

4 

5 

6 

7 

8 

%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 

cf 

cf 

cf 

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 

cf 

cf 

ef 

•'• 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 

18,712 -2.7 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 Corrections 

cf 

cf 

cf 

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•52 

o.08 

28.53 

58.0 

58.0 

23,36 

361.7 

5.8 

3.0 

16.5 

0.84 

28.52 

0.09 

28.53 

58.0 

58.0 

23.36 

360.3 

6.2 

3.0 

16.6 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. 04111/06 
Location: 

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 16.58 
Location: 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 Reviewer 
Location: 

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 

10 

11 

12 

13 

14 

15 

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 

4 

5 

16 

17 

18 

19 

20 

21 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

Average 0.14 

QA/QC Reviewer 

5.7 
Location: 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 

3.0 

3.0 

3.0 

3.0 

% 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" 

1 

2 

3 

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 Reviewer 
Location: 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 Reviewer 
Location: 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 acfin 
Locatiou: 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 

PITOT ID PR-02 Est. Dn: 0.390 inche• 

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-I 

2 

3 

4 

5 

6 

B-I 

2 

3 

4 

5 

6 

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 Reviewer 
Location: Start Time: 2:18 PM 

Date: End Time: 3:22 PM 

A-I 

2 

3 

4 

5 

6 

B-I 

2 

3 

4 

5 

6 

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 

cf 

cf 

% 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 

Qa 

1,190 acmm 

42,005 acfm -2.1 
I, 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 

6,0 

3.0 

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 25,012 
Location: 

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 

59 
Appendix C 
Your 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) 332-9169 
Maxxam 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 

ug 

ug 

ug 

ug 

ug 

ug 

ug 

ug 

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) 332-9169 
Maxxam 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 

5555 North Service Road. Burlington, Ontario, Canada L7L 5H7 

Page 3 of 6 

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

MATRIX 

QC Type Parameter yyyy/mm/dd Value %Recovery Units QC Limits SPIKE 

(Y74401) Hydrochloric Acid 2008/05/29 0, RDL=400 97 ug 80- 120 

Spiked 

Hydrofluoric Acid 2008/05/29 0, RDL=200 103 ug 80 120 Blank Hydrochloric Acid 2008/05/29 0, RDL=200 96 ug 90 110 Hydrofluoric Acid 2008/05/29 0, RDL=200 98 Method ug 90 110 Blank Hydrochloric Acid 2008/05/29 ND, RDL=200 ug Hydrofluoric Acid 2008/05/29 ND, RDL=200 RPD ug 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) 332-9169 

SAIVIPLE 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 D 
Model %: 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 ORIFICE READINGSd8 

(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 

100 

150 

300 

500 

150 

300 

150 

300 

0 

32 

68 

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 

300 

500 

760 

960 

533 

154 

306 

505 

74 

766 

965 

73 534 

-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. Green 
E. 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 06 
E, 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,,06 
Model #: 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 ORIFICE READINGSdH 

(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 

151 

306 

150 610 

766 

611 

300 760 766 

-0.2 

-0.8 

0 46O 0 460 0.0 

32 492 29 489 0.6 

68 528 66 526 0.4 

460 

5O 510 

100 

150 

47 

98 

150 

306 

509 

68 

300 

500 

71 

560 

460 

507 

558 

610 

766 

969 

528 

610 

760 

960 

531 

0.0 

0.6 

0.4 

0.0 

-0.8 

-0.9 

0.6 

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. Green 
Location: 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 1 
From: 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